BOOK 1

Book Cover

Transmittal Letter

i

Title Page

ii

Disclaimer

iii

Abstract

TFD-1

Table of Contents

ES-1

List of Tables, Figures and Drawings

E-1

Executive Summary

Experimental

Results and Discussion

RD-1

Conclusion

C-1

References

R-1

List of Acronyms

A-1

TASK 1

1.0

PROJECT PLAN

1-1

1.1

Project Management Plan

1-1

Work Breakdown Structure

1-1

Schedule and Milestones

1-1

Manning and Project Cash Flow Projections

1-1

DOE Review

1-1

Final Issue

1-2

CONCEPT DEFINITION, DEVELOPMENT, AND TECHNICAL ASSESSMENT

2-1

Overview

2-1

Overall Concept Definition and Development

2-2

Market

2-2

Technical

2-4

Economics/Optimizations

2-7

2.2

Alternative Site Design Options - Assessment and Selection

2-13

2.2.1

Introduction

2-13

2.2.2

Results and Discussion

2-15

2.2.3

Conclusions

2-94

2.3

Design Considerations for Advanced Subsystems

2-98

2.3.1

Fischer-Tropsch Synthesis

2-99

2.3.2

Gas Turbine

2-102

2.3.3

Fischer-Tropsch Product Upgrading

2-105

2-A

Attachment 2-A; F-T Product Upgrade Options Study

2A-1

2-B

Attachment 2-B; F-T Wastewater Treating/Utilization Study

2B-1

2-C

Attachment 2-C: F-T Feed Gas H₂:CO Optimum Ratio Study

2C-1

2-D

Attachment 2-D: F-T Feed Gas Optimum Percent CO₂ Study

2D-1

2-E

Attachment 2-E: Acid Gas Removal Selection Study

2E-1

2-F

Attachment 2-F: Evaluation of a Combined Primary and Tail Gas

2F-1

Treating Amine System

3.0

TECHNICAL ASSESSMENT OF SUBSYSTEMS

3-1

Overview

3-1

3.1

Basic Engineering Design Data

3-2

3.2

Air Separation Unit

3-3

3.2.1

Process Arrangement

3-3

3.2.2

Design Basis

3-3

3.3

Gasification

3-9

3.4

Acid Gas Removal

3-11

3.4.1

Stripping Nitrogen

3-11

3.5

Sulfur Recovery Unit/Tail Gas Treating Unit

3-13

3.6

Fischer-Tropsch Synthesis

3-15

3.6.1

Battery Limit Conditions

3-15

3.6.2

Syngas

3-16

3.6.3

Zinc Oxide Bed Design Basis

3-17

3.6.4

Fischer-Tropsch Synthesis Reactor Yields

3-17

3.6.5

Fischer-Tropsch Catalyst Properties

3-17

3.6.6

Catalyst Activation

3-17

3.7

Gas Turbine/Generator

3-18

3.8

Steam System

3-22

3.8.1

Steam System Header Pressure

3-22

3.8.2

Steam Condensate Systems

3-22

3.8.3

Water Systems

3-22

3.9

Fischer-Tropsch Product Upgrading

3-23

3.9.1

Scope of Work

3-23

3.9.2

Feedstock and Product Properties

3-24

3.9.3

Feed Rates and Process Yields

3-29

3.9.4

Hydrogen Make-Up Gas

3-29

3.9.5

Unit Design Basis

3-30

3.9.5.1

Service Factor

3-30

3.9.5.2

Design Considerations

3-30

3.9.6

Battery Limit Conditions

3-31

3.9.7

Unit Turn-Down

3-31

3.10

Off Site

3-31

3.10.1

Purge Nitrogen

3-31

3.10.2

Flare System

3-32

3.10.3

Secondary Fuel Specifications

3-32

3.10.4

Plant and Instrument Air

3-33

3.10.5

Electric Power

3-33

3.10.6

Cooling Water

3-34

3.11

Unit/Equipment Numbering

3-35

BOOK 2

TASK 4

4.0

SUBSYSTEM DESIGN SPECIFICATIONS

4-1

Overview

4-1

4.1

EECP Concept

4-2

4.1.1

Concept Process Description

4-2

4.1.2

Overall Block Flow Diagrams

4-4

4.1.3

Refinery Integration

4-9

4.1.4

Pinch Analysis

4-10

4.2

Process Description

4-10

4.2.1

Air Separation Unit

4-10

4.2.3

Acid Gas Removal Unit

4-14

4.2.4

Fischer-Tropsch Synthesis

4-15

4.2.6

Power Block

4-20

4.2.7

SRU/TGTU Process Description

4-23

4.2.8

Steam System Process Description

4-24

4.2.9

Off Site

4-25

4.3

Process Flow Sketches

4-26

4.3.1

Air Separation Unit

4-26

4.3.2

Gasification unit

4-26

4.3.3

Acid Gas Removal Unit

4-26

4.3.4

F-T Synthesis Unit

4-26

4.3.5

F-T Upgrading Unit

4-26

4.3.6

Power Block Unit

4-26

4.3.7

Sulfur Recovery Unit/Tail Gas Treating Unit

4-26

4.3.8

Steam System

4-27

4.3.9

Off Site

4-27

4.3.10

Power Distribution Network

4-27

4.4

Stream Summaries

4-50

4.4.1

ASU Stream Summaries

4-50

4.4.2

Gasification

4-51

4.4.3

Acid Gas Removal

4-54

4.4.4

F-T Synthesis

4-54

4.4.5

F-T Upgrading

4-65

4.4.6

Power Block

4-66

4.4.7

SRU/TGTU

4-68

4.5

Equipment List

4-70

4.5.1

ASU

4-70

4.5.2

Gasification

4-70

4.5.3

AGR

4-73

4.5.4

F-T Synthesis

4-74

4.5.5

F-T Product Upgrading Equipment List

4-75

4.5.6

Power Block

4-77

4.5.7

SRU/TGTU

4-77

4.5.8

Steam System Equipment List

4-78

4.5.9

Off Site Equipment List

4-79

4.6

Utility/Catalyst/Chemical Summary

4-80

4.6.1

ASU

4-83

4.6.2

Gasification

4-83

4.6.3

AGR

4-86

4.6.4

F-T Synthesis

4-87

4.6.5

F-T Upgrading

4-91

4.6.6

Power Block

4-92

4.6.7

SRU/TGTU

4-92

4.6.8

Steam System

4-95

4.6.9

Off Site

4-95

4.6.10

Overall Utility Plan

4-95

4.7

Subsystem Plot Plans

4-96

4.7.1

Overall Plot Plan

4-96

4.7.2

Air Separation Unit

4-96

4.7.3

Gasification

4-96

4.7.4

AGR

4-96

4.7.5

F-T Synthesis

4-96

4.7.6

F-T Upgrading

4-96

4.7.7

Power Block

4-96

4.7.8

SRU/TGTU/AGR

4-96

4.8

Technical Barriers

4-105

4.8.1

F-T Synthesis

4-105

4.8.1.1

Reactor Design Concerns

4-106

4.8.2

Power Block

4-112

4.8.3

F-T Product Upgrading

4-112

4.8.4

Technical Barriers - Acid Gas Removal (AGR)

4-118

4.8.5

Risk Assessment

4-119

TASK 4 - ATTACHMENTS

4-A

Attachment A: Pinch Analysis

4A-1

4-B

Attachment B; Facilities Reliability Study

4B-1

TASK 5

5.0

MARKET ASSESSMENT

5-1

Overview

5-1

5.1

Market Analysis of Products

5-1

5.1.1

Diesel

5-1

5.1.2

Finished Waxes

5-3

5.1.3

F-T Naphtha

5-6

5.1.4

Power

5-8

5.1.5

Sulfur

5-9

5.2

Market Assessment of Technology

5-11

5.2.1

Feedstock Availability

5-11

5.2.2

Environmental Factors

5-12

5.2.3

Technology Factors

5-12

5.3

Fischer-Tropsch Product Slate and Analysis

5-15

5.3.1

Diesel

5-15

5.3.2

Naphtha

5-16

5.3.3

Specialty Low and Medium Melt Waxes

5-18

5.3.4

Specialty High Melt Waxes

5-19

5.4

Full-Scale Commercial Plant

5-20

5.4.1

Price and Feedstock Availability

5-20

5.4.2

Proximity to Markets

5-21

5.4.3

Environmental Considerations

5-21

5.4.4

Infrastructure and Process Integration

5-22

TASK 6

6.0

PRELIMINARY SITE ANALYSIS

6-1

Overview

6-1

6.1

Site Selection Process

6-1

6.1.1

Synergy with Existing Infrastructure

6-1

6.1.2

Construction Requirements

6-1

6.1.3

Site Access

6-4

6.1.4

Environmental Requirements

6-4

6.1.5

Community

6-4

6.1.6

Geotechnical and Topographic Investigation

6-4

6.1.7

Economic Factors

6-4

6.1.8

Site Commitment to Project

6-4

6.2

Identify Specific Sites

6-4

6.3

Identify Additional Commitments/Parties for EECP Participation

6-7

7.0

ENVIRONMENTAL ASSESSMENT

7-1

Overview

7-1

7.1

Summary

7-1

7.1.1

NEPA Requirements

7-1

7.1.2

Air Permit Requirements

7-1

7.1.3

Wastewater Permit Requirements

7-2

7.1.4

Solid Waste Permit Requirements

7-2

7.2

Emission Levels

7-2

7.3

Adaptability for CO₂ Sequestration

7-6

7.3.1

Introduction

7-6

7.3.2

Sequestration Options

7-7

7.3.3

CO₂ Sequestration

7-9

7.4

Water Use and Remediation

7-11

7.5

Solid Waste Byproducts

7-11

7.6

NEPA Requirements

7-12

7.7

Permitting Requirements

7-13

7.7.1

Air

7-13

7.7.2

Wastewater

7-16

7.7.3

Solid Waste

7-17

7.8

Integration of Existing Facilities with New Treatment Facilities

7-17

7.8.1

Wastewater Treatment

7-17

7.8.2

Solid Waste Disposal

7-18

TASK 8

8.0

ECONOMIC ASSESSMENT

8-1

Overview

8-1

8.1

Feedstock Cost and Product Price Evaluation

8-2

8.1.1

Economic Parameters

8-4

8.1.2

Economic Sensitivity Analysis

8-4

8.1.3

Taxes, Royalties, and Inflation

8-4

8.2

Cost Estimates

8-5

8.2.1

Capital Estimates Methodology

8-5

8.2.2

Operating Costs

8-11

8.2.3

Refinery Site Maintenance

8-12

8.3

Role of Government Incentives for Commercial Viability of EECP

8-13

8.3.1

Tax Relief

8-13

8.3.2

Energy Policy Act (EPACT) Alternate Fuels

8-14

8.3.3

Long-Term F-T Liquids Purchase Agreement

8-14

8.3.4

Cost Sharing

8-14