Impact of Development Technology on Indirect Liquefaction

Section 1 1273kb	List of Illustrations				ix
	List of Tables				xi
	1.0	Executive Summary			1
		1.1	Background		1
		1.2	SASOL Technology		3
		1.3	Advanced Gasifiers		7
		1.4	Advanced Synthesis		11
		1.5	R&D Recommendations		14
	2.0	Introduction			19
Section 2 690kb	3.0	Indirect Liquefaction: State of Technology SASOL I and II			23
		3.1	Introduction		23
		3.2	SASOL I		23
		3.3	SASOL II		33
Section 3 1222kb	4.0	SASOL-U.S. (Base Case)			37
		4.1	Introduction		37
		4.2	System Description		37
			4.2.1	Coal Preparation	39
			4.2.2	Preparation of Synthesis Gas	39
			4.2.3	Synthesis and Upgrading	44
			4.2.4	Auxiliary Processes	48
			4.2.5	Offsites	49
		4.3	Material and Energy Balance		50
		4.4	Capital and Operating Costs		56
Section 4 1060kb		4.5	Cost of Products Produced		60
		4.6	All-Liquid Output		65
		4.7	Conclusions		72
	5.0	Gasification for Indirect Liquefaction			75
		5.1	Introduction		75
		5.2	The BGC-Lurgi Gasifier		78
			5.2.1	Description	78
Section 5 1460kb			5.2.2	BGC/Lurgi Utilization in a SASOL Type Plant	83
		5.3	Texaco and Shell-Koppers Gasifiers		93
			5.3.1	Entrained Flow Gasifiers	93
			5.3.2	Operations Experience of Texaco and Shell-Koppers	95
			5.3.3	Interpreting Texaco and Shell-Koppers Published Data	96
			5.3.4	Critical Evaluation Factors for Texaco and Shell-Koppers	98
			5.3.5	Indirect Liquefaction with Texaco and Shell-Koppers Gasification	101
Section 6 1189kb			5.3.6	All-Liquid Products	109
			5.3.7	Cost Impact of Texaco and Shell-Koppers Gasification	112
			5.3.8	Environmental Considerations	116
			5.3.9	Conclusions	116
	6.0	Advanced Synthesis Processes			119
		6.1	Background and Fundamentals		119
		6.2	Conventional F-T Synthesis Reactors		121
		6.3	General Principles of the Liquid Phase Fischer-Tropsch Synthesis		121
			6.3.1	Fluid Dynamic Behavior in 3-Phase F-T Reactors	124
		6.4	Description of the F-T Slurry Reactor Units		127
			6.4.1	Catalysts	130
Section 7 1253kb			6.4.2	Operational Results	132
			6.4.3	Operating Differences	135
			6.4.4	Reactor Operability	138
		6.5	Product Distribution		139
			6.5.1	Chemical Class Analysis of F-T Products	141
		6.6	Process Potentials and Implications		143
	7.0	Advanced Gasifier - Synthesis Combination Process Evaluation			147
		7.1	Process Evaluation for Combination of a BGC Lurgi Gasifier with a Kolbel Synthesis Unit		147
Section 8 1288kb			7.1.1	BGC-Kolbel All-Liquids Case	156
			7.1.2	Impact of BGC-Kolbel on Construction Costs	159
			7.1.3	Impact of a BGC-Kolbel on Product Cost	164
		7.2	Process Evaluation for Combination of a Texaco Gasifier with a Kolbel Synthesis Unit		166
			7.2.1	Impact of Texaco-Kolbel on Construction Costs	169
			7.2.2	Impact of Texaco-Kolbel on Product Cost	171
		7.3	Process Evaluation for Combination of a Shell-Koppers Gasifier with a Kolbel Synthesis Unit		173
			7.3.1	Impact of Shell-Koppers/Kolbel on Construction Costs	177
			7.3.2	Impact of Shell-Koppers/Kolbel on Product Cost	178
Section 9 1322kb	8.0	Sensitivity Analyses			183
		8.1	Introduction		183
		8.2	The Sensitivity of Gasoline Prices to SNG Value		183
		8.3	Sensitivity of Entrained Flow Gasifier Performance to Excess Moisture in the Gasification Reaction		188
			8.3.1	Introduction	188
			8.3.2	Theoretical Consideration	188
			8.3.3	Results and Discussion	191
	9.0	Conclusion and Research and Development Recommendations			197
		9.1	Advanced Gasifiers		197
			9.1.1	Conclusion	197
			9.1.2	R&D Recommendations	198
		9.2	Synthesis Processes		201
Appendices 2047kb	Appendix A			BGC - Lurgi Performance with Western Coal	A-1
	Appendix B			Process Details for Combination of Advanced Gasifiers with Fischer-Tropsch Synthesis	B-1
	Appendix C			Plant Construction Cost Analysis	C-1
	Appendix D			Analysis of Product Costs	D-1
	References				E-1