Masterclass

Synopsis

The continued concern with the long term supply of crude oil, the demand for clean fuels and the ubiquitous availability of coal is focusing interest in the conversion of coal into liquid fuels. The workshop discusses the main issues to be addressed in developing an economically viable coal to liquids technology. The course gives a technical and economic assessment of the major routes for conversion ranging from gasification to pyrolysis and hydrogenation routes. For gasification the technology for conversion via the Fischer-Tropsch route, via methanol and to ammonia are discussed and the underlying economics developed.

The Workshop is in 8 Modules

1. The Need and the Problem
The supply of energy to the major markets of the world is at a critical crossroad. The indigenous gas supplies in Europe and the USA are failing to keep up with demand and there is increasing emphasis on imports. At the same time there is
an international move to clean fuels, in particular low sulfur gasoline and diesel.

This session will address the issues of:

• Drivers for clean fuels
• Gas supply
• Crude oil supply
• Problems with conventional approaches
• Coal availability

2. Chemical Intermediates
CTL technologies require the conversion of gas into an intermediate comprising hydrogen and carbon monoxide known as synthesis gas. From synthesis gas there is a variety of approaches to the production of liquids or hydrogen. The production of synthesis gas is capital and energy intensive and there are several alternative approaches. After production the synthesis gas has to be tailored for the particulars of the downstream process and there are several alternatives

• Coal Gasification
• Proprietary Gasifiers
• Impact of coal properties (rank, ash, sodium) on gasifier selection
• Relative Performance
• Production economics
• Water Gas Shift and Acid Gas Removal.

3. CTL – The Fischer-Tropsch Process
The Fischer-Tropsch Process produces extremely clean fuels, especially diesel fuel. The process has been under development for 80 years but there are few commercial plants. Although the process is simple, the detail of maximizing yield and product quality makes the process complex and costly. This session will overview the status and process economics for this GTL route, identifying the principal issues of concern.

• FT prior to 1980
• Approach to maximising diesel
• Modern commercial plants – Sasol, MossGas, Shell, Qatar
• Next generation plants
• Product quality
• Process economics

4. Coal to SNG and LNG
Coal can be converted to synthetic natural gas (SNG). Although produced by physical separation, the production of LNG is quite complex and could potentially be produced from SNG. Storage, transport and re-gasification are also critical cost issues for LNG. This session compares the various alternatives for the production of SNG and LNG and gives estimates for production costs.

• SNG production technology and costs
• Comparison of SNG and Coal Seam Gas with Natural Gas
• LNG production methods and costs
• Storage, transport and re-gasification
• Comparing LNG with CTL

5. CTL via Methanol and Derivatives
Synthesis gas can be converted into methanol. Methanol can be traded as a chemical or used as a clean fuel. Synthesis gas composition influences methanol synthesis productivity and issues using coal versus gas will be discussed. This
session will analyse the process technology and economics for the production of methanol and methanol derivatives DME, gasoline, olefins and resins.

• Technology for production of methanol
• New technology for the production of DME
• Coal to gasoline via methanol
• Coal to olefins via methanol
• Coal to plastics

6. Alternative Technologies
Although coal gasification is the major route of interest for coal conversion into liquids and chemicals, other routes are commercially available or in a high state of development. The session will survey the technology and process economics for these routes.

• Underground coal gasification
• Coal pyrolysis routes
• Coal hydrogenation
• Comparison of the hydrogenation route to the gasification route
• Coal to ammonia
• Coal to acetylene to chemicals

7. Greenhouse Mitigation and Mitigation Costs
The elimination of carbon dioxide emissions is of great concern to many governments. In some countries carbon taxes are levied on emitted carbon dioxide. All of the processes discussed emit carbon dioxide and the process
production economics will be profoundly affected. This session will address greenhouse mitigation costs to these processes.

• The Kyoto Protocol
• Carbon emissions from CTL, GTL and LNG
• Emissions trading and carbon taxes
• Geo-sequestration and sequestration costs
• Impact of carbon costs on process economics

8. Critical Comparisons
This session presents cases studies for the conversion of hypothetical coal reserves. The process economics for alternative approaches will be developed and critical compared – SNG, Power, FT Diesel, Methanol and Gasoline.