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Coal to Ammonia - Industrial Cost Analysis
Coal to Ammonia Presented at the Iowa Energy Center Meeting Ammonia-The Key to a Hydrogen Economy By Mark Ibsen Rentech Development Corporation October 13, 2005 1 Presentation • Rentech Introduction • Producing Ammonia from Coal/Petroleum Coke Gasification • What is Fischer-Tropsch? • East Dubuque, Illinois • Environmental Benefits • Food Security and Energy Security-Fuel for First Responders, and the US Military 2 Rentech – A Brief History • A 23 year old Denver, Colorado Energy Technology Company – Traded as “RTK” on the American Stock Exchange • Engaged in the Fischer-Tropsch Development – Coal-to-Liquids (FT/CTL) business – NG-to Liquidss (FT/GTL) business • Licenses its patented and proprietary technology – 20 U.S. and 1 foreign process and materials patents • Rentech Development Corporation – Subsidiary of Rentech Inc. – Responsible for ownership and development – Gas-to-Liquid and Coal-to-Liquid Projects 3 Coal to Ammonia a New Concept? • Not really but for the United States, yes • Today, in the US there are two projects operating – North Dakota Gasification – Coffeyville Resources • World Wide a number of facilities – China (2500 small local facilitates) – Portugal (uses refinery bottoms) – Germany, Czech, India, Brazil all have ammonia plants from coal • Key driver, high NG costs 4 Coal Gasification & Ammonia Coal - 2500 stpd Coal Handling Coal to Ammonia Syngas Water H2/CO CO2 BFW Slurry Gasifier SynGas Cooling/ Cleaning Process Boiler O2 Export Slag ASU Acid Gas Removal Sour Shift Steam Guard Beds H2S Hot BFW Claus Unit O2 Process Condensate Water Recycle Air Sulphur Loading N2 PSA Offgas PSA HRSG Existing CO2 Removal HTS Rctrs LTS Rctrs H2 Purge to Vent Hot BFW NH3 Loop ~ LP MP HP Steam Turbine NH3 - 1500 stpd Power - 10-20 MW Parasitic Power 5 Color Legends: Gasification Misc Ammonia Indicates units that may or may not be needed. North Dakota Coal Gasification 6 7 Syngas Derived Products Ammonia UAN Urea Hydrogen + Carbon Monoxide (H2+CO) Ultra-Clean Fischer Tropsch Transportation Fuels Synhytech – Pueblo, Colorado, 1992 Syngas Electricity (IGCC) Methanol/DME/Propylene Synthetic Natural Gas Hydrogen Carbon Dioxide 8 Gasification Ideal for Syngas Derived Products Ammonia UAN Urea Hydrogen + Carbon Monoxide (H2+CO) Ultra-Clean Fischer Tropsch Transportation Fuels Synhytech – Pueblo, Colorado, 1992 Coal Coal Coal Gasification Gasification Syngas Electricity (IGCC) Methanol/DME/Propylene Synthetic Natural Gas Hydrogen Carbon Dioxide 9 10 Illinois Project 11 First Mover Opportunity: Producing Fertilizer, Ultra-Clean Fuels & Electricity From Coal Deploy gasification to save and create jobs while increasing energy and food security through the production of ammonia and FT liquids using Illinois coal as the plant feedstock. 12 Fischer-Tropsch (FT) Synthesis • Invented by German chemists Franz Fischer and Hans Tropsch in 1923. Used by Germany during WWII to produce 600,000 bbl/year of fuels from coal and coke • Commercially proven worldwide 197,000 BPD Current Production • Since 1950s ~ currently 160,000 bbl/day from coal by Sasol • Since 1993 ~ 23,000/bbl/day from natural gas by Petro SA using Sasol technology • Since 1995 ~ 15,000/bbl/day from natural gas by Shell in Malaysia 13 4 FT is Commercially Proven Worldwide SASOL (S. Africa) 45 years commercial – 160,000 b/d+ – Feedstock Coal SASOL’S SOUTH AFRICAN FACILITY MossGas (S. Africa) 11 years commercial – 22,500 b/d+ – Feedstock Natural Gas Shell (Malaysia) 9 years commercial – 15,000 b/d+ – Feedstock Natural Gas 14 6 Why Rentech? Catalyst Flexibility CTL RENTECH SASOL GTL CONOCO EXXON SHELL CHEVRON/SASOL World’s Largest FT Slurry Reactor – Synhytech, 1992 15 7 Rentech CTL with Fertilizer Air Power ASU Vent to Vent or Sequestration N2 O2 CO2 BFW Gasifiers Waste Heat Boiler or Quench Ammonia Plant Syngas Conditioning & Purification Fertilizer Sales Syngas Exp. Slag Coal Prep. Pet-coke or Coal Process Condensate Recycle Exp. Sulphur Water for Slurry or Heat for Drying Steam H2 Rem. Steam BFW Steam BFW Off-gas to Fuel Gas Turbine Tail-Gas to Fuel HRSG FT Synthesis ~ H2 for FT Product Upgrade Crudes Off-gas to Fuel ~ Steam Turbine Parasitic Power Product Upgrade FT DIESEL NAPHTHA Power Sales 16 East Dubuque Plant 17 4,000,000 2,000,000 5,000,000 10.00 4,500,000 9.00 ammonia production 3,500,000 7.00 3,000,000 6.00 2,500,000 5.00 natural gas price 4.00 1,500,000 IL #6 Coal Price 500,000 - 18 $ /M M B tu 1,000,000 1 9 9 6 -0 1 1 9 9 6 -0 2 1 9 9 6 -0 3 1 9 9 6 -0 4 1 9 9 7 -0 1 1 9 9 7 -0 2 1 9 9 7 -0 3 1 9 9 7 -0 4 1 9 9 8 -0 1 1 9 9 8 -0 2 1 9 9 8 -0 3 1 9 9 8 -0 4 1 9 9 9 -0 1 1 9 9 9 -0 2 1 9 9 9 -0 3 1 9 9 9 -0 4 2 0 0 0 -0 1 2 0 0 0 -0 2 2 0 0 0 -0 3 2 0 0 0 -0 4 2 0 0 1 -0 1 2 0 0 1 -0 2 2 0 0 1 -0 3 2 0 0 1 -0 4 2 0 0 2 -0 1 2 0 0 2 -0 2 2 0 0 2 -0 3 2 0 0 2 -0 4 2 0 0 3 -0 1 2 0 0 3 -0 2 2 0 0 3 -0 3 2 0 0 3 -0 4 2 0 0 4 -0 1 2 0 0 4 -0 2 2 0 0 4 -0 3 2 0 0 4 -0 4 m a te ria l to n s U.S. Ammonia Production vs. Natural Gas & Coal Price 8.00 3.00 2.00 1.00 0.00 Source: Ammonia production, U.S. Department of Commerce; natural gas price - average spot-deliverd-to-pipeline price, Natural Gas Week. The RC Plant Post Conversion to Coal Feedstock Integrated Manufacturing Process CONVERSION Coal Internal Power Steam 5200 tpd Water Air Air Separation Plant Coal Gasification - Syngas Production Power Plant PRODUCTS Export Power Tail Gas FT Product Upgrade FT Synthesis ULS FT Diesel Naphtha Sulfur N2 EXISTING PLANT NH3 Production H2 Ammonia Synthesis Carbon Dioxide Plant CO2 NH3 NH3 Sales Urea Air Nitric Acid Plant CO2 Sales Nitric Acid Urea Plant Granular Urea Sales Urea Solutions Sales Nitric Acid Sales Ammonium Nitrate/ Blending Plant UAN Sales 19 Coal Gasification Yielding Rentech FT Fuels & Power & Ammonia Coal - 5200 stpd E. Dubuque AgriEnergy (Simple Recycle FT Process, 1 Gasifier) Coal Handling Water CO2 BFW Slurry Gasifier Syngas SynGas Cooling/ Cleaning Process Boiler O2 AGR Steam H2 S Claus Unit Hot BFW Export Slag Guard Beds (Rectisol) ASU Air H2/CO - 0.68 Air Process Condensate Water Recycle Sulphur Loading N2 H2 to Prod Upgrade Steam BFW H2 Purge to Fuel 450 MMbtu/h PSA Existing CO2 Removal New LTS Rctrs New HTS Rctrs FT Synthesis Purge to Vent FT Water & Ox H2 Crudes NH3 Loop H2 Gasification/FT Steam Product Upgrade Naphtha Turbine ~ LP MP HP 1.1 MMscfd H2 DIESEL Storage/Loading ~ NAPHTHA Storage/Loading Diesel - 4700 bpd Steam Turbine Naphtha- 900 bpd NH3 - 920 stpd Air Parasitic Power Power - 40 MW Color Legends: 20 Gasification FT Unit Coal NH3 Misc Indicates units that may or may not be needed. East Dubuque Plant Polygeneration Model Estimated Inputs and Production • Coal feedstock 5,200 TPD Products (45% Increase in Tons Shipped) • Ammonia production 920 TPD • FT Fuels (80% diesel) 5,600 BPD • 248,000 gallons per day • Electricity production • Electricity export 160 MW(e) 40+ MW(e) 21 Benefits of Polygeneration from Coal • Standard pulverized coal power plant: 35% • Combined cycle natural gas power plant: 45% • Coal gasification to produce fertilizer, ultraclean fuels, & electricity: 50+% 22 Coal Cleaner? Plant Regulated Emissions With a Production increase of 45% in Tons Shipped 3500 3000 >30% Decrease In Criteria Pollutant Emissions Tons/Yr 2500 2000 Existing Tons/yr Converted Ton/yr 1500 1000 500 0 Existing Tons/yr Converted Ton/yr Total Emissions of: PM10 VO CO NOx SO2 23 Ultra-Clean FT Diesel Fuel from Coal • Biodegradable • < 1ppm Sulfur • High Cetane •Stable long storage life Emissions Relative to a Typical Diesel Fuel (Percentage) 0 FT Diesel -5 -9 -10 -15 -20 -25 -28 -30 -33 -35 -40 -45 Conventional Diesel -42 Hydrocarbon Carbon Monoxide N0x Particulates Source: An average of several government funded studies by NREL & SwRI FTD from coal is an “alternative fuel” under 1992 Energy Policy Act (EPACT) 24 OSD Clean Fuel Initiative Vision: DoD catalyze the commercial industry to produce clean fuels for the military from secure domestic resources using environmentally sensitive processes that create jobs and wealth in the United States Dr. Theodore K. Barna Assistant Deputy Under Secretary of Defense Advanced Systems and Concepts Pentagon 3D833 703-695-9873 Ted.Barna@OSD.mil 25 DoD Impact Secure and reliable sources of energy Currently dependent on foreign oil jet fuels, 73.5% Becoming dependent on foreign refined fuels ground fuels, 15.1% marine fuels, 7.9% Supply chain vulnerability Dependent on mega refineries- Gulf Coast Military Demand Approx 4% of US Consumption Natural disasters or Terrorist threats Ref: DESC Help Book Need for cleaner fuels Fuel Costs Potential limits on deployments Possible conflict with EU rules M illio n s o f D o lla rs DoD exempt from some EPA regulations 6000 5000 4000 3000 2000 1000 0 Army Navy Air Force Marines 97 98 99 0 1 2 3 4 5 Fiscal Year 26 Total Energy Development (TED) Use all secure indigenous sources of energy Coal, shale oil, petroleum coke, renewables Dispersed production facilities Minimize government funding—focus on qualification and certification Make a better fuel from coal and petroleum coke (Fischer Tropsch fuels) and oil shale Low (or no) sulfur, cleaner burning, bio-degradable, low (or no) aromatics, reduced particulate emissions Blends near term, neat fuel future goal Stable fuel for long term secure storage of refined fuel for emergency use Use Environmentally sensitive processes to produce fuel - Clean Coal Technologies such as the Fischer-Tropsch process, Mahogany Shale Research Project - CO2 sequestration for enhanced oil recovery (EOR) 27 Reduced Exhaust Emissions with FT Fuel Relative to Low-Sulfur Diesel Fuel 0% HC CO -10% % Reductions -20% CO2 -4% -17% NOx PM -13% -15% -30% -40% -45% -50% -60% -62% -70% -72% -60% Transient Hot Start testNRTC cycles Hot Start NRTC* -52% -55% -80% *Non-Road Transient Composite FT fuel burns more completely and emissions are significantly cleaner than EPA certified low-sulfur diesel fuel tested in 6.5L diesel engine. Over 50% reduction in particulate emissions in transient mode. 28 Reduced Particulate Emissions with FT Fuel Relative to JP-8 0% % Change in Particle Number Density y 12.5 -12% 25 37.5 50 62.5 75 87.5 100 -13% -25% -25% -30% -33% -41% -50% -50% -51% -57% -61% -75% -68% Cruise -75% -78% Idle -86% -92% -100% 12.5 25 37.5 50 62.5 75 87.5 -96% 100 % Volume of FT Fuel in JP-8 Even moderate fractions of FT fuel blended in JP-8 significantly reduce exhaust emission particulates in T63 turbine engine testing. 96% reduction* in particulate emissions at idle conditions. 29 * Note: Results are highly dependent on engine model/year and composition of baseline fuel. Summary • Coal to Ammonia is not a new concept • The Poly-generation concept improves plant efficiency and diversifies product mix • Conversion of exiting facilities improves project schedule, reduces cost and utilizes existing plants • The Ammonia and Fuels provide for Food and Fuels security for the United States • Both Ammonia and FT liquids are a steps toward the Hydrogen Economy • Polygeneration provides diversity and stability to ammonia plants during market swings. 30 Questions 31
