Indirect Coal Liquefaction

Shell Coal Gasification with

Fischer-Tropsch Synthesis

Karsten Radtke (speaker),Uhde GmbH (Germany)

John W. Rich Jr., Robert Hoppe, WMPI, Inc. (USA)

ThyssenKrupp GroupID102

Workforce: 185,000Sales: € 41 bn

Steel Automotive Elevator

Carbon Steel

Stainless Steel

SpecialMaterials

Body & Chassis(North America)

Body & Chassis(Europe/Asia/Pacific/Latin America)Powertrain(Global)

Steel Capital goods

Services

MaterialsServices Europe

Materials ServicesNorth America

IndustrialServices

Special Products

Services

Technologies

Uhde

Metal Cutting

PlantTechnology

Marine Systems

MechanicalEngineering

Transrapid

WMPI Project Waste Coal to Ultra Clean Liquid Fuels

Integration of three major blocks:1. Gasification of Waste Coal to Produce Synthesis Gas2. Conversion of Synthesis Gas using Fischer-Tropsch

Technology to Liquid Fuels3. Combustion of Tail Gas to produce Electric Power and

Steam

The Team

• Waste Management and Processors Inc. (Owner)

• Nexant (Owner’s Engineer)

• Shell Global Solutions (Licensor)

• Sasol Technology / ChevronTexaco (Licensor)

• Uhde (Engineering and turnkey contractor)

• Black & Veatch (Uhde’s U.S. gasification alliance partner)

WMPI, Inc.

U.S. Department of EnergyClean Coal Power Initiative (CCPI)

100,000,000 US-Dollars (granted)

National U.S. Energy Bill

WMPI Ultra Clean Fuels

Indirect Coal LiquefactionPlant

5,000 bpd

Diverse Support Mechanisms (pending)

Gasification PortfolioApplication defines Process

Shell SCGPKoppers-Totzek

Shell SGPHigh-Temperature Winkler

(HTW)

Winkler /HTW

Fluidized Bed

750-950 °C

< 30 bar

Dry Solid

1926 (Winkler)(Leuna)

WachtbergBerrenrath

Oulu Wesseling

40 Plants

Koppers-Totzek

Entrained Flow

1400-1600 °C

atm.

Dry Solid

1950 (Tippy Oy)

TalkhaNew Delhi

ModderfonteinMurphy Hill

77 Plants

Shell SCGP(Prenflo)

Entrained Flow

1500-1600 °C

25 - 45 bar

Dry Solid

1979(Hamburg)

FürstenhausenHouston

BuggenumPuertollano

5 Plants

Shell SGP

Entrained Flow

1300-1400 °C

35 - 65 bar

Liquid, Gas

Uhde‘s 1st: 1964(Belgium)

PernisLeunaHaldiaNangal

168 Plants

Process

Principle

Temp.

Pressure

Feeding

First Plants

Plants(Examples)

References

Uhde’s Gasification Portfolio

TGP TCGP SGP SCGP Prenflo HTW

K-TDevelopment of Uhde‘s Gasification Portfolio

Shell Coal Gasification IGCC (253 MWe)Buggenum, The Netherlands

Coal/Biomass gasificationfor power generation

IGCC Puertollano 318 MWel, net

(feedstock: petcoke / coal)

Coal/Petcoke/Biomass gasificationfor power generation

Coal / Waste Gasificationfor liquid fuels (methanol, gasoline)

Uhde‘s GTL/BTL/CTL Activities• WMPI - 5,000 bpd, SCPG + FT Synthesis: Uhde is selected EPC Contractor

• DKRW - 30,000 bpd, SCGP + FT Synthesis: Uhde is selected EPC Contractor

• 4 further U.S. projects (confidential) - 30.000 bpd each, SCGP + FT Synthesis:

Uhde is selected EPC Contractor

• German/Chinese Sustainable Fuel Partnership (GCSFP):

=> (German/Chinese governments, Shell, VW, BMW, DaimlerChrysler, BP,

Bosch, Uhde) - concepts include CTL, BTL, Biodiesel, Hydrogen)

• BTL Pilot Plant, IEC Freiberg: Engineering phase for modified HTW (PHTW)

based pilot plant - Methanol to Synfuel (MtS)

• Syntroleum: GTL Sweet Water Project, Basic Engineering

• UK Wesseling Methanol-to-Gasoline (Mobil MTG) plant at :

=> Brown Coal gasification to Gasoline (HTW + MTG)

• HTW Gasification for biomass (peat) to methanol, Oulo, Finland

• Direct Coal Liquefaction development (1970‘s) - not commercialised

Plant Site: Gilberton, Pennsylvania, U.S.A.

Project Black Box

WMPICoal Liquefaction

Plant

Coal (Culm)

Air

Ultra Clean Fuels

Power

Slag

Sulfur

Flux

Fly Ash

Fischer Tropsch / Coal to Liquids

Gasification CO-Shift Acid GasRemoval

PSA

Coal

FischerTropsch

Heavy EndsRecovery

ProductWork-up

WaterTreatment

Gas TurbineSteam Syst.

Effluent Water

DieselNaphtha

Hydrogen

FT WAXFT Cond-

ensate

Internal Recycle

Power

Steam

FT-Reaction Chemistry:

CO + 2 H2 → -CH2- + H2O;∆H = - 165 kJ/mol

Fischer Tropsch - Products

1.) Ultra Clean Fuels (Naphtha, Diesel, Jet)

- High Cetane (> 70)

- Free of Sulfur (< 1ppm)

- Free of Aromatics (< 1ppm) and heavy metals

2.) Specialties

- Lube Oils

- Paraffins (e.g. for detergents, solvents etc.)

- Paraffin Waxes (e.g. for candles, colours, pharmaceuticals etc.)

Biomass

(e.g. 30 %)

Coal

(e.g. 70 %)

FeedstockPreparation

MillingGasification

Fischer-Tropsch

Synthesis

Ultra Clean Fuels ProductionFeedstock: Coal + Biomass

DieselBlending

Merchant “ultra clean”Biomass/Coal derived Diesel

Refinery

Syngas

Crude Oil DerivedDiesel

(e.g. 90 %)

F-T Diesel (e.g. 10 %)

Replacement ofNatural Gas with

Coal/Biomass derived Syngas XNatural Gas

Coal + Biomass=>

Ultra Clean Diesel Blend

Process Units (Simplified Block Flow diagram)

Solids Processing

Raw Culm

Raw Tailings

+10” reject(Rock)

¾” reject(Rock)

28 mesh reject(Rock)

Culm / Tailings

Processing

Coal Milling &

DryingGasification

Slag fines

Fluxant

Fly ash

Slag

Petcoke

Raw gas

Coal Dust

¾” carbon

28 mesh carbon

Homogeneously mixed Feedstock

Shell SCGP Process Line-Up

DRY SOLIDSREMOVAL

WETSCRUBBING

Coal Feeding

MILLING/DRYING

MILLING AND DRYINGFLY ASH TO

HP STEAM

MP STEAM

Slag

COAL/PETCOKE FLY ASHRECIRC. QUENCH GAS

GASIFIER

SALTS SULPHUR

CLEAN

SYNGAS

WATERTREATMENT

900 °C

GAS TREATING

FLY ASH SYSTEM

1600 °C

Shell Coal Gasification Process (SCGP)Solid Feedstocks

Erection of the Coal/Petcoke Gasifierin Puertollano, Spain

Membrane Wall protected by the slag layer

Shell Coal/Coke Gasification SCGP

BFW, 40-70 bar

Water Tube(membrane wall)

Gasification Chamber > 1500 °C

molten slag flows downwards

solidified slagmolten slag

.

Membrane wall for gasifier(test piece)

IGCC Puertollano 318 MWel, net

(feedstock: petcoke / coal)

Preliminary Plot Plan

Project Benefits

•• Economical BenefitsEconomical Benefits1. Coal Production & Revitalization 2. Creating Jobs: Construction and Operating3. Energy Diversification & Independence

•• Environmental BenefitsEnvironmental Benefits1. Waste Utilization2. Ultra Clean Fuels3. Extreme low emissions from production and fuel use

Project Execution Structure

GasificationIsland

Syngas toLiquids Unit

DownstreamUnits

PowerBlock

ASU

Shell / Uhde

BasicEngineering

Krupp UhdeSingle Point Responsibility

Licensors

Basic Engineering

Sasol / ChevTx

Basic Engineering

B&V

BasicEngineering

Uhde & B&V - Task Force Detail Engineering, Procurement, Supervision, Commissioning

B&V - Civil and Erection

ASUVendor

Package Unit

Lump Sum Turn Key Contract

WMPI

Uhde / Black & Veatch Project Directorate

Single Point Responsibility

Utilities

B&V

BasicEngineering

Utilities

Summary

• Estimated net plant efficiency: 42%

• Economical & Marketable Fuels & Power

• Advanced Technologies for Future Needs

• Demonstrate Operability, Reliability

Conclusion

The WMPI Project:

Will be America’s first Coal-to-Liquids plant in commercial size and act as

demonstration plant.

=> Establishment of sustainable CTL market in the U.S. and worldwide.