Post on 28-Oct-2019
transcript
Outline
� Air Liquide E&C Perspective
� Next Generation Lurgi FBDB TM Gasification
� Lurgi FBDB™ Clean Conversion Vision
� Next Generation Lurgi FBDB™ Mk Plus™
Air Liquide, world leader in gases for industry, he alth and the environment2 22/05/2012
� Next Generation Lurgi FBDB™ Mk Plus™
� Reduced Capex, Opex and Environmental Footprint
� Gas Liquor Recovery: Zero Liquid Discharge
� Conclusion
AIR LIQUIDE: CLEAN CONVERSION WITH LURGI FBDB™
Air Liquide, world leader in gases for industry, he alth and the environment3 22/05/2012
Lurgi FBDB™ in Our Clean Conversion Vision
H2 for Refineries
SMRs
Fertilizers
Chemicals
CO2
N2 Wash + H2
Methanol Synthesis
Chemical SynthesisDME/MTP
Raw Material
Syngas Final Products
CO Cold Box
PSA / Mem-brane
(Sulfur)Rectisol
ProcessesSyngas Purification
Residue
Natural Gas
Coal
Biomass
GasificationFBDB/MPG
(CO2)Rectisol Stage 1
Air Liquide, world leader in gases for industry, he alth and the environment4 22/05/2012
Fertilizers
Power
SNG
Sulfur
Turbine
Methanation
N2 Wash + H2
Fischer-Tropsch
Syngas for DRI
Sulfur Recovery
CO Shift
Rectisol Stage 1
Biomass
AL E&C Capability
ASU
Reforming
Synfuels
Lurgi FBDB™ Coal-to-X Syngas
Air Liquide
ASU
Lurgi Rectisol ®Gas
Purification
Lurgi OxyClaus ®Sulfur Recovery
Elemental Sulfur
CO2
Syngas
Air Liquide
LNW Unit
N2
Lurgi
Ammonia Syngas
(Fuel Gas)
Lurgi MPG ®Gasification
Lurgi FBDB™
Gasification
Lurgi
CO Shift
and
Coal
Preparation
HP Steam
Air Liquide, world leader in gases for industry, he alth and the environment5 22/05/2012
Lurgi
GLS Process™
Lurgi Phenosolvan ® & Lurgi CLL™
Gas Liquor Recovery and Water Treatment
Liquid Ammonia
ZLD – Water Reuse
Purification
HP Steam
Lurgi
Methanation SNG
(Rectisol Naphtha)
(Phenols)
(Clear Tar / Oil)
Gasification and
Gas Cooling
Ash
Lurgi FBDB™ Gasification
0.5
0.6
0.7
0.8
0.9
1
Gas
Coal
Gasifier top
Drying
Devolatilization
Air Liquide, world leader in gases for industry, he alth and the environment6 22/05/2012
0
0.1
0.2
0.3
0.4
0.5
0 300 600 900 1200 1500
Temperature [°C]
Ash
Gasifier bottom
Gasification
Combustion
Lurgi FBDB™ Operating Range
� Coal suitability, complex function of
� Lump coal typically 5 – 50 mm with < 5% above and below
� Ash fluid temperature > 1200°C under oxidizing conditions
� Combined total ash and moisture < 50%
50
45
40
35
30
25
20
15
wt-% Ash
Angul JSPL
Secunda Sasol
Shanxi Tianji
Henan Yima
North Dakota DGC
50
45
40
35
30
25
20
15
wt-% Ash
Angul JSPL
Secunda Sasol
Shanxi Tianji
Henan Yima
North Dakota DGC
Air Liquide, world leader in gases for industry, he alth and the environment7 22/05/2012
� Combined total ash and moisture < 50%
� Thermal and mechanical strength
� Caking in range of proven proprietary internals5 8 10 15 20 25 30 35 40 45 50 wt-% Moisture
15
10
5
North Dakota DGC
5 8 10 15 20 25 30 35 40 45 50 wt-% Moisture
15
10
5
North Dakota DGC
� Green area shows proven operating range of Lurgi FB DBTM
� All ranks of coal proven in operation
� Lignite, sub-bituminous, bituminous, anthracite
THE NEXT GENERATION – LURGI FBDB™ Mk Plus™
Air Liquide, world leader in gases for industry, he alth and the environment8 22/05/2012
Rationale for New Development
� SNG and Other Growth Markets in China and Worldwide :
� Low rank coal capitalization → Domain of Lurgi FBDB TM Gasification
� Environmental stewardship → Major focus of Lurgi
� Lurgi’s FBDB TM Technology and Downstream Units updated for:
� Competitive pricing, e.g. SNG versus Natural Gas
Air Liquide, world leader in gases for industry, he alth and the environment9 22/05/2012
• Reduction of CAPEX
• Improvement of OPEX
� Reduction of Environmental Impact:
• Gas liquor treatment and water re-use ( Zero Liquid Discharge )
• Fugitive emissions
• Carbon dioxide emissions mitigation
Lurgi´s New Gasification Module – Mk Plus™
� Targets of the development
� Improved economics by increasing capacity of Lurgi FBDB TM module
� Improved environmental footprint (water, carbon dioxide) of Lurgi FBDB TM
� Remaining safe, robust and easy to operate
� Using proven technology and equipment in a new and innovative way
• Controlled development – rather as evolution
Air Liquide, world leader in gases for industry, he alth and the environment10 22/05/2012
• Controlled development – rather as evolution
• Minimum risk
• Commercialized without building demonstration plant
Gain by Change
Risk
Mk 4
Target zone fornew gasification module
Latest MK4
(Design
pressure:
40barg)
Continuous
technology
improvement
for MK4
Rich references of Mk4
101 gasifiers globally
Continuous technology
improvement
1970s-2010)
Quantify
influence
of diameter
Lurgi FBDBTM Mk Plus™ Development Basis� Starting point: Mark 4 from Jindal Steel & Power Lt d. (JSPL) Angul project
� Lessons learned from 30 years of Sasol (Secunda, RSA) and DGC (North Dakota, USA)
� Latest JSPL (Angul, India) 40 barg design pressureSte
p 1
Ste
p 2
� Increase of the diameter
� Capacity Gain
Air Liquide, world leader in gases for industry, he alth and the environment11 22/05/2012
MK4 MK5
Design improvement based
on experience from Mk5
Ruhr-100 pilot plant
maximum operation
pressure: 100bar)
MK+ - Lurgi
new FBDB
Gasifier
Quantify benefits of high
pressure gasification
Gasification
database
under high
pressure and
some special
design
features
of diameter
increase
Ste
p 2 � Capacity Gain
� Definition point: Mark 5
� Sasolburg 1980’s and 1990’s
Ste
p 3
� Increase of the operating pressure
� Capacity, efficiency, environmental footprint, direct methane gain
� Optimum design pressure: 60 barg for capex and scale-up risk
� Process validation from extensive Ruhr 100 large pilot tests
Latest MK4
(Design
pressure:
40barg)
Continuous
technology
improvement
for MK4
Rich references of Mk4
101 gasifiers globally
Continuous technology
improvement
1970s-2010)
Quantify
influence
of diameter
Lurgi FBDBTM Mk Plus™ Development Basis� Starting point: Mark 4 from Jindal Steel & Power Lt d. (JSPL) Angul project
� Lessons learned from 30 years of Sasol (Secunda, RSA) and DGC (North Dakota, USA)
� Latest JSPL (Angul, India) 40 barg design pressureSte
p 1
Ste
p 2
� Increase of the diameter
� Capacity Gain
Air Liquide, world leader in gases for industry, he alth and the environment12 22/05/2012
MK4 MK5
Design improvement based
on experience from Mk5
Ruhr-100 pilot plant
maximum operation
pressure: 100bar)
MK+ - Lurgi
new FBDB
Gasifier
Quantify benefits of high
pressure gasification
Gasification
database
under high
pressure and
some special
design
features
of diameter
increase
Ste
p 2 � Capacity Gain
� Definition point: Mark 5
� Sasolburg 1980’s and 1990’s
Ste
p 3
� Increase of the operating pressure
� Capacity, efficiency, environmental footprint, direct methane gain
� Optimum design pressure: 60 barg for capex and scale-up risk
� Process validation from extensive Ruhr 100 large pilot tests
The Lurgi FBDB™ Gasifier� LURGI FBDB ™ Mark 4 Gasifier
� Outside diameter: 4.13 m
� Height: 12.5 m
� Design pressure: 40 barg
� Raw Gas Loading, dry: up to 60000 Nm³/h
� Secunda, DGC, Tianji, Yima, Angul
� LURGI FBDB ™ Mk Plus ™ Gasifier
� Outside diameter: 5.05 m
� Height: 17.0 m
� Design pressure: 60 barg
� Raw Gas Loading, dry: up to 120000 Nm³/h
� Next Generation
Air Liquide, world leader in gases for industry, he alth and the environment13 22/05/2012
1950s - 2010 2011 - >
Twin Coal Lock
Reactor
Gas Off-take
Wash Cooler
The Lurgi FBDB™ Gasifier – Sketch
Air Liquide, world leader in gases for industry, he alth and the environment14 22/05/2012
Rotating Grate
Ash Lock
Twin Coal Lock System
� Mk4 coal lock limited capacity insufficient for the factor 2 in coal rate required� Operating frequency not practical beyond 6 cycles/hour
� Increased Mk4 coal lock size has negative impact on tightness and lifetime of the larger cones� High risk option, therefore not pursued
� Twin locks system implemented� Standard proven design of Mk4 coal lock
� Standard proven design of Mk4 cone valves
� Standard proven operating cycle frequency
Air Liquide, world leader in gases for industry, he alth and the environment15 22/05/2012
Standard proven operating cycle frequency� Limited increase in the thickness of the lock
� Saves 2/3 of the pressurization gas
� Modified coal feed arrangement
� References� Ruhr 100 large pilot FBDB gasifier, Dorsten (Germany) 1979 - 1985� Slagging gasifier (70 barg design pressure), Westfield (Scotland) 1991
� SVZ (32 barg design pressure), Schwarze Pumpe (Germany) 2000 - 2007
Effect of the Mk Plus™ on undisclosed project
� Impact of pressure – specific figures per ton dry, ash free
HP Steam
kg / tdafMk4 Mk Plus™
� Coal data
� Moisture, ar 8%
� Ash, ad 20%
� Volatiles, daf 43%
� FC, daf 57%
� AFT 1500°C
CH4
Nm3 / tdafMk4 Mk Plus™
+ 20.3% 223 268
CO2
Nm3 / tdafMk4 Mk Plus™
- 4.5% 574 548
Air Liquide, world leader in gases for industry, he alth and the environment16 22/05/2012
GL to unit 6
kg / tdafMk4 Mk Plus™
- 15% 983 835
- 7.6% 1181 1091
O2
Nm3/ tdafMk4
Mk Plus™
- 9% 290 264
CH4 + (CO+H2)/4
Nm3 / tdaf
Mk4 Mk Plus™
+ 2.4% 524 537
HHV dry gas
MJ / tdaf
Mk4 Mk Plus™
+ 0.9% 25471 25709
Lurgi FBDB™ Benefits of Mk Plus™ - Opex
� Higher efficiency & reduced cost� 10 % decrease of the SNG cost by example
� Carbon conversion > 99%
� Thermal efficiency (exiting gasifier) > 94%
� Cold gas efficiency > 87%
� Lower coal consumption
� Lower oxygen consumption per t of coal
Air Liquide, world leader in gases for industry, he alth and the environment17 22/05/2012
� Lower oxygen consumption per t of coal
� Reduced steam consumption per t of coal
� Higher methane yield per t of coal
� Reduced gross tar yield per t of coal
� Increased oil and naphtha yield per t of coal
� Increased gasification rate per gasifier x-area
� Gain on compression of SNG
Lurgi FBDB™ Benefits of Mk Plus™ - Capex � Number of Lurgi FBDB TM modules
� Example, only 20 Mk Plus™ for 4 BCMY SNG (compare to 40 Mark4)
� Reduction of over 300 equipment numbers for a 4 BCM Y SNG project
� Reduction of plot size
� Reduction of capex ~20% across the Lurgi FBDB TM process chain
� Savings in downstream units
� CO Shift & Rectisol®
• Reduced capex due to higher operating pressure and process effects
Air Liquide, world leader in gases for industry, he alth and the environment18 22/05/2012
• Reduced capex due to gas composition improvement
• Reduced refrigeration requirement (more efficient high pressure absorptio n)
• Reduced methane Loss (optimized process scheme, co-absorption)
� Gas Liquor Separation, Phenosolvan ®, Lurgi CLL TM and Waste Water Treatment
• Reduced capex due to less gas liquor
� Methanation
• Reduced capex due to higher operating pressure
• Reduced recycle because of higher methane content in feed gas
• Smaller reactor as half of the feed is methane (CH 4)
LURGI FBDBTM GASIFICATION ISLAND – GAS LIQUOR RECOVERY
Air Liquide, world leader in gases for industry, he alth and the environment19 22/05/2012
From Gas Liquor to Zero Liquid Discharge
� Full chain of purification of the water
Lurgi FBDB™
Gasification
CO Shift &
Gas Cooling
Coal
HP Steam
Raw syngas
Air Liquide, world leader in gases for industry, he alth and the environment20 22/05/2012
Zero Liquid Discharge
Liquid AmmoniaCrude PhenolsClear Tar / Oil
Lurgi
GLS Process™
Phenosolvan®
Phenols
Recovery
Lurgi CLL™
NH3 Recovery
Waste Water
Treatment
Gas LiquorDephenolized
Gas LiquorStripped
Gas Liquor
Mud liquor CO2, H2S, solvent
Acid GasCO2, H2S, HCN
Organics
Waste Water Treatment� Bio – Treatment
� Particular care of high Chemical Oxygen Demand (COD) and higher phenols
� Complete re-use of waste water in the process → Zero Liquid Discharge� Bio-treatment followed by reverse osmosis technology
� Alternative specification of water effluent to coun try standardsPart of the LURGI FBDB TM Coal Gasification Island
Bio -treatment
Air Liquide, world leader in gases for industry, he alth and the environment21 22/05/2012
Bio -treatment
Dual sludge system with recycle and proprietary
carrier material
Salts
Cooling water Make-up Stripped Gas Liquor
Sludge excess
Post-treatment
Special reverse osmosis
Crystallization unit
Sludge excess
~99% Recovery
CONCLUSION
Air Liquide, world leader in gases for industry, he alth and the environment22 22/05/2012
Lurgi FBDB™ Mk Plus™ Gasification
� Proven Operation
� Innovative use of referenced technology for no scale-up risk
� Safe and forgiving operation
� Beneficial for low rank coal
� Financially Secure Investment
� Track record
� On-stream factor (availability)
� Fewer Mk Plus™ gasification modules for same output
Air Liquide, world leader in gases for industry, he alth and the environment23 22/05/2012
� Fewer Mk Plus™ gasification modules for same output
� High Efficiency and Reduced Cost of SNG
� Reduced steam consumption and lower oxygen consumption (per t of coal)
� Higher direct methane production
� Approximately 10% decrease of the SNG cost
� Roughly 20% CAPEX reduction across the Lurgi FBDBTM process chain
� Environmental Compliance
� Complete process water re-use→ Zero Liquid Discharge
� World bank standards met
4 000 Air Liquide E&C Colleagues Thank You
Air Liquide, world leader in gases for industry, he alth and the environment24 22/05/2012
E-mail: daniel.vandermerwe@airliquide.com
Air Liquide E&C in Perspective
Revenue
€14.5
Gas and UtilitySupply
89%� Industrial Merchant� Large Industries� Electronics� Healthcare
Air Liquide, world leader in gases for industry, he alth and the environment25 22/05/2012
billion
Technologies EngineeringServices
5%
Lurgi FBDB™ Project Execution
E
PProcurement
- Global sourcing- Purchasing of equipment, bulks and spare parts- Sub-contracting
Engineering- Study- FEED- Licensing- Basic and detailed engineering
Pro
ject
Man
agem
ent
Air Liquide, world leader in gases for industry, he alth and the environment26 22/05/2012
P
CConstruction
- Site advisory and management- Site fabrication- Installation- Commissioning and start-up
- Sub-contracting- Expediting and Inspection- Logistics
Pro
ject
Man
agem
ent
…..Your Support for Lifetime Project Success