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February 11, 2016 | Air Liquide Global E&C Solutions | New Delhi
Syn Gas GenerationVarious Routes – Multiple Products
June 14, 2012 l Siddhartha Mukherjee | Air Liquide Global E&C Solutions | New DelhiFebruary 11, 2016 | Air Liquide Global E&C Solutions | New Delhi
New Delhi
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PUBLIC
Global E&C Solutions Communications
� Clean Conversion – Our Story� Coal Gasification and its Applications
� SNG� Ammonia� Methanol� Methanol > Propylene� Hydrogen
Syngas Generation - Various Routes, Multiple Products
Air Liquide, world leader in gases for industry, he alth and the environment2 Gasification India 2016
� Hydrogen� Hydrogen and Carbon Monoxide� DRI Gas
� Residue Gasification � Steam Methane Reforming� Associated Technologies � Wrap-up and Summary
AL Global E&C Solutions PerspectiveClean Conversion – Our Story
Air Liquide, world leader in gases for industry, he alth and the environment3 Gasification India 2016
Our value addition
We know…
Coal
Drivers and our contribution
■ fluctuating price of oil & gasin many locations
■ Growing domestic demand forfuel and petrochemical products
■ Reduction of dependency onC
Air Liquide, world leader in gases for industry, he alth and the environment4 Gasification India 2016
Oxygen
Syngas
and theproducts.
■ Reduction of dependency onfuel and petrochemicals imports
■ Abundance of coal
H2CO
O2
CH3OHSynfuel
■ NG, LPG, Naphtha• SMR, ATR• CO Shift, Amine Wash• Coldbox, PSA
■ Coal, Heavy Residue• Gasification
Clean Conversion
O2
C
H2O +
Air Liquide, world leader in gases for industry, he alth and the environment5
+
• Gasification• CO Shift, Rectisol™• Coldbox, PSA
■ Synthesis• Methanol, DME• MTP, Acrylic Acid• Synfuels, Ammonia
H2CO
Gasification India 2016
Raw Material
Residue
Natural Gas
Coal
Biomass
CO Cold Box
PSA
Syngas Treating
AGR
Syngas
GasificationMethanol
Synthesis
DME
MTP ™
Acrylic Acid
Methanol
Final Products
DME
Propylene
Acrylic Acid
Clean Conversion
Air Liquide, world leader in gases for industry, he alth and the environment6
Biomass
Sulfur Recovery
CO ShiftAmineWash
ASU
Reforming Fischer Tropsch
Methanation
Ammonia
Syn fuels
SNG
Ammonia
DRI
Gasification India 2016
GasificationLurgi FBDB™Lurgi MPG™
RawMaterial
Residue
Natural Gas
Coal
Biomass
Final Products
AL Cold Box
ALPSA
Syngas and Synthesis
Technology and Design by Air Liquide
MethanolLurgi
Methanol
LurgiDME
LurgiMTP ™
Lurgi NKAcrylic Acid
DME
Propylene
Acrylic Acid
LurgiRectisol ™
Air Liquide, world leader in gases for industry, he alth and the environment7
Biomass
LurgiOxyClaus
™
CO ShiftAmineWash
ALASU
Lurgi SMRLurgi ATRLurgi POX
Acrylic Acid
GTL.F1Fischer Tropsch
Methanation
Syn fuels
SNG
Ammonia Ammonia
DRI
Gasification India 2016
AL Global E&C Solutions PerspectiveCoal Gasification and its Applications
Air Liquide, world leader in gases for industry, he alth and the environment8 Gasification India 2016
Lurgi FBDB™ Coal-to-X Syngas
Air Liquide ASU
Lurgi Rectisol ®
GasPurification
Lurgi OxyClaus® Sulfur Recovery
Elemental Sulfur
CO2
Syngas, DRI, Power
Air Liquide LNW Unit
N2
Methanation
Ammonia Syngas
SNG
(Fuel Gas)
Lurgi MPG® Gasification
GasificationLurgiCO Shift /Gas Cooling
CoalPreparation
HP Steam
Air Liquide, world leader in gases for industry, he alth and the environment9 Gasification India 2016
CO
HydrogenAir LiquideCO Cold Box
Lurgi GLS Process™
Lurgi Phenosolvan® & Lurgi CLL™Gas Liquor Recovery and Water Treatment
Liquid Ammonia
ZLD – Water Reuse
(Rectisol Naphtha)
(Phenols)
(Clear Tar / Oil)
Ash
Air LiquidePSA
LurgiMethanol Synth.
Methanol-Propylene
Coal to H2 and NH3: Fujian Gasification Project
ASUGasification
CO-Shift Nitrogen WashAmmonia
Air Liquide, world leader in gases for industry, he alth and the environment10
78 000 Nm3/h H2 + 900 tpd NH 3
Lurgi Rectisol™& OxyClaus™ PSA
ASU, Gasification, Rectisol™, SRU OxyClaus ™, Liquid Nitrogen Wash,Ammonia Synthesis, PSA, Integration/OSBL
H2NH3
Gasification India 2016
Coal to Ammonia: TGI/SCJ
Air Liquide, world leader in gases for industry, he alth and the environment1111
ASUGasification
Lurgi Rectisol™& OxyClaus™
Nitrogen Wash
Ammonia
ASU, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash
H2 N2180 000 Nm3/h N2+H2
Gasification India 2016
Coal to Propylene: Shenhua Ningxia
Air Liquide, world leader in gases for industry, he alth and the environment12
ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™
5000 tpd MeOH to each MTP™
Gasification India 2016
ASUGasification
CO-Shift,Rectisol®Oxy Claus ™
Mega-Methanol®
MTP®
Gasification trainMethanol
DMERectisol®
Coal to Methanol and Propylene: Shenhua Ningxia
Air Liquide, world leader in gases for industry, he alth and the environment1313
MTP®
ASURectisol®(4 trains)
Methanol
Synfuels
Methanol train
ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™
Gasification
Gasification India 2016
ASU Lurgi Rectisol ™&OxyClaus ™
Coal to DRI Gas: Jindal Steel and Power
Lurgi FBDB™Gasification
Air Liquide, world leader in gases for industry, he alth and the environment1414
ASU, Lurgi FBDB™ Gasification, Phenosolvan™, CLL™, Rec tisol™, SRU OxyClaus™
Lurgi CLL™
Phenosolvan ™
225 000 Nm3/h CO+H2+CH4H2
COCH4
Gasification India 2016
AL Global E&C Solutions PerspectiveResidue Gasification - MPG®
Air Liquide, world leader in gases for industry, he alth and the environment15 Gasification India 2016
� 45 years prior operating experience with heavy residues
� 25 plants (78 reactors) for oil residue gasification built by Lurgi under Shell license (Lurgi/SGP) until ’97
� In 1997, Burner Technology acquired from SVZ Schwarze Pumpe (Eastern Germany)
���� Lurgi’s Multi Purpose Gasification■ Boiler & Quench design
MPG® Summary
Air Liquide, world leader in gases for industry, he alth and the environment16 Gasification India 201616
■ Boiler & Quench design
� Existing Reference operating in Brazil (Fosfertil) since 2001■ Commercial size reference
� HP POX - Pilot plant - since 2002■ R&D development – Process performances –
Validation of design rules� Engineering Contract for Gasification at present
under execution
Multi
Purpose
Gasification
45 years experiencein residue gasification:� 75 units� 62.5 x 106 m3 /d
Pur
chas
es fr
om S
VZ
2001
Ulta
fert
il
2002
HD
PO
X
2005
Nor
th W
est
Upg
rade
r
Residue Gasification References
Air Liquide, world leader in gases for industry, he alth and the environment17 Gasification India 201617
Year Country Feed Product Capacity Technology/License
From 1956 to 1997 Lurgi was exclusive licensor of the Shell Gasification Technology (SGP). In this time Lurgi designed 26 Partial Oxidation Plants with 76 Reactors producing 63.000.000 Nm³/d of Syngas.
(1997)* Germany Coal oil/Tar, Slurries
Methanol Synthesis Gas and Power
800.000 Nm³/d MPG
2000 Brazil Asphalt, others Ammonia Synthesis Gas, Burner Revamp
850.000 Nm³/d MPG
2002 Germany Natural Gas, Residue
Raw Synthesis Gas 36.000 Nm³/d MPG
2005 Canada Hydrocracked Residue
Hydrogen 3.500.000 Nm³/d MPG
()* MPG reference plant technology purchased by Lurgi, operated for more than 30 years
1950 1960 1970 1980 1990 2000
Fixed Bed Grate Gasifier
Gasification� 62.5 x 106 m3N/d
2010
MPG® Residue-to-X Syngas
Air Liquide ASU
Lurgi Rectisol ®
Gas
Lurgi OxyClaus® Sulfur Recovery
Elemental Sulfur
CO2
Syngas, DRI, Power
Air Liquide LNW Unit
N2
Methanation
Ammonia Syngas
SNG
(Fuel Gas)
MPG®LurgiCO Shift /
Feed
HP Steam
Air Liquide, world leader in gases for industry, he alth and the environment18 Gasification India 2016
CO
HydrogenAir LiquideCO Cold Box
Metal Ash Recovery System
GasPurification
Methanation SNG
Metal Ash
Gas Cooling
Air LiquidePSA
LurgiMethanol Synth.
Methanol-Propylene
Waste Water
AL Global E&C Solutions PerspectiveSteam Methane Reforming
Air Liquide, world leader in gases for industry, he alth and the environment19 Gasification India 2016
World Map & References - Lurgi ReformerTM
HAINAN MethanolLocation: China / HainanProduct: 2.000 mtpd MethanolStart-up: 2006
Degussa Rheinfelden Location: GermanyProduct: 8.000 Nm³/h HydrogenStart-up: 1997
TITAN and ATLAS MethanolLocation: TrinidadProduct: 2.500/5.000 mtpd MethanolStart-up: 1999 / 2004
Messer DormagenLocation: GermanyProduct: 7.000 Nm³/h COStart-up: 2002
GLIMARLocation: PolandProduct: 10.000 Nm³/h HydrogenStart-up: -
YARACO1 / YARACO 2Location: ChinaProduct: 9.200Nm³/h COStart-up: 1998 / 2005
DALIANLocation: ChinaProduct: 72.000 Nm³/h HydrogenStart-up: 2006
PEMEX CadereytaLocation: MexicoProduct: 67.250 Nm³/h Hydrogen
AIR LIQUIDE Gulf Coast SMR H2Location: Texas / USAProduct: 130.000 Nm³/h HydrogenStart-up: 2011 (Project in Progress)
PRAXAIR RichmondLocation: CaliforniaProduct: 204.000 Nm³/h HydrogenStart-up: 2010 (under construction)
LOTOS HGU 2Location: PolandProduct: 100.000 Nm³/h HydrogenStart-up: 2009 (under construction)
AIR LIQUIDE HERACLESLocation: NetherlandsProduct: 130.000 Nm³/h HydrogenStart-up: 2011 (Project in Progress)
Air Liquide, world leader in gases for industry, he alth and the environment20 Gasification India 2016
Batamas MEGAHLocation: MalaysiaProduct: 3.000 Nm³/h HydrogenStart-up: 1994
BASF – BPC KuantanLocation: MalaysiaProduct: 58.000 Nm³/h SyngasStart-up: 2000
P.T. Kaltim Methanol IndustryLocation: MalaysiaProduct: 2.000 mtpd MethanolStart-up: 1998
Cleveland-Cliffs Location: TrinidadProduct: 41.500 Nm³/h HydrogenStart-up: 1998
PEMEX MaderoLocation: MexicoProduct: 49.170 Nm³/h HydrogenStart-up: 2001
Repsol YPFLocation: ArgentinaProduct: 1.210 mtpd MethanolStart-up: 2002
PMLLocation: Malaysia / LabuanProduct: 5.000 mtpd MethanolStart-up: 2009
Melaka HPU 2Location: MalaysiaProduct: 45.000 Nm³/h HydrogenStart-up: 2008
National Petrochemical Co. (Kharg)Location: IranProduct: 2.000 mtpd MethanolStart-up: 1999
Product: 67.250 Nm³/h HydrogenStart-up: 2000
ZAGROS 1 / ZAGROS 2Location: IranProduct: 5.000/5.000 mtpd MethanolStart-up: 2006 / 2009
SIPCHEM COLocation: Saudi ArabiaProduct: 30.520 Nm³/h COStart-up: 2009
Large Plants Designed by Air Liquide
■ Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA, multi-feed)
■ Largest single-train H 2 plant: 160 750 Nm3/h H2
■ Largest single-train synthesis gas plant: 530 780 Nm3/h, dry equivalent to 321 230 Nm3/h H2 (Lurgi’s MEGA-MeOH plants)
Air Liquide, world leader in gases for industry, he alth and the environment21 Gasification India 2016
■ World largest single-train CO plant: 43.2 tons/h CO
■ Largest Steam Reformer: 720 tubes , 1250 GJ/h
■ Number of Mega-H2 plant references with capacities ≥ 130 000 Nm3/h H2 in last 10 years: 7
Latest References – H2 Plants (medium/large size)
Region Feed Capacity (Nm3/h) Scope Award
Russia NG 100 000 H2 Lic.+ B.E. 2013
Middle East NG, LPG 60 000 H2 Lic.+ B.E. 2013
Middle East NG 68 550 H2 Lic.+ B.E. 2012
North America NG 160 750 H2 EPC 2011
Russia NG, Naphtha 83 165 H2 Lic.+ B.E. 2011
Middle East NG, Naphtha 60 000 H Lic.+ B.E. 2011
Air Liquide, world leader in gases for industry, he alth and the environment22 Gasification India 2016
Middle East NG, Naphtha 60 000 H2 Lic.+ B.E. 2011
Middle East LPG, Naphtha, ROG, NG
339 300 H2 (2 train + S/A PSA)
EPC 2010
North America NG 130 000 H2 EPC 2009
Europe NG 130 000 H2 EPC 2009
Latest References – H2 and CO Plants
Region Feed Capacity (Nm3/h) Scope Award
Europe NG 8 500 CO EPC 2013
Europe NG 14 500 CO60 000 H2
EPC 2012
Europe NG 10 000 CO24 100 H2
EPC 2012
Asia NG 9 800 CO EPC 2010
Air Liquide, world leader in gases for industry, he alth and the environment23 Gasification India 2016
Asia NG 9 800 CO35 600 H2
EPC 2010
Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA)
Air Liquide, world leader in gases for industry, he alth and the environment24 Gasification India 2016
Process Gas
Fuel Gas
Combustion Air
Flue Gas
Lurgi Reformer® - Isometric Arrangement
Air Liquide, world leader in gases for industry, he alth and the environment25 Gasification India 201625
Arrangement Drawing
Hydrogen
Lurgi SMR Feed-to-X Syngas
Air LiquideASU
Air LiquideCO Cold Box
N2
PSA
Ammonia Syngas
SMR
Feed
CO2 Removal
HP Steam
Air Liquide, world leader in gases for industry, he alth and the environment26 Gasification India 2016
CO
Methanol-Propylene
ATR
Methanol Synthesis
CO Shift
Next Generation Coal Gasification IslandAssociated Technologies
Air Liquide, world leader in gases for industry, he alth and the environment27 Gasification India 2016
Commercially well referenced technologies
■ ASU: > 350 in the last 40 years
■ Lurgi FBDB™: > 120 reactors
■ Rectisol™ : > 100 Lurgi Rectisol■ Cold Box > 90 CO purification and NWU■ PSA >70 Hydrogen Purification
Air Liquide, world leader in gases for industry, he alth and the environment28 Gasification India 2016
■ PSA >70 Hydrogen Purification
■ Methanol: > 50 plants; 9 coal based.■ MTP™ : 2 running
■ Claus : >170 Claus Units■ OxyClaus™ SRU: > 40 burners
Air Liquide: Air Gases■ Operating >350 Air Separation Units
Total gaseous production
> 120,000 tpd
> 95,000 tpd
O2
N
Air Liquide, world leader in gases for industry, he alth and the environment29 Gasification India 2016
> 95,000 tpd
■ The world leader in large scale air separation units� > 160 ASUs with a capacity > 1,000 tpd� > 60 ASUs with a capacity > 2,000 tpd� The largest single train plant under engineering (capacity of 5,000
TPD at 1620 m above sea level)
N2
Air Liquide’s Lurgi FBDB TM
■ Lurgi FBDB TM MK+TM: Proven Operation� Innovative use of referenced technology for no scale-up risk � Safe & forgiving operation� Beneficial for low rank coal� Improved Capex and Opex
■ Financially Secure Investment
■ High Efficiency and reduced cost of SNG
H2CO CH4
Air Liquide, world leader in gases for industry, he alth and the environment30 Gasification India 2016
■ High Efficiency and reduced cost of SNG� Reduced steam consumption & lower oxygen consumption � Higher direct methane production
■ Environmental Compliance� Complete process water re-use ���� Zero Liquid Discharge� World bank standards
Best efficiency for high moisture & high ash coalespecially for SNG production.
H2O
Air Liquide’s Lurgi Rectisol TM
■ > 60 Years of design expertise and operational feedback
■ Reference situation� 21 references 2011 - today� 42 references since 2000� Over 100 references in total� Complete CO2 and Sulfur removal .
H2CO
Air Liquide, world leader in gases for industry, he alth and the environment31 Gasification India 2016
■ Applications� Coal-, petcoke-, refinery residue- gasification� Power, DRI, H2
� Synthesis : MeOH, NH3, Urea, MEG, SNG,Fischer-Tropsch, polymers …,
� Multi-product streams
Outstanding track record in a variety of applicatio ns!CO2 S
Air Liquide’s Cryogenic Gas Treating
■ > 90 Cold boxes referenced
■ Syngas Final treating� Remove impurities in syngas e.g. CH4, N2…� Produce pure syngas.� Composition ratio adjustment H2/N2=3:1…
■ Applications
H2CON2
CH4
Air Liquide, world leader in gases for industry, he alth and the environment32 Gasification India 2016
■ Applications� Pure CO, H2, CO+H2, H2+N2
■ Distillation packing: high efficiency & load variety .■ Stainless steel cold box: easy onsite works .■ Expansion turbine: product gas as medium .■ Cold integration with Rectisol™.
Worldwide largest CO purificationsand ammonia syngas preparations all by Air Liquide!
� > 40 Years of design expertise and operational feedback
� 51 Plants with a total capacity of 33.5 MMTPY.
� Extremely quick transfer of reaction heat:
� Quasi isothermal operationOverheating of catalyst impossible
CH3OH
Air Liquide’s Lurgi Methanol
Air Liquide, world leader in gases for industry, he alth and the environment33 Gasification India 2016
� Long catalyst operational life
� Low recycle ratiosHigh steam production
� Safe and uniform temperature control
The outstanding advantage ofLurgi Methanol is the Water Cooled Reactor with superior heat removal ability.
33
Food for Thought and Wrap-up
Air Liquide, world leader in gases for industry, he alth and the environment34 Gasification India 2016
Value addition
We know…
Air Liquide’s value addition
C CH4
■ Cutting-edge, commercially proven proprietary technologiesaddressing the growing markets for
coal-based & natural gas basedfuels and petrochemicals :
Air Liquide, world leader in gases for industry, he alth and the environment35 Gasification India 2016
Oxygen
Syngas
and theproducts.
H2CO
O2
CH3OHSynfuel
fuels and petrochemicals :
■ Synfuels/Diesel■ Methanol, DME■ Propylene■ Ammonia■ Hydrogen
Wrap-Up - FBDBTM
■ FBDBTM Excellent Technology for High Ash Coals
■ Appropriate Technology for the following applications:� Substitute Natural Gas SNG� Direct Reduction of Iron DRI� Coal to Liquids CTL� NH3 with CH4 co-production
■ About 155 Steam Reformers built Wide feedstock range - Light/heavy natural gas, LPG, associated gas,
Air Liquide, world leader in gases for industry, he alth and the environment36 Gasification India 2016
� Wide feedstock range - Light/heavy natural gas, LPG, associated gas, naphtha, mixed feed
4
� Wide product range - hydrogen, CO, towngas, syngas for products like oxo-alcohols, methanol, ammonia
■ Lurgi MPG Gasification MPGTM
� Proven technology for handling heavy refinery residues
� Also capable of handling emulsions and slurries with particles in the mm range
■ A Real One-Stop-Shop � Proven technologies integrated into a single package
4,000 Air Liquide Global E&C Solutions Colleagues Thank You!
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Air Liquide, world leader in gases for industry, he alth and the environment37 Gasification India 2016
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