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Preliminary Screening - Technical and Economic Assessment of Synthesis Gas to Fuels and Chemicals with Emphasis on the Potential for Biomass-Derived Syngas - 2003

Spath, P. L.
Dayton, D. C.

National Renewable Energy Laboratory

In this pdf format, this document has 160 pages and is 1.54MB.

Table of Contents

Executive Summary/Conclusions i
Acknowledgements vii
1 Introduction 1
2 Hydrogen 5
  2.1 Summary 5
2.2 Introduction 7
2.3 Technology Description 7
2.4 Hyrdogen From Other Compounds 8
2.5 Chemistry 8
2.6 Catalysts 9
2.7 Reactors 10
2.8 Gas Cleanliness Requirements 10
2.9 Status/Technology Developers 11
2.10 Process Performance 12
2.11 Environment Performance 12
2.12 Cost 13
2.13 R&D Needs 14
2.14 References 14
3 Ammonia 16
  3.1 Summary 16
3.2 Introduction 18
3.3 Technology Description 19
3.4 Chemistry 20
3.5 Catalysts 21
3.6 Reactors 23
3.7 Gas Cleanliness Requirements 25
3.8 Status/Technology Developers 26
3.9 Environmental Performance 27
3.10 Cost 27
3.11 R&D Needs 28
3.12 References 28
4 Methanol and Methanol Derivative (including formaldehyde, acetic acide, MTG, MTO, MOGD, TIGAS, and DME) 29
  4.1 Summary 29
4.2 Introduction 31
4.3 Technology Description 31
4.4 Reactors 32
4.5 Chemistry 34
4.6 Catalysts 35
4.7 Gas Cleanliness Requirements 36
4.8 Status/Technology Developers 38
4.9 Process Performance 39
4.10 Uses 40
4.11 Environmental Performance 47
4.12 Cost of Methanol 47
4.13 R&D Needs 51
4.14 References 52
5 Ethanol 58
  5.1 Summary 58
5.2 Introduction 60
5.3 Technology Description 61
5.4 Chemistry and Microbiology 63
5.5 Fermentor Design 65
5.6 Gas Cleanliness Requirements 65
5.7 Status/Technology Developers 65
5.8 Environmental Performance 66
5.9 Cost 67
5.10 R&D Needs 68
5.11 References 69
6 Mixed Higher Alcohols 70
  6.1 Summary 70
6.2 Introduction 72
6.3 Technology Description 73
6.4 Chemistry 73
6.5 Catalysts 76
6.6 Reactors 79
6.7 Gas Cleanliness Requirements 79
6.8 Status/Technology Developers 79
6.9 Environmental Performance 83
6.10 Cost 83
6.11 R&D Needs 83
6.12 References 85
7 Fischer-Tropsch Synthesis 90
  7.1 Summary 90
7.2 Introduction 92
7.3 Technology Description 93
7.4 Chemistry 94
7.5 Catalysts 96
7.6 Reactors 97
7.7 Gas Cleanliness Requirements 99
7.8 Status/Technology Developers 101
7.9 Process Performance 102
7.10 Environmental Performance 102
7.11 Cost 103
7.12 R&D Needs 106
7.13 References 107
8 Oxosynthesis 111
  8.1 Summary 111
8.2 Introduction 113
8.3 Technology Description 113
8.4 Chemistry 114
8.5 Catalysts 115
8.6 Gas Cleanliness Requirements 116
8.7 Status/Technology Developers 116
8.8 Cost 119
8.9 R&D Needs 119
8.10 References 120
9 Isosynthesis 121
  9.1 Summary 121
9.2 Introduction 123
9.3 Technology Description 123
9.4 Chemistry 123
9.5 Catalysts 124
9.6 Gas Cleanliness Requirements 125
9.7 Status/Technology Developers 125
9.8 R&D Needs 125
9.9 References 125
10 Yields, Energy, Economics 127
  10.1 Summary 127
10.2 Product Yields 129
10.3 Life Cycle Energy Ratios 131
10.4 Petroleum Product Replacement 133
10.5 Economics 135
10.6 References 141
 
LIST OF FIGURES
Figure 1: Diagram of Syngas Conversion Processes Covered in This Report 3
Figure 2: Block Flow Diagram of Hydrogen via Steam Methane Reforming 8
Figure 3: Generic Ammonia Synthesis Process Flow Diagram 19
Figure 4: Various Ammonia Converter Designs 24
Figure 5: Simplified Methanol Synthesis Process Flow Diagram 31
Figure 6: Syngas to Ethanol Simplified Block Flow Diagram 61
Figure 7: FTS General Process Flow Diagram 93
Figure 8: Anderson-Shulz-Flory Distribution 95
Figure 9: Types of Fischer-Tropsch Synthesis Reactors 98
Figure 10: Schematic Flow Diagram of the LP Oxo Process 117
Figure 11: Product Yields from Fossil and Biomass Resources 130
Figure 12: Life Cycle Fossil Energy Ratio 132
Figure 13: Life Cycle Primary Energy Ratio 132
Figure 14: Potential Replacement of Petroleum Products with Biomass Fuels (Energy Basis) 134
Figure 15: Product Price in $/GJ (LHV) 139
Figure 16: Capital Cost Breakdown for Biomass to MeOH Systems 140
 
LIST OF TABLES
Table 1: Summary of Product Information - Facts, Advantages, & Disadvantages iii
Table 2: Summary of Syngas Conversion Processes and Conditions v
Table 3: Summary of Poisons vi
Table 4: Catalytic Steam Reforming Licensors 11
Table 5: Commercial Suppliers of PSA Units 12
Table 6: Comparison of Biomass Based Hydrogen Studies 13
Table 7: Hydrogen Cost Data from other Sources 14
Table 8: Summary of Commercial Ammonia Synthesis Catalyst Compositions 23
Table 9: Summary of Ammonia Synthesis Catalyst Poisons 26
Table 10: Comparison of Ammonia Economics 27
Table 11: Commercial Methanol Synthesis Catalyst Formulations 36
Table 12: MeOH Gaseous Contaminant Constraints 38
Table 13: Methanol Technology Suppliers 39
Table 14: Conversions for Methanol, Methanol/DME, and DME 45
Table 15: Comparison of Coal Based Methanol Economic Studies 48
Table 16: Comparison of Biomass Based Methanol Studies 49
Table 17: Comparison of Formaldehyde Production Costs 50
Table 18: Comparison of Coal Based MTG Economic Studies 51
Table 19: Ethanol Yields on a Common Basis 63
Table 20: Summary of USDA Survey Result (Cash Costs in $/gal of ethanol) 68
Table 21: Companies and Information Regarding Mixed Alcohols Research 82
Table 22: EcaleneTM Composition 83
Table 23: Comparison of Mixed Higher Alcohol Economics From Natural Gas 84
Table 24: Syngas Impurities and Tolerances for Fischer-Tropsch 100
Table 25: Price Ranges for Natural Gas, Gasoline, and Diesel 104
Table 26: Comparison of Biomass Based Fischer Tropsch Studies 106
Table 27: Summary of U.S. Oxo Chemical Producers 118
Table 28: U.S. Prices for Oxo Chemicals 119
Table 29: Feedstock to Product Material Balance Information 129
Table 30: Life Cycle Energy Ratios (LHV basis) 131
Table 31: Economic Parameters for Discounted Cash Flow Analysis 136
Table 32: Summary of Cases Examined 137
Table 33: Base Case Minimum Product Selling Price 138
Table 34: Price of Commercial Products 138
Table 35: Sensitivity - Minimum Product Selling Price 139