eastman and gasification: the next step - building … and gasification: the next step - building on...
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Eastman and Gasification:
The Next Step - Building on Past Success
By: Bill Trapp
Eastman Chemical Company
Gasification Technologies 2001 Conference
October 7 - 10, 2001
Eastman and Gasification:
The Next Step - Building on Past Success
By: Bill Trapp
Eastman Chemical Company
Gasification Technologies 2001 Conference
October 7 - 10, 2001EASTMAN
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hFounded in 1920 as part of EastmanKodak - wood to methanol plant
hApproximately $5 B in sales annually
hOver 400 Chemicals, Fibers and Plastics
hHeadquarters - Kingsport, TN
hManufacturing sites around the world
EASTMAN
E A ST M A N
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GasificationMeOH
CarbonylationMeOAc
Esterification Spinning/
Compounding
Sales / DiketeneDerivatives/SolventEsters
Coal
Oxygen
CO
H2
Ac2O HOAc
CelluloseEsters
Sales
Cellulose
PlasticizersDyes
Acetate Tow
Plastic EstersFilm base
Purch. MethanolChemicalsfrom Coalfacility
Acetyl Flow at Eastman
Acetate Yarn
“Acetyl” means any chemical derivedfrom acetic acid or acetic anhydride
CH3COH
O
(acetic acid)CH3CO
O
CCH3
O
(acetic anhydride)
EASTMAN
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GasificationMeOH
CarbonylationMeOAc
Esterification Spinning/
Compounding
Sales / DiketeneDerivatives/SolventEsters
Coal
Oxygen
CO
H2
Ac2O HOAc
CelluloseEsters
Sales
Cellulose
PlasticizersDyes
Acetate Tow
Plastic EstersFilm base
Purch. MethanolChemicalsfrom Coalfacility
Acetyl Flow at Eastman
Acetate Yarn
EASTMAN
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History of Chemicals from Coal Facility
• Prior to Coal Gas, all acetyl chemicals made frompetroleum
• Start-up of complex in 1983 (1/2 of acetyl demand)
• Expansion of downstream plants 1991, (100% ofacetyl demand)
• Debottlenecking - 1991 to Present Approx. 1300 Tons/Day of Coal converted to Higher Value Chemicals (Ac2O, HOAc)
EASTMAN
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Coal
Syngas
ParticulateRemoval
SyngasConversion
TexacoGasifier
Slag/Soot
Steam
SolidsCo-products
Sulfur
CO2
GasificationBasics
Eastman’s Configuration
Chemicals Ac20,HOAc, MeOH, MeOAc
Oxygen
RE
CT
ISO
L
SulfurRecovery
SCOT/Claus
Air
Pro
duct
s
CO
CO/H2Separation
(Lurgi)
CO2/H2SRemoval
EASTMAN
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Coal
Syngas
ParticulateRemoval
SyngasConversion
TexacoGasifier
Slag/Soot
Steam
SolidsCo-products
Sulfur
CO2
GasificationBasics
Eastman’s Configuration
Chemicals Ac20,HOAc, MeOH, MeOAc
Oxygen
RE
CT
ISO
L
SulfurRecovery
SCOT/Claus
Air
Pro
duct
s
CO
CO/H2Separation
(Lurgi)
CO2/H2SRemoval
Syn Gas
CO
Methanol MethylAcetate
Acetic Acid/Anhydride
Fibers
Plastics
Solvents
Trade Sales
EASTMAN
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Eastman, AirProducts, DOEJoint Venture
Liquid PhaseMethanol
Plant
EASTMAN
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Syngas
ParticulateRemoval
SyngasConversion
Gasifier
Slag/Soot
Steam
SolidsCo-products
Sulfur
CO2
GasificationBasicsPower Option
Chemicals Ac20,HOAc, MeOH, MeOAc
Oxygen
SulfurRecovery
CO
CO2/H2SRemoval
Electricity
SyngasCombustion Turbine
SteamTurbine
Coal
PetroleumCoke
Refinery Co-products
EASTMAN
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Electricity
Coal
PetroleumCoke
Refinery Co-products
Steam
Syngas
ParticulateRemoval
SyngasConversion
Total Package
Gasifier
Slag/Soot
Steam
Combustion Turbine
SteamTurbine
Bac
k-up
/Pe
akin
g Fu
el
SolidsCo-products
Sulfur
CO2 &Sulfur
Removal
CO2
GasificationBasics
Chemicals
Oxygen
EASTMAN
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• Decouples reliability of gasification blockand power block– Produce MeOH while turbine is down or off
peak demand
– Feed MeOH to turbine while gasifier is down
• Use MeOH to supplement when gasifier israte limited
• Sell excess MeOH during low demand
• Use MeOH as start-up fuel
• Produce higher value chemicals forinternal use or resale
Chemical Co-production Benefits
EASTMAN
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Keys to Success
• Production Rate
• Reliability
• Maintenance
• Safety
• Environment
• Continual Improvement
EASTMAN
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– Stable, continuous demand fordownstream chemicals
– Continous debottlenecking of downstreamplants keeps demand growing
– No back-up supply
– “Downtime domino”
Production Rate & Reliability
Current full rate is approximately 140% of the original design
EASTMAN
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Not Needed0.0%
Planned1.2%
Unplanned1.0%
Onstream97.8%
Downtime2.2%
Not Needed Planned Unplanned Onstream
8/99 - 9/01 (Two Year Maintenance Cycle)Gasification Unit Operating Statistics
EASTMAN
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8/99 - 9/01 (Two Year Maintenance Cycle)Gasification Unit Operating Statistics
Secondary Measures:
Forced Outage Rate = 1% Unplanned Outage/(On-stream + Unplanned)
Capacity Factor = 120% Annual production/(Design full rate X 365 days)
EASTMAN
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MaintenanceMaintenance
1. Continually balancing reliability vs maintenance staffing
2. New process to increase % “planned” maintenance
3. Improvement projects targeted at increased reliability
4. Bi-annual shutdown efficiency improvements
5. Overall cost trending down
EASTMAN
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Safety
• Plant Site OSHA-R rate is 1.1
• Gasification area OSHA-R 1.0
• Last work day out case was 10 years ago
• Plant site received Tennessee OSHA “VolunteerStar” certification
EASTMAN
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EnvironmentEnvironment
• Sulfur removal is 99.9%
• NOX is not an issue
• Mercury removal since start-up
• Patented sulfur-free start-up process
• Excellent record and reputation with EPAauditors
• Sulfur removal is 99.9%
• NOX is not an issue
• Mercury removal since start-up
• Patented sulfur-free start-up process
• Excellent record and reputation with EPAauditors
EASTMAN
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Major Improvements and Enhancements
h Feed Injector Design Improvements
h Alternate Feedstocks
h Complex Shutdown Planning/Execution
h Gasifier “Quick-Switch”
h State-of-the-art Distributive Control System
h On-site expertise on refractory changeouts
h Sulfur-free start-up
Continual Improvement
EASTMAN
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Where is Gasification going ?
• Most flexible (power, chemicals or both)
• Power industry holds the most promise(number of projects and scale)
• Raw material is cheap and stable
• “Cleanest” coal technology• SOX, NOX, PM very low
• Some improvement on CO2, Best option for CO2sequestration
• Hg removal economical
• Proven technology
EASTMAN
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Where is Gasification going ?
It’s on the verge of taking off!
EASTMAN
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So what’s the problem ?
Where is Gasification going
• Capital Cost
– Reliability
EASTMAN
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So what’s the problem ?
Where is Gasification going
• Capital Cost– This will naturally come down with
duplication and scale– PC and NG are mature and have a
head start
EASTMAN
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So what’s the problem ?
Where is Gasification going
– Reliability
–Eastman can solve this problem
EASTMAN
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Eastman will begin exploring O&M servicesoptions for the gasification industry
Building on past success
h Proven track record (18+ years experience)
h Industry leading performance
h Vast support services
h Commitment to excellence
EASTMAN
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Let’s take the next step together
EASTMAN