1. Advanced Coal Technologies (ACT), LLC “Coal21st” Coal Refining Process
March 2007

2. ENERGY SYSTEMATICS PRIMARY ENERGY SYSTEMS SECONDARY ENERGY SYSTEMS
Molecular (burning fossil fuels, producing ethanol from biomass)
Atomic/Nuclear (fission and fusion)
Solar (solar electric, solar thermal, wind)
SECONDARY ENERGY SYSTEMS
Hydrogen systems
Electron systems (electricity)

8. ACT Coal 21st Process Inputs and Outputs
6 Mw
Internally Generated
(140 tpd)
160 tpd
(Benzene, Toluene, and Xylene) at 75 tpd
1000 tpd
Naphtha
32 tpd
A simple diagram describes the process flows in the Coal 21st coal refinery and the conversion of 1000 tpd into 1. methane which is converted into syngas for low emission Fisher Tropes (FT) diesel fuel, naphtha, and lubricants plus H2 and CO recycled back to drive the reaction 2. liquid fuels and aromatics (bunker C or #4 fuel oil, BTX, and naphtha) and 3. low sulfur, high ash carbon or char (as an environmentally friendly boiler fuel.
6 tpd
40 tpd
370 tpd

9. Value of 100 tpd Coal 21st Coal Refinery Products
Price
Quantity
Daily Value
Annual Value
LED
500
$/ton 14
tons
$ 7,000
$ ,172,,000
BTX
1,000 8
$ 8,000
$ ,482,000
naphtha 3
$ 1,500
$ ,000
fuel oil 16
NH3
300 1 $
$ ,000
sulfur
100 4 $
$ ,000
Char Price 60 37
$ 2,220
$ ,000
Total
$/ton 83
$ 27,420
$ ,507,000
LED is low emission diesel, sometimes referred to as “green diesel” and represents the value of the H2 and CO that is left over from the Partial Oxidation (POX) process which converts the methane into the H2 and CO. Half of the H2 and CO is used to drive the HDP reactor and the other half can be used to make LED or any high value petrochemical. .

10. Ultimate Integrated Coal Refining Process Flow
AIR SEPARATION
NITROGEN
Or CO2
OXYGEN
STEAM
INERT
GAS FOR
DRY FEED
PARTIAL
OXIDATION
POX
REACTOR
CO / CH4 RICH
RECYCLE GAS H2
COAL
PREPARATION
AND
FEED
SYNGAS
1600 F to 2200OF
HOT POX
GAS
Optional H2, CO
Gas
Separation for hydro-treatment
FISHER TROPSE
(FT)
SYNTHESIS OF
HIGH VALUE
DIESEL FT
DIESEL
$$$
STEAM H2
SYNGAS
SWEET GAS
AROMATIC s, OILS
AND
SYNGASES
COOLING,
LIQUIDS
CONDENSATION,
AMMONIA
RECOVERY
OPTIONAL
SHIFT AND / OR
STEAM
REFORM
REACTOR
ACID GAS
REMOVAL
AGR
HDP
REACTOR
AND
CHAR
WATER QUENCH
STEAM
SULFUR OR
SULFURIC ACID
A very detailed process flow diagram showing alternate use of residual syngas for FT LED production, possible recycle of BTX to the HDP unit or reformed into syngas for production of more FT LED, selling of hot , 600 F char to a close coupled boiler, etc.
AROMATIC OILS
AMMONIA
OR OIL
INJECTED TO
PRODUCE
MORE
SYNGAS
OPTIONAL OIL QUENCH OILS
OPTIONAL RECYCLE AROMATIC OILS
RECYCLE
RECOVER
HYDRO
TREATED
OILS
BTX
HOT
CHAR
(LOW S&N)
OPTIONAL
RECOVERY OR
RECYCLE
CLOSE COUPLED
EXISTING PC, BOILER,
OR CFBC, OR PCFBC
POWER FOR
COAL REFINERY
NAPHTHA
ON SITE
USE
YES
FUEL OIL
EXCESS POWER
TO GRID
MAKE UP
BFW
SLAG
SYNTHETIC
COAL
$$$ NO
TRANSMISSION
TOWERS
PRODUCE PITCH
OR BINDER
WITH CHAR
TRAIN

11. ACT proprietary Information
Hydrodisportionation (HDP) operation and design
Optimization of Flash Hydropyrolysis conditions
Separation of char from gas
Slot/star feed system for fast pressurized non-agglomerating feed of coal
Recycle of methane to POX for hydrogen conservation and H2 and CO production to initiate Flash Hydropyrolysis
Integration of ACT Flash Hydropyrolysis system with oil refinery downstream system.
Production of syngas for SASOL conversion to low emission diesel.
ACT has proprietary concepts, processes, information, and technology as well as patents.

12. Example of what an ACT Coal 21st Coal Refinery would look like (Using the DOE/SC Power System Development Facility for Scale)
Fuel Handling
This is a picture in the day and at night of the DOE/SC PSDF which is similar in scale to the ACT coal refinery. The fuel handling would be the latest improved version of the PSDF fuel handling facility which has been a very successful pressurized pulverized coal feed system. A meeting with ACT in the US could be arranged for the DOE/SC PSDF which is about an hour from the Birmingham, AL airport.

13. ACT 100 tpd Optimization Plant Specifications
Confidential information in a separate document provided to interested parties

14. Coal21st: Economic Benefits
High value chemicals produced: primarily benzene with some toluene and xylene (BTX) for chemical processing facilities.
Benzene is a raw material for production of phenol, malic acid, caprolactam, alkylbenzene, styrene, and dye stuff intermediates.
Toluene (Methylbenzene) is a Solvent for paint and rubber, and Raw material for toluene di-isocyanate, benzoic acid, and dye stuff intermediate.
Xylene is solvent for paint and insecticide, and raw material for paraxylene, orthoxylene, and ethylbenzene
Naphtha as N-dodecane with boiling point (bp) of 4210 F
Fuel Oil as N-pentadecane with bp of 5190 F
Other oils like thiophene with some sulfur (bp 1830 F) pyrrole with some nitrogen (bp 2660 F), heavy oils like chrysene (bp 8260 F)
Low sulfur diesel, methanol, or other chemicals from residue syngas.
Low sulfur, low nitrogen, high Btu solid fuel-Char
Economic Benefits are shown as high value liquid fuels and petrochemicals.

15. Why ACT’s Coal 21st Coal Refining Process?
Highest throughput (lowest residence time 0.1 to 3.0 seconds) of all synfuels process resulting in lowest capital cost (HDP should be factor of >10 times cheaper than equivalent sized gasifier with residence times in the minutes).
Coal 21st maximizes yield of high value aromatics as BTX plus naphtha and fuel oils (can be used directly or refined further into diesel fuel, gasoline)
Low emissions of CO2 as BTX when converted primarily into paint and plastics traps about 8% of the carbon. Low emission diesel (LED) has a Cetane number of 78, twice that of conventional diesel. This increases miles per gallon and reduces CO2 another 0.7%. The result is a total potential reduction of about 8.7% over burning the coal for electricity.
Potential to be a more flexible and robust design with possible recycle of aromatics, steam reforming of aromatics into syngas, conversion of syngas into multiple products
Low sulfur solid fuel (char) produced as compliance solid fuel for existing and new coal fired power plants
High Return on Equity (24% for 100 tpd to 232% for 30,000 tpd) is possible due to the low cost of the HDP, high throughput. (assuming $30 per ton for coal and > $250 per ton for products).
Benefits of the Coal 21st Process are listed. Note that the overall reduction in CO2 with ACT’s COAL 21st Coal Refining process is nearly 10% over the CO2 that would be emitted by burning the coal directly while at the same time providing a potentially high ROE for ACT coal refineries.

16. Coal21st Societal & Environmental Benefits
Twenty 30,000 tpd Coal21st Coal Refineries would generate char for 25,000 MW of clean power and produce 640,000 bbl/day of very low sulfur liquids thereby decreasing dependence on imported or domestic oil.
Burning char instead of coal reduces SOx (>85%) and NOx (65%), toxics (mercury, chlorine, etc. total), particulates ( microns) without flue gas desulfurization for SOx or SCR for NOx
Low emissions of CO2 as BTX when converted primarily into paint and plastics traps about 8% of the carbon. Low emission diesel (LED) has a Cetane number of 78, twice that of conventional diesel. This increases miles per gallon and reduces CO2 another 0.7%. The result is a total potential reduction of about 8.7% over burning the coal for electricity.
Syngas produced by Fisher-Tropsch (FT) yields low emission diesel (LED) with 1 ppm sulfur (exceeds new EPA standards) plus low sulfur naphtha and high value lubricants.
Coal refineries can use any local, poor quality, high cost coals (insensitive to coal prices).
Coal refineries will draw other petrochemical industries to the location spurring economic development

17. IDC is Interest During Construction
Range of capital costs as a function of size. It is assumed that costs in Taiwan will be 63% of the costs in the US. A 100 tpd ACT Coal 21st coal refinery process is assumed to cost about $24 million and a 300 tpd is estimated to cost about $52 million. The risks of failure increase with size based on today’s base of knowledge. Success of the 100 tpd is estimated to be > 80%.
IDC is Interest During Construction
Initial 100 tpd is estimated to cost $21 million ($10million equity) in Asia

18. 100 tpd is estimated to yield 24% ROE
Range of ROE as a function of size based on coal input in 1,000 tpd. Note that a 100 tpd unit has a respectable 24% ROE at a $24 million total investment cost. ROE increases significantly up to 5,000 tpd maxing out at 30,000 tpd.
100 tpd is estimated to yield 24% ROE

19. Potential Competitive Coal Conversion Technologies for FT diesel production
International production from associated natural gas (flare gas) and FT diesel synthesis using Gas to Liquids (GTL Processes) requires mega gas fields.
Encoal mild gasification produces a char and a reduced sulfur residual fuel oil at high cost
Domestic production of FT diesel from GTL synthesis with natural gas (which is not economic with high natural gas prices in the US).
Coal gasification for FT diesel production (like the Gilberton project in Pennsylvania) which is higher in capital cost and lower in ROE than Coal 21st coal refining process.
Headwaters’ Hydrogen Technology’s expensive but high yield coal gasification to GTL or direct coal hydro-cracking with recycled heavy process liquids and use of external hydrogen (currently being licensed in China). Lower ROE than Coal21st.
Potential competition are too capital intense and have lower ROEs

20. Shell Gasification Markets are Really Coal to Chemicals in China?
Shell Coal Gasification Process is being implemented in China to produce ammonia, urea, methanol, etc.; though it is more expensive than ACT’s Coal 21st process.