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STATUS OF COAL PROJECTS (Underline denotes changes since June 1994) COMMERCIAL AND R&D PROJECTS (Continued) The products of Sasol Two and Three, other than liquid fuels, include ethylene, alcohols, acetone, methyl ethyl ketone, pitch, tar acids, and sulfur, produced for Sasol's Chemical Division, ammonia for the group's Fertilizer and Explosives Divisions, and propylene for the Polymer Division. The primary fuels produced by Sasol at Secunda are probably among the most environmen tally acceptable in the world. The gasoline that is produced has zero sulfur content, is low in aromatics and the level of oxygenates means a relatively high octane number. An oxygenate-containing fuel, as a result of the lower combustion temperature, results in a generally lower level of reactive exhaust constituents. The blending of synthetic gasoline with alcohols (ethanol as well as high fuel alcohols) presented a particular challenge to Sasol. Sasol erected research and development facilities to optimize and characterize fuel additives. Whereas carburetor corrosion with alcohol-containing gasoline occurs with certain alloys used for carburetors, Sasol has now developed its own package of additives to the point where a formal guarantee is issued to clients who use Sasol fuel. The diesel fuel is a zero sulfur fuel with a high cetane number and a paraffin content that will result in a lower particulate emission level than normal refinery fuel. Sasol's Mining Division manages the six Sasol-owned collieries, which have an annual production in excess of 43 million tons of coal. The collieries comprised of the three Secunda Collieries (including the new open cast mines, Syferfontein and Wonderwater), which form the largest single underground coal mining complex in the world, and the Sigma Colliery in Sasolburg. A technology company, Sastech, is responsible for the Group's entire research and development program, process design, engineer ing, project management, and transfer of technology. Sasol approved in 1990 six new projects costing $451 million as part of an overall $3.5 billion program over the next five years. The first three projects are scheduled for completion by January 1993. Sasol has increased its production of ethylene by 55,000 tons per year, to a current level of 400,000 tons per year, by expanding its ethylene recovery plant at Secunda. The company's total wax producing capacity will be doubled from its current level of 64,000 tons per year to 120,000 tons per year. The 70,000 ton per year Sasol One ammonia plant is to be replaced by a 240,000 ton per year plant, which is expected to supply South Africa's current ammonia supply shortfall. A new facility, Sasol One, to manufacture paraffinic products for detergents was commissioned in March 1993. An n-butanol plant to recover acetaldehyde from the Secunda facilities and to produce 17300 tons per year of n-butanol was com missioned during 1992. Sasol will construct a delayed coker facility to produce green coke, and a calciner to calcinate the green coke to anode coke and needle coke. The anode coke is suitable for use in the aluminum smelting industry. They are scheduled to be in production by July 1993. A flexible plant to recover 100,000 tons per year of 1-hexane or 1-pentone will be built to come online in January 1994. The tech nology was developed in-house by Sasol. A krypton/xenon gas recovery plant adjacent to Secunda oxygen units was commissioned in 1993. A major renewal project at Sasol One includes the replacement of the fixed bed Fischer-Tropsch plant with the new Sasol Slurry Bed Reactor. The renewal also includes shutting down much of the synthetic fuels capability at this plant. Project Cost': SASOL Two $2.9 Billion SASOL Three $3.8 Billion *At exchange rates ruling at construction - SCOTIA COAL SYNFUELS PROJECT DEVCO; Alastair Gillespie* Associates Limited; Gulf Canada Products Company; NOVA; Nova Scotia Resources Limited; and Petro-Canada (C-500) The consortium conducted a feasibility study of a coal liquefaction plant in Cape Breton, Nova Scotia using local coal to produce gasoline and diesel fuel. The plant would be built either in the area of the Point Tupper Refinery or near the coal mines. The 25,000 barrels per day production goal would require approximately 23 million tonnes of coal per year. A contract was completed with Chevron Research Inc. to test the coals in their two-stage direct liquefaction process (CCLP). A feasibility report was com pleted and options financeability discussed with governments concerned and other parties. 4-72 SYNTHETIC FUELS REPORT, JANUARY 1995
STATUS OF COAL PROJECTS (Underline denotes changes since June 1994) COMMERCIAL AND R&D PROJECTS (Continued) Scotia Synfuels Limited has been incorporated to carry on the work of the consortium. Scotia Synfuels has down-sized the project to 12300 barrels per day based on a coprocessing concept and purchased the Point Tupper site from Ultramar Canada Inc. Recent developments in coprocessing technology have reduced the capital cost estimates to US$375 million. Net operating costs are es timated at less than US$20 per barrel. In late 1988 Hydrocarbon Research Inc. (HRI) was commissioned by Scotia Synfuel Ltd. to perform microautoclave and bench scale tests to demonstrate the feasibility of their co-processing technology using Harbour seam coal and several oil feedstocks. In early 1989, Bantrel Inc. (a Canadian engineering firm affiliated with Bechtel Inc.), was commissioned to develop a preliminary process design. Scotia Synfuels and partners have concluded an agreement with the Nova Scotia government supported by the. federal government for financial assistance on a $23 million coprocessing feasibility study. The study was completed in 1990. In 1992 Scotia Synfuels Limited arranged with partners to finance the reactivation of the oil storage and ocean terminal facilities at the Point Tupper. Nova Scotia site. Total investment in this reactivation project has been about C$100 million. This project was developed with the view towards supporting the development of a commercial Synfuels Project at the site. In 1993. Scotia Synfuels Limited formed a partnership with CORPOVEN. SA. to evaluate coprocessing of Boscan residuum (with high sulfur and high metals content) and Nova Scotia coal. This program was supported by the Nova Scotia government. Hydrocarbon Research Inc. was again contracted for a bench test program. Hydrotreatment tests of the hydrocarbons from the HRI coprocessing program were contracted to the CANMET laboratories. Bantrel Inc. was engaged to modify the process design developed in the 1989 program to reflect the new feedstocks. Economic analvsis indicated that a coprocessing plant based on Bos can Crude and Nova Scotia coal would be attractive at oil prices of about $US18 per barrel- In the recent program two plant cases of 14,000 barrels/day and 19.000 barrels per day of petroleum products were developed. The products consisted of high quality naphtha (34%); #2 diesel fuel (56%) and low sulfur heavy distillate (10%). Coal conversion in the coprocessing tests was in excess of 90 percent and residuum conversion was in excess of 85 percent- Scotia Synfuels Limited is currently developing financing for the next phase of the project which is estimated to be C$133 to C$15 million. Project Cost: Approximately $23 million for the feasibility study Approximately C$500 million for the plant - SEP IGCC POWERPLANT Demkolec BV. (SEP) (C-520) In 1989, Demkolec, a wholly owned subsidiary of Samenwerkende Elektriciteits-Produktiebedrijven (SEP), the Central Dutch electricity generating board, started to build a 253 megawatt integrated coal gasification combined cycle (IGCC) powerplant, to be ready in 1993. SEP gave Comprimo Engineering Consultants in Amsterdam an order to study the gasification technologies of Shell, Texaco and British Gas/Lurgi. In April 1989 it was announced that the Shell process had been chosen. The location of the coal gasification/combined cycle demonstration station is Buggenum, in the province of Limburg, The Netherlands. The coal gasification facility will employ a single 2,000 ton per day gasifier designed on the basis of Shell technology. The clean gas will fuel a single shaft Siemens V94.2 gas turbine (156 MWe) coupled with steam turbine (128 MWe) and generator. The coal gasification plant will be fully integrated with the combined cycle plant, including the boiler feed water and steam systems; addition ally the compressed air for the air separation plant will be provided as a bleed stream from the compressor of the gas turbine. The design heat rate on internationally traded Australian coal (Drayton) is 8,240 BTU/kWh based on coal higher value heating (HHV). Environmental permits based on NO emissions of 0.17 Ib/MMBTU and SO emissions of 0.06 lb/MMBTU were obtained in April 1990. Construction began in July 1990 and start of operation is scheduled for September 1993. When operation begins, the Dem kolec plant will be the largest coal gasification combined cycle powerplant in the world. Commissioning of the main plant system is scheduled to take place in January through July 1993. After three years of demonstration (1994 to 1996), the plant will be handed over to the Electricity Generating Company of South Netherlands (N.V. EPZ). Project Cost: Dfl. 880 million (1989) 4-73 SYNTHETIC FUELS REPORT, JANUARY 1995
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OIL SHALE COAL OIL SANDS NATURAL GA
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THE SINOR SYNTHETIC FUELS REPORT is
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INTERNATIONAL Oil Shale to Play Rol
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project AcnvrriES Shell MDS Product
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Amoco Primrose Lake Project Gets Gr
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Construction Begins on TECO's Polk
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GENERAL be even more cost-effective
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GENERAL assumed to occur, the suppl
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GENERAL nfflcant implications for a
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GENERAL needs in the next century.
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GENERAL IGT oxygen-blown system bas
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GENERAL VERMONT BIOMASS GASIFIER WI
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GENERAL 50 megawatts; 2) basing the
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GENERAL in the amount of nitrogen i
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COMING EVENTS JUNE 19-21 , CALGARY,
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OIL SHALE A December 1994 stock ana
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OIL SHALE FIGURE 2 HRS PILOT PLANT
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OIL SHALE 200 g 150 v a i a 100 10
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OIL SHALE the company. Earlier in 1
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OIL SHALE TABLE 1 ECONOMICS OF A 10
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OIL SHALE 3.8-centimeter diameter f
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OIL SHALE TABLE 1 ADSORPTION (MOL%)
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OIL SHALE UJ oc o CD 2 > CC tu > o
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OIL SHALE TABLE 1 OIL SHALE RF HEAT
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OIL SHALE , FIGURE 1 MAP OF MAIN OI
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OIL SHALE Timahdit TABLE 1 RESERVE
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OIL SHALE 2-24 THE SYNTHETIC FUELS
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STATUS OF OIL SHALE PROJECTS (Under
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STATUS OF OIL SHALE PROJECTS COMPLE
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STATUS OF OIL SHALE PROJECTS INDEX
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OIL SANDS The company said the larg
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OIL SANDS 12.0 million m3/yr level
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OIL SANDS TABLE 1 ACTUAL AND PREDIC
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0/L SANDS phalt Ridge, near Vernal,
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OIL SANDS ENERGY POLICY & FORECASTS
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OIL SANDS Reservoir/ Bitumen Proper
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OIL SANDS proved environmental miti
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OIL SANDS timized combination of th
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OIL SANDS Chakrabarty and Longo pre
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OIL SANDS Contents, Wt% of Tar Sand
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OIL SANDS results In increased poll
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OIL SANDS West Newport, USA at 33 y
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OIL SANDS was shown that the volume
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OIL SANDS FIGURE 1 LOCATION OF THE
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OIL SANDS As compared to SI, ISC re
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OIL SANDS 3-32 THE SYNTHETIC FUELS
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STATUS OF OIL SANDS PROJECTS (Under
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STATUS OF OIL SANDS PROJECTS COMPLE
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STATUS OF OIL SANDS PROJECTS COMPLE
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STATUS OF OIL SANDS PROJECTS INDEX
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3-62 SYNTHETIC FUELS REPORT, JANUAR
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COAL Removing that moisture is the
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COAL - NOx production: lower than 7
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COAL lav eotl ii - l! FIGURE 1 NEDO
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COAL Another one-third of the site
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COAL v.v C SOURCE: DOE Solid Waste
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COAL Re* Cetl In Flrod Heater Exeha
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COAL Proximate Analysis SYNCOAL QUA
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COAL CORPORATIONS SASOL MADE MAJOR
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COAL Unlike traditional ethylene ol
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COAL SOURCE: IGT IGT is actively pa
Page 156 and 157: COAL ENERGY POLICY & FORECASTS CHIN
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Page 160 and 161: COAL be maintained on a sustainable
Page 162 and 163: COAL associated techno-economic stu
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Page 166 and 167: COAL producing 250 million standard
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Page 170 and 171: COAL Process Description In the HYC
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Page 174 and 175: COAL selected power generation, C02
Page 176 and 177: COAL Some similar solvents are alre
Page 178 and 179: COAL Cofiring MGP Wastes In Utility
Page 180 and 181: COAL uuc stomace TANKS SOURCE: HATT
Page 182 and 183: STATUS OF COAL PROJECTS (Underline
Page 214 and 215: Project Sponsors COMPLETED AND SUSP
Page 216 and 217: STATUS OF COAL PROJECTS COMPLETED A
Page 228 and 229: STATUS OF COAL PROJECTS INDEX OF CO
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Page 234 and 235: NATURAL GAS regulations of the Cali
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Page 238 and 239: NATURAL GAS The BNL process employs
Page 240 and 241: NATURAL GAS produce the radicals In
Page 242 and 243: NATURAL GAS 5-10 THE SYNTHETIC FUEL
Page 244 and 245: STATUS OF NATURAL GAS PROJECTS (Und
Page 246: 5-14 SYNTHETIC FUELS REPORT, JANUAR
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