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Air Liquide Gasification Development

International Freiberg Conference Update 2015

Air Liquide Global E&C Solutions l Dr. Stephan Schwinghammer, Frederic Judas & Daniel van der Merwe

Market success respects diversity

■ Diverse capabilities of Air Liquide by example:

China: Coal to ammonia

China: SNG optimized for water scarcity

India : DRI

Africa: Large ASU capacity

Asia: Remote manufacture of large ASUs

The Americas: Latest applications of our residue gasifierpp g

Middle East: IGCC syngas from residue gasification

Europe: Next generation green syngas Europe: Next generation green syngas

■ For diverse requirements of global market

© Air Liquide, world leader in gases for industry, health and the environmentIFC 20152

Air Liquide global diversity

Large Industries Industrial MerchantAir gases and hydrogen15-year contractsPipeline networksIndustrial basins

Bulk and cylinder gases80 countriesWide variety of sectors and customer sizesIndustrial basins

ElectronicsC

Healthcare Other activitiesCarrier gasesSpecialty gases Equipment and Installations

HospitalsHomecareHygiene

Welding & CuttingDivingSpecialty chemicals

Global E&C SolutionsDesign, Engineering & Construction

of leading-edge processing facilities


Proprietary heavy carbon technologies

N2

SNG/LNGAir

SeparationLurgi OxyClaus™

Sulfur RecoveryElemental Sulfur

CO2

Lurgi MPG™

Gasification Lurgi

MegaMethanol™

Lurgi Rectisol ™

AGR H2 / CO

Cryogenics

SeparationAmmonia SyngasLurgi FBDB™

GasificationCO Shift

Gas Cooling

Lurgi

MegaDME™CO

CoalAGR H2 / COGasification Gas Cooling

Lurgi MTP™

AcrylicPSA

H2

Lurgi

GLS Process™

Lurgi Phenosolvan ™ & Lurgi CLL™

With ZLD Gas Liquor Recovery

Rectisol Naphtha

Phenols GTL.F1

FT

Acid

Liquid Ammonia

Water Re use (ZLD)

Clear Tar / Oil


Water Re use (ZLD)

Global technology integration for syngas products

innovates, develops, designs, builds, owns and operates

ASUGasification

CO-Shift Nitrogen WashAmmonia

Lurgi Rectisol™& OxyClaus™

PSA

• Above example 78 000 Nm3/h H2 + 35 tpd NH3 HNH3

• Client-specific product slate and project scope • Typical variations: CO-coldbox, PSA, NWU, NH3• Optimal technology selection and integration is project-specific

G ifi t h l l t d f ti l j t TCO d li bilit

H2


• Gasifier technology selected for optimal project TCO and reliability

55

Fujian: Full HyCO OTF based on coal gasification

Liquid ammonia

Cooling water, Electrical substation, flare, BFW, buildings ( warehouse, admin, canteen, etc.)

ASUN2

NH3 synthesis

Liquid ammoniaN2, IA & plant air

Gasification CO Shift Rectisol

NWURawgas

O2

Hydrogen

PSA

Coal Milling

and Drying

CoalCO2

Acid Gas

PSA

Coal Blending

Water pre- treatment

Air Liquide China Scope SRU

WW to

110 kV, demin water, Steamraw water Fire water

All by-products (slag & S cake & HP steam)

WW to Industry park


raw water, Fire water

Development of Lurgi FBDBTM coal gasifier

1st Generation from 1932 (29 MWHHV)• Capacity: up to 10,000 Nm3/h• Design Pressure: 20 barg

I Di t 1600 2600

1932

• Inner Diameter: 1600-2600 mm• Height: 6000-8000 mm

2nd Generation from 1952 Lurgi Mark1-3 (117-147 MWHHV)• Capacity: 13,000-20,000 Nm3/h

D i P 20 30 b

1952• Design Pressure: 20-30 barg• Inner Diameter: 2600-3660 mm• Height: 6800-8400 mm

3rd Generation from 1969 Lurgi MkIV™ (240 MWHHV)1969 3rd Generation from 1969 Lurgi MkIV (240 MWHHV) • Capacity: up to 65,000 Nm3/h• Design Pressure: 30-34 barg• Inner Diameter: 3848-3862 mm• Height: 12,500 mm

L i MkV™ (340+ MW )1978 Lurgi MkV™ (340+ MWHHV) • Capacity: 90,000 Nm3/h +• Design Pressure: 30 barg• Inner Diameter: 4700 mm• Height: 12,500 mm

1978

4th Generation from 2011 Lurgi MK+TM (500 MWHHV) • Capacity: 120,000 Nm3/h• Design Pressure: 60 barg• Inner Diameter: 4700 mm• Height : 17,000 mm

2011


Height : 17,000 mm

Benefits for Coal to SNG projects

■ Lurgi MK+™: innovative use of referenced technology prevents scale gy pup risks

■ Improved Opex and lower Capexcompared to MkIVTMcompared to MkIVTM

Higher direct production of CH4 Reduced coal, O2 and HP Steam

iconsumption Higher thermal efficiency

■ 10 to 15% decrease of the SNGO2 O2

%cost versus MkIVTM

■ Part of the SNG is produced byETF gasification for coal fines

LurgiFBDB™ MK+™

Coarse Coal Rectisol™ Methanation50% to 75%

SNG

ETF gasification for coal fines(ETF: 50% higher SNG cost)

Fine coal ETF Rectisol™ MethanationSNG

© Air Liquide, world leader in gases for industry, health and the environmentIFC 20158 IFC 2015

Resource challenge: gasification vs water

Catch 22: In many cases, coal resources exist in reversedistribution to water: Where coal aggregates, water is scarce Where water aggregates, coal is scarce

vs.


China prioritizes water resource management!

vs.

Strict water resources impact assessments for gasification projects Water-saving technology to improve water-saving water-use efficiency Water-saving technology to improve water-saving, water-use efficiency New environmental management measures to treat/prevent water contamination Tight guidelines developed by NDRC


From Gas Liquor to Zero Liquid Discharge

Air Liquide unique solution

CO Shift &Gas Cooling

Coal

SteamRaw syngas Lurgi FBDB™

Gasification

Gas condensates

S l t dR f d Selected technologies forcomplete waste

water purification

Referenced technology for Phenols and

Ammonia removal water purificationAmmonia removal


Global technology integration for ZLD

Full chain of purification of the water

CO Shift &Gas Cooling

Coal

SteamRaw syngas Lurgi FBDB™

Gasification

Gas condensates

Gas LiquorDephenolized

Gas LiquorStripped

Gas Liquor

Zero LiquidDischarge

Gas LiquorSeparation

Phenosolvan™Phenols Recovery

CLLTM

NH3 RecoveryWaste Water

Treatment

Liquid AmmoniaCrude PhenolsClear Tar / Oil


qPhenols

12

Technology selection for ZLD

Achievement: Global solution for optimal technology train

MUTAG (Multi Umwelttechnologie AG ) for bio-treament■ Reduction of COD by 90%

G d f ( Dilli G )■ Good references (ex: Dillingen, Germany)■ 2 step process: protection of the nitrification bacteria

Aquatech for post treatment■ References in China (Tuke, YTH, Shenhua Xinjian)

(54 Zero Liquid Discharge Systems around the world)■ Possibility to reach high quality water with the HERO system (advanced

reverse osmosis process)


Coal to syngas for DRI

• FT Products

■ Lurgi FBDBTM Gasification

Chemicals / Fuels

Chemicals / Fuels

• FT Products• Ammonia• Methanol• Hydrogenyd oge

Steel Industry

Steel Industry • Reduction Gas for DRI

IndustrialIndustrialIndustrial Gas

Networks

Industrial Gas

Networks

• Synthetic Natural Gas (SNG)


Coal to DRI Gasification Project Completion■ Customer: JSPL■ Location: Orissa, India

D i d t

Plant in commercial operationProduction of DRI syngas on May 27th 2014

■ Design process data: Sub. Coal 35% ash 7 Lurgi MkIV™ gasifiers

Lurgi MkIV™ Gasifiers Lurgi CLL™

g g 225,000 Nm3/h DRI SG LHV: 3,500 kcal/Nm3

H2/CO ti 1 7 H2/CO ratio: 1.7■ Scope for complete gas

island - gasification, Lurgi Phenosolvan™ gRectisol™ , SRU PDP / BE / DE Prop Equipment supply Prop Equipment supply Operators training Start-up assistance


Air Liquide oxygen supply to coal gasification

SASOL South Africa

5000 tpd

© Air Liquide, world leader in gases for industry, health and the environmentIFC 201516 16

Africa CtL: A new record ASU capacity

■ Customer Name : Sasol■ Project Scope : OTF■ Project Scope : OTF■ Products : Oxygen & Argon■ Location : Secunda, South Africa■ Capex : Euro 200 million■ Commissioning : December 2017

■ 5 000 tpd oxygen from 0,83 bar atmosphere■ Equivalent to 5 800 tpd oxygen at sea level■ Argon and limited oxygen is for Air Liquide offtake

R li bilit f t d f ll it li i th TCO d t■ Reliability, safety and fully capitalizing the TCO advantage:■ At this capacity requires real expertise and innovation


Innovation: Our Remote Manufacturing Yard (RMY)

RMY at a glance:● Mobile solution for manufacturing and delivering large Air Separation Unit pressure vessels● Mobile solution for manufacturing and delivering large Air Separation Unit pressure vessels● Dismountable workshop, located close to our end-user customers, anywhere in the world● Present location: Xinjiang, China● Operational status: Delivering equipment since 2014.

Purpose and Missions:● Provide manufacturing flexibility and agilityg y g y● Serve all parts of the world, specifically landlocked areas● Reduce the logistic risks of large equipment to remote areas ● Meet our customers’ needs by increasing our proximity

Develop new approach and manufacturing differentiation in our offer


● Develop new approach and manufacturing differentiation in our offer

Lurgi MPG™: 40 years residue gasification experience

■ Lurgi MPG™ technology quench and boiler configuration availableg

■ Feedstock Flexibility No limitations on flash point of

feedstockfeedstock Viscosity up to 300 cSt Particles up to 1 mm

■ Long burner life time results in higher reliability and availability of plant

■ Inherent safety by pressurized■ Inherent safety by pressurized cooling water system

■ Simultaneous feeding of immiscible f d t kfeedstock

■ Commercial NH3 syngas since 2002■ New generation operational now


■ New generation operational now

19

NWR Upgrader general setup

■ One out of three phasesDiluent and Naphta

Bitumen BlendFeedstock

Diluent and Naphta32,501 bpd

ULS DieselCrude and

Vacuum UnitHydrocracker& Hydrotreater

77,080 bpd

Dilbit51 760 bpd

ULS Diesel36,178 bpd

HydrogenResid

51,760 bpd

Synbit25,320 bpd

LS VacuumGas Oil8,276 bpdHydrogen

HydrogenHydrocracker Butane771 bpd

Multi PurposeGasification

High Quality CO2


Courtesy NWR

20

NWR Air Liquide EPC effective end of 2013

Feedstock Pure dry CO to EOR

St

LP-Steam

Hydrogen

Pure, dry CO2 to EOR148 t/h

CO2Compression

3 x 50 %

~ 52 t/h

Steam 97% pureRectisol™MPG™

QuenchRaw Gas

ShiftGas

CoolingMetha-nation

~ 26 t/h~ 129,000 Nm3/h

H2S+CO2O2 Sulfur

Air + O2Claus Off-GasClaus~ 37,000 Nm3/h

Carbon Slurry

Process WaterFiltASU Waste Water

AirFilter cake

FilterASU aste ateTreatment


Air

21

Conclusion: A comprehensive bottom of the barrel solution

■ Typical Refinery Set-up

LPG

Diesel

Different Oil Fractionsfrom refinery Hydrocracker

Acid GasesSolvent

De-Asphalting Power /

Off-Gases

VacuumResiduefrom

Chemicals

Ai Li id l t

Hydrogeng Power /

HP Steam

SulphurAsphalt

refinery Air Liquide plants:Integrated Power,

Oxygen, Gasification, Hydrogen Chemicals

CO2 forsequestration

Hydrogen, ChemicalsSteam & Sulphur

Air Liquide Global E&C Solutions is capable to solve the “bottom of the barrel” problems in refineries.

Common Off-Site Facilities


barrel problems in refineries.

22

Residue gasification syngas cleaning

■ Project Name: IGCC-AGR■ Capacity : 2,4 million Nm3/h raw gas■ Air Liquide scope: AGR■ Air Liquide technology: Rectisol™■ Air Liquide technology: Rectisol™■ Location : Middle East■ E&C Centre : Delhi

■ Executed process design package within 5 months in 2014■ VGR(Vacuum Gas Residue)/HSFO(High Sulfur Fuel Oil) gasification.■ Status:

Detail Engineering HAZOP Study Completed Detail Engineering HAZOP Study Completed 30% Model Review Completed


Sourcing green residue■ Client: Karlsruhe Institute of Technology■ Project Name : bioliq™ I & II Pilot plant■ Feed material: Non-food chain biomass■ Product : Syngas for new generation

cleaning and conversioncleaning and conversion■ Air Liquide scope: Fast pyrolysis, Oxygen

and Gasification■ Status: Fully operational

Local pre-transport

GasificationPyrolysis with full carbon recovery

Industrial center

GasificationPyrolysis with full carbon recovery


Diversity of 4,000 Air Liquide Global E&C Solutions colleagues

Innovative Green

Moscow

FrankfurtCalgary Donetsk

Bussy-St-GeorgesEnnery

Gasification

Shanghai

Beijing

New DelhiDubai

Houston

Montreal Krakow

o ets

Kobe

Doha

ChampignyVitry

Kuala Lumpur

Hangzou / Hangzhou

Dubai

Ras Al Khaimah

ChennaiSingapore

Abu DhabiMiddle East and American Residue Gasification

Diversity createssustainable growth!

Sao PauloJohannesburg

Engineering centers

Manufacturing workshops

Selangor

Afro Asian Coal Gasification

sustainable growth!

Manufacturing workshops

Business offices

Cryogenic equipmentcenters

Diverse Client needs:- Technology development, licensing or EPCM


centers - Over-the-fence oxygen, syngas or gases

Frederic Judas, Director TechnologyAir Liquide Global E&C Solutions Germany GmbHfrederic judas@airliquide [email protected]+49 69 5808 2081

Dr. Stephan Schwinghammer, Director Technologyp g , gyAir Liquide Global E&C Solutions Shanghai Co., [email protected]+86 21 6091 9048

Daniel van der Merwe, Head of CtXAir Liquide Global E&C Solutions Shanghai Co., Ltd.daniel vandermerwe@airliquide [email protected]+86 21 6091 9058

air liquide gasification development - tu-freiberg.de · air liquide gasification development...

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