EPA-600/2-75-70 Environmental Protection Technology Series
October 1975
EPA Program Status Report
Synthetic Fuels Program
\
Office of Research and Development
U.S. Environmental Protection Agency
Washington, D.C. 20460
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and appli-
cation of environmental technology. Elimination of traditional grouping
was conciously planned to foster technology transfer and a maximum
interface In related fields. The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION TECHNOWGY
series. This series describes research performed to develop and demon-
strate instrumentation, equipment and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution.
This work provides the new or improved technology required for the
control and treatment of pollution sources to meet environmental quality
standards.
This report has been reviewed by the Office of Research and Development.
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October 1975
EPA PROGRAM STATUS REPORT
SYNTHETIC FUELS PROGRAM
Prepared Initially by
Bruce Truett
The MITRE Corporation
Washington Operations
McLean, Virginia 22101
Revised and Finalized by
Robert G. Murray
Stanford Research Institute
Menlo Park, California 94025
and
Dr. Gary Foley, Chairman
Advanced Fossil Fuels Sector Group
Office of Energy, Minerals and Industry
Environmental Protection Agency
Washington, D.C.
Prepared for
The Environmental Protection Agency
Washington, D.C. 20460
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TABLE OF CONTENTS
1. INTRODUCTION AND SUMMARY 1
2. PROGRAM OVERVIEW 3
2.1 Background „ . 3
2.2 Program Objectives and Responsibilities .... 4
2.3 Technology Involved: Its Importance,
Advantages and Limitations 5
2.4 Program Benefits 8
3. CURRENT PROGRAM STATUS 9
3.1 Characterization of Feedstock 9
3.2 Assessment of Environmental Effects
of Conversion Processes 10
3.3 Control Technology Development and Assessment . 11
3.4 Demetallization, Desulfurization and
Denitrification of Oils (Shale, Petroleum,
and Synthetic) 11
3.5 Pollution Potential from Utilization of
Synthetic Fuels; Definition of Control Needs. 12
3.6 Technology for Recovery of Byproducts 13
3.7 Assessment of Waste Management Problems .... 13
4. SUMMARY OF ACCOMPLISHMENTS 15
5. APPENDICES 17
Appendix A - Funding Level of Program Areas . . 19
Appendix B - EPA Reports on Synthetic Fuels . . 25
ill
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1. INTRODUCTION AND SUMMARY
The Environmental Protection Agency (EPA) Synthetic Fuels Program
is one of several technology advancement programs directed toward pro-
viding the necessary technology for meeting near-term and long-term
energy requirements in an environmentally acceptable manner. The
primary concern of the program is the control and prevention of environ-
mental pollution from the conversion of coal and other fossil fuels
to synthetic fuels, and from the utilization of synthetic fuels. The
program is an outgrowth of EPA's Fuel Cleaning Program, and has been
in operation since 1972. It has developed a substantial data base on
the pollution potential of fossil fuels used as raw material for pro-
duction of synthetic fuels, and a broad expertise that can now be
focused on the task of assisting energy producers and consumers in
meeting energy needs and environmental goals.
The Synthetic Fuels Program has two principal thrusts. One is
the establishment of control requirements to prevent or minimize envi-
ronmental pollution from the production and utilization of synthetic
fuels. The second is the development of advanced technology for con-
trolling the release of pollutants. Initial efforts in the program
are concentrated on assessing the potential environmental effects of
coal conversion. The assessment is based on the characteristics of
coals and oil shale as well as the reactions and equipment character-
istics of candidate conversion processes. To date, efforts involving
the development of technology for controlling the release of pollutants
have been directed primarily toward the desulfurization of hot, acidic
gas streams in gasification processes and the demetallization and
desulfurization of oils. The technology development effort was expanded
in FY 1975 to include pollution controls for coal liquefaction, coal
solvent refining, and oil shale processing.
There are, to date, a number of significant accomplishments of
the program which have current or long-term impact on the Nation's
energy problem. These include:
• Characterization of the pollution potential of over 100 U.S.
coals likely to be used in conversion processes to make clean fuels
• Identification of the pollution potential and evaluation of
available pollution control in five gasification processes
and two liquefaction processes.
• Bench-scale demonstration of a highly effective method for
desulfurization of high-temperature, acidic gases.
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• Evaluation of catalysts for demetallization of oils.
• Analysis of the problems and opportunities of retrofitting
industrial processes to use low-Btu synthetic gas.
• A symposium on environmental aspects of fuel conversion which
provided a focal point for data dissemination and discussion
of these factors.
Continuation of the Synthetic Fuels Program will involve assess-
ing the environmental impact of additional conversion processes; a
more in-depth data acquisition and assessment program; expanded effort
in defining control requirements for conversion processes and developing
necessary control technology; and new initiatives in defining control
requirements. New initiatives are desirable in the areas of trans-
portation and utilization of synthetic fuels, examination of specific
water quality effects from conversion processes, and research into the
control requirements for waste streams and the potential for recovery
of valuable byproducts from wastes which would otherwise be environ-
mentally hazardous. Timely accomplishment of the program will result in
well-defined environmental control requirements and identification of
control techniques in a time frame that allows process developers to
incorporate the necessary control technology into their process design,
thereby avoiding the costs and inefficiencies of retrofitting.
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2. PROGRAM OVERVIEW
2.1 Background
The United States has a growing demand for fuels to meet increas-
ing energy requirements in an environmentally acceptable manner. The
Nation's largest fossil fuel resource is its coal reserves. Most U.S.
coals, when burned in a conventional manner, introduce several types
of pollutants into the environment in quantities that have proven to
be unacceptable from the standpoint of environmental quality. Coal
can, however, be converted to solid, liquid, or gaseous synthetic fuels
of lower pollutant content. Under the mandates of the Air Quality Act
of 1963, the Water Pollution Control Act Ammendments of 1972, and the
Solid Waste Disposal Act of 1965, EPA initiated a program to reduce
pollutant emissions and discharges from processes that produce synthe-
tic fuels from coal, so that an adequate, reliable supply of fuels
with low pollution potential would be available to meet future energy
requirements.
The production of synthetic fuels from coal is not new, either in
concept or practice. Early in this century, many American and Euro-
pean cities had "gas works" that produced manufactured gas from coal
for both domestic and industrial use. With the advent of pipelines
for transporting large quantities of natural gas and other improvements
in the processing and shipment of liquefied petroleum gas, the use of
manufactured gas from coal has been largely supplanted by -petroleum-
derived gases of higher heating value. More recently, coal-to-gas
conversion has been performed on a commercial scale in plants currently
in operation in Europe and South Africa.
The technology for producing liquid fuels from coal has also
existed for several decades. During World War II, a fuel oil suitable
for vehicle use was produced from coal on a commercial scale in Ger-
many. The technology, which became available to the United States
after the war, proved far too expensive to compete with petroleum fuels.
Much of the current work on coal liquefaction is directed toward im-
proved process efficiency and improved quality of the resulting fuel.
The earlier applications of coal conversion to liquid or gaseous
fuels were intended primarily to produce more convenient forms of
fuel for household, industrial, and vehicular use, rather than clean-
burning fuels for reduction of environmental pollution. Nevertheless,
the synthetic fuels generally burn cleaner than the original coal,
and can be made extremely clean (low sulfur, low ash) by inclusion of
pollutant removal steps in the conversion process. The pollution-
causing substances must then be dealt with during conversion. Thus,
the conversion process itself is a potential source of environmental
pollution.
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EPA's Synthetic Fuels Program began in 1972 as an effort of its
Fuel Cleaning Program, which had been underway for several years. Both
were directed toward development of technologies for producing clean
(low-polluting) fuels from coal and other energy resources. The Federal
Government's Synthetic Fuels Program was expanded and accelerated under
the impetus of the 1973 energy shortage and attendant increases in the
price of petroleum. This program now under the direction of the Energy
Research and Development Administration (ERDA) addresses the production
of solid, liquid, and gaseous fuels from coal and oil shale. EPA's por-
tion of the Federal program is aimed toward insuring that clean fuels
are available to meet standards and that adequate technology exists for
controlling the release of environmental pollutants during production
and utilization of these advanced fuels.
2.2 Program Objectives and Responsibilities
The overall objective of the Synthetic Fuels Program is to insure
that adequate technology is available to control, within acceptable
levels, the discharge of environmental pollutants from the production
and utilization of synthetic fuels from coal or oil shale. Implicit
in this objective is the schedule requirement that the necessary con-
trol technology be developed in time to permit its incorporation into
planned commercial-scale conversion facilities.
To support this general objective, the following intermediate
goals have been defined for the Synthetic Fuels Program:
• Determine the pollution potential of major fossil fuels
(principally coal and oil shale) through analysis of
domestic reserves.
• Assess pollution potential from storage and preconversion
processing of fossil fuels; define control requirements and
develop the necessary control technology.
• Assess the pollution potential of proposed coal conversion
processes, including identification of pollutants occurring
at major and secondary processing steps.
• Define the requirements for fuel product quality from the
viewpoint of combustion pollutants and pollution due to
accidental release during storage or transportation and
develop the control technology where required.
• Encourage the development of adequate control technology
by other governmental agencies and commercial firms in-
volved in synthetic fuel production.
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• Evaluate the adequacy of control measures presently
available and proposed for use with future fuel
conversion facilities.
• Assess the pollution potential of the transportation,
storage and utilization of synthetic fuels. Define control
technology requirements.
• Assess the pollution potential of disposal of wastes from
synthetic fuel production. Define control requirements,
and develop the required control technology.
• Investigate and assess the potential for recovery of wastes
or pollutants as byproducts.
• Obtain a viable data base that can be used by EPA regu-
latory divisions in setting environmental standards for
synthetic fuel production and utilization.
These intermediate goals have been used as the basis for defining
and shaping the individual projects of the EPA Synthetic Fuels Program.
The definition of control requirements is being accomplished in
conjunction with EPA's Environmental Effects Program and regulatory
activity. Requirements are expected to be in the form of allowable
limits (rates and concentrations) within which polluting substances
might be released to the environment without imposing a health hazard
or inflicting other environmental damage or degradation.
Primary responsibility for developing the in-process technology
necessary to meet pollution control requirements resides with those
organizations (government and private) who are developing the basic
conversion process. If this responsibility is not met, EPA may be
required to pursue in-process development in specific areas. EPA is
undertaking the major responsibility for the development of any needed
add-on control measures and will be evaluating the effectiveness and
overall adequacy of all control methods proposed or developed either by
EPA or by other organizations. EPA has also undertaken the coordination
of all governmental research and development efforts for environmental
control of synthetic fuel production and use.
2.3 Technology Involved: Its Importance, Advantages and Limitations
The principal raw materials to be used in the production of syn-
thetic fuels will be coal and oil shale. Coal is by far the most im-
portant both in size of resource base and in its geographic distri-
bution. Oil shale will contribute a smaller portion of synthetic fuels
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but, because of its geographic concentration, could create severe waste
disposal problems. Many of the problems of waste disposal are similar
for coal and oil shale; both contain solid residues that must be dis-
posed of in fixed landfills; both raw materials contain heavy metals,
nitrogen and sulfur that can form pollutants during the conversion to
fuels. Some liquefaction processes concentrate organic constituents
(polycyclic aromatic compounds) that are known to be carcinogenic and
are normally decomposed during combustion, in intermediate materials and
possibly in the final products.
The magnitude of potential polluting substances present in or
formed during the conversion of solid fossil fuels to clean usable
forms of fuels is found to vary from several percent in the case of
sulfur down to a few parts per million in the case of mercury or other
trace components. To put the potential problem in perspective, a
coal gasification plant capable of producing 250 million standard cubic
feet per day of pipeline gas from Eastern U.S. bituminous coal will
require about 26,000 tons per day of coal input. Assuming 3.5 percent
by weight sulfur content'in the feed, a typical value for eastern bi-
tuminous coal, 1,820,000 pounds of sulfur per day will flow through
the plant and must be accounted for. If 95 percent of this sulfur is
controlled, the plant could still emit 180,000 pounds of sulfur dioxide
(S02) Per day. If o'ne part per million of mercury occurs as a trace
element in the coal, the plant must account for 52 pounds per day of
mercury in the products or waste streams.
There is available technology for controlling the release of the major
pollutants. In most conversion processes, much of the organic sulfur com-
pounds is converted to hydrogen sulfide which can be reduced to elemental
sulfur, a potentially valuable byproduct, by the Glaus reaction which re-
moves about 95 percent of the sulfur. An alternate, the Stretford process,
removes about 99 percent. Polycyclic aromatic solvents can be retained in
the process equipment for reuse or for conversion to clean fuel products,
or can easily be decomposed by thermal oxidation. These and other demon-
strated control measures have been incorporated into the design of many of
the proposed plants. The removal of some of the pollutant-causing materials
is, in fact, necessary for the efficient operation of certain conversion
processes. Some pollutant removal processes are intricate and expensive,
with expense increasing sharply with the degree of removal required. A
major problem is the determination of where, in the overall conversion
process, specific control measures should be applied to effect adequate
control of pollutant discharges from major process streams and all secon-
dary and waste streams.
The control of pollutant discharges may be far from complete, however.
Approximately 300 compounds, many of which are potential pollutants, have
been identified among the products of reactions involved in the conver-
sion of coal to synthetic fuels. The relative quantities of these
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compounds in the products and waste streams have not been fully deter-
mined for conversion processes. Some of these compounds are water
soluble and, if they enter sources of water supply, would have detri-
mental effects on conventional water treatment systems. Attention
has recently been focused on the chlorine content of coal and its
effects on the types of pollutants that might be released. Significant
levels of chlorine in coal could yield chlorinated hydrocarbons among
the products of conversion, which are serious environmental pollutants.
The course of heavy metals from the raw material, some of which
are known to be toxic and suspected of being carcinogenic, is not well
understood for many conversion processes. Some processes require
removal of heavy metals from the process stream to prevent poisoning
of process catalysts. Removal can be accomplished in greater or lesser
degree by a variety of demetallization processes, usually expensive,
such as scavenging, oil extraction, chelation, or formation of eutectic
slags. Portions of the heavy metal content may emerge in the synthetic
fuels produced; other portions may be released to the environment in
liquid or gaseous discharges or may be retained in the walls of the
reaction vessels or tubing. Much of the heavy metal content will prob-
ably be concentrated in the ash and other solid wastes from the con-
version process, where the metals can be stabilized for safe disposal
or subsequent recovery. The adequacy of existing treatment methods
requires further evaluation based upon developing information on the
nature and quantities of metallic constituents of feedstocks.
Both gasification and liquefaction plants will have the opportunity
to produce valuable organic liquid byproducts from waste streams. The
process steps required to separate these byproducts from other plant
streams affect the operation of the waste control units, such as waste-
water treatment, as well as plant facilities, such as the recirculating
water system. The existing control technology for sulfur and some
organic pollutants, currently designed into major process streams for
many of the proposed conversion plants, is probably adequate also for
controlling discharges from this secondary byproduct production. It
must, however, be carefully adapted to these applications in the light
of emerging information on the content and concentrations of secondary-
stream constituents.
Product quality will also affect ultimate emission of effluents
into the environment. As an example, the nitrogen content of the product
oils from coal liquefaction or oil shale is a problem. The removal of
the nitrogen may be accomplished in the conversion process or in a
properly designed combustion system neither of which is well developed
technology.
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2.4 Program Benefits
The major benefit of the EPA Synthetic Fuels Program will be to
maintain a clean, healthful.environment while providing the capability
of utilizing the Nation's most plentiful fossil energy resource to form
clean, convenient fuels for industrial and domestic use. An indirect
benefit that will result from early identification of pollutants and
control measures is the avoidance of problems of retrofitting existing
equipment. Potential secondary benefits of environmental control lie
in the recovery of sulfur, trace metals, phenols and valuable organic
compounds as coproducts, and the recovery of ash and other solid products
(for uses such as fill material or concrete aggregate) from the process
wastes.
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3. CURRENT PROGRAM STATUS
The Synthetic Fuels Program began at a modest level of effort in
1972 and was significantly expanded during FY 1975. The enlarged
program currently includes the following activity categories:
1. Characterization of Feedstock (Pollution Potential
and Energy Content)
2. Assessment of Environmental Effects of Conversion
Processes
3. Development and Evaluation of Control Technology
for Pollutant Removal from Conversion Plants
4. Demetallization, Denitrification, and Desulfurization
of Oils (Shale, Petroleum, and Synthetic)
5. Determination of Pollution Potential of Synthetic
Fuels Utilization; Definition of Control Needs
6. Assessment and Development of Technology for Removal
of Pollutants and Their Recovery as Byproducts (Energy
and Chemicals)
7. Assessment of Waste Management Problems (Solids,
Liquids, and Gaseous).
Certain of the above categories (Numbers 1, 2, 3, 4, and 5) repre-
sent continuations of work initiated in the earlier years of the Syn-
thetic Fuels Program. A number of solid accomplishments (identified
in Section 4) were realized during this interim period of low budget
effort. The remaining categories (Numbers 6 and 7) are just beginning
(FY 1975), and the environmental assessment work in Number 3 is being
greatly expanded under the FY 1975 budget. Under the current program,
major funding is for environmental assessment and control technology
development. Approximate funding levels for program elements are
shown in Appendix A. The general content of major program elements is
discussed below.
3.1 Characterization of Feedstock
The Illinois State Geological Survey has examined the occurrence
and distribution of trace elements in coal which potentially could
become volatile in a high-temperature process. Coals are being analyzed
by the Institute of Gas Technology to determine the quantity of pollu-
tion-causing substances in major fossil fuel reserves. The work to
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date has involved analysis of the mineral content of eastern and mid-
western coals, including trace metal residues.
Analyses of the mineral matter in coal is being continued at a
low level of effort. Recently analyses have been performed on 101
whole coal samples and 32 separate fractions of washed coals, for 10
major and 23 trace elements. Previous tests were conducted on 1500
coal samples including some trace element analysis on 400 of them.
A more comprehensive coverage of western coals and oil shale is planned
for inclusion in subsequent years' programs.
3.2 Assessment of Environmental Effects of Conversion Processes
This program began about two years ago with an effort to identify
and estimate quantities of potential pollutants released to the environ-
ment by specific conversion processes, to assess the effects of these
substances on the environment, and to evaluate measures employed to
control the release of certain pollutants. To date, reports have been
issued for the following conversion processes:
- Koppers-Totzek Process (gasification)
- Synthane Process (gasification)
- Lurgi Process (gasification)
- CO- Acceptor Process (gasification)
- BIGAS Process (gasification)
- COED Process (liquefaction)
- SRC Process (liquefaction)
This work was done by Exxon Research and Engineering.
This effort is being expanded to include other processes for coal
gasification (to both high-Btu and low-Btu products), liquefaction
(including solvent refined solid products), and extraction of fuels
from oil shale. Two important aspects of the expanded program are the
acquisition of pollutant-discharge data from full-scale plants abroad
and from pilot and demonstration plants funded by ERDA in the United
States.
Arrangements for obtaining this kind of information from operational
Lurgi gasification plants are in progress with four foreign countries.
Negotiations are presently underway with ERDA to obtain similar data
from existing and planned demonstration units in the United States.
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EPA is currently negotiating separate contracts for environmental
assessments of the production of low-Btu gas, high-Btu gas, oil from
shale, and liquid fuels from coal. Also under negotiation is an en-
vironmental assessment of the probable future synthetic fuels industry
utilizing systems analysis methods.
EPA has recently published a report on the Institute of Gas
Technology assessment of the fate of trace constituents of coal during
gasification. Trace metals in particular were found to be discharged
by several different mechanisms, such as fumes and deposits on cata-
lysts, in addition to remaining in the ash or being deposited within
the reactor.
3.3 Control Technology Development and Assessment
While the environmental assessment work has been oriented toward
overall systems for producing a given type of fuel (such as Lurgi
gasification), the control technology effort is oriented toward unit
processes, most of which find application in several types of overall
systems.
The problem of removing sulfur-and other pollutants from gas
streams at high temperatures has received much of the early attention
in this program. It .is estimated that overall thermal efficiency of
gasification processes is improved by 5 to 9 percent by cleaning the
gas streams at high temperatures instead of cooling the stream before
cleanup. Cleaning the hot, acidic gas streams continues to present
major technical problems in several gasification processes. Considerable
success has been achieved by Conoco Coal in the development of a desul-
furization process for fuel gases at high temperatures. Bench-scale
work has produced 97 to 99 percent desulfurized gas stream, and a pilot
plant demonstration is being considered as a possible joint ERDA/EPA
program. During FY 1975, the Synthetic Fuels Program is initiating
additional R&D projects on fuel gas cleanup, including desulfurization
and particulate removal of high-temperature/pressure process streams.
3.4 Demetallization, Desulfurization and Denitrification of Oils
(Shale, Petroleum, and Synthetic)
The Synthetic Fuels Program includes research, development, and
demonstration of procedures for removing metals, sulfur, and other
potential pollutants from liquid fuels. Attention is currently focused
on residual oils derived from petroleum, which are widely used as
power plant fuels. Technology developed for this application is ex-
pected to be adaptable for removal of pollutants from shale oils and
synthetic liquid fuels derived from coal. The program includes identi-
fication of potential pollutants in oils and development of methods
for their removal.
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A literature survey has assembled and analyzed available data on
domestic and imported crude oils. These data provide the initial basis
for an inventory of potential pollutants whose fate must be followed
in further oil processing and utilization. This work was performed
by Exxon Research beginning in 1972.
Much of the oil available to the United States is high-sulfur,
high-metals-content residual oil. Currently, much residual oil cannot
be desulfurized economically to meet environmental requirements because
metals in the oil poison the desulfurization catalyst. Since vanadium
and nickel are two of the major poisons, a program is underway to
develop a low cost method for removing them prior to conventional desul-
furization. The program is evaluating various scavenger and catalyst
combinations. The residual oils being used in the investigations are
vacuum bottoms with 3 to 3.5 percent sulfur and 400 to 1,000 ppm (parts
per million) total vanadium and nickel. Successful completion of this
project will result in a clean fuel for use in existing large installa-
tions. This work, begun in 1972, is being performed by Hydrocarbon
Research, Inc. It should be noted that a large effort is being put
into smaller areas of research by industry aimed primarily at methods
for making quality products from poor feedstocks. In this regard it
is necessary to purify the refinery feedstock by removing metals, sulfur
and nitrogen before it can be upgraded to a high-octane gasoline. The
EPA program complements this work.
A research project is underway to investigate the kinetics of
simultaneous hydrodesulfurization and hydrodenitrification of liquid
fuels. These reactions are being studied to determine the conditions
at which they compete for the same supply of hydrogen and at which they
may be aiding each other. By removing such compounds from the fuel
prior to combustion, part of the potential for producing air polluting
oxides of sulfur and nitrogen is removed. Results of this type of work
are aimed at long-term applications and may be useful in producing
clean fuels from liquids derived from coal or oil shale. This work is
being performed for EPA by the Massachusetts Institute of Technology.
3.5 Pollution,Potential from Utilization of Synthetic Fuels;
Definition of Control Needs
This program is to assess the potential pollution problems from
the transportation and utilization of synthetic fuels, and to identify
technological measures needed to control the associated release of
pollutants.
The magnitude of potential pollution problems associated with the
use or transport of synthetic fuels depends in large measure on the
effectiveness of pollutant removal measures during production of the
fuels. If sulfur in the raw material is removed during manufacture
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of synthetics, there should be no problem of sulfur oxides in the com-
bustion gases when the fuel is burned. Similarly, there should be no
problem for trace metals or their compounds. But few pollutant removal
measures are totally effective, and it is therefore necessary to examine
the products of combustion (gaseous, liquid, and solid) for potential
environmental pollutants. Since certain classes of synthetic fuels
derived from coals (in particular, the liquids) 'contain different pro-
portions of organic compounds than liquid fuels derived from petroleum,
it is necessary to examine their combustion products to determine
whether new and possibly hazardous compounds are formed by combustion
reactions.
The problems and opportunities of retrofitting coal gasifiers to
industrial plants was examined by Battelle for EPA. The study showed
that such retrofitting would reduce emissions from existing coal fired
plants as well as provide a nonpolluting fuel for plants now using
gas or oil which may not be available for this purpose in the future.
Another potential problem relates to the nitrogen content of syn-
thetic fuels obtained from coal. Nitrogen compounds are not removed
by all processes that convert coal to synthetic fuels, and may, in fact,
be concentrated in the synthetic fuel produced. These substances could
cause formation of nitrogen oxides during combustion, producing unaccept-
ably high concentrations of oxides of nitrogen (NO ) in the combustion
gases.
3.6 Technology for Recovery of Byproducts
This program will assess the pollution potential of byproducts from
systems that produce synthetic fuels, to define technology needed for
control of pollutants from byproducts, and to evaluate technology for
environmentally acceptable separation and recovery of byproducts. This
is a new part of the Synthetic Fuels Program, being initiated in FY 1975.
Earlier work in this area to identify most urgent needs and to pro-
vide a basis for indicating potential control methods included a study
of the pollutants and potential byproducts in process streams of the
P&M solvent refined coal process. Pittsburg and Midway Coal Company
examined nitrogen, sulfur, and trace metals in the secondary (byproduct
and product) processing steps. In April of 1975 a report on potentially
hazardous emissions from the extraction and processing of coal and oil
was published by Battelle. This was an extensive preliminary examina-
tion and cataloging of organic and organometallic compounds.
3.7 Assessment of Waste Management Problems
Wastes referred to here are both solids and liquids from coal con-
'Version, oil shale retorting and upgrading and petroleum refining. In
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oil shale retorting about 85 percent of the raw material must be dis-
posed of as solid waste; in coal the solid wastes will vary from 5 to
20 percent of the feed material. In petroleum refining the quantity
of solids to be disposed of is relatively small but may contain signi-
ficant amounts of soluble materials. Both conversion and refining
operations must dispose of spent catalysts, treatment sludges, blowdown
streams and off-specification materials produced during plant start-up
and upsets.
This program is intended to investigate impacts of specific waste
products on the environment and to devise methods for controlling
or disposing of such wastes to prevent environmental damage. Initial
attention will be directed toward two problems: (1) the effects of
liquid wastes from coal conversion and petroleum refining on the aquatic
environment with emphasis on aquatic organisms, and (2) assessment of
the effects of "rain-out" from coal conversion processes on aquatic
ecosystems.
EPA is currently negotiating to have a single contractor identify
problems and develop controls in the area of waste storage and disposal
and byproduct utilization in advanced fuels processing plants.
Problems associated with atmospheric, groundwater or aquifer
transport of pollutants from the vicinity of fuel processing plants
to other areas are under investigation. Specifically, waste materials
from coal or oil shale solids disposal may enter groundwater ecosystems.
Atmospheric emissions from a fuel processing plant may enter lakes or
streams through normal weather phenomena such as rain. Studies are
underway to characterize the transport and fate of energy related pollu-
tants in marine waters and to determine the effect of waste products
on aquatic organisms. Other studies seek better methods for conserving
water usage in fuel conversion processes and mitigating the effect, of
disposing of waste heat in the Great Lakes basin.
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4. SUMMARY OF ACCOMPLISHMENTS
The Synthetic Fuels Program has thus far produced the following
substantive results:
• Analyzed over 1500 coal samples from more than 100 Eastern
and Midwestern coal sources and characterized them for
pollution potential.
• Identified potential pollutant releases by five conversion
processes:
- Koppers-Totzek gasification
- Synthane gasification
- Lurgi gasification
- C0« Acceptor gasification
- BIGAS gasification
- COED liquefaction
- SRC liquefaction
• Developed and demonstrated highly effective desulfurization
process for high-temperature gas stream (at bench scale).
• Developed design for pilor-scale unit to demonstrate
desulfurization of high-temperature gas stream.
• Completed an analysis of high-temperature versus low-
temperature cleanup of gas streams, with emphasis on
application of combined cycles. (There was a difference
in efficiency of about 5 percent in favor of cleanup at
high temperature.)
• Produced an inventory of potential pollutants in crude
oils from specific locations (domestic and foreign).
• Determined the fundamental characteristics of the reactions
involved in simultaneous hydrodesulfurization and denitrifi-
cation.
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Identified specific catalysts that tend to optimize
demetallization of oils, and preliminary estimates
of catalytic demetallization and desulfurization of
specific Venezuelan and Iranian oils.
Completed an analysis of problems and opportunities
in retrofitting industrial processes to utilize low-
Btu gas. (The analysis indicated that industrial
processes representing a significant portion of
energy use in industry could be adapted to low-Btu
gas use.)
Examined commercial-scale gasification plants in five
foreign countries. Contracting for operational data
and pollutant-emission measurement program on Lurgi
units in several countries.
Sponsored a symposium in 1974 that produced a com-
prehensive report on the state-of-knowledge on
environmental effects on fuel conversion processes.
Published a survey of potentially hazardous emissions
from the extraction and processing of coal and oil.
16
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5. APPENDICES
CONTENTS: Page No.
Appendix A - Funding Level of Program Areas 19
Appendix B - EPA Reports on Synthetic Fuels 25
17
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APPENDIX A - FUNDING LEVEL OF PROGRAM AREAS
$ THOUSANDS
EAP
Identification
Numbe r
121NA-A-01-0
FY FY FY FY
TITLE OR SUBJECT 72 73 74 75
FEEDSTOCK CHARACTERIZATION
Input Material Characteri-
zation of Coal for Syn— >- i
thetic Fuel Process 150
Total
Through
1974
*
475
111. Geol.
Survey
121NA-A-01-0 Input Material Characteri-
zation of Coals and
Liquids for Synthetic Fuel
Process
120 450
ASSESS ENVIRONMENTAL IMPACT
OF SYNTHETIC FUEL PRODUCTION
021NA-B01-1 Evaluation of Pollution
Potential and Pollution Con-
trol in Fossil Fuel Conver-
sion Processes
121NA-A01-0 Environmental Assessment
and Data Acquisition - Low-
Btu Gas Fuel
121NA-A01-0 Ditto - High-Btu Gas Fuel
322NA-A01-0 Ditto - Oil Shale
122NA-A01-0 Ditto - Liquefaction
0603E-A01-0 Environmental Assessment of
ERDA Synthetic Fuel Facilities
(Interagency—with ERDA)
50
350
50
200
0
655
540
260
560
860
400
(Exxon
Research)
Part of ongoing program since 1966.
19
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FUNDING LEVEL OF PROGRAM AREAS (CONTINUED)
$ THOUSANDS
EAP
Identification
Numbe r
Total
FY FY FY FY Through
TITLE OR SUBJECT 72 73 74 75 1974
220-2B-B01-0
Assess Environmental
Impact of Oil Refining
(Corvallis)
250
220-2P-A01-0
Environmental Assessment
and Data Acquisition for
Oil Refining Water Prob-
lems (Usage/Contamination)
Trace Metal Discharges
from (and Deposition within
Gasifiers)
250
150
(IGT)
010NA-A01-0 Environmental Assessment -
Systems Analysis and Sup-
port in Synthetic Fuel Area
DEVELOP CONTROL TECHNOLOGY
FOR SYNTHETIC FUELS PRODUC-
TION PROCESS
255
0103E-A01-2
0563E-A01-2
0543E-A04-2
Control Technology Develop-
ment for Synthetic Fuels—
Systems Analysis and Program
Support
Control Technology Evalua-
tion and Development—Conver-
sion Process Output Gases
Develop HTP Particulate
Removal from Gaseous Efflu-
ents (Evaluate Operation
Parameters and Make Bench-
Scale Evaluation
180
25 200
175
20
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FUNDING LEVEL OF PROGRAM AREAS (CONTINUED)
$ THOUSANDS
EAP
Identification
Number
TITLE OR SUBJECT
FY
72
FY
73
FY
74
FY
75
Total
Through
1974
0543E-A01-2
0543E-A02-2
Raw and Acid Gas Cleanup
Test Facilities: In-House
Bench and Pilot Studies
(RTP)
Raw Gas Cleanup by
Dolomite (Consol)
355
1800
(Inter-
agency with
ERDA)
High-Temperature vs. Low -
Temperature Gas Cleanup—
Relative Efficiencies
400
(United
Aircraft
Research)
DEMETALLIZATION, DESULFURI-
ZATION, DENITRIFICATION OF
OILS (PETROLEUM, SHALE,
SYNTHETIC)
-252-2E-A01-2
Develop Technology for
Demetallization and Deni-
trification of Oil
100
100
(Hydro-
carbon
Research)
40
(MIT)
BYPRODUCT RECOVERY AND
POLLUTANT CONTENT
054-3E-A03 Development of Controls for
Products and Byproducts
(Identify Most Urgent Needs;
Survey Potential Control
Methods)
180
21
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FUNDING LEVEL OF PROGRAM AREAS (CONTINUED)
EAP
Identification
Numbe r
TITLE OR SUBJECT
$ THOUSANDS
Total
FY FY FY FY Through
72 73 74 75 1974
Nitrogen, Sulfur, and Trace
Metal Balances in Secondary
Processing of Synthetic
Fuels (Begins with SRC)
40
(P&M)
Review of Pollutants in
Products
10
(Battelle)
POLLUTION POTENTIAL FROM
UTILIZATION AND TRANSPORTA-
TION OF SYNTHETIC FUELS
Retrofit of Industrial Pro-
cesses to Utilize Low-Btu
Synthetic Gas
Utilization and Disposal of
Wastes
150
(Battelle)
180
WASTE MANAGEMENT
0543E-A05-2
0103E-A02-2
Develop Controls for Utili-
zation and Disposal of Con-
version Feed/Storage/
Preparation Wastes (Survey
Methods and Control;
Identify Problems)
Synthetic Fuels Control
Technology Development Sup-
port from CINN re: Solid
Wastes Management
200
50
22
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FUNDING LEVEL OF PROGRAM AREAS (CONCLUDED)
$ THOUSANDS
EAP
Identification
Number
Total
FY FY FY FY Through
TITLE OR SUBJECT 72 73 74 75 1974
021NA-A03-0
1513K-A01-1
1443A-A01-3
1443A-A02-2
Environmental Assessment
and Data Acquisition for
Water-Related Problems/
Synthetic Fuels Study Sup-
port RTP/CRV
Evaluation of Water Conser-
vation Alternative for Coal
Gasification and Liquefac-
tion (Corvallis)
Determine Effects of "Rain-
Out" on Aquatic Ecosystems
from Conversion of Coal
(Corvallis)
Determine Effects of Power
Plant Chemical and Waste
Products of Coal Conversion
on Aquatic Organisms
(Corvallis)
50
200
300
40
23
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APPENDIX B - EPA REPORTS ON SYNTHETIC FUELS
The following reports were published before January 1975:
EPA No.
650/2-73-004
650/2-73-039
650/2-73-041
650/2-73-041a
650/2-73-042
650/2-73-049
NTIS No.
1AB013
1AB013
1AB013
PB 241-901/AS
1AB013
1AB013
25
Fate of Trace Constituents of Coal
During Gasification," Institute of
Gas Technology, IIT Center, Chicago,
IL. Order from: NTIS-PB 223 001/AS
$3.75.
"Chemically Active Fluid-Bed Process
for Sulfur Removal During Gasifica-
tion of Heavy Fuel Oil—Second Phase,
Esso Research Company, Linden, NJ.
Order from: Pending
"Demetallization of Heavy Residual
Oils," W. C. Rovesti and R. H. Wolk,
Hydrocarbon Research Incorporated,
Trenton, NJ. Order from: NTIS-PB
227 568 $10.25.
"Demetallization of Heavy Residual
Oils—Phase II," HRI (February 1975).
"Gasification of Fossil Fuels Under
Oxidative, Reductive, and Pyrolytic
Conditions," Scientific Research
Instruments Corporation, Baltimore,
MD. Order from: NTIS-PB 228 668/AS
$7.00.
"Production of Clean Fuel Gas From
Bituminous Coal," Consolidation Coal
Company, Incorporated, Research
Division Library, PA. Order from:
NTIS-PB 232 695/AS $8.50.
-------
R2-73-249
PB 225-039/AS
Potential Pollutants in Fossil
Fuels, Esso Research Company, Linden,
NJ (June 1973).
R2-73-272
650/2-74-009a
PB 223-653/AS
1AB013
650/2-74-009b
1AB013
Limited Oil Gasification Experiment,
IMC (June 1973) 40 pages.
"Evaluation of Pollution Control in
Fossil Fuel Conversion Processes—
Gasification: Section I: Koppers-
Totzek Process" by E. M. Magee,
C. E. Jahnig, and H. Shaw, Esso
Research and Engineering Company,
Linden, NJ. Order from: NTIS-PB
231 675/AS $4.25.
"Evaluation of Pollution Control in
Fossil Fuel Conversion Processes—
Gasification: Section I: Synthane
Process" by C. D. Kalfadelis and
E. M. Magee, Esso Research and
Engineering Company, Linden, NJ.
Order from: NTIS-PB 237 113/AS $4.75.
650/2-74-009C
1AB013
"Evaluation of Pollution Control in
Fossil Fuel Conversion Processes—
Gasification: Section I: Lurgi Process,'
Exxon Research and Engineering Company,
Linden, NJ. Order from: NTIS-PB 237
694/AS $4.75.
650/2-74-009d
1AB013
650/2-74-009e
PB-240-371/AS
650/2-74-009f
PB 241-792/AS
26
Evaluation of Pollution Control in
Fossil Fuel Conversion Processes—
o
Gasification: Section I: CO .Acceptor
Process," Exxon Research and Engineering
Company, Linden, NJ. Order from:
Pending.
"Evaluation of Pollution Control in
Fossil Fuel Conversion Processes—
Liquefaction: Section 1; COED Process"
(January 1975) .
"Evaluation of Pollution Control in
Ftossil Fuel Conversion Processes—
Liquefaction: Section 2: SRC Process.
-------
650/2-74-009g
PB 243-694/AS
650/2-74-025
1AB013
650/2-74-048
1AB015
"Evaluation of Pollution Control in
Fossil Fuel Conversion Processes—
Gasification: Section 5: Bi-Gas Pro-
cess" (May 1975).
"Applicability of the Meyers Process
of Chemical Desulfurization of Coal:
Initial Survey of Fifteen Coals" by
A. A. Lee, J. W. Hamersma, M. L.
Kraft, C. A. Flegal, and R. A. Meyers,
TRW Systems Group, Redondo Beach, CA.
Order from: NTIS-PB 232 083/AS $7.00.
"Development of an Approach to Iden-
tification of Emerging Technology and
Demonstration Opportunities," Battelle
Columbus Laboratories, Columbus, OH.
Order from: NTIS-PB 233 646 $8.50.
650/a-74-052
1AB013
Study of Potential Problems and
Optimum Opportunities in Retrofitting
Industrial Processes to Low and Inter-
mediate Energy Gas from Coal," Battelle
Columbus Laboratories, Columbus, OH.
Order from: NTIS-PB 237 116/AS $5.75.
650/2-74-054
1AB013
650/2-74-069
1AA010
"Occurrence and Distribution of Poten-
tially Volatile Trace Elements in Coal,'
Illinois State Geological Survey,
Springfield, IL. Order from: NTIS-PB
238 091/AS $4.75.
"instrumentation and Methodology for
the Assay of Polynuclear Aromatic
Hydrocarbons," Exxon Research and
Engineering Company, Linden, NJ.
Order from: Pending.
650/2-74-072
LAB013
"Sasol Type Process for Gasoline,
Methanol, SNG, and Low-BTU Gas from
Coal" by F. K. Chan, Kellogg Company,
Houston, TX. Order from: NTIS-PB
237 670/AS $4.75.
27
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650/2-74-082
1AB013
650/2-74-099
1AB013
650/2-74-109
1AB013
650/2-74-118
1AB013
660/2-74-050
IBB036
660/2-74-052
1BB039
660/2-74-067
1BB040
"Refinery Catalytic Cracker Regen-
erator SOX Control Process Survey,"
Monsanto Research Corporation, Dayton,
OH. Order from: NTIS-PB 237 756/AS
$7.50.
"Environmental Considerations for Oil
Shale Development," Battelle Columbus
Laboratories, Columbis, OH. Order
from: Pending.
"Chemically Active Fluid-Bed Process
for Sulphur Removal During Gasifica-
tion of Heavy Fuel Oil—Second Phase,"
ESSO Research Centre, Berkshire,
England. Order from: Pending.
"Symposium Proceedings: Environmental
Aspects of Fuel Conversion Technology,"
St. Louis, MO, Research Triangle
Institute, Research Triangle Park, NC
(May 1974). Order from: Pending.
"Research Study of Coal Preparation
Plant and By-Product Coke Plant
Effluents" by E. F. Pearson, C. F.
and T. Steel Corporation, Pueblo, CO.
Order from: Pending.
"Evaluation of Irrigation Scheduling
for Salinity Control in Grand Valley"
by G. V. Skogerboe, W. R. Walker,
J. H. Taylor, and R. S. Bennett,
Colorado State University, Fort Collins,
CO. Order from: GPO-EP1.23/2:660/2-
74-052 $1.30. NTIS-PB 235 633/AS.
"Pollution Problems and Research Needs
for an Oil Shale Industry," by F. M.
Pfeffer, Robert S. Kerr Environmental
Research Laboratory, EPA, Ada, OK.
Order from: GPO-EP1.23/2:660/2-74-067
$0.85. NTIS-PB 236 608/AS.
28
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660/2-74-077
1BA024
650/2-75-011
650/2-75-038
"Organic Compounds Entering Ground-
water from a Landfill," by J. Robertson,
G. R. Toussaint, and M. A. Jerque,
University of Oklahoma, Norman, OK.
Order from: GPQ-EP1.23/2:660/2-74-077
$1.15. NTIS-PB 237 969/AS.
"Sulfur and Nitrogen Balances in the
Solvent Refined Coal Process," PAMCO
(January 1975).
"Potentially Hazardous Emissions from
the Extraction and Processing of Coal
and Oil," Battelle Columbus Laboratories,
Columbis, OH. (April 1975), 162 p.
Order from: NTIS-PB 241 803/6WP.
29
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
EPA Program Status Report
Synthetic Fuels Program
5. REPORT DATE
October 1975
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Bruce Truett, Robert G. Murray, Dr. Gary Foley
3. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Office of Energy, Minerals, & Industry
U.S. Environmental Protection Agency
Washington, D.C. 20460
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-01-2940
Task 026
12. SPONSORING AGENCY NAME AND ADDRESS
Office of Energy, Minerals, & Industry
U.S. Environmental Protection Agency
Washington, D.C. 20460
13. TYPE OF REPORT AND PERIOD COVERED
Final - FY75
14. SPONSORING AGENCY CODE
IS. SUPPLEMENTARY NOTES
EPA Contact: Dr. Gary Foley -- (202) 426-4567
16. ABSTRACT
The status of EPA's Synthetic Fuels Program as of September, 1974 is presented
in nontechnical language. This program is a part of EPA's work directed toward
providing the necessary technology for meeting near-term and long-term energy
requirements in an environmentally acceptable manner. The program is aimed at
controlling and preventing environmental pollution when coal and other fossil
hydrocarbons are converted to synthetic fuels and are utilized as products.
Program objectives and responsibility are presented in relation to funding level.
Significant accomplishments of the program are summarized, and the thrust of
future research is discussed. A bibliography of R&D reports directly related to
the synthetic fuel program is attached.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
l>. IDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Coal gasification
Coal liquefaction
Synthetic fuels
Environmental effects
Conversion processes
Waste management
Shale oil
Program status
Program objectives
3. DISTRIBUTION STATEMENT
Release Unlimited
19. SECURITY CLASS /This Report/
Unclassified
21. NO. OF PAGES
32
20. SECURITY CLASS (Tnis page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
31
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