Mk Plus™ The Next Generation Lurgi FBDB™ Gasification

Mk Plus™ The Next Generation Lurgi FBDB™ GasificationLeipzig, 22/05/2012 Dr. Henrik Timmermann

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™


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


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


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


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


� 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™


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


• 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


• 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


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


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


1950s - 2010 2011 - >

Twin Coal Lock

Reactor

Gas Off-take

Wash Cooler

The Lurgi FBDB™ Gasifier – Sketch


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


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


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


� 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


• 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


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


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


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


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


� 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


E-mail: [email protected]

Air Liquide E&C in Perspective

Revenue

€14.5

Gas and UtilitySupply

89%� Industrial Merchant� Large Industries� Electronics� Healthcare


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


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

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