Up-Date on Lurgi Syngas · PDF file24/10/2003 GTC2003, San Francisco Up-Date on Lurgi Syngas...

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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

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

Africa39,3%

Far East & Oceania

West. Europe

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®

MtPower

MtSynfuels®

Acrylic AcidMTP®

Natural Gas /Associated Gas

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

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

Purpose

Gasification

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

N/d Syngas

Special Features of MPG

Feed "

QuenchWater

O2 Steam

Gas-offtake

Soot Slurry

Feed A " Feed B"

SteamCooling Water

Comparison Quench/Boiler

Feed "

Soot Slurry

QuenchWater

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

CO-ShiftUnit

RectisolCO2 Removal

LiquidN2 Wash

NH3Synthesis

CarbonRecovery

UnitClaus Unit Urea

Synthesis

Air Separation

HP-SteamBoiler

HP-Steam

SulfurSoot and AshPellets

Pure CO2 Urea

LiquidAmmonia

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

1100 1200 1300 1400

Temperature, °C

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

stemNatural

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 dr_holger_schlichting@lurgi.de

Internet: www.lurgi.de

? Comments ?

Reaction to Load Changes

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

, % Oil-FlowO2-Flow

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

T-TopT-MiddleT-Bottom

World Oil and Gas Reserves II

5.16.37.3 38

NorthAmerica

S & CAmerica

Europe Africa MiddleEast

Russia AsiaPacific

rillio

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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