heavy residue gasification with poly-generation … residue gasification with poly-generation...

Heavy Residue Gasification with Poly-generation Hydrogen Sourcing for Refineries Rotterdam 11/03/2014 l Max-Michael Weiss, Stefan Walter l Air Liquide Global E&C Solutions Germany GmbH

Air Liquide, world leader in gases, technologies and services for Industry and Health 2 11/03/2014 IChemE Rotterdam

General Outline

■ Hydrogen Sourcing for Refineries

■ Comparison on POX technologies

■ Shell PER+ poly-generation set-up

■ North West Redwater Upgrader, an actual POX project

■ Rectisol as an enabler for poly-generation

■ Conclusions


The Air Liquide Group

50,000

employees

Revenue 2013

€15,2 billion

Present in

80 countries

Air Liquide Global E&C

Solutions Germany GmbH


Hydrogen Sourcing for Refineries

■ Produced by the owner:

Steam Reforming of Natural Gas

Partial Oxidation of Heavy Residues

Gasification of Pet Coke

Recovered from Refinery Off-Gases

Or

Delivered Over-The-Fence


Poly-generation by POX of hydrocarbons

■ Definition:

Gasification plant generating several products,

e.g. hydrogen plus power and/or different chemical products

■ Syngas treatment (Shift/ AGR) is the key to the products!

■ Power: < 15 ppm S, max. H2 OR H2 + CO2 (CCS: yes or no)

■ Hydrogen: < 0.1 ppm S, min 97 % H2 (or higher)

■ Ammonia: < 0.1 ppm S, min 98 % H2 & pure nitrogen

■ Methanol: < 0.1 ppm S, H2/CO ~ 2

■ SNG: < 0.1 ppm S, H2/CO ~ 3

■ CCS needed?


POX technologies history

■ Shell Gasification Process – SGP

Lurgi was exclusive licensor until 1997

Last plant w/i this agreement: Shell‘s PER+ hydrogen plant

■ Lurgi Multi Purpose Gasification – MPG®

Originating from SVZ, operated for > 30 years

Active in the market since 1998

Latest plant: NorthWest Redwater Upgrader


Poly-generation : PER+ plant fact sheet

■ Situation beginning of the 90ties:

Refinery economically and environmentally out-dated

Need for up-grading

■ Decision:

New Cracker + new auxilliary Power Plant

Safe baseload-plant for securing Cracker hydrogen needs

All heavy residues to be gasified

Surplus syngas used for electric power production

Full heat-integration of the hydrogen plant & the refinery

Start-up 1998


Poly-Generation POX at Shell Pernis Refinery: PER+

■ Heavy residue feed 1,650 t/d

■ SGP in boiler mode

(only available option)

■ Full heat integration (BFW & steam)

■ Base-load 285 t/d hydrogen

■ Branch-off of un-shifted syngas

before Rectisol fine-wash,

CO2 in syngas as mass-flow to CC

■ Production of 142 MWel

3 * SGP reactor

3 * Effluent boiler

3 * SGP scrubber

Rectisol Treating

CO Shift

Rectisol CO2

Methanation

SARU

Stripper

Oxygen

1,572 t/d

Cracked Residue

1,650 t/d

Steam

825 t/d

BFW

Saturated steam

3,895 t/d

Raw syngas

3,654 t/d

Sour gas

Fuelgas to

Gas turbines

142 MW

CO2

H2

285 t/d

Steam

1,057 t/d

BFW

383 t/d

CO-Shift feed


Lurgi MPG® - Technology Advantages

■ Lurgi MPG® technology, quench and

boiler configuration available

■ Feedstock Flexibility:

No limitations on flash point of

feedstock

Viscosity up to 300 cSt

Particles up to 2 mm

■ Long burner life time results in higher

reliability and availability of plant

■ Inherent safety by pressurized

cooling water system

■ Simultaneous feeding of immiscible

feedstock

Picture:

Operating since 2002 @ Brazil


Lurgi MPG® : Flexibility for Liquids and Slurries, SVZ proven

Component

Actual Operating Ranges:

Quench Configuration

Operating Limits:

Boiler Configuration

Oil Mode

Waste/

Slurry Mode

C % wf 65 – 90 90 65 – 90

H % wf 9 – 14 14 9 – 14

S % wf 6 6 6

CI % wf 2 8 50 ppm (wt)

LHV MBTU/lb

(MJ/kg)

15 – 18

(35 – 42)

2 – 13

(5 – 30)

15 – 18

(35 – 42)

Toluene

insolubles

% wf 6 45

Ash % wf 3 25 0.4

Water % wf 2 5 – 30

Viscosity cSt (at burner) 200 300 200

Particle size mm - 2


Lurgi MPG® - Multi Purpose Gasification - The secrets

Feed

Quench

Water

O2 + Steam

Gas-offtake

Soot Slurry

Feed A Feed B

Steam Cooling Water

O2


MPG application: NorthWest Redwater Upgrader (NWR)

■ Site: 45 km NE of Edmonton,

Alberta Province, Canada

■ Joint Venture between

North West Upgrader and Canadian

Natural Resources Ltd

■ Enhance as the CO2 off-taker

providing the CO2 grid

http://www.northwestupgrading.com/imageviewer.php?pic=/upload/body_image/8/06/unknown.gif


NWR Plant General Setup

■ One out of three phases

Hydrogen

Crude and

Vacuum Unit

Resid

Hydrocracker

Hydrocracker

& Hydrotreater

Multi Purpose

Gasification

Bitumen Blend

Feedstock

77,080 bpd

Dilbit

51,760 bpd

Synbit

25,320 bpd

Courtesy NWR

Diluent and Naphta

32,501 bpd

ULS Diesel

36,178 bpd

LS Vacuum

Gas Oil

8,276 bpd

Butane

771 bpd

High Quality CO2

Hydrogen


NWR Hydrogen Plant Flow Scheme

H2S+CO2

Feedstock

Steam

Carbon Slurry

Air

O2

LP-Steam

Sulfur

Process Water

Air + O2

Claus Off-Gas

Hydrogen

97% pure

Pure, dry CO2 to EOR

148 t/h

Filter cake

Rectisol® MPG®

Quench

Raw Gas

Shift

Gas

Cooling

Metha-

nation

Filter ASU Waste Water

Treatment

Claus

CO2

Compression

3 x 50 %

~ 52 t/h

~ 26 t/h

~ 37,000 Nm3/h

~ 129,000 Nm3/h


NWR Project Status

■ NWU awarded to Lurgi EPC order in 2007/ paused in 2008

■ NWU & CNRL joined to NWR in 2011

■ NWR project sanctioned in November 2012

■ Air Liquide Global E&C Solutions engineering RFC ongoing since

■ NWR final investment decision made in January 2013

■ Air Liquide EPC contract effective December 2013


Lurgi Rectisol® - an enabler for poly generation plants

■ Acid Gas Removal (AGR): Physical Absorption

■ Solvent: Methanol @ low temperatures

■ The standard for high-pure synthesis gas

■ Applicable in combination with sweet or sour CO shift

■ Achieving pure, dry CO2 for sequestration

■ First commercial plant on CCS in gasification:

Dakota Gasification Co. (DGC) 1984

Weyburn > Sequestration by EOR


Lurgi Rectisol® Technology - Shenhua Ningxia 2009


■ Typical Refinery set-up

Acid

Gases

Conclusion: A comprehensive bottom of the barrel solution …

Air Liquide Global E&C Solutions is

capable to solve the “bottom of the

barrel” problems in refineries.

Common Off-Site Facilities

Solvent

De-Asphalting

LPG

Diesel

Power /

HP Steam

Sulphur

Different Oil Fractions

from refinery

Asphalt

Off-

Gases

Vacuum

Residue

from

refinery

CO2 for

sequestration

Chemicals

Hydrocracker

Air Liquide plants:

Integrated Power,

Oxygen, Gasification,

Hydrogen, Chemicals

Steam & Sulphur

Hydrogen


... and a low carbon footprint Refinery

■ Lurgi MPG® heavy bottoms gasification

is a reliable source for hydrogen with

No consumption of Natural Gas

No disposal of coke and asphaltenes necessary

Can take all refinery wastes

■ Lurgi Rectisol® Technology secures high quality products

and pure, dry CO2, ready for sequestration

■ Both together providing the flexible basis for poly-generation

and full integration w/i a refinery

Thank you for your kind attention ! Max-Michael Weiss

Director Innovation, Clean Conversion

Phone: +49 69 5808 3452

[email protected]

Stefan Walter

Head of gasification department

+49 69 5808 1429

[email protected]

heavy residue gasification with poly-generation … residue gasification with poly-generation...

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