The goal of this final project report is to comprehensively summarize the work for public domain conducted on project DE-FE 0031520. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Center for Applied Energy Research (UKy-CAER) (Recipient) has completed a Front End Engineering Design (FEED) study 5 MWe polygeneration unit using the Coal Fields Regional Industrial Park in Hazard, Kentucky (KY) as a model location and using coal recovered from the adjacent Pads Branch Impoundment as feed. The scope of work is a thorough study that can be used as a template for the application of the proposed technology throughout Eastern KY and other coal communities nationwide. The Technology Design Basis was developed based on three elements: basic site characteristics
fuel feedstock
and environmental health and safety requirements. The Basic Engineering Design Elements include the preliminary process design (the process area descriptions
the Block Flow Diagram (BFD), Process Flow Diagrams (PFDs) and Piping and Instrumentation Diagrams (P&IDs), process simulation outputs and Heat and Mass Balance (H&MB) stream tables, the major process equipment and instrumentation lists which includes specifications and materials of construction)
the cost estimate (capital cost estimate, operational cost estimate, and comparison with state-of-the-art commercial scale similar technologies, options to lower cost, construction cost and schedule estimate)
and other supporting elements (guidelines for execution and management of the project), logistical summary, and balance of plant summary, the Environmental Health and Safety (EH&S) assessment
and a Social and Economic Impact (S&EI) assessment. All project milestones, deliverables and success criteria were met. The proposed 5 MWe polygeneration facility being fed from impoundment recovered coal has been shown to be technically feasible. Annual revenues are estimated at $2.4M from electricity, steam and hydrocarbon production
annual operating expenses are $5.2M ($2.9 M in operating expenses, and $2.4M in indirect expenses). The gasifier facility, as configured during the FEED, will lose money when operating under commercial operating conditions and terms. However, eight options improving the economics can be considered during the detailed design phase to make the facility profitable by taking advantage of the positive differential of revenue to variable operating costs, and reducing the influence of fixed operating costs. Coupled with the findings from the S&EI assessment estimating a total economic impact of $374M for the proposed polygeneration facility at >
$1.5B, if three additional such projects are implemented, clearly positive economics are demonstrated. No EH&S issues are identified that would prohibit proceeding with the project, although permitting efforts are estimated to take 3-5 years.