air liquide lurgi 2016 overview of coal heavy oil ch4 to syngas h2 ammonia methanol reference...

February 11, 2016 | Air Liquide Global E&C Solutions | New Delhi

Syn Gas GenerationVarious Routes – Multiple Products

June 14, 2012 l Siddhartha Mukherjee | Air Liquide Global E&C Solutions | New DelhiFebruary 11, 2016 | Air Liquide Global E&C Solutions | New Delhi

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Global E&C Solutions Communications

� 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, he alth and the environment2 Gasification India 2016

� Hydrogen� Hydrogen and Carbon Monoxide� DRI Gas

� Residue Gasification � Steam Methane Reforming� Associated Technologies � Wrap-up and Summary

AL Global E&C Solutions PerspectiveClean Conversion – Our Story


Our value addition

We know…

Coal

Drivers and our contribution

■ fluctuating price of oil & gasin many locations

■ Growing domestic demand forfuel and petrochemical products

■ Reduction of dependency onC


Oxygen

Syngas

and theproducts.

■ Reduction of dependency onfuel and petrochemicals imports

■ Abundance of coal

H2CO

O2

CH3OHSynfuel

■ 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, he alth and the environment5

+

• Gasification• CO Shift, Rectisol™• Coldbox, PSA

■ Synthesis• Methanol, DME• MTP, Acrylic Acid• Synfuels, Ammonia

H2CO

Gasification India 2016

Raw Material

Residue

Natural Gas

Coal

Biomass

CO Cold Box

PSA

Syngas Treating

AGR

Syngas

GasificationMethanol

Synthesis

DME

MTP ™

Acrylic Acid

Methanol

Final Products

DME

Propylene

Acrylic Acid

Clean Conversion


Biomass

Sulfur Recovery

CO ShiftAmineWash

ASU

Reforming Fischer Tropsch

Methanation

Ammonia

Syn fuels

SNG

Ammonia

DRI


GasificationLurgi FBDB™Lurgi MPG™

RawMaterial

Residue

Natural Gas

Coal

Biomass

Final Products

AL Cold Box

ALPSA

Syngas and Synthesis

Technology and Design by Air Liquide

MethanolLurgi

Methanol

LurgiDME

LurgiMTP ™

Lurgi NKAcrylic Acid

DME

Propylene

Acrylic Acid

LurgiRectisol ™


Biomass

LurgiOxyClaus

™

CO ShiftAmineWash

ALASU

Lurgi SMRLurgi ATRLurgi POX

Acrylic Acid

GTL.F1Fischer Tropsch

Methanation

Syn fuels

SNG

Ammonia Ammonia

DRI


AL Global E&C Solutions PerspectiveCoal Gasification and its Applications


Lurgi FBDB™ Coal-to-X Syngas

Air Liquide ASU

Lurgi Rectisol ®

GasPurification

Lurgi OxyClaus® Sulfur Recovery

Elemental Sulfur

CO2

Syngas, DRI, Power

Air Liquide LNW Unit

N2

Methanation

Ammonia Syngas

SNG

(Fuel Gas)

Lurgi MPG® Gasification

GasificationLurgiCO Shift /Gas Cooling

CoalPreparation

HP Steam


CO

HydrogenAir LiquideCO 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 LiquidePSA

LurgiMethanol Synth.

Methanol-Propylene

Coal to H2 and NH3: Fujian Gasification Project

ASUGasification

CO-Shift Nitrogen WashAmmonia


78 000 Nm3/h H2 + 900 tpd NH 3

Lurgi Rectisol™& OxyClaus™ PSA

ASU, Gasification, Rectisol™, SRU OxyClaus ™, Liquid Nitrogen Wash,Ammonia Synthesis, PSA, Integration/OSBL

H2NH3


Coal to Ammonia: TGI/SCJ


ASUGasification

Lurgi Rectisol™& OxyClaus™

Nitrogen Wash

Ammonia

ASU, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash

H2 N2180 000 Nm3/h N2+H2


Coal to Propylene: Shenhua Ningxia


ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™

5000 tpd MeOH to each MTP™


ASUGasification

CO-Shift,Rectisol®Oxy Claus ™

Mega-Methanol®

MTP®

Gasification trainMethanol

DMERectisol®

Coal to Methanol and Propylene: Shenhua Ningxia


MTP®

ASURectisol®(4 trains)

Methanol

Synfuels

Methanol train

ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™

Gasification


ASU Lurgi Rectisol ™&OxyClaus ™

Coal to DRI Gas: Jindal Steel and Power

Lurgi FBDB™Gasification


ASU, Lurgi FBDB™ Gasification, Phenosolvan™, CLL™, Rec tisol™, SRU OxyClaus™

Lurgi CLL™

Phenosolvan ™

225 000 Nm3/h CO+H2+CH4H2

COCH4


AL Global E&C Solutions PerspectiveResidue Gasification - MPG®


� 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


■ 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

Multi

Purpose

Gasification

45 years experiencein residue gasification:� 75 units� 62.5 x 106 m3 /d

Pur

chas

es fr

om S

VZ

2001

Ulta

fert

il

2002

HD

PO

X

2005

Nor

th W

est

Upg

rade

r

Residue Gasification References


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

Gasification� 62.5 x 106 m3N/d

2010

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®LurgiCO Shift /

Feed

HP Steam


CO

HydrogenAir LiquideCO Cold Box

Metal Ash Recovery System

GasPurification

Methanation SNG

Metal Ash

Gas Cooling

Air LiquidePSA

LurgiMethanol Synth.

Methanol-Propylene

Waste Water

AL Global E&C Solutions PerspectiveSteam Methane Reforming


World Map & References - Lurgi ReformerTM

HAINAN MethanolLocation: China / HainanProduct: 2.000 mtpd MethanolStart-up: 2006

Degussa Rheinfelden Location: GermanyProduct: 8.000 Nm³/h HydrogenStart-up: 1997

TITAN and ATLAS MethanolLocation: TrinidadProduct: 2.500/5.000 mtpd MethanolStart-up: 1999 / 2004

Messer DormagenLocation: GermanyProduct: 7.000 Nm³/h COStart-up: 2002

GLIMARLocation: PolandProduct: 10.000 Nm³/h HydrogenStart-up: -

YARACO1 / YARACO 2Location: ChinaProduct: 9.200Nm³/h COStart-up: 1998 / 2005

DALIANLocation: ChinaProduct: 72.000 Nm³/h HydrogenStart-up: 2006

PEMEX CadereytaLocation: MexicoProduct: 67.250 Nm³/h Hydrogen

AIR LIQUIDE Gulf Coast SMR H2Location: Texas / USAProduct: 130.000 Nm³/h HydrogenStart-up: 2011 (Project in Progress)

PRAXAIR RichmondLocation: CaliforniaProduct: 204.000 Nm³/h HydrogenStart-up: 2010 (under construction)

LOTOS HGU 2Location: PolandProduct: 100.000 Nm³/h HydrogenStart-up: 2009 (under construction)

AIR LIQUIDE HERACLESLocation: NetherlandsProduct: 130.000 Nm³/h HydrogenStart-up: 2011 (Project in Progress)


Batamas MEGAHLocation: MalaysiaProduct: 3.000 Nm³/h HydrogenStart-up: 1994

BASF – BPC KuantanLocation: MalaysiaProduct: 58.000 Nm³/h SyngasStart-up: 2000

P.T. Kaltim Methanol IndustryLocation: MalaysiaProduct: 2.000 mtpd MethanolStart-up: 1998

Cleveland-Cliffs Location: TrinidadProduct: 41.500 Nm³/h HydrogenStart-up: 1998

PEMEX MaderoLocation: MexicoProduct: 49.170 Nm³/h HydrogenStart-up: 2001

Repsol YPFLocation: ArgentinaProduct: 1.210 mtpd MethanolStart-up: 2002

PMLLocation: Malaysia / LabuanProduct: 5.000 mtpd MethanolStart-up: 2009

Melaka HPU 2Location: MalaysiaProduct: 45.000 Nm³/h HydrogenStart-up: 2008

National Petrochemical Co. (Kharg)Location: IranProduct: 2.000 mtpd MethanolStart-up: 1999

Product: 67.250 Nm³/h HydrogenStart-up: 2000

ZAGROS 1 / ZAGROS 2Location: IranProduct: 5.000/5.000 mtpd MethanolStart-up: 2006 / 2009

SIPCHEM COLocation: Saudi ArabiaProduct: 30.520 Nm³/h COStart-up: 2009

Large Plants Designed by Air Liquide

■ Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA, multi-feed)

■ Largest single-train H 2 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

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


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

Latest References – H2 and CO Plants

Region Feed Capacity (Nm3/h) Scope Award

Europe NG 8 500 CO EPC 2013

Europe NG 14 500 CO60 000 H2

EPC 2012

Europe NG 10 000 CO24 100 H2

EPC 2012

Asia NG 9 800 CO EPC 2010


Asia NG 9 800 CO35 600 H2

EPC 2010

Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA)


Process Gas

Fuel Gas

Combustion Air

Flue Gas

Lurgi Reformer® - Isometric Arrangement


Arrangement Drawing

Hydrogen

Lurgi SMR Feed-to-X Syngas

Air LiquideASU

Air LiquideCO Cold Box

N2

PSA

Ammonia Syngas

SMR

Feed

CO2 Removal

HP Steam


CO

Methanol-Propylene

ATR

Methanol Synthesis

CO Shift

Next Generation Coal Gasification IslandAssociated Technologies


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


■ PSA >70 Hydrogen Purification

■ Methanol: > 50 plants; 9 coal based.■ MTP™ : 2 running

■ Claus : >170 Claus Units■ OxyClaus™ SRU: > 40 burners

Air Liquide: Air Gases■ Operating >350 Air Separation Units

Total gaseous production

> 120,000 tpd

> 95,000 tpd

O2

N


> 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

Air Liquide’s Lurgi FBDB TM

■ Lurgi FBDB TM 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

H2CO CH4


■ 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 coalespecially for SNG production.

H2O

Air Liquide’s Lurgi Rectisol TM

■ > 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


■ 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 applicatio ns!CO2 S

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

H2CON2

CH4


■ 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 purificationsand ammonia syngas preparations all by Air Liquide!

� > 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 operationOverheating of catalyst impossible

CH3OH

Air Liquide’s Lurgi Methanol


� Long catalyst operational life

� Low recycle ratiosHigh steam production

� Safe and uniform temperature control

The outstanding advantage ofLurgi Methanol is the Water Cooled Reactor with superior heat removal ability.

33

Food for Thought and Wrap-up


Value addition

We know…

Air Liquide’s value addition

C CH4

■ Cutting-edge, commercially proven proprietary technologiesaddressing the growing markets for

coal-based & natural gas basedfuels and petrochemicals :


Oxygen

Syngas

and theproducts.

H2CO

O2

CH3OHSynfuel

fuels and petrochemicals :

■ Synfuels/Diesel■ Methanol, DME■ Propylene■ Ammonia■ Hydrogen

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,


� 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 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

4,000 Air Liquide Global E&C Solutions Colleagues Thank You!

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