U.S. Liquid Transport Fuels

Transcription

1 Coal (and Biomass) to Liquid Fuels James Katzer House Energy Briefing 131 Longworth House Office Bldg 3:, March 18, 9 1 U.S. Liquid Transport Fuels 4% of our total primary energy consumption comes form crude oil 7% of total U.S. oil product consumption is in transportation sector U.S. consumes 13.7 million bbl of liquid transportation fuels per day out of a total oil product consumption of 19.5 million bbl per day Over 9% of our transportation fuels come from crude oil 33 % of U.S. eq emissions come from transportation sector U.S. transportation sector emissions are about 1.9 gigatonnes of eq per year 2 1

2 Crude Oil Refining Schematic 3 Objectives Costs, performance, and life-cycle GHG emissions for key liquefaction processes for coal and biomass to gasoline and diesel, without and with geologic storage in a uniform framework. Numbers are based on: Consistent design basis and philosophy One capital cost base Same financial parameters & operating conditions Fixed fuel costs (coal $42/ton; biomass $8/ton dry) Existing commercial technology Kreutz, T.G., E.D. Larson, G. Liu, and R.H. Williams. 8. Fischer Tropsch Fuels from Coal and Biomass. In 25th Annual International Pittsburgh Coal Conference. Pittsburgh 4 2

3 Options for Coal To Liquids Gasification F-T Refining Coal Gasification Liquefaction Refining Water Gasification MeOH MTG All are 3 Step Process Thermal Efficiencies are Essentially Governed by C/H ratios Coal has a ratio of ~C/H.All Fuels are ~C/H 2 Coal ( which is CH) goes to Fuels (C/H 2 ) plus + Liquid Fuels 5 Comparison of Liquifaction Approaches Compound Low Temp FT* Co High Temp FT* Fe H Coal TM** Direct Liquifaction MTG*** Methane 5 Requires 8?.7 Ethylene Significant 4 - Ethane 1 Processing to Make Propylene 2 Transportation 11.2 Propane 1 Fuels Butylenes Butane C5 16C Distillate Heavy Oil/Wax Water Sol. Oxygenates Total Liquid yield loss accompanies refining steps * Steyberg & Dry, Fischer Tropsch Technology, Elsevier, 4 (All FT yields are prior to refining for gasoline octane,and diesel pour point improvement) ** H-Coal data from HRI1982 publication *** Final plant product with gasoline Octane 92 R+O 6 3

4 Coal to FT Fuels 1 without Storage coal Grinding & Slurry Prep water ASU 17% of capital Air Separ Unit Gasification & Quench slag Syngas Scrubber Water Gas Shift ATR gas expander cooling Syngas Clean-up including 17% Recycle Compr. steam syngas Acid Gas Removal unconverted syngas + C 1 -C 4 FT gases F-T raw FT Synthesis product Refinery H 2 Prod HC Recovery purge gas light ends syncrude F-T Refining FT Synthesis with recycle 13% flue gas Power Island net export electricity finished gasoline & diesel blendstocks Power Island 18% Coal prep and Gasif 3% Coal to Synthesis Gas Conversion, 64% Refrigeration Plant Regenerator H 2 S + To Claus/SCOT Refining 5% methanol Coal Feed, Net Power, Effic, TPC, Spec. Cost Fuel Cost, Br'evn Crude LC GHG Ratio, Tonnes/day MW LHV % billion 7 $ $/SDB $/gge Cost, $/bbl FT/PD fuels CTL RC V 24, , With venting, CTL produces over twice the life-cycle GHG emissions. The front end comprises 6 to 7 % of the total capital cost. 1. 5, bbl/day total diesel plus gasoline 7 Coal to FT Fuels 1 with Storage flue gas Recycle Compr. unconverted syngas + C 1 -C 4 FT gases purge gas Power Island net export electricity coal ATR steam syngas F-T raw FT Synthesis product HC Recovery light ends syncrude F-T Refining finished gasoline & diesel blendstocks Grinding & Slurry Prep water Gasification & Quench slag Syngas Scrubber Water Gas Shift gas expander cooling Acid Gas Removal Refinery H 2 Prod 15 bar to pipeline Refrigeration Plant H 2 S + To Claus/SCOT Regenerator methanol Coal Feed, Net Power, Effic, TPC, Spec. Cost Fuel Cost, Br'evn Crude LC GHG Ratio, Tonnes/day MW LHV % billion 7 $ $/SDB $/gge Cost, $/bbl FT/PD fuels CTL RC V 24, , CTL RC S 24, , With geologic storage, the life-cycle GHG emissions of CTL fuels can be equivalent to those of petroleum-derived fuels, and can be cost competitive Process design changes can reduce LC GHG emissions ratio to less than 1., but at a cost Cost of avoided is only $11/tonne of because separation & capture are integral to the CTL process 1. 5, bbl/d total diesel and gasoline 8 4

5 Coal Plus Biomass to FT Fuels flue gas Recycle Compr. unconverted syngas + C 1 - C 4 FT gases purge gas Power Island net export electricity coal ATR steam syngas F-T raw FT Synthesis product HC Recov very light ends syncrude F-T Refining finished gasoline & diesel blendstocks Grinding & Slurry Prep water Gasification & Quench slag Syngas Water Gas Scrubber Shift steam gas expander cooling Acid Gas Removal Refinery H 2 Prod biomass Chopping & Lock hopper FB Gasifier & Cyclone Tar Cracking gas cooling Filter Refrigeration Plant H 2S + To Claus/SCOT dry ash Regenerator methanol Coal Feed Biomass Feed Fuels TPC Spec. Cost Fuel Cost LC GHG Ratio tonnes/day tonnes/day bbl/day billion 7 $ $/SDB $/gge Alt/ PD fuels CBTL-RC-V 1 2,75 3,58 1, , CBTL-RC-S 1 2, , , With V, CBTL can produce fuels with less GHG emissions than petroleum-derived fuels; with S, carbon-free fuels Fuel cost higher for CBTL due to smaller scale plant and high biomass cost vs. CTL; avoided is $15/tonne In CBTL, coal augments limited biomass supply and reduces cost 1. Coal to biomass energy ratio = 57% / 43%, Illinois #6/switch grass 9 Breakeven Crude Oil Cost, at $ Price 1 Breake even Crude Oil Cost, $/bbl CTL-V 1 CTL-S 2 CBTL-V 3 CBTL-S 4 CTL-OT-V 5 CTL-OT-S 6 CBTL-OT-V 7 CBTL-OT-S 8 1 5

6 Breakeven Crude Oil Price at $5/tonne eq Price 1 Breakev ven Crude Oil Price, $/bb bl CTL-V 1 CTL-S 2 CBTL-V 3 CBTL-S 4 CTL-OT-V 5 CTL-OT-S 6 CBTL-OT-V 7 CBTL-OT-S 8 11 Effect of Price on Breakeven Crude Oil Cost 14 Brea akeven Crude Oil Price, $/bb bl CTL-RC-V CTL-RC-S CBTL-RC-V CBTL-RC-S Life-cycle Greenhouse Gas Price, $/tonne eq 12 6

7 CTL Potential: Recycle with Storage Produce liquid transportation fuels with life cycle eq emissions equivalent to those from petroleum-derived fuels Replace 2.25 million bbl/day of transport fuels in 15 yrs Net decarbonized power capacity, 15 GW e, equivalent to IGCC with CCS Use 44 million tons/yr coal $12/tonne avoided cost 13 CTL Potential: Once-Through with Storage Produce liquid transportation fuels: 2.5 million bbl/day liquid fuels with 25 % increase over petroleum-derived fuels 2.5 million bbl/day liquid fuels with emissions comparable to petroleum-derived fuels, with 9% biomass added 2.5 million bbl/day liquid fuels, with ATR 1% lower LC GHG emissions ratio than petroleum-derived fuels (increased cost) Net decarbonized power capacity 73 GW e, equivalent to IGCC with CCS Use 6 million tons/yr coal $18/tonne avoided cost 14 7

8 CBTL Potential Recycle (2 million tons/yr coal, 245 million tons/yr dry biomass) Vent 2. million bbl/day liquid id transport t fuels with 9% of the eq emissions of petroleum-derived fuels 19 GW e power generation capacity (IGCC emissions) Store 2. million bbl/day zero life-cycle GHG emission liquid transport fuels 15 GW e decarbonized power generation capacity (IGCC with CCS emissions) $15/tonne avoided cost Once-Through h with Storage (275 million tons of coal, same biomass) 1.6 million bbl/day zero life cycle GHG emission transport fuels 55 GW e decarbonized power generation capacity (IGCC with CCS) $21/tonne avoided cost 15 Observations Geologic storage technology is key to viability of coal-to-liquids liquids technologies Coal-to-fuels plants can produce competitive transport fuels with no increase in eq emissions Coal-to-fuels plants can provide decarbonized electricity at 1/3 to 1/2 the eq avoided cost of stand-alone power plants 16 8

9 Observations cont d Addition of less than 1% biomass to CTL can reduce eq emissions of fuel to less than petroleum-derived fuels Increased biomass to ~ 4 energy % results in zero-carbon fuels and decarbonized electricity (IGCC-CCS) at somewhat higher cost, due to biomass cost There is still no free lunch, all of this has impacts 17 Thank You 18 9

10 Proposed U.S. CTL Projects 19 Fuel Costs for Different Routes Fuel Cost, $/gge CTL RC V CTL RC S CTG RC V CTG RC S BTL RC V BTL RC S CBTL RC V CBTL RC S 1

11 Breakeven Crude Oil Cost, $ Price 1 Breake even Crude Oil Cost, $/bbl CTL-V 1 CTL-S 2 CBTL-V 3 CBTL-S 4 BTL-V 5 BTL-S 6 21 Crude Oil Breakeven Cost for $5/tonne eq Price 1 Breake even Crude Oil Cost, $/bbl CTL-V 1 CTL-S 2 CBTL-V 3 CBTL-S 4 BTL-V 5 BTL-S

12 Coal to Gasoline 1 (MTG) with Storage flue gas coal Grinding & Slurry Prep water air Oxygen Plant Gasification & Quench slag Syngas Scrubber Water Gas Shift gas cooling Acid Gas Removal Recycle Compr. Methanol Synthesis recycled syngas Methanol Recovery purge gas Power Island methanol (1.5% H 2 O) net export electricity LPG + fuel gas MTG Reactor 15 bar to pipeline water Refining Finished Gasoline Refrigeration Plant Regenerator H 2 S + To Claus/SCOT methanol Coal Feed, Net Power, Effic, TPC, Spec. Cost Fuel Cost, Br'evn Crude LC GHG Ratio, Tonnes/day MW LHV % billion 7 $ $/SDB $/gge Cost, $/bbl FT/PC fuels CTL RC V 24, , CTL RC S 24, , CTG RC S 21, , Methanol synthesis and MTG more selective, less expensive and require little refining LPG sale rather than combustion for power reduces gasoline cost by about $./gal 1. 5, bbl/d total gasoline 23 Direct Coal Liquefaction Coal Gasification or Methane Reforming H 2 S, NH 3, CO x Make-up Hydrogen Recycle H 2 Gas Recovery Treatment C 1 C 2 LPG Coal + Catalyst Power Gen. Coal Liquefactio n H-Donor Slurry Slurry Fractionation Hydrotreating Refining Gasoline Diesel Fuel Heavy Vacuum Gas Oil (HVGO) Power, MW De-Ashed Oil (DAO) Solvent De-ashing Ash Reject 24 12

13 Life Cycle Greenhouse Gas Emissions Diesel Gasoline CBTL CCS,FT CBTL V,FT BTL CCS,CCS BTL V,FT CTL MTG,CCS CTL V,MTG CTL CCS,FT CTL V,FT Life-Cycle Greenhouse Gas Emissions, kg eq /gallon gasoline equivalent 25 Direct Coal Table Liquefaction II Products Produced by a Direct Coal Liquefaction Plant Producing 5, bpsd of C5+ Products Product Distribution lb/hr stpd bpsd MMBtu/h Plant Input Coal 1,55,621, 18,67.5 Fuel Gas 785 Liquid Products Naphtha 135,747 1,629 12,365 Light Distillate 61, ,943 Heavy Distillate 426,9 5,123 32,691 Total Liquids 623,763 7,485 5, Lbs/bbl Sulfur 22, Ammonia 18, Phenol 2, , Refuse bbl/day (from Coal liquid Cleaning)* products 27,9 3, Slag to (from Wt Gasification)* % of total hydrocarbon 175,877 products are 2,111 light gases *Moisture free basis 26 13

14 14 Effect of Price on Breakeven Crude Oil Cost Breakeven Crude Oil Price, $/bbl CTL-RC-V CTL-RC-S Life-cycle Greenhouse Gas Price, $/tonne eq 27 Coal to FT Fuels and Enhanced Power Production with Storage air Oxygen Plant coal Grinding & Gasification Slurry Prep & Quench water slag N 2 to gas turbine Syngas Water Gas Scrubber Shift gas expander cooling Acid Gas Removal Refinery H 2 Prod F-T raw FT Synthesis product syngas unconverted syngas + C 1 -C 4 FT gases enriched methanol HC Recovery finished gasoline & diesel blendstocks syncrude Refining F-T N 2 light ends Saturator flue gas GTCC net export Power electricity Island CO Removal 2 15 bar to pipeline H 2 S + To Claus/SCOT Regenerator methanol Refrigeration Plant Coal Feed, Fuels, Net Power, Effic, TPC, Spec. Cost Fuel Cost, Br'evn Crude LC GHG Ratio, Tonnes/day bbl/day MW LHV % billion 7 $ $/SDB $/gge Cost, $/bbl FT/PC fuels CTL RC V 24,3 5, , CTL RC S 24,3 5, , CTG RC S 21,1 5, , CTL OT S 33,1 5, , methanol Once through reduces cost in synthesis loop but has bigger power plant and more coal processing Power system expansion uses FT heat and comes at lower marginal cost than IGCC plant cost LC GHG Ratio could be reduced if a reformer and/or shift and additional removal added avoided cost is $18/tonne 28 14

15 Effect of Life-Cycle GHG Price on Breakeven Crude Oil Cost 16 Brea akeven Crude Oil Cost, $/bb bl CBTL-RC-S CTL-OT-S CBTL-OT-V CTL-RC-S CBTL-OT-S CTL-OT-V Life-Cycle Greenhouse Gas Price, $/tonne eq