Coefficient of Thermal Expansion and their Importance.pptx
Air liquide lurgi 2016 overview of coal heavy oil ch4 to syngas h2 ammonia methanol reference projects
1. February 11, 2016 | Air Liquide Global E&C Solutions | New Delhi
Syn Gas Generation
Various Routes – Multiple Products
June 14, 2012 l Siddhartha Mukherjee | Air Liquide Global E&C Solutions | New Delhi
February 11, 2016 | Air Liquide Global E&C Solutions | New Delhi
New Delhi
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Global E&C Solutions Communications
2. Clean Conversion – Our Story
Coal Gasification and its Applications
SNG
Ammonia
Methanol
Methanol > Propylene
Hydrogen
Syngas Generation - Various Routes, Multiple Products
Air Liquide, world leader in gases for industry, health and the environment2 Gasification India 2016
Hydrogen
Hydrogen and Carbon Monoxide
DRI Gas
Residue Gasification
Steam Methane Reforming
Associated Technologies
Wrap-up and Summary
3. AL Global E&C Solutions Perspective
Clean Conversion – Our Story
Air Liquide, world leader in gases for industry, health and the environment3 Gasification India 2016
4. Our value addition
We know…
Coal
Drivers and our contribution
■ fluctuating price of oil & gas
in many locations
■ Growing domestic demand for
fuel and petrochemical products
■ Reduction of dependency on
C
Air Liquide, world leader in gases for industry, health and the environment4 Gasification India 2016
Oxygen
Syngas
and the
products.
■ Reduction of dependency on
fuel and petrochemicals imports
■ Abundance of coal
H2CO
O2
CH3OH
Synfuel
5. ■ NG, LPG, Naphtha
• SMR, ATR
• CO Shift, Amine Wash
• Coldbox, PSA
■ Coal, Heavy Residue
• Gasification
Clean Conversion
O2
C
H2O +
Air Liquide, world leader in gases for industry, health and the environment5
+
• Gasification
• CO Shift, Rectisol™
• Coldbox, PSA
■ Synthesis
• Methanol, DME
• MTP, Acrylic Acid
• Synfuels, Ammonia
H2CO
Gasification India 2016
7. Gasification
Lurgi FBDB™
Lurgi MPG™
Raw
Material
Residue
Natural
Gas
Coal
Biomass
Final Products
AL
Cold Box
AL
PSA
Syngas and Synthesis
Technology and Design by Air Liquide
Methanol
Lurgi
Methanol
Lurgi
DME
Lurgi
MTP ™
Lurgi NK
Acrylic Acid
DME
Propylene
Acrylic Acid
Lurgi
Rectisol ™
Air Liquide, world leader in gases for industry, health and the environment7
Biomass
Lurgi
OxyClaus
™
CO Shift
Amine
Wash
AL
ASU
Lurgi SMR
Lurgi ATR
Lurgi POX
Acrylic Acid
GTL.F1
Fischer
Tropsch
Methanation
Syn fuels
SNG
Ammonia Ammonia
DRI
Gasification India 2016
8. AL Global E&C Solutions Perspective
Coal Gasification and its Applications
Air Liquide, world leader in gases for industry, health and the environment8 Gasification India 2016
9. Lurgi FBDB™ Coal-to-X Syngas
Air Liquide
ASU
Lurgi Rectisol®
Gas
Purification
Lurgi OxyClaus®
Sulfur Recovery
Elemental Sulfur
CO2
Syngas, DRI, Power
Air Liquide
LNW Unit
N2
Methanation
Ammonia Syngas
SNG
(Fuel Gas)
Lurgi MPG®
Gasification
Gasification
Lurgi
CO Shift /
Gas Cooling
Coal
Preparation
HP Steam
Air Liquide, world leader in gases for industry, health and the environment9 Gasification India 2016
CO
Hydrogen
Air Liquide
CO Cold Box
Lurgi
GLS Process™
Lurgi Phenosolvan® & Lurgi CLL™
Gas Liquor Recovery and Water Treatment
Liquid Ammonia
ZLD – Water Reuse
(Rectisol Naphtha)
(Phenols)
(Clear Tar / Oil)
Ash
Air Liquide
PSA
Lurgi
Methanol Synth.
Methanol-Propylene
10. Coal to H2 and NH3: Fujian Gasification Project
ASU
Gasification
CO-Shift Nitrogen Wash
Ammonia
Air Liquide, world leader in gases for industry, health and the environment10
78 000 Nm3/h H2 + 900 tpd NH3
Lurgi
Rectisol™
&
OxyClaus™ PSA
ASU, Gasification, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash,
Ammonia Synthesis, PSA, Integration/OSBL
H2
NH3
Gasification India 2016
11. Coal to Ammonia: TGI/SCJ
Air Liquide, world leader in gases for industry, health and the environment1111
ASU
Gasification
Lurgi
Rectisol™
&
OxyClaus™
Nitrogen
Wash
Ammonia
ASU, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash
H2 N2
180 000 Nm3/h N2+H2
Gasification India 2016
12. Coal to Propylene: Shenhua Ningxia
Air Liquide, world leader in gases for industry, health and the environment12
ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™
5000 tpd MeOH to each MTP™
Gasification India 2016
14. ASU Lurgi
Rectisol™
&
OxyClaus ™
Coal to DRI Gas: Jindal Steel and Power
Lurgi
FBDB™
Gasification
Air Liquide, world leader in gases for industry, health and the environment1414
ASU, Lurgi FBDB™ Gasification, Phenosolvan™, CLL™, Rectisol™, SRU OxyClaus™
Lurgi CLL™
Phenosolvan ™
225 000 Nm3/h CO+H2+CH4
H2
CO
CH4
Gasification India 2016
15. AL Global E&C Solutions Perspective
Residue Gasification - MPG®
Air Liquide, world leader in gases for industry, health and the environment15 Gasification India 2016
16. 45 years prior operating experience with heavy
residues
25 plants (78 reactors) for oil residue gasification
built by Lurgi under Shell license (Lurgi/SGP) until
’97
In 1997, Burner Technology acquired from SVZ
Schwarze Pumpe (Eastern Germany)
Lurgi’s Multi Purpose Gasification
■ Boiler & Quench design
MPG® Summary
Air Liquide, world leader in gases for industry, health and the environment16 Gasification India 2016
16
■ Boiler & Quench design
Existing Reference operating in Brazil (Fosfertil)
since 2001
■ Commercial size reference
HP POX - Pilot plant - since 2002
■ R&D development – Process performances –
Validation of design rules
Engineering Contract for Gasification at present
under execution
17. Multi
Purpose
Gasification
45 years experience
in residue gasification:
75 units
62.5 x 106 m3 /d
PurchasesfromSVZ
2001Ultafertil
2002HDPOX
2005NorthWestUpgrader
Residue Gasification References
Air Liquide, world leader in gases for industry, health and the environment17 Gasification India 2016
17
Year Country Feed Product Capacity Technology/
License
From 1956 to 1997 Lurgi was exclusive licensor of the Shell Gasification Technology (SGP). In this time
Lurgi designed 26 Partial Oxidation Plants with 76 Reactors producing 63.000.000 Nm³/d of Syngas.
(1997)* Germany Coal oil/Tar,
Slurries
Methanol Synthesis Gas
and Power
800.000 Nm³/d MPG
2000 Brazil Asphalt, others Ammonia Synthesis Gas,
Burner Revamp
850.000 Nm³/d MPG
2002 Germany Natural Gas,
Residue
Raw Synthesis Gas 36.000 Nm³/d MPG
2005 Canada Hydrocracked
Residue
Hydrogen 3.500.000 Nm³/d MPG
()* MPG reference plant technology purchased by Lurgi, operated for more than 30 years
1950 1960 1970 1980 1990 2000
Fixed Bed Grate Gasifier
Gasification62.5 x 106 m3
N/d
2010
18. MPG® Residue-to-X Syngas
Air Liquide
ASU
Lurgi Rectisol®
Gas
Lurgi OxyClaus®
Sulfur Recovery
Elemental Sulfur
CO2
Syngas, DRI, Power
Air Liquide
LNW Unit
N2
Methanation
Ammonia Syngas
SNG
(Fuel Gas)
MPG®
Lurgi
CO Shift /
Feed
HP Steam
Air Liquide, world leader in gases for industry, health and the environment18 Gasification India 2016
CO
Hydrogen
Air Liquide
CO Cold Box
Metal Ash
Recovery System
Gas
Purification
Methanation SNG
Metal Ash
Gas Cooling
Air Liquide
PSA
Lurgi
Methanol Synth.
Methanol-Propylene
Waste Water
19. AL Global E&C Solutions Perspective
Steam Methane Reforming
Air Liquide, world leader in gases for industry, health and the environment19 Gasification India 2016
20. World Map & References - Lurgi ReformerTM
HAINAN Methanol
Location: China / Hainan
Product: 2.000 mtpd Methanol
Start-up: 2006
Degussa Rheinfelden
Location: Germany
Product: 8.000 Nm³/h Hydrogen
Start-up: 1997
TITAN and ATLAS Methanol
Location: Trinidad
Product: 2.500/5.000 mtpd Methanol
Start-up: 1999 / 2004
Messer Dormagen
Location: Germany
Product: 7.000 Nm³/h CO
Start-up: 2002
GLIMAR
Location: Poland
Product: 10.000 Nm³/h Hydrogen
Start-up: -
YARACO1 / YARACO 2
Location: China
Product: 9.200Nm³/h CO
Start-up: 1998 / 2005
DALIAN
Location: China
Product: 72.000 Nm³/h Hydrogen
Start-up: 2006
PEMEX Cadereyta
Location: Mexico
Product: 67.250 Nm³/h Hydrogen
AIR LIQUIDE Gulf Coast SMR H2
Location: Texas / USA
Product: 130.000 Nm³/h Hydrogen
Start-up: 2011 (Project in Progress)
PRAXAIR Richmond
Location: California
Product: 204.000 Nm³/h Hydrogen
Start-up: 2010 (under construction)
LOTOS HGU 2
Location: Poland
Product: 100.000 Nm³/h Hydrogen
Start-up: 2009 (under construction)
AIR LIQUIDE HERACLES
Location: Netherlands
Product: 130.000 Nm³/h Hydrogen
Start-up: 2011 (Project in Progress)
Air Liquide, world leader in gases for industry, health and the environment20 Gasification India 2016
Batamas MEGAH
Location: Malaysia
Product: 3.000 Nm³/h Hydrogen
Start-up: 1994
BASF – BPC Kuantan
Location: Malaysia
Product: 58.000 Nm³/h Syngas
Start-up: 2000
P.T. Kaltim Methanol Industry
Location: Malaysia
Product: 2.000 mtpd Methanol
Start-up: 1998
Cleveland-Cliffs
Location: Trinidad
Product: 41.500 Nm³/h Hydrogen
Start-up: 1998
PEMEX Madero
Location: Mexico
Product: 49.170 Nm³/h Hydrogen
Start-up: 2001
Repsol YPF
Location: Argentina
Product: 1.210 mtpd Methanol
Start-up: 2002
PML
Location: Malaysia / Labuan
Product: 5.000 mtpd Methanol
Start-up: 2009
Melaka HPU 2
Location: Malaysia
Product: 45.000 Nm³/h Hydrogen
Start-up: 2008
National Petrochemical Co. (Kharg)
Location: Iran
Product: 2.000 mtpd Methanol
Start-up: 1999
Product: 67.250 Nm³/h Hydrogen
Start-up: 2000
ZAGROS 1 / ZAGROS 2
Location: Iran
Product: 5.000/5.000 mtpd Methanol
Start-up: 2006 / 2009
SIPCHEM CO
Location: Saudi Arabia
Product: 30.520 Nm³/h CO
Start-up: 2009
21. Large Plants Designed by Air Liquide
■ Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA, multi-feed)
■ Largest single-train H2 plant: 160 750 Nm3/h H2
■ Largest single-train synthesis gas plant: 530 780 Nm3/h, dry
equivalent to 321 230 Nm3/h H2 (Lurgi’s MEGA-MeOH plants)
Air Liquide, world leader in gases for industry, health and the environment21 Gasification India 2016
■ World largest single-train CO plant: 43.2 tons/h CO
■ Largest Steam Reformer: 720 tubes, 1250 GJ/h
■ Number of Mega-H2 plant references with capacities ≥ 130 000 Nm3/h
H2 in last 10 years: 7
22. Latest References – H2 Plants (medium/large size)
Region Feed Capacity (Nm3/h) Scope Award
Russia NG 100 000 H2 Lic.+ B.E. 2013
Middle East NG, LPG 60 000 H2 Lic.+ B.E. 2013
Middle East NG 68 550 H2 Lic.+ B.E. 2012
North America NG 160 750 H2 EPC 2011
Russia NG, Naphtha 83 165 H2 Lic.+ B.E. 2011
Middle East NG, Naphtha 60 000 H Lic.+ B.E. 2011
Air Liquide, world leader in gases for industry, health and the environment22 Gasification India 2016
Middle East NG, Naphtha 60 000 H2 Lic.+ B.E. 2011
Middle East LPG, Naphtha,
ROG, NG
339 300 H2 (2
train + S/A PSA)
EPC 2010
North America NG 130 000 H2 EPC 2009
Europe NG 130 000 H2 EPC 2009
23. Latest References – H2 and CO Plants
Region Feed Capacity (Nm3/h) Scope Award
Europe NG 8 500 CO EPC 2013
Europe NG 14 500 CO
60 000 H2
EPC 2012
Europe NG 10 000 CO
24 100 H2
EPC 2012
Asia NG 9 800 CO EPC 2010
Air Liquide, world leader in gases for industry, health and the environment23 Gasification India 2016
Asia NG 9 800 CO
35 600 H2
EPC 2010
24. Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA)
Air Liquide, world leader in gases for industry, health and the environment24 Gasification India 2016
25. Process Gas
Fuel Gas
Combustion Air
Flue Gas
Lurgi Reformer® - Isometric Arrangement
Air Liquide, world leader in gases for industry, health and the environment25 Gasification India 2016
25
Arrangement Drawing
26. Hydrogen
Lurgi SMR Feed-to-X Syngas
Air Liquide
ASU
Air Liquide
CO Cold Box
N2
PSA
Ammonia Syngas
SMR
Feed
CO2 Removal
HP Steam
Air Liquide, world leader in gases for industry, health and the environment26 Gasification India 2016
CO
Methanol-Propylene
ATR
Methanol
Synthesis
CO Shift
27. Next Generation Coal Gasification Island
Associated Technologies
Air Liquide, world leader in gases for industry, health and the environment27 Gasification India 2016
28. Commercially well referenced technologies
■ ASU: > 350 in the last 40 years
■ Lurgi FBDB™: > 120 reactors
■ Rectisol™ : > 100 Lurgi Rectisol
■ Cold Box > 90 CO purification and NWU
■ PSA >70 Hydrogen Purification
Air Liquide, world leader in gases for industry, health and the environment28 Gasification India 2016
■ PSA >70 Hydrogen Purification
■ Methanol: > 50 plants; 9 coal based.
■ MTP™ : 2 running
■ Claus : >170 Claus Units
■ OxyClaus™ SRU: > 40 burners
29. Air Liquide: Air Gases
■ Operating >350 Air Separation Units
Total gaseous production
> 120,000 tpd
> 95,000 tpd
O2
N
Air Liquide, world leader in gases for industry, health and the environment29 Gasification India 2016
> 95,000 tpd
■ The world leader in large scale air separation units
> 160 ASUs with a capacity > 1,000 tpd
> 60 ASUs with a capacity > 2,000 tpd
The largest single train plant under engineering (capacity of 5,000
TPD at 1620 m above sea level)
N2
30. Air Liquide’s Lurgi FBDBTM
■ Lurgi FBDBTM MK+TM: Proven Operation
Innovative use of referenced technology for no scale-up risk
Safe & forgiving operation
Beneficial for low rank coal
Improved Capex and Opex
■ Financially Secure Investment
■ High Efficiency and reduced cost of SNG
H2
CO CH4
Air Liquide, world leader in gases for industry, health and the environment30 Gasification India 2016
■ High Efficiency and reduced cost of SNG
Reduced steam consumption & lower oxygen consumption
Higher direct methane production
■ Environmental Compliance
Complete process water re-use Zero Liquid Discharge
World bank standards
Best efficiency for high moisture & high ash coal
especially for SNG production.
H2O
31. Air Liquide’s Lurgi RectisolTM
■ > 60 Years of design expertise and operational feedback
■ Reference situation
21 references 2011 - today
42 references since 2000
Over 100 references in total
Complete CO2 and Sulfur removal.
H2CO
Air Liquide, world leader in gases for industry, health and the environment31 Gasification India 2016
■ Applications
Coal-, petcoke-, refinery residue- gasification
Power, DRI, H2
Synthesis: MeOH, NH3, Urea, MEG, SNG,
Fischer-Tropsch, polymers …,
Multi-product streams
Outstanding track record in a variety of applications!
CO2 S
32. Air Liquide’s Cryogenic Gas Treating
■ > 90 Cold boxes referenced
■ Syngas Final treating
Remove impurities in syngas e.g. CH4, N2…
Produce pure syngas.
Composition ratio adjustment H2/N2=3:1…
■ Applications
H2CO
N2
CH4
Air Liquide, world leader in gases for industry, health and the environment32 Gasification India 2016
■ Applications
Pure CO, H2, CO+H2, H2+N2
■ Distillation packing: high efficiency & load variety.
■ Stainless steel cold box: easy onsite works.
■ Expansion turbine: product gas as medium.
■ Cold integration with Rectisol™.
Worldwide largest CO purifications
and ammonia syngas preparations all by Air Liquide!
33. > 40 Years of design expertise and operational
feedback
51 Plants with a total capacity of 33.5 MMTPY.
Extremely quick transfer of reaction heat:
Quasi isothermal operation
Overheating of catalyst impossible
CH3OH
Air Liquide’s Lurgi Methanol
Air Liquide, world leader in gases for industry, health and the environment33 Gasification India 2016
Long catalyst operational life
Low recycle ratios
High steam production
Safe and uniform temperature control
The outstanding advantage of
Lurgi Methanol is the Water Cooled Reactor
with superior heat removal ability.
33
34. Food for Thought and Wrap-up
Air Liquide, world leader in gases for industry, health and the environment34 Gasification India 2016
35. Value addition
We know…
Air Liquide’s value addition
C CH4
■ Cutting-edge, commercially proven
proprietary technologies
addressing the growing markets for
coal-based & natural gas based
fuels and petrochemicals:
Air Liquide, world leader in gases for industry, health and the environment35 Gasification India 2016
Oxygen
Syngas
and the
products.
H2CO
O2
CH3OH
Synfuel
fuels and petrochemicals:
■ Synfuels/Diesel
■ Methanol, DME
■ Propylene
■ Ammonia
■ Hydrogen
36. Wrap-Up - FBDBTM
■ FBDBTM Excellent Technology for High Ash Coals
■ Appropriate Technology for the following applications:
Substitute Natural Gas SNG
Direct Reduction of Iron DRI
Coal to Liquids CTL
NH3 with CH4 co-production
■ About 155 Steam Reformers built
Wide feedstock range - Light/heavy natural gas, LPG, associated gas,
Air Liquide, world leader in gases for industry, health and the environment36 Gasification India 2016
Wide feedstock range - Light/heavy natural gas, LPG, associated gas,
naphtha, mixed feed4
Wide product range - hydrogen, CO, towngas, syngas for products like
oxo-alcohols, methanol, ammonia
■ Lurgi MPG Gasification MPGTM
Proven technology for handling heavy refinery residues
Also capable of handling emulsions and slurries with particles in the mm range
■ A Real One-Stop-Shop
Proven technologies integrated into a single package
37. 4,000 Air Liquide Global E&C Solutions Colleagues Thank You!
Hangzhou
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/Seine
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/Marne
Frankfurt
Hyderabad
Air Liquide, world leader in gases for industry, health and the environment37 Gasification India 2016
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