Further Development and Commercial Progress

of CFB Gasification and BGL Gasification Technologies

Werner-Fr. Staab, Head of Sales (Thermal Processes)

ENVIROTHERM GmbH, Essen / Germany

werner_staab@envirotherm.de

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Envirotherm’s Gasification Technologies

Why Coal Gasification in India?

• Demand for clean gas in various industries for

o production of ammonia, methanol and other base chemicals

o power generation

o heating purposes

• Lack of sufficient natural gas resources

• Abundant coal reserves

Envirotherm’s solution:

• Two proprietary gasification technologies

o CFB Gasification: Circulating Fluidized Bed

o BGL Gasification: Slagging Fixed Bed

state of the art technologies with

distinct advantages for multiple applications

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Envirotherm’s Gasification Technologies

Crude Gas

Recycling

Cyclone

Fuel

Nozzle Grate

Ash

Seal Pot

CFB

Gasifier

BGL Gasifier CFB Gasifier

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BGL Gasification: Main Features

• high pressure, oxygen blown fixed bed slagging

gasifier, for application in chemical/power industry

• high cold gas efficiency

• high carbon conversion

• low oxygen and steam consumption

• low gas condensate production

• non-leachable vitrified slag; for reuse

• medium calorific syngas

• fuel flexibility: nearly all types of (high ash) coal

and other carbonaceous fuels, e.g. waste

• increased specific reactor throughput

• higher fines content acceptable in feed

• optional recycle of tars/oils to extinction

• gasifier vessel is made from mild steel

• modular design (spare/reliability)

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Crude Gas

Recycling

Cyclone

Fuel

Nozzle Grate

Ash

Seal Pot

CFB

Gasifier

CFB Gasification: Main Features

• fuel flexibility: nearly all types of (high ash) coal

and other carbonaceous fuels, e.g. waste

• gasifier vessel is made from mild steel

• modular design (spare/reliability)

• near atmospheric circulating fluidized bed

gasifier, well suited for fuel gas production

• air blown gasifier, no ASU required

• low calorific syngas

• excellent heat and mass transfer due to high

turbulence of inert bed inventory

• high thermal stability

• high carbon conversion

• HP steam production

• bottom ash can be reutilized

• low requirement for fuel preparation

ENVIROTHERM

• Increase in reactor diameter to 4.2m higher throughput

• Increase in operation pressure (up to 40bar) higher CH4 content, less tars and oils

• Stirrer implementation for caking coals, if required

BGL Gasifier: Development

6

0

1

2

3

4

5

200 400 600 800 1000 1200 1400 1600 1800 2000

Gasif

ier

inn

er

dia

mete

r in

m

Fuel throughput in t/d

Plant Start up Feedstock

BGL 1 1975 Coal

BGL 2 1981 Coal

BGL 3 SVZ 2000 Coal & up to 80% Waste

BGL 3 Hulunbeier 2011 Lignite

BGL 3 Yituo 2012 Hard coal

BGL 3 Shriram 2013 High ash hard coal

BGL 4 project Lignite

BGL 1

BGL 2

BGL 3

Yituo BGL 3

SVZ

BGL 3

Shriram

BGL 3

Hulunbeier

BGL 4

Development Phase Commercial Phase

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• Fluid bed technology was developed in the early 1920s

• Circulating Fluidized Bed (CFB) process was developed applying high “slip velocity”,

was introduced to power plants and the process was applied to gasification of various

feedstock

• Proven technology with numberless references

• Envirotherm’s reference plants include

o first CFB gasification in the cement industry – Ruedersdorf, Germany

o CFB gasification of high ash Indian coal – Barbil, India

Next steps will be taken for achieving

• increased unit capacities to reduce specific gas costs;

• improved gas quality by application of oxygen rather than air as gasification agent.

CFB Gasifier: Development

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Current Contracts

Envirotherm’s Gasification Technologies

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Current Contracts

China

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BGL Gasifier

Current Contracts – Hulunbeier

Client Yuntianhua United Commerce Co., Ltd. Kunming, Yunnan, PRC

Hulunbeier New Gold Chemical Co., Ltd., Hailaer, Hulunbeier, Inner Mongolia, PRC

Location of facility Hulunbeier, Inner Mongolia, PRC

Application Syngas for the production of 500,000 t/y Ammonia & 800,000 t/y Urea

Feedstock Domestic dried and briquetted lignite

Features Two (2) + one (1) BGL gasifiers (40 bar (g) operating pressure)

Synthesis gas production 119.000 Nm³/h (H2+CO)

Scope of Supply Process Design Package for gasification and gas liquor separation

Plant erection and commissioning assistance

Process performance guarantees

Start-up (expected) Summer 2011

Project challenges Construction only during summer months possible

(winter temperatures approaching -45 °C)

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Progress Site clearance and civil work commenced: May 2008

Process Design Package delivered: 4th Quarter 2008

Detailed Design completed: 3rd Quarter 2009

Gasifier installations on site: 2009-2010

Classroom training for operational staff: August 2010

Court

esy o

f H

ulu

nbeie

r N

ew

Gold

Chem

ical C

o.

Ltd

.

BGL Gasifier

Current Contracts – Hulunbeier

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Gasifier Reactor Transport over more than 1,000 km Distance

Court

esy o

f T

Z E

ngin

eerin

g C

o.

Ltd

.

BGL Gasifier

Current Contracts – Hulunbeier

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Gasifier Building (2010)

BGL Gasifier

Current Contracts – Hulunbeier

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View to Gasifier Building (2010)

BGL Gasifier

Current Contracts – Hulunbeier

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Client China Yituo Group Co. Ltd., Luoyang, Henan Province, PRC

Location of Facility Luoyang, Henan Province, PRC

Application Fuel gas for industrial complex

Feedstock Local hard coal

Features One (1) + one (1) BGL gasifiers

Gas production 43.000 Nm³/h

Scope of Supply PDP for gasification, gas cooling and gas liquor separation

Plant erection and commissioning assistance

Process performance guarantees

Start-up (expected) 2012

Progress Process Design Package delivered in April 2010

Detailed Design commenced in August 2010

BGL Gasifier

Current Contracts – Yituo

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Current Contracts

India

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Client Shriram EPC Ltd., Chennai, India

Location of Facility Dhamra, Orissa, India

Application Syngas for the production of synthetic ammonia

Feedstock High ash domestic hard coal (132 t/h, 3,200 t/d)

Features Two (2) BGL gasifiers, one relocated from Germany, second gasifier

built identically to relocated one

Raw gas production 150.000 Nm³/h

Scope of Supply Relocation and reengineering for existing BGL,

Basic engineering for new BGL

Plant erection and commissioning assistance on request

Process performance guarantees

Project management for downstream ammonia plant

Start-up (expected) 4th Quarter of 2013

Progress Basic Engineering completed 4th Quarter 2010

Existing BGL Gasifier transported to India in September 2010

Existing ammonia currently on the way to India

BGL Gasifier

Current Contracts – Shriram EPC

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Dismantling of the former SVZ BGL Gasification for Relocation

BGL Gasifier

Current Contracts – Shriram EPC

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Client Jindal Steel & Power, Ltd., Delhi, India

Location of Facility Barbil, Orissa, India

Application Producer gas for pellet plant

Feedstock High ash domestic hard coal (46 t/h, 1,100 t/d)

Features Two (2) CFB gasifiers

Raw gas production 98.000 Nm³/h

Scope of Supply Basic Engineering for gasifier island

Commissioning assistance

Process performance guarantees

Start-up 2010

Progress Gas successfully produced in 4th Quarter 2010

Optimization in 2011

CFB Gasifier

Current Contracts – Jindal Steel & Power

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Solid

Fuel

Bed

Material

Bed Ash

Air

Air

Air

Air C.W.

C.W.

Cyclone CFB

Gasifier

Radiation

Pass

Turbine / Generator

Steam Drum

Deaerator

Su

pe

rhe

ate

r

Eva

po

rato

r Quench

Wet ESP

Clean Fuel Gas

Recirculation Pump

Ash Tar

Dust

Water

Prim. Air

Sec. Air

C.W.

Seal Pot

Water

Features and Principle Flow Sheet:

• location: Barbil, Orissa / India

• number of gasifiers: 2

• feedstock: Indian hard coal, 27% ash, 8% moisture, 23t/h per gasifier

• producer gas: 49,000 Nm³/h per gasifier

CFB Gasifier

Current Contracts – Jindal Steel & Power

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BGL Gasifier:

• unique gasifier design offers major advantages including high fuel flexibility

and low consumption of steam and oxygen

• applicable for all gasification routes

• currently seven gasifiers under construction or in detailed design phase for

production of fertilizers, fuel gas and chemical base products

• start up of first multiple train BGL gasifier plant in mid 2011

CFB Gasifier:

• high fuel flexibility, esp. for high ash coal

• smooth operation, no temperature peaks

• simple and robust design, running reference plants

• economic solution for low calorific fuel gas production

• optimization on high ash Indian coal in 2011

BGL and CFB Gasifier: Summary

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Envirotherm GmbH

Ruhrallee 185

D – 45136 Essen

info@envirotherm.de

www.envirotherm.de

Phone +49 201 6346 400

58 m

(190 ft)

0 m

20 m

(66 ft)

Thank you

for

your attention!