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1
Coal to Ammonia
Presented at theIowa Energy Center Meeting
Ammonia-The Key to a Hydrogen Economy
By Mark Ibsen
Rentech Development Corporation
October 13, 2005
2
Presentation• Rentech Introduction• Producing Ammonia from Coal/Petroleum Coke
Gasification• What is Fischer-Tropsch?• East Dubuque, Illinois • Environmental Benefits• Food Security and Energy Security-Fuel for First
Responders, and the US Military
3
Rentech – A Brief History
• A 23 year old Denver, Colorado Energy Technology Company– Traded as “RTK” on the American Stock Exchange
• Engaged in the Fischer-Tropsch Development– Coal-to-Liquids (FT/CTL) business – NG-to Liquidss (FT/GTL) business
• Licenses its patented and proprietary technology– 20 U.S. and 1 foreign process and materials patents
• Rentech Development Corporation – Subsidiary of Rentech Inc. – Responsible for ownership and development – Gas-to-Liquid and Coal-to-Liquid Projects
4
Coal to Ammonia a New Concept?
• Not really but for the United States, yes• Today, in the US there are two projects operating
– North Dakota Gasification – Coffeyville Resources
• World Wide a number of facilities – China (2500 small local facilitates)– Portugal (uses refinery bottoms) – Germany, Czech, India, Brazil all have ammonia plants from coal
• Key driver, high NG costs
5Color Legends:
Coal Gasification & Ammonia
SlurryGasifier
Coal Handling
ProcessBoiler
Steam
Parasitic Power Power - 10-20 MW
Hot BFW
SynGas Cooling/Cleaning
Steam Turbine
~
SyngasH2/CO
N2
O2
ASU
Air
HP
Acid Gas Removal
BFW
Gasification Misc
CO2
Indicates units that may or may not be needed.
Process CondensateWater Recycle
ClausUnit
SulphurLoading
H2S
Coal to Ammonia
NH3 - 1500 stpd
ExistingCO2
RemovalPSA
LTSRctrs
NH3Loop
H2
MPLP
Purge to Vent
PSA Offgas
ExportSlag
Ammonia
Water
Coal - 2500 stpd
O2
GuardBeds
Sour Shift
HTSRctrs
HRSG
Hot BFW
8
SyngasSyngas Derived ProductsDerived Products
Syngas Electricity (IGCC)
Methanol/DME/Propylene
Synthetic Natural Gas
Hydrogen
Carbon Dioxide
Ultra-Clean Fischer Tropsch Transportation Fuels
AmmoniaUANUreaHydrogen + Carbon
Monoxide (H2+CO)
Synhytech – Pueblo, Colorado, 1992
9
Gasification Ideal for Gasification Ideal for SyngasSyngas Derived Derived ProductsProducts
Coal Syngas Electricity (IGCC)
Methanol/DME/Propylene
Synthetic Natural Gas
Hydrogen
Carbon Dioxide
Ultra-Clean Fischer Tropsch Transportation Fuels
CoalGasification
CoalGasification
AmmoniaUANUreaHydrogen + Carbon
Monoxide (H2+CO)
Synhytech – Pueblo, Colorado, 1992
12
First Mover Opportunity: First Mover Opportunity: Producing Fertilizer, UltraProducing Fertilizer, Ultra--Clean Clean
Fuels & Electricity From CoalFuels & Electricity From Coal
Deploy gasification to save and create jobs while Deploy gasification to save and create jobs while increasing energy and food security through the increasing energy and food security through the
production of ammonia and FT liquids using Illinois coal production of ammonia and FT liquids using Illinois coal as the plant feedstock.as the plant feedstock.
13
Fischer-Tropsch (FT) Synthesis
• Invented by German chemists Franz Fischer and Hans Tropsch in 1923. Used by Germany during WWII to produce 600,000 bbl/year of fuels from coal and coke
• Commercially proven worldwide197,000 BPD Current Production
• Since 1950s ~ currently 160,000 bbl/day from coal by Sasol
• Since 1993 ~ 23,000/bbl/day from natural gas by Petro SA using Sasol technology
• Since 1995 ~ 15,000/bbl/day from natural gas by Shell in Malaysia
4
14
FT is Commercially Proven Worldwide
SASOL SASOL (S. Africa)45 years commercial– 160,000 b/d+– Feedstock Coal
SASOL’S SOUTH AFRICAN FACILITYSASOL’S SOUTH AFRICAN FACILITY
MossGas MossGas (S. Africa)11 years commercial– 22,500 b/d+– Feedstock Natural
Gas
Shell Shell (Malaysia)9 years commercial– 15,000 b/d+– Feedstock Natural
Gas
6
15
Why Rentech?
Catalyst Flexibility
World’s Largest FT SlurryReactor – Synhytech, 1992
GTLGTLCONOCOEXXONSHELL
CHEVRON/SASOL
CTLCTLRENTECH
SASOL
7
16
Rentech CTL with Fertilizer
CoalPrep.
BFWSteam
Parasitic Power
Power Sales
ProductUpgrade
Syngas
N2
O2
NAPHTHA
FTDIESEL
H2 for FT Product Upgrade
BFW
FTSynthesis
Off-gas to Fuel
Crudes
ProcessCondensate
Recycle
Tail-Gas to Fuel
Exp. Sulphur
AirPower
HRSG
Water for Slurryor Heat for Drying
Gas Turbine
Pet-cokeor Coal
CO2
to Vent or Sequestration
~
~
Steam Turbine
BFW
AmmoniaPlant
Exp. Slag
Steam
Off-gas to Fuel
H2
Rem.
Gasifiers SyngasConditioning & Purification
Steam
Fertilizer Sales
ASU Vent
Waste Heat
Boileror Quench
18
U.S. Ammonia Production vs. Natural Gas & Coal Price
-500,000
1,000,0001,500,0002,000,0002,500,0003,000,0003,500,0004,000,0004,500,0005,000,000
1996
-01
1996
-02
1996
-03
1996
-04
1997
-01
1997
-02
1997
-03
1997
-04
1998
-01
1998
-02
1998
-03
1998
-04
1999
-01
1999
-02
1999
-03
1999
-04
2000
-01
2000
-02
2000
-03
2000
-04
2001
-01
2001
-02
2001
-03
2001
-04
2002
-01
2002
-02
2002
-03
2002
-04
2003
-01
2003
-02
2003
-03
2003
-04
2004
-01
2004
-02
2004
-03
2004
-04
mat
eria
l ton
s
0.001.002.003.004.005.006.007.008.009.0010.00
$/MM
Btu
ammonia production
natural gas price
Source: Ammonia production, U.S. Department of Commerce; natural gas price - average spot-deliverd-to-pipeline price, Natural Gas Week.
IL #6 Coal Price
19
The RC Plant Post Conversion to Coal Feedstock Integrated Manufacturing Process
Ammonia Synthesis
Carbon Dioxide Plant
Urea Plant
Nitric Acid Plant
Ammonium Nitrate/ Blending
Plant
Coal Gasification
- Syngas Production
FTSynthesis
FT Product Upgrade
Air Separation
Plant
Air
Water
Coal
5200 tpd
CO2 Sales
Power Plant
Urea Solutions Sales
Granular Urea Sales
UAN Sales
Nitric Acid Sales
ULS FT Diesel
Naphtha
Export Power
PRODUCTS
Air
CO2
NH3
Urea
Nitric Acid
H2N2
NH3 Sales
Internal PowerSteam
Tail Gas
Sulfur
NH3
Production
EXISTING PLANT
CONVERSION
20Color Legends:
Coal Gasification Yielding Rentech FT Fuels & Power & Ammonia(Simple Recycle FT Process, 1 Gasifier)
SlurryGasifier
Coal Handling
ProcessBoiler
Naphtha Turbine
BFW Steam
Steam
Parasitic Power Power - 40 MW
Hot BFW
Air
SynGas Cooling/Cleaning
Steam Turbine
~
ProductUpgrade
SyngasH2/CO - 0.68
N2
O2
ASU
Air
HP
Gasification/FTSteam
FT Water & Ox
NAPHTHAStorage/Loading
DIESELStorage/Loading
AGR (Rectisol)
BFW
FT UnitGasification Coal
CO2
FTSynthesis
Indicates units that may or may not be needed.
GuardBeds
Crudes
Process CondensateWater Recycle
ClausUnit
SulphurLoading
Air
H2S
E. DubuqueAgriEnergy
NH3 - 920 stpd
NewHTS
Rctrs
ExistingCO2
RemovalPSA
NewLTS
Rctrs
NH3Loop
H2
MPLP
Purge to Vent
H2
Purge to Fuel 450 MMbtu/h
H2 to Prod Upgrade
H2
ExportSlag
NH3
Water
Misc
~Diesel - 4700 bpd
Naphtha- 900 bpd
Coal - 5200 stpd
1.1 MMscfd H2
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East Dubuque Plant Polygeneration ModelEast Dubuque Plant Polygeneration ModelEstimated Inputs and ProductionEstimated Inputs and Production
• Coal feedstock 5,200 TPD
Products (45% Increase in Tons Shipped)
• Ammonia production 920 TPD • FT Fuels (80% diesel) 5,600 BPD
• 248,000 gallons per day
• Electricity production 160 MW(e) • Electricity export 40+ MW(e)
22
Benefits of Benefits of PolygenerationPolygeneration from Coalfrom Coal
• Standard pulverized coal power plant: 35%
• Combined cycle natural gas power plant: 45%
• Coal gasification to produce fertilizer, ultra-clean fuels, & electricity: 50+%
23
Coal Cleaner?Plant Regulated Emissions
0
500
1000
1500
2000
2500
3000
3500
Existing Tons/yr Converted Ton/yr
Existing Tons/yr Converted Ton/yr
Total Emissions of: PM10VOCONOxSO2
Tons
/Yr
>30% DecreaseIn Criteria Pollutant
Emissions
With a Production increase of 45% in Tons Shipped
24
UltraUltra--Clean FT Diesel Fuel from CoalClean FT Diesel Fuel from Coal
-42
-33
-9
-28
-45
-40
-35
-30
-25
-20
-15
-10
-5
0
Hydrocarbon Carbon Monoxide N0x Particulates
Emis
sion
s R
elat
ive
to a
Typi
cal D
iese
l Fu
el (
Per
cen
tage
)
Source: An average of several government funded studies by NREL & SwRI
FT Diesel
ConventionalDiesel
FTD from FTD from coal is an coal is an
“alternative “alternative fuel” under fuel” under
1992 Energy 1992 Energy Policy Act Policy Act (EPACT)(EPACT)
•• BiodegradableBiodegradable•• < 1ppm Sulfur< 1ppm Sulfur•• High CetaneHigh Cetane••Stable long storage lifeStable long storage life
25
OSD Clean Fuel Initiative
Dr. Theodore K. BarnaAssistant Deputy Under Secretary of DefenseAdvanced Systems and ConceptsPentagon [email protected]
Vision: DoD catalyze the commercial industry to produce clean fuels for the military from secure domestic resources using environmentally
sensitive processes that create jobs and wealth in the United States
26
Secure and reliable sources of energy Currently dependent on foreign oil
Becoming dependent on foreign refined
fuels
Supply chain vulnerability
Dependent on mega refineries- Gulf Coast
Natural disasters or Terrorist threats
Need for cleaner fuels
DoD exempt from some EPA regulations
Potential limits on deployments
Possible conflict with EU rules
DoD Impact
ground fuels, 15.1%
marine fuels, 7.9%
jet fuels, 73.5%
Military DemandApprox 4% of US Consumption
Fuel Costs
0100020003000400050006000
97 98 99 0 1 2 3 4 5
Fiscal Year
Mill
ions
of D
olla
rs
Army
Navy
Air Force
Marines
Ref: DESC Help Book
27
Total Energy Development (TED)Use all secure indigenous sources of energy
Coal, shale oil, petroleum coke, renewablesDispersed production facilities
Minimize government funding—focus on qualification and certification
Make a better fuel from coal and petroleum coke (Fischer Tropsch fuels) and oil shale
Low (or no) sulfur, cleaner burning, bio-degradable, low (or no) aromatics, reduced particulate emissionsBlends near term, neat fuel future goal Stable fuel for long term secure storage of refined fuel for emergency use
Use Environmentally sensitive processes to produce fuel- Clean Coal Technologies such as the Fischer-Tropsch process,
Mahogany Shale Research Project- CO2 sequestration for enhanced oil recovery (EOR)
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-62%
-45%
-4%
-13%
-55%
-72%
-60%
-17% -15%
-52%
-80%
-70%
-60%
-50%
-40%
-30%
-20%
-10%
0%HC CO CO2 NOx PM
% R
educ
tions
Hot StartNRTC
FT fuel burns more completely and emissions are significantly cleaner than
EPA certified low-sulfur diesel fuel tested in 6.5L diesel engine.
Transienttest cycles
Hot StartNRTC*
Reduced Exhaust Emissions with FT Fuel Relative to Low-Sulfur Diesel Fuel
*Non-Road Transient CompositeOver 50% reduction in particulate emissions
in transient mode.
29
Even moderate fractions of FT fuel blended in JP-8 significantly reduce exhaust emission particulates
in T63 turbine engine testing.
Reduced Particulate Emissions with FT Fuel Relative to JP-8
96% reduction* in particulate emissions
at idle conditions.
-12% -13%
-33%
-41%
-57%
-68%
-78%
-25%-30%
-50%
-61%
-75%
-86%-92%
-51%
-96%-100%
-75%
-50%
-25%
0%12.5 25 37.5 50 62.5 75 87.5 100
% Volume of FT Fuel in JP-8
% C
hang
e in
Par
ticle
Num
ber D
ensi
ty
CruiseIdle
12.5 25 37.5 50 62.5 75 87.5 100
y
* Note: Results are highly dependent on engine model/year and composition of baseline fuel.
30
Summary• Coal to Ammonia is not a new concept• The Poly-generation concept improves plant efficiency
and diversifies product mix• Conversion of exiting facilities improves project
schedule, reduces cost and utilizes existing plants • The Ammonia and Fuels provide for Food and Fuels
security for the United States • Both Ammonia and FT liquids are a steps toward the
Hydrogen Economy• Polygeneration provides diversity and stability to
ammonia plants during market swings.