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Special Feature on Coal Liquefaction
H&WB’s Biofuels
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H&WB has completed Step 1 (Initial Evaluation) of the Philippines Coal Hybrid Liquefaction Project and is now looking for strategic partners to initially invest up to US$50 million for the final feasibility study that would include a Basic Engineering Design, Front-end Engineering & Design (FEED), licensing fees and initial working capital.

Project Rationale
The Philippines has relied on imported crude oil from the Middle East to fill the gap in its domestic requirements. During the last five years (1999 to 2003), the country has been importing an average of 94% of its crude oil requirements from the Middle East. The high dependence on imported oil makes the country vulnerable to oil supply disruption.

The Philippines Energy Plan for 2005-2014 has placed a high priority on the development and implementation of projects aimed at cutting dependence on imported oil and on the development of renewable and alternative energy sources. Of particular interest are coal-to-clean-fuels technologies, considering that the Philippines have significant coal reserves with an estimated resource potential of 2.36 billion metric tons.

Project Development
A four-step plan has been developed with the aim to start the construction of the facilities in 2009.

Step 1 involves the initial evaluation of the overall plan and consists of six tasks. These tasks are:
Task 1 – Project scoping
Task 2 – Preliminary site/coal selection
Task 3 – Process plant configuration
Task 4 – Preliminary techno-economic assessment
Task 5 – Project development plan
Task 6 – Detailed plan for Steps 2 and 3

The final report for Step 1, which summarizes findings under this initial evaluation step, is available upon request.

 
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  • Products
  • Approximately 61,200 barrels per day (BPSD) of liquid fuels

  • Over 500 metric tons per day of elemental sulfur

  • 67-MW of power that can be exported to the grid or supplied to a dedicated off-taker.

  • Liquid Fuels
  • LPG - 11,100 BPSD

  • Naphtha - 27,200 BPSD

  • Distillate - 6,500 BPSD

  • Gas oil - 2,800 BPSD

  • Diesel - 13,400 BPSD

  • All CTL products have the advantage of low sulfur when compared with conventional petroleum products.
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Liquid Fuel
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Special Feature on Coal Liquefaction
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. Coal is not a perfect fuel, but so is the “black gold” or crude that oil consumers worldwide are currently hooked into.

Trite as it may seem, but the “dirtiest fuel tag” on coal lingers to this day. Yet note that, paradoxically, utilizing it to sustain a country’s energy needs thrives inescapably as it remains the most abundant fossil fuel on a global scale.

Talking of long-term prospects, the line of arguments evidently will not just be confined on which fuel could provide sustainability of supply; but will also bring into spotlight the role of coal in the so-called “clean energy future”, primarily in policy statements tussling various players into the “renewables versus fossil fuel debate.”

Petroleum, on the same token, is notoriously labeled as harmful to the environment, from its dirty exhaust to the toxic mess it leaves when spilled.

So what choices are available in our hands?

Pulling off a low-emission economy
Renewable sources of energy, no doubt, have a pivotal role to play in achieving a lower-emission economy; but by themselves, they cannot do well to meet growing energy demand. Unfortunately, the technology is not currently available for renewables to replace all, or even large part of the country and the world’s fossil fuel generation.

At current pace of global energy trends, coal sensibly has a key spot in the present energy mix of some economies, the Philippines included.

By estimate of the World Energy Council (WEC), global coal reserves hover at roughly 984 billion tons (minus yet the undiscovered exploitable resources), which have equivalent energy value of 4.6 trillion barrels of oil; a far cry from the calculated remaining oil reserve of 1.7 trillion barrels; and for which $16 trillion worth of investments should still be pumped in between now and 2025 to ensure that oil supply winds up until the next 40 years.

Locally, planners at the Department of Energy(DOE) penciled in total coal resource potential for the country at 2.37 billion metric tons. Production, it was said, has been consistently maintained at 1.1 million to 1.4 million metric tons range; and peaking at 2.0 million MT in 2003. The 2003 coal production was able to displace about 6.55 million barrels of fuel oil equivalent, which translated into $176.82 million foreign savings for the country based on a reference price of $28 per barrel of oil.

Sounds like there is no sure-fire way to make coal as a cleaner alternative to other conventional and proposed alternative fuels? Not really. With the advent of clean coal technologies designed to capture pollutants trapped in coal before the impurities can escape into the atmosphere and harm the environment, the ‘dirty fuel’ hogwash could well be thrown behind the times, experts say.

Ultra-clean fuels from coal
In dire search for alternative that can both reduce pollution and help rip up the country’s dependence on oil imports, the DOE recently introduced the idea of adopting a modern technology that would produce liquid fuel products using coal as a raw material.

The challenge, of course, would be for the country’s energy managers to find ways to produce safe, efficient and effective fuel for the country’s transport system and even for wider energy needs, like in the power industry. By and large, this shall be carried out with the precept that these shall be utilized in an environmentally friendly way; and setting on one hand, the prime concern of enhancing the country’s level of energy self-sufficiency.

Through an integrated gasification combined cycle (IGCC) technology, which is conscientiously becoming a buzzword in next-generation energy undertakings, US firm Headwaters Technology Innovation, Inc., offers this application for the more advanced stage of production of the so-called synthetic liquid fuels (such as gasoline, diesel, jet fuel, liquefied petroleum gas and petrochemical products) that shall be extracted out from coal resource.

The coal-based oil products are technically referred to as synthetic gases because producing them involves a chemical process called ‘gasification’; done by heating coal with steam and the result would be a mixture of carbon monoxide and hydrogen – or gas. The atoms making up coal are broken down into simpler molecules – and the result would be liquid fuels, as ultra-clean as they can get.

The upside of this process, according to Dr. Theo L. K. Lee, vice president and chief technology officer of Hydrocarbon Technologies, Inc., a subsidiary of Headwaters for its China operations, is that by turning coal into gas, the impurities in coal– like sulfur, nitrogen and other trace elements, can be almost entirely filtered out in the conversion process; thus, avoiding the phenomenon where pollutants are spewed out into the air, contrary to what normally occurs in conventional method of coal combustion.

The hot combustion gases or the so-called ‘waste heat’, tied to the over-all conversion process, he further explained, can also be used to spin a gas turbine to generate electricity.

The scientific approach of converting coal into syngases (synthetic gases) has been a long-proven experiment that was originally undertaken via the so-called Fischer-Tropsch synthesis (to give credit to its pioneers) for a coal-to-oil demonstration plant in the 1940s; until such time that evolution of technology came into fore. Project proponents said the Fischer-Tropsch method would also be initially adopted in the proposed hybrid coal liquefaction plant, to serve as the first phase of the integrated coal-to-gasoline facility in the country.

New frontiers
Given a judicious employment of this technology - and perhaps, with a bit of luck – the government is optimistic that its foray into this alternative fuel technology would come into fruition.

Energy Undersecretary Peter Anthony A. Abaya, who should be credited for tugging his way to bring in the planned $2.2 billion investment for a coal-to-gasoline facility by Headwaters, pointed out that this venture brings great promise of enabling the country of further reducing its dependence on oil imports by utilizing “our indigenous coal resource,” adding that this will yield much-needed savings to partly bail out the country from the current financial crash it is currently mired in.

Given that the estimated consumption of the domestic oil market is at 350,000 barrels per day, Abaya noted the estimated savings could reach up to $1.2 billion annually; coming in as direct reduction to the country’s oil import bill.

“Aside from dollar savings, we can also count on cheaper prices of diesel and gasoline produced out of coal as a raw material over the long-term; if compared to existing pump prices of products coming from crude,” he added.

In contrast to the potential of other alternative fuels, which could just be positioned as a blend or additives to conventional fuels, Abaya noted that those extracted from coal are aligned as replacement fuels.

“The only alternative fuels we know of are coco-diesel and ethanol, but these are blends, not replacements. This one is same exact fuel, diesel, gasoline, LPG, jet fuel and petrochemical products, from a different resource, not crude but coal,” he stressed.

Setting up a production facility with 50,000 to 70,000 barrels of capacity per day is seen displacing roughly one-seventh of the current level of the country’s oil imports.

The Philippine project is being patterned with the US firm’s $2.0 billion venture in China with a partnership deal with the Shenhua Group, also with 50,000 barrels per day capacity, due for commercial operation in 2007.

The first phase calls for the establishment of a 25-kilogram per day pilot plant to serve as part of the experiment to determine the feasibility of the use of our indigenous coal.

Barring any hitches in project implementation, can one really imagine a scenario, wherein in 2009 when the coal-to-gasoline facility is due to come on stream, the Philippines would be able to take pride of an energy output coming primarily from its normally “rejected” low-grade coal transformed into a product with very low sulfur content and a gasification process that can run power facilities where there’s no pollution, as a result?

“That one would be a classic case where it pays to be dirty,” Abaya quipped; noting further that the “brown” or lignite coal the Philippines known to be rich of, has been initially found to be the perfect type that could be utilized to extract the liquid fuel products.

If government goals are realized, that would certainly be a great story this country can tell the whole world in post-Kyoto Protocol environment. Hopefully, that would come a moment soon.

Money makes the world go round, so they say. Some people though argue that power (or leadership) actually does the trick.

By implication, any price increase impinging on budgets of ordinary consumers, especially those surviving on measly incomes, would just mirror a government’s failure of affording the economic security its people rightly deserves.

One need not necessarily state the obvious; but at present, two of the most basic commodities –oil and electricity – have been triggering direct assault on the pockets of the individual Filipino consumers and threaten the economy to a slump.

As the public is being awakened to energy issues and crisis concerns, with the government unable to maneuver the situation due to decimated budget to finance much-needed infrastructure, the Arroyo administration is being prodded to put its foot forward in setting off at the policy table an energy program that will truly and fairly address the various concerns of stakeholders – primarily the consumers’ bid for cost-competitive, reliable and sustainable energy supply.

The current woes of the energy sector are nothing new. In fact, we had already been through two of the worst crisis in our history – the oil shock of the 70’s; and the power crisis of the 1990’s typified by 10 to 12 hours of blackouts at its peak.

The key question is: have we learned our lesson? Maybe, not? If we ever learn from our mistakes and shield ourselves from being shafted again, only time and future circumstances can tell.

Re-thinking energy policy
Our experiences of the past crisis, should have given us some time to move beyond and rise above the situation, but we have failed. Now, would it not be foolhardy to wait until we are struck by another round of crisis?

The country’s energy problems actually layered up from various factors, such as lack of planning on the part of policymakers, embracing wrong yet politically-palatable decisions and exacerbated by external or world events encroaching on supply and pricing fundamentals.

Policymakers are given another chance to re-think the country’s energy policy; and government planners are being called upon to take cognizant of the available and abundant resources in re-directing the country’s energy future.

To that end, President Gloria Macapagal Arroyo set out a policy statement directing her energy officials to prioritize enhancing the country’s energy self-sufficiency to 60%, from the current 53%, before she steps down from power in year 2010. This way, the Chief Executive noted, the money stays at home and will consequently help reinvigorate the local economy.

The lists would be endless for the array of exploitable indigenous and renewable resources that will define the country’s energy future. Of course, all it takes would be grit and resolve in the exercise of government’s power so it can corner that much-needed money to re-energize its flagging economy for the long-term.

Upsurge in fuel prices
The country’s dependence on foreign oil was again laid bare when prices were hitting drastic upswings in recent months, with the cost of oil nudging over $50 per barrel at its peak in August last year. New historic highs were again recorded this month for the price of both unleaded and diesel oil at over $58 per barrel, as based on the Mean of Platts Singapore (MOPS), which is the spot price reference for the new players of the domestic oil market who are dependent on finished product imports.

Modern society loves cars; and this fixation brings with it continued dependence on oil being the most influential substance in people’s daily lives. Market experts said the current price upsurge is just providing a taste of things yet to come; as analysts are forecasting that prices may stay at $35 to $40 per barrel range for a longer period. Fingers are being crossed that if ever, hopefully, crisis proportions would not replicate the period when the Organization of Petroleum Exporting Countries (OPEC) grabbed the oil-thirsty Western economies by the throat leading prices to reach sky-high, from a low of $2.30 per barrel in 1972 and soaring to $11.51 per barrel after four years. The industry’s rancid years stretched up to the 80’s when the spot price of crude oil peaked at roughly $40 per barrel.

History points out that being oil-import dependent, a regime of high-priced oil normally wipes out the country’s economic gains.

So, how long can we actually get out from dilemma of high oil prices? Apparently, the government’s proposal to use coal as an alternative raw material to produce part of the country’s oil requirements has yet to stand the test of daylight. But, it might be worth the experiment, especially with forecasts that oil production worldwide would be trailing downward in due time, thus, exerting even more intense pressure on prices.

“Under the current high oil price and unstable supply scenario, coal-to-liquids is a viable option for providing clean transportation fuels,” said Dr. Theo L.K. Lee, vice president and chief technology officer of US firm Headwaters Technology Innovation.

The negotiations for the project started November 19 last year with Filipino firm CPI Energies stirring the wheel to convince the American investors to take a serious look of sinking in capital for the venture.

After barely three months, a memorandum of understanding (MOU) was signed in Malacañang signaling the project’s take off from the drawing board.

It was a challenging investment proposition, related CPI Energies president Antonio A. Ver, who traveled to New Jersey to open the doors of negotiations for the project, as he noted that this was the period when reports were rife that the country was about to be slapped with a rating downgrade; which typically threatens to dampen investor confidence.

“The project is now taking off,” he stressed, adding that preparations are getting headway for the required pre-feasibility study. CPI Energy lends consultancy services for the project’s implementation.

The parties are now targeting to move at pre-feasibility and feasibility studies; banking partly on the technical assistance extended by the US Department of Energy (US-DOE) for initiatives on tapping alternative fuels.

“The US government remains committed to the resolve of promoting alternative fuels…and the Philippines is certainly one of the considered niche market for these initiatives,” enthused US Ambassador Francis J. Ricciardone.

If the proposed facility would be proven commercially viable, the aim would be to move ahead on identifying the site for the facility; set parameters on testing procedures for the coal supply from the Philippines that would be shipped to the US for testing at Headwaters’ New Jersey-based research and development (R&D) facility; and will culminate at firming up commercial agreement for the project, prior to engineering design, procurement and actual construction. The Asian Development Bank, through its private sector credit window, is expected to participate in funding infusion.

The project blueprint also calls for a larger market to be catered by the coal-to-liquid facility; as it is being positioned as “regional hub” for Southeast Asia; given the country’s strategic proximity to coal shipping routes and coal sources.

Meanwhile, Lee explained that a two-phased process -- direct and indirect coal liquefaction --will be employed to produce the liquid fuels.

“Coal/oil co-processing is a lower cost and lower risk option for introducing coal liquids,” he added.

Cost comparisons
Setting apart environmental concern, as emissions of noxious substances is expected to be taken cared of by efficient clean coal technology application, it was contended that the basic merit of using coal is that remains a cheaper option, be it in its utilization as raw material for liquid fuels, such as diesel and gasoline; or in running turbines to generate electricity.

While the spot prices of steaming coal have likewise been posting up trend since 2003; peaking at roughly $70 to $80 per ton last year, it was explained that the price movements, if quantified per unit calorific value (at a reference of 1,000 kcal), this would turn out very small as compared to price increases registered for oil and other fossil fuels.

Primary factors reported to have driven up coal prices were increased demand, primordially that of China; and a decline in the additional export capacities of some countries either due to lower production triggered by coal mine accidents, lack of infrastructure that has been causing even demurrage (delays in coal loading and shipments) and or restrictions on export policies imposed by governments of producing countries. Australia raised the issue of foreign exchange concerns; while Indonesia’s case of lower exports can be traced to production cut-off because of its inability to pursue near-term development of new coalmines.

The situation was further complicated by the failure of the United States to assume its normal role as “swing producer”, from which it was supposedly increase coal supply to the market when the coal prices climbed in order to contain price rise. This was attributed to firm domestic demand and the decline in its export capacity because of price slump that started in 1998.

With these as backdrop and the price increases not expected to taper off soon, government planners articulated that it would be all the more that the development of the country’s indigenous coal resources would finally be given an aggressive push.

For the planned 50,000 barrels per day coal-to-gasoline facility, Energy undersecretary Peter Anthony A. Abaya emphasized that the price reference they are looking at would be at $10 to $15 per metric ton or an equivalent crude price of $26 per barrel. The coal feed is set at 12,800 tons per stream day for the proposed plant size.

“Looking at current prices, there’s already an apparent savings for the consumers,” he stressed, noting that Headwaters could come into market as a competitor to the well-entrenched oil players, as it does make economic sense creating a wider base of competition in the deregulated industry. It would be noted that Dubai crude prices (used as benchmark by local refiners) are currently hovering at $38 to $40 per barrel range; and coal prices are still at a high of $40 to $50 per ton.

In tandem with this, is a plan to construct a 300-megawatt power plant to utilize the steam that turns up from the liquefaction process. About 100-MW will be allotted for the facility’s use and the other 200-MW is aligned to be sold to the grid.

“So, aside from providing cheaper alternative for transport fuel, the project would also be of help in providing a solution to the threatening power crisis,” Abaya has emphasized.

Re-defining the country’s fiscal future
It is worthy to note that policy directions currently being embraced by the government always take into account the very urgent need to clear up its fiscal mess.

Plugging the very big hole in the budget is one of the toughest battle the Arroyo administration has yet to win. It already lined up proposed measures (with some emerging very controversial) that may help it finally balance the country’s budget; and such agenda is also very much intertwined in all of its economic policies, those of the energy sector included.

By the end of 2004, the fiscal deficit was expected to top off at less than P200 billion; which could account for 4.2-percent of the gross domestic product. According to the National Economic and Development Authority (NEDA), this will cause the consolidated public sector deficit (CPSD) to rise to 6.7 percent of GDP; as compared to 5.6 percent in 2003.

The country’s socio-economic planning body further noted that with the national debt already at P3.459 trillion as of last year, this will demand 76 percent use of the GDP. But if the debts of the technically-bankrupt National Power Corporation (NPC) will be factored in, it said that this will make the ratio of public debt to GDP to about 135-percent.

Abaya clarified that when they were inviting the Headwaters project, the country’s fiscal problem has been part of the equation; anchoring on foreign exchange savings that could be generated from the development of indigenous resource; aside from the perceptible benefit of security of supply and the eventual provision of jobs and business opportunities once the project has taken off from the drawing board.

One of the crucial decision points to date would be the identification of project site – one that could offer sustainable coal reserve to power the facility over long years.

Semirara, which is currently the largest coal-producing site in the country, has always been a preferred site, but Abaya disclosed they are open to options, depending on what may come out at feasibility studies.

Still as price surge and energy shortages are becoming more pronounced -- and as their effects begin to ripple against the nation – no one in the country shall afford to be careless or take the current situation for granted. And facing such a critical situation, every bit of conservation and value-creating endeavors would help. In the final analysis, capital must flow to where they are most needed to avoid new round of energy crisis.
(With the permission of Myrna M. Velasco)

 
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  • February 11, 2007: Headwaters agrees to go ahead to Pre-FEED and F-T PDU; infusing US$6.6 Million to the project
  • January 27, 2007:
    PAFC presents the project in PNOC’s Strategic Planning Conference
  • September 7 to 8, 2006:
    Philippines major coal mine company visits Headwaters R&D Center in Lawrenceville, NJ and US Gas Technology Institute, Des Plaines, IL.
  • August 16, 2006:
    PNOC Alternative Fuels Corporation’s Chairman, a Director and a senior manager visit Headwaters pilot plant in Lawrenceville, NJ
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