Coal liquefaction

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Coal liquefaction is a process of converting coal into liquid hydrocarbons: liquid fuels and petrochemicals. This process is often known as "Coal to X" or "Carbon to X", where X can be many different hydrocarbon-based products. However, the most common process chain is "Coal to Liquid Fuels" (CTL). [1]

Contents

Historical background

Coal liquefactions originally was developed at the beginning of the 20th century. [2] The best-known CTL process is Fischer–Tropsch synthesis (FT), named after the inventors Franz Fischer and Hans Tropsch from the Kaiser Wilhelm Institute in the 1920s. [3] The FT synthesis is the basis for indirect coal liquefaction (ICL) technology. Friedrich Bergius, also a German chemist, invented direct coal liquefaction (DCL) as a way to convert lignite into synthetic oil in 1913.

Coal liquefaction was an important part of Adolf Hitler's four-year plan of 1936, and became an integral part of German industry during World War II. [4] During the mid-1930s, companies like IG Farben and Ruhrchemie initiated industrial production of synthetic fuels derived from coal. This led to the construction of twelve DCL plants using hydrogenation and nine ICL plants using Fischer–Tropsch synthesis by the end of World War II. In total, CTL provided 92% of Germany's air fuel and over 50% of its petroleum supply in the 1940s. [2] The DCL and ICL plants effectively complemented each other rather than competed. The reason for this is that coal hydrogenation yields high quality gasoline for aviation and motors, while FT synthesis chiefly produced high-quality diesel, lubrication oil, and waxes together with some smaller amounts of lower-quality motor gasoline. The DCL plants were also more developed, as lignite – the only coal available in many parts of Germany – worked better with hydrogenation than with FT synthesis. After the war, Germany had to abandon its synthetic fuel production as it was prohibited by the Potsdam conference in 1945. [4]

South Africa developed its own CTL technology in the 1950s. The South African Coal, Oil and Gas Corporation (Sasol) was founded in 1950 as part of industrialization process that the South African government considered essential for continued economic development and autonomy. [5] South Africa had no known domestic oil reserves at the time, and this made the country very vulnerable to disruption of supplies coming from outside, albeit for different reasons at different times. Sasol was a successful way to protect the country's balance of payment against the increasing dependence on foreign oil. For years its principal product was synthetic fuel, and this business enjoyed significant government protection in South Africa during the apartheid years for its contribution to domestic energy security. [6] Although it was generally much more expensive to produce oil from coal than from natural petroleum, the political as well as economic importance of achieving as much independence as possible in this sphere was sufficient to overcome any objections. Early attempts to attract private capital, foreign or domestic, were unsuccessful, and it was only with state support that the coal liquefaction could start. CTL continued to play a vital part in South Africa's national economy, providing around 30% of its domestic fuel demand. The democratization of South Africa in the 1990s made Sasol search for products that could prove more competitive in the global marketplace; as of the new millennium the company was focusing primarily on its petrochemical business, as well as on efforts to convert natural gas into crude oil (GTL) using its expertise in Fischer–Tropsch synthesis.

CTL technologies have steadily improved since the Second World War. Technical development has resulted in a variety of systems capable of handling a wide array of coal types. However, only a few enterprises based on generating liquid fuels from coal have been undertaken, most of them based on ICL technology; the most successful one has been Sasol in South Africa. CTL also received new interest in the early 2000s as a possible mitigation option for reducing oil dependence, at a time when rising oil prices and concerns over peak oil made planners rethink existing supply chains for liquid fuels.

Methods

Specific liquefaction technologies generally fall into two categories: direct liquefaction (DCL) and indirect liquefaction (ICL) processes. Direct processes are based on approaches such as carbonization, pyrolysis, and hydrogenation. [7]

Indirect liquefaction processes generally involve gasification of coal to a mixture of carbon monoxide and hydrogen, often known as synthesis gas or simply syngas. Using the Fischer–Tropsch process syngas is converted into liquid hydrocarbons. [8]

In contrast, direct liquefaction processes convert coal into liquids directly without having to rely on intermediate steps by breaking down the organic structure of coal with application of hydrogen-donor solvent, often at high pressures and temperatures. [9] Since liquid hydrocarbons generally have a higher hydrogen-carbon molar ratio than coals, either hydrogenation or carbon-rejection processes must be employed in both ICL and DCL technologies.

At industrial scales (i.e. thousands of barrels/day) a coal liquefaction plant typically requires multibillion-dollar capital investments. [10]

Pyrolysis and carbonization processes

A number of carbonization processes exist. The carbonization conversion typically occurs through pyrolysis or destructive distillation. It produces condensable coal tar, oil and water vapor, non-condensable synthetic gas, and a solid residue - char.

One typical example of carbonization is the Karrick process. In this low-temperature carbonization process, coal is heated at 680 °F (360 °C) to 1,380 °F (750 °C) in the absence of air. These temperatures optimize the production of coal tars richer in lighter hydrocarbons than normal coal tar. However, any produced liquids are mostly a by-product and the main product is semi-coke - a solid and smokeless fuel. [2]

The COED Process, developed by FMC Corporation, uses a fluidized bed for processing, in combination with increasing temperature, through four stages of pyrolysis. Heat is transferred by hot gases produced by combustion of part of the produced char. A modification of this process, the COGAS Process, involves the addition of gasification of char. [11] The TOSCOAL Process, an analogue to the TOSCO II oil shale retorting process and Lurgi–Ruhrgas process, which is also used for the shale oil extraction, uses hot recycled solids for the heat transfer. [11]

Liquid yields of pyrolysis and the Karrick process are generally considered too low for practical use for synthetic liquid fuel production. [12] The resulting coal tars and oils from pyrolysis generally require further treatment before they can be usable as motor fuels; they are processed by hydrotreating to remove sulfur and nitrogen species, after which they are finally processed into liquid fuels. [11]

In summary, the economic viability of this technology is questionable. [10]

Hydrogenation processes

Friedrich Bergius Bergius.jpg
Friedrich Bergius

One of the main methods of direct conversion of coal to liquids by hydrogenation process is the Bergius process, developed by Friedrich Bergius in 1913. In this process, dry coal is mixed with heavy oil recycled from the process. A catalyst is typically added to the mixture. The reaction occurs at between 400 °C (752 °F) to 500 °C (932 °F) and 20 to 70  MPa hydrogen pressure. The reaction can be summarized as follows: [7]

After World War I several plants based on this technology were built in Germany; these plants were extensively used during World War II to supply Germany with fuel and lubricants. [13] The Kohleoel Process, developed in Germany by Ruhrkohle and VEBA, was used in the demonstration plant with the capacity of 200 ton of lignite per day, built in Bottrop, Germany. This plant operated from 1981 to 1987. In this process, coal is mixed with a recycle solvent and iron catalyst. After preheating and pressurizing, H2 is added. The process takes place in a tubular reactor at the pressure of 300 bar (30 MPa) and at the temperature of 470 °C (880 °F). [14] This process was also explored by SASOL in South Africa.

During the 1970s and 1980s, Japanese companies Nippon Kokan, Sumitomo Metal Industries, and Mitsubishi Heavy Industries developed the NEDOL process. In this process, coal is mixed with a recycled solvent and a synthetic iron-based catalyst; after preheating, H2 is added. The reaction takes place in a tubular reactor at a temperature between 430 °C (810 °F) and 465 °C (870 °F) at the pressure 150-200 bar. The produced oil has low quality and requires intensive upgrading. [14] H-Coal process, developed by Hydrocarbon Research, Inc., in 1963, mixes pulverized coal with recycled liquids, hydrogen and catalyst in the ebullated bed reactor. Advantages of this process are that dissolution and oil upgrading are taking place in the single reactor, products have high H/C ratio, and a fast reaction time, while the main disadvantages are high gas yield (this is basically a thermal cracking process), high hydrogen consumption, and limitation of oil usage only as a boiler oil because of impurities. [11]

The SRC-I and SRC-II (Solvent Refined Coal) processes were developed by Gulf Oil and implemented as pilot plants in the United States in the 1960s and 1970s. [14]

The Nuclear Utility Services Corporation developed hydrogenation process which was patented by Wilburn C. Schroeder in 1976. The process involved dried, pulverized coal mixed with roughly 1wt% molybdenum catalysts. [7] Hydrogenation occurred by use of high temperature and pressure synthesis gas produced in a separate gasifier. The process ultimately yielded a synthetic crude product, naphtha, a limited amount of C3/C4 gas, light-medium weight liquids (C5-C10) suitable for use as fuels, small amounts of NH3 and significant amounts of CO2. [15] Other single-stage hydrogenation processes are the Exxon Donor Solvent Process, the Imhausen High-pressure Process, and the Conoco Zinc Chloride Process. [14]

There are also a number of two-stage direct liquefaction processes; however, after the 1980s only the Catalytic Two-stage Liquefaction Process, modified from the H-Coal Process; the Liquid Solvent Extraction Process by British Coal; and the Brown Coal Liquefaction Process of Japan have been developed. [14]

Shenhua, a Chinese coal mining company, decided in 2002 to build a direct liquefaction plant in Erdos, Inner Mongolia (Erdos CTL), with barrel capacity of 20 thousand barrels per day (3.2×10^3 m3/d) of liquid products including diesel oil, liquefied petroleum gas (LPG) and naphtha (petroleum ether). First tests were implemented at the end of 2008. A second and longer test campaign was started in October 2009. In 2011, Shenhua Group reported that the direct liquefaction plant had been in continuous and stable operations since November 2010, and that Shenhua had made 800 million yuan ($125.1 million) in earnings before taxes in the first six months of 2011 on the project. [16]

Chevron Corporation developed a process invented by Joel W. Rosenthal called the Chevron Coal Liquefaction Process (CCLP). [17] It is unique due to the close-coupling of the non-catalytic dissolver and the catalytic hydroprocessing unit. The oil produced had properties that were unique when compared to other coal oils; it was lighter and had far fewer heteroatom impurities. The process was scaled-up to the 6 ton per day level, but not proven commercially.

Indirect conversion processes

Indirect coal liquefaction (ICL) processes operate in two stages. In the first stage, coal is converted into syngas (a purified mixture of CO and H2 gas). In the second stage, the syngas is converted into light hydrocarbons using one of three main processes: Fischer–Tropsch synthesis, methanol synthesis with subsequent conversion to gasoline or petrochemicals, and methanation. Fischer–Tropsch is the oldest of the ICL processes.

In methanol synthesis processes syngas is converted to methanol, which is subsequently polymerized into alkanes over a zeolite catalyst. This process, under the moniker MTG (MTG for "Methanol To Gasoline"), was developed by Mobil in the early 1970s, and is being tested at a demonstration plant by Jincheng Anthracite Mining Group (JAMG) in Shanxi, China. Based on this methanol synthesis, China has also developed a strong coal-to-chemicals industry, with outputs such as olefins, MEG, DME and aromatics.

Methanation reaction converts syngas to substitute natural gas (SNG). The Great Plains Gasification Plant in Beulah, North Dakota is a coal-to-SNG facility producing 160 million cubic feet per day of SNG, and has been in operation since 1984. [18] Several coal-to-SNG plants are in operation or in project in China, South Korea and India.

In another application of gasification, hydrogen extracted from synthetic gas reacts with nitrogen to form ammonia. Ammonia then reacts with carbon dioxide to produce urea. [19]

The above instances of commercial plants based on indirect coal liquefaction processes, as well as many others not listed here including those in planning stages and under construction, are tabulated in the Gasification Technologies Council's World Gasification Database. [20]

Environmental considerations

Typically coal liquefaction processes are associated with significant CO2 emissions from the gasification process or as well as from generation of necessary process heat and electricity inputs to the liquefaction reactors, [10] thus releasing greenhouse gases that can contribute to anthropogenic global warming. This is especially true if coal liquefaction is conducted without any carbon capture and storage technologies. [21] There are technically feasible low-emission configurations of CTL plants. [22]

High water consumption in the water-gas shift reaction or steam methane reforming is another adverse environmental effect. [10]

CO2 emission control at Erdos CTL, an Inner Mongolian plant with a carbon capture and storage demonstration project, involves injecting CO2 into the saline aquifer of Erdos Basin, at a rate of 100,000 tonnes per year. [23] [ third-party source needed ] As of late October 2013, an accumulated amount of 154,000 tonnes of CO2 had been injected since 2010, which reached or exceeded the design value. [24] [ third-party source needed ]

In the United States, the Renewable Fuel Standard and low-carbon fuel standard, such as enacted in the State of California, reflect an increasing demand for low carbon footprint fuels. Also, legislation in the United States has restricted the military's use of alternative liquid fuels to only those demonstrated to have life-cycle GHG emissions less than or equal to those of their conventional petroleum-based equivalent, as required by Section 526 of the Energy Independence and Security Act (EISA) of 2007. [25]

Research and development of coal liquefaction

The United States military has an active program to promote alternative fuels use, [26] and utilizing vast domestic U.S. coal reserves to produce fuels through coal liquefaction would have obvious economic and security advantages. But with their higher carbon footprint, fuels from coal liquefaction face the significant challenge of reducing life-cycle GHG emissions to competitive levels, which demands continued research and development of liquefaction technology to increase efficiency and reduce emissions. A number of avenues of research & development will need to be pursued, including:

Since 2014, the U.S. Department of Energy and the Department of Defense have been collaborating on supporting new research and development in the area of coal liquefaction to produce military-specification liquid fuels, with an emphasis on jet fuel, which would be both cost-effective and in accordance with EISA Section 526. [27] Projects underway in this area are described under the U.S. Department of Energy National Energy Technology Laboratory's Advanced Fuels Synthesis R&D area in the Coal and Coal-Biomass to Liquids Program.

Every year, a researcher or developer in coal conversion is rewarded by the industry in receiving the World Carbon To X Award. The 2016 Award recipient is Mr. Jona Pillay, executive director for Gasification & CTL, Jindal Steel & Power Ltd (India). The 2017 Award recipient is Dr. Yao Min, Deputy General Manager of Shenhua Ningxia Coal Group (China). [28]

In terms of commercial development, coal conversion is experiencing a strong acceleration. [29] Geographically, most active projects and recently commissioned operations are located in Asia, mainly in China, while U.S. projects have been delayed or canceled due to the development of shale gas and shale oil.

Coal liquefaction plants and projects

World (Non-U.S.) Coal to Liquid Fuels Projects

World (Non-U.S.) Coal to Liquid Fuels Projects [20] [30]
ProjectDeveloperLocationsTypeProductsStart of Operations
Sasol Synfuels II (West) & Sasol Synfuels III (East)Sasol (Pty) Ltd.Secunda, South AfricaCTL160,000 BPD; primary products gasoline and light olefins (alkenes)1977(II)/1983(III)
Shenhua Direct Coal Liquefaction PlantShenhua GroupErdos, Inner Mongolia, ChinaCTL (direct liquefaction)20,000 BPD; primary products diesel fuel, liquefied petroleum gas, naphtha2008
Yitai CTL PlantYitai Coal Oil Manufacturing Co., Ltd.Ordos, Zhungeer, ChinaCTL160,000 mt/a Fischer–Tropsch liquids2009
Jincheng MTG PlantJincheng Anthracite Mining Co., Ltd.Jincheng, ChinaCTL300,000 t/a methanol from MTG process2009
Sasol SynfuelsSasol (Pty) Ltd.Secunda, South AfricaCTL3,960,000 (Nm3/d) syngas capacity; Fischer–Tropsch liquids2011
Shanxi Lu'an CTL PlantShanxi Lu'an Co. Ltd.Lu'an, ChinaCTL160,000 mt/a Fischer–Tropsch liquids2014
ICM Coal to Liquids PlantIndustrial Corporation of Mongolia LLC (ICM)Tugrug Nuur, MongoliaCTL13,200,000 (Nm3/d) syngas capacity; gasoline2015
Yitai Yili CTL PlantYitai Yili Energy Co.Yili, ChinaCTL30,000 BPD Fischer–Tropsch liquids2015
Yitai Ordos CTL Plant Phase IIYitaiOrdos, Zhungeer-Dalu, ChinaCTL46,000 BPD Fischer–Tropsch liquids2016
Yitai Ürümqi CTL PlantYitaiGuanquanbao, Urunqi, ChinaCTL46,000 BPD Fischer–Tropsch liquids2016
Shenhua Ningxia CTL ProjectShenhua Group Corporation LtdChina, Yinchuan, NingxiaCTL4 million tonnes/year of diesel & naphtha2016
Clean Carbon IndustriesClean Carbon IndustriesMozambique, Tete provinceCoal waste-to-liquids65,000 BPD fuel2020
Arckaringa ProjectAltona EnergyAustralia, SouthCTL30,000 BPD Phase I 45,000 BPD + 840 MW Phase IITBD

U.S. Coal to Liquid Fuels Projects

U.S. Coal to Liquid Fuels Projects [20] [31]
ProjectDeveloperLocationsTypeProductsStatus
Adams Fork Energy - TransGas WV CTLTransGas Development Systems (TGDS)Mingo County, West VirginiaCTL7,500 TPD of coal to 18,000 BPD gasoline and 300 BPD LPGOperations 2016 or later
American Lignite Energy (aka Coal Creek Project)American Lignite Energy LLC (North American Coal, Headwaters Energy Services)MacLean County, North DakotaCTL11.5 million TPY lignite coal to 32,000 BPD of undefined fuelDelayed/Cancelled
Belwood Coal-to-Liquids Project (Natchez)RentechNatchez, MississippiCTLPetcoke to up to 30,000 BPD ultra-clean dieselDelayed/Cancelled
CleanTech Energy ProjectUSA Synthetic Fuel Corp. (USASF)WyomingSynthetic crude30.6 mm bbls/year of synthetic crude (or 182 billion cubic feet per year)Planning/financing not secured
Cook Inlet Coal-to Liquids Project (aka Beluga CTL)AIDEA and Alaska Natural Resources to LiquidsCook Inlet, AlaskaCTL16 million TPY coal to 80,000 BPD of diesel and naphtha; CO2 for EOR; 380 MW electrical generationDelayed/Cancelled
Decatur Gasification PlantSecure EnergyDecatur, IllinoisCTL1.5 million TPY of high-sulfur IL coal generating 10,200 barrels per day of high quality gasolineDelayed/Cancelled
East Dubuque PlantRentech Energy Midwest Corporation (REMC)East Dubuque, IllinoisCTL, polygeneration1,000 tpd ammonia; 2,000 BPD clean fuels and chemicalsDelayed/Cancelled
FEDC Healy CTLFairbanks Economic Development Corp. (FEDC)Fairbanks, AlaskaCTL/GTL4.2-11.4 million TPY Healy-mined coal; ~40k BPD liquid fuels; 110MWPlanning
Freedom Energy Diesel CTLFreedom Energy Diesel LLCMorristown, TennesseeGTLUndeterminedDelayed/Cancelled
Future Fuels Kentucky CTLFuture Fuels, Kentucky River PropertiesPerry County, KentuckyCTLNot specified. Coal to methanol and other chemicals (over 100 million tons of coal supply)Active
Hunton "Green Refinery" CTLHunton EnergyFreeport, TexasCTLBitumen crude oil to 340,000 BPD jet and diesel fuelDelayed/Cancelled
Illinois Clean Fuels ProjectAmerican Clean Coal FuelsColes County, IllinoisCTL4.3 million TPY coal/biomass to 400 million GPY diesel and jet fuelDelayed/Cancelled
Lima Energy ProjectUSA Synthetic Fuel Corp. (USASF)Lima, OhioIGCC/SNG/H2, polygenerationThree Phases: 1) 2.7 million barrels of oil equivalent (BOE), 2) expand to 5.3 million BOE (3) expand to 8.0 million BOE (47 billion cf/y), 516 MWActive
Many Stars CTLAustralian-American Energy Co. (Terra Nova Minerals or Great Western Energy), Crow NationBig Horn County, MontanaCTLFirst phase: 8,000 BPD liquidsActive (no new information since 2011)
Medicine Bow Fuel and Power ProjectDKRW Advanced FuelsCarbon County, WyomingCTL3 million TPY coal to 11,700 BPD of gasolineDelayed/Cancelled
NABFG Weirton CTLNorth American Biofuels GroupWeirton, West VirginiaCTLUndeterminedDelayed/Cancelled
Rentech Energy Midwest FacilityRentech Energy Midwest Corporation (REMC)East Dubuque, IllinoisCTL1,250 BPD dieselDelayed/Cancelled
Rentech/Peabody Joint Development Agreement (JDA)Rentech/Peabody CoalKentuckyCTL10,000 and 30,000 BPDDelayed/Cancelled
Rentech/Peabody MinemouthRentech/Peabody CoalMontanaCTL10,000 and 30,000 BPDDelayed/Cancelled
Secure Energy CTL (aka MidAmericaC2LMidAmericaC2L / SiemensMcCracken County, KentuckyCTL10,200 BPD gasolineActive (no new information since 2011)
Tyonek Coal-to-Liquids (formerly Alaska Accelergy CTL Project)Accelergy, Tyonek Native Corporation (TNC)Cook Inlet, AlaskaCBTLUndefined amount of coal/biomass to 60,000 BPD jet fuel/gasoline/diesel and 200-400 MW electricityPlanning
US Fuel CTLUS Fuel CorporationPerry County/Muhlenberg County, KentuckyCTL300 tons of coal into 525 BPD liquid fuels including diesel and jet fuelActive

See also

Related Research Articles

Syngas, or synthesis gas, is a mixture of hydrogen and carbon monoxide, in various ratios. The gas often contains some carbon dioxide and methane. It is principally used for producing ammonia or methanol. Syngas is combustible and can be used as a fuel. Historically, it has been used as a replacement for gasoline, when gasoline supply has been limited; for example, wood gas was used to power cars in Europe during WWII.

<span class="mw-page-title-main">Gasification</span> Form of energy conversion

Gasification is a process that converts biomass- or fossil fuel-based carbonaceous materials into gases, including as the largest fractions: nitrogen (N2), carbon monoxide (CO), hydrogen (H2), and carbon dioxide (CO2). This is achieved by reacting the feedstock material at high temperatures (typically >700 °C), without combustion, via controlling the amount of oxygen and/or steam present in the reaction. The resulting gas mixture is called syngas (from synthesis gas) or producer gas and is itself a fuel due to the flammability of the H2 and CO of which the gas is largely composed. Power can be derived from the subsequent combustion of the resultant gas, and is considered to be a source of renewable energy if the gasified compounds were obtained from biomass feedstock.

The Fischer–Tropsch process (FT) is a collection of chemical reactions that converts a mixture of carbon monoxide and hydrogen, known as syngas, into liquid hydrocarbons. These reactions occur in the presence of metal catalysts, typically at temperatures of 150–300 °C (302–572 °F) and pressures of one to several tens of atmospheres. The Fischer–Tropsch process is an important reaction in both coal liquefaction and gas to liquids technology for producing liquid hydrocarbons.

In industrial chemistry, coal gasification is the process of producing syngas—a mixture consisting primarily of carbon monoxide (CO), hydrogen, carbon dioxide, methane, and water vapour —from coal and water, air and/or oxygen.

<span class="mw-page-title-main">Sasol</span> South African integrated energy and chemical company

Sasol Limited is an integrated energy and chemical company based in Sandton, South Africa. The company was formed in 1950 in Sasolburg, South Africa, and built on processes that German chemists and engineers first developed in the early 1900s. Today, Sasol develops and commercializes technologies, including synthetic fuel technologies, and produces different liquid fuels, chemicals, coal tar, and electricity.

<span class="mw-page-title-main">Synthetic fuel</span> Fuel from carbon monoxide and hydrogen

Synthetic fuel or synfuel is a liquid fuel, or sometimes gaseous fuel, obtained from syngas, a mixture of carbon monoxide and hydrogen, in which the syngas was derived from gasification of solid feedstocks such as coal or biomass or by reforming of natural gas.

<span class="mw-page-title-main">Biomass to liquid</span>

Biomass to liquid is a multi-step process of producing synthetic hydrocarbon fuels made from biomass via a thermochemical route.

<span class="mw-page-title-main">Gas to liquids</span> Conversion of natural gas to liquid petroleum products

Gas to liquids (GTL) is a refinery process to convert natural gas or other gaseous hydrocarbons into longer-chain hydrocarbons, such as gasoline or diesel fuel. Methane-rich gases are converted into liquid synthetic fuels. Two general strategies exist: (i) direct partial combustion of methane to methanol and (ii) Fischer–Tropsch-like processes that convert carbon monoxide and hydrogen into hydrocarbons. Strategy ii is followed by diverse methods to convert the hydrogen-carbon monoxide mixtures to liquids. Direct partial combustion has been demonstrated in nature but not replicated commercially. Technologies reliant on partial combustion have been commercialized mainly in regions where natural gas is inexpensive.

<span class="mw-page-title-main">Bergius process</span>

The Bergius process is a method of production of liquid hydrocarbons for use as synthetic fuel by hydrogenation of high-volatile bituminous coal at high temperature and pressure. It was first developed by Friedrich Bergius in 1913. In 1931 Bergius was awarded the Nobel Prize in Chemistry for his development of high-pressure chemistry.

<span class="mw-page-title-main">Karrick process</span>

The Karrick process is a low-temperature carbonization (LTC) and pyrolysis process of carbonaceous materials. Although primarily meant for coal carbonization, it also could be used for processing of oil shale, lignite or any carbonaceous materials. These are heated at 450 °C (800 °F) to 700 °C (1,300 °F) in the absence of air to distill out synthetic fuels–unconventional oil and syngas. It could be used for a coal liquefaction as also for a semi-coke production. The process was the work of oil shale technologist Lewis Cass Karrick at the United States Bureau of Mines in the 1920s.

An integrated gasification combined cycle (IGCC) is a technology using a high pressure gasifier to turn coal and other carbon based fuels into pressurized gas—synthesis gas (syngas). It can then remove impurities from the syngas prior to the electricity generation cycle. Some of these pollutants, such as sulfur, can be turned into re-usable byproducts through the Claus process. This results in lower emissions of sulfur dioxide, particulates, mercury, and in some cases carbon dioxide. With additional process equipment, a water-gas shift reaction can increase gasification efficiency and reduce carbon monoxide emissions by converting it to carbon dioxide. The resulting carbon dioxide from the shift reaction can be separated, compressed, and stored through sequestration. Excess heat from the primary combustion and syngas fired generation is then passed to a steam cycle, similar to a combined cycle gas turbine. This process results in improved thermodynamic efficiency, compared to conventional pulverized coal combustion.

Pyrolysis oil, sometimes also known as bio-crude or bio-oil, is a synthetic fuel with limited industrial application and under investigation as substitute for petroleum. It is obtained by heating dried biomass without oxygen in a reactor at a temperature of about 500 °C (900 °F) with subsequent cooling, separation from the aqueous phase and other processes. Pyrolysis oil is a kind of tar and normally contains levels of oxygen too high to be considered a pure hydrocarbon. This high oxygen content results in non-volatility, corrosiveness, partial miscibility with fossil fuels, thermal instability, and a tendency to polymerize when exposed to air. As such, it is distinctly different from petroleum products. Removing oxygen from bio-oil or nitrogen from algal bio-oil is known as upgrading.

Renewable Fuels are fuels produced from renewable resources. Examples include: biofuels, Hydrogen fuel, and fully synthetic fuel produced from ambient carbon dioxide and water. This is in contrast to non-renewable fuels such as natural gas, LPG (propane), petroleum and other fossil fuels and nuclear energy. Renewable fuels can include fuels that are synthesized from renewable energy sources, such as wind and solar. Renewable fuels have gained in popularity due to their sustainability, low contributions to the carbon cycle, and in some cases lower amounts of greenhouse gases. The geo-political ramifications of these fuels are also of interest, particularly to industrialized economies which desire independence from Middle Eastern oil.

<span class="mw-page-title-main">Secunda CTL</span>

Secunda CTL is a synthetic fuel plant owned by Sasol at Secunda, Mpumalanga in South Africa. It uses coal liquefaction to produce petroleum-like synthetic crude oil from coal. The process used by Sasol is based on the Fischer–Tropsch process. It is the largest coal liquefaction plant and the largest single emitter of greenhouse gas in the world.

Second-generation biofuels, also known as advanced biofuels, are fuels that can be manufactured from various types of non-food biomass. Biomass in this context means plant materials and animal waste used especially as a source of fuel.

<span class="mw-page-title-main">Ze-gen</span> Converting waste into synthesis gas since 2004

Ze-gen, Inc. was a renewable energy company developing advanced gasification technology to convert waste into synthesis gas. Founded in 2004, Ze-gen was a venture-backed company based in Boston, Massachusetts.

Hydrothermal liquefaction (HTL) is a thermal depolymerization process used to convert wet biomass, and other macromolecules, into crude-like oil under moderate temperature and high pressure. The crude-like oil has high energy density with a lower heating value of 33.8-36.9 MJ/kg and 5-20 wt% oxygen and renewable chemicals. The process has also been called hydrous pyrolysis.

Syngas to gasoline plus (STG+) is a thermochemical process to convert natural gas, other gaseous hydrocarbons or gasified biomass into drop-in fuels, such as gasoline, diesel fuel or jet fuel, and organic solvents.

Worldwide commercial synthetic fuels plant capacity is over 240,000 barrels per day (38,000 m3/d), including indirect conversion Fischer–Tropsch plants in South Africa, Qatar, and Malaysia, and a Mobil process plant in New Zealand.

Exxon donor solvent process (EDS) is a coal liquefaction process developed by Exxon Research and Engineering Company, starting in 1966. The process converts solid coal directly to liquid synthetic fuels which could be used as a substitute for petroleum products. The process does not involve an intermediate step of coal gasification. Exxon operated a pilot plant in Texas from 1980 until 1982.

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