LURGI FBDB™ MK+™ Gasification Technology · 2018. 4. 17. · The Lurgi FBDB™ Gasifier LURGI...

LURGI FBDB™ MK+™ Gasification Technology

6th International Freiberg ConferenceDresden / Radebeul – May 19 – 22nd, 2014

Air Liquide Global E&C Solutions Germany l Lurgi FBDB technology

Outline

■ Mk+ Gasification Module

■ Benefits for Coal to SNG Projects

■ Update on SNG Projects in China

■ Highlights on Key Innovations

Air Liquide, world leader in gases for industry, he alth and the environment

■ Highlights on Key Innovations� Purification of the gas liquor for ZLD solution� Dry ash handling

■ Status JSPL Coal to DRI Project in India

2 6th IFC - May 21st 2014 - Germany

Basis of Lurgi FBDBTM Mk PlusTM Development

Step 1: Starting point: Mark 4 from Jindal Steel & Power Ltd. (JSPL) Angul project

� Lessons learnt from 30 years of operation of Sasol (Secunda, RSA) and DGC (North Dakota, USA) plants

� Latest project: JSPL Angul, India, 40 barg design pressure

Step 2: Increase of the diameter � Reason: Gain in terms of capacity � Definition point: Lurgi Mark 5

Latest MK4 (Design

pressure : 40barg)

Design improvement based

Continuous technology

improvement of MK 4

Rich references of Mk 4101 gasifiers globally

Continuous technologyimprovement

1970s-2010)

Quant ifyinfluence

of diameter increase


� Definition point: Lurgi Mark 5 (Sasolburg 1985 to 2004)

Step 3: Increase of the operating pressure

� Gain in capacity, efficiency, environmental footprint and methane yield

� Optimum pressure: 60 barg for Capex and scale-up risk

� Validation of the gasification process calculations with the Ruhr 100 pilot plant test results and data


MK4 MK5

Design improvement based on experience from Mk 5

Ruhr-100 pilot plantmaximum operation pressure : 100bar)

MK+ - Lurgi new FBDB

GasifierQuantify benefits of high

pressure gasification

Gasification database

under high pressure and some special

design features

increase

The Lurgi FBDB™ Gasifier� LURGI FBDB ™ Mark4 Gasifier

� Outside diameter: 4.13 m

� Height: 12.5 m

� Design pressure: 40 barg

� Raw Gas Loading, dry: up to 60000 Nm³/h

� LURGI FBDB ™ Mark+™ Gasifier

� Outside diameter: 5.05 m

� Height：17.0 m

� Design pressure: ：60 barg

� Raw Gas Loading, dry: up to 120000 Nm³/h


1950s - 2010 2011 - …

4

� 2500 t/d coal feed

� 500 MWth

6th IFC - May 21st 2014 - Germany

Benefits for Coal to SNG projects■ MK+ : innovative use of referenced

technology for no scale up risks

■ Improved Opex and lower Capexcompared to Mk4■ Higher direct production of CH4■ Reduced coal, O2 and HP Steam

consumption

Air Liquide, world leader in gases for industry, he alth and the environment5 6th IFC - May 21st 2014 - Germany

consumption■ Higher thermal efficiency

■ 10 to 15% decrease of the SNGcost versus Mk4

■ Part of the SNG is produced byETF gasification for coal fines.

(ETF: 50% higher SNG cost)

FBDB MK+Coarse Coal

Fine coal ETF Rectisol

Rectisol Methanation

Methanation

50% to 75%

O2

SNG

O2

SNG

Update on SNG projects in China

■ 2 plants started-up with a total capacity of 2.7 BCMY of SNG ■ Datang Keqi phase 1■ Qinghua Yili phase 1

■ More than 20 new projects got the NDRC Lutiaoin 2013

■ 2 main locations for SNG projects■ Inner Mongolia province


■ Inner Mongolia province■ Xinjiang province

■ Challenges■ Magnitude of the Capex (large projects)■ Management of the project risks■ Highest standards for emissions and effluents■ Scarcity of the water

From Gas Liquor to Zero Liquid Discharge

■ Full chain of purification of the water – Unique offer from Air Liquide■ Solution based on fully referenced technologies■ Recycle of the purified water as make-up to cooling water circuit

Lurgi FBDB™ Gasification

CO Shift &Gas Cooling

Coal

Steam

Raw syngas

Acid GasRecycle of the water is a must

for CtSNG projects

O2


Cooling waterMake-up

Liquid AmmoniaCrude PhenolsClear Tar / Oil

Gas LiquorDephenolized

Gas LiquorStripped

Gas Liquor

Mud liquor CO2, H2S, solvent

Acid GasCO2, H2S, HCN Organics

Gas LiquorSeparation

Phenosolvan®Phenols Recovery

CLLNH3 Recovery

Waste WaterTreatment


for CtSNG projects(<5 twater /kNm3)

Phenosolvan / CLL / WWT: Economics

Spec Unit RMB/unitCW 30°C T 0.2TW 45°C T 0.57Demin water 30°C T 8LP Steam 4.5 bar T 70MP Steam 8.5 bar T 85N2 7 bar Nm³ 0.165Power kWh 0.42Caustic As pure Kg 3.1solvent (DIPE) Kg 11.5CTA T 2800Ammonia T 2500

■ Make-up water for the cooling water system produced by WWT

■ WWT consists of advanced bio-treatment followed by high efficiency RO and evaporation / crystallization units

■ Impact WWT on SNG cost: 2.5%■ Large credit coming from co-products

Air Liquide, world leader in gases for industry, he alth and the environment8

Ammonia T 2500

Flow 550 t/h of GL Phenosolvan CLL WWT TotalCAPEX M€ 48 32 41 121OPEX RMB/t 4.1 35.2 5.8 45.1CAPEX + OPEX RMB/t 21.6 46.9 20.2 88.7Credit co-products RMB/t 13 22 0 35Net TCO RMB/t 8.6 24.9 20.2 53.7% Total TCO 16% 46% 38% 100%% of SNG cost 1.1% 3.2% 2.5% 6.8%Ref 1.7 for 2 BCMY

6th IFC - May 21st 2014 - Germany

■ Large credit coming from co-products

Evaluation of dry ash handling for FBDB■ Wet sluice way system

■ Most commonly applied worldwide■ Very reliable■ Wet ash to be disposed off or sold■ Loss of water with the ash■ ~ 3€ / t of ash (handling / separation)

■ Incentives for dry ash


■ Incentives for dry ash handling■ No water consumption■ No effluent water to treat■ Lower operating costs■ Broader opportunities to

sell the ash

Optimized dry ash handling solution

■ Ash disposal cost reduced by ■ by 5% (no ash

sold)■ by 11% (10% of

the ash sold)

Interesting competitive solution of the ash

management for FBDB


■ Referenced and proven equipment (power plants) ■ Easy operation and maintenance■ Solution with high availability (> 99.5%)

■ Footprint reduced by 65%


Magaldi group: dependable by innovation since 1929

The Magaldi Group, founded in 1929,

World leader in mechanical transportation of hot and abrasive bulk materials

for coal-fired power plants, cement manufacturers, steel mills, foundries, mines etc.


Magaldi develops and provides technologies for the safe and environmental friendly handling of raw materials and ash in the coal fired power plants

Magaldi group: dependable by innovation since 1929

■ The Superbelt ® ensures the safest and most reliable transportation of abrasive and hot bulk material, associated with maximum life time.


■ Hundreds of successful installations in Power Industry (hot bottom ash, mill rejects, Eco ash); Foundries (hot castings, sand, molds, scraps); Cement Industry (hot clinkers); Metallurgical plants (hot DRI, metal sinter etc.).

■ The Magaldi ECOBELT ®®®® is a steel belt conveyor completely enclosed in a dust-proof steel casing, unique in its design and able to transport materials with aggressive properties, both chemical and physical, without any release to the external environment.

JSPL Coal to DRI Gasification Project

Commissioning completedStart-up on-going

■ Customer: JSPL■ Location: Orissa, India■ Key Process data:

■ Sub. Coal 35% ash■ 7 MK4 gasifiers■ 225,000 Nm3/h DRI SG■ LHV: 3,500 kcal/Nm3

Mk4 Gasifiers CLL


■ H2/CO ratio: 1.7 ■ Scope for complete gas

island - gasification, Rectisol , SRU■ PDP / BE / DE■ Prop Equipt supply■ Operators training■ Start-up assistance

Photos site Jan 2014 – Courtesy JSPL

Phenosolvan

JSPL Coal to DRI Gasification Project


Contact informationMr Frederic Judas, Director TechnologyCoal to Gas Product LineAir Liquide Global E&C Solutions Germany [email protected]: + 49 69 5808 2081Tel: + 49 69 5808 2081

4,000 Air Liquide Global E&C Solutions Colleagues Thank You!

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LURGI FBDB™ MK+™ Gasification Technology · 2018. 4. 17. · The Lurgi FBDB™ Gasifier LURGI...

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