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Keys to Optimized & Integrated Poly-Gen Projects
Thomas Haberle , Chris GeraghtyGTC, San Francisco, Oct. 10th, 2011
Linde Overview
Linde Role in Gasification Projects
Recent Examples of Technical & Commercial Integration
Key Learnings & Conclusions
Presentation Outline
Leveraging Synergies
3
The Linde Group Overview
1879
$18 billion
50,000
>100
Linde EngineeringTechnology-focused
Air Separation
Global #1
Hydrogen/Syn Gas
Global #2
Olefins
Global #2
Natural Gas
Global #3
HyCO Tonnage Plants
>70 plants
ASU Tonnage Plants
>300 plants
ECOVAR Std Plants
>800 plants
Linde GasWorld-class operations
Founded
Sales (2010)
Employees
Countries
Clean Coal Gasification Process and Downstream ProductsLinde technology and product coverage
H2
CO
H2/CO
NH3/Urea
SNG
MeOH/MTO
CTL
Power
End Products
Raw Syngas
e.g. Coal Slurry
Slag
O2
FEEDSCoal & Petcoke (CTX)
CO2Steam Traces
Syngas Island
Gas Conditioning
Clean Syngas
Feasibility & Value Integration Studies EPC O&M & BOO
ASU
Shift Rectisol
Sulfur recovery
Extensive & varied projects as well as operations create key know-how for optimizing integration
Operations
Linde operates four (4) gasification/POX units allowing for continuous improvements
Large-Scale ASU’s & Rectisol® Units 65 Rectisol references globally with nearly all
gasification technologies
Extensive experience with wide range of technologies, feedstocks, and product schemes
Over 20 large-scale ASU’s constructed for China-based gasification projects in last 10 years.
Linde ASU’s at two (2) US gasification sites –Dakota Gasification & Coffeyville Resources
Largest ASU scheme ever constructed – 30,000 tpd for Shell-Pearl
Brisbane, AusSingapore Syngas
La Porte Syngas Clear Lake CO
Shell Pearl
Linde Overview
Linde Role in Gasification Projects
Recent Examples of Technical & Commercial Integration
Key Learnings & Conclusions
Presentation Outline
7
The Texas Clean Energy Polygeneration ProjectLinde as EPC-partner for the syngas island
— Economically optimized (urea, power, CO2)— 90% carbon capture, nearly 100% sulfur removal— Significant Linde role as
— EPC contractor for syngas island including gasification, syngas conversion (NH3 & Urea)
— O&M provider together with Siemens
Gasifiers Gas cond.shift, Rectisol
LindeASU
Power plant
CO2compression
Urea plantAmmonia loop
Coal storageand prep.
GOX
GAN
CO2 connection pipeline
NH3
CO2
“H2“
CO2
SG
GAN
Power Off-take
CO2 to EOR
Urea Off-take
PLAR
Coal Supply
Balance of plant H2SO4
Sulfuric AcidOff-Take
H2
Linde EPC/Technology
Gasifier / Power Technology
Owner EPC scope
Gasifiers Gas cond.shift, Rectisol
LindeASU
Power plant
CO2compression
Urea plantAmmonia loop
Coal storageand prep.
GOX
GAN
CO2 connection pipeline
NH3
CO2
“H2“
CO2
SG
GAN
Power Off-take
CO2 to EOR
Urea Off-take
PLAR
Coal Supply
Balance of plant H2SO4
Sulfuric AcidOff-Take
H2
Linde EPC/Technology
Gasifier / Power Technology
Owner EPC scope
The Texas Clean Energy Polygeneration ProjectLinde as EPC- and O&M partner for the syngas island
TCEP ProjectKey Activities to Further Project Competitiveness
Integration of all process units to Optimize business case While retaining flexibility and redundancy
Joint Linde / Siemens RAM and technical risk assessment studies of entire facility
Combining engineering and operations
Comprehensive cost reduction efforts to review all aspects of project jointly by engineering and operations
Teams focusing on design, purchasing, redundancy
Process
Cost
Reliability
Iterative optimisation
TCEPKey Improvements & Overall Results
Some examples of key improvements Optimized syngas utilization (increased urea production) Integrated material selection for entire plant Optimized steam to CO ratio for CO-shift Optimized utility back-up (O2/N2) and intermediate product storage
based on RAM analysis Optimized redundancy 1 x 100% vs. 2 x 100% for Hg absorbers,
H2SO4 plants, CO2 compression, shift configuration
Key Results Over 15% capex reduction on syngas conditioning Optimized process configuration for Reliability / Availability Equipment optimization Alignment of material selections
Optimized integration considering operability, business case impacts
Case Study: SNG, Linde gas conditioning concept with Topsoe methanation
SyngasfromGasification
Shift Gas coolingShifted
SulfurRecovery
ShiftedRectisol
CommonRegeneration
Methanation(TREMP) SNG
Conventional BFD:
SNGSyngasfromGasification
Shift Gas coolingShifted
Gas coolingUnshifted
SulfurRecovery
ShiftedRectisol
UnshiftedRectisol
CommonRegeneration
Methanation(TREMP)
Improved BFD:
Oxygen
8170 sTPD
Coal
7290 sTPD
Coke
3800 sTPD
GASIFICATION
SYNGASCONDITIONING
METHANATION
5.3 MMsTePY
CO2 to Storage
213.000 Nm³/h Synthetic Natural
Gas
Slag750 sTPD
Outside of Project
Scope
Sulfur440 sTPD
Vented until regulatory and economic environment
justify storage.
Source: Conoco Philips / Peabody Presentation Feb. 2008
Conoco Phillips/Peabody Kentucky Coal-to-SNG ProjectLinde: gas conditioning / Topsoe: Methanation
POSCO-SNG ProjectGeneral Information
POSCO SNG PlantProduct:500,000 t/y Pipeline-ready SNG
Purity:98 % purity@70 bar
Gasification:Conoco Phillips E-Gas (2 gasifiers + 1 spare unit)
Gas ConditioningLinde Shift (Topsoe-Catalyst)Linde Rectisol + DesulfurizationTopsoe Methanation
Feedstock:Some 4000 tons/d of Coal and/or Petcoke
Commissioning: Planned for 2013
Case Study:Polygeneration of SNG and NH3 (UREA)
Gasification(entrained flow)Coal Shift
Rectisol
Regeneration
Rectisol
PSAH2 to NH3 loop
Methanation SNG
Fuel
Gasification(entrained flow)Coal Shift
Rectisol
Regeneration
Rectisol
TSA + NWUNH3 syngas
Methanation SNG
Fuel
Gasification(fixed bed)Coal Shift
Rectisol
Regeneration
Rectisol
NH3 syngas
Methanation SNG
Fuel
one combined coldbox
CH4
TSA + NWU
CO+N2 / CH4separation
Technology Focus
Successful Total Solution
Look at the project scheme as a system,not in blocks
Capabilities & Experience
Look at the project as a whole
BUT …
Avoid over-integration
Operability Considerations
Heat
Integration
Reliability vs.
Redundancy
Layout Optimization
Back-up Storage
Optimization
Optimized unit
capacity
Design Margin Optimiz.
Global / Coordinated
Procurement
ASU Merchant Synergies
Importance ofOptimization & Integration
< 20% of people attempting to climb Mount Everest are successful in reaching the summit
… but some do!
How can we get gasification projects over the finish line??
It will not happen without optimization & integration of the overall scheme considering all specific aspects of the case
