integration of kbr’s trig & ammonia technologies – … · integration of kbr’s trig &...
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Integration of KBR’s TRIG & Integration of KBR’s TRIG & Ammonia Ammonia Integration of KBR’s TRIG & Integration of KBR’s TRIG & Ammonia Ammonia Technologies Technologies –– Low Rank Coal Low Rank Coal to to AmmoniaAmmonia
©2015 KBR, Inc. All Rights Reserved 1
Manoj Nagvekar
Structure Structure –– Streamlined / FocusedStreamlined / Focused
KBRKBR
Technology & C lti
Technology & C lti
Engineering &Engineering & GovernmentGovernmentConsultingConsulting ConstructionConstruction ServicesServices
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Technology & Consulting BusinessTechnology & Consulting Business
KBR Technology& Consulting
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Portfolio OfferingsPortfolio OfferingsDownstream & Syngas TechnologiesDownstream & Syngas Technologies
Veba�Combi�Cracking�(VCC™)• Convert�Heavy�Hydrocarbon�Streams�to�Fuels• Produces On-Spec Fuels with 95%+ Once-Produces�On Spec�Fuels�with�95%+�Once
Through�Conversion
KBR Catalytic Olefins Technology (K-COT™)KBR�Catalytic�Olefins�Technology�(K-COT )• Highest�Propylene-to-Ethylene�Ratio• Flexibility�to�Process�High- or�Low-Quality�
Feedstocks
Fertilizer�Technology• Global�Market�Leader�in�Ammonia�Technology
O 200 Pl t Gl b ll• Over�200�Plants�Globally• Energy�Efficient�Technology
Transport�Integrated�Gasification�(TRIG™)• Only�Gasification�Technology�Designed�to�
Process�High-Moisture,�High-Ash�Coals
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g , g• Chemicals,�Synthetic�Natural�Gas,�or�Power�
Applications
KBR Technology KBR Technology BBusiness usiness SSegmentsegments
SScope• Licensed Technology
• Proprietary Equipment and Catalysts
Refining
Olefins • Proprietary Equipment and Catalysts
• Basic Engineering and Design
• Support for Detailed Engineering
Chemicals
Ammonia and Syngas
• Commissioning and Start-Up Services
• Plant Operations Management Systems
Coal Monetization
Automation and Process T h l gi • Operator Training Simulators
• Technical Services and Studies
• Revamping and Retrofits
Technologies
Proprietary Equipment
• Revamping and Retrofits
©2015 KBR, Inc. All Rights Reserved 5
OutlineOutline
KBR TRIG™ Coal Gasification Technologygy
• Low Rank Coal – A Low Cost Feedstock Opportunity
• KBR’s Technology Solution for Low Rank Coals
• KBR’s Coal to Ammonia Process
• Coal to Ammonia Economics
• TRIG Projects• TRIG Projects
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Feedstock for AmmoniaFeedstock for Ammonia
GLOBAL AMMONIA CAPACITY
Source: International Fertilizer Association 2012
205.2 Million tonnes, 2012
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Syngas for AmmoniaSyngas for Ammonia
Ammonia is very price
y gy g
o a s e y p cesensitive
TRIG uses inexpensive TRIG uses inexpensive feedstock for syngas production
KBR Coal to Ammonia process is robust and energy-efficient
Low CAPEX and OPEX due to KBR Integration
©2015 KBR, Inc. All Rights Reserved 8
TRIG TRIG developed by developed by KBR, KBR, Southern Southern Company with support from U S Company with support from U S DOEDOECompany with support from U.S. Company with support from U.S. DOEDOE
KBR-Southern Alliance:TRIG Collaborative blending of skills
and strengths of each company
Technology available for Industrial and Power applications of TRIG using low-rank coalsof TRIG using low rank coals
KBR leads marketing and licensing activitieslicensing activities
TRIG: Advanced gasification technology solution ready to unlock the potential of low rank coals for you!
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Proven Technology Proven Technology Platform for Platform for Low Low R k C lR k C lTRIG Leverages Long History of Fluid Catalytic Cracking (FCC) Expertise
Rank CoalsRank Coals
Late1930s
FirstCommercial
FCC Unitfor Exxon
1942
1951
Orthoflow™A Design
Orthoflow™C D i
Early1960s
C Design
ResidFCCs
19761980s 1990 1996 1996 2014
Orthoflow™ F Design
Design Based Pilot Plant Grand Forks, ND PSDF at TRIG In Kemper on FCC Technology
Tech Center 2,600 Hours Test Run
Wilsonville, AL. >14,600 hrs in gasification >2,200 hrs on Mississippi Lignite thru Dec ‘09
County, MS, USA , DongGuan, China& Inner Mongolia, China
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TRIG: The TRIG: The beginning of opportunitiesbeginning of opportunities
Syngas for DRI / St lTM Cyclones Syngas
SNG
DRI / SteelTM
CTL
SNG
Liquid Fuels
Chemicals/C l
Riser
Loop -seal
Coal
Chemicals/Fertilizers
O 2/AirSteam
CoalStandpipe
J -LegJ -Leg
CoalPower
Ash O2/Air
Char
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TRIG specifically developed for low rank coals!
KBR Proprietary Coal to Ammonia KBR Proprietary Coal to Ammonia ProcessProcess
Syngas Generation using
Transport Gasifier + Syngas +KBR Ammonia
SynthesisTransport GasifierTechnology
(TRIG)
+ Purification + Synthesis Technology
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Syngas Generation via TRIGSyngas Generation via TRIGy gy gAIR
ASUN2
HP STEAM
KBR SYNGAS PARTICULATE
O2STEAM 98.0 mol%
TO SYNGAS TREATMENT
TRANSPORT GASIFIER (TRIG)
SYNGAS COOLER CONTROL
DEVICE
TREATMENT
COAL PREPARATION &
COARSEASH
FINEASHPREPARATION &
MILLING BFW
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COAL FEED
Syngas CoolerSyngas Coolery gy gAIR
ASUN2
HP STEAM
KBR SYNGAS PARTICULATE
O2
TO SYNGAS TREATMENT
STEAM ~ 980 0C ~ 370 0C
TRANSPORT GASIFIER (TRIG)
SYNGAS COOLER CONTROL
DEVICE
TREATMENT
COAL PREPARATION &
COARSEASH
FINEASHPREPARATION &
MILLING BFWS
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COAL FEED
Particulate ControlParticulate ControlAIR
ASUN2
HP STEAM
KBR SYNGAS PARTICULATE
O2STEAM
TO SYNGAS TREATMENT
TRANSPORT GASIFIER (TRIG)
SYNGAS COOLER CONTROL
DEVICE
TREATMENT
COAL PREPARATION &
COARSEASH
< 0.1 ppmw particulates
FINEASHPREPARATION &
MILLING BFWS
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COAL FEED
Syngas PurificationSyngas Purification
CO2H2SCO ~ 2.0 – 4.0 mol%COS ~ 1 – 10 ppmv
CO + H2O CO2 + H2
COS + H O CO + H S 22COS + H2O CO2 + H2S
SOUR GAS SHIFT
(TWO STAGE)
WASTE HEAT RECOVERY
MERCURY REMOVAL
ACID GAS REMOVAL
UNIT
SYNGASFROM
STEAM
S/G ~ 1.0 CO2 ~ 2.0 - 5.0 mol%H2S ~ 0
SYNGAS SATURATOR
FROM PCD
PSACONDENSATE
TAIL GAS TO FUEL
HS/G H2
BLOWDOWN
S/G ~ 0.2 H2 > 99.5 mol%
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KBR Ammonia Synthesis LoopKBR Ammonia Synthesis Loop
Synloop Purge to NH3 Scrubber/PSA
SyngasCompressor
N2 from ASU
RefrigerationC
p(2-stage)H/N = 3.0
H2 from PSA
Compressor
HP Steam15500
kPa
BFW
UnitizedChiller
CWHorizontalMagnetiteConverter
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Converter (3-Bed) Ammonia Product
Advantages of KBR Coal to Ammonia Advantages of KBR Coal to Ammonia PPProcessProcessFlexibility of Feedstock
S it bl f t b d t l t t Suitable for most abundant, lowest cost coals
Suitable for high ash coalsIncreased Gasifier Reliability Lower operating temperature No internals 60+ years of successful FCC experience No Spare Required
Lower Capital CostLower Capital Cost Compact gasifier design Less expensive materials of construction Single TRIG for up to 2000 MTPD NH Single TRIG for up to 2000 MTPD NH3
No slag handling equipment KBR Synloop – lower pressure drop, fewer
equipment items
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equipment items
Advantages of KBR Coal to Ammonia Advantages of KBR Coal to Ammonia PPHigher Energy Efficiency
ProcessProcess
High carbon conversion> 99% typical High g d h t High grade process heat recovery
Medium-low grade process heat recovery recovery
High Quality Syngas Particulate free Negligible tars and oils
Environmentally Friendly No black ater No black water Low net water requirement Efficient CO2 capture
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Efficient CO2 capture
Economic ConsiderationsEconomic Considerations
Lower OPEXo e O Lower specific energy
consumption Suitable for lowest cost,
most abundant coals TRIG has high reliability TRIG has high reliability
Lower CAPEX Single TRIG up to 2000 g p
MTPD NH3
KBR Synloop with fewer equipment
Expected cost lower than competing designs
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competing designs
Coal to Ammonia Coal to Ammonia -- EconomicsEconomics
Basis: 2000 MTPD Ammonia
Coal Feed: ~4200 MTPD (~ 4100 kcal/kg HHV arb)
Coal Price: $20/MT
Estimated Cost of Ammonia Production: $295/MT/
Current Price is approximately $500/MT
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Coal to Ammonia Coal to Ammonia -- Impact on Project Impact on Project E iE iEconomicsEconomics
Cost Basis: Capital Structure: Tax rate: 25%
60% Debt / 40% Equity China Cost of Financing: 8%
Cost Basis: Capital Structure: Tax rate: 25%
Variation in Cost of Ammonia Production, $/MT
©2015 KBR, Inc. All Rights Reserved 22
KBR Gasification Projects KBR Gasification Projects –– Global Global F iF i
Berun TRIG In Operation
I C t tiBasic Design
FootprintFootprint
In ConstructionEst’d Start-up
UND Pilot
PSDF Demo SKI PilotYanchang Demo
Kemper TRIGIGCC Project
DongGuanTRIG IGCCTRIG IGCC
PSDF Demo
DongGuan IGCC 1600 MTPD
Berun TRIG
Yanchang Demo100 MTPD
PSDF Demo50 MTPD
1996 2012 2013 2015 2016 2017 2018 20192011
Berun TRIG1000 MTPD
2014UND Pilot SKI Pilot
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Kemper TRIG IGCC 582 MW
3 MTPD 3 MTPD
TRIG 600 TRIG 600 MW Lignite IGCC MW Lignite IGCC Project:Project:Mi i i i USAMi i i i USAKemper County IGCC Project
Mississippi, USAMississippi, USA
Plant owned and operated by Mississippi Power Company (MPC) d th S th t (MPC) and the Southeast Mississippi Electric Power Authority (SMEPA)
Lignite-fueled 2-on-1 Integrated Gasification Combined Cycle (IGCC) facility using air blown (IGCC) facility using air-blown TRIG gasification
65% CO2 capture (EOR use)65% CO2 capture (EOR use)
Commissioning in progress
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Kemper County TRIG IGCC OverviewKemper County TRIG IGCC Overview 2x1 Integrated Gasification Combined Cycle (IGCC)
– 2 Transport Gasifiers2 Siemens SGT6 5000F CTs– 2 Siemens SGT6 - 5000F CTs
– 1 Toshiba Steam Turbine– 582 MW peak and 524 MW on syngas
Heat Rate: 12 810 kJ/kWh
Plant SitePlant Site
– Heat Rate: 12,810 kJ/kWh– UOP’s Selexol Process for H2S and CO2 removal– Haldor Topsøe’s Wet Sulfuric Acid for H2SO4 production – 65% CO2 capture (~360 kg/MWh emission rate)65% CO2 capture ( 360 kg/MWh emission rate)– Mine Mouth Lignite
Owner & Operator: Mississippi Power
B P d t ( t i t ) By-Products (metric tonnes per year)
– 2,720,000 Carbon dioxide used for EOR– 122,000 Sulfuric acid– 18,000 Ammonia
Kemper Lignite CompositionAverage Range
LHV kcal/kg 2572 2317 – 2854Moisture % 45 5 42 – 50
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Moisture % 45.5 42 – 50Ash % 12 8.6 – 17
Sulfur % 1 .35 – 1.7
Key Startup Milestones Key Startup Milestones CompletedCompletedKey Milestones
Completion Date
Admin/Control Building - DCS Control System Functional
21-Sep-12
Start Filling Treated Effluent Reservoir 15-Oct-12 Station Service Energized 8-Nov-12 Water Treatment Plant Commissioning
Completion 30-Mar-13
C li g T C l ti 10 A 13 Cooling Tower Completion 10-Apr-13 Fire Auxiliary Boiler 5-Aug-13 First Fire Combustion Turbine – A 28-Aug-13 First Fire Combustion Turbine – B 4-Sep-13 Steam Turbine – Sync To Grid 5-Oct-13Steam Turbine Sync To Grid Gasifier First Fire – A and B 5-Mar-15• Reliable Syngas To Combustion Turbine A TBD• Reliable Syngas To Combustion Turbine B TBD
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