Great Plains Synfuels Plant - globalsyngas.org · • Daily production: 170mmscfd natural gas. AIR...

Great PlainsSynfuels PlantGreat PlainsSynfuels PlantThe Hidden Value of Lignite The Hidden Value of Lignite

A look at the past

•• Plant origins: ‘70s energy shortagesPlant origins: ‘70s energy shortages•• Consortium began building in 1981Consortium began building in 1981•• Gas Produced in July 1984Gas Produced in July 1984•• DGC began operating facility in 1988DGC began operating facility in 1988

Synfuels plant: What is it?Synfuels plant: What is it?

•• Work force: more than 700 peopleWork force: more than 700 people•• Daily production: 170mmscfd Daily production: 170mmscfd

natural gasnatural gas

AIRAIRSEPARATIONSEPARATION

OXYGENOXYGEN

STEAMSTEAM

COALCOALGASIFICATIONGASIFICATION

GAS GAS COOLINGCOOLING

& & SHIFTSHIFT

GAS GAS PURIFICATIONPURIFICATION

LIQUID NITROGENLIQUID NITROGEN

KRYPTON / XENONKRYPTON / XENON

HH22++

METHANATIONMETHANATION&&

COMPRESSIONCOMPRESSION

ASHASHGAS LIQUORGAS LIQUOR

SNGSNG

DGLDGL

CRUDE PHENOLCRUDE PHENOLPHENOLPHENOLCRESYLIC ACIDCRESYLIC ACID

VACUUM BOTTOMSVACUUM BOTTOMS

AMMONIUM AMMONIUM SULFATESULFATE

FGDFGDPHOSAMPHOSAM

PHENOSOLVANPHENOSOLVANGRAVIMETRICGRAVIMETRICSEPARATIONSEPARATION

PURIFICATIONPURIFICATION&&

DISTILLATIONDISTILLATION

TAR OILTAR OILTO BOILERSTO BOILERS

AQUAAQUANHNH33

WASTE GASWASTE GASTO BOILERSTO BOILERS

NAPHTHANAPHTHA

PROCESSPROCESSWATERWATER

OXYGENOXYGEN

STEAMSTEAM

& & SHIFTSHIFT

HH22++

SNGSNG

DGLDGL

FGDFGDPHOSAMPHOSAM

AQUAAQUANHNH33

NAPHTHANAPHTHA

OXYGENOXYGEN

STEAMSTEAM

& & SHIFTSHIFT

HH22++

SNGSNG

DGLDGL

FGDFGDPHOSAMPHOSAM

AQUAAQUANHNH33

NAPHTHANAPHTHA

OXYGENOXYGEN

STEAMSTEAM

& & SHIFTSHIFT

HH22++

SNGSNG

DGLDGL

FGDFGDPHOSAMPHOSAM

AQUAAQUANHNH33

NAPHTHANAPHTHA

OXYGENOXYGEN

STEAMSTEAM

& & SHIFTSHIFT

HH22++

SNGSNG

DGLDGL

FGDFGDPHOSAMPHOSAM

AQUAAQUANHNH33

NAPHTHANAPHTHA

OXYGENOXYGEN

STEAMSTEAM

& & SHIFTSHIFT

HH22++

SNGSNG

DGLDGL

FGDFGDPHOSAMPHOSAM

AQUAAQUANHNH33

NAPHTHANAPHTHA

SECURING THE FUTURE

• Increased Throughput• Improved Reliability• Reduced Odor/Environmental Emissions• Plant Diversification

Presentation

1. Environmental Emission Projects2. Plant Odor Control Projects3. Plant Diversification

A Unique Scrubber A Unique Scrubber

•• Original SRU unable to meet permitted levelOriginal SRU unable to meet permitted level•• Task Force reviewed all possible optionsTask Force reviewed all possible options•• Ammonium Sulfate Forced Oxidation FGDAmmonium Sulfate Forced Oxidation FGD

A Unique ScrubberA Unique Scrubber

•• Scrubber doing well on SO2 removalScrubber doing well on SO2 removal•• Converts a waste stream into a saleable Converts a waste stream into a saleable

fertilizer (DakSul 45fertilizer (DakSul 45®®))

•• Problems: Particulates and stack plumeProblems: Particulates and stack plume•• DGC committed another $7.6 millionDGC committed another $7.6 million•• Working with Health Dept. to resolveWorking with Health Dept. to resolve

The challengeThe challenge

The solution

• Add a wet electrostatic precipitator

• $40 million dollar project

• Construction complete, unit tested and in compliance by June 1, 2003

Wet Electrostatic Precipitator Construction

PLANT ODOR CONTROL

• Cooling Tower is largest contributor to off-site odors.– Superstill overhead condensate contains ppm

concentrations of ammonia and nitriles– A stripper and absorber will selectively

remove these odorous compounds

OXYGENOXYGEN

STEAMSTEAM

& & SHIFTSHIFT

HH22++

SNGSNG

DGLDGL

FGDFGDPHOSAMPHOSAM

AQUAAQUANHNH33

NAPHTHANAPHTHA

OXYGENOXYGEN

STEAMSTEAM

& & SHIFTSHIFT

HH22++

COCOHH22 + CO+ CO AMMONIAAMMONIA

SYNTHESISSYNTHESIS

SNGSNG

NHNH33

DGLDGL

FGDFGDPHOSAMPHOSAM

AQUAAQUANHNH33

NAPHTHANAPHTHA

COCO22OXYGENOXYGEN

STEAMSTEAM

& & SHIFTSHIFT

HH22++

COCOHH22 + CO+ CO AMMONIAAMMONIA

SYNTHESISSYNTHESIS

SNGSNG

NHNH33

DGLDGL

FGDFGDPHOSAMPHOSAM

AQUAAQUANHNH33

NAPHTHANAPHTHA

COCO22COMPRESSIONCOMPRESSION

ANHYDROUS AMMONIA

• Good market prices in 1994 for ammonia• Poor market prices in 1994 for methane• NH3 needed for new FGD scrubber• Feed gas available, no need for primary

reformer• Plant located in an agricultural region

• Used 1000 tpd Braun plant• On-line sooner and at a lower cost• Considered an alternate product

•• Contract to sell to PanCanadianContract to sell to PanCanadian•• Enhanced oil recovery in SaskatchewanEnhanced oil recovery in Saskatchewan•• Groundbreaking held May 12, 1999Groundbreaking held May 12, 1999

COCO22 COMPRESSION UNITCOMPRESSION UNIT

A pipeline to CanadaA pipeline to Canada

30% gross revenue30% gross revenue

CURRENTCURRENT

FUTUREFUTURE

50% gross revenue50% gross revenue

FUTURE

• Additional CO2 sales• Production of Ethanol• Additional Cresylic Acids• Extraction of Argon

Great PlainsSynfuels PlantGreat PlainsSynfuels Plant

Great Plains Synfuels Plant - globalsyngas.org · • Daily production: 170mmscfd natural gas. AIR...

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Transcript of Great Plains Synfuels Plant - globalsyngas.org · • Daily production: 170mmscfd natural gas. AIR...