Lurgi’s MPG Gasification plus Rectisol Gas Purification ... · 16 08.11.2005 GTC 2005, San...

© Lurgi AG

Lurgi’s MPG Gasification plus Rectisol® Gas Purification –Advanced Process Combination for Reliable Syngas Production

Ulrich Koss, Holger SchlichtingGasification Technologies 2005San Francisco, 9. – 12. October 2005

08.11.2005 GTC 2005, San Francisco, 9.-12. Oct. 20052

MPG - Multi Purpose Gasification

ContentContent

Multi Purpose Gasification– History of Lurgi’ Gasification Know-How– Features of MPG– HP-Pox Demonstration Plant– Application in Ammonia Plant

Gas Purification Technology– Advantages of Rectisol for a Hydrogen Plant


MPG - Multi Purpose GasificationLurgi’s Gasification TechnologiesLurgi’s Gasification Technologies

75% of Syngas

from

Coal World Wide

produced in this

type Gasifier

30 years operation

with slurry

feedstockOperates since 5

years with

feedstock mixture

of coal, petcoke

and municipal

waste



Special Features of MPGSpecial Features of MPG

Feed

QuenchWater

O2 + Steam

Gas-offtake

Soot Slurry

Feed A Feed BSteamCooling Water

O2

5

MPG - Multi Purpose GasificationAdvantages of MPG

• Feedstock Flexibility• No limitations on Flash Point of

Feedstock• Viscosity up to 300 cSt• Particles up to 1 mm

• Life Time of Burner Higher Reliability and Availability

• Restart without Inspection• Inherent Safety by pressurized Cooling

Water System• Low Feedstock Pressure Drop allows

for cheaper Oil-Pumps • Simultaneous feeding of immiscible

Feedstock• Integrated Heat-up Burner

Client did not inspect burner even

during 2 weeks general turnaround


MPG - Multi Purpose GasificationComparison Quench/BoilerComparison Quench/Boiler

Feed

Soot Slurry

QuenchWater

Oxidant(O2 Air)Steam

Feed

Oxidant(O2 Air)Steam

Syngas

Syngas

Burner

Boiler Configuration

Sat. HP-steam

HeatRecovery

Boiler

Quench Configuration



Comparison Quench versus Boiler ConfigurationComparison Quench versus Boiler Configuration

Boiler Configuration

Feedstock limitations due to possible Boiler fouling

HP-Steam availablehighest thermal efficiency

2 step gas cleaningstrong Claus gas

Higher costs for boiler(normally payback < 2 years)

Quench Configuration

Feedstock flexibility

MP-steam availabletrade off efficiency versus costs

Fastest route to hydrogenbut weak Claus gas

Lowest cost for hydrogen production unit


MPG - Multi Purpose GasificationHP-POX Demonstration Plant at Technical University of Freiberg, Saxonia, Germany



HP-POX Demonstration Plant

Multi Process Test Facility:

ATR, Gas-Pox, MPG (liquid feedstock)

Feedstock:Liquid Feedstock 500 kg/h

Natural Gas 500 m3/h(0.5 MMSCFD)

Reactor:Operating Pressure 100 bar


MPG - Multi Purpose GasificationHP-POX Demonstration Plant

WaterTreatment

Storage

Compressor

Pump andVaporizier

Steam Generator

Soot Water Cooler

Fresh water

LiquidFeeds

NitrogenSupply

Instrument AirSupply

MeasuringStation

Power Supply AnalyticalArea

DesulphurisationReactor

Flar

e Sy

stemNatural

Gas

Liquid O2

Soot Water

Flue Gas



MPG-Reactor in Asphalt based NH3-PlantMPG-Reactor in Asphalt based NH3-Plant


MPG - Multi Purpose GasificationFeedstock and Product

Feedstock:Residue Asphalt 970 t/dC/H-Ratio 8.8 kg/kg

Ash Content 0.04 wt%

Viscosity at 180°C 360 cSt

Viscosity at 290°C 20 cSt

Flash Point 170 °C

Products:Ammonia 1350 t/dEquivalent H2 113 000 Nm3/h

(100 MMSCFD)Urea 2000 t/d

13


Fertilizer Plant Based on Residue Asphalt

Gasification+ WHB

RectisolH2S Removal CO-Shift Rectisol

CO2 RemovalLiquid

N2 WashNH3

Synthesis

CarbonRecovery Claus Unit Urea

Synthesis

Air Separation

HP-SteamBoiler

Air

Feed

HP-Steam

SulfurSoot and AshPellets

Pure CO2Urea

LiquidAmmonia

O2

RefrigerationUnit

Pure Hydrogen



Raw Syngas

Natural Gas

Off-Gas

Rectisol®

Purisol®

aMDEA

MDEA / DEA

Others Tail Gas Treating

Sulphur

Ultra Pure Syngas

Turbine Gas

Pipeline Gas

Pure Off-Gas

Pure CO2 By-Product

Sulphur Recovery

Own TechnologySpecific Expertise

Lurgi´s Gas PurificationTechnology Ownership



Product Gas Purity

Rectisol® 0.1 - 1 ppm H2S + COS10 - 50 ppm CO2

Purisol® 5 - 50 ppm H2S, no COS removal

MDEA 3 - 50 ppm H2S; no COS removal

aMDEA® 1- 50 ppm H2S5 - 50 ppm CO2

Selection of Appropriate Gas Purification Process



MPG based H2 PlantMPG based H2 Plant

HydrogenRectisol® PSA

High BTULow SulfurFuel Gas

Pure CO2

Waste WaterTreatment

Process Water

OxyClaus®

Sulphur

O2

H2S+CO2

Feedstock

MPGQuench

Steam

CarbonSlurry

MARS

Metals/AshAir

ASU

O2

Raw GasShift

GasCooling

LP-Steam

Metha-nation

97%HydrogenSelective

AGR

Impure CO2

Low BTUS > 100 ppm

Fuel Gas



“Five-in-one”:1. Trace contaminant removal COS, CS2, NH3, HCN, Hg …….

2. Deep Desulfurization directly to synthesis feed quality (Total S < 0.1 ppmv)only with Rectisol® !

3. Bulk CO2 removal 100 % CO2 can be recovered

4. CO2 purification Total S < 5 ppmV in CO2 Stream

5. Acid Gas Enrichment Claus-suited acid gas even at a CO2/H2S ratio of > 500

one Rectisol® compares with five tasks to be performed in five processes steps

Rectisol® - A costly technology?

So, set up the right B.L. when comparing costs!



Trace Contaminants

Carbonyls

COS

NH3

Mercaptans

HCN

Hg

CS2

VOC´s

© Wilhelm Busch

It´s the small bugs that can bother you most!


MPG - Multi Purpose Gasification1950- 2005: The Rectisol® Story

Capacity Installed & Operating

0

50

100

150

200

250

300

350

1960 1965 1970 1975 1980 1985 1990 1995 2000 2005

Mio

Nm

3/da

y ex

Gas

ifiers

Pure IGCC

Others

Rectisol

Today, Rectisol purifies

75 % of the world´s syntheticgas produced from oil residue, coal, & wastes

90 % of synthesis gasproduced by gasification (non-IGCC use)

Source: GTC Gasification Data Base



SummarySummary

A Gasification Plant consists not only of the gasifier

Consider optimum integration of the required process steps– Gasification– CO-Shift Conversion– Gas Purification– Soot Water Handling– Claus Process

Advantages of Rectisol Gas Purification are worldwide recognized

6 new Rectisol plants in the last 2 years



Dr. Holger SchlichtingProcess Manager MPGDept. A-TEEPhone +49 69 5808 1418Fax +49 69 5808 2645e-mail [email protected]

? Comments ?Contact :

Ulrich KossHead Syngas TechnologyDept. A-TEPhone +49 69 5808 3740Fax +49 69 5808 2645e-mail [email protected]

Lurgi AGD-60295 Frankfurt am MainGermanyInternet: www.lurgi.de



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Lurgi’s MPG Gasification plus Rectisol Gas Purification ... · 16 08.11.2005 GTC 2005, San...

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