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© SRI Consulting PEP Report 245B Abstract Process Economics Program Report 245B DIMETHYL ETHER (DME) FROM COAL (November 2009) Dimethyl ether (DME) is a clean energy source that can be manufactured from various raw materials such as petroleum residues, coal bed methane, and biomass as well as natural gas and coal. When combusted, DME generates absolutely no SOx or black smoke (soot) when burned. Practical use of DME is advancing in the fields of power generation, automotive/industrial diesel engines, and domestic household use among other possible applications because of its excellent physical, chemical, and storage properties. The demand for this fuel in Asia is rising rapidly to provide both household and transportation energy. The technological developments for DME production as a fuel started from natural gas around the mid 1990’s and targeted the use of DME as an LPG alternative, a transportation fuel for diesel engines, and fuel for gas turbines. DME became well-known as a potential multi- source multi-purpose fuel produced by indirect processes. Although DME can be produced easily by the dehydration of methanol, a direct process for integrated production began to be researched in Europe, the U.S. and Japan. Today, DME can be produced either directly from synthesis gas or by the indirect method which passes through methanol production. Because we recently evaluated the production of DME from natural gas in PEP Report 245A, in this report we describe and review the economic units involved in the integrated production of DME from coal. This report is unique in that it highlights all major aspects of coal gasification, production and utilization of DME as a fuel (including storage, transportation, and distribution) and a projection of future market potential from fundamentals, in addition to presenting our traditional techno-economic analysis. Finally, process economics for integrated production of DME from coal using an alternative indirect process technology developed by Haldor Topsoe are provided and compared with a direct process technology developed by JFE.

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© SRI Consulting PEP Report 245B

Abstract Process Economics Program Report 245B

DIMETHYL ETHER (DME) FROM COAL (November 2009)

Dimethyl ether (DME) is a clean energy source that can be manufactured from various raw materials such as petroleum residues, coal bed methane, and biomass as well as natural gas and coal. When combusted, DME generates absolutely no SOx or black smoke (soot) when burned. Practical use of DME is advancing in the fields of power generation, automotive/industrial diesel engines, and domestic household use among other possible applications because of its excellent physical, chemical, and storage properties. The demand for this fuel in Asia is rising rapidly to provide both household and transportation energy.

The technological developments for DME production as a fuel started from natural gas around the mid 1990’s and targeted the use of DME as an LPG alternative, a transportation fuel for diesel engines, and fuel for gas turbines. DME became well-known as a potential multi-source multi-purpose fuel produced by indirect processes. Although DME can be produced easily by the dehydration of methanol, a direct process for integrated production began to be researched in Europe, the U.S. and Japan. Today, DME can be produced either directly from synthesis gas or by the indirect method which passes through methanol production.

Because we recently evaluated the production of DME from natural gas in PEP Report 245A, in this report we describe and review the economic units involved in the integrated production of DME from coal. This report is unique in that it highlights all major aspects of coal gasification, production and utilization of DME as a fuel (including storage, transportation, and distribution) and a projection of future market potential from fundamentals, in addition to presenting our traditional techno-economic analysis.

Finally, process economics for integrated production of DME from coal using an alternative indirect process technology developed by Haldor Topsoe are provided and compared with a direct process technology developed by JFE.

SRIC agrees to assign professionally qualified personnel to the preparation of theProcess Economics Program’s reports and will perform the work in conformance with generallyaccepted professional standards. No other warranties expressed or implied are made. Becausethe reports are of an advisory nature, neither SRIC nor its employees will assume any liability forthe special or consequential damages arising from the Client’s use of the results contained in thereports. The Client agrees to indemnify, defend, and hold SRIC, its officers, and employeesharmless from any liability to any third party resulting directly or indirectly from the Client’s use ofthe reports or other deliverables produced by SRIC pursuant to this agreement

For detailed marketing data and information, the reader is referred to one of the SRIConsulting programs specializing in marketing research. THE CHEMICAL ECONOMICSHANDBOOK Program covers most major chemicals and chemical products produced in theUnited States and the WORLD PETROCHEMICALS PROGRAM covers major hydrocarbons andtheir derivatives on a worldwide basis. In addition the SRIC DIRECTORY OF CHEMICALPRODUCERS services provide detailed lists of chemical producers by company, product, andplant for the United States, Western Europe, Canada, and East Asia, South America and Mexico.

© SRI Consulting iii PEP Report 245B

CONTENTS

1  INTRODUCTION ........................................................................................................ 1-1

BACKGROUND.......................................................................................................... 1-1

Potential Japanese Markets for DME......................................................................... 1-6

Power Generation....................................................................................................... 1-7

Transportation Fuel .................................................................................................... 1-7

Industry ....................................................................................................................... 1-8

Household and Commercial ....................................................................................... 1-8

Other Potential Asian Markets.................................................................................... 1-9

DME Production……………………………………………… ........................................ 1-11

Characteristics of DME as a Fuel……........................................................................ 1-11

REPORT OVERVIEW ................................................................................................ 1-12

2  SUMMARY ................................................................................................................. 2-1 

DME AS A FUEL ........................................................................................................ 2-1

Production................................................................................................................... 2-2

Markets ....................................................................................................................... 2-7

Small and Medium Sized Power Plants (1 MW to 250 MW)................................ 2-7

Diesel Power Generation Systems....................................................................... 2-9

Micro Gas Turbine Systems ................................................................................. 2-10

Technology ................................................................................................................. 2-10

Indirect DME Technology ..................................................................................... 2-10

Direct DME Technology........................................................................................ 2-11

DME from Coal ..................................................................................................... 2-13

Haldor Topsoe Indirect Process for Production of DME.................................. 2-16

JFE Direct Process for Production of DME ..................................................... 2-16

Economics .................................................................................................................. 2-18

Conclusions……… ..................................................................................................... 2-21

Economics ............................................................................................................ 2-21

Safety and Environmental Impact ........................................................................ 2-22

© SRI Consulting iv PEP Report 245B

CONTENTS (Continued)

Technical Challenges ........................................................................................... 2-22

Delivery Network .................................................................................................. 2-23

Cooperation with Domestic LGP Industry ............................................................ 2-23

Promoting an Understanding with Domestic Utility and Automotive Companies. 2-23

DME's Significance as a Power Generation Fuel............................................ 2-23

DME's Importance as the Next Generation Clean Transportation Fuel .......... 2-24

Policy Support............................................................................................................. 2-24

International Cooperation ........................................................................................... 2-24

3  INDUSTRY STATUS.................................................................................................. 3-1 

INTRODUCTION ........................................................................................................ 3-1

COAL OVERVIEW ..................................................................................................... 3-3

Coal Gasification Industry........................................................................................... 3-6 

Drivers for Coal Gasification....................................................................................... 3-12 

Oil and Gas Prices...................................................................................................... 3-13 

Energy Security .......................................................................................................... 3-15 

Environmental Policy .................................................................................................. 3-15 

DIMETHYL ETHER .................................................................................................... 3-16

DME Capacity............................................................................................................. 3-17 

China .......................................................................................................................... 3-18

United States .............................................................................................................. 3-19 

Japan .......................................................................................................................... 3-20 

COAL TO DME OUTLOOK ........................................................................................ 3-21

Domestic Fuel............................................................................................................. 3-21

Transportation Fuel .................................................................................................... 3-21

4 TECHNOLOGY REVIEW ........................................................................................... 4-1

INTRODUCTION ........................................................................................................ 4-1

COAL .......................................................................................................................... 4-2

Composition................................................................................................................ 4-3

© SRI Consulting v PEP Report 245B

CONTENTS (Continued)

Caloric Value .............................................................................................................. 4-3

Moisture ...................................................................................................................... 4-4

Ash.............................................................................................................................. 4-4

Grindability Index........................................................................................................ 4-6

Coal Preparation......................................................................................................... 4-7 

Coal Water Slurry Gasifiers ........................................................................................ 4-7

GASIFICATION .......................................................................................................... 4-8

Gasification Chemistry................................................................................................ 4-8

Stoichiometric and Thermal Constraints .................................................................... 4-10

Kinetics of Coal Gasification....................................................................................... 4-11

Gasifier Reactor Design ............................................................................................. 4-11

Comparison of Gasification Technologies.................................................................. 4-13

Entrained Flow Gasifiers ............................................................................................ 4-14

Commercial Gasifier Comparisons............................................................................. 4-16

GE Gasifier versus Shell Gasifier......................................................................... 4-16

GE Gasifier versus E-Gas Gasifier....................................................................... 4-18

GE Gasification Process…......................................................................................... 4-20

Quench Mode ....................................................................................................... 4-21

Syngas Cooler Mode............................................................................................ 4-22

Slurry Options....................................................................................................... 4-24

Syngas Cooling .................................................................................................... 4-25

OXYGEN SUPPLY ..................................................................................................... 4-26

GAS CLEANUP SYSTEM .......................................................................................... 4-27

Particulate Removal ................................................................................................... 4-28

Syngas Scrubber/Sour Water Stripper ....................................................................... 4-28

Carbonyl Sulfide Hydrolysis........................................................................................ 4-30

Acid Gas Removal...................................................................................................... 4-31

Chemical Solvents................................................................................................ 4-34

© SRI Consulting vi PEP Report 245B

CONTENTS (Continued)

Physical Solvents ................................................................................................. 4-38

Rectisol Based Acid Gas Removal Processes........................................................... 4-41

Selexol Based Acid Gas Removal Processes............................................................ 4-46

Mixed Amine/Physical Solvent ............................................................................. 4-48

Sterically Hindered Amines .................................................................................. 4-49

Water Gas Shift .......................................................................................................... 4-50

High Temperature Shift ........................................................................................ 4-51

Low Temperature Shift ......................................................................................... 4-52

Sour Gas Shift ...................................................................................................... 4-52

Sulfur Recovery .......................................................................................................... 4-54

Claus Process ...................................................................................................... 4-54

Claus Unit Operating Reliability ....................................................................... 4-63

Thermal Reactor ......................................................................................... 4-64

Boiler........................................................................................................... 4-66

Burner ......................................................................................................... 4-66

Other Equipment......................................................................................... 4-67

Controls and Shutdown Function .................................................................... 4-68

Combustion Control .................................................................................... 4-69

Scot Process ........................................................................................................ 4-70

Claus SRU Thermal Incinerators..................................................................... 4-73

Mercury Removal ....................................................................................................... 4-75

Activated Carbon .................................................................................................. 4-78

Zeolites ................................................................................................................. 4-79

Other Methods...................................................................................................... 4-79

DME SYNTHESIS ...................................................................................................... 4-80

Methanol Dehydration ................................................................................................ 4-81

Two-Step or Indirect Dimethyl Ether Process ............................................................ 4-81

Two-Step Processes .................................................................................................. 4-81

Single Step DME Process .......................................................................................... 4-82

Liquid-Phase Processes............................................................................................. 4-84

© SRI Consulting vii PEP Report 245B

CONTENTS (Continued)

SIMULATION MODEL................................................................................................ 4-84

5 DIMETHYL ETHER FROM COAL BY INTEGRATED METHANOL/DME HALDOR TOPSOE PROCESS .................................................................................................. 5-1

MAIN REACTIONS..................................................................................................... 5-1

Catalysts ..................................................................................................................... 5-3

Reaction Conditions ................................................................................................... 5-3

Reactor ....................................................................................................................... 5-4

Product Separation and By-products ......................................................................... 5-4

SYSTEM DESIGN BASIS AND ASSUMPTIONS ...................................................... 5-4

Plant Configuration ..................................................................................................... 5-4

Extent of CO2 Removal............................................................................................... 5-5

Carbonyl Hydrolysis.............................................................................................. 5-6

Mercury Removal ................................................................................................. 5-6

Acid Gas Removal................................................................................................ 5-7

Shift Converter...................................................................................................... 5-8

Sulfur Recovery and Tailgas Treating.................................................................. 5-8

BASIS FOR ESTIMATES AND EVALUATION .......................................................... 5-8

PROCESS DESCRIPTION ........................................................................................ 5-12

Section 100 - Coal Receiving and Storage ................................................................ 5-13

Section 200 - Air Separation Plant ............................................................................. 5-13

Section 300 - Coal Preparation and Gasification ....................................................... 5-14

Section 400 - Shift, Cooling, and Mercury Removal .................................................. 5-15

Section 500 - CO2 Removal and Rectisol .................................................................. 5-16

Section 600 - Claus/SCOT ......................................................................................... 5-16

Claus Sub-Section................................................................................................ 5-16

SCOT Sub-Section ............................................................................................... 5-17

Section 700 - Dimethyl Ether Synthesis and Purification ........................................... 5-17

Stream Flows.............................................................................................................. 5-18

© SRI Consulting viii PEP Report 245B

CONTENTS (Continued)

PROCESS DISCUSSION........................................................................................... 5-25

Process Assumptions ................................................................................................. 5-25

Process Conditions..................................................................................................... 5-25

Product Separation..................................................................................................... 5-25

Reactor Design........................................................................................................... 5-26

Steam Generation ...................................................................................................... 5-26

High Pressure Steam ........................................................................................... 5-26

Medium Pressure Steam...................................................................................... 5-26

Low Pressure Steam ............................................................................................ 5-26

MATERIALS OF CONSTRUCTION ........................................................................... 5-27

WASTE STREAMS..................................................................................................... 5-27

COST ESTIMATES .................................................................................................... 5-28

Fixed Capital Costs .................................................................................................... 5-28

Production Costs ........................................................................................................ 5-29

CONCLUSION............................................................................................................ 5-29

6  SINGLE-STEP SYNTHESIS OF DIMETHYL ETHER FROM COAL BY JFE PROCESS .................................................................................................................. 6-1 

MAIN REACTIONS..................................................................................................... 6-1

Reaction Conditions ................................................................................................... 6-3

Reactor ....................................................................................................................... 6-3

Product Separation & Byproducts .............................................................................. 6-4

SYSTEM DESIGN BASIS AND ASSUMPTIONS ...................................................... 6-4

Plant Configuration ..................................................................................................... 6-4

Extent of CO2 Removal............................................................................................... 6-5

Carbonyl Hydrolysis.............................................................................................. 6-6

Shift Converter...................................................................................................... 6-6

Mercury Removal ................................................................................................. 6-6

Acid Gas Removal................................................................................................ 6-7

© SRI Consulting ix PEP Report 245B

CONTENTS (Continued)

Sulfur Recovery and Tailgas Treating.................................................................. 6-8

BASIS FOR ESTIMATES AND EVALUATION .......................................................... 6-8

Section 100 - Coal Receiving and Storage ............................................................... 6-13

Section 200 - Air Separation Plant ............................................................................. 6-13

Section 300 - Coal Preparation and Gasification ....................................................... 6-13

Section 400 - Shift, Cooling, Mercury Removal.......................................................... 6-15

Section 500 - CO2 Removal and Rectisol .................................................................. 6-15

Section 600—Claus/SCOT......................................................................................... 6-16

Section 700—Dimethyl Ether Synthesis and Purification........................................... 6-16

Stream Flows........................................................................................................ 6-17

PROCESS DISCUSSION........................................................................................... 6-23

Process Assumptions ................................................................................................. 6-23

Process Conditions..................................................................................................... 6-23

Product Separation..................................................................................................... 6-23

Reactor Design........................................................................................................... 6-23

Steam Generation ...................................................................................................... 6-23

High Pressure Steam ........................................................................................... 6-24

Medium Pressure Steam...................................................................................... 6-24

Low Pressure Steam ............................................................................................ 6-24

MATERIALS OF CONSTRUCTION ........................................................................... 6-24

WASTE STREAMS..................................................................................................... 6-25

SAFETY AND HANDLING ......................................................................................... 6-25

Storage Facilities ........................................................................................................ 6-25

Cryogenic Storage................................................................................................ 6-25

High Pressure Storage ......................................................................................... 6-26

Spherical Storage Tanks ................................................................................. 6-27

Cylindrical Storage Tanks................................................................................ 6-28

Storage Terminal .................................................................................................. 6-28

© SRI Consulting x PEP Report 245B

CONTENTS (Concluded)

Unloading Facilities.......................................................................................... 6-29

Cryogenic Storage Tanks ................................................................................ 6-29

Transfer Facilities ............................................................................................ 6-29

Transportation ............................................................................................................ 6-30

Marine Transportation .......................................................................................... 6-30

Refrigerated Tankers ....................................................................................... 6-30

Pressurized Tankers........................................................................................ 6-31

Land Transportation ............................................................................................. 6-31

Rail Cars .......................................................................................................... 6-31

Tank Trucks ..................................................................................................... 6-32

Gas Cylinders .................................................................................................. 6-32

Stability of DME .......................................................................................................... 6-33

Auto-Oxidation of DME......................................................................................... 6-33

Stability Evaluation of DME .................................................................................. 6-34

COST ESTIMATES .................................................................................................... 6-35

Fixed-Capital Costs .................................................................................................... 6-35

Production Costs ........................................................................................................ 6-36

CONCLUSION............................................................................................................ 6-36

APPENDIX A: PATENT SUMMARY TABLES.................................................................. A-1

APPENDIX B: DESIGN AND COST BASIS...................................................................... B-1

APPENDIX C: CITED REFERENCES............................................................................... C-1

APPENDIX D: PATENT REFERENCES BY COMPANY.................................................. D-1

APPENDIX E: PROCESS FLOW DIAGRAM.................................................................... E-1

© SRI Consulting xi PEP Report 245B

ILLUSTRATIONS

2.1 Clean Syngas Composition for DME..................................................................... 2-14

3.1 Energy Demand by Region ................................................................................... 3-1

3.2 Coal Reserves by Region...................................................................................... 3-3

3.3 Coal Demand by World Region............................................................................. 3-4

3.4 U.S. Coal Demand................................................................................................. 3-5

3.5 Fuel Cost at Electricity Generating Plants............................................................. 3-5

3.6 World Gasification Capacity by Fuel Type ............................................................ 3-7

3.7 Cumulative Growth in World Gasification Capacity............................................... 3-8

3.8 Coal Gasification Capacity by Region................................................................... 3-9

3.9 Coal Gasification Capacity by Product .................................................................. 3-10

3.10 Coal Gasification Capacity by Technology............................................................ 3-10

3.11 Products from Coal Gasification............................................................................ 3-11

3.12 Gasification Plants and Technology...................................................................... 3-12

3.13 Historical Fuel Prices............................................................................................. 3-14

3.14 Historical Coal and Natural Gas Prices................................................................. 3-14

3.15 Chinese DME Demand.......................................................................................... 3-19

3.16 U.S. DME Demand ................................................................................................ 3-20

4.1 Entrained Flow Gasifiers ....................................................................................... 4-15

4.2 GE Gasifier Schematic .......................................................................................... 4-20

4.3 GE Gasification System Direct Quench Processing Scheme............................... 4-22

4.4 GE Gasification in Syngas Convective Cooler Mode............................................ 4-23

4.5 Sour Water Stripper............................................................................................... 4-28

4.6 Basic COS Hydrolysis Process Scheme............................................................... 4-31

4.7 Downstream Processing Options .......................................................................... 4-32

4.8 Bulk Amine Based Acid Gas Removal System ..................................................... 4-35

4.9 Typical Acid Gas Absorption Using Chemical Sorbent ......................................... 4-37

4.10 Typical Acid Gas Absorption Using Physical Solvents.......................................... 4-39

© SRI Consulting xii PEP Report 245B

ILLUSTRATIONS (Concluded)

4.11 Equilibrium Data on Various Solvents ................................................................... 4-41

4.12 Rectisol Configurations ......................................................................................... 4-42

4.13 Basic Rectisol CO2 Capture System ..................................................................... 4-44

4.14 Simplified Rectisol Process Flow Diagram............................................................ 4-45

4.15 Basic Selexol Process Scheme............................................................................. 4-46

4.16 Selexol AGR Process for Sulfur Removal and CO2 Capture ................................ 4-47

4.17 Selexol AGR Process for Sulfur Removal w/o CO2 Capture................................. 4-48

4.18 Water Gas Shift With A Saturate/Desaturate Configuration Process Flow Schematic .............................................................................................................. 4-51

4.19 Water Gas Shift Reaction Scheme........................................................................ 4-53

4.20 Process Flow Schematic For Generic Claus Process ......................................... 4-54

4.21 Standard Claus Process........................................................................................ 4-55

4.22 Typical SCOT Tail Gas Treatment Plant ............................................................... 4-72

4.23 IGCC With Mercury Removal ................................................................................ 4-78

4.24 Haldor-Topsoe DME Process Scheme ................................................................. 4-82

4.25 Basic Single Step DME Plant Process Scheme.................................................... 4-83

5.1 Dimethyl Ether Haldor Topsoe Integrated Process - Block Flow Diagram ........... E-3

5.2 Raw and Clean Syngas Composition.................................................................... 5-5

5.3 Dimethyl Ether Synthesis and Purification - Process Flow Diagram..................... E-5

6.1 Dimethyl Ether JFE Integrated Process - Block Flow Diagram............................. E-7

6.2 Raw and Clean Syngas Composition.................................................................... 6-5

6.3 Dimethyl Ether Synthesis and Purification - Process Flow Diagram..................... E-9

© SRI Consulting xiii PEP Report 245B

TABLES

1.1 Recoverable Reserves and Distribution of Energy Resources............................. 1-2

1.2 Potential Market Demand in Japan for Fuel Grade DME by 2020........................ 1-9

1.3 Potential Market Demand in Other Asian Markets for Fuel Grade DME by 2020. 1-10

2.1 Existing DME Production Capacity in China ......................................................... 2-2

2.2 Confirmed DME Expansion Projects in China....................................................... 2-4

2.3 Coal to DME Gasification Operating Configuration and Operating Conditions..... 2-15

2.4 DME from Coal - Total Capital Investment Profiles............................................... 2-18

2.5 Process Economic Comparison ............................................................................ 2-19

2.6 DME from Coal - Total Direct Capital vs Capacity ................................................ 2-20

2.7 Alternative DME Process Product Values............................................................. 2-20

3.1 Fuel Properties ...................................................................................................... 3-16

3.2 World DME Producers........................................................................................... 3-17

3.3 Syngas Requirement for Chemical Applications ................................................... 3-22

4.1 Coal to DME Processing Steps ............................................................................. 4-2

4.2 Typical Compositions of US Coal from Different Sources .................................... 4-5

4.3 Ash Content and Ash Fusion Temperatures of Some U.S. Coals and Lignite ..... 4-6

4.4 Chemical Reactions............................................................................................... 4-9

4.5 Typical Raw Syngas Composition......................................................................... 4-10

4.6 Advantages and Limitations of Gasifiers ............................................................... 4-12

4.7 Gasification Technologies ..................................................................................... 4-13

4.8 Salient Characteristics of Major Gasification Technologies .................................. 4-16

4.9 Raw Syngas Composition by Gasifier ................................................................... 4-19

4.10 Applications for Synthesis Gas.............................................................................. 4-19

4.11 Product Gas Purity ................................................................................................ 4-34

4.12 Sulfur Removal Reactions..................................................................................... 4-56

4.13 Mercury Contents of Coal...................................................................................... 4-76

4.14 Typical Metal Contaminants in US Coals .............................................................. 4-77

© SRI Consulting xiv PEP Report 245B

TABLES (Continued)

4.15 DOE Illinois No.6 High-Volatile B Bituminuous Specifications.............................. 4-85

4.16 Raw Syngas Composition ..................................................................................... 4-87

5.1 Dimethyl Ether from Coal By the Integrated Methanol DME Haldor-Topsoe Process Patent Summary...................................................................................... A-3

5.2 Gasification Chemistry........................................................................................... 5-2

5.3 Haldor-Topsoe DME Synthesis ............................................................................. 5-2

5.4 Design Specifications for Gas Clean Up Systems ................................................ 5-6

5.5 Process Sections................................................................................................... 5-9

5.6 DME from Coal by Integrated Methanol-DME Haldor-Topsoe Process Basis for Estimates and Evaluations ..................................................................... 5-10

5.7 Syngas Composition Specifications ...................................................................... 5-13

5.8 DME from Coal By the Integrated Methanol DME Haldor-Topsoe Process Stream Flows......................................................................................................... 5-19

5.9 Major Waste Streams............................................................................................ 5-27

5.10 DME from Coal By the Integrated Methanol DME Haldor-Topsoe Process Total Capital Investment........................................................................................ 5-30

5.11 DME from Coal By the Integrated Methanol DME Haldor-Topsoe Process Variable Costs ....................................................................................................... 5-31

5.12 DME from Coal By the Integrated Methanol DME Haldor-Topsoe Process Production Costs ................................................................................................... 5-32

5.13 DME from Coal By the Integrated Methanol DME Haldor-Topsoe Process Utilities Summary by Section................................................................................. 5-33

5.14 DME from Coal By the Integrated Methanol DME Haldor-Topsoe Process Utilities Summary................................................................................................... 5-35

5.15 DME Synthesis and Purification - Haldor Topsoe Process Total Capital Investment........................................................................................ 5-36

5.16 DME Synthesis and Purification - Haldor Topsoe Process Variable Costs ....................................................................................................... 5-37

5.17 Dimethyl Ether Synthesis and Purification - Haldor Topsoe Process Production Costs ................................................................................................... 5-38

5.18 Dimethyl Ether Synthesis and Purification - Haldor Topsoe Process Major Equipment ................................................................................................... 5-39

© SRI Consulting xv PEP Report 245B

TABLES (Concluded)

6.1 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Patent Summary.................................................................................................... A-5

6.2 Syngas Production Chemistry ............................................................................... 6-2

6.3 JFE DME Synthesis............................................................................................... 6-2

6.4 Design Specifications for Gas Clean Up Systems ................................................ 6-6

6.5 Process Sections................................................................................................... 6-9

6.6 Basis for Estimates and Evaluations Design Basis for Coal to DME Via JFE Single Step Process ............................... 6-10

6.7 Syngas Composition Specifications ...................................................................... 6-12

6.8 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Stream Flows......................................................................................................... 6-18

6.9 Major Waste Streams............................................................................................ 6-25

6.10 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Total Capital Investment........................................................................................ 6-37

6.11 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Variable Costs ....................................................................................................... 6-38

6.12 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Production Costs ................................................................................................... 6-39

6.13 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Utilities Summary by Section................................................................................. 6-40

6.14 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Utilities Summary................................................................................................... 6-42

6.15 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Total Capital Investment........................................................................................ 6-43

6.16 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Variable Costs ....................................................................................................... 6-44

6.17 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Production Costs ................................................................................................... 6-45

6.18 Single-Step Synthesis of Dimethyl Ether From Coal by the JFE Process Major Equipment ................................................................................................... 6-46