syn gas generation different routes various...
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June 14, 2012 l Siddhartha Mukherjee | Air Liquide Global E&C Solutions | New Delhi
February 16, 2016 | Air Liquide Global E&C Solutions | New Delhi
New Delhi
Syn Gas Generation Different Routes – Various Products
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Global E&C Solutions Communications
Air Liquide, world leader in gases for industry, health and the environment 2 6th World PetroCoal Congress2016
Clean Conversion – Our Story
Coal Gasification and its Applications SNG
Ammonia
Methanol
Methanol > Propylene
Hydrogen
Hydrogen and Carbon Monoxide
DRI Gas
Residue Gasification
Steam Methane Reforming
Associated Technologies
Wrap-up and Summary
Syngas Generation - Various Routes, Multiple Products
Air Liquide, world leader in gases for industry, health and the environment 3 6th World PetroCoal Congress 2016
AL Global E&C Solutions Perspective
Clean Conversion – Our Story
Air Liquide, world leader in gases for industry, health and the environment 4 6th World PetroCoal Congress2016
Our value addition
We know…
Coal
Oxygen
Syngas
and the products.
Drivers and our contribution
■ fluctuating price of oil & gas
in many locations
■ Growing domestic demand for
fuel and petrochemical products
■ Reduction of dependency on
fuel and petrochemicals imports
■ Abundance of coal H2 CO
O2
C
CH3OH
Synfuel
Air Liquide, world leader in gases for industry, health and the environment 5 6th World PetroCoal Congress 2016
+
■ NG, LPG, Naphtha
• SMR, ATR
• CO Shift, Amine Wash
• Coldbox, PSA
■ Coal, Heavy Residue
• Gasification, MPG
• CO Shift, Rectisol
• Coldbox, PSA
■ Synthesis
• Methanol, DME
• MTP, Acrylic Acid
• Synfuels, Ammonia
Clean Conversion
H2 CO
O2
C
H2O +
Air Liquide, world leader in gases for industry, health and the environment 6 6th World PetroCoal Congress 2016
Raw
Material
Residue
Natural
Gas
Coal
Biomass
Sulfur
Recovery
CO
Cold Box
PSA
CO Shift
Syngas Treating
AGR
Amine
Wash
Syngas
ASU
Gasification
Reforming
Methanol
Synthesis
DME
MTP ™
Acrylic Acid
Fischer Tropsch
Methanation
Ammonia
Methanol
Final Products
DME
Propylene
Acrylic Acid
Syn fuels
SNG
Ammonia
DRI
Clean Conversion
Air Liquide, world leader in gases for industry, health and the environment 7 6th World PetroCoal Congress 2016
Gasification
Lurgi FBDB™
Lurgi MPG™
Raw
Material
Residue
Natural
Gas
Coal
Biomass
Final Products
Lurgi
OxyClaus
™
AL
Cold Box
AL
PSA
CO Shift Amine
Wash
Syngas and Synthesis
AL
ASU
Lurgi SMR
Lurgi ATR
Lurgi POX
Technology and Design by Air Liquide
Methanol Lurgi
Methanol
Lurgi DME
Lurgi MTP ™
Lurgi NK Acrylic Acid
GTL.F1 Fischer Tropsch
Methanation
DME
Propylene
Acrylic Acid
Syn fuels
SNG
Ammonia Ammonia
DRI
Lurgi
Rectisol ™
Air Liquide, world leader in gases for industry, health and the environment 8 6th World PetroCoal Congress 2016
AL Global E&C Solutions Perspective
Coal Gasification and its Applications
Air Liquide, world leader in gases for industry, health and the environment 9 6th World PetroCoal Congress2016
Lurgi FBDB™ Coal-to-X Syngas
CO
Hydrogen Air Liquide
CO Cold Box
Air Liquide
ASU
Lurgi
GLS Process™
Lurgi Phenosolvan® & Lurgi CLL™
Gas Liquor Recovery and Water Treatment
Liquid Ammonia
ZLD – Water Reuse
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)
(Rectisol Naphtha)
(Phenols)
(Clear Tar / Oil)
Lurgi MPG®
Gasification
Gasification
Lurgi
CO Shift /
Gas Cooling
Coal
Preparation
HP Steam
Ash
Air Liquide
PSA
Lurgi
Methanol Synth.
Methanol-Propylene
Air Liquide, world leader in gases for industry, health and the environment 10 6th World PetroCoal Congress 2016
78 000 Nm3/h H2
900 tpd NH3
Coal to H2 and NH3: Fujian Gasification Project
ASU
Gasification
CO-Shift
Lurgi
Rectisol™
OxyClaus™
Nitrogen Wash
Ammonia
PSA
H2
NH3
Air Liquide, world leader in gases for industry, health and the environment 11 6th World PetroCoal Congress 2016
Coal to Ammonia: TGI/SCJ
11
ASU
Gasification
Lurgi
Rectisol™
&
OxyClaus™
Nitrogen
Wash
Ammonia
ASU, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash
H2 N2
180 000 Nm3/h N2+H2
Air Liquide, world leader in gases for industry, health and the environment 12 6th World PetroCoal Congress 2016
Coal to Propylene: Shenhua Ningxia
ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™
5000 tpd MeOH to each MTP™
Air Liquide, world leader in gases for industry, health and the environment 13 6th World PetroCoal Congress 2016 13
ASU
Gasification
CO-Shift,
Rectisol®
Oxy Claus™
Mega-
Methanol®
MTP®
MTP®
ASU
Rectisol®
(4 trains)
Methanol
Synfuels
Methanol train
Gasification train
Methanol
DME
Rectisol®
Coal to Methanol and Propylene: Shenhua Ningxia
ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™
Gasification
Air Liquide, world leader in gases for industry, health and the environment 14 6th World PetroCoal Congress 2016 14
ASU
Lurgi
Rectisol™
&
OxyClaus ™
Coal to DRI Gas: Jindal Steel and Power
ASU, Lurgi FBDB™ Gasification, Phenosolvan™, CLL™, Rectisol™, SRU OxyClaus™
Lurgi
FBDB™
Gasification
Lurgi CLL™
Phenosolvan ™
225 000 Nm3/h CO+H2+CH4 H2
CO
CH4
Air Liquide, world leader in gases for industry, health and the environment 15 6th World PetroCoal Congress 2016
AL Global E&C Solutions Perspective
Residue Gasification - MPG®
Air Liquide, world leader in gases for industry, health and the environment 16 6th World PetroCoal Congress2016 16
45 years 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
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
MPG® Summary
Air Liquide, world leader in gases for industry, health and the environment 17 6th World PetroCoal Congress2016 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
Multi
Purpose
Gasification
45 years experience
in residue gasification:
75 units
62.5 x 106 m3N/d
2010
Pu
rch
ase
s fro
m S
VZ
20
01
Ulta
fert
il
2002 H
D P
OX
200
5 N
ort
h W
est
Up
gra
de
r
Residue Gasification References
Air Liquide, world leader in gases for industry, health and the environment 18 6th World PetroCoal Congress2016 18
Feed
Soot Slurry
Quench
Water
Oxidant (O2 Air) Steam
Feed
Oxidant (O2 Air) Steam
Syngas
Syngas
Boiler Mode
Sat. HP-steam
Heat Recovery
Boiler
Quench Mode
MPG® Gasification – Quench / Boiler
Air Liquide, world leader in gases for industry, health and the environment 19 6th World PetroCoal Congress2016 19
CO-Shift MP-Boiler Final Cooler Gas Scrubbing Feedstock
O2 / Steam
Metals Ash Process Water
MPG® - Quench Configuration
Air Liquide, world leader in gases for industry, health and the environment 20 6th World PetroCoal Congress2016 20
MPG® - Boiler Configuration
Air Liquide, world leader in gases for industry, health and the environment 21 6th World PetroCoal Congress2016
MPG® Residue-to-X Syngas
CO
Hydrogen Air Liquide
CO Cold Box
Air Liquide
ASU
Metal Ash
Recovery System
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)
Metal Ash
MPG®
Lurgi
CO Shift /
Gas Cooling
Feed
HP Steam
Air Liquide
PSA
Lurgi
Methanol Synth.
Methanol-Propylene
Waste Water
Air Liquide, world leader in gases for industry, health and the environment 22 6th World PetroCoal Congress 2016
AL Global E&C Solutions Perspective
Steam Methane Reforming
Air Liquide, world leader in gases for industry, health and the environment 23 6th World PetroCoal Congress2016
World Map & References - Lurgi ReformerTM
Batamas MEGAH
Location: Malaysia
Product: 3.000 Nm³/h Hydrogen
Start-up: 1994
HAINAN Methanol
Location: China / Hainan
Product: 2.000 mtpd Methanol
Start-up: 2006
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
Degussa Rheinfelden
Location: Germany
Product: 8.000 Nm³/h Hydrogen
Start-up: 1997
Cleveland-Cliffs
Location: Trinidad
Product: 41.500 Nm³/h Hydrogen
Start-up: 1998
TITAN and ATLAS Methanol
Location: Trinidad
Product: 2.500/5.000 mtpd Methanol
Start-up: 1999 / 2004
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
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
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
PEMEX Cadereyta
Location: Mexico
Product: 67.250 Nm³/h Hydrogen
Start-up: 2000
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)
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
Air Liquide, world leader in gases for industry, health and the environment 24 6th World PetroCoal Congress2016
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)
■ 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
Air Liquide, world leader in gases for industry, health and the environment 25 6th World PetroCoal Congress2016
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 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
Air Liquide, world leader in gases for industry, health and the environment 26 6th World PetroCoal Congress2016
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
35 600 H2
EPC 2010
Air Liquide, world leader in gases for industry, health and the environment 27 6th World PetroCoal Congress2016
Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA)
Air Liquide, world leader in gases for industry, health and the environment 28 6th World PetroCoal Congress2016
28
Process Gas
Fuel Gas
Combustion Air
Flue Gas
Arrangement Drawing
Lurgi Reformer® - Isometric Arrangement
Air Liquide, world leader in gases for industry, health and the environment 29 6th World PetroCoal Congress2016
Hydrogen
Lurgi SMR Feed-to-X Syngas
CO
Air Liquide
ASU
Air Liquide
CO Cold Box
N2
PSA
Ammonia Syngas
SMR
Methanol-Propylene
Feed
CO2 Removal
ATR
Methanol
Synthesis
CO Shift
HP Steam
Air Liquide, world leader in gases for industry, health and the environment 30 6th World PetroCoal Congress 2016
Next Generation Coal Gasification Island
Associated Technologies
Air Liquide, world leader in gases for industry, health and the environment 31 6th World PetroCoal Congress2016
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
■ Methanol: > 50 plants; 9 coal based.
■ MTP™ : 2 running
■ Claus : >170 Claus Units
■ OxyClaus™ SRU: > 40 burners
Air Liquide, world leader in gases for industry, health and the environment 32 6th World PetroCoal Congress2016
Air Liquide: Air Gases
■ Operating >350 Air Separation Units
Total gaseous production
> 120,000 tpd
> 95,000 tpd
■ The largest single train plant (capacity of 5,000 tpd) under
engineering
O2
N2
Air Liquide, world leader in gases for industry, health and the environment 33 6th World PetroCoal Congress2016
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
Reduced steam consumption & lower oxygen consumption
Higher direct methane production
■ Environmental Compliance
Complete process water re-use Zero Liquid Discharge
World bank standards
H2
CO CH4
Best efficiency for high moisture & high ash coal
especially for SNG production.
H2O
Air Liquide, world leader in gases for industry, health and the environment 34 6th World PetroCoal Congress2016
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.
■ 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!
H2 CO
CO2 S
Air Liquide, world leader in gases for industry, health and the environment 35 6th World PetroCoal Congress2016
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
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!
H2 CO
N2
CH4
Air Liquide, world leader in gases for industry, health and the environment 36 6th World PetroCoal Congress2016
> 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
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.
CH3OH
Air Liquide’s Lurgi Methanol
36
Air Liquide, world leader in gases for industry, health and the environment 37 6th World PetroCoal Congress 2016
Food for Thought and Wrap-up
Air Liquide, world leader in gases for industry, health and the environment 39 6th World PetroCoal Congress2016
Wrap-Up - FBDBTM
■ FBDBTM Excellent Technology for High Ash Content 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,
naphtha, mixed feed 4
Wide product range - hydrogen, CO, towngas, syngas for products like
oxo-alcohols, methanol, ammonia
■ Lurgi 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
Air Liquide, world leader in gases for industry, health and the environment 40 6th World PetroCoal Congress2016
4,000 Air Liquide Global E&C Solutions Colleagues Thank You!
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