Air liquide lurgi 2016 overview of coal heavy oil ch4 to syngas h2 ammonia methanol reference projects
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Air liquide lurgi 2016 overview of coal heavy oil ch4 to syngas h2 ammonia methanol reference projects
- 1. February 11, 2016 | Air Liquide Global E&C Solutions | New Delhi Syn Gas Generation Various Routes – Multiple Products June 14, 2012 l Siddhartha Mukherjee | Air Liquide Global E&C Solutions | New Delhi February 11, 2016 | Air Liquide Global E&C Solutions | New Delhi New Delhi Classification Level: Business Owner: Distribution List: PUBLIC Global E&C Solutions Communications
- 2. Clean Conversion – Our Story Coal Gasification and its Applications SNG Ammonia Methanol Methanol > Propylene Hydrogen Syngas Generation - Various Routes, Multiple Products Air Liquide, world leader in gases for industry, health and the environment2 Gasification India 2016 Hydrogen Hydrogen and Carbon Monoxide DRI Gas Residue Gasification Steam Methane Reforming Associated Technologies Wrap-up and Summary
- 3. AL Global E&C Solutions Perspective Clean Conversion – Our Story Air Liquide, world leader in gases for industry, health and the environment3 Gasification India 2016
- 4. Our value addition We know… Coal Drivers and our contribution ■ fluctuating price of oil & gas in many locations ■ Growing domestic demand for fuel and petrochemical products ■ Reduction of dependency on C Air Liquide, world leader in gases for industry, health and the environment4 Gasification India 2016 Oxygen Syngas and the products. ■ Reduction of dependency on fuel and petrochemicals imports ■ Abundance of coal H2CO O2 CH3OH Synfuel
- 5. ■ NG, LPG, Naphtha • SMR, ATR • CO Shift, Amine Wash • Coldbox, PSA ■ Coal, Heavy Residue • Gasification Clean Conversion O2 C H2O + Air Liquide, world leader in gases for industry, health and the environment5 + • Gasification • CO Shift, Rectisol™ • Coldbox, PSA ■ Synthesis • Methanol, DME • MTP, Acrylic Acid • Synfuels, Ammonia H2CO Gasification India 2016
- 6. Raw Material Residue Natural Gas Coal Biomass CO Cold Box PSA Syngas Treating AGR Syngas Gasification Methanol Synthesis DME MTP ™ Acrylic Acid Methanol Final Products DME Propylene Acrylic Acid Clean Conversion Air Liquide, world leader in gases for industry, health and the environment6 Biomass Sulfur Recovery CO Shift Amine Wash ASU Reforming Fischer Tropsch Methanation Ammonia Syn fuels SNG Ammonia DRI Gasification India 2016
- 7. Gasification Lurgi FBDB™ Lurgi MPG™ Raw Material Residue Natural Gas Coal Biomass Final Products AL Cold Box AL PSA Syngas and Synthesis Technology and Design by Air Liquide Methanol Lurgi Methanol Lurgi DME Lurgi MTP ™ Lurgi NK Acrylic Acid DME Propylene Acrylic Acid Lurgi Rectisol ™ Air Liquide, world leader in gases for industry, health and the environment7 Biomass Lurgi OxyClaus ™ CO Shift Amine Wash AL ASU Lurgi SMR Lurgi ATR Lurgi POX Acrylic Acid GTL.F1 Fischer Tropsch Methanation Syn fuels SNG Ammonia Ammonia DRI Gasification India 2016
- 8. AL Global E&C Solutions Perspective Coal Gasification and its Applications Air Liquide, world leader in gases for industry, health and the environment8 Gasification India 2016
- 9. Lurgi FBDB™ Coal-to-X Syngas Air Liquide ASU 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) Lurgi MPG® Gasification Gasification Lurgi CO Shift / Gas Cooling Coal Preparation HP Steam Air Liquide, world leader in gases for industry, health and the environment9 Gasification India 2016 CO Hydrogen Air Liquide CO Cold Box Lurgi GLS Process™ Lurgi Phenosolvan® & Lurgi CLL™ Gas Liquor Recovery and Water Treatment Liquid Ammonia ZLD – Water Reuse (Rectisol Naphtha) (Phenols) (Clear Tar / Oil) Ash Air Liquide PSA Lurgi Methanol Synth. Methanol-Propylene
- 10. Coal to H2 and NH3: Fujian Gasification Project ASU Gasification CO-Shift Nitrogen Wash Ammonia Air Liquide, world leader in gases for industry, health and the environment10 78 000 Nm3/h H2 + 900 tpd NH3 Lurgi Rectisol™ & OxyClaus™ PSA ASU, Gasification, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash, Ammonia Synthesis, PSA, Integration/OSBL H2 NH3 Gasification India 2016
- 11. Coal to Ammonia: TGI/SCJ Air Liquide, world leader in gases for industry, health and the environment1111 ASU Gasification Lurgi Rectisol™ & OxyClaus™ Nitrogen Wash Ammonia ASU, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash H2 N2 180 000 Nm3/h N2+H2 Gasification India 2016
- 12. Coal to Propylene: Shenhua Ningxia Air Liquide, world leader in gases for industry, health and the environment12 ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™ 5000 tpd MeOH to each MTP™ Gasification India 2016
- 13. ASU Gasification CO-Shift, Rectisol® Oxy Claus™ Mega- Methanol® MTP® Gasification train Methanol DME Rectisol® Coal to Methanol and Propylene: Shenhua Ningxia Air Liquide, world leader in gases for industry, health and the environment1313 MTP® ASU Rectisol® (4 trains) Methanol Synfuels Methanol train ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™ Gasification Gasification India 2016
- 14. ASU Lurgi Rectisol™ & OxyClaus ™ Coal to DRI Gas: Jindal Steel and Power Lurgi FBDB™ Gasification Air Liquide, world leader in gases for industry, health and the environment1414 ASU, Lurgi FBDB™ Gasification, Phenosolvan™, CLL™, Rectisol™, SRU OxyClaus™ Lurgi CLL™ Phenosolvan ™ 225 000 Nm3/h CO+H2+CH4 H2 CO CH4 Gasification India 2016
- 15. AL Global E&C Solutions Perspective Residue Gasification - MPG® Air Liquide, world leader in gases for industry, health and the environment15 Gasification India 2016
- 16. 45 years prior 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 MPG® Summary Air Liquide, world leader in gases for industry, health and the environment16 Gasification India 2016 16 ■ 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
- 17. Multi Purpose Gasification 45 years experience in residue gasification: 75 units 62.5 x 106 m3 /d PurchasesfromSVZ 2001Ultafertil 2002HDPOX 2005NorthWestUpgrader Residue Gasification References Air Liquide, world leader in gases for industry, health and the environment17 Gasification India 2016 17 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 Gasification62.5 x 106 m3 N/d 2010
- 18. MPG® Residue-to-X Syngas Air Liquide ASU Lurgi Rectisol® Gas Lurgi OxyClaus® Sulfur Recovery Elemental Sulfur CO2 Syngas, DRI, Power Air Liquide LNW Unit N2 Methanation Ammonia Syngas SNG (Fuel Gas) MPG® Lurgi CO Shift / Feed HP Steam Air Liquide, world leader in gases for industry, health and the environment18 Gasification India 2016 CO Hydrogen Air Liquide CO Cold Box Metal Ash Recovery System Gas Purification Methanation SNG Metal Ash Gas Cooling Air Liquide PSA Lurgi Methanol Synth. Methanol-Propylene Waste Water
- 19. AL Global E&C Solutions Perspective Steam Methane Reforming Air Liquide, world leader in gases for industry, health and the environment19 Gasification India 2016
- 20. World Map & References - Lurgi ReformerTM HAINAN Methanol Location: China / Hainan Product: 2.000 mtpd Methanol Start-up: 2006 Degussa Rheinfelden Location: Germany Product: 8.000 Nm³/h Hydrogen Start-up: 1997 TITAN and ATLAS Methanol Location: Trinidad Product: 2.500/5.000 mtpd Methanol Start-up: 1999 / 2004 Messer Dormagen Location: Germany Product: 7.000 Nm³/h CO Start-up: 2002 GLIMAR Location: Poland Product: 10.000 Nm³/h Hydrogen Start-up: - YARACO1 / YARACO 2 Location: China Product: 9.200Nm³/h CO Start-up: 1998 / 2005 DALIAN Location: China Product: 72.000 Nm³/h Hydrogen Start-up: 2006 PEMEX Cadereyta Location: Mexico Product: 67.250 Nm³/h Hydrogen AIR LIQUIDE Gulf Coast SMR H2 Location: Texas / USA Product: 130.000 Nm³/h Hydrogen Start-up: 2011 (Project in Progress) PRAXAIR Richmond Location: California Product: 204.000 Nm³/h Hydrogen Start-up: 2010 (under construction) LOTOS HGU 2 Location: Poland Product: 100.000 Nm³/h Hydrogen Start-up: 2009 (under construction) AIR LIQUIDE HERACLES Location: Netherlands Product: 130.000 Nm³/h Hydrogen Start-up: 2011 (Project in Progress) Air Liquide, world leader in gases for industry, health and the environment20 Gasification India 2016 Batamas MEGAH Location: Malaysia Product: 3.000 Nm³/h Hydrogen Start-up: 1994 BASF – BPC Kuantan Location: Malaysia Product: 58.000 Nm³/h Syngas Start-up: 2000 P.T. Kaltim Methanol Industry Location: Malaysia Product: 2.000 mtpd Methanol Start-up: 1998 Cleveland-Cliffs Location: Trinidad Product: 41.500 Nm³/h Hydrogen Start-up: 1998 PEMEX Madero Location: Mexico Product: 49.170 Nm³/h Hydrogen Start-up: 2001 Repsol YPF Location: Argentina Product: 1.210 mtpd Methanol Start-up: 2002 PML Location: Malaysia / Labuan Product: 5.000 mtpd Methanol Start-up: 2009 Melaka HPU 2 Location: Malaysia Product: 45.000 Nm³/h Hydrogen Start-up: 2008 National Petrochemical Co. (Kharg) Location: Iran Product: 2.000 mtpd Methanol Start-up: 1999 Product: 67.250 Nm³/h Hydrogen Start-up: 2000 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
- 21. 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) Air Liquide, world leader in gases for industry, health and the environment21 Gasification India 2016 ■ 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
- 22. 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 H Lic.+ B.E. 2011 Air Liquide, world leader in gases for industry, health and the environment22 Gasification India 2016 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
- 23. 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 EPC 2010 Air Liquide, world leader in gases for industry, health and the environment23 Gasification India 2016 Asia NG 9 800 CO 35 600 H2 EPC 2010
- 24. Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA) Air Liquide, world leader in gases for industry, health and the environment24 Gasification India 2016
- 25. Process Gas Fuel Gas Combustion Air Flue Gas Lurgi Reformer® - Isometric Arrangement Air Liquide, world leader in gases for industry, health and the environment25 Gasification India 2016 25 Arrangement Drawing
- 26. Hydrogen Lurgi SMR Feed-to-X Syngas Air Liquide ASU Air Liquide CO Cold Box N2 PSA Ammonia Syngas SMR Feed CO2 Removal HP Steam Air Liquide, world leader in gases for industry, health and the environment26 Gasification India 2016 CO Methanol-Propylene ATR Methanol Synthesis CO Shift
- 27. Next Generation Coal Gasification Island Associated Technologies Air Liquide, world leader in gases for industry, health and the environment27 Gasification India 2016
- 28. 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 Air Liquide, world leader in gases for industry, health and the environment28 Gasification India 2016 ■ PSA >70 Hydrogen Purification ■ Methanol: > 50 plants; 9 coal based. ■ MTP™ : 2 running ■ Claus : >170 Claus Units ■ OxyClaus™ SRU: > 40 burners
- 29. Air Liquide: Air Gases ■ Operating >350 Air Separation Units Total gaseous production > 120,000 tpd > 95,000 tpd O2 N Air Liquide, world leader in gases for industry, health and the environment29 Gasification India 2016 > 95,000 tpd ■ The world leader in large scale air separation units > 160 ASUs with a capacity > 1,000 tpd > 60 ASUs with a capacity > 2,000 tpd The largest single train plant under engineering (capacity of 5,000 TPD at 1620 m above sea level) N2
- 30. 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 H2 CO CH4 Air Liquide, world leader in gases for industry, health and the environment30 Gasification India 2016 ■ 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 Best efficiency for high moisture & high ash coal especially for SNG production. H2O
- 31. 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. H2CO Air Liquide, world leader in gases for industry, health and the environment31 Gasification India 2016 ■ 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! CO2 S
- 32. 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 H2CO N2 CH4 Air Liquide, world leader in gases for industry, health and the environment32 Gasification India 2016 ■ 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!
- 33. > 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 CH3OH Air Liquide’s Lurgi Methanol Air Liquide, world leader in gases for industry, health and the environment33 Gasification India 2016 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. 33
- 34. Food for Thought and Wrap-up Air Liquide, world leader in gases for industry, health and the environment34 Gasification India 2016
- 35. Value addition We know… Air Liquide’s value addition C CH4 ■ Cutting-edge, commercially proven proprietary technologies addressing the growing markets for coal-based & natural gas based fuels and petrochemicals: Air Liquide, world leader in gases for industry, health and the environment35 Gasification India 2016 Oxygen Syngas and the products. H2CO O2 CH3OH Synfuel fuels and petrochemicals: ■ Synfuels/Diesel ■ Methanol, DME ■ Propylene ■ Ammonia ■ Hydrogen
- 36. Wrap-Up - FBDBTM ■ FBDBTM Excellent Technology for High Ash 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, Air Liquide, world leader in gases for industry, health and the environment36 Gasification India 2016 Wide feedstock range - Light/heavy natural gas, LPG, associated gas, naphtha, mixed feed4 Wide product range - hydrogen, CO, towngas, syngas for products like oxo-alcohols, methanol, ammonia ■ Lurgi MPG Gasification 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
- 37. 4,000 Air Liquide Global E&C Solutions Colleagues Thank You! Hangzhou Shanghai Harima BeijingNew Delhi Houston Memphis Lorton Montreal Vitry /Seine Bussy-Saint-Georges Ennery Moscow Krakow Champigny /Marne Frankfurt Hyderabad Air Liquide, world leader in gases for industry, health and the environment37 Gasification India 2016 Sao Paulo Johannesburg Singapore Dubai Riyadh Chennai Engineering centers Manufacturing workshops Business offices Cryogenic equipment centers