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IHS Chemical Process Economics Program Report 148C Synthesis Gas Production from Coal and Petroleum Coke Gasification By Jamie Lacson
IHS Chemical
Process Economics Program
Report 148C
Synthesis Gas Production from Coal and
Petroleum Coke Gasification
By Jamie Lacson
IHS Chemical Process Economics Program | Report 148C
September 2013 © 2013 IHS
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IHS Chemical Process Economics Program | Report 148C
September 2013 © 2013 IHS
PEP Report 148C
Synthesis Gas Production from Coal and Petroleum Coke Gasification
By Jamie Lacson
September 2013
Abstract
In regions with limited access to low-cost natural gas, coal gasification is becoming an important route to
the manufacture of synthesis gas. Coal gasification technologies have advanced significantly in recent
years, in terms of feed handling capacity and efficiency, particularly with the development of entrained-
flow gasifiers. Coal gasification has been based, for the most part, on bituminous coals. Gasification of
lower rank coals has been limited. However, the nature of the coal market and the abundance of lower grade
coals naturally foster an interest in the use of lower grade coals such as subbituminous coal and lignite. In
addition, refineries around the world are producing a large stockpile of petroleum coke that can be gasified
to produce synthesis gas. Petroleum coke, limited by proximity to refineries, is an opportunity feedstock,
which can sometimes be a lower cost fuel.
This report will present syngas processes and economics modules for the utilization of the following solid
feedstocks:
Bituminous coal
Subbituminous coal
Lignite
Petroleum coke
The solid feedstocks are converted to synthesis gas via oxygen-blown entrained-flow gasifiers. The
gasification technologies covered in this report include the following:
GE Energy quench gasifier
GE Energy radiant gasifier
Shell Coal Gasification Process (SCGP) gasifier
E-Gas™ gasifier (CB&I, formerly ConocoPhillips)
Siemens Fuel Gasifier (SFG)
The report is accompanied by a Microsoft Excel workbook (PEPSyngas™) containing syngas modules
from gasification of coal and petroleum coke (PEP Report 148C) and natural gas reforming (PEP Report
148B) available to PEP clients. The workbook module contains a user interface (written by the author in
Visual Basic for Applications 7.0). The output in each module will consist of stream flow, mass, energy
balance, production costs, and capital costs for any combination of feedstock and gasification technology
to produce synthesis gas of essentially any H2/CO molar ratio at the capacity and operating conditions
specified. This modular approach allows for immediate implementation of the syngas economics output of
any module for downstream product needs, which can be used for assessing the competitiveness of new
projects. The report also includes background technical information on the various feedstocks, gasifier
technologies, and end-use applications of synthesis gas.
IHS Chemical Process Economics Program | Report 148C
Contents
September 2013 iii © 2013 IHS
Glossary ..................................................................................................................................................... xxi
1. Introduction........................................................................................................................................... 1-1
Capital cost estimate methodologies..................................................................................................... 1-2
Process simulation methodologies ........................................................................................................ 1-2
2. Summary ............................................................................................................................................... 2-1
Background ........................................................................................................................................... 2-1
Coal market ........................................................................................................................................... 2-2
Features of syngas supply and use ........................................................................................................ 2-3
Supply aspects .................................................................................................................................... 2-4
Demand aspects .................................................................................................................................. 2-4
PEPSyngas™ features ........................................................................................................................ 2-5
Gasifiers .............................................................................................................................................. 2-5
ROI and profitability........................................................................................................................... 2-5
Design bases and costs........................................................................................................................ 2-6
Synthesis gas process economics .......................................................................................................... 2-6
Gasification of coal by rank ................................................................................................................ 2-21
3. Industry status ....................................................................................................................................... 3-1
Energy prices ........................................................................................................................................ 3-1
Coal supply ........................................................................................................................................... 3-4
Petroleum coke ..................................................................................................................................... 3-7
Gasification capacity ............................................................................................................................ 3-9
Gasification feedstock ........................................................................................................................ 3-10
4. Technology review ............................................................................................................................... 4-1
Feedstock .............................................................................................................................................. 4-1
Anthracite ........................................................................................................................................... 4-2
Bituminous coal .................................................................................................................................. 4-2
Subbituminous coal ............................................................................................................................ 4-3
Lignite ................................................................................................................................................. 4-3
Caloric value ....................................................................................................................................... 4-5
Grindability ......................................................................................................................................... 4-6
Moisture .............................................................................................................................................. 4-6
Ash ...................................................................................................................................................... 4-6
Volatile matter .................................................................................................................................... 4-8
Fixed carbon ....................................................................................................................................... 4-8
Feedstock preparation ........................................................................................................................... 4-9
Coal water slurry................................................................................................................................. 4-9
Dry feeding ......................................................................................................................................... 4-9
Gasification ........................................................................................................................................... 4-9
Gasification chemistry ...................................................................................................................... 4-10
Stoichiometric and thermal constraints............................................................................................. 4-11
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Contents (continued)
September 2013 iv © 2013 IHS
Kinetics of gasification ..................................................................................................................... 4-12
Gasifier reactor design ...................................................................................................................... 4-13
Comparison of gasification technologies .......................................................................................... 4-14
Entrained-flow gasifiers ...................................................................................................................... 4-15
GE Energy ........................................................................................................................................ 4-18
Shell Coal Gasification Process (SCGP) .......................................................................................... 4-21
E-Gas™ gasifier (CB&I, formerly ConocoPhillips) ........................................................................ 4-22
Siemens/SFG gasifier ....................................................................................................................... 4-24
Selective comparison of gasification technologies ............................................................................. 4-26
Air separation ................................................................................................................................... 4-27
NOx abatement ............................................................................................................................. 4-27
Gas clean-up system ........................................................................................................................... 4-28
Particulate removal ........................................................................................................................... 4-28
Syngas scrubber/sour water stripper ................................................................................................. 4-28
Wet scrubbing ............................................................................................................................... 4-28
Sour water stripper ........................................................................................................................ 4-29
Water gas shift .................................................................................................................................. 4-29
High temperature shift .................................................................................................................. 4-30
Low temperature shift ................................................................................................................... 4-31
Sour gas shift ................................................................................................................................. 4-31
Carbonyl sulfide hydrolysis .............................................................................................................. 4-31
Acid gas removal .............................................................................................................................. 4-32
Chemical solvents ......................................................................................................................... 4-33
Physical solvents ........................................................................................................................... 4-34
Sulfur recovery ................................................................................................................................. 4-35
Claus process................................................................................................................................. 4-36
SCOT process ............................................................................................................................... 4-37
Mercury removal .............................................................................................................................. 4-39
5. Synthesis gas for chemicals .................................................................................................................. 5-1
Ammonia .............................................................................................................................................. 5-3
Methanol ............................................................................................................................................... 5-4
Hydrogen .............................................................................................................................................. 5-5
Carbon monoxide .................................................................................................................................. 5-5
Oxo-alcohols ......................................................................................................................................... 5-5
Synthetic fuels ...................................................................................................................................... 5-6
6. PEPSyngas™ module ........................................................................................................................... 6-1
Features and limitations ........................................................................................................................ 6-1
Features of PEPSyngas™ ................................................................................................................... 6-2
ROI and profitability........................................................................................................................... 6-2
Definitions ............................................................................................................................................ 6-3
IHS Chemical Process Economics Program | Report 148C
Contents (continued)
September 2013 v © 2013 IHS
Design bases ......................................................................................................................................... 6-4
Gasification and reforming selection (step 1) ....................................................................................... 6-5
Gasification (step 2) .............................................................................................................................. 6-6
Gasifier technology ............................................................................................................................. 6-6
Gasifier feedstock ............................................................................................................................. 6-10
Operating conditions ......................................................................................................................... 6-12
Operating temperature ................................................................................................................... 6-12
Operating pressure ........................................................................................................................ 6-14
Natural gas reforming (step 2) ............................................................................................................ 6-14
Reforming technology ...................................................................................................................... 6-14
Syngas end product ........................................................................................................................... 6-15
Synthesis gas composition (step 3) ..................................................................................................... 6-15
H2/CO molar ratio ............................................................................................................................. 6-16
CO2 composition ............................................................................................................................... 6-17
Syngas production rate ..................................................................................................................... 6-18
Regional selections (optional step 4) .................................................................................................. 6-18
Economics (optional step 5) ............................................................................................................... 6-19
Results ................................................................................................................................................ 6-20
Stream table ...................................................................................................................................... 6-25
Utilities summary.............................................................................................................................. 6-34
Capital cost ....................................................................................................................................... 6-34
Variable cost ..................................................................................................................................... 6-34
Production cost ................................................................................................................................. 6-35
7. Synthesis gas for methanol from bituminous coal via gasification ...................................................... 7-1
Methanol syngas specifications ............................................................................................................ 7-1
Main reactions ...................................................................................................................................... 7-2
Plant configuration ................................................................................................................................ 7-3
Oxygen supply .................................................................................................................................... 7-4
Feedstock preparation ......................................................................................................................... 7-4
Syngas cooling and heat recovery ...................................................................................................... 7-4
Particulate removal ............................................................................................................................. 7-4
Water gas shift/carbonyl hydrolysis ................................................................................................... 7-4
Mercury removal ................................................................................................................................ 7-5
Acid gas removal ................................................................................................................................ 7-5
Sulfur recovery and tail gas treating ................................................................................................... 7-5
Synthesis gas (SR = 2.036) by GE quench gasification........................................................................ 7-7
Process description ............................................................................................................................. 7-7
Section 100—air separation ............................................................................................................ 7-7
Section 200—gasification ............................................................................................................... 7-8
Section 300—gas clean-up .............................................................................................................. 7-8
IHS Chemical Process Economics Program | Report 148C
Contents (continued)
September 2013 vi © 2013 IHS
Water gas shift ............................................................................................................................. 7-9
Gas cooling .................................................................................................................................. 7-9
Mercury removal ......................................................................................................................... 7-9
Acid gas removal ......................................................................................................................... 7-9
Sulfur plant ................................................................................................................................ 7-10
Investment costs ............................................................................................................................... 7-12
Production costs ................................................................................................................................ 7-14
Synthesis gas (SR = 2.036) by GE radiant gasification ...................................................................... 7-17
Process description ........................................................................................................................... 7-17
Section 100—air separation .......................................................................................................... 7-17
Section 200—gasification ............................................................................................................. 7-17
Section 300—gas clean-up ............................................................................................................ 7-18
Water gas shift ........................................................................................................................... 7-18
Gas cooling ................................................................................................................................ 7-18
Mercury removal ....................................................................................................................... 7-19
Acid gas removal ....................................................................................................................... 7-19
Sulfur plant ................................................................................................................................ 7-19
Investment costs ............................................................................................................................... 7-21
Production costs ................................................................................................................................ 7-23
Synthesis gas (SR = 2.036) by Shell gasification ............................................................................... 7-26
Process description ........................................................................................................................... 7-26
Section 100—air separation .......................................................................................................... 7-26
Section 200—gasification ............................................................................................................. 7-27
Section 300—gas clean-up ............................................................................................................ 7-28
Water gas shift ........................................................................................................................... 7-28
Gas cooling ................................................................................................................................ 7-28
Mercury removal ....................................................................................................................... 7-28
Acid gas removal ....................................................................................................................... 7-29
Sulfur plant ................................................................................................................................ 7-29
Investment costs ............................................................................................................................... 7-31
Production costs ................................................................................................................................ 7-33
Synthesis gas (SR = 2.036) by E-Gas™ gasification ......................................................................... 7-36
Process description ........................................................................................................................... 7-36
Section 100—air separation .......................................................................................................... 7-36
Section 200—gasification ............................................................................................................. 7-36
Section 300—gas clean-up ............................................................................................................ 7-37
Water gas shift ........................................................................................................................... 7-37
Gas cooling ................................................................................................................................ 7-38
Mercury removal ....................................................................................................................... 7-38
Acid gas removal ....................................................................................................................... 7-38
IHS Chemical Process Economics Program | Report 148C
Contents (continued)
September 2013 vii © 2013 IHS
Sulfur plant ................................................................................................................................ 7-39
Investment costs ............................................................................................................................... 7-41
Production costs ................................................................................................................................ 7-43
Synthesis gas (SR = 2.036) by Siemens SFG gasification.................................................................. 7-46
Process description ........................................................................................................................... 7-46
Section 100—air separation .......................................................................................................... 7-46
Section 200—gasification ............................................................................................................. 7-46
Section 300—gas clean-up ............................................................................................................ 7-47
Water gas shift ........................................................................................................................... 7-47
Gas cooling ................................................................................................................................ 7-48
Mercury removal ....................................................................................................................... 7-48
Acid gas removal ....................................................................................................................... 7-48
Sulfur plant ................................................................................................................................ 7-49
Investment costs ............................................................................................................................... 7-50
Production costs ................................................................................................................................ 7-52
Process discussion .............................................................................................................................. 7-55
GE Energy ........................................................................................................................................ 7-55
Shell .................................................................................................................................................. 7-55
E-Gas ................................................................................................................................................ 7-56
Siemens ............................................................................................................................................. 7-56
By-products ...................................................................................................................................... 7-56
Heat recovery and shift steam requirement ...................................................................................... 7-57
8. Synthesis gas for hydrogen from subbituminous coal via gasification ................................................. 8-1
Synthesis gas (96% CO shift) by GE quench gasification .................................................................... 8-3
Process description ............................................................................................................................. 8-3
Section 100—air separation ............................................................................................................ 8-3
Section 200—gasification ............................................................................................................... 8-3
Section 300—gas clean-up .............................................................................................................. 8-4
Water gas shift ............................................................................................................................. 8-5
Gas cooling .................................................................................................................................. 8-5
Mercury removal ......................................................................................................................... 8-5
Acid gas removal ......................................................................................................................... 8-5
Sulfur plant .................................................................................................................................. 8-6
Investment costs ................................................................................................................................. 8-8
Production costs ................................................................................................................................ 8-10
Synthesis gas (96% CO shift) by GE radiant gasification .................................................................. 8-13
Process description ........................................................................................................................... 8-13
Section 100—air separation .......................................................................................................... 8-13
Section 200—gasification ............................................................................................................. 8-13
Section 300—gas clean-up ............................................................................................................ 8-14
IHS Chemical Process Economics Program | Report 148C
Contents (continued)
September 2013 viii © 2013 IHS
Water gas shift ........................................................................................................................... 8-14
Gas cooling ................................................................................................................................ 8-14
Mercury removal ....................................................................................................................... 8-15
Acid gas removal ....................................................................................................................... 8-15
Sulfur plant ................................................................................................................................ 8-16
Investment costs ............................................................................................................................... 8-17
Production costs ................................................................................................................................ 8-19
Synthesis gas (96% CO shift) by Shell gasification ........................................................................... 8-22
Process description ........................................................................................................................... 8-22
Section 100—air separation .......................................................................................................... 8-22
Section 200—gasification ............................................................................................................. 8-22
Section 300—gas clean-up ............................................................................................................ 8-23
Water gas shift ........................................................................................................................... 8-24
Gas cooling ................................................................................................................................ 8-24
Mercury removal ....................................................................................................................... 8-24
Acid gas removal ....................................................................................................................... 8-24
Sulfur plant ................................................................................................................................ 8-25
Investment costs ............................................................................................................................... 8-27
Production costs ................................................................................................................................ 8-29
Synthesis gas (96% CO shift) by E-Gas gasification.......................................................................... 8-32
Process description ........................................................................................................................... 8-32
Section 100—air separation .......................................................................................................... 8-32
Section 200—gasification ............................................................................................................. 8-32
Section 300—gas clean-up ............................................................................................................ 8-33
Water gas shift ........................................................................................................................... 8-33
Gas cooling ................................................................................................................................ 8-34
Mercury removal ....................................................................................................................... 8-34
Acid gas removal ....................................................................................................................... 8-34
Sulfur plant ................................................................................................................................ 8-35
Investment costs ............................................................................................................................... 8-36
Production costs ................................................................................................................................ 8-38
Synthesis gas (96% CO shift) by Siemens SFG gasification .............................................................. 8-41
Process description ........................................................................................................................... 8-41
Section 100—air separation .......................................................................................................... 8-41
Section 200—gasification ............................................................................................................. 8-41
Section 300—gas clean-up ............................................................................................................ 8-42
Water gas shift ........................................................................................................................... 8-42
Gas cooling ................................................................................................................................ 8-43
Mercury removal ....................................................................................................................... 8-43
Acid gas removal ....................................................................................................................... 8-43
IHS Chemical Process Economics Program | Report 148C
Contents (continued)
September 2013 ix © 2013 IHS
Sulfur plant ................................................................................................................................ 8-44
Investment costs ............................................................................................................................... 8-45
Production costs ................................................................................................................................ 8-47
Process discussion .............................................................................................................................. 8-50
9. Synthesis gas for Fischer-Tropsch synthesis from petroleum coke via gasification ............................ 9-1
Synthesis gas (H2/CO = 2.1) by GE quench gasification ...................................................................... 9-3
Process description ............................................................................................................................. 9-3
Section 200—gasification ............................................................................................................... 9-4
Section 300—gas clean-up .............................................................................................................. 9-4
Water gas shift ............................................................................................................................. 9-5
Gas cooling .................................................................................................................................. 9-5
Mercury removal ......................................................................................................................... 9-5
Acid gas removal ......................................................................................................................... 9-5
Sulfur plant .................................................................................................................................. 9-6
Investment costs ................................................................................................................................. 9-8
Production costs ................................................................................................................................ 9-10
Synthesis gas (H2/CO = 2.1) by GE radiant gasification .................................................................... 9-13
Process description ........................................................................................................................... 9-13
Section 100—air separation .......................................................................................................... 9-13
Section 200—gasification ............................................................................................................. 9-13
Section 300—gas clean-up ............................................................................................................ 9-14
Water gas shift ........................................................................................................................... 9-14
Gas cooling ................................................................................................................................ 9-14
Mercury removal ....................................................................................................................... 9-15
Acid gas removal ....................................................................................................................... 9-15
Sulfur plant ................................................................................................................................ 9-15
Investment costs ............................................................................................................................... 9-17
Production costs ................................................................................................................................ 9-19
Synthesis gas (H2/CO = 2.1) by Shell gasification ............................................................................. 9-22
Process description ........................................................................................................................... 9-22
Section 100—air separation .......................................................................................................... 9-22
Section 200—gasification ............................................................................................................. 9-22
Section 300—gas clean-up ............................................................................................................ 9-23
Water gas shift ........................................................................................................................... 9-24
Gas cooling ................................................................................................................................ 9-24
Mercury removal ....................................................................................................................... 9-24
Acid gas removal ....................................................................................................................... 9-24
Sulfur plant ................................................................................................................................ 9-25
Investment costs ............................................................................................................................... 9-27
Production costs ................................................................................................................................ 9-29
IHS Chemical Process Economics Program | Report 148C
Contents (continued)
September 2013 x © 2013 IHS
Synthesis gas (H2/CO = 2.1) by E-Gas™ gasification........................................................................ 9-32
Process description ........................................................................................................................... 9-32
Section 100—air separation .......................................................................................................... 9-32
Section 200—gasification ............................................................................................................. 9-32
Section 300—gas clean-up ............................................................................................................ 9-33
Water gas shift ........................................................................................................................... 9-33
Gas cooling ................................................................................................................................ 9-34
Mercury removal ....................................................................................................................... 9-34
Acid gas removal ....................................................................................................................... 9-34
Sulfur plant ................................................................................................................................ 9-35
Investment costs ............................................................................................................................... 9-36
Production costs ................................................................................................................................ 9-38
Synthesis gas (H2/CO = 2.1) by Siemens SFG gasification ................................................................ 9-41
Process description ........................................................................................................................... 9-41
Section 100—air separation .......................................................................................................... 9-41
Section 200—gasification ............................................................................................................. 9-41
Section 300—gas clean-up ............................................................................................................ 9-42
Water gas shift ........................................................................................................................... 9-42
Gas cooling ................................................................................................................................ 9-43
Mercury removal ....................................................................................................................... 9-43
Acid gas removal ....................................................................................................................... 9-43
Sulfur plant ................................................................................................................................ 9-44
Investment costs ............................................................................................................................... 9-45
Production costs ................................................................................................................................ 9-47
Process discussion .............................................................................................................................. 9-50
H2/CO ratio and CO content ............................................................................................................. 9-50
Methane content................................................................................................................................ 9-50
10. Coal rank and gasification .................................................................................................................. 10-1
Coal properties and gasifiers .............................................................................................................. 10-2
Calorific value .................................................................................................................................. 10-2
Moisture ............................................................................................................................................ 10-2
Ash .................................................................................................................................................... 10-3
Grindability ....................................................................................................................................... 10-3
Results ................................................................................................................................................ 10-3
GE coal characteristics ..................................................................................................................... 10-4
Shell coal characteristics ................................................................................................................... 10-5
E-Gas coal characteristics ................................................................................................................. 10-6
Siemens coal characteristics ............................................................................................................. 10-7
Lower rank coal ................................................................................................................................ 10-24
Appendix A: Feedstock analysis ............................................................................................................... A-1
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Contents (concluded)
September 2013 xi © 2013 IHS
Appendix B: Patent summary tables ......................................................................................................... B-1
Appendix C: Design and cost bases .......................................................................................................... C-1
Appendix D: Cited references ................................................................................................................... D-1
Appendix E: Process flow diagrams ......................................................................................................... E-1
IHS Chemical Process Economics Program | Report 148C
Figures
September 2013 xii © 2013 IHS
2.1 Syngas capacity and fossil fuel prices ............................................................................................. 2-2
2.2 PEP reports and reviews on synthesis gas sources and applications ............................................... 2-4
2.3 GE gasifier raw syngas production and H2/CO molar ratio........................................................... 2-22
2.4 Shell gasifier raw syngas production and H2/CO molar ratio ........................................................ 2-22
2.5 E-Gas gasifier raw syngas production and H2/CO molar ratio ...................................................... 2-23
2.6 Siemens gasifier raw syngas production and H2/CO molar ratio .................................................. 2-23
3.1 Primary energy sources 2013 .......................................................................................................... 3-1
3.2 US energy prices .............................................................................................................................. 3-2
3.3 US coal prices .................................................................................................................................. 3-3
3.4 US primary energy production ........................................................................................................ 3-3
3.5 World coal reserves ......................................................................................................................... 3-4
3.6 Coal production by region ............................................................................................................... 3-5
3.7 World coal production ..................................................................................................................... 3-6
3.8 Refinery operations block diagram.................................................................................................. 3-8
3.9 World gasification capacity by feed type ...................................................................................... 3-11
3.10 World gasification capacity by product type ................................................................................. 3-11
3.11 Selected gasifier capacity .............................................................................................................. 3-17
3.12 Selected gasifier installations by region ........................................................................................ 3-17
3.13 Selected gasifier capacity by region .............................................................................................. 3-18
3.14 Gasifier technology by feedstock group ........................................................................................ 3-18
3.15 Gasifier technology by product type ............................................................................................. 3-19
4.1 Synthesis gas production ................................................................................................................. 4-1
4.2 Coalification process ....................................................................................................................... 4-1
4.3 Conversion in years ......................................................................................................................... 4-2
4.4 Carbon and moisture content of coal ............................................................................................... 4-4
4.5 Approximate analysis ...................................................................................................................... 4-5
4.6 Gross calorific value limits .............................................................................................................. 4-5
4.7 Gasifier flow .................................................................................................................................. 4-15
4.8 Gasifier feed .................................................................................................................................. 4-16
4.9 Entrained-flow gasifier schematic ................................................................................................. 4-16
4.10 GE quench gasifier ........................................................................................................................ 4-19
4.11 GE radiant gasifier ......................................................................................................................... 4-20
4.12 Shell gasifier with syngas cooler ................................................................................................... 4-21
4.13 E-Gas gasifier ................................................................................................................................ 4-23
4.14 Siemens SFG gasifier .................................................................................................................... 4-25
4.15 Water gas shift with saturate/desaturate configuration .................................................................. 4-30
4.16 COS hydrolysis .............................................................................................................................. 4-32
4.17 Selexol process scheme ................................................................................................................. 4-35
4.18 Three-stage Claus diagram ............................................................................................................ 4-36
4.19 Typical SCOT tail gas treatment plant .......................................................................................... 4-38
IHS Chemical Process Economics Program | Report 148C
Figures (continued)
September 2013 xiii © 2013 IHS
5.1 PEP reports and reviews on synthesis gas applications ................................................................... 5-2
6.1 PEPSyngas™ user input parameters ............................................................................................... 6-4
6.2 PEPSyngas™ gasifier selection ....................................................................................................... 6-6
6.4 PEPSyngas™ feedstock selection ................................................................................................. 6-10
6.5 Proximate analysis ......................................................................................................................... 6-12
6.6 Effect of gasifier temperature on contained syngas and steam ...................................................... 6-13
6.7 Effect of gasifier temperature on contained syngas quench water ................................................ 6-13
6.8 Natural gas reforming technology selection .................................................................................. 6-15
6.9 Natural gas reforming end product selection ................................................................................. 6-15
6.10 Product syngas customization ....................................................................................................... 6-16
6.11 Region selection ............................................................................................................................ 6-18
6.12 Variable costs customization ......................................................................................................... 6-19
6.13 Process economics customization ................................................................................................. 6-20
6.14 GE quench gasifier block flow diagram ........................................................................................ 6-21
6.15 GE radiant gasifier block flow diagram ........................................................................................ 6-22
6.16 Shell gasifier block flow diagram .................................................................................................. 6-23
6.17 E-Gas gasifier block flow diagram ................................................................................................ 6-24
6.18 Siemens SFG gasifier block flow diagram .................................................................................... 6-25
6.19 Synthesis gas from steam methane reforming for hydrogen (Uhde) block flow diagram ............. 6-27
6.20 Synthesis gas from steam methane reforming for hydrogen (Praxair) block flow diagram .......... 6-28
6.21 Synthesis gas from steam methane reforming for methanol (Toyo) block flow diagram ............. 6-29
6.22 Synthesis gas from combined reforming for methanol (Lurgi) block flow diagram ..................... 6-30
6.23 Synthesis gas from combined reforming for methanol (HT) block flow diagram ........................ 6-31
6.24 Synthesis gas from combined reforming for methanol (JM) block flow diagram ......................... 6-32
6.25 Synthesis gas from autothermal reforming for Fischer Tropsch (HT) block flow diagram .......... 6-33
6.26 Synthesis gas from partial oxidation reforming for Fischer Tropsch (Shell) block flow
diagram .......................................................................................................................................... 6-33
7.1 Synthesis gas by GE quench gasification process flow diagram .................................................... E-3
7.2 Synthesis gas by GE radiant gasification process flow diagram .................................................... E-5
7.3 Synthesis gas by Shell gasification process flow diagram ............................................................. E-7
7.4 Synthesis gas by E-Gas™ gasification process flow diagram ........................................................ E-9
7.5 Synthesis gas by Siemens SFG gasification process flow diagram .............................................. E-11
7.6 Bituminous coal raw syngas composition ..................................................................................... 7-57
7.7 Subbituminous coal raw syngas composition ................................................................................ 7-58
7.8 Lignite A raw syngas composition ................................................................................................ 7-58
7.9 Petroleum coke raw syngas composition ....................................................................................... 7-59
10.1 Coal rank: Low Volatile Bituminous Coal
Seam (mine)/region: Pocahontas No. 3 ......................................................................................... 10-9
10.2 Coal rank: Medium Volatile Bituminous Coal
Seam (mine)/region: Upper Freeport ........................................................................................... 10-10
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Figures (concluded)
September 2013 xiv © 2013 IHS
10.3 Coal rank: High Volatile A Bituminous Coal
Seam (mine)/region: Pittsburgh No.8 .......................................................................................... 10-11
10.4 Coal rank: High Volatile B Bituminous Coal
Seam (mine)/region: Hunter Valley/New South Wales ............................................................... 10-12
10.5 Coal rank: High Volatile B Bituminous Coal
Seam (mine)/region: Jinbei/Shanxi ............................................................................................. 10-13
10.6 Coal rank: High Volatile B Bituminous Coal
Seam (mine)/region: Arthur Taylor/South Africa ....................................................................... 10-14
10.7 Coal rank: High Volatile C Bituminous Coal
Seam (mine)/region: Illinois No. 6 .............................................................................................. 10-15
10.8 Coal rank: High Volatile C Bituminous Coal
Seam (mine)/region: Dartbrook/New South Wales ..................................................................... 10-16
10.9 Coal rank: High Volatile C Bituminous Coal
Seam (mine)/region: Wannian/Hebei .......................................................................................... 10-17
10.10 Coal rank: Subbituminous Coal A
Seam (mine)/region: Rihandnagar/Singrauli ............................................................................... 10-18
10.11 Coal rank: Subbituminous Coal B
Seam (mine)/region: Rosebud/Montana ...................................................................................... 10-19
10.12 Coal rank: Subbituminous Coal C
Seam (mine)/region: Wyodak/Powder River Basin .................................................................... 10-20
10.13 Coal rank: Lignite A
Seam (mine)/region: Texas Lignite ............................................................................................. 10-21
10.14 Coal rank: Lignite B
Seam (Mine)/Region: High Na Lignite/North Dakota ................................................................ 10-22
10.15 Fuel rank: Coke
Seam (mine)/region: Petroleum coke .......................................................................................... 10-23
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2.1 Design features of entrained-flow gasifiers ..................................................................................... 2-5
2.2 Synthesis gas (stoichiometric ratio = 2.036) production costs for bituminous coal ........................ 2-7
2.3 Synthesis gas (stoichiometric ratio = 2.036) production costs for subbituminous coal .................. 2-8
2.4 Synthesis gas (stoichiometric ratio = 2.036) production costs for lignite ....................................... 2-9
2.5 Synthesis gas (stoichiometric ratio = 2.036) production costs for petroleum coke ....................... 2-10
2.6 Synthesis gas for hydrogen production costs for bituminous coal ................................................ 2-12
2.7 Synthesis gas for hydrogen production costs for subbituminous coal ........................................... 2-13
2.8 Synthesis gas for hydrogen production costs for lignite ................................................................ 2-14
2.9 Synthesis gas for hydrogen production costs for petroleum coke ................................................. 2-15
2.10 Synthesis gas for Fischer-Tropsch fuel production costs for bituminous coal .............................. 2-17
2.11 Synthesis gas for Fischer-Tropsch fuel production costs for subbituminous coal ........................ 2-18
2.12 Synthesis gas for Fischer-Tropsch fuel production costs for lignite ............................................. 2-19
2.13 Synthesis gas for Fischer-Tropsch fuel production costs for petroleum coke ............................... 2-20
2.14 Feedstock prices for US Gulf Coast .............................................................................................. 2-21
3.1 World gasification plants ............................................................................................................... 3-12
4.1 Coal specific gravity ........................................................................................................................ 4-2
4.2 Classification of anthracitic and bituminous coals by rank ............................................................. 4-4
4.3 Gross calorific value limits .............................................................................................................. 4-6
4.4 Ash fusion temperatures .................................................................................................................. 4-7
4.5 Coal class ......................................................................................................................................... 4-8
4.6 Chemical reactions ........................................................................................................................ 4-11
4.7 Typical raw syngas composition ................................................................................................... 4-12
4.8 Advantages and limitations of gasifiers ......................................................................................... 4-13
4.9 Gasification technologies .............................................................................................................. 4-14
4.10 Entrained-flow gasifier and feedstock ........................................................................................... 4-17
4.11 Salient characteristics of major gasification technologies ............................................................. 4-17
4.12 Typical syngas composition from coal-based E-Gas™ gasifier .................................................... 4-24
4.13 SFG coal gasification—typical syngas composition ..................................................................... 4-26
4.14 Chemical solvents .......................................................................................................................... 4-33
4.15 Physical solvents ........................................................................................................................... 4-34
4.16 Mercury contents of coal ............................................................................................................... 4-39
5.1 Syngas molar ratio ........................................................................................................................... 5-3
6.1 PEPSyngas™ terms ......................................................................................................................... 6-3
6.2 Gasifier design bases ....................................................................................................................... 6-5
6.3 GE Energy quench gasifier .............................................................................................................. 6-7
6.4 GE Energy radiant gasifier .............................................................................................................. 6-7
6.5 Shell gasifier .................................................................................................................................... 6-8
6.3 E-Gas gasifier .................................................................................................................................. 6-9
6.6 Siemens gasifier ............................................................................................................................... 6-9
6.7 Gas clean-up section ...................................................................................................................... 6-10
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6.8 Feedstock composition .................................................................................................................. 6-11
6.9 Typical syngas H2/CO molar ratio ................................................................................................. 6-16
6.10 Stoichiometric values .................................................................................................................... 6-17
6.11 Location-based factors and labor rate ............................................................................................ 6-19
6.12 Stream descriptions ....................................................................................................................... 6-26
7.1 Syngas for methanol synthesis ........................................................................................................ 7-1
7.2 Syngas impurities and tolerances in methanol synthesis ................................................................. 7-2
7.3 Design specifications for gas clean-up systems............................................................................... 7-4
7.4 Bituminous coal feedstock properties.............................................................................................. 7-6
7.5 Synthesis gas (SR = 2.036) from bituminous coal by the GE quench gasifier
Stream flows .................................................................................................................................. 7-11
7.6 Synthesis gas (SR = 2.036) from bituminous coal by the GE quench gasifier
Utilities summary .......................................................................................................................... 7-12
7.7 Synthesis gas (SR = 2.036) from bituminous coal by the GE quench gasifier
Capital investment ......................................................................................................................... 7-13
7.8 Synthesis gas (SR = 2.036) from bituminous coal by the GE quench gasifier
Variable costs ................................................................................................................................ 7-15
7.9 Synthesis gas (SR = 2.036) from bituminous coal by the GE quench gasifier
Production costs............................................................................................................................. 7-16
7.10 Synthesis gas (SR = 2.036) from bituminous coal by the GE radiant gasifier
Stream flows .................................................................................................................................. 7-20
7.11 Synthesis gas (SR = 2.036) from bituminous coal by the GE radiant gasifier
Utilities summary .......................................................................................................................... 7-21
7.12 Synthesis gas (SR = 2.036) from bituminous coal by the GE radiant gasifier
Capital investment ......................................................................................................................... 7-22
7.13 Synthesis gas (SR = 2.036) from bituminous coal by the GE radiant gasifier
Variable costs ................................................................................................................................ 7-24
7.14 Synthesis gas (SR = 2.036) from bituminous coal by the GE radiant gasifier
Production costs............................................................................................................................. 7-25
7.15 Synthesis gas (SR = 2.036) from bituminous coal by the Shell gasifier
Stream flows .................................................................................................................................. 7-30
7.16 Synthesis gas (SR = 2.036) from bituminous coal by the Shell gasifier
Utilities summary .......................................................................................................................... 7-31
7.17 Synthesis gas (SR = 2.036) from bituminous coal by the Shell gasifier
Capital investment ......................................................................................................................... 7-32
7.18 Synthesis gas (SR = 2.036) from bituminous coal by the Shell gasifier
Variable costs ................................................................................................................................ 7-34
7.19 Synthesis gas (SR = 2.036) from bituminous coal by the Shell gasifier
Production costs............................................................................................................................. 7-35
7.20 Synthesis gas (SR = 2.036) from bituminous coal by the E-Gas gasifier
Stream flows .................................................................................................................................. 7-40
7.21 Synthesis gas (SR = 2.036) from bituminous coal by the E-Gas gasifier
Utilities summary .......................................................................................................................... 7-41
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7.22 Synthesis gas (SR = 2.036) from bituminous coal by the E-Gas gasifier
Capital investment ......................................................................................................................... 7-42
7.23 Synthesis gas (SR = 2.036) from bituminous coal by the E-Gas gasifier
Variable costs ................................................................................................................................ 7-44
7.24 Synthesis gas (SR = 2.036) from bituminous coal by the E-Gas gasifier
Production costs............................................................................................................................. 7-45
7.25 Synthesis gas (SR = 2.036) from bituminous coal by the Siemens gasifier
Stream flows .................................................................................................................................. 7-49
7.26 Synthesis gas (SR = 2.036) from bituminous coal by the Siemens gasifier
Utilities summary .......................................................................................................................... 7-50
7.27 Synthesis gas (SR = 2.036) from bituminous coal by the Siemens gasifier
Capital investment ......................................................................................................................... 7-51
7.28 Synthesis gas (SR = 2.036) from bituminous coal by the Siemens gasifier
Variable costs ................................................................................................................................ 7-53
7.29 Synthesis gas (SR = 2.036) from bituminous coal by the Siemens gasifier
Production costs............................................................................................................................. 7-54
8.1 Powder River Basin Wyodak feedstock properties ......................................................................... 8-2
8.2 Synthesis gas (~96% CO shift) from subbituminous coal by the GE quench gasifier
Stream flows .................................................................................................................................... 8-7
8.3 Synthesis gas (~96% CO shift) from subbituminous coal by the GE quench gasifier
Utilities summary ............................................................................................................................ 8-8
8.4 Synthesis gas (~96% CO shift) from subbituminous coal by the GE quench gasifier
Capital investment ........................................................................................................................... 8-9
8.5 Synthesis gas (~96% CO shift) from subbituminous coal by the GE quench gasifier
Variable costs ................................................................................................................................ 8-11
8.6 Synthesis gas (~96% CO shift) from subbituminous coal by the GE quench gasifier
Production costs............................................................................................................................. 8-12
8.7 Synthesis gas (~96% CO shift) from subbituminous coal by the GE radiant gasifier
Stream flows .................................................................................................................................. 8-16
8.8 Synthesis gas (~96% CO shift) from subbituminous coal by the GE radiant gasifier
Utilities summary .......................................................................................................................... 8-17
8.9 Synthesis gas (~96% CO shift) from subbituminous coal by the GE radiant gasifier
Capital investment ......................................................................................................................... 8-18
8.10 Synthesis gas (~96% CO shift) from subbituminous coal by the GE radiant gasifier
Variable costs ................................................................................................................................ 8-20
8.11 Synthesis gas (~96% CO shift) from subbituminous coal by the GE radiant gasifier
Production costs............................................................................................................................. 8-21
8.12 Synthesis gas (~96% CO shift) from subbituminous coal by the Shell gasifier
Stream flows .................................................................................................................................. 8-26
8.13 Synthesis gas (~96% CO shift) from subbituminous coal by the Shell gasifier
Utilities summary .......................................................................................................................... 8-27
8.14 Synthesis gas (~96% CO shift) from subbituminous coal by the Shell gasifier
Capital investment ......................................................................................................................... 8-28
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8.15 Synthesis gas (~96% CO shift) from subbituminous coal by the Shell gasifier
Variable costs ................................................................................................................................ 8-30
8.16 Synthesis gas (~96% CO shift) from subbituminous coal by the Shell gasifier
Production costs............................................................................................................................. 8-31
8.17 Synthesis gas (~96% CO shift) from subbituminous coal by the E-Gas gasifier
Stream flows .................................................................................................................................. 8-35
8.18 Synthesis gas (~96% CO shift) from subbituminous coal by the E-Gas gasifier
Utilities summary .......................................................................................................................... 8-36
8.19 Synthesis gas (~96% CO shift) from subbituminous coal by the E-Gas gasifier
Capital investment ......................................................................................................................... 8-37
8.20 Synthesis gas (~96% CO shift) from subbituminous coal by the E-Gas gasifier
Variable costs ................................................................................................................................ 8-39
8.21 Synthesis gas (~96% CO shift) from subbituminous coal by the E-Gas gasifier
Production costs............................................................................................................................. 8-40
8.22 Synthesis gas (~96% CO shift) from subbituminous coal by the Siemens gasifier
Stream flows .................................................................................................................................. 8-44
8.23 Synthesis gas (~96% CO shift) from subbituminous coal by the Siemens gasifier
Utilities summary .......................................................................................................................... 8-45
8.24 Synthesis gas (~96% CO shift) from subbituminous coal by the Siemens gasifier
Capital investment ......................................................................................................................... 8-46
8.25 Synthesis gas (~96% CO shift) from subbituminous coal by the Siemens gasifier
Variable costs ................................................................................................................................ 8-48
8.26 Synthesis gas (~96% CO shift) from subbituminous coal by the Siemens gasifier
Production costs............................................................................................................................. 8-49
9.1 Petroleum coke feedstock properties ............................................................................................... 9-2
9.2 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE quench gasifier
Stream flows .................................................................................................................................... 9-7
9.3 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE quench gasifier
Utilities summary ............................................................................................................................ 9-8
9.4 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE quench gasifier
Capital investment ........................................................................................................................... 9-9
9.5 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE quench gasifier
Variable costs ................................................................................................................................ 9-11
9.6 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE quench gasifier
Production costs............................................................................................................................. 9-12
9.7 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE radiant gasifier
Stream flows .................................................................................................................................. 9-16
9.8 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE radiant gasifier
Utilities summary .......................................................................................................................... 9-17
9.9 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE radiant gasifier
Capital investment ......................................................................................................................... 9-18
9.10 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE radiant gasifier
Variable costs ................................................................................................................................ 9-20
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9.11 Synthesis gas (H2/CO = 2.1) from petroleum coke by the GE radiant gasifier
Production costs............................................................................................................................. 9-21
9.12 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Shell gasifier
Stream flows .................................................................................................................................. 9-26
9.13 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Shell gasifier
Utilities summary .......................................................................................................................... 9-27
9.14 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Shell gasifier
Capital investment ......................................................................................................................... 9-28
9.15 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Shell gasifier
Variable costs ................................................................................................................................ 9-30
9.16 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Shell gasifier
Production costs............................................................................................................................. 9-31
9.17 Synthesis gas (H2/CO = 2.1) from petroleum coke by the E-Gas gasifier
Stream flows .................................................................................................................................. 9-35
9.18 Synthesis gas (H2/CO = 2.1) from petroleum coke by the E-Gas gasifier
Utilities summary .......................................................................................................................... 9-36
9.19 Synthesis gas (H2/CO = 2.1) from petroleum coke by the E-Gas gasifier
Capital investment ......................................................................................................................... 9-37
9.20 Synthesis gas (H2/CO = 2.1) from petroleum coke by the E-Gas gasifier
Variable costs ................................................................................................................................ 9-39
9.21 Synthesis gas (H2/CO = 2.1) from petroleum coke by the E-Gas gasifier
Production costs............................................................................................................................. 9-40
9.22 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Siemens gasifier
Stream flows .................................................................................................................................. 9-44
9.23 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Siemens gasifier
Utilities summary .......................................................................................................................... 9-45
9.24 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Siemens gasifier
Capital investment ......................................................................................................................... 9-46
9.25 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Siemens gasifier
Variable costs ................................................................................................................................ 9-48
9.26 Synthesis gas (H2/CO = 2.1) from petroleum coke by the Siemens gasifier
Production costs............................................................................................................................. 9-49
10.1 Gasifier feedstock .......................................................................................................................... 10-1
10.2 GE coal characteristics ................................................................................................................. 10-5
10.3 Shell coal characteristics ............................................................................................................... 10-6
10.4 E-Gas coal characteristics .............................................................................................................. 10-7
10.5 Siemens coal characteristics .......................................................................................................... 10-8
10.6 Coal rank: Low Volatile Bituminous Coal
Seam (mine)/region: Pocahontas No. 3 ......................................................................................... 10-9
10.7 Coal rank: Medium Volatile Bituminous Coal
Seam (mine)/region: Upper Freeport ........................................................................................... 10-10
10.8 Coal rank: High Volatile A Bituminous Coal
Seam (mine)/region: Pittsburgh No.8 .......................................................................................... 10-11
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10.9 Coal rank: High Volatile B Bituminous Coal
Seam (mine)/region: Hunter Valley/New South Wales ............................................................... 10-12
10.10 Coal rank: High Volatile B Bituminous Coal
Seam (mine)/region: Jinbei/Shanxi ............................................................................................. 10-13
10.11 Coal rank: High Volatile B Bituminous Coal
Seam (mine)/region: Arthur Taylor/South Africa ....................................................................... 10-14
10.12 Coal rank: High Volatile C Bituminous Coal
Seam (mine)/region: Illinois No. 6 .............................................................................................. 10-15
10.13 Coal rank: High Volatile C Bituminous Coal
Seam (mine)/region: Dartbrook/New South Wales ..................................................................... 10-16
10.14 Coal rank: High Volatile C Bituminous Coal
Seam (mine)/region: Wannian/Hebei .......................................................................................... 10-17
10.15 Coal rank: Subbituminous Coal A
Seam (mine)/region: Rihandnagar/Singrauli ............................................................................... 10-18
10.16 Coal rank: Subbituminous Coal B
Seam (mine)/region: Rosebud/Montana ...................................................................................... 10-19
10.17 Coal rank: Subbituminous Coal C
Seam (mine)/region: Wyodak/Powder River Basin .................................................................... 10-20
10.18 Coal rank: Lignite A
Seam (mine)/region: Texas Lignite ............................................................................................. 10-21
10.19 Coal rank: Lignite B
Seam (mine)/region: High Na Lignite/North Dakota .................................................................. 10-22
10.20 Fuel rank: Coke
Seam (mine)/region: Petroleum coke .......................................................................................... 10-23
10.21 Illinois #6 vs. Wyoming PRB coal salt compositions of ash ....................................................... 10-24
