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Air Liquide Engineering & Construction
for the Mongolian coal industry
ULAANBAATAR, 9TH OF FEBRUARY 2012
14:50-15:10 Rev 2
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AIR LIQUIDE : Our Offer at a Glance
LURGI FBDB™ Gasification Process
The Next GenerationTechnologies for Clean Syngas
Improved Rectisol® Process & Zero Sulfur
Energy-efficient Ammonia SyngasSyngas Product Technologies
Enhanced Lurgi SNG
Lurgi Methanol
Integrated GTL.F1 Liquid FuelsNext Step AIR LIQUIDE Contribution
Outline
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Lurgi New Gasification Module – Mark +
AIR LIQUIDE: Our Offer at a Glance
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Global Portfolio
Hydrogen/SyngasLurgi Reformer, MPG Gasifier, ATR,
Lurgi FBDB, CoGen
Hydrogen RecoveryMEDAL membranes, Cold Box, PSA
Oxygen / Nitrogen ASU, Membrane
Sulphur RecoveryOxy‐Claus, Tail Gas Treating LTGT, MAXISULF, AQUISULF, OMNISULF,
SULFREEN, HYDROSULFREEN
PetrochemicalsE‐PTA, Acrylic Acid, Butadiene, PA, Olefins,
Polymers, Distapex (Aromatics)
CO2 Recovery /Gas CleaningCompression and Purification UnitShift, Amine Wash, Rectisol, Purisol
Chemical ConversionMethanol, Megamethanol, MTP, Melamine
Biofuels / Oleochemicals
Consulting
Feasibility Studies
Global Procurement
Basic and Detail Engineering
Authority Engineering
Project Management
Construction/Management
Revamping/Retrofitting
Technical Services
Gas Supply Technologies EngineeringH2 HydrogenO2 OxygenN2 Nitrogen
UtilitiesSteam, power, demineralized water & compressed dry air
CO2 for water treatment
Specialty Gases
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Manufacturing workshops Engineering centers
Air Liquide Engineering & Construction
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H2 for Refineries
SMRs
Fertilizers
Chemicals
Power
SNG
CO2
Sulfur
Turbine
Methanation
N2 Wash + H2
Fischer-Tropsch
Methanol Synthesis
Chemical SynthesisDME/MTP
Syngas for DRI
Raw Material Syngas Final Products
Sulfur Recovery
CO Cold Box
PSA / Mem-brane
CO Shift
(Sulfur)Rectisol Stage
1
ProcessesSyngas Purification
Residue
Natural Gas
Coal
Biomass
AL and Lurgi Capability
ASU
GasificationFBDB/MPG
Reforming
Technology Portfolio –Clean Conversion Processes
(CO2)Rectisol Stage
1
Synfuels
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Air Liquide
ASU
Integrated Lurgi Coal Gas Island
Lurgi
GLS Process™Lurgi Phenosolvan ® & CLL™
Gas Liquor Recovery and Water Treatment
Liquid Ammonia
Treated Water
Lurgi Rectisol®Gas
Purification
Lurgi OxyClaus ®Sulfur Recovery
Elemental Sulfur
CO2
HP Steam
Syngas
Air Liquide
LNW Unit
N2
Lurgi
Methanation
Ammonia Syngas
SNG
(Fuel Gas)
(Rectisol Naphtha)
(Phenols)
(Clear Tar / Oil)
Lurgi MPG ®Gasification
Lurgi FBDB™
Gasification
Lurgi
CO Shift &
Gas Cooling
Coal
Preparation
HP Steam
Ash
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Lurgi FBDBTM Gasification Island –Typical Footprint
Gas Cooling
Gasification Modules
Gas Liquor Separation
Rectisol®
SRU
Phenosolvan®
Lurgi CLLTM
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Lurgi New Gasification Module – Mark +
LURGI Coal Technologies –LURGI FBDBTM Gasification Process
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Coal is widely Dispersed in the World and provides countries with a Strategic Energy Security Component
Gasification produces a Valuable Synthesis Gas for the production of Chemicals, Petrochemical, Fuels and Power
Gasification can meet the Most Stringent Environmental StandardsWorld Bank Standards (for Financing Needs)
Country Specifications (for Permitting Requirements)
Applied to Gaseous, Water and Solids Emissions
Helps in dealing with the Carbon Dioxide Issue
Lurgi’s Fixed Bed Dry Bottom Technology is well placed to Meet the Demands of the Market Place
Rationale for Lurgi Coal Gasification
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Mark +
Lurgi FBDBTM Benefits of Mk+ - Gasifier
Higher efficiency & reduced cost of eg. SNG
Lower specific coal, steam & oxygen consumptions
Higher specific byproduct values
Number of pieces of equipment greatly reduced
Reduced downstream capex due to higher operating pressure
Reduced capex due to less gas liquor circulation
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Coal
Preparation
LurgiFBDBTM Gasification
Unit 03
Gas CoolingUnit 04
Elemental Sulphur
CO2 Rich Gas
Rectisol Naphtha
Liquid Ammonia
Phenols
Tar / Oil
Ash Handling
Gas LiquorSeparation
Unit 05
Phenosolvan®
Unit 06NH3 Recovery
Unit 07
GasPurification(Rectisol®)
Unit 08
SulphurManagement
Unit 09Recompres.
Unit 03
•No Emissions (start-up, normal, emergency cases)•Efficient Waste Heat Recovery
Emissions
• Any water effluent compliant to most stringent regulations• Re-use the water in the process as BFW
Waste Water
Treatment
Bolier
Feed
Water
ASU
Syngas
Environment – Emissions and Effluents
•Coarse non-hazardous •Construction
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Lurgi New Gasification Module – Mark +
LURGI Technologies for Clean Syngas -Improved Rectisol® Process
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Lurgi Rectisol®The „5 in 1“ Solution
Feed Stock
Syn Gas
Gasification
SulfurRemoval
CO2Removal
SulfurRecovery
H2SCO2
CO2CO2
CompressorCO2
Treatment
Acid GasEnrichment
TraceRemoval
COS Hydrolysis
Syngas suitable for catalytic synthesis
processes
CO2 suitable for compression, synthesis,
or venting
1. Trace contaminant removal
2. Deep Desulfurization
3. Bulk CO2 removal
4. CO2 purificationCO2 Capture Ready
5. Acid Gas Enrichment
Acid gas suitable forsulfur recovery
processes
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Intensive Redevelopment Since 2009Operational Expenses Reduced by 30%Result: New contract every 2 months
Rectisol® Improvement Program –Results
-10% OPEX
Capex saving
Capex saving
-10% OPEX
-10% to 20% OPEX
Re-assessment and validation of thermodynamics
Validation of EquipmentEfficiencies of trays
Application of packings(where no fouling occurs)
Heat exchanger with small pinch(where no fouling occurs)
Modfied heat integration
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Lurgi New Gasification Module – Mark +
Lurgi’s Sulfur Removal Technology –Zero Emission Concept
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Sulfur Recovery
97 % Claus withtwo catalytical stages
98 % Claus withthree catalytic stages
99,0 – 99,6%
Claus withtwo cat. stages plus
Sulfreen / Hydrosulfreen
99,9% Claus withtwo catalytic stages plus LTGT
100,0% Tailgas recycle(Emission Free Claus)
Sulfur Recovery Concepts
China:Acc. GB16297-1996:<960mg/M3 in stack gasRecovery >99.8%
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96 % 97% 98% 99% 99,3% 99,5% 99,8% 99,9% 100 %100
Sulphur Recovery
Cos
t Ind
ex
2-Rx Claus
3-Rx Claus
2Rx + LTGTIncluding Regeneration
Emission Free Design
Lurgi OxyClaus® TechnologyEmissions Free – Total Investment Costs
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Lurgi New Gasification Module – Mark +
Air Liquide Cryogenics Technologies for Ammonia Syngas
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Nitrogen Wash Unit
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Typical Cold Box System
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Air Liquide Cold Box References
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Lurgi’s Poly-generation Vision
MARKET DRIVEN
Coal
processing
Steam / power
generation
Utilities
and
amenities
MODULAR ECONOMY OF SCALE
ASU
Oxygen
FBDB
Gasification
FBDB
Gasification
MPG
Gasification
GasWork-up
(Rectisol plus)
LiquidWork-up
(GLS plus)
INFRASTRUCTURE
SYNGAS ISLAND
SNG
Methanol
CTL
DRI
FBDB
Gasification
FBDB
Gasification
Power
Ammonia
FBDB
Gasification
FBDB
Gasification
ASU
Oxygen
DME Acrylic Acid
MTO
MTG
MTP Polypropylene
Etc
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Lurgi New Gasification Module – Mark +
LURGI Technologies for SNG Route –Enhanced Methanation Process
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Enhanced Methanation Technology -Gains
Higher Maximum Operating Temperature AllowsGeneration of Higher Temperature Steam
Improved OPEX
Reduced Recycle Gas Flow (Smaller Capex)
Choice Between Medium Temperature and High Temperature Processes
Flexibility of Methanation Process to Upstream Gasification, Steam Production Needs
Medium Temperature
Methanation
High Temperature
Methanation
Catalyst G1 – 85 HT G1 - 85
Maximum Temperature (Deg C) 480 650
Guaranteed Catalyst Life (Years) 3 2
Recycle Compressor (Volume) 100 % 70%
Power Consumption 100 % 40%
Steam Superheating Temp. (Deg C) 460 510
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Design of High Temperature and Low Delta Pressure
Methanation Process With Ensured Link to
Commercial Reference
Performance of HT G1-85 in Pilot Plant (650°C Maximum Temperature)
Low Pressure Drop CatalystMech. Stability
Activity
G1-85 Operation in Dakota Gasification (480°C Max Temp.)
Performance of G1-85 in Pilot Plant (480°C Max. Temp.)
Low Pressure Drop Catalyst
Mech.StabilityActivity
Enhanced Methanation Technology -Validated
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Lurgi‘s Methanol Technology
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1969 First LP-Methanol Catalyst Test
1970 Cooperation with Süd-Chemie for Catalyst 1970
Operation of 100 Tubes-Reactor Demonstration Unit
1972 First 3 LP-Methanol Plants in Operation
1997 MegaMethanolTM Concept Published
2006 Six contracts awarded for MegaMethanolTM plants
2011 Six MegaMethanolTM plants in operation
LURGI’s Methanol Technology Milestones
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Feedstock Natural Gas31 Plants with a total capacity of 21.40 MMTPY
thereof 17 Plants using Conventional Steam Reforming 13 Plants using Combined Reforming
1 Plant using Autothermal Reforming
Feedstock Natural Gas plus Naphtha4 Plants with a total capacity of 0.60 MMTPY
Feedstock Coal Gas7 Plants with a total capacity of 4.90 MMTPY
Feedstock Heavy Residue7 Plants with a total capacity of 2.00MMTPY
Total : 50 Plants with a total capacity of 29.90 MMTPY
Syngas OptionsPossible Feedstocks
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AIR LIQUIDE Liquid Fuels Development
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GTL.F1 AG
The Company
Operated by Lurgi GmbH partnered by PetroSA
1986 Start of F-T technology development by Statoil
1987/88 First catalyst and reactor patents
2002-08 Construction/ operation Semi-commercial demo
2009/10 Award of first F-T & Upgrading project
The Technologies
Fischer-Tropsch Technology based on
- advanced Slurry Bubble Column Reactor concept
- proprietary Cobalt catalyst
Integrates- Air Liquide/Lurgi’s technology portfolio for syngas production & purification- Proprietary FT technology- Integrated upgrading technology from third party
FT Demo-Unit Mossel Bay
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Air Liquide
ASU
CTL: Integration and Options
Lurgi
GLS Process™Lurgi Phenosolvan ® & CLL™
Gas Liquor Recovery and Water Treatment
Lurgi Rectisol®Gas
Purification
Lurgi OxyClaus ®Sulfur Recovery
GTL.F1
Synthesis
GTL.F1
Fuel Workup
Lurgi ATR
Lurgi FBDB™
Gasification
Lurgi
CO Shift &
Gas Cooling
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AIR LIQUIDE Engineering Capability
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Project Execution ExpertiseTypical Cost Reduction Potentials
HIGH
LOWSTART COMPLETE
Cost Reduction Potentials
Abi
lity
to In
fluen
ce C
ost
Conceptual Planning
Design
Procurement
Construction
Start-up
Time
Lurgi has considerable experience in value engineering and life cycle cost optimization.
Cost reductions can be realized by early involvement during conceptual engineering, bankable feasibility study and front-end engineering.
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Characterization of the CoalAir Liquide Frankfurt Research & Technology Center (FRTC) ensures Proper Coal Characterization, key to
The Gasifier
Downstream – CO Shift, Rectisol, SRU, Synthesis Products
Water Optimisation
StudiesProject Feasibility (Process Configuration: Coal to Product)
Project Economics (CAPEX/OPEX)
Environmental Impact of the Processes
Scheduling
Purchasing Optimization
Licensing and Engineering and Procurement Services
Next Steps
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Lurgi New Gasification Module – Mark +
Thank you for your interest.For more details please contact us:
CONTACT:Deepak WADHWA - [email protected] President E&C Sales, North & Southeast Asia Pacific & India
PRESENTER:Daniel VAN DER MERWE - [email protected] Solutions Development Manager, Engineering Services Asia