© SRI Consulting, IHS Inc. PEP Report 279

Abstract

Process Economics Program Report 279

COAL TO OLEFINS

(October 2011)

As demand for oil and natural gas outpaces discoveries of new reserves, coal will regain its importance as a source of energy and as a chemical feedstock. At current production levels, proven coal reserves are estimated to last over a century, with recoverable reserves in around 70 countries. In contrast, proven oil and gas reserves are equivalent to around 50 years at current production levels while two-thirds of these reserves are concentrated in the Middle East and Russia. The challenge is how to harness this enormous amount of coal resource, which constitutes about 30% of world energy demand, economically without adverse impact on the environment.

Ethylene and propylene are by far the two largest-volume chemicals produced by the petrochemicals industry. In 2010, about 127 million metric tons of ethylene and 82 million metric tons of propylene were produced worldwide. The majority of light olefins are produced by the petrochemicals industry either from pyrolysis (steam cracking) of NGLs and naphtha or from fluid catalytic cracking (FCC) of naphtha. The recent dramatic increase in oil prices is reviving a strong interest in the production of light olefins from nonpetroleum sources such as coal.

In this report, we evaluate chemical applications of coal: the partial oxidation of coal to produce synthesis gas (syngas), followed by synthesis of methanol from syngas, and the catalytic conversion of methanol to light olefins. We develop and present conceptual designs and preliminary economics for the integration of GE Energy gasification technology with the UOP/Hydro methanol to olefins (MTO) process and the Shell Coal Gasification Company (SCGP) technology with the Lurgi (now Air Liquide) MTP methanol-to-propylene process.

Process Economics Program

A private report by the

Report No. 279

COAL TO OLEFINS

by Jamie Lacson

October 2011

Menlo Park, California 94025

SRIC agrees to assign professionally qualified personnel to the preparation of the

Process Economics Program’s reports and will perform the work in conformance with generally

accepted professional standards. No other warranties expressed or implied are made. Because

the reports are of an advisory nature, neither SRIC nor its employees will assume any liability for

the special or consequential damages arising from the Client’s use of the results contained in the

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harmless from any liability to any third party resulting directly or indirectly from the Client’s use of

the reports or other deliverables produced by SRIC pursuant to this agreement.

For detailed marketing data and information, the reader is referred to one of the SRI

Consulting programs specializing in marketing research. THE CHEMICAL ECONOMICS

HANDBOOK Program covers most major chemicals and chemical products produced in the

United States and the WORLD PETROCHEMICALS PROGRAM covers major hydrocarbons and

their derivatives on a worldwide basis. In addition the SRIC DIRECTORY OF CHEMICAL

PRODUCERS services provide detailed lists of chemical producers by company, product, and

plant for the United States, Western Europe, Canada, and East Asia, South America and Mexico.

CONTENTS

© SRI Consulting, IHS Inc. iii PEP Report 279

GLOSSARY ........................................................................................................................ XVI

1 INTRODUCTION ........................................................................................................ 1-1

CAPITAL COST ESTIMATE METHODOLOGIES...................................................... 1-3

PROCESS SIMULATION METHODOLOGIES .......................................................... 1-3

2 SUMMARY ................................................................................................................. 2-1

INDUSTRY STATUS .................................................................................................. 2-5

COAL TO OLEFINS ................................................................................................... 2-6

OUTLOOK .................................................................................................................. 2-8

3 INDUSTRY STATUS .................................................................................................. 3-1

COAL GASIFICATION ............................................................................................... 3-1

Gasification Capacity .................................................................................................. 3-3

Drivers for Coal Gasification ....................................................................................... 3-8

Energy Prices ........................................................................................................ 3-9

Energy Security ..................................................................................................... 3-10

Environmental Policy ............................................................................................. 3-10

Coal to Chemicals Outlook ......................................................................................... 3-11

OLEFINS INDUSTRY ................................................................................................. 3-11

Ethylene Industry ........................................................................................................ 3-12

Ethylene Feedstock Considerations ...................................................................... 3-12

Ethylene End Uses ................................................................................................ 3-13

Propylene Industry ...................................................................................................... 3-14

Propylene Sources ..................................................................................................... 3-15

Steam Cracking ..................................................................................................... 3-15

Fluid Catalytic Cracking ......................................................................................... 3-16

Propane Dehydrogenation ..................................................................................... 3-16

Olefin Metathesis ................................................................................................... 3-17

Propylene End Uses ................................................................................................... 3-17

PRICES ...................................................................................................................... 3-20

CHEMICALS FROM COAL ........................................................................................ 3-25

4 TECHNOLOGY REVIEW ........................................................................................... 4-1

CONTENTS (Continued)

© SRI Consulting, IHS Inc. iv PEP Report 279

COAL GASIFCATION ................................................................................................ 4-1

Composition ................................................................................................................ 4-1

Caloric Value .............................................................................................................. 4-2

Moisture ...................................................................................................................... 4-2

Ash .............................................................................................................................. 4-2

Feedstock Preparation ............................................................................................... 4-4

Gasification Chemistry ................................................................................................ 4-4

Stoichiometric and Thermal Constraints .................................................................... 4-5

Kinetics of Coal Gasification ....................................................................................... 4-6

Gasifier Reactor Design ............................................................................................. 4-7

Comparison of Gasification Technologies .................................................................. 4-9

Entrained Flow Gasifiers ............................................................................................ 4-10

Air Separation ............................................................................................................. 4-12

NOx Abatement ..................................................................................................... 4-12

Gas Cleanup System .................................................................................................. 4-13

Particulate Removal .............................................................................................. 4-13

Syngas Scrubber/Sour Water Stripper .................................................................. 4-13

Wet Scrubbing .................................................................................................. 4-13

Sour Water Stripper .......................................................................................... 4-14

Water Gas Shift ..................................................................................................... 4-14

High Temperature Shift ..................................................................................... 4-14

Low Temperature Shift ..................................................................................... 4-16

Sour Gas Shift ................................................................................................... 4-16

Carbonyl Sulfide Hydrolysis ................................................................................... 4-16

Acid Gas Removal ................................................................................................. 4-17

Chemical Solvents ............................................................................................ 4-18

Physical Solvents .............................................................................................. 4-18

Mixed Amine/Physical Solvent .......................................................................... 4-21

Sulfur Recovery ..................................................................................................... 4-22

Claus Process ................................................................................................... 4-22

SCOT Process .................................................................................................. 4-24

Mercury Removal .................................................................................................. 4-25

Activated Carbon .............................................................................................. 4-27

Zeolites ............................................................................................................. 4-27

Other Methods .................................................................................................. 4-28

CONTENTS (Continued)

© SRI Consulting, IHS Inc. v PEP Report 279

METHANOL SYNTHESIS .......................................................................................... 4-28

METHANOL TO OLEFINS ......................................................................................... 4-29

UOP/Hydro MTO Process .......................................................................................... 4-29

Commercial Developments ................................................................................... 4-30

MTO Catalyst Development .................................................................................. 4-31

MTO Reactor Design Consideration ..................................................................... 4-32

UOP/Hydro MTO Reaction Conditions ............................................................. 4-32

MTO Reaction Mechanism ............................................................................... 4-33

MTO Process Chemistry and Kinetics ................................................................... 4-33

Kinetic Models Based on ZSM-5 ...................................................................... 4-33

Kinetic Models Based on SAPO-34 .................................................................. 4-33

Product Recovery .................................................................................................. 4-34

Lurgi MTP Methanol to Propylene Process ................................................................ 4-34

ZSM-5 Catalyst ................................................................................................. 4-35

MTP Reactor Design and Operation ..................................................................... 4-36

Product Recovery .................................................................................................. 4-37

JGC/Mitsubishi DTP® Process .................................................................................. 4-37

DICP Methanol to Olefins (DMTO) ............................................................................. 4-38

5 COAL TO SYNTHESIS GAS ..................................................................................... 5-1

STEAM REFORMING AND PARTIAL OXIDATION .................................................. 5-1

Synthesis Gas (H2:CO = 2:1) from Natural Gas by Steam Reforming ....................... 5-1

Synthesis Gas (H2:CO = 2:1) from Natural Gas by Partial Oxidation ........................ 5-4

Synthesis Gas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation ............. 5-6

Gasification Technology for Synthesis Gas ................................................................ 5-8

System Design Basis and Assumptions ..................................................................... 5-11

Plant Configuration ................................................................................................ 5-13

Oxygen Supply .................................................................................................. 5-14

Feedstock Preparation ...................................................................................... 5-14

Syngas Cooling and Heat Recovery ................................................................. 5-14

Particulate Removal .......................................................................................... 5-14

Water Gas Shift/Carbonyl Hydrolysis ............................................................... 5-15

Mercury Removal .............................................................................................. 5-15

Acid Gas Removal ............................................................................................ 5-15

Sulfur Recovery and Tail Gas Treating ............................................................. 5-15

SYNTHESIS GAS BY THE GE ENERGY GASIFICATION ....................................... 5-16

CONTENTS (Continued)

© SRI Consulting, IHS Inc. vi PEP Report 279

Process Description .................................................................................................... 5-17

Section 100—Air Separation Unit .......................................................................... 5-17

Section 200—Gasification ..................................................................................... 5-18

Quench Mode ................................................................................................... 5-18

Radiant Mode .................................................................................................... 5-19

Slag Handling .................................................................................................... 5-19

Section 300—Gas Cleanup ................................................................................... 5-19

Scrubber Water ................................................................................................. 5-19

Shift Conversion ................................................................................................ 5-19

Gas Cooling ...................................................................................................... 5-20

Mercury Removal .............................................................................................. 5-20

Acid Gases Removal ........................................................................................ 5-20

Sulfur Plant and Tail Gas Treating .................................................................... 5-21

GE Quench Mode ....................................................................................................... 5-22

Cost Estimates ........................................................................................................... 5-27

Capital Costs ......................................................................................................... 5-27

Production Costs ................................................................................................... 5-30

GE Radiant Cooler Mode ........................................................................................... 5-33

Cost Estimates ........................................................................................................... 5-39

Capital Costs ......................................................................................................... 5-39

Production Costs ................................................................................................... 5-42

SYNTHESIS GAS BY THE SHELL COAL GASIFICATION PROCESS .................... 5-45

Process Description .................................................................................................... 5-46

Section 100—Air Separation and Oxygen Compression ...................................... 5-46

Section 200—Coal Gasification ............................................................................. 5-46

Convective Mode .............................................................................................. 5-47

Quench Mode ................................................................................................... 5-47

Section 300—Gas Cleanup ................................................................................... 5-48

Scrubber Water ................................................................................................. 5-48

Shift Conversion ................................................................................................ 5-48

Gas Cooling ...................................................................................................... 5-49

Mercury Removal .............................................................................................. 5-49

Acid Gases Removal ........................................................................................ 5-49

Sulfur Plant and Tail Gas Treating .................................................................... 5-49

SCGP Syngas Cooler Mode ....................................................................................... 5-50

Cost Estimates ........................................................................................................... 5-56

CONTENTS (Continued)

© SRI Consulting, IHS Inc. vii PEP Report 279

Capital Costs ......................................................................................................... 5-56

Production Cost ..................................................................................................... 5-59

SCGP Quench Mode .................................................................................................. 5-62

Cost Estimates ........................................................................................................... 5-68

Capital Costs ......................................................................................................... 5-68

Production Cost ..................................................................................................... 5-71

PROCESS DISCUSSION ........................................................................................... 5-75

Simulation Results ...................................................................................................... 5-76

Heat Recovery and Shift Steam Requirement ........................................................... 5-77

Effect of Coal Cost and Capital Investment Cost on Syngas Product Value ............. 5-79

Material Improvement ................................................................................................. 5-79

Gas Cleaning Process Improvement .......................................................................... 5-80

6 SYNTHESIS GAS TO METHANOL ........................................................................... 6-1

METHANOL SYNGAS SPECIFICATIONS ................................................................ 6-2

MAIN REACTIONS ..................................................................................................... 6-4

PROCESS DESCRIPTION ........................................................................................ 6-6

Methanol by the ICI Two-Stage Reforming LCM Process ......................................... 6-6

COST ESTIMATES .................................................................................................... 6-7

7 COAL TO OLEFINS ................................................................................................... 7-1

PROCESS DESCRIPTION ........................................................................................ 7-4

Section 100—Air Separation Unit ............................................................................... 7-4

Section 200—Gasification .......................................................................................... 7-4

Slag Handling ........................................................................................................ 7-5

Section 300—Gas Cleanup ........................................................................................ 7-6

Scrubber Water ..................................................................................................... 7-6

Shift Conversion .................................................................................................... 7-6

Gas Cooling ........................................................................................................... 7-6

Mercury Removal .................................................................................................. 7-6

Acid Gases Removal ............................................................................................. 7-6

Sulfur Plant and Tail Gas Treating ........................................................................ 7-7

Section 400—Methanol Synthesis ............................................................................. 7-8

Section 500—Methanol Conversion ........................................................................... 7-9

CONTENTS (Concluded)

© SRI Consulting, IHS Inc. viii PEP Report 279

Section 600—Product Separation .............................................................................. 7-10

PROCESS DISCUSSION ........................................................................................... 7-27

COST ESTIMATES .................................................................................................... 7-29

Capital Costs .............................................................................................................. 7-29

Production Costs ........................................................................................................ 7-32

8 COAL TO PROPYLENE ............................................................................................ 8-1

PROCESS DESCRIPTION ........................................................................................ 8-5

Section 100—Air Separation and Oxygen Compression ........................................... 8-5

Section 200—Coal Gasification .................................................................................. 8-5

Section 300—Gas Cleanup ........................................................................................ 8-6

Scrubber Water ..................................................................................................... 8-6

Shift Conversion .................................................................................................... 8-7

Gas Cooling ........................................................................................................... 8-7

Mercury Removal .................................................................................................. 8-7

Acid Gases Removal ............................................................................................. 8-8

Sulfur Plant and Tail Gas Treating ........................................................................ 8-8

Section 400—Methanol Synthesis ............................................................................. 8-9

Section 500—Methanol Conversion ........................................................................... 8-10

Section 600—Propylene Recovery ............................................................................ 8-11

PROCESS DISCUSSION ........................................................................................... 8-29

COST ESTIMATES .................................................................................................... 8-30

Capital Costs .............................................................................................................. 8-30

Production Costs ........................................................................................................ 8-34

APPENDIX A PATENT SUMMARY TABLES ................................................................ A-1

APPENDIX B DESIGN AND COST BASES................................................................... B-1

APPENDIX C CITED REFERENCES ............................................................................. C-1

APPENDIX D PATENT REFERENCES BY COMPANY ................................................ D-1

APPENDIX E PROCESS FLOW DIAGRAMS ................................................................ E-1

FIGURES

© SRI Consulting, IHS Inc. ix PEP Report 279

1.1 Products from Coal Gasification ............................................................................ 1-1

2.1 Coal to Methanol ................................................................................................... 2-1

2.2 Syngas from Coal Gasification Investment Cost ................................................... 2-4

2.3 Syngas Product Value by Gasifier Type ................................................................ 2-5

2.4 Olefins Product Value ............................................................................................ 2-8

2.5 Coal to Olefins Process Economics and Coal Price.............................................. 2-9

3.1 Coal Reserves by Region ...................................................................................... 3-2

3.2 Coal Gasification Syngas Capacity by Region—2011 .......................................... 3-3

3.3 World Gasification Capacity .................................................................................. 3-4

3.4 Coal Gasification Cumulative Capacity by Product ............................................... 3-5

3.5 Coal Gasification Capacity by Feedstock—2011 .................................................. 3-6

3.6 Coal Gasification Capacity by Product—2011 ...................................................... 3-6

3.7 Total Coal Gasifiers from GE and SCGP .............................................................. 3-7

3.8 Energy Prices ........................................................................................................ 3-10

3.9 Olefins Value Chain ............................................................................................... 3-12

3.10 Ethylene End Uses—2011 .................................................................................... 3-14

3.11 Percent of World Propylene Consumption by Grade—2011 ................................. 3-17

3.12 World Refinery-Grade Propylene Consumption—2011 ........................................ 3-18

3.13 World Chemical-Grade Propylene Consumption—2011 ....................................... 3-18

3.14 World Polymer-Grade Propylene Consumption—2011 ........................................ 3-19

3.15 Steam Coal Prices ................................................................................................. 3-20

3.16 Methanol Production by Source ............................................................................ 3-21

3.17 Historical USGC Methanol Prices.......................................................................... 3-22

3.18 Ethylene and Propylene Prices ............................................................................. 3-23

3.19 Propylene/Ethylene Price Ratio ............................................................................. 3-24

3.20 Projected Propylene/EthyleneSupply and Demand Ratio ..................................... 3-25

4.1 Coal to Olefins Processing Steps .......................................................................... 4-1

4.2 Entrained Flow Gasifier ......................................................................................... 4-11

4.3 Water Gas Shift with a Saturate/Desaturate Configuration Process Flow

Schematic .............................................................................................................. 4-15

4.4 COS Hydrolysis ..................................................................................................... 4-17

4.5 Basic Rectisol Configuration .................................................................................. 4-20

FIGURES (Continued)

© SRI Consulting, IHS Inc. x PEP Report 279

4.6 Basic Selexol Process Scheme ............................................................................. 4-21

4.7 Three-Stage Claus Schematic ............................................................................... 4-23

4.8 Typical Scot Tail Gas Treatment Plant .................................................................. 4-24

5.1 Syngas from Coal by the GE Quench Gasifier

Process Flow Diagram .......................................................................................... E-3

5.2 Syngas from Coal by the GE Radiant Gasifier

Process Flow Diagram .......................................................................................... E-5

5.3 Syngas from Coal by the Shell Convective Gasifier

Process Flow Diagram .......................................................................................... E-7

5.4 Syngas from Coal by the Shell Quench Gasifier

Process Flow Diagram .......................................................................................... E-9

5.5 Effect of Gasifier Temperature on Coal and Oxygen Feed Rate .......................... 5-9

5.6 Effect of Pressure on Methane Content ................................................................ 5-10

5.7 Raw Syngas Composition ..................................................................................... 5-11

5.8 GE Radiant and Quench Gasifier .......................................................................... 5-16

5.9 GE Direct Quench Process Scheme ..................................................................... 5-22

5.10 Syngas from Coal by the GE Quench Gasifier

Effect of Capacity on Investment ........................................................................... 5-30

5.11 Syngas from Coal by the GE Quench Gasifier

Effect of Operating Rate on Product Value ........................................................... 5-33

5.12 GE Gasification in Radiant-Convective Cooler Mode............................................ 5-34

5.13 Syngas from Coal by the GE Radiant Gasifier

Effect of Capacity on Investment ........................................................................... 5-42

5.14 Syngas from Coal by the GE Radiant Gasifier

Effect of Operating Rate on Product Value ........................................................... 5-45

5.15 Shell Gasifier ......................................................................................................... 5-51

5.16 Syngas from Coal by the Shell Convective Gasifier

Effect of Capacity on Investment ........................................................................... 5-59

5.17 Syngas from Coal by the Shell Convective Gasifier

Effect of Operating Rate on Investment ................................................................ 5-62

5.18 SCGP with Water Quench ..................................................................................... 5-63

5.19 Syngas from Coal by the Shell Quench Gasifier

Effect of Capacity on Investment ........................................................................... 5-71

5.20 Syngas from Coal by the Shell Quench Gasifier

Effect of Operating Rate on Product Value ........................................................... 5-75

5.21 Syngas from Coal Gasification Investment Cost ................................................... 5-76

FIGURES (Continued)

© SRI Consulting, IHS Inc. xi PEP Report 279

5.22 Coal and Oxygen Flow .......................................................................................... 5-77

5.23 Raw Syngas Composition ..................................................................................... 5-78

5.24 Syngas Product Value by Gasifier Type ................................................................ 5-79

6.1 Syngas Value Chain .............................................................................................. 6-1

6.2 Methanol Total Fixed Capital Cost by Technology ................................................ 6-9

6.3 Methanol Battery Limits Investment Breakdown by Technology ........................... 6-10

6.4 North America Coal and Natural Gas Prices ......................................................... 6-11

7.1 Coal ReceIving and Storage

Process Flow Diagram) ......................................................................................... E-11

7.2 Coal to Olefins Air Separation Unit and Coal Gasification

Process Flow Diagram .......................................................................................... E-13

7.3 Coal to Olefins Gas Cleanup (1 of 2)

Process Flow Diagram .......................................................................................... E-15

7.4 Coal to Olefins Gas Cleanup (2 of 2)

Process Flow Diagram .......................................................................................... E-17

7.5 Coal to Olefins Methanol Synthesis

Process Flow Diagram .......................................................................................... E-19

7.6 MTO Methanol Conversion

Process Flow Diagram .......................................................................................... E-21

7.7 MTO Product Separation

Process Flow Diagram .......................................................................................... E-23

7.8 Coal to Ethylene Simplified Block Flow Diagram .................................................. 7-2

7.9 Coal to Olefins

Effect of Capapcity on Investment ......................................................................... 7-32

7.10 Coal to Olefins

Effect of Operating Rate on Product Value ........................................................... 7-36

7.11 Ethylene and Propylene Prices ............................................................................. 7-37

7.12 Coal to Olefins

Process Economics and Coal Price ...................................................................... 7-38

8.1 Coal to Propylene Air Separation Unit and Coal Gasification

Process Flow Diagram .......................................................................................... E-25

8.2 Coal to Propylene Gas Cleanup (1 of 2)

Process Flow Diagram .......................................................................................... E-27

8.3 Coal to Propylene Gas cleanup (2 of 2)

Process Flow Diagram .......................................................................................... E-29

8.4 Coal to Propylene Methanol Synthesis

Process Flow Diagram .......................................................................................... E-31

FIGURES (Concluded)

© SRI Consulting, IHS Inc. xii PEP Report 279

8.5 MTP Methanol Conversion

Process Flow Diagram .......................................................................................... E-33

8.6 MTP Product Recovery

Process Flow Diagram .......................................................................................... E-35

8.7 Coal to Olefins Simplified Block Flow Diagram ..................................................... 8-2

8.8 Coal to Propylene

Effect of Capacity on Investment ........................................................................... 8-35

8.9 Coal to Propylene

Effect of Operating Rate on Product Value ........................................................... 8-38

8.10 Coal to Propylene

Process Economics and Coal Price ...................................................................... 8-39

TABLES

© SRI Consulting, IHS Inc. xiii PEP Report 279

2.1 Syngas from Coal Gasification

Production Costs ................................................................................................... 2-3

2.2 Coal to Olefins Process Economics ...................................................................... 2-7

3.1 Coal Gasification from GE and SCGP Technology ............................................... 3-8

3.2 Chemical Production from Coal Gasification ......................................................... 3-26

3.3 World Coal-to-Propylene Plants ............................................................................ 3-28

4.1 Typical Compositions of Coal from Different Sources ........................................... 4-3

4.2 Chemical Reactions ............................................................................................... 4-5

4.3 Typical Raw Syngas Composition ......................................................................... 4-6

4.4 Advantages and Limitations of Gasifiers ............................................................... 4-8

4.5 Gasification Technologies ..................................................................................... 4-9

4.6 Salient Characteristics of Major Gasification Technologies .................................. 4-11

4.7 Chemical Solvents ................................................................................................. 4-18

4.8 Physical Solvents .................................................................................................. 4-19

4.9 Product Gas Purity ................................................................................................ 4-22

4.10 Sulfur Removal Reactions ..................................................................................... 4-23

4.11 Mercury Contents of Coal ...................................................................................... 4-26

4.12 Typical Metal Contaminants in Us Coals ............................................................... 4-26

5.1 Synthesis Gas (H2:CO = 2:1) from Natural Gas by Steam Reforming

with H2 Skimming

Production Costs ................................................................................................... 5-3

5.2 Synthesis Gas (H2:CO = 2:1) from Natural Gas by Partial Oxidation

Production Costs ................................................................................................... 5-5

5.3 Synthesis Gas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation

Production Costs ................................................................................................... 5-7

5.4 Gasifier Fuel .......................................................................................................... 5-12

5.5 Gasifier Configurations .......................................................................................... 5-13

5.6 Design Specifications for Gas Cleanup Systems .................................................. 5-14

5.7 Major Process Blocks ............................................................................................ 5-17

5.8 Syngas from Coal by the GE Quench Gasifier

Stream Flows ......................................................................................................... 5-23

5.9 Syngas from Coal by the GE Quench Gasifier

Utilities Summary ................................................................................................... 5-26

5.10 Syngas from Coal by the GE Quench Gasifier

Total Capital Investment ........................................................................................ 5-28

TABLES (Continued)

© SRI Consulting, IHS Inc. xiv PEP Report 279

5.11 Syngas from Coal by the GE Quench Gasifier

Capital Investment by Section ............................................................................... 5-29

5.12 Syngas from Coal by the GE Quench Gasifier

Production Costs ................................................................................................... 5-31

5.13 Syngas from Coal by the GE Radiant Gasifier

Stream Flows ......................................................................................................... 5-35

5.14 Syngas from Coal by the GE Radiant Gasifier

Utilities Summary ................................................................................................... 5-38

5.15 Syngas from Coal by the GE Radiant Gasifier

Total Capital Investment ........................................................................................ 5-40

5.16 Syngas from Coal by the GE Radiant Gasifier

Capital Investment by Section ............................................................................... 5-41

5.17 Syngas from Coal by the GE Radiant Gasifier

Production Costs ................................................................................................... 5-43

5.18 Syngas from Coal by the Shell Convective Gasifier

Stream Flows ......................................................................................................... 5-52

5.19 Syngas from Coal by the Shell Syngas Cooler Gasifier

Utilities Summary ................................................................................................... 5-55

5.20 Syngas from Coal by the Shell Convective Gasifier

Total Capital Investment ........................................................................................ 5-57

5.21 Syngas from Coal by the Shell Convective Gasifier

Capital Investment by Section ............................................................................... 5-58

5.22 Syngas from Coal by the Shell Convective Gasifier

Production Costs ................................................................................................... 5-60

5.23 Syngas from Coal by the Shell Quench Gasifier

Stream Flows ......................................................................................................... 5-64

5.24 Syngas from Coal by the Shell Quench Gasifier

Utilities Summary ................................................................................................... 5-67

5.25 Syngas from Coal by the Shell Quench Gasifier

Total Capital Investment ........................................................................................ 5-69

5.26 Syngas from Coal by the Shell Quench Gasifier

Capital Investment by Section ............................................................................... 5-70

5.27 Syngas from Coal by the Shell Quench Gasifier

Production Costs ................................................................................................... 5-73

6.1 Syngas for Methanol Synthesis ............................................................................. 6-3

6.2 Syngas Impurities and Tolerances in Methanol Synthesis .................................... 6-4

6.3 Methanol Process Licensors ................................................................................. 6-5

6.4 Composition of Methanol Synthesis Catalysts ...................................................... 6-5

TABLES (Concluded)

© SRI Consulting, IHS Inc. xv PEP Report 279

6.5 Methanol Synthesis

Production Costs ................................................................................................... 6-8

7.1 Coal to Ethylene

System Design Bases and Assumptions ............................................................... 7-3

7.2 Major Process Blocks ............................................................................................ 7-4

7.3 Coal to Ethylene Process

Stream Flows ......................................................................................................... 7-12

7.4 Coal to Ethylene Process

Major Equipment ................................................................................................... 7-21

7.5 Coal to Ethylene Process

Utilities Summary ................................................................................................... 7-26

7.6 UOP/Hydro Process MTO Conversion Zone ......................................................... 7-28

7.7 Main Waste Effluent Streams ................................................................................ 7-28

7.8 Coal to Ethylene Process

Total Capital Investment ........................................................................................ 7-30

7.9 Coal to Ethylene Process

Capital Investment by Section ............................................................................... 7-31

7.10 Coal to Olefins Process

Production Costs ................................................................................................... 7-34

8.1 Coal to Propylene

Design Bases and Assumptions ............................................................................ 8-4

8.2 Major Process Blocks ............................................................................................ 8-5

8.3 Coal to Propylene Process

Stream Flows ......................................................................................................... 8-13

8.4 Coal to Propylene Process

Major Equipment ................................................................................................... 8-23

8.5 Coal to Propylene Process

Utilities Summary ................................................................................................... 8-28

8.6 Main Waste Effluent Streams ................................................................................ 8-30

8.7 Coal to Propylene Process

Total Capital Investment ........................................................................................ 8-32

8.8 Coal to Propylene Process

Capital Investment by Section ............................................................................... 8-33

8.9 Coal to Propylene Process

Production Costs ................................................................................................... 8-36