recent selexol tm, polysep tm and polybed tm operating … · uop llc, des plaines, illinois, usa...

Recent SelexolRecent Selexol TMTM, PolySep, PolySep TMTM and PolyBedand PolyBed TMTM

Operating Experience with Operating Experience with GasificationGasificationfor Power and Hydrogenfor Power and Hydrogen

Daniel J. Kubek, Curtis R. Sharp, & Douglas E. KuperDaniel J. Kubek, Curtis R. Sharp, & Douglas E. KuperUOP LLC, Des Plaines, Illinois, USAUOP LLC, Des Plaines, Illinois, USA

Michael E. ClarkMichael E. ClarkUOP LLC, Houston, Texas, USAUOP LLC, Houston, Texas, USA

Maurizio Di Dio & Michael WhysallMaurizio Di Dio & Michael WhysallUOP NV, Antwerp, BelgiumUOP NV, Antwerp, Belgium

Gasification Technologies 2002Gasification Technologies 200227 27 -- 30 October 2002 30 October 2002 San Francisco, California, USASan Francisco, California, USA

UOP GTC-01

Technologies for Synthesis Gas TreatmentTechnologies for Synthesis Gas Treatment–– SELEXOL ProcessSELEXOL Process -- Acid Gas RemovalAcid Gas Removal

–– POLYSEP Membrane SystemPOLYSEP Membrane System -- HH22 Recovery and HRecovery and H22/CO /CO AdjustmentAdjustment

–– POLYBED PSA SystemPOLYBED PSA System -- HH22 PurificationPurification

Recent Operating ExperienceRecent Operating Experience–– SARLUX IGCC ProjectSARLUX IGCC Project

at Sarroch, Sardinia, Italyat Sarroch, Sardinia, Italy

–– FARMLAND Ammonia Fertilizer ProjectFARMLAND Ammonia Fertilizer Projectat Coffeyville, Kansas, USAat Coffeyville, Kansas, USA

Presentation OverviewPresentation Overview

UOP GTC-02

Presentation Overview Presentation Overview (continued)(continued)

Case Study:Case Study:Refinery Hydrogen & Power ProductionRefinery Hydrogen & Power Production–– Gasification of Refinery ResiduesGasification of Refinery Residues

for Hydrogen and Powerfor Hydrogen and Power–– Benefits of High Purity HydrogenBenefits of High Purity Hydrogen

for Hydrotreaters & Hydrocrackersfor Hydrotreaters & Hydrocrackers•• Existing unitsExisting units•• Grass root unitsGrass root units

ConclusionsConclusionsUOP GTC-03

Selexol ProcessSelexol Process

Cyclic absorption/regeneration process for Cyclic absorption/regeneration process for selective removal of Hselective removal of H22S, COS, & COS, COS, & CO22

Uses a physical solventUses a physical solvent{Chemical formula CH{Chemical formula CH33O(CO(C22HH44O)O)nnCHCH33 where n is between 3 & 9}where n is between 3 & 9}

SelectivitySelectivity–– HH22S / COS / CO22 ~ 9~ 9–– COCO22 / H/ H22 ~ 76~ 76

55 operating units in syngas and natural gas 55 operating units in syngas and natural gas serviceservice

UOP GTC-04

PolySep Membrane SystemPolySep Membrane SystemGasGas--permeable hollow fiber polymer membranespermeable hollow fiber polymer membranesConcentration (or Recovery) of HConcentration (or Recovery) of H22 and adjustment of and adjustment of syngas Hsyngas H22/CO ratio/CO ratioSeparation based on difference in permeation rates Separation based on difference in permeation rates between Hbetween H22 and impurities (Hand impurities (H22 is fast)is fast)Partial pressure difference Partial pressure difference across membrane provides across membrane provides driving forcedriving forceSupplied as a skidSupplied as a skid--mounted mounted systemsystem~ 40 operating units~ 40 operating units

UOP GTC-05

PolyBed PSA SystemPolyBed PSA SystemPressure Swing AdsorptionPressure Swing Adsorption

Multiple vessels containing adsorbentMultiple vessels containing adsorbentImpurities adsorbed at high partial pressureImpurities adsorbed at high partial pressureImpurities desorbed at low partial pressure to Impurities desorbed at low partial pressure to regenerate bedregenerate bedHH22 recovered at high purity (typically 99 to recovered at high purity (typically 99 to 99.9999 vol%)99.9999 vol%)Supplied as a skidSupplied as a skid--mounted systemmounted system~ 700 operating units~ 700 operating units

UOP GTC-06

Sarlux S.r.L.Sarlux S.r.L.Sarroch, Sardinia, ItalySarroch, Sardinia, Italy

IGCC ComplexIGCC Complex

UOP GTC-07

Sarlux IGCC ComplexSarlux IGCC ComplexFeedstock:Feedstock: 173 T/H visbreaker 173 T/H visbreaker

residue to gasifierresidue to gasifierProducts:Products: 35.8 MM SCFD H35.8 MM SCFD H22

for SARAS for SARAS hydrocracker, 550 hydrocracker, 550 MW electricity, & MW electricity, & sulfursulfur

Commissioning:Commissioning: August 2000August 2000Process LicensorsProcess LicensorsGasification:Gasification: ChevronTexacoChevronTexacoAcid Gas Removal:Acid Gas Removal: UOP SelexolUOP SelexolHH22 Purification:Purification: UOP PolySep UOP PolySep

Membrane & Membrane & PolyBed PSAPolyBed PSA

Sulfur:Sulfur: LurgiLurgiUOP GTC-08

Sarlux Block Flow DiagramSarlux Block Flow Diagram

PolySep Membrane

Gas Cooling& COS

Hydrolysis

ElectricElectricPowerPower

Raw HydrogenRaw Hydrogen

ElementalElementalSulfurSulfur

SteamSteamforfor

ExportExport

OO22

FeedFeedClaus Plant

AirAir

High Purity HydrogenHigh Purity Hydrogenfor SARAS Hydrocrackerfor SARAS Hydrocracker

Gasifierwith Quench& Scrubbing

SELEXOL

Air Separation Unit

Combined Cycle Power

Plant

PolyBedPSA

Tail GasTail Gas

Purified SyngasPurified Syngas

UOP GTC-09

Sarlux Selexol UnitsSarlux Selexol Units

Two parallel UOP Selexol UnitsTwo parallel UOP Selexol Units

UOP GTC-10

Sarlux HSarlux H22 Purification UnitPurification Unit

UOP PolyBed PSA Unit & UOP PolySep Membrane SkidsUOP PolyBed PSA Unit & UOP PolySep Membrane Skids

UOP GTC-11

Sarlux Gas Purification BlockSarlux Gas Purification Block

Operating ResultsFeed Stream 410 MM SCFD (total for 2 trains)Treated Syngas

Product Purity 17 mole ppm H2S + COSto Gas Turbine

Hydrogen ProductH2 Production > 35.8 MM SCFD for HydrocrackerH2 Purity > 99.9 mole %

Acid GasProduct Purity > 60 mole % H2S to Claus

Operating ResultsOperating ResultsFeed StreamFeed Stream 410 MM SCFD (total for 2 trains)410 MM SCFD (total for 2 trains)Treated SyngasTreated Syngas

Product PurityProduct Purity 17 mole ppm H17 mole ppm H22S + COSS + COSto Gas Turbineto Gas Turbine

Hydrogen ProductHydrogen ProductHH22 ProductionProduction > 35.8 MM SCFD for Hydrocracker> 35.8 MM SCFD for HydrocrackerHH22 PurityPurity > 99.9 mole %> 99.9 mole %

Acid GasAcid GasProduct PurityProduct Purity > 60 mole % H> 60 mole % H22S to ClausS to Claus

UOP GTC-12

Farmland IndustriesFarmland IndustriesCoffeyville, Kansas, USACoffeyville, Kansas, USA

Gasification Ammonia ComplexGasification Ammonia Complex

UOP GTC-13

Farmland Ammonia Fertilizer ComplexFarmland Ammonia Fertilizer Complex

Feedstock:Feedstock: 45 T/H petroleum coke45 T/H petroleum cokeProducts:Products: 90 MM SCFD High Purity H90 MM SCFD High Purity H22

10.6 MM SCFD CO10.6 MM SCFD CO22

Commissioning:Commissioning: July 2000July 2000

Process LicensorsProcess LicensorsGasification:Gasification: ChevronTexacoChevronTexacoGas Purification Block:Gas Purification Block:

-- Acid Gas Removal:Acid Gas Removal: UOP Selexol (2UOP Selexol (2--stage unit)stage unit)-- HH22 Purification:Purification: UOP PolyBed PSAUOP PolyBed PSA

Sulfur:Sulfur: Black & Veatch PritchardBlack & Veatch PritchardAmmonia / UAN:Ammonia / UAN: Ammonia Casale / WeatherlyAmmonia Casale / Weatherly

UOP GTC-14

Farmland Block Flow DiagramFarmland Block Flow Diagram

Air SeparationUnit

AmmoniaSynthesis

NN22

PolyBedPSA

UAN Plant

NHNH3 3 ProductProduct

UANUANProductProduct

OO22 High Purity HydrogenHigh Purity Hydrogen Purified COPurified CO22

QuenchGasification

SyngasScrubbing

CO Shift & Gas Cooling

SELEXOL2-stage

Petroleum Petroleum CokeCoke

Tail GasTail Gas

AirAir

Claus Plant

Acid GasAcid Gas

Raw CORaw CO22

CO2Purification

COCO22 VentVentRaw HRaw H22

UOP GTC-15

Farmland Ammonia Fertilizer ComplexFarmland Ammonia Fertilizer Complex

UOP GTC-16

Farmland Gas Purification BlockFarmland Gas Purification Block

Operating ResultsOperating ResultsRaw HRaw H22 from Selexol unit to PSA unitfrom Selexol unit to PSA unit–– > 93 mole % H> 93 mole % H22–– < 5 mole % CO< 5 mole % CO22–– < 1 ppm H< 1 ppm H22S & < 1 ppm COSS & < 1 ppm COS

High Purity HHigh Purity H22 product from PSA to ammonia syngas loopproduct from PSA to ammonia syngas loop–– 90 MM SCFD High Purity H2 (> 99.9%)90 MM SCFD High Purity H2 (> 99.9%)–– 90 % hydrogen recovery90 % hydrogen recovery

Raw CORaw CO22 from Selexol unit to COfrom Selexol unit to CO22 purification reactorpurification reactor–– 10.6 MM SCFD Raw CO2 (> 95 mole %)10.6 MM SCFD Raw CO2 (> 95 mole %)–– < 1 ppm H< 1 ppm H22S & < 10 ppm COSS & < 10 ppm COS

UOP GTC-17

Case StudyCase StudyRefinery Gasification Complex for Refinery Gasification Complex for

Hydrogen & Power ProductionHydrogen & Power Production

UOP GTC-18

Case Study: Refinery Gasification ComplexCase Study: Refinery Gasification Complexfor Hydrogen & Power Productionfor Hydrogen & Power Production

ScopeScopeGasification complex converts Petroleum Coke to SyngasGasification complex converts Petroleum Coke to SyngasUses low value (or negative value) feedUses low value (or negative value) feedPower, steam, and hydrogen produced for export back to Power, steam, and hydrogen produced for export back to the refinerythe refinery–– Production of ultra high purity hydrogen ( > 99.9 mole % Production of ultra high purity hydrogen ( > 99.9 mole %

HH22) for hydroprocessing units) for hydroprocessing units–– Removal of CORemoval of CO22 stream for sequestration and dilution of gas stream for sequestration and dilution of gas

turbine feed (> 98 mole % COturbine feed (> 98 mole % CO22))–– Removal of concentrated HRemoval of concentrated H22S stream to Claus (35 to 65 mole S stream to Claus (35 to 65 mole

% H% H22S)S)

UOP GTC-19


Feed & Product SummaryFeed & Product SummaryFeedstockFeedstock–– 100 T/H petroleum coke100 T/H petroleum coke

ProductsProducts–– 500 MW electricity500 MW electricity–– 80 MM SCFD Ultra High Purity H80 MM SCFD Ultra High Purity H22

–– SteamSteam–– COCO22

UOP GTC-20

Process TechnologiesProcess TechnologiesGasificationGasificationCOS HydrolysisCOS Hydrolysis** on unshifted Syngas to Gas Turbineon unshifted Syngas to Gas TurbineCO Shift on Syngas to HCO Shift on Syngas to H22 PurificationPurificationGas Purification BlockGas Purification Block–– Acid Gas RemovalAcid Gas Removal UOP Selexol (2UOP Selexol (2--stage)stage)–– HH22 Purification: Purification: 99.9 % H99.9 % H22 with PSAwith PSA

95.0 % H95.0 % H22 with Methanatorwith Methanator

Claus UnitClaus Unit* requirement depends on split between power & H* requirement depends on split between power & H22 productionproduction


oror

UOP GTC-21


Study of HStudy of H22 Purity Purity -- Options ConsideredOptions ConsideredOption 1:Option 1:–– Single stage of CO shift with “partial” COSingle stage of CO shift with “partial” CO22

removalremoval–– PSA with 99.9 mol% HPSA with 99.9 mol% H22 puritypurity

Option 2:Option 2:–– Two stages of CO shift with “complete” COTwo stages of CO shift with “complete” CO22

removalremoval–– Methanation with 95 mol% HMethanation with 95 mol% H22 puritypurity

UOP GTC-22

Case Study: Option 1 Case Study: Option 1 -- PSA SystemPSA System

RawRawHH22 PolyBed

PSA

High High Purity HPurity H22

NN22 / CO/ CO22DiluentDiluent

PSAPSATail GasTail Gas

1-Stage CO Shift & Gas

Cooling

Treated Treated UnshiftedUnshifted

SyngasSyngas

Air Separation Unit

COS Hydrolysis & Gas CoolingGasifier with

Quench & Scrubbing

NN22

OO22

Steam for ExportSteam for Export

FeedFeed

AirAir

Acid GasAcid Gas

Tail GasTail Gas


Plant

Claus Plant


Electric PowerElectric Power

NN22

SELEXOL2-stage

UOP GTC-23

Case Study: Option 2 Case Study: Option 2 -- MethanatorMethanator

Low Low Purity HPurity H22

Methanator

RawRawHH222-Stage CO

Shift & Gas Cooling

Treated Treated UnshiftedUnshifted

SyngasSyngas

Air Separation Unit

COS Hydrolysis & Gas CoolingGasifier with

Quench & Scrubbing

NN22

OO22

Steam for ExportSteam for Export

SELEXOL2-stage

FeedFeed

AirAir

Acid GasAcid Gas

Tail GasTail Gas


Plant

Claus Plant


Electric PowerElectric Power

NN22

UOP GTC-24

Advantages of High Purity HAdvantages of High Purity H22 in in Refinery HydrotreatingRefinery Hydrotreating

Advantages of 99.9 % HAdvantages of 99.9 % H22 over 95 % Hover 95 % H22

Minimize capital cost of new hydroprocessing Minimize capital cost of new hydroprocessing unitsunitsMinimize operating costs by extending catalyst Minimize operating costs by extending catalyst life life -- by as much as 100%by as much as 100%Increase throughput of existing unitsIncrease throughput of existing units

UOP GTC-25

Advantages of High Purity HAdvantages of High Purity H22 in in Refinery HydrotreatingRefinery Hydrotreating

Advantages of PSA over MethanationAdvantages of PSA over MethanationPSA removes CO and COPSA removes CO and CO22 to ppm levelsto ppm levelsCO ShiftCO Shift–– 11--stage required for PSAstage required for PSA–– 2 to 3 stages required for Methanation2 to 3 stages required for Methanation

COCO22 Slip in Selexol UnitSlip in Selexol Unit–– PSA allows higher slip (%) since it is not sensitive to CO + PSA allows higher slip (%) since it is not sensitive to CO +

COCO22 levels in feedlevels in feed–– Methanation requires low slip (ppm level) since CO + COMethanation requires low slip (ppm level) since CO + CO22

levels levels >> 1.5 % cause excessive temperature exotherm1.5 % cause excessive temperature exothermPSA can remove NPSA can remove N22 and Ar and Ar -- thus Othus O22 purity is not criticalpurity is not critical

UOP GTC-26

Benefits of 99.9% PSA HBenefits of 99.9% PSA H22 vs. 95% vs. 95% Methanator HMethanator H22 for Existing Unitsfor Existing Units

Existing Hydrotreater #1Existing Hydrotreater #1Basis:Basis: 40,000 BPD operating with 95% makeup H40,000 BPD operating with 95% makeup H22

Benefit:Benefit: 30 vs. 17 month cycle resulting in $500,000/yr30 vs. 17 month cycle resulting in $500,000/yrlower annualized turnaround costlower annualized turnaround cost

Existing Hydrotreater #2Existing Hydrotreater #2Basis:Basis: 16,500 BPD operating with 95% makeup H16,500 BPD operating with 95% makeup H22

Benefit:Benefit: 5 vs. 3.5 year cycle resulting in $100,000/yr5 vs. 3.5 year cycle resulting in $100,000/yrlower annualized turnaround costlower annualized turnaround cost

UOP GTC-27

Benefits of 99.9% PSA HBenefits of 99.9% PSA H22 vs. 95% vs. 95% Methanator HMethanator H22 for Existing Unitsfor Existing Units

Existing HydrocrackerExisting HydrocrackerBasis:Basis: 44,500 BPD operating with 90% makeup H44,500 BPD operating with 90% makeup H22

from Methanator and Platforming net gasfrom Methanator and Platforming net gas

Benefit:Benefit: 4 vs. 3 year cycle resulting in $1.2 million/yr4 vs. 3 year cycle resulting in $1.2 million/yrlower annualized turnaround costlower annualized turnaround cost

oror

Equivalent cycle length and 8% more feedEquivalent cycle length and 8% more feedresulting in $3 million/yr higher profitresulting in $3 million/yr higher profit

UOP GTC-28

Benefits of 99.9% PSA HBenefits of 99.9% PSA H22 vs. 95% vs. 95% Methanator HMethanator H22 for Grass Roots Unitsfor Grass Roots Units

Grass Roots HydrotreaterGrass Roots HydrotreaterBasis:Basis: Hydrotreater for UltraHydrotreater for Ultra--Low Sulfur DieselLow Sulfur Diesel

Production Production -- 5 ppm Sulfur Product,5 ppm Sulfur Product,50,000 BPD capacity designed for 95%50,000 BPD capacity designed for 95%makeup Hmakeup H22

Benefit:Benefit: Equivalent cycle length with 160 psi lowerEquivalent cycle length with 160 psi lowerdesign pressure resulting in 13% lowerdesign pressure resulting in 13% lowercapital cost capital cost -- an $8 million savingsan $8 million savings

UOP GTC-29

UOP Gas Purification Block ConclusionsUOP Gas Purification Block ConclusionsSarlux & Farmland Units DemonstrateSarlux & Farmland Units Demonstrate

UOP Gas Purification Block optimizes acid gas UOP Gas Purification Block optimizes acid gas removal and hydrogen purificationremoval and hydrogen purificationSelexol, PolySep Membrane, & PolyBed PSA are well Selexol, PolySep Membrane, & PolyBed PSA are well suited for gasification servicesuited for gasification serviceHigh overall sulfur recovery (> 99.75%)High overall sulfur recovery (> 99.75%)High HHigh H22S concentration in acid gas to Claus unitS concentration in acid gas to Claus unitBulk COBulk CO22 removal if necessaryremoval if necessaryVery stable operationVery stable operationMinimal operator attention requiredMinimal operator attention required

UOP GTC-30

CoCo--production of Power & High Purity Hproduction of Power & High Purity H22using PolySep Membrane and PolyBed PSAusing PolySep Membrane and PolyBed PSA

in a Refinery Gasification Complexin a Refinery Gasification ComplexHigh Purity HHigh Purity H22 for Existing Hydroprocessing Unitsfor Existing Hydroprocessing Units–– Extension of cycle time to reduce OPEX for HydrotreaterExtension of cycle time to reduce OPEX for Hydrotreater–– Extension of cycle time or increase in capacity for Extension of cycle time or increase in capacity for

HydrocrackerHydrocracker

High Purity HHigh Purity H22 for Grass Roots Hydroprocessing Unitsfor Grass Roots Hydroprocessing Units–– Reduction in CAPEX & OPEX for HydrotreatersReduction in CAPEX & OPEX for Hydrotreaters–– Similar benefit for HydrocrackersSimilar benefit for Hydrocrackers

UOP Gas Purification Block ConclusionsUOP Gas Purification Block Conclusions

UOP GTC-31

Questions?Questions?

UOP GTC-32

UOP GTC-33

recent selexol tm, polysep tm and polybed tm operating … · uop llc, des plaines, illinois, usa...

Documents