the lurgi gasification island -...

I AIR LIQUIDE, THE WORLD LEADER IN GASES, TECHNOLOGIES AND SERVICES FOR INDUSTRY AND HEALTH

Feb 16th , 2017

Chandrashekhar Jain • Technology

Presentation - 7th World Petro Coal Congress, Delhi

Lurgi Gasification Island : A Bird’s Eye View

THIS DOCUMENT IS PUBLIC

New Delhi • February 16th, 2017

Chandrashekhar Jain • Technology Department


The Lurgi

Gasification Island:

A Bird’s Eye View

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Feb 16th , 2017





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THROUGH SIX PRODUCT LINES

DRIVEN BY TECHNOLOGIES

Standard plant • 1000+ ref

• N2 generators

• Fast time to market

Cryogenics • Air gases, HyCO, He

• 1000+ references

• Records of size and

efficiency

Hydrocarbons • NG treatment

• LNG & Rega

• Sulfur management

Downstream &

Petrochemicals

• Leader for MeOH

• High eff Rectisol

• Coal gasification

Hydrogen • Up to 200 kNm3/h

• PSA techno

• High performance

Oleo chemicals

• Leader in Fatty Acids

& Fatty Alcohols

• Glycerol to Propylene Glycol

• Highly eff. Biodiesel

WE SERVE MARKETS AND

IT’S VALUE CHAIN

Helium

Coal

Syngas

Natural

Gas & LNG

Sulfur

Methanol Oxygen

Nitrogen

Hydrogen

EPC and

operation

support

Air Liquide Global E&C Solutions

3

1600+

Patents


Feb 16th , 2017





Full coverage of the entire project life cycle

Licensing engineering

services & proprietary

equipment

Process Technology

High-end engineering

& design capabilities

Conceptual & Front-End

Engineering Design

Project management

and execution services

Integrated Solutions

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Committed to deliver technological projects

Regions and Main Centers

Main

Engineering

Centers

Manufacturing

Sites

Paris

Frankfurt

Krakow

Delhi

Shanghai

Hangzhou

Kobe

E&C’s Regions

Ras al Khaimah (Emirates)

Vitry-sur-Seine (France)

Hangzhou (China)

Asia Middle East & Africa Europe Americas

Houston

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Feb 16th , 2017





The Lurgi Gasification Island – Fujian, China

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Feb 16th , 2017





Technology portfolio ■ Gasification

Multipurpose Gasification (MPGTM)

Coal Gasification (FBDBTM)

■ Air Separation Unit (ASU) Standard Cryogenic Air Separation Units

Custom Cryogenic Air Separation Units

Adsorption based Air Separation Units (EOX)

N2 Plants

■ Gas Cleaning RectisolTM , Purisol

MDEA / DEA / aMDEA washes

Sour Water Stripping (SWS)

N2 wash

Membrane technologies

■ Sulfur Management (SRU) Claus / OxyclausTM

Lurgi Tailgas Treatment (LTGTTM) / AGE

AquisulfTM

Emission Free SRU

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Feb 16th , 2017





Technology portfolio ■ MeOH and Downstream

Mega MethanolTM

Methanol to Propylene (MTPTM)

Mega DMETM

Acrylic Acid

■ Synfuels (XtL) Gas to Liquids (GtL)

Coal to Liquids (CtL)

Biomass to Syngas

■ Syngas / H2 / CO

Partial Oxidation (MPGTM)

Steam & Autothermal Reforming

PSA technologies

CO shift

Cryogenic CO separation units

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Feb 16th , 2017





The MPGTM

Technology

9

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fit the

available

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Feb 16th , 2017





MPGTM (Multi Purpose Gasification) Burners

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MPGTM Highlights

■ FEED Flexibility Natural Gas

Coal tar/Oil (No limitations on Flash point)

Heavy Refinery Residues (300 cSt)

Asphalt

Slurries of coal (1 mm)

■ Applications NH3 , H2

Power

CO and Oxo-Synthesis gas

Methanol

FT Synthesis Gas

■ Environment RectisolTM Technology secures high quality products and pure, dry CO2

Emission Free SRU (Sx)

Zero Effluent Discharge - Water Treatment (H2O)

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MPG TM : Multi Purpose Gasification

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HP POX Freiberg, Germany

13

Funded by

■ German Federal Ministry of Economics and Technology (BMWi)

■ Saxon ministry of Science and the Fine Arts (SMWK)

Operated by

Institut of

Energy Process Engineering and

Chemical Engineering


Feb 16th , 2017





Northwest Redwater Project MPGTM Complex (130,000 Nm3/h H2)

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North West Redwater Upgrader General Setup

■ One out of three phases

Hydrogen

Crude and

Vacuum Unit

Resid

Hydrocracker

Hydrocracker

& Hydrotreater

Multi Purpose

Gasification

Bitumen Blend

Feedstock

77,080 bpd

Dilbit

51,760 bpd

Synbit

25,320 bpd

Diluent and Naphta

32,501 bpd

ULS Diesel

36,178 bpd

LS Vacuum

Gas Oil

8,276 bpd

Butane

771 bpd

High Quality CO2

Hydrogen

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NWR Hydrogen Plant Flow Scheme

H2S+CO2

Feedstock

Steam

Carbon Slurry

Air

O2

LP-Steam

Sulfur

Process Water

Air + O2

Claus Off-Gas

Hydrogen

97% pure

Pure, dry CO2 to EOR

148 t/h

Filter cake

Rectisol® MPG®

Quench

Raw Gas

Shift

Gas

Cooling

Metha-

nation

Filter ASU Waste Water

Treatment

Claus

CO2

Compression

3 x 50 %

~ 52 t/h

~ 129,000 Nm3/h

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Feb 16th , 2017





The FBDB TM

Gasifiers

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Lurgi FBDBTM Gasifiers

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Gas Liquor to Zero Liquid Discharge

■ Full chain of purification of the water

Lurgi FBDB™

Gasification

CO Shift &

Gas Cooling

Coal

Steam

Raw syngas

Zero Liquid

Discharge

Liquid Ammonia Crude Phenols Clear Tar / Oil

Gas Liquor

Dephenolized

Gas Liquor

Stripped

Gas Liquor

Mud liquor CO2, H2S, solvent

Acid Gas

CO2, H2S, HCN Organics

Gas Liquor

Separation

Phenosolvan®

Phenols

Recovery

Lurgi CLLTM

NH3 Recovery

Waste Water

Treatment

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Feb 16th , 2017





Process Parameters of Reference Plants

SASOL

Synfuels

Dakota

Gasificatio

n

Company

Yima Tianji Coal

Chemical

Company

Jindal Steel &

Power Ltd.

Secunda

(South Africa)

Beulah

(United

States)

Henan

(PRC)

Shanxi

(PRC)

Angul

(India)

Coal classification Sub-bituminous LigniteSub-

bituminousAnthracite Sub-bituminous

Moisture ar wt.-% 9% 37% 20% 10% 14%

Proximate analysis

Ash wt.-% dry 31% 10% 12% 15% 37%

Volatiles wt.-% daf 32% 47% 60% 15% 50%

Fixed carbon wt.-% daf 68% 53% 40% 85% 50%

Ultimate analysis

C wt.-% daf 80 72 72 90 73

H wt.-% daf 5 5 7 5 6

O wt.-% daf 12 21 20 4 19

N wt.-% daf 2.0 1.0 1.1 1.5 1.7

S wt.-% daf 1.6 1.3 0.2 0.3 0.8

HHV Coal (daf) kJ/kg (calc.) 31400 28450 30500 35300 29850

IDT °C 1350 1210 1200 1430 1300

AFT °C 1410 1250 1250 1510 1640

CO2 vol % 28.0 33.4 29.2 24.3 27.7

H2S vol % 0.4 0.4 0.1 0.1 0.2

CnHm vol % 0.4 0.7 0.5 0.4 0.7

CO vol % 22.4 14.6 16.6 28.0 22.4

H2 vol % 39.4 39.1 42.6 37.7 37.7

CH4 vol % 9.0 11.6 10.8 8.8 11.0

N2 vol % 0.4 0.2 0.3 0.7 0.3

Raw Gas (dry basis) Nm3/tdaf 2320 2000 2200 2650 1890

Tar / Oil / Naphtha kg/tdaf 33 66 37 8 84

Total Phenols kg/tdaf 6 17 3 3 9

NH3 kg/tdaf 18 10 11 13 16

Oxygen Nm3/tdaf 350 240 320 460 290

HP Steam kg/tdaf 1330 1770 1350 1460 1240

LURGI FBDBTM

Plant Reference

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Feb 16th , 2017





Air Separation

Unit

Acid Gas

Removal

Sulfur Recovery

Unit Elemental Sulfur

CO2

SNG

Syngas for DRI

N2

Methanation

Gasification

HP Steam

Ash

Coal

Preparation

CO Shift

(depending on

raw gas

composition)

Production of Syngas for DRI and SNG for Fuel

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Feb 16th , 2017





CO2

N2

Gasification

HP Steam

Ash

Coal

Preparation

Production of NH3 Syngas

Elemental Sulfur Air Separation

Unit

Sulfur Recovery

Unit

CO Shift Acid Gas

Removal

Liquid

Nitrogen Wash Ammonia Syngas

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Feb 16th , 2017





Hydrogen

Production of H2

Elemental Sulfur

HP Steam

CO2

N2

Air Separation

Unit

Sulfur Recovery

Unit

Gasification

CO Shift Acid Gas

Removal

Pressure

Swing Adsorption

Ash

Coal

Preparation

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Feb 16th , 2017





Production of H2 & CO

Elemental Sulfur

HP Steam

CO2

N2

CO

Hydrogen

Air Separation

Unit

Sulfur Recovery

Unit

Gasification

CO Shift

(depending on

the

split required)

Acid Gas

Removal

Ash

Coal

Preparation

CO

Cold Box

Pressure

Swing Adsorption

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Feb 16th , 2017





Production of CH3OH

Elemental Sulfur

HP Steam

CO2

N2

Methanol

Air Separation

Unit

Sulfur Recovery

Unit

Gasification

CO Shift

(depending on

raw gas

composition)

Acid Gas

Removal

Ash

Coal

Preparation

Methanol

Synthesis

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Feb 16th , 2017





World’s Largest Coal Gasification to SynFuels Complex

SASOL Synfuels, Secunda, South Africa 80 x LURGI FBDBTM units – Start-up: 1979 – Coal: Sub-bituminous coal – Products: Syngas to FT fuels

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Feb 16th , 2017





Lignite Reference – Lurgi FBDBTM

Dakota Gasification Company – Beulah, North Dakota, USA 14 x LURGI FBDBTM units – Start-up: 1985 – Coal: Lignite coal – Products: (SNG) and CO2

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Feb 16th , 2017





Sub-bituminous Reference – Lurgi FBDBTM

Yima Coal Gasification, Henan Province, PRC 2 x LURGI FBDBTM units – Start-up: 2000 – Coal: Sub-bituminous coal – Product: Methanol

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Feb 16th , 2017





Anthracite Reference – Lurgi FBDBTM

Tianji Coal Chemical Company, Shanxi Province, PRC 5 x LURGI FBDBTM units – Start-up: 1987 – Coal: Anthracite coal – Product: NH3

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Feb 16th , 2017





Indian Reference – Lurgi FBDBTM

Jindal Steel & Power Ltd, Angul Orrisa, India 7 x LURGI FBDBTM units – Start-up: ongoing – Coal: High ash Indian coal – Product: Reduction gas for DRI

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Feb 16th , 2017





RectisolTM

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Feb 16th , 2017





RectisolTM

H2S Wash

CO2 Wash

Prewash

Cold

Flash

Regen.

Hot

Regen.

MeOH /

H2O

Separ.

SynGas

RawGas

Condensate

CO2 Product Offgas Claus Gas

Water

Trace contaminant removal

COS, CS2, NH3, HCN, RSH, Hg,

Fe and Ni carbonyls and BTX

Deep Desulphurisation

COS + H2S < 0.1 ppm

CO2 < 10 ppm

Bulk CO2 Removal

Dry CO2 ; total S < 5 ppmv

Ready for Sequestration

Claus Suited

Acid Gas

> 30-50% H2S

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Feb 16th , 2017





Lurgi RectisolTM

33

■ > 60 Years of design expertise and operational feedback

■ Reference situation

21 references 2011 - today

42 references since 2000

Over 100 references in total

■ 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 applications!

H2 CO

CO2 S


Feb 16th , 2017





Sulphur

Recovery Unit

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Feb 16th , 2017





Acid Gas

Oxygen

Fuel Gas

MP-Steam HP-Steam

Claus

Combustion

Chamber

Air

Reactor

LP-

Stream Reactor

Tailgas

Sulfur

BFW

SWS Gas

BFW

Sulphur Recovery Unit

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Feb 16th , 2017





Lurgi OxyClausTM Burner

S t e a m

F u e l G a s P i l o t

O x y g e n

H 2 S A c i d G a s P r o c e s s A i r

C o m b u s t i o n A i r

S W S G a s

O x y g e n

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Feb 16th , 2017





Emission Free SRU

OxyClaus® Hydro-

genation

& Quench

Sulphur

Handling

Acid Gas Incinerator Rectisol®

Syn Gas

Raw

Gas

Recycle to Oxyclaus®

Claus

Tail Gas

Sulphur

Amine

Wash

LTGT®

Sulphur

Degassing

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Feb 16th , 2017





Emission Free SRU

■ Lower CAPEX

■ Lower OPEX

■ Smaller PLOT AREA

■ Reduced EMISSION

OxyClaus® Hydro-

genation

& Quench

Sulphur

Handling

Acid Gas

Incinerator

Rectisol®

Syn Gas

Raw

Gas

Recycle to Oxyclaus®

Claus

Tail Gas

Sulphur

LTGT®

Sulphur

Degassing

Start up only

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Feb 16th , 2017





ASU

Air Separation Unit

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Feb 16th , 2017





Operational Experience

40

More Than 7000 Km Of Pipelines

O2, N2, H2, He, CO with

Pressure between 400 Up To 2800 PSI

Around 500 Large Units In Operation,

Around 400 ASUs Up To 3400 MTPD GOX,

Around 50 HYCO UP TO 300t/d CO & 88MMscf/d H2,

Around 20 Cogen Trains : @ 50MWe & 110kp/h HP Steam,


Feb 16th , 2017





Manufacturing

41


Feb 16th , 2017





CO Cold Box

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Feb 16th , 2017





Air Liquide’s Cryogenic Gas Treating

43

■ > 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

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 purifications

and ammonia syngas preparations all by Air Liquide!

H2 CO

N2

CH4


Feb 16th , 2017





Pressure

Swing Adsorption

(PSA)

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Feb 16th , 2017





Air Liquide PSA – Highlights

45

■ Air Liquide has large experience as a Hydrogen PSA Operator

and extensive references for building PSA’s

■ Air Liquide has designed and manufactured 70 PSA’s for Third

Party and Group

■ Well known with designing PSA’s operating on CO Cold Box H2

rich gas

■ As an operator Air Liquide operates 69 H2 PSAs world wide

■ High toughness Steel for adsorber vessels (very low P, S and C

content) for increased service life under cycling and hydrogen

environment

■ More stringent than any code or other manufacturer’s standard

■ PWHT on adsorber vessels and skid piping

■ Carefully selected Valves and Accessoires,


Feb 16th , 2017





Mega MethanolTM

>5000 tpd

46

CO + 2 H2 ↔ CH3OH + heat

CO2 + 3 H2 ↔ CH3OH + H2O + heat

H2 – CO2 = 2

CO + CO2


Feb 16th , 2017





Lurgi Methanol Technology - Highlights

47

> 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 operation

Overheating of catalyst impossible

Long catalyst operational life

Low recycle ratios

High steam production

Safe and uniform temperature control

Outstanding advantage of Lurgi Methanol

Technology is the Water Cooled Reactor with

superior heat removal ability.


Feb 16th , 2017





PML MegaMethanol (Labuan Island, East Malaysia)

48

Flare MeOH

Columns ASU

Cold Box

MeOH

Reactors SMR Gas Receiving

Terminal


Feb 16th , 2017





MTPTM

CH3OH -> C3H6

49


Feb 16th , 2017





MTPTM Propylene – Process Diagram

50

Conclusion

MTP-Gasoline 540 t/d

Fuel Gas Internal use

Process Water 2,800 t/d Internal Use (+)

Product

Conditioning MTP-LPG 109 t/d

Water Recycle

Olefin Recycle

MegaMethanol®

1,667 Mt/a = 5,000 t/d

Product

Fractionation

MTP Reactors (2 Operating + 1 Regenerating)

60 t/d

Optional

DME

Pre-

Reactor

Propylene

1,410 t/d 1)

Ethylene


Feb 16th , 2017





MTPTM Technical Highlights

■ Proprietary zeolite catalyst

■ Maximized propylene production

Selectivity > 65 % (product slate)

Yield > 28 % Wt. on methanol feed

■ Methanol conversion > 99%

■ Low coking catalyst (< 0.5% carbon

loss)

■ In-Situ regeneration

■ Option for some ethylene production

■ Valuable co-products (gasoline, LPG)

Shenhua Ningxia Coal Industry Group Co. Ltd

MTPTM Propylene - Highlights

51


Feb 16th , 2017





Coal to Propylene: Shenhua Ningxia, China

52

ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™

5000 tpd MeOH to each MTP™

PP MTP Methanol

Rectisol Gasification


Feb 16th , 2017





Summary and Conclusion – A One-Stop-Shop

The Complete Gas Island

53

the lurgi gasification island -...

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