COAL TO DIESEL

Akshay Kulkarni (2009CH10055) Rajat Yadav (2009CH10093) Tarang Gupta (2009CH10103)

COAL TO LIQUID

Coal can be converted to liquid fuels either by removal of carbon or addition of hydrogen; the first approach is known as carbonization, and the second is known as liquefaction Coal liquefaction is the conversion of coal into a synthetic oil in order to supplement natural sources of petroleum It is an attractive technology because
It is well developed and thus could be implemented fairly rapidly There are relatively large quantities of coal reserves Stable supplies of coal, however, are readily available worldwide, and the known resources of minable coal are four times that of oil.

WHY CTL?

Energy Security: Size of coal resources Distribution of resources

70% of oil and gas supplies located in politically unstable countries

Environment Utilization of clean coal technology Sequestration technology expected Flexibility Advanced technology Co-production capability Economics Competitive with alternatives World oil price volatility

WAY TO PROCEED

It is widely believed that indirect liquefaction is more efficient than direct coal liquefaction techniques currently available.
Source: Exxon mobil

INDIRECT LIQUEFACTION
APPROACH IN PHASES:

Syn Gas preparation

Syn Gas conditioning Fischer Tropsch Synthesis

Purification
Baliban, R. C., Elia, J. A., & Floudas, C. A. (2012). Simultaneous process synthesis, heat, power, and water integration of thermochemical hybrid biomass, coal,and natural gas facilities. Computers and Chemical Engineering, 37(10), 297327.

PHASE 1: SYNGAS PREPARATION

PROCESS FLOW DIAGRAM

As a pretreatment operation Jaw crusher and BATAC Jig are being used to crush coal particles and wash the coal and reduce the ash content For air separation, fractional distillation is being used. Air is first cooled to liquid air and then gradually heated

We intend to use Texaco gasifier for coal based feed which is slurry based entrained bed gasifier
H2/CO ratio will be more; no limit on moisture content of feed Lower capital cost

Specifications of the gasification process

INPUT Coal Air 60 138.6111 101.353 1312.073 718.3767 96171.57 768089.4 2774576 -1983390 3307.469 OUTPUT Cooledsyngas 100 101.3529586 51606.51132 1059594.466 -82384.66543

Temperature Pressure (kPa) Molar Flow (kgmol/hr) Mass Flow (kg/hr) Molar Enthalpy (kJ/kgmol)

Coal Molecular weight 1186 as hypo compound and density as 785 kg/m3
INPUT CO H2 H2S N2 CO2 He Coal O2 H2O SELEXOL Coal 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.9000 0.0000 0.1000 0.0000 Air 0.0000 0.0000 0.0000 0.7900 0.0000 0.0000 0.0000 0.2100 0.0000 0.0000 OUTPUT Cooledsyngas 0.6296 0.3148 0.0185 0.0000 0.0370 0.0000 0.0000 0.0000 0.0000 0.0000

DISCUSSION

Since we are going to produce diesel, the H2/CO ratio required for the low temperature FT synthesis is around 1.8-2 but the H2/CO ratio of the syngas coming out of the Slurry feed Entrained Flow gasifier is even lower than 1 i.e. 0.5 Texaco Entrained flow gasifier produces more than 12% CO2 in the raw output syngas and CO2 sequestration is very costly Solution to first problem is conditioning of syngas by water gas shift reaction which converts H2O and CO into hydrogen CO2 is then captured by dissolving in a commercial solvent Selexol

En.wikipedia.org/wiki/selexol

PHASE 2: SYNGAS CONDITIONING

Cyclone separation and desulfurization precedes water gas shift reaction for coarse impurities and sulfur removal and gas clean up

CONDITIONING OF SYNGAS Objective: was to attain H2/CO ratio from 0.5 to 1.8

Before Fisher-Tropsch processes the H2/CO ratio must be adjusted to meet the stoichiometry of the reaction Water gas shift reaction is used for this purpose CO+H2O CO2 +H2 H= -41.1 kj/mol Commonly two stage shift reactors, high temperature and low temperature are used to achieve the high reaction rate and efficiency but here only high temperature is considered Syngas conditioning refers to hydrogen enrichment in syngas composition Compressor and coolers are installed to regulate right temperature and pressure

Water Gas Shift Reaction Operating temperature for HTS ranges from 350-600oC For iron-based catalyst HTS operation, the catalyst is combination of Fe3O4, the stable iron phase under reaction conditions, combined with chromia, lowers the catalyst sintering by textural promotion Composition of this HTS catalyst is approximately 55 wt.% Fe and 6 wt.% Cr. The catalyst is usually unsupported and available commercially in tablet or ring form

CO2 Capture To capture CO2 and other acidic gases we use Selexol (Licensed by UOP) sorbent which absorbs acidic compounds

OPERATION SPECIFICATIONS
Temperature Pressure (kPa) Molar Flow (kgmol/hr) Mass Flow (kg/hr) Molar Enthalpy (kj/kgmol) INPUT Cooled syngas 100 101.3529586 51606.51132 1059594.466 -82384.66543 OUTPUT Cooled Mixture 37.7778 3378.4320 28200.6197 893030.8509 -248241.8660 OUTPUT Conditioned syngas 0.4467 0.5533 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

CO H2 H2S N2 CO2 He Coal O2 H2O SELEXOL

INPUT Cooledsyngas 0.6296 0.3148 0.0185 0.0000 0.0370 0.0000 0.0000 0.0000 0.0000 0.0000

Water 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 1.0000 0.0000

PHASE 3: FISCHER TROPSCH SYNTHESIS

Process flow diagram

For diesel production we use low temperature shift reaction as high molecular weight paraffins and naphthenes are desired We use slurry bubble column reactor at about 200-2400c at the pressure of about 27 bar and can be used with both Fe and Co based catalyst for high molecular weight products Advantages:
The cost of a reactor train is only 25% of that of a multi-tubular system. The differential pressure over the reactor is about four times lower which results in lower gas compression costs. The lower catalyst loading translates to four-fold lower catalyst consumption per tonne of product. The slurry bed is more isothermal and so can operate at a higher average temperature resulting in higher conversions. On-line removal/addition of catalyst allows longer reactor runs

Solvent specification for slurry:

Properties of paraffin oil, C16H34(at 523 K):

Liquid phase properties Density Viscosity Surface tension Heat capacity Diffusivity of H2 Diffusivity of CO Distribution coefficient for H2 Distribution coefficient for CO Thermal conductivity 640kg/m3 0.00029Pa.s 0.001N/m 0.113W/m/K 45.5X10-9 m2/s 17.2X10-9m2/s 2.96 2.48 1500J/kg/K

Catalyst to be used
Cobalt based catalyst as it supports low temperature operations; composition: 20% Co, 8.5% Zr/ Al2O3 Cobalt-based catalyzed reaction nCO + (2n+1) H2 -> CnH2n+2+ n H2O H0298= -165 kJ.mol-1CO

REACTION SPECIFICATIONS
INPUT Supplimented Inlet Temperature 257.0382 OUTPUT Cooled Mixture 37.7778

Pressure (kPa)
Molar Flow (kgmol/hr) Mass Flow (kg/hr) Molar Enthalpy (kj/kgmol)

3378.4320
65528.5809 893030.1680 -42639.9333

3378.4320
28200.6197 893030.8509 -248241.8660

Discussion

Gaseous products are mixed with liquid products and then cooled and sent for purification so that diesel can be separated

8th Mustafhi Article on Coal Benefeaction. Humboldt Wedag. http://fossil.energy.gov/international/Publications/Coal_Beneficiation_Worksh op/8th_

CO H2 H2S N2 CO2 He Coal O2 H2O SELEXOL Ethane Propene Propane i-Butanal 1-Butanol 13-C4Diol 1-Pentanol n-Pentanal n-Hexanal 1-Hexanol Nonane n-C15 n-C22 n-C25 Methane SO2

INPUT Supplimented Inlet 0.4467 0.5533 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

OUTPUT Cooled Mixture 0.0421 0.2550 0.0000 0.0000 0.3334 0.0000 0.0000 0.0000 0.3284 0.0000 0.0003 0.0002 0.0002 0.0001 0.0001 0.0001 0.0001 0.0001 0.0001 0.0001 0.0140 0.0092 0.0053 0.0110 0.0000 0.0000

PHASE 4: PURIFICATION
Process flow diagram

The product gas stream from SBCR is at 2200C

This gas stream is cooled to 380C and 3 bar pressure

The cooled stream is then directed to the three phase separator

Three phase separator separates the entire mixture into three new streams: Unreacted syn gas C1-C4 HCs C4+ Hydrocarbons (diesel, naphtha) Water Mixture of the unreacted syngas and diesel, naphtha is then sent to a splitter which again separates it into diesel, naphtha, wax and impurities (unreacted gases) components

As final step this is to purify the product that is diesel and also to separate naphtha, remaining impurities, and heavy liquid residue

Reaction specifications:
INPUT OUTPUT

Impuritie Cooled Mixture Naptha A Diesel A s

Temperature Pressure (kPa) Molar Flow (kgmol/hr) Mass Flow (kg/hr) Molar Enthalpy (kj/kgmol) 37.7778 3378 28200 893030 25.0000 101 394 50611 25.0000 101 411 102149 21.1111 22686 17810 462381

Cracking Stream
233.8889 3378 310 109382

-248241

-275720

-510051

-218121

-482788

COMPONENT WISE MATERIAL BALANCE

INPUT Cooled Mixture 0.0421 0.2550 0.0000 0.0000 0.3334 0.0000 0.0000 0.0000 0.3284 0.0003 0.0003 0.0002 0.0002 0.0001 0.0001 0.0001 0.0001 0.0001 0.0001 0.0001 0.0140 0.0092 0.0053 0.0110 0.0000 Naptha A 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 1.0000 0.0000 0.0000 0.0000 0.0000 OUTPUT Diesel A Impurities Cracking Stream 0 6.66E-02 0.0000 0 0.403586 0.0000 0 2.67E-06 0.0000 0 0 0.0000 0 0.524693 0.0000 0 0 0.0000 0 0 0.0000 0 0 0.0000 0 2.64E-03 0.0000 0 4.18E-04 0.0000 0 4.14E-04 0.0000 0 2.71E-04 0.0000 0 2.73E-04 0.0000 0 2.01E-04 0.0000 0 2.01E-04 0.0000 0 1.60E-04 0.0000 0 1.40E-04 0.0000 0 1.38E-04 0.0000 0 1.31E-04 0.0000 0 1.33E-04 0.0000 0 0 0.0000 0.633067 0 0.0000 0.366933 0 0.0000 0 0 1.0000 0 0 0.0000 CO H2 H2S N2 CO2 He Coal O2 H2O Ethane Propene Propane i-Butanal 1-Butanol 13-C4Diol 1-Pentanol n-Pentanal n-Hexanal 1-Hexanol Nonane n-C15 n-C22 n-C25 Methane SO2

DISCUSSION

1 kg Coal leads to the production of 0.2 kg Diesel and Naphtha products. The amount of cracking stream (methane) formed is about 0.14kg.

Impurities contain a very low mass percentage of hydrogen and majorly Carbon Dioxide.
Process Specification:
Overall Material Balance Overall Heat Balance Compositions

BARRIERS TO COAL-TO-LIQUIDS

Technical

Integrated operations of advanced CTL technologies have never been demonstrated Uncertainties about future world oil production High capital and operations costs Investment risks Energy price volatility

Economic

Environmental

CO2 and criteria pollutant emission Expansion of coal production and requisite infrastructure (railroads, railcars, etc.) Water use
Competition for critical process equipment, engineering, and skilled labour Who would take the lead in commercial deployment? Part power part liquid fuels Public resistance to coal use

Commercial Deployment

Social

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