Commercial-Scale Demonstration of the Liquid-Phase Methanol (LPMEOH™) Process Coal Processing for Clean Fuels Indirect Liquefaction Timeline | References | Contacts | Map | PDF Version

Project Objective

To demonstrate on a commercial scale the production of methanol from coal-derived synthesis gas using the LPMEOH™ process; and to determine the suitability of methanol produced during this demonstration for use as a chemical feedstock or as a low-SO_x, low-NO_x alternative fuel in stationary and transportation applications. To demonstrate, if practical, the production of dimethyl ether (DME) as a mixed coproduct with methanol.

Technology/Project Description

This project is demonstrating, at commercial scale, the LPMEOH™ process to produce methanol from coal-derived synthesis gas. The combined reactor and heat removal system is different from other commercial methanol processes. The liquid phase not only suspends the catalyst but functions as an efficient means to remove the heat of reaction away from the catalyst surface. This feature permits the direct use of synthesis gas streams as feed to the reactor without the need for phase-shift conversion.

Methanol fuel testing will be conducted in off-site stationary and mobile applications, such as fuel cells, buses, and distributed electric power generation. Design verification testing for the production of DME as a mixed coproduct with methanol for use as a storable fuel is planned , and a decision on whether or not to demonstrate will be made. Eastern high-sulfur bituminous coal (Mason seam) containing 3% sulfur (5% maximum) and 10% ash will be used.

Air Products LPMEOH™ Process Flow Diagram Larger jpeg or wmf version

Project Status/Accomplishments

Construction was completed in January of 1997. Following commissioning and shakedown activities, the first production of methanol from the 80,000 gal/day unit occurred on April 2, 1997. The first stable operation of the process demonstration unit at nameplate capacity occurred on April 6, 1998. A stable test period at over 92,000 gal/day revealed no system limitations. The startup also proceeded without injury or environmental incidents.

During calendar year 1997, availability of the process demonstration unit exceeded 92%. The hydrogen to carbon monoxide (H₂/CO) ratio in the reactor feed stream was varied from 0.4 to 5.6 with no negative effects on catalyst performance. The operation of the demonstration unit confirmed the engineering methods used in the design of the LPMEOH™ Reactor, and several parameters (such as the overall heat transfer coefficient of the internal heat exchanger) were demonstrated at greater than 115% of design levels.

Operation during 1998 has resulted in significant accomplishments. The design catalyst loading in the LPMEOH™ Reactor has been exceeded without indications of mass transfer limitations. Since being restarted with fresh catalyst in December of 1997, the demonstration facility has operated at greater than 99% availability, and 67 days of what would be a 94-day period of continuous operation was in progress as of September 30, 1998. Catalyst life has met or exceeded the design target for operation in the environment of trace poisons present in coal-derived synthesis gas. Process variable studies to maximize the reactor volumetric productivity and determine the long-term catalyst performance are on-going. Since startup, the demonstration facility has produced over 25 million gallons of methanol, all of which has been accepted by Eastman Chemical Company for use in downstream chemical processes.

Commercial Applications

The LPMEOH™ process has been developed to enhance integrated gasification combined-cycle (IGCC) power generation by producing a clean burning, storable liquid fuel--methanol--from the clean coal-derived gas. Methanol also has a broad range of commercial applications, can be substituted for conventional fuels in stationary and mobile combustion applications, is an excellent fuel for utility peaking units, contains no sulfur, and has exceptionally low-NO_x characteristics when burned. Methanol can be produced from coal as a coproduct in an IGCC facility.

DME has several commercial uses. In a storable blend with methanol, the mixture can be used as peaking fuel in IGCC electric power generating facilities. Blends of methanol and DME can also be used as a chemical feedstock for the synthesis of chemicals or new, oxygenate fuel additives. Pure DME is an environmentally friendly aerosol for personal products.

Typical commercial-scale LPMEOH™ units are expected to range in size from 50,000 to 300,000 gal/day of methanol produced when associated with commercial IGCC power generation trains of 200-500 MWe. Air Products expects to market the technology through licensing, owning/ operating, and tolling arrangements.

Contacts

Edward C. Heydorn, Project Manager
Air Products and Chemicals, Inc.
7201 Hamilton Boulevard
Allentown, PA 18195-1501
(610) 481-7099
(610) 706-7299 (fax)
mailto:%20heydorec@apci.com

Edward Schmetz, DOE/HQ, (301) 903-3931 edward.schmetz@hq.doe.gov

Robert M. Kornosky, NETL, (412) 386-4521 mailto:kornosky@fetc.doe.gov