Air Liquide Gasification Development -...
Transcript of Air Liquide Gasification Development -...
Air Liquide Gasification Development
International Freiberg Conference Update 2015
Air Liquide Global E&C Solutions l Dr. Stephan Schwinghammer, Frederic Judas & Daniel van der Merwe
Market success respects diversity
■ Diverse capabilities of Air Liquide by example:
China: Coal to ammonia
China: SNG optimized for water scarcity
India : DRI
Africa: Large ASU capacity
Asia: Remote manufacture of large ASUs
The Americas: Latest applications of our residue gasifierpp g
Middle East: IGCC syngas from residue gasification
Europe: Next generation green syngas Europe: Next generation green syngas
■ For diverse requirements of global market
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Air Liquide global diversity
Large Industries Industrial MerchantAir gases and hydrogen15-year contractsPipeline networksIndustrial basins
Bulk and cylinder gases80 countriesWide variety of sectors and customer sizesIndustrial basins
ElectronicsC
Healthcare Other activitiesCarrier gasesSpecialty gases Equipment and Installations
HospitalsHomecareHygiene
Welding & CuttingDivingSpecialty chemicals
Global E&C SolutionsDesign, Engineering & Construction
of leading-edge processing facilities
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Proprietary heavy carbon technologies
N2
SNG/LNGAir
SeparationLurgi OxyClaus™
Sulfur RecoveryElemental Sulfur
CO2
Lurgi MPG™
Gasification Lurgi
MegaMethanol™
Lurgi Rectisol ™
AGR H2 / CO
Cryogenics
SeparationAmmonia SyngasLurgi FBDB™
GasificationCO Shift
Gas Cooling
Lurgi
MegaDME™CO
CoalAGR H2 / COGasification Gas Cooling
Lurgi MTP™
AcrylicPSA
H2
Lurgi
GLS Process™
Lurgi Phenosolvan ™ & Lurgi CLL™
With ZLD Gas Liquor Recovery
Rectisol Naphtha
Phenols GTL.F1
FT
Acid
Liquid Ammonia
Water Re use (ZLD)
Clear Tar / Oil
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Water Re use (ZLD)
Global technology integration for syngas products
innovates, develops, designs, builds, owns and operates
ASUGasification
CO-Shift Nitrogen WashAmmonia
Lurgi Rectisol™& OxyClaus™
PSA
• Above example 78 000 Nm3/h H2 + 35 tpd NH3 HNH3
• Client-specific product slate and project scope • Typical variations: CO-coldbox, PSA, NWU, NH3• Optimal technology selection and integration is project-specific
G ifi t h l l t d f ti l j t TCO d li bilit
H2
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• Gasifier technology selected for optimal project TCO and reliability
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Fujian: Full HyCO OTF based on coal gasification
Liquid ammonia
Cooling water, Electrical substation, flare, BFW, buildings ( warehouse, admin, canteen, etc.)
ASUN2
NH3 synthesis
Liquid ammoniaN2, IA & plant air
Gasification CO Shift Rectisol
NWURawgas
O2
Hydrogen
PSA
Coal Milling
and Drying
CoalCO2
Acid Gas
PSA
Coal Blending
Water pre- treatment
Air Liquide China Scope SRU
WW to
110 kV, demin water, Steamraw water Fire water
All by-products (slag & S cake & HP steam)
WW to Industry park
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raw water, Fire water
Development of Lurgi FBDBTM coal gasifier
1st Generation from 1932 (29 MWHHV)• Capacity: up to 10,000 Nm3/h• Design Pressure: 20 barg
I Di t 1600 2600
1932
• Inner Diameter: 1600-2600 mm• Height: 6000-8000 mm
2nd Generation from 1952 Lurgi Mark1-3 (117-147 MWHHV)• Capacity: 13,000-20,000 Nm3/h
D i P 20 30 b
1952• Design Pressure: 20-30 barg• Inner Diameter: 2600-3660 mm• Height: 6800-8400 mm
3rd Generation from 1969 Lurgi MkIV™ (240 MWHHV)1969 3rd Generation from 1969 Lurgi MkIV (240 MWHHV) • Capacity: up to 65,000 Nm3/h• Design Pressure: 30-34 barg• Inner Diameter: 3848-3862 mm• Height: 12,500 mm
L i MkV™ (340+ MW )1978 Lurgi MkV™ (340+ MWHHV) • Capacity: 90,000 Nm3/h +• Design Pressure: 30 barg• Inner Diameter: 4700 mm• Height: 12,500 mm
1978
4th Generation from 2011 Lurgi MK+TM (500 MWHHV) • Capacity: 120,000 Nm3/h• Design Pressure: 60 barg• Inner Diameter: 4700 mm• Height : 17,000 mm
2011
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Height : 17,000 mm
Benefits for Coal to SNG projects
■ Lurgi MK+™: innovative use of referenced technology prevents scale gy pup risks
■ Improved Opex and lower Capexcompared to MkIVTMcompared to MkIVTM
Higher direct production of CH4 Reduced coal, O2 and HP Steam
iconsumption Higher thermal efficiency
■ 10 to 15% decrease of the SNGO2 O2
%cost versus MkIVTM
■ Part of the SNG is produced byETF gasification for coal fines
LurgiFBDB™ MK+™
Coarse Coal Rectisol™ Methanation50% to 75%
SNG
ETF gasification for coal fines(ETF: 50% higher SNG cost)
Fine coal ETF Rectisol™ MethanationSNG
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Resource challenge: gasification vs water
Catch 22: In many cases, coal resources exist in reversedistribution to water: Where coal aggregates, water is scarce Where water aggregates, coal is scarce
vs.
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China prioritizes water resource management!
vs.
Strict water resources impact assessments for gasification projects Water-saving technology to improve water-saving water-use efficiency Water-saving technology to improve water-saving, water-use efficiency New environmental management measures to treat/prevent water contamination Tight guidelines developed by NDRC
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From Gas Liquor to Zero Liquid Discharge
Air Liquide unique solution
CO Shift &Gas Cooling
Coal
SteamRaw syngas Lurgi FBDB™
Gasification
Gas condensates
S l t dR f d Selected technologies forcomplete waste
water purification
Referenced technology for Phenols and
Ammonia removal water purificationAmmonia removal
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Global technology integration for ZLD
Full chain of purification of the water
CO Shift &Gas Cooling
Coal
SteamRaw syngas Lurgi FBDB™
Gasification
Gas condensates
Gas LiquorDephenolized
Gas LiquorStripped
Gas Liquor
Zero LiquidDischarge
Gas LiquorSeparation
Phenosolvan™Phenols Recovery
CLLTM
NH3 RecoveryWaste Water
Treatment
Liquid AmmoniaCrude PhenolsClear Tar / Oil
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qPhenols
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Technology selection for ZLD
Achievement: Global solution for optimal technology train
MUTAG (Multi Umwelttechnologie AG ) for bio-treament■ Reduction of COD by 90%
G d f ( Dilli G )■ Good references (ex: Dillingen, Germany)■ 2 step process: protection of the nitrification bacteria
Aquatech for post treatment■ References in China (Tuke, YTH, Shenhua Xinjian)
(54 Zero Liquid Discharge Systems around the world)■ Possibility to reach high quality water with the HERO system (advanced
reverse osmosis process)
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Coal to syngas for DRI
• FT Products
■ Lurgi FBDBTM Gasification
Chemicals / Fuels
Chemicals / Fuels
• FT Products• Ammonia• Methanol• Hydrogenyd oge
Steel Industry
Steel Industry • Reduction Gas for DRI
IndustrialIndustrialIndustrial Gas
Networks
Industrial Gas
Networks
• Synthetic Natural Gas (SNG)
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Coal to DRI Gasification Project Completion■ Customer: JSPL■ Location: Orissa, India
D i d t
Plant in commercial operationProduction of DRI syngas on May 27th 2014
■ Design process data: Sub. Coal 35% ash 7 Lurgi MkIV™ gasifiers
Lurgi MkIV™ Gasifiers Lurgi CLL™
g g 225,000 Nm3/h DRI SG LHV: 3,500 kcal/Nm3
H2/CO ti 1 7 H2/CO ratio: 1.7■ Scope for complete gas
island - gasification, Lurgi Phenosolvan™ gRectisol™ , SRU PDP / BE / DE Prop Equipment supply Prop Equipment supply Operators training Start-up assistance
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Air Liquide oxygen supply to coal gasification
SASOL South Africa
5000 tpd
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Africa CtL: A new record ASU capacity
■ Customer Name : Sasol■ Project Scope : OTF■ Project Scope : OTF■ Products : Oxygen & Argon■ Location : Secunda, South Africa■ Capex : Euro 200 million■ Commissioning : December 2017
■ 5 000 tpd oxygen from 0,83 bar atmosphere■ Equivalent to 5 800 tpd oxygen at sea level■ Argon and limited oxygen is for Air Liquide offtake
R li bilit f t d f ll it li i th TCO d t■ Reliability, safety and fully capitalizing the TCO advantage:■ At this capacity requires real expertise and innovation
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Innovation: Our Remote Manufacturing Yard (RMY)
RMY at a glance:● Mobile solution for manufacturing and delivering large Air Separation Unit pressure vessels● Mobile solution for manufacturing and delivering large Air Separation Unit pressure vessels● Dismountable workshop, located close to our end-user customers, anywhere in the world● Present location: Xinjiang, China● Operational status: Delivering equipment since 2014.
Purpose and Missions:● Provide manufacturing flexibility and agilityg y g y● Serve all parts of the world, specifically landlocked areas● Reduce the logistic risks of large equipment to remote areas ● Meet our customers’ needs by increasing our proximity
Develop new approach and manufacturing differentiation in our offer
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● Develop new approach and manufacturing differentiation in our offer
Lurgi MPG™: 40 years residue gasification experience
■ Lurgi MPG™ technology quench and boiler configuration availableg
■ Feedstock Flexibility No limitations on flash point of
feedstockfeedstock Viscosity up to 300 cSt Particles up to 1 mm
■ Long burner life time results in higher reliability and availability of plant
■ Inherent safety by pressurized■ Inherent safety by pressurized cooling water system
■ Simultaneous feeding of immiscible f d t kfeedstock
■ Commercial NH3 syngas since 2002■ New generation operational now
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■ New generation operational now
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NWR Upgrader general setup
■ One out of three phasesDiluent and Naphta
Bitumen BlendFeedstock
Diluent and Naphta32,501 bpd
ULS DieselCrude and
Vacuum UnitHydrocracker& Hydrotreater
77,080 bpd
Dilbit51 760 bpd
ULS Diesel36,178 bpd
HydrogenResid
51,760 bpd
Synbit25,320 bpd
LS VacuumGas Oil8,276 bpdHydrogen
HydrogenHydrocracker Butane771 bpd
Multi PurposeGasification
High Quality CO2
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Courtesy NWR
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NWR Air Liquide EPC effective end of 2013
Feedstock Pure dry CO to EOR
St
LP-Steam
Hydrogen
Pure, dry CO2 to EOR148 t/h
CO2Compression
3 x 50 %
~ 52 t/h
Steam 97% pureRectisol™MPG™
QuenchRaw Gas
ShiftGas
CoolingMetha-nation
~ 26 t/h~ 129,000 Nm3/h
H2S+CO2O2 Sulfur
Air + O2Claus Off-GasClaus~ 37,000 Nm3/h
Carbon Slurry
Process WaterFiltASU Waste Water
AirFilter cake
FilterASU aste ateTreatment
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Air
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Conclusion: A comprehensive bottom of the barrel solution
■ Typical Refinery Set-up
LPG
Diesel
Different Oil Fractionsfrom refinery Hydrocracker
Acid GasesSolvent
De-Asphalting Power /
Off-Gases
VacuumResiduefrom
Chemicals
Ai Li id l t
Hydrogeng Power /
HP Steam
SulphurAsphalt
refinery Air Liquide plants:Integrated Power,
Oxygen, Gasification, Hydrogen Chemicals
CO2 forsequestration
Hydrogen, ChemicalsSteam & Sulphur
Air Liquide Global E&C Solutions is capable to solve the “bottom of the barrel” problems in refineries.
Common Off-Site Facilities
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barrel problems in refineries.
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Residue gasification syngas cleaning
■ Project Name: IGCC-AGR■ Capacity : 2,4 million Nm3/h raw gas■ Air Liquide scope: AGR■ Air Liquide technology: Rectisol™■ Air Liquide technology: Rectisol™■ Location : Middle East■ E&C Centre : Delhi
■ Executed process design package within 5 months in 2014■ VGR(Vacuum Gas Residue)/HSFO(High Sulfur Fuel Oil) gasification.■ Status:
Detail Engineering HAZOP Study Completed Detail Engineering HAZOP Study Completed 30% Model Review Completed
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Sourcing green residue■ Client: Karlsruhe Institute of Technology■ Project Name : bioliq™ I & II Pilot plant■ Feed material: Non-food chain biomass■ Product : Syngas for new generation
cleaning and conversioncleaning and conversion■ Air Liquide scope: Fast pyrolysis, Oxygen
and Gasification■ Status: Fully operational
Local pre-transport
GasificationPyrolysis with full carbon recovery
Industrial center
GasificationPyrolysis with full carbon recovery
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Diversity of 4,000 Air Liquide Global E&C Solutions colleagues
Innovative Green
Moscow
FrankfurtCalgary Donetsk
Bussy-St-GeorgesEnnery
Gasification
Shanghai
Beijing
New DelhiDubai
Houston
Montreal Krakow
o ets
Kobe
Doha
ChampignyVitry
Kuala Lumpur
Hangzou / Hangzhou
Dubai
Ras Al Khaimah
ChennaiSingapore
Abu DhabiMiddle East and American Residue Gasification
Diversity createssustainable growth!
Sao PauloJohannesburg
Engineering centers
Manufacturing workshops
Selangor
Afro Asian Coal Gasification
sustainable growth!
Manufacturing workshops
Business offices
Cryogenic equipmentcenters
Diverse Client needs:- Technology development, licensing or EPCM
© Air Liquide, world leader in gases for industry, health and the environmentIFC 20152525
centers - Over-the-fence oxygen, syngas or gases
Frederic Judas, Director TechnologyAir Liquide Global E&C Solutions Germany GmbHfrederic judas@airliquide [email protected]+49 69 5808 2081
Dr. Stephan Schwinghammer, Director Technologyp g , gyAir Liquide Global E&C Solutions Shanghai Co., [email protected]+86 21 6091 9048
Daniel van der Merwe, Head of CtXAir Liquide Global E&C Solutions Shanghai Co., Ltd.daniel vandermerwe@airliquide [email protected]+86 21 6091 9058