up-date on lurgi syngas · pdf file24/10/2003 gtc2003, san francisco up-date on lurgi syngas...

24/10/2003 GTC2003, San Francisco

Up-Date on Lurgi Syngas Technologies


Gasification Technologies 2003, San Francisco H. Schlichting

Lurgi Oel.Gas.Chemie GmbH



! Overview on World Gas Market

! Comparison of Syngas Production Technologies

! Application of MPG

! HP-POX-Pilot Plant

The Presentation will cover…….



World Oil and Gas Reserves

0

20

40

60

80

100

120

140

160

World OilReserves

World GasReserves

Source: Erdöl Erdgas Kohle, July/August 2001

[years]

known today (proven)

including new discoveries



Flared Natural Gas

better use:make 130 Mt/a of methanol!build 74 MegaMethanol (and MTP)plants!

total amount flared worldwide:100 *109 m³ per year(250.000 MMSCFD)

North America16,7%

Middle East

14,7%

Africa39,3%

Far East & Oceania

7,7%

West. Europe

3,1%

E.Europe&FSU6,8%

C&S America11,6%

Source: Energy Information Administration (EIA): ”International Natural Gas Information” 14 Feb 2001, http://www.eia.doe.gov

monetizing flared gas by producing

valuable products using the Lurgi‘s

Gas-to-Chemicals (GTC) technologies



General Gas to Chemicals Processing Routes

Fuel GasLPGNaphthaDieselWaxesAmmoniaFuel CellsChemicals (MTBE, Acetic Acid, Formaldehyde, ...)Diesel, transport. fuelsPropylene/PolypropyleneAcrylic Acid/AcrylatesEthylene/PropylenePower/Fuel/DME(Diesel)Hydrogen

MegaSyn®

Fischer Tropsch

SynthesisUpgrading

Mega-Methanol®

MTO

MtPower

MTH

MtSynfuels®

Acrylic AcidMTP®

Natural Gas /Associated Gas

MTC

Lurgiproprietary process

Megammonia®



Typical Single-Train Capacities of Various Syngas Technologies

100 1,000 10,000 100,000 1,000,000

MeOHReforming

MPG- Part ialOxidat ion

AutothermalReforming

SteamReforming

Capacity [Nm³ dry syngas/h]



H2/CO Ratios of Syngas Generated from Natural Gas

1 2 3 4 5

M PG

ATR

CM R

SM R

H2/CO Ratio of Syngas

SMR = Steam Methane ReformingCMR= Combined Methane ReformingATR = Autothermal ReformingMPG = Multi Purpose Gasification



Development of Lurgi‘s Gasification Related Process Know How

1950 1960 1970 1980 1990 2000

Fixed Bed Grate Gasifier

Multi

Purpose

Gasification

45 years experiencein residue gasification:! 75 units! 62.5 x 106 m3

N/d Syngas

year



Special Features of MPG

Feed "

QuenchWater

O2 Steam

Gas-offtake

#

#

#

#

Soot Slurry

Feed A " Feed B"

SteamCooling Water

O2

"""



Comparison Quench/Boiler

Feed "

Soot Slurry

QuenchWater

Oxidant(O2 Air)Steam

#

#

#

#

Feed

Oxidant(O2 Air)Steam

#

Syngas

# Syngas

Burner

Boiler Mode

Sat. HP-steam

"

HeatRecovery

Boiler

"

Quench Mode



Application of MPG in a Fertilizer Plant Based on Asphalt Gasification


Up-Date on Lurgi Syngas TechnologiesMPG - Lurgi Multi Purpose Gasification

Fertilizer Plant Based on Residue Asphalt

GasificationUnit

RectisolH2S Removal

Unit

CO-ShiftUnit

RectisolCO2 Removal

Unit

LiquidN2 Wash

Unit

NH3Synthesis

Unit

CarbonRecovery

UnitClaus Unit Urea

Synthesis

Air Separation

Unit

HP-SteamBoiler

Air

Feed

HP-Steam

SulfurSoot and AshPellets

Pure CO2 Urea

LiquidAmmonia

O2

RefigerationUnit



Feedstock and Product

Feedstock:Residue Asphalt 970 t/dC/H-Ratio 8.8 kg/kgAsh Content 0.04 wt%Viscosity at 180°C 360 cStViscosity at 290°C 20 cStFlash Point 170 °C

Products:Ammonia 1350 t/dUrea 2000 t/d



Project Driving Forces

$ Fluctuating feedstock properties $ Reliability proven commercially for slurry feeds

$ Reduce Load of HP-steam $ Atomizing of oil with steam

Operational Problems in Plant

$ Safety requires laborious procedure after each shut-down

Features of MPG Burner

$ Design of burner with inherent safety

system by stop of oil preheater allows high viscous feedstock

$ Burner lifetime limited due to safety causes high maintenance effort

$ Long burner lifetime reduces maintenance effort



Gasifier Operation

$ Smooth start-up with automatic start-up system

$ Start directly with residue asphalt at 100 % load

$ Operation with oil viscosity above 100 cSt

$ Start with cold oil of high viscosity

$ Quick take over of gas to production

$ Lower reactor wall temperatures

$ Load changes easy controllable



0

3

6

9

1100 1200 1300 1400

Temperature, °C

Rea

ctor

Hei

ght

MPG BurnerMPG Burner: AverageMPG Burner: CFD-SimulationOriginal BurnerOriginal Burner: Average

Reactor Temperature Profile

+ Lower maximum wall temperature reduces thermal stress of refractory

MPG - Lurgi Multi Purpose Gasification



HP-POX Pilot Plant

Feedstock:Liquid Feedstock 500 kg/h

Natural Gas 500 m3/h

Reactor:Design Pressure 100 bar



HP-POX Pilot Plant

Flue GasFresh water

WaterTreatment

Steam Generator

Storage

Compressor

Pump andVaporizier

Soot Water Cooler

LiquidFeeds

NitrogenSupply

Instument AirSupply

MeasuringStation

Power Supply AnalyticalArea

DesulphurisationReactor

Flar

e Sy

stemNatural

Gas

Liquid O2

Soot Water



Contact :

Dr. Holger SchlichtingProcess ManagerLurgi Oel·Gas·Chemie GmbH

Dept. A-GPGG Phone +49 69 5808 1418Lurgiallee 5 Fax +49 69 5808 2639D-60295 Frankfurt am MainGermany e-mail [email protected]

Internet: www.lurgi.de

? Comments ?



Reaction to Load Changes

88

90

92

94

96

98

100

102

14:30 15:00 15:30 16:00 16:30 17:00Time

O2-

Flow

, % ;

Oil-

Flow

, % Oil-FlowO2-Flow

1160

1200

1240

1280

1320

14:30 15:00 15:30 16:00 16:30 17:00Time

Rea

ctor

Tem

pera

ture

s, °

C

T-TopT-MiddleT-Bottom



World Oil and Gas Reserves II

10.3

56.7

49.5

11.2

5.16.37.3 38

106

282

215

12

68

100

10

20

30

40

50

60

NorthAmerica

S & CAmerica

Europe Africa MiddleEast

Russia AsiaPacific

Gas

Res

erve

s, T

rillio

n m

³

0

100

200

300

Life

time,

yea

rs

Source: Shell / EFI Conference 2000, Oil & Gas Journal


Up-Date on Lurgi Syngas TechnologiesUses of Natural Gas

Gas SalesRe-injectionNatural Gas

Power Generation

Fischer-TropschProducts Methanol

RefineriesFuel

Clean FuelsClean FuelsLubricantsLubricantsWaxWaxAlpha OlefinsAlpha Olefins

UreaAcrylonitrileFertilisers

DME, FormaldehydeSolvents, MTBEClean Fuels, Fuel Cells Power Generation

Acetic Acid

Propylene

Syngas (CO, H2)

Hydrogen Ammonia

LNG5%5%



Autothermal Reforming

Feed+steam#O2

"Combustion

Catalytic reactions

Temperature: 950–1050 °C1740 –1920 °F

Pressure: 30–40 bar435–580 psi

#SYNGAS



MPG- Multi Purpose Gasification

SYNGAS#

Feed (Natural gas, heavy oil, chemical residues)

#O2/ Steam"

Partial oxidation

Steam reactions

Temperature: 1200–1450 °C2190–2640 °F

Pressure: 30–70 bar435–1015 psi



Reactor Heat-Up$ Integrated heat-up burner

provides pilot flame up to self-ignition temperature of fuel gas

$ Fuel gas and air fed via product lances

+ Controlled temperature increase

+ Replacement of pilot burner by dummy tube in less than 15 min.

+ No handling at open hot reactor flange



Scope of Project

$ New Burner Cooling Water Circuit

$ Modification of Oxygen Line

$ Installation of New Steam Line

$ Modification of Control System

up-date on lurgi syngas · pdf file24/10/2003 gtc2003, san francisco up-date on lurgi syngas...

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