Syn Gas Generation Different Routes Various...

June 14, 2012 l Siddhartha Mukherjee | Air Liquide Global E&C Solutions | New Delhi

February 16, 2016 | Air Liquide Global E&C Solutions | New Delhi

New Delhi

Syn Gas Generation Different Routes – Various Products

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Global E&C Solutions Communications

Air Liquide, world leader in gases for industry, health and the environment 2 6th World PetroCoal Congress2016

Clean Conversion – Our Story

Coal Gasification and its Applications SNG

Ammonia

Methanol

Methanol > Propylene

Hydrogen

Hydrogen and Carbon Monoxide

DRI Gas

Residue Gasification

Steam Methane Reforming

Associated Technologies

Wrap-up and Summary

Syngas Generation - Various Routes, Multiple Products

Air Liquide, world leader in gases for industry, health and the environment 3 6th World PetroCoal Congress 2016

AL Global E&C Solutions Perspective

Clean Conversion – Our Story


Our value addition

We know…

Coal

Oxygen

Syngas

and the products.

Drivers and our contribution

■ fluctuating price of oil & gas

in many locations

■ Growing domestic demand for

fuel and petrochemical products

■ Reduction of dependency on

fuel and petrochemicals imports

■ Abundance of coal H2 CO

O2

C

CH3OH

Synfuel


+

■ NG, LPG, Naphtha

• SMR, ATR

• CO Shift, Amine Wash

• Coldbox, PSA

■ Coal, Heavy Residue

• Gasification, MPG

• CO Shift, Rectisol

• Coldbox, PSA

■ Synthesis

• Methanol, DME

• MTP, Acrylic Acid

• Synfuels, Ammonia

Clean Conversion

H2 CO

O2

C

H2O +


Raw

Material

Residue

Natural

Gas

Coal

Biomass

Sulfur

Recovery

CO

Cold Box

PSA

CO Shift

Syngas Treating

AGR

Amine

Wash

Syngas

ASU

Gasification

Reforming

Methanol

Synthesis

DME

MTP ™

Acrylic Acid

Fischer Tropsch

Methanation

Ammonia

Methanol

Final Products

DME

Propylene

Acrylic Acid

Syn fuels

SNG

Ammonia

DRI

Clean Conversion


Gasification

Lurgi FBDB™

Lurgi MPG™

Raw

Material

Residue

Natural

Gas

Coal

Biomass

Final Products

Lurgi

OxyClaus

™

AL

Cold Box

AL

PSA

CO Shift Amine

Wash

Syngas and Synthesis

AL

ASU

Lurgi SMR

Lurgi ATR

Lurgi POX

Technology and Design by Air Liquide

Methanol Lurgi

Methanol

Lurgi DME

Lurgi MTP ™

Lurgi NK Acrylic Acid

GTL.F1 Fischer Tropsch

Methanation

DME

Propylene

Acrylic Acid

Syn fuels

SNG

Ammonia Ammonia

DRI

Lurgi

Rectisol ™



Coal Gasification and its Applications


Lurgi FBDB™ Coal-to-X Syngas

CO

Hydrogen Air Liquide

CO Cold Box

Air Liquide

ASU

Lurgi

GLS Process™

Lurgi Phenosolvan® & Lurgi CLL™

Gas Liquor Recovery and Water Treatment

Liquid Ammonia

ZLD – Water Reuse

Lurgi Rectisol® Gas

Purification

Lurgi OxyClaus®

Sulfur Recovery Elemental Sulfur

CO2

Syngas, DRI, Power

Air Liquide

LNW Unit

N2

Methanation

Ammonia Syngas

SNG

(Fuel Gas)

(Rectisol Naphtha)

(Phenols)

(Clear Tar / Oil)

Lurgi MPG®

Gasification

Gasification

Lurgi

CO Shift /

Gas Cooling

Coal

Preparation

HP Steam

Ash

Air Liquide

PSA

Lurgi

Methanol Synth.

Methanol-Propylene


78 000 Nm3/h H2

900 tpd NH3

Coal to H2 and NH3: Fujian Gasification Project

ASU

Gasification

CO-Shift

Lurgi

Rectisol™

OxyClaus™

Nitrogen Wash

Ammonia

PSA

H2

NH3

http://www.airliquide.com/


Coal to Ammonia: TGI/SCJ

11

ASU

Gasification

Lurgi

Rectisol™

&

OxyClaus™

Nitrogen

Wash

Ammonia

ASU, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash

H2 N2

180 000 Nm3/h N2+H2




Coal to Propylene: Shenhua Ningxia

ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™

5000 tpd MeOH to each MTP™

Air Liquide, world leader in gases for industry, health and the environment 13 6th World PetroCoal Congress 2016 13

ASU

Gasification

CO-Shift,

Rectisol®

Oxy Claus™

Mega-

Methanol®

MTP®

MTP®

ASU

Rectisol®

(4 trains)

Methanol

Synfuels

Methanol train

Gasification train

Methanol

DME

Rectisol®

Coal to Methanol and Propylene: Shenhua Ningxia

ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™

Gasification

Air Liquide, world leader in gases for industry, health and the environment 14 6th World PetroCoal Congress 2016 14

ASU

Lurgi

Rectisol™

&

OxyClaus ™

Coal to DRI Gas: Jindal Steel and Power

ASU, Lurgi FBDB™ Gasification, Phenosolvan™, CLL™, Rectisol™, SRU OxyClaus™

Lurgi

FBDB™

Gasification

Lurgi CLL™

Phenosolvan ™

225 000 Nm3/h CO+H2+CH4 H2

CO

CH4



Residue Gasification - MPG®

Air Liquide, world leader in gases for industry, health and the environment 16 6th World PetroCoal Congress2016 16

45 years operating experience with heavy residues

25 plants (78 reactors) for oil residue gasification

built by Lurgi under Shell license (Lurgi/SGP) until

’97

In 1997, Burner Technology acquired from SVZ

Schwarze Pumpe (Eastern Germany)

Lurgi’s Multi Purpose Gasification

■ Boiler & Quench design

Existing Reference operating in Brazil (Fosfertil)

since 2001

■ Commercial size reference

HP POX - Pilot plant - since 2002

■ R&D development – Process performances –

Validation of design rules

Engineering Contract for Gasification at present

under execution

MPG® Summary


Year Country Feed Product Capacity Technology/License

From 1956 to 1997 Lurgi was exclusive licensor of the Shell Gasification Technology (SGP). In this time Lurgi designed 26 Partial Oxidation Plants with 76 Reactors producing 63.000.000 Nm³/d of Syngas.

(1997)* Germany Coal oil/Tar, Slurries

Methanol Synthesis Gas and Power

800.000 Nm³/d MPG

2000 Brazil Asphalt, others Ammonia Synthesis Gas, Burner Revamp

850.000 Nm³/d MPG

2002 Germany Natural Gas, Residue

Raw Synthesis Gas 36.000 Nm³/d MPG

2005 Canada Hydrocracked Residue

Hydrogen 3.500.000 Nm³/d MPG

()* MPG reference plant technology purchased by Lurgi, operated for more than 30 years

1950 1960 1970 1980 1990 2000

Fixed Bed Grate Gasifier

Multi

Purpose

Gasification

45 years experience

in residue gasification:

75 units

62.5 x 106 m3N/d

2010

Pu

rch

ase

s fro

m S

VZ

20

01

Ulta

fert

il

2002 H

D P

OX

200

5 N

ort

h W

est

Up

gra

de

r

Residue Gasification References


Feed

Soot Slurry

Quench

Water

Oxidant (O2 Air) Steam

Feed

Oxidant (O2 Air) Steam

Syngas

Syngas

Boiler Mode

Sat. HP-steam

Heat Recovery

Boiler

Quench Mode

MPG® Gasification – Quench / Boiler


CO-Shift MP-Boiler Final Cooler Gas Scrubbing Feedstock

O2 / Steam

Metals Ash Process Water

MPG® - Quench Configuration


MPG® - Boiler Configuration


MPG® Residue-to-X Syngas

CO

Hydrogen Air Liquide

CO Cold Box

Air Liquide

ASU

Metal Ash

Recovery System

Lurgi Rectisol® Gas

Purification

Lurgi OxyClaus®

Sulfur Recovery Elemental Sulfur

CO2

Syngas, DRI, Power

Air Liquide

LNW Unit

N2

Methanation

Ammonia Syngas

SNG

(Fuel Gas)

Metal Ash

MPG®

Lurgi

CO Shift /

Gas Cooling

Feed

HP Steam

Air Liquide

PSA

Lurgi

Methanol Synth.

Methanol-Propylene

Waste Water



Steam Methane Reforming


World Map & References - Lurgi ReformerTM

Batamas MEGAH

Location: Malaysia

Product: 3.000 Nm³/h Hydrogen

Start-up: 1994

HAINAN Methanol

Location: China / Hainan

Product: 2.000 mtpd Methanol

Start-up: 2006

BASF – BPC Kuantan

Location: Malaysia

Product: 58.000 Nm³/h Syngas

Start-up: 2000

P.T. Kaltim Methanol Industry

Location: Malaysia


Start-up: 1998

Degussa Rheinfelden

Location: Germany


Start-up: 1997

Cleveland-Cliffs

Location: Trinidad


Start-up: 1998

TITAN and ATLAS Methanol

Location: Trinidad

Product: 2.500/5.000 mtpd Methanol

Start-up: 1999 / 2004

PEMEX Madero

Location: Mexico


Start-up: 2001

Repsol YPF

Location: Argentina


Start-up: 2002

Messer Dormagen

Location: Germany

Product: 7.000 Nm³/h CO

Start-up: 2002

GLIMAR

Location: Poland


Start-up: -

YARACO1 / YARACO 2

Location: China

Product: 9.200Nm³/h CO

Start-up: 1998 / 2005

DALIAN

Location: China


Start-up: 2006

PML

Location: Malaysia / Labuan


Start-up: 2009

Melaka HPU 2

Location: Malaysia


Start-up: 2008

National Petrochemical Co. (Kharg)

Location: Iran


Start-up: 1999

PEMEX Cadereyta

Location: Mexico


Start-up: 2000

AIR LIQUIDE Gulf Coast SMR H2

Location: Texas / USA


Start-up: 2011 (Project in Progress)

PRAXAIR Richmond

Location: California


Start-up: 2010 (under construction)

LOTOS HGU 2

Location: Poland


Start-up: 2009 (under construction)

AIR LIQUIDE HERACLES

Location: Netherlands


Start-up: 2011 (Project in Progress)

ZAGROS 1 / ZAGROS 2

Location: Iran

Product: 5.000/5.000 mtpd Methanol

Start-up: 2006 / 2009

SIPCHEM CO

Location: Saudi Arabia

Product: 30.520 Nm³/h CO

Start-up: 2009

http://upload.wikimedia.org/wikipedia/commons/1/17/BlankMap-World-noborders.png


Large Plants Designed by Air Liquide

■ Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA, multi-feed)

■ Largest single-train H2 plant: 160 750 Nm3/h H2

■ Largest single-train synthesis gas plant: 530 780 Nm3/h, dry

equivalent to 321 230 Nm3/h H2 (Lurgi’s MEGA-MeOH plants)

■ World largest single-train CO plant: 43.2 tons/h CO

■ Largest Steam Reformer: 720 tubes, 1250 GJ/h

■ Number of Mega-H2 plant references with capacities ≥ 130 000 Nm3/h

H2 in last 10 years: 7


Latest References – H2 Plants (medium/large size)

Region Feed Capacity (Nm3/h) Scope Award

Russia NG 100 000 H2 Lic.+ B.E. 2013

Middle East NG, LPG 60 000 H2 Lic.+ B.E. 2013

Middle East NG 68 550 H2 Lic.+ B.E. 2012

North America NG 160 750 H2 EPC 2011

Russia NG, Naphtha 83 165 H2 Lic.+ B.E. 2011

Middle East NG, Naphtha 60 000 H2 Lic.+ B.E. 2011

Middle East LPG, Naphtha,

ROG, NG

339 300 H2 (2

train + S/A PSA)

EPC 2010

North America NG 130 000 H2 EPC 2009

Europe NG 130 000 H2 EPC 2009


Latest References – H2 and CO Plants

Region Feed Capacity (Nm3/h) Scope Award

Europe NG 8 500 CO EPC 2013

Europe NG 14 500 CO

60 000 H2

EPC 2012

Europe NG 10 000 CO

24 100 H2

EPC 2012

Asia NG 9 800 CO

35 600 H2

EPC 2010


Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA)


28

Process Gas

Fuel Gas

Combustion Air

Flue Gas

Arrangement Drawing

Lurgi Reformer® - Isometric Arrangement

SMR/Steam Reformer Gen. Arrangement .pdf


Hydrogen

Lurgi SMR Feed-to-X Syngas

CO

Air Liquide

ASU

Air Liquide

CO Cold Box

N2

PSA

Ammonia Syngas

SMR

Methanol-Propylene

Feed

CO2 Removal

ATR

Methanol

Synthesis

CO Shift

HP Steam


Next Generation Coal Gasification Island

Associated Technologies


Commercially well referenced technologies

■ ASU: > 350 in the last 40 years

■ Lurgi FBDB™: > 120 reactors

■ Rectisol™ : > 100 Lurgi Rectisol

■ Cold Box > 90 CO purification and NWU

■ PSA >70 Hydrogen Purification

■ Methanol: > 50 plants; 9 coal based.

■ MTP™ : 2 running

■ Claus : >170 Claus Units

■ OxyClaus™ SRU: > 40 burners


Air Liquide: Air Gases

■ Operating >350 Air Separation Units

Total gaseous production

> 120,000 tpd

> 95,000 tpd

■ The largest single train plant (capacity of 5,000 tpd) under

engineering

O2

N2


Air Liquide’s Lurgi FBDBTM

■ Lurgi FBDBTM MK+TM: Proven Operation

Innovative use of referenced technology for no scale-up risk

Safe & forgiving operation

Beneficial for low rank coal

Improved Capex and Opex

■ Financially Secure Investment

■ High Efficiency and reduced cost of SNG

Reduced steam consumption & lower oxygen consumption

Higher direct methane production

■ Environmental Compliance

Complete process water re-use Zero Liquid Discharge

World bank standards

H2

CO CH4

Best efficiency for high moisture & high ash coal

especially for SNG production.

H2O


Air Liquide’s Lurgi RectisolTM

■ > 60 Years of design expertise and operational feedback

■ Reference situation

21 references 2011 - today

42 references since 2000

Over 100 references in total

Complete CO2 and Sulfur removal.

■ Applications

Coal-, petcoke-, refinery residue- gasification

Power, DRI, H2

Synthesis: MeOH, NH3, Urea, MEG, SNG, Fischer-Tropsch, polymers …,

Multi-product streams

Outstanding track record in a variety of applications!

H2 CO

CO2 S


Air Liquide’s Cryogenic Gas Treating

■ > 90 Cold boxes referenced

■ Syngas Final treating

Remove impurities in syngas e.g. CH4, N2…

Produce pure syngas.

Composition ratio adjustment H2/N2=3:1…

■ Applications

Pure CO, H2, CO+H2, H2+N2

■ Distillation packing: high efficiency & load variety.

■ Stainless steel cold box: easy onsite works.

■ Expansion turbine: product gas as medium.

■ Cold integration with Rectisol™.

Worldwide largest CO purifications

and ammonia syngas preparations all by Air Liquide!

H2 CO

N2

CH4


> 40 Years of design expertise and operational

feedback

51 Plants with a total capacity of 33.5 MMTPY.

Extremely quick transfer of reaction heat:

Quasi isothermal operation

Overheating of catalyst impossible

Long catalyst operational life

Low recycle ratios

High steam production

Safe and uniform temperature control

The outstanding advantage of

Lurgi Methanol is the Water Cooled Reactor

with superior heat removal ability.

CH3OH

Air Liquide’s Lurgi Methanol

36


Food for Thought and Wrap-up

http://upload.wikimedia.org/wikipedia/commons/4/4b/Methane-3D-space-filling.svg


Wrap-Up - FBDBTM

■ FBDBTM Excellent Technology for High Ash Content Coals

■ Appropriate Technology for the following applications:

Substitute Natural Gas SNG

Direct Reduction of Iron DRI

Coal to Liquids CTL

NH3 with CH4 co-production

■ About 155 Steam Reformers built

Wide feedstock range - Light/heavy natural gas, LPG, associated gas,

naphtha, mixed feed 4

Wide product range - hydrogen, CO, towngas, syngas for products like

oxo-alcohols, methanol, ammonia

■ Lurgi MPGTM

Proven technology for handling heavy refinery residues

Also capable of handling emulsions and slurries with particles in the mm range

■ A Real One-Stop-Shop

Proven technologies integrated into a single package


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

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/Seine

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/Marne

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Engineering centers Manufacturing workshops Business offices Cryogenic equipment centers

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Syn Gas Generation Different Routes Various...

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