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2011
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 Generation Technologies for Clean Syngas
Improved Rectisol Process & Zero Sulfur
Energy-efficient Ammonia Syngas Syngas Product Technologies
Enhanced Lurgi SNG
Lurgi Methanol Integrated GTL.F1 Liquid Fuels
Next 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/SyngasLurgiReformer,MPGGasifier,ATR,
LurgiFBDB,CoGen
Hydrogen
RecoveryMEDALmembranes,ColdBox,PSA
Oxygen/NitrogenASU,Membrane
SulphurRecoveryOxy
Claus,
Tail
Gas
Treating
LTGT,
MAXISULF,AQUISULF,OMNISULF,
SULFREEN,HYDROSULFREEN
PetrochemicalsEPTA,AcrylicAcid,Butadiene,PA,Olefins,
Polymers,Distapex(Aromatics)
CO2Recovery
/Gas
CleaningCompressionandPurificationUnit
Shift,AmineWash,Rectisol,Purisol
ChemicalConversionMethanol,Megamethanol,MTP,Melamine
Biofuels
/
Oleochemicals
Consulting
Feasibility
Studies
Global
Procurement
BasicandDetailEngineering
AuthorityEngineering
Project
Management
Construction/Management
Revamping/Retrofitting
Technical
Services
GasSupply Technologies Engineering
H2Hydrogen
O2OxygenN2Nitrogen
UtilitiesSteam,
power,
demineralized
water&compresseddryair
CO2forwatertreatment
SpecialtyGases
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Manufacturing workshops Engineering centers
Air Liquide Engineering & Construction
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H2 forRefineries
SMRs
Fertilizers
Chemicals
Power
SNG
CO2
Sulfur
Turbine
Methanation
N2 Wash + H2
Fischer-Tropsch
Methanol
Synthesis
ChemicalSynthesis
DME/MTP
Syngas for DRI
Raw
MaterialSyngas Final Products
Sulfur
Recovery
CO
Cold Box
PSA /
Mem-brane
CO Shif t
(Sulfur)Rectiso
l Stage
1
ProcessesSyngas Purification
Residue
Natural
Gas
Coal
Biomass
AL and Lurg iCapability
ASU
Gasification
FBDB/MPG
Reforming
Technology Portfolio
Clean Conversion Processes
(CO2)
Rectiso
l Stage
1
Synfuels
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Ai r 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
GasPurification
Lurgi OxyClaus
Sulfur Recovery
Elemental Sulfur
CO2
HP Steam
Syngas
Ai r 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
Gasif ication produces a Valuable Synthesis Gas for the production
of Chemicals, Petrochemical, Fuels and Power
Gasification can meet the Most Stringent Environmental Standards
World 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
Lurgis Fixed Bed Dry Bottom Technology is well placed to Meet the
Demands of the Market Place
Rationale for Lurgi Coal Gasif ication
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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 c irculation
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Coal
Preparation
Lurgi
FBDBTM Gasification
Unit 03
Gas Cooling
Unit 04
Elemental Sulphur
CO2 Rich Gas
Rectisol Naphtha
Liquid Ammonia
Phenols
Tar / Oil
Ash Handling
Gas Liquor
Separation
Unit 05
Phenosolvan
Unit 06
NH3 Recovery
Unit 07
Gas
Purification
(Rectisol)
Unit 08
Sulphur
Management
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
Sulfur
Removal
CO2Removal
Sulfur
RecoveryH2S
CO2
CO2CO2
CompressorCO2
Treatment
Acid Gas
Enrichment
Trace
Removal
COSHydrolysis
Syngas suitable forcatalytic synthesis
processes
CO2 suitable forcompression, 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 2009
Operational 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 Equipment
Efficiencies 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 +
Lurgis Sulfur Removal Technology
Zero Emission Concept
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Sulfur Recovery
97 % Claus with
two catalytical stages
98 % Claus with
three catalytic stages
99,0 99,6%
Claus withtwo cat. stages plus
Sulfreen / Hydrosulfreen
99,9% Claus with
two catalytic stages plus LTGT 100,0% Tailgas recycle
(Emission Free Claus)
Sulfur Recovery Concepts
China:
Acc. GB16297-1996:
99.8%
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96 % 97% 98% 99% 99,3% 99,5% 99,8% 99,9% 100 %100
Sulphur Recovery
Co
stIndex
2-Rx
Claus
3-Rx
Claus
2Rx + LTGT
Including Regeneration
Emission
Free Design
Lurgi OxyClaus Technology
Emissions Free Total Investment Costs
200
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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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2011
Lurgis 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
Gas
Work-up(Rectisol plus)
Liquid
Work-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
MTPPolypropylene
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 Allows
Generation 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 ProcessWith Ensured Link to
Commercial Reference
Performance of HT G1-85 in
Pilot Plant (650C Maximum
Temperature)
Low Pressure Drop Catalyst
Mech. StabilityActivity
G1-85 Operation in
Dakota Gasification
(480C Max Temp.)
Performance of
G1-85 in Pilot Plant
(480C Max. Temp.)
Low Pressure Drop
Catalyst
Mech.
Stability
Activity
Enhanced Methanation Technology -
Validated
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Lurgis Methanol Technology
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1969 First LP-Methanol Catalyst Test
1970 Cooperation with Sd-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
LURGIs Methanol Technology Milestones
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Feedstock Natural Gas
31 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 Options
Possible Feedstocks
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AIR LIQUIDE Liquid Fuels Development
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2011
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/Lurgis technology portfolio for syngas production & purification
- Proprietary FT technology
- Integrated upgrading technology from third party
FT Demo-Unit Mossel Bay
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Ai r Liquide
ASU
CTL: Integration and Options
Lurgi
GLS Process
Lurgi Phenosolvan & CLL
Gas Liquor Recovery and Water Treatment
Lurgi Rectisol
GasPurification
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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Lurgi New Gasification Module Mark +
AIR LIQUIDE Engineering Capability
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Project Execution Expertise
Typical Cost Reduction Potentials
HIGH
LOW
START COMPLETE
Cost Reduction Potentials
Abilityto
Inf
luenceCost
Conceptual Planning
Design
Procurement
Construction
Start-up
Time
Lurgi has considerable experience in value engineering and life cycle costoptimization.
Cost reductions can be realized by early involvement during conceptualengineering, bankable feasibility study and front-end engineering.
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Characterization of the Coal
Air Liquide Frankfurt Research & Technology Center (FRTC) ensures Proper Coal
Characterization, key to
The Gasifier Downstream CO Shift, Rectisol, SRU, Synthesis Products
Water Optimisation
Studies
Project 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]
Vice President E&C Sales, North & Southeast Asia Pacific & India
PRESENTER:
Daniel VAN DER MERWE - [email protected]
Lurgi Solutions Development Manager, Engineering Services Asia