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Dr. Ankit A. Jain & Dr. Ajay Gupta
Refining R&D Jamnagar
Direct Coal Liquefaction: Comprehensive Review Of Current
State Of The Art
Presented at 6th World Petrocoal Congress, 15-17th Feb, 2016, New Delhi
DISCLAIMER
Any statement, opinion, prediction, comment, or observation made in this
presentation/publication are those of the presenter/author only and in no condition should be
construed necessarily representing the policy and intent of Reliance Industries Ltd. (RIL).
The information presented herein are of the presenter/author’s own and in no way RIL
attracts any liability for any inconsistency or irregularity in terms of the accuracy
completeness, veracity, or truth of the content of the presentation/publication. In addition,
RIL shall not be liable for any copyright infringement and misrepresentation for the
presented content as the content is presumed in good faith to be a creation of
presenter’s/author’s own mind.
The scope of this presentation/publication is strictly for knowledge sharing purposes and
not necessarily to provide any advice or recommendation to the audience/readers. Any
endorsement, recommendation, suggestion, or advice made by the presenter/author shall be
in his personal capacity and not in professional capacity as an employee of RIL. Any person
acting on such endorsement, recommendation, suggestion, or advice will himself/herself be
responsible for any injury/damage.
© Reliance Industries Ltd., 2015
Dhirubhai H. Ambani Founder Chairman Reliance Group
• 1966- Establishes Textile mill in Naroda
• 1977- Public share offering Raised money from public
offerings oversubscribed 7X
• 1982- Builds fiber/filament plant in Patalganga
• 1995- Builds Polyolefin plants at Hazira
• 1997- Builds multi-feed cracker at Hazira
• 1999- Builds Jamnagar refinery
• 2002- Acquired IPCL a state run company
• 2008- Builds JERP refinery at Jamnagar
• 2009- Begins KG D6 gas production
• 2013- Builds PBR/SBR plants at Hazira
• 2014- Builds PTA plant at Dahej
• 2014- Builds PET plant at Dahej
RIL - BRIEF INTRODUCTION
© Reliance Industries Ltd., 2015
An
nu
al
oil
pro
du
ctio
n
Calendar Year
Peak Oil
Which year ?
Already reached ?Phase 1
- Easy to extract oil
- Oil > Demand Phase 2
- Tougher to extract oil
- Oil < Demand
Drivers for Coal Liquefaction (CTL)
Coal Resource
CTL Technology
Energy Market
Ideal Scenario for a CTL project
Available
High
demand/prices
Suitable for
high ash coal
Hubbert’s Curve (adapted [1])
World coal reserves [2]
Coal liquefaction [3]
[1] Ivanhoe, L.F., 1996. Updated Hubbert curves analyze world oil supply. World Oil, 217(11).
[2] WEB: http://chartsbin.com/view/n1n
[3] Shui, H., Cai, Z. & Xu, C., 2010. Recent advances in direct coal liquefaction. Energies, 3(2), pp.155–170.
Routes of coal liquefaction
• Indirect coal to liquid (ICL): Reaction of coal with steam/oxygen
(primarily CO + H2) which is then converted into liquids via Fischer-
Tropsch (F-T) reaction.
• Direct coal to liquid (DCL): Hydrogenation at relatively high
temperature and pressure.
nCH0.8 + xH2 → −CH2 − n
CH0.8 + H2O O2 → CO + H2 → −CH2 − + H2O
https://en.wikipedia.org/wiki/Friedrich_Bergius
Studies comparing the two routes of CTL
• Comparison of DCL and ICL [4-7]
• Relative analysis ([8])
[4] J. P. Longwell, E. S. Rubin and J. Wilson, Prog. Energy Combust. Sci., 1995, 21, 269–360.
[5] T. B. Simpson, Energy Fuels, 2002, 16, 1599–1600.
[6] Z. Zhang and Z. Men, Petroleum Refinery Engineering, Lianyou Sheji Bianjibu, 2003, vol. 33, pp. 58–61.
[7] R. H. Williams and E. D. Larson, Energy Sustainable Dev., 2003, 7,103–129.
[8] Coal liquefaction technologies- direct and indirect routes. Theo LK Lee, Headwater technology innovation group (USA) (online ppt)
[9] http://www.processonline.com.au/content/software-it/article/cutting-time-to-market-of-coal-to-liquid-energy-projects-1369718154 (last accessed, 12th Feb. 2016)
• Advantage DCL o 5-10 % more thermally efficient
o Lesser water consumption
o Lesser production of CO2
o Lower capital cost (~ 30 %)
o Higher liquid yields
o Can process wide stock of coal
Relative economic data Hybrid Direct Indirect
Total capital 1.031 1 1.135
Coal cost 1 1.018 1.160
Total operating cost 1 1.057 1.137
Required selling price 1 1.008 1.093
Hybrid DCL/ICL diagram [9]
DCL Technologies
1900 1920 1940 1960 1980 2000 2020
Tech
nic
al L
evel
Year
Two stage
Single stage
Single stage, very high pressure
Bergius Process, IG Fabren Process
ERC, EDS, SRC I, SRC II, H-Coal,IGOR+, IHP, CZC, NEDOL
BCL, LSE, CSTL, CCLP, ITSL, etc.- Better catalyst- Milder reaction conditions- Hydrogenated solvent
• DCL processes aim to add
hydrogen to the organic structure
of coal
• DCL technologies
Single stage processes
Two stage processes
• Co-processing (petroleum derived
oil/ coal) technologies
CTL
GTL
Brief history of DCL technologies [10]
[10] Dong, Xiucheng, et al. "EROI Analysis for Direct Coal Liquefaction without and with CCS: The Case of the Shenhua DCL Project in China." Energies 8.2 (2015): 786-807.
Hydrogen/carbon ratio [4]
Single/Two stage processes
• Two stage DCL process give distillate products via
two reactors or reactor train in series
o Primary reactor: Solubilize coal
(with/without low activity disposable
catalyst)
o Second reactor: Heavy coal liquids are hydro
treated in presence of a high activity catalyst
to produce additional distillates
• Single stage DCL process give distillates products via
one primary reactors or train of reactor in series
Schematic diagram: H-Coal process [11] Schematic diagram: Catalytic two stage liquefaction process [11]
[10] Department of trade and industry, 1999. Technology status: coal liquefaction, London.
Single Stage Processes
No. Technology Company
1 IGOR (VCC)
Process
Ruhrkohle, Germany
Veba Oil, Germany
(Now: BP/KBR)
2 NEDOL Process NEDO, Japan
3 H-Coal Process HRI, USA
4 Exxon Donor
Solvent (EDS)
Exxon, USA
5 Solvent Refined
Coal (SRC-I and
SRC-II)
Gulf Oil, USA
6 Imhausen High-
Pressure Process
Germany
7 Conoco Zinc
Chloride Process
Conoco, USA
No. Technology Company
1 Catalytic Two-stage Liquefaction (DOE, HTI, USA)
2 Liquid Solvent Extraction (British Coal Corporation,
UK)
3 Brown Coal Liquefaction (NEDO, Japan)
4 Consol Synthetic Fuel (CSF) (Consolidation Coal Co,
USA)
5 Chevron Coal Liquefaction
(CCLP)
(Chevron, USA)
6 Kerr-McGee ITSL (Kerr-McGee, USA)
7 Mitsubishi Solvolysis (Mitsubishi Heavy
Industries, Japan)
8 Pyrosol (Saarbergwerke, Germany)
9 Amoco CC-TSL (Amoco, USA)
10 Supercritical Gas Extraction
(SGE)
(British Coal Corporation,
UK)
11 Integrated Two-stage liquefaction (Lummus, USA)
Technologies differ on the reaction scheme/ catalyst / hydrogenation solvent
NEDOL, IGOR+,CTSL, LSE are considered ready for commercialization by developers
Three phase (slurry/ebullated) bed reactors used in most process
DCL Technologies
Process Organization Capacity Year Operating parameters Remarks
NEDOL Process
New Energy
Development
Organization
(NEDO), Japan
150 TPD
(Kashima, Japan)
1996-
2000
(1) 435-446 deg. C, 150-200
bar
- Fe based catalyst
- Solvent hydrogenation
step at 320 deg. C
-
IGOR+ Ruhrkohle, Germany
Veba Oil, Germany
200 TPD
(Bottrop,
Germany)
1981-
1987 470 deg. C, 300 bar
- Fe based catalyst
- Feasibility studies for
CCRI (China) done for
5000 TPD
Catalytic two stage
liquefaction process
(CTSL)
Headwaters Inc.,
USA
200 TPD
(Cattlesburg,
Kentucky, USA)
1980-
1992
(1) 400 deg. C, 170 bar
(2) 440 deg. C, 170 bar
- Fe based catalyst in
first reactor
Liquid solvent
extraction process
(LSE)
British Coal
Corporation, UK
2.5 TPD
(Point of Ayr,
North Wales)
1973-
1995
(1) 410-440 deg. C, 10-20 bar
(2) 400-440 deg. C, 200 bar
- Detailed design of 65
TPD demo plant done
- Non catalytic process
Shenhua DCL Plant
Organization Shenhua Group Corporation
(Largest coal supplier in world)
Design basis 12000 MT/day (4.38 MMTPA)
~ 50000 barrels of oil per day
Project period 2004 (construction)- 2008 (Phase 1 commission)
Cost of project US $.1.52 billion (1997 projection) [11]
Revenues $ 125.1 million (six months operation in earnings
before taxes) (~ 22000 barrels of oil per day) [12]
Remarks - Based on catalytic two stage liquefaction (CTSL)
process (Headwaters Inc.) [13]
- Bench scale, pilot scale and demo scale plant
facilities developed
- In-house catalyst (Fe based) development
- Project management (ABB Lummus Global) [14]
Shenhua DCL Plant, Inner Mongolia [13]
[11] Comolli, Alfred G., et al. "The Shenhua coal direct liquefaction plant." Fuel Processing Technology 59.2 (1999): 207-215.
[12] http://www.reuters.com/article/2011/09/08/shenhua-oil-coal-idUSL3E7K732020110908
[13] https://www.netl.doe.gov/File%20Library/events/2012/co2%20capture%20meeting/Z-Ye-Shenhua-Group-Demonstration-Project.pdf (last accesed, 12th June, 2015)
[14] http://www.abb.com/cawp/seitp202/03ea4f3dc6ed15df85256c94006ae156.aspx (last accessed, 12th June, 2015)
Expected payback period: 3-4 years
YPC (Yulin) Co-processing Unit
Organization Yanchang petroleum company (Yulin, China)
Technologist Kellogg Brown & Root (KBR, USA) (VCC)
Design basis 450 KTA ( AR/FCC Slurry + Coal 60:40 ratio) [15]
Project period 2011 – 2015 (Commissioned Jan 2015)
Cost of project NA
Revenues NA
Remarks - Based on single stage liquefaction process (IGOR)
- China V specifications attained
Feed stock
Residue + Coal wt (%) 100
Conversion
Residue wt (%) 95
Coal wt (%) XX
Products
Naptha wt (%) XX
Diesel wt (%) XX
3500 bpd VCC reactor [15]
[15] https://www.usea.org/sites/default/files/event-/Wang%20Mingfeng-EN.pdf
DCL Economics
S. No. Source Equivalent crude required selling price Basis
1 Sun et al. (2005) $31.73 CTSL
2 NETL report (2007) $54-$60
3 Bloomberg (2007) $30 Shenhua Plant
4 Bartis et al. (2008) $62-$75
5 Winslow and Schemtz (2009) $38.06 CTSL
6 Hydrocarbons-technology (2010) $67-$82 Shenhua Plant
7 Reuters (2011) $60 Shenhua Plant
1. Sun, Qingyun, et al. "Comparative analysis of costs of alternative coal liquefaction processes." Energy & fuels 19.3 (2005): 1160-1164.
2. https://www.netl.doe.gov/File%20Library/newsroom/accomp_fy07.pdf , (Last accessed, 12th June 2015)
3. http://www.bloomberg.com/apps/news?pid=conewsstory&refer=conews&tkr=YZC:US&sid=a6VwxDlvG4nM (Last accessed: 8th June 2015)
4. Bartis, T.J., Camm, F., Ortiz, D.S., “Producing Liquid Fuels from Coal: Prospects and Policy Issues”, Rand Corporation, CA (2008).
5. Winslow, J, Schemtz, E, Direct Coal Liquefaction Overview (2009). http://bellona.org/filearchive/fil_Direct_Coal_Liquefaction_Overview.pdf (Last retrieved, 20 May, 2015)
6. http://www.hydrocarbons-technology.com/projects/shenhua/ (Last acceses, 24th May, 2015)
7. http://www.reuters.com/article/2011/09/08/shenhua-oil-coal-idUSL3E7K732020110908 (Last accessed: 19th May 2015).
Detailed feasibility studies of DCL (Indian application) is essential to understand its potential (economic
competitiveness) for production of chemical and fuels
Factors affecting the DCL yield
• Pretreatment of coal
• Preheat treatment
• Hydrothermal treatment
• Drying and oxidation
• Coal swelling in solvents
• Coal rank
• Solvents
• Hydrogen transfer mechanisms
• Catalyst mediated hydrogen transfer
• Catalysts in direct coal liquefaction
• Dissolution catalysts • (Fe-based catalysts, non Fe-based catalysts, Acid Catalyts)
• Catalyst for coal liquids upgrading
• Catalyst deactivation
Summary and Conclusion
• Various single and two stage processes have been developed for DCL. IGOR/VCC, NEDOL in
single stage and LSE, CTSL in two stage processes are available for licensing.
• Equivalent crude selling price for DCL to be profitable range between $30-$82. Detailed feasibility
studies of DCL is essential to understand its potential for production of chemical and fuels.
• Hybrid DCL/ICL plant are more cost competitive, feasibility studies of such plants need to be
looked into.
• Shenhua commercial DCL plant in China has shown acceptable liquid yields as per figures in open
literature. Plant at YPC, China based on VCC technology has shown excellent conversion for co-
processing residue and coal.
• Shenhua corporations have developed their commercial plants (scaling from lab, bench, pilot to
demo scale facilities) and in the process filed ~104 patents (37 granted) between 2004-2010.
• R&D facilities for DCL in India need to be developed for understanding the kinetics and
hydrodynamics of DCL technologies specific to coal of our interest.
• Consortium of Public-Private companies, CSIR, Academia labs need to formulated to develop
CTX technologies.
Path Forward Thank You &
Jai Hind !
The man who moves a mountain begins by carrying away small stones – Confucius