ThyssenKrupp Uhde's commercially proven PRENFLO® and ...

ThyssenKrupp Uhde‘s commercially provenPRENFLO® and HTWTM Gasification TechnologiesHalle (Saale), June 13, 2013

Claudio Marsico – Director Sales – Gas Technologies Division

2. ibi Fachsymposium

2. ibi FachsymposiumJune 13, 2013 – Halle (Saale) – Page 2Copyright TK Uhde 2012

ThyssenKrupp and Uhde

Uhde‘s experience and expertise in gasification

PRENFLO (PSG / PDQ)

High Temperature Winkler (HTW)

Updates on Projects and Alliances

Presentation Outline

Summary


ThyssenKrupp Group

ThyssenKrupp AG

Steel Europe

Elevator Technology

Industrial Solutions

Components Technology

Workforce: ~150,000

Material Services

TK Fördertechnik

Marine Systems

TK Polysius

TK Uhde

vereinfacht, vorläufig


From the idea to operation of a chemical plant

Operation and service phase

Project implementation phase

Training of operating personnelPlant maintenance and operation

Materials management and spare partsPlant optimisation and upgrading

Licence award or procurementBasic / detail engineering

Procurement / inspection / shippingProject execution

ConstructionCommissioning

Project development / market studyFeasibility study

Project financing

Concept development and assessmentExecution of R&D projects

Acquisition of technologies / companies

Research phase

Bid phase


Site-SeeingMore than 2.000 plants built by Uhde on all continents

130 plants

115 plants375 plants120 plants

105 plants500 plants150 plants

Fertilisers RefineriesNitric acid Aromatics185 plants 380 plants 75 plants

Org. Chemicals/petrochemicalsHydrogen, ammonia, methanol Plastics, synthetic fibres Polyester / polyamides400 plants

Electrolysis Coke Plant Technologies Tank storage facilities Industrial plants150 plants


Overview of our Product divisions

ElectrolysisAmmonia &Urea

Hydrogen &Nitrates

RefiningTechnologies

Org. Chemicals/PolymersGas Technologies Polyester Coke Plant

Technologies




PRENFLO (PSG / PDQ)




Summary


fossil fuel prices

fossil fuel availability

proven technology

clean technology

polygeneration

CCS

sellable by-productsfossil fuel flexibility ideal for low rank fuel

Feedstock Technology Product

Market drivers for gasification of solids


Energy reserves (Giga tons, oil equivalent)


Synthesis Gas as a Central Part of Uhde‘s Process ChainGasification: Feedstock - Process - Product

Gas, Naphtha

Oil/Residues

SteamReformer/ ATR

SteamReformer/ ATR

HTWGasificationHTWGasification

Synthesis Gas

CO +H2

Synthesis Gas

CO +H2

Methanol

Ammonia

Power Plant(IGCC)

FischerTropschSynthesis

CO-Conversion

Methanation

DieselDiesel

Petrol + LPGPetrol + LPG

Urea

Diesel, NaphthaDiesel, Naphtha

PetroleumCoke

Hard Coal

Biomass

PRENFLOGasificationPRENFLOGasification

Biomass

Brown Coal

Waste

LubricantsLubricants

MTO

MTG

Feedstock Gasification Syngas ProductFurther processing

HydrogenHydrogen

SyntheticNaturalGasSyntheticNaturalGas

ElectricityElectricity

FertilizerFertilizer

Oil GasificationOil Gasification


PRENFLOPSG, PDQ

entrained-flow gasification

HTW (High Temperature Winkler)fluidized-bed gasification

Various Materials require various Gasification Technologies Uhde‘s Gasification Portfolio


Gasification Technologies

550 °C 1350 – 1600 °C800 – 1100 °C


Uhde‘s Gasifiers

PSG PDQ HTWEntrained-flow gasification Fluidized bed gasification




PRENFLO (PSG / PDQ)




Summary


PRENFLO burner test rig6 t/d (450 m³n/h syngas)

PRENFLO Fürstenhausen48 t/d (3,500 m³n/h syngas)

PRENFLO Puertollano 2,400 t/d (180,000 m³n/h syngas)

Start Up: 1984

Start Up: 1985

Start Up: 1998

Scale Up Factor:8

Scale Up Factor:50

Koppers-TotzekStart of development 1941

57 yearsShell-Koppers pilot plant Hamburg150 t/d coal

Start Up: 1978

DevelopmentsFrom Koppers-Totzek to PRENFLO


Koppers-Totzek gasification plant in Modderfontein, S. Africa(Design capacity: 1,000 t/d of ammonia)


Koppers-Totzek gasification plant in India(Capacity: 900 t/d of ammonia)


Features• dry coal/petcoke powder

feed• 4 horizontal co-annular

burners• membrane wall• waste heat boiler (PSG)

PRENFLO with Steam Generation (PSG)1000 MWth, 40 bar


PRENFLO Plant in Fürstenhausen, Germany


ELCOGAS IGCC plant: Gasification Island, Spain


Dry-fed, single train IGCC with CCS Pilot Plant at Elcogas, Spain300 MW net based on petcoke / coal feedstock

PRENFLO Gasification

Gas Treatment

Coal PreparationASU

CombinedCycle

New CO2 capturePilot Plant

implemented


Features• dry coal/petcoke powder

feed• 4 horizontal co-annular

burners• membrane wall• direct water quench

PRENFLO with Direct Quench (PDQ)1000 MWth, 40 bar




PRENFLO (PSG / PDQ)




Summary


Start Up: 1988

HTW-Peat Gasification, Kemira

HTW- Pilot PlantRheinbraun Wachtberg40 t/d Lignite, 10 bar

HTW- Demonstration PlantRheinbraun Berrenrath720 t/d Lignite, 10 bar

KoBra IGCC RWE, Hürth3700 t/d Lignite 27 bar

Start Up: 1978

Start Up: 1986

Engineering: 1994

Scale Up Factor:18

Scale Up Factor:5

Atmospheric Winkler generators1956 – 1964 260 t/d Lignite

>20 Years

HTW Laboratory PlantRWTH-Aachen12 t/d Coal, Atm.

Start Up: 1974

HTW-Pilot Plant (WVW)Rheinbraun Wesseling185 t/d Lignite, 25 bar

Start Up: 1989

DevelopmentsThe HTW Process


HTW High Temperature Winkler - Gasifier


HTW- Laboratory Plant (PDU)RWTH Aachenapprox. 50 kg/h1974


HTW Pilot PlantRWE-Plant-WachtbergFrechen / Germany1,6 t/h1978 - 1985


HTW PlantWVW- UK-WesselingWesseling / Germany7,7 t/h Lignite10 – 25 bar1988 - 1990


HTW Syngas PlantKemira OyOulu / Finnland30 t/h Peat≈ 300 t/d NH3

1988 - 1991


25 t/h dried lignite – 140 MWth34,000 m³/h of syngas≈ 300 t/d Methanol67,000 total operating hours84 % availability (last 10 years) 1986 - 1997

HTW Commercial Scale Demo PlantBerrenrath/Germany


KoBra - Engineering 1993 - 1994


HTW-Precon-GasificationNiihama / Japan48 t/d Municipal Waste1999 - 2002

Sumitomo Heavy Industries Ltd.




PRENFLO (PSG / PDQ)




Summary


ICM‘s 18,000 bbl/d CTL Plant in MongoliaCoal-to-Gasoline (CTG) plant *

*) Photo Courtesy TransgasDevelopment

#1 coal preparation

#2 coal gasification

#3 CO-shift reactor

#4 acid gas removal

#5 methanol synthesis #6 methanol-to-gasoline #7 gasoline storage

PRENFLO PDQ gasifiers

ApplyingTK Uhde‘s PRENFLOGasification Technology


ICM‘s 18,000 bbl/d CTL Plant in MongoliaPresentation of Feasibility Study

Ulaanbaatar, Mongolia, June, 2008


ICM‘s 18,000 bbl/d CTL Plant in MongoliaMongolia and Germany sign co-operation agreement

CTL project is of strategic importance

Ulaanbaatar, Mongolia, October, 2011


ICM‘s 18,000 bbl/d CTL Plant in MongoliaSigning of agreement between Gov’t of Mongolia andTK Uhde in presence of Mongolian President Elbegdorj

ThyssenKrupp Schloss Landsberg, Essen, Germany, March 31, 2012


ICM‘s 18,000 bbl/d CTL Plant in MongoliaSigning of PRENFLO licence agreement between ICM andTK Uhde in presence of Mongolian President Elbegdorj

ThyssenKrupp Schloss Landsberg, Essen, Germany, March 31, 2012


ICM‘s 18,000 bbl/d CTL Plant in MongoliaMinister Battulga at ThyssenKrupp’s Reference Plant

Elcogas, Puertollano, Spain, April 08, 2013


JAM Project in China – Commissioning in 2009Converting Coal into Gasoline

Pilot Plant100,000 tpa of gasoline

Commercial Plant1,000,000 tpa of gasoline

Basic Engg. for MTG concluded


TransGas Coal-to-Liquids complex (18,000 bbl/d)PRENFLO with MTG based on coal

Mingo County, West Virginia



TransGas Coal-to-Liquids complex (18,000 bbl/d) Ground Breaking Ceremony, 09 May 2011, West VirginiaPlant Site

U.S. Senator Joe Manchin III. and WV Governor Earl Ray Tomblin


TargetDevelopment and commercialisation of integrated process chain for production of 2nd generation biofuels

UhdeTotal

CEAIFP

Sofi-proteol

Axens

BioTfueL – integrated process chainPRENFLO with FT based on solid and liquid feedstock



Life-cycle analysis for optimum equilibrium between technical-economicalperformance and environmental demands

Coal

Petcoke

Wood

Straw etc.

Feedstock Pretreatment Gasification Gas Treatment

Milling

Torrefaction CO-Shift

Synthesis

GaselTM

Fischer-Tropsch

Synthesis and Product

Upgrading

Biodiesel; BiokeroseneAGR

Liquid Residues

BioTfueL – integrated process chainPRENFLO with FT based on solid and liquid feedstock


SGCE – 9,500 bpd CTL, MozambiquePRENFLO PDQ for high-ash coal



Biomass-to-Methanol Plant, Hagfors / Värmland / SwedenArtist View

Photo courtesy VärmlandsMetanol AB

ApplyingTK Uhde‘s HTWGasification Technology


C.GEN – 450 MWe IGCC with CCS, Killingholme, UKPRENFLO PDQ selected

Optional hydrogen production

Carbon capture & storage

Synergies due tomaximum integrationinto existingindustrial network

High level ofstandardization –beneficial for futureplants

Feedstock: hard coal,petcoke and biomass



Alliancesand to co-operate in the field of coal gasification

JV KEPCO-Uhde Inc. founded in July 2011 in Seoul, South Korea


Alliancesin the field of Coal-to-Liquids

A) Coal-to-GASOLINE via Methanol (MTG)

B) Coal-to-DIESEL via Fischer-Tropsch

+

+


Co-operationsLessons learnt from operators

A) PRENFLO entrained-flow Gasification Technology

B) HTW fluidised-bed Gasification Technology

+

+




PRENFLO (PSG / PDQ)




Summary


Gasification is a proven technology, a vast number of gasifiers are operating since decades successfully on commercial basisGasification allows flexibility in feedstock and polygenerationof productsGasification is environmental friendly

Uhde has more than 70 years of experience in gasification based on 8 different gasification technologies… received more than 100 contract awards for gasifiers

… has proven single sourcing capability

… has built the world‘s largest solid fuel based, single train IGCC

… is a process oriented EPC contractor and not only licensor

… has built more than 2,000 plants worldwide

Summary


Gasification Uhde „Site“-SeeingKoppers-Totzek gasificationModderfontein, South Africacoal-to-ammonia/fertilisers

GE (Texaco) coal gasificationOberhausen, Germanycoal-to-hydrogen & oxochemicals

HTW coal gasificationBerrenrath, Germanycoal-to-methanol

PRENFLO coal gasificationFürtenhausen, Germanycoal-to-methanol

PRENFLO IGCCPuertollano, Spainpetcoke/coal-to-power

HTW MSW gasificationNiihama, Japanwaste-to-energy


SummaryUhde is Technology Provider and EPC Contractor


PRENFLO IGCC, Puertollano, SpainSummer 2013

Thank you for your attentionThank you for your attention

[email protected]

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