a new hp version of lurgi’s fbdb gasifier is bringing more ... · pdf filea new hp...

GAP Conference Beijing 20112011

A new HP version of Lurgi’s FBDBTM

gasifier is bringing more value to clients

Max-Michael Weiss Air Liquide E&C/ Lurgi GmbH, Frankfurt, Germany

2GTC Conference San Francisco 2011 © Lurgi GmbH

AIR LIQUIDE Group at a Glance

New Lurgi FBDBTM Development Rationale for New Developments

Development Steps and Status

Benefits of Pressure Increase

Lurgi RECTISOL® rejuvenation

Lurgi Methanation technology upgrade

Coal to SNG Application benefits

Conclusions / Summary

Outline


Lurgi New Gasification Module – Mark +

AIR LIQUIDE Group at a Glance


1902 - 1990

1991 - 2000

2001 - 2008

AIR LIQUIDE - Brief Facts: Founded in 1902 (Lurgi in 1897)

Present in 75 Countries,

> 43,000 Employees,

8 R&D Centers,

Sales 2010 = €13.5 Billion

LURGI – Brief Facts: Member of AIR LIQUIDE Group Since July

2007

Part of Engineering & Construction (E&C)

Enhanced Technologies

Gasification

Conversion

Integrated Solutions Provider

Sales of Engineering

& Construction

8%

7%Sales of RelatedActivitiesSales of

Gas & Services

85%

Lurgi within the Air Liquide Group


Rationale for New Developments


Upcoming SNG Market & Others in China and Worldwide ask for Low Rank Coal Capitalization → Domain of Lurgi FBDBTM Gasification

Environmental Stewardship

Lurgi’s Fixed Bed Dry Bottom Technology and Downstream Units have been updated for: Competitive Pricing, e.g. SNG vs Natural Gas

Reduction of CAPEX and

Improvement of OPEX

Reduction of Environmental Impact:

Gas/Liquid Treatment & Water re-use (Zero liquid discharge)

Fugitive Emissions and

Carbon Dioxide Emissions Mitigation

Rationale for New Development ofLurgi’s FBDBTM Gasification Mark+


GasPurification(Rectisol)

Elemental Sulfur

CO2 Rich Gas

Rectisol Naphtha

Sulfur

Recovery

HP Steam

SNGMethanation

Effluent Water

FBDB™

GasificationCO Shift &

Gas Cooling

Liquid Ammonia

Phenols

Clear Tar / Oil

Gas LiquorSeparation

Phenosolvan

Phenols

Recovery

CLL / NH3

Recovery

Waste Water

Treatment

Coal

ASU

HP Steam

Ash

Lurgi’s Coal to SNG Technologies:Latest Improvements


The Lurgi FBDBTM GasifierSuitable for Low Rank Coal

Coal suitability, a complex function of Particle Size Distribution: Lump coal, typically 5 – 50

mm

Ash Fusion Temperature: typically above 1200°C

Combined total ash and moisture content of no more than 50%

Good thermal and mechanical strength

Caking coal can be accommodated by the inclusion of proprietary internals into the gasifier vessel

Green highlighted area shows proven operating range for Lurgi FBDBTM Gasifier

All ranks of coal proven in operation Lignite, Sub-bituminous, Bituminous, Semi-Anthracite

5 8 10 15 20 25 30 35 40 45 50 wt-% Moisture

50

45

40

35

30

25

20

15

10

wt-% Ash

5

Angul JSPL

Secunda Sasol

Shanxi Tianji

Henan Yima

North Dakota DGC

5 8 10 15 20 25 30 35 40 45 50 wt-% Moisture

50

45

40

35

30

25

20

15

10

wt-% Ash

5

Angul JSPL

Secunda Sasol

Shanxi Tianji

Henan Yima

North Dakota DGC


Development Steps to Mark+ and its commercial status


The new Lurgi FBDBTM Gasifier: Mark +

LURGI FBDBTM Mark 4 Gasifier Outside diameter: 4.13 m

Height: 12.5 m

Design pressure: 40 barg

Secunda (RSA), DGC (USA), Tianji (PRC), Yima (PRC), Angul (India)

LURGI FBDBTM Mark + Gasifier Outside diameter: 5.05 m

Height: 17.0 m

Design pressure: 60 barg

Next Generation

2011 -1950s - 2010


Name Mk4 (Mark4) Mk+ (Mark Plus)

Nomenclature Mk4-HP40 Mk5E-HP60

Raw Gas Loading (Nm³/h), dry Up to 60,000 Up to 120,000

Outside diameter (m) 4.13 5.05

Overall Height (m) 12.5 17

Design Pressure (barg) 40 60

Step 2

Step 3

Step 1

Lurgi New Gasification Module – Evolution


Ruhr 100 Gasifier 1979 - 1985

Pilot plant Ruhr 100

Ruhrgas @ Dorsten / Germany

Main characteristics Operating pressure 25 to 100 bar

Diameter: 1.5 m

6,100 hours of operation

25,000 t of coal gasified

2 coal locks (‘twin locks’)


Development diagram of Mk+

Latest MK4 (Design

pressure: 40barg)

MK4 MK5

Design improvement based on experience from Mk5

Ruhr-100 pilot plant�maximum operation

pressure: 100bar)

MK+ - Lurgi new FBDB

Gasifier

Continuous technology

improvement for MK4

Rich references of Mk4�101 gasifiers globally�Continuous technology

improvement�1970s-2010)

Quantify benefits of high pressure gasification

Gasification database

under high pressure and some special

design features

Quantifyinfluence

of diameter increase

STEP 1

STEP 2

STEP 3


The Lurgi FBDBTM Gasifier – Sketch

Twin Coal Lock

Reactor

Gas Off-take

Wash Cooler

Rotating Grade

Ash Lock


Lurgi FBDBTM Benefits of Mk+:Impact of Design Pressure and Dimension

Results for a Chinese 4 BCMY SNG Project:

Number of Lurgi FBDBTM gasification modules i.e. ~ 20 Mark + instead of ~ 40 Mark 4

Number of pieces of equipment greatly reduced (less number of modules)

Benefits on the economics:Expected 10 % decrease of the SNG cost (60 barg vs 40 barg) Number of gasification modules halved

Reduction of over 300 Equipment numbers

Reduction of plot size

Reduction of CAPEX up to 20% for the Lurgi FBDBTM process chain

Higher Operating Pressure Reduces CAPEX and OPEX of Downstream units i.e. Rectisol and Methanation


Commercial interest in Mark+

Mark+ versus Mark 4: Lower coal and specific oxygen / steam consumption

Higher specific methane yield

Excellent savings in SNG and DRI applications

NO demo unit required

Ready for implementation on projects

Resulting in:

Mk+ being selected by a number of clients in China and India



LURGI Technologies for SNG Route –Improved Rectisol® Process


Intensive Development Program Undertaken Since 2009 Operational Expenses Reduced by More Than 30%

Attributes of the Lurgi Rectisol®

Easy To Maintain

Stable And Robust Operation

On Line Cleaning Design

Unique Know-how for Trace Components Characterization in The Feed Gas

Carbon Dioxide Capture (Sequestration Ready)

Datang MTP

Lurgi Rectisol® Process – Adapted to Project Needs


Advantages of the Lurgi Rectisol®

Improved proprietary database

Optimized Heat Exchanger Design

Improved Heat Integration

Reduced Capex Design

References in China in 2010 Longyu

LuoYang

Lurgi Rectisol® Process – Adapted to Project Needs



LURGI Technologies for SNG Route –Enhanced Methanation Process


Lurgi’s References –FBDBTM Gasification, Rectisol®, Methanation

Dakota Gasification Company – Beulah, North Dakota, USA 14 x LURGI FBDBTM units – Start-up: 1985 – Coal: Lignite coal –

Products: Synthetic Natural Gas (SNG) and CO2 for EOR (Weyburn/ Saskatchewan)


Medium Temperature

Methanation

High Temperature

Methanation

Catalyst G1 – 85 HT G1 - 85

Maximum Temperature (oC) 480 650

Guaranteed Catalyst Life (Years)

3 2

Recycle Compressor (Volume) 100 % 70%

Power Consumption 100 % 40%

Steam Superheating Temp. (oC) 460 510

Lurgi and BASF Exclusive Partners on Methanation Technology – Since 1974

Developed a High Temperature Process in 2010 Using Proprietary Catalyst

Less Catalyst Volume

Low Pressure Drop (Reflected in Lower Power Consumption)

Long Catalyst Life and Robustness

Enhanced Methanation Technology


Higher Maximum Operating Temperature Allows Generation of Higher Temperature Steam

Improved OPEX

Reduced Recycle Gas Flow (Smaller Capex)

Overall Gains for Customers Choice – Choose Between MT- and HT- Processes

Flexibility of Methanation Process to Upstream Gasification Type and Steam Quality Needs

Enhanced Methanation Technology -Gains



LURGI Technologies for SNG Route –Summary


New Lurgi FBDB™ Gasifier Module – Mark + Greatly improves economics

Rectisol®

Significantly Improved Process Definition

Improved Heat Exchange and Integration Design –> 30 % Less Operating Expense

Reliability of Operation and Linked to Gasification and Methanation Processes

New High Temperature Methanation Process Validated Process Based on MT Methanation Process in North Dakota

Intensive Testing of Catalyst for Yield and Deactivation Characterization

Significant Power Consumption and Capex Reduction

Summary on SNG plant


Proven Operation Referenced

Forgiving Operation

Beneficial for Low Value Coal

Safe

Financially Secure Investment Track Record

On-stream Factor (Availability)

High Conversion of Coal Important as Coal Costs Increase

Low Oxygen Need

No Scale-up Risk Process Performance Guarantees

Environmental Compliance Water Effluent

World Bank Standards

The Next Generation Lurgi FBDBTM Gasifier Conclusion for Mark+


End

Thank you for your kind attention !

Speaker contact:Max-Michael Weiss, AL International Senior Expert/ Innovation-DevelopmentAir Liquide E&C/ Lurgi GmbH Frankfurt/ GermanyPhone: +49 69 5808 3452E-mail: [email protected]

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