lurgi fbdb™ mk+™ gasification...
TRANSCRIPT
LURGI FBDB™ MK+™ Gasification Technology
6th International Freiberg ConferenceDresden / Radebeul – May 19 – 22nd, 2014
Air Liquide Global E&C Solutions Germany l Lurgi FBDB technology
Outline
■ Mk+ Gasification Module
■ Benefits for Coal to SNG Projects
■ Update on SNG Projects in China
■ Highlights on Key Innovations
Air Liquide, world leader in gases for industry, he alth and the environment
■ Highlights on Key Innovations� Purification of the gas liquor for ZLD solution� Dry ash handling
■ Status JSPL Coal to DRI Project in India
2 6th IFC - May 21st 2014 - Germany
Basis of Lurgi FBDBTM Mk PlusTM Development
Step 1: Starting point: Mark 4 from Jindal Steel & Power Ltd. (JSPL) Angul project
� Lessons learnt from 30 years of operation of Sasol (Secunda, RSA) and DGC (North Dakota, USA) plants
� Latest project: JSPL Angul, India, 40 barg design pressure
Step 2: Increase of the diameter � Reason: Gain in terms of capacity � Definition point: Lurgi Mark 5
Latest MK4 (Design
pressure : 40barg)
Design improvement based
Continuous technology
improvement of MK 4
Rich references of Mk 4101 gasifiers globally
Continuous technologyimprovement
1970s-2010)
Quant ifyinfluence
of diameter increase
Air Liquide, world leader in gases for industry, he alth and the environment
� Definition point: Lurgi Mark 5 (Sasolburg 1985 to 2004)
Step 3: Increase of the operating pressure
� Gain in capacity, efficiency, environmental footprint and methane yield
� Optimum pressure: 60 barg for Capex and scale-up risk
� Validation of the gasification process calculations with the Ruhr 100 pilot plant test results and data
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MK4 MK5
Design improvement based on experience from Mk 5
Ruhr-100 pilot plantmaximum operation pressure : 100bar)
MK+ - Lurgi new FBDB
GasifierQuantify benefits of high
pressure gasification
Gasification database
under high pressure and some special
design features
increase
The Lurgi FBDB™ Gasifier� LURGI FBDB ™ Mark4 Gasifier
� Outside diameter: 4.13 m
� Height: 12.5 m
� Design pressure: 40 barg
� Raw Gas Loading, dry: up to 60000 Nm³/h
� LURGI FBDB ™ Mark+™ Gasifier
� Outside diameter: 5.05 m
� Height:17.0 m
� Design pressure: :60 barg
� Raw Gas Loading, dry: up to 120000 Nm³/h
Air Liquide, world leader in gases for industry, he alth and the environment
1950s - 2010 2011 - …
4
� 2500 t/d coal feed
� 500 MWth
6th IFC - May 21st 2014 - Germany
Benefits for Coal to SNG projects■ MK+ : innovative use of referenced
technology for no scale up risks
■ Improved Opex and lower Capexcompared to Mk4■ Higher direct production of CH4■ Reduced coal, O2 and HP Steam
consumption
Air Liquide, world leader in gases for industry, he alth and the environment5 6th IFC - May 21st 2014 - Germany
consumption■ Higher thermal efficiency
■ 10 to 15% decrease of the SNGcost versus Mk4
■ Part of the SNG is produced byETF gasification for coal fines.
(ETF: 50% higher SNG cost)
FBDB MK+Coarse Coal
Fine coal ETF Rectisol
Rectisol Methanation
Methanation
50% to 75%
O2
SNG
O2
SNG
Update on SNG projects in China
■ 2 plants started-up with a total capacity of 2.7 BCMY of SNG ■ Datang Keqi phase 1■ Qinghua Yili phase 1
■ More than 20 new projects got the NDRC Lutiaoin 2013
■ 2 main locations for SNG projects■ Inner Mongolia province
Air Liquide, world leader in gases for industry, he alth and the environment6 6th IFC - May 21st 2014 - Germany
■ Inner Mongolia province■ Xinjiang province
■ Challenges■ Magnitude of the Capex (large projects)■ Management of the project risks■ Highest standards for emissions and effluents■ Scarcity of the water
From Gas Liquor to Zero Liquid Discharge
■ Full chain of purification of the water – Unique offer from Air Liquide■ Solution based on fully referenced technologies■ Recycle of the purified water as make-up to cooling water circuit
Lurgi FBDB™ Gasification
CO Shift &Gas Cooling
Coal
Steam
Raw syngas
Acid GasRecycle of the water is a must
for CtSNG projects
O2
Air Liquide, world leader in gases for industry, he alth and the environment
Cooling waterMake-up
Liquid AmmoniaCrude PhenolsClear Tar / Oil
Gas LiquorDephenolized
Gas LiquorStripped
Gas Liquor
Mud liquor CO2, H2S, solvent
Acid GasCO2, H2S, HCN Organics
Gas LiquorSeparation
Phenosolvan®Phenols Recovery
CLLNH3 Recovery
Waste WaterTreatment
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for CtSNG projects(<5 twater /kNm3)
Phenosolvan / CLL / WWT: Economics
Spec Unit RMB/unitCW 30°C T 0.2TW 45°C T 0.57Demin water 30°C T 8LP Steam 4.5 bar T 70MP Steam 8.5 bar T 85N2 7 bar Nm³ 0.165Power kWh 0.42Caustic As pure Kg 3.1solvent (DIPE) Kg 11.5CTA T 2800Ammonia T 2500
■ Make-up water for the cooling water system produced by WWT
■ WWT consists of advanced bio-treatment followed by high efficiency RO and evaporation / crystallization units
■ Impact WWT on SNG cost: 2.5%■ Large credit coming from co-products
Air Liquide, world leader in gases for industry, he alth and the environment8
Ammonia T 2500
Flow 550 t/h of GL Phenosolvan CLL WWT TotalCAPEX M€ 48 32 41 121OPEX RMB/t 4.1 35.2 5.8 45.1CAPEX + OPEX RMB/t 21.6 46.9 20.2 88.7Credit co-products RMB/t 13 22 0 35Net TCO RMB/t 8.6 24.9 20.2 53.7% Total TCO 16% 46% 38% 100%% of SNG cost 1.1% 3.2% 2.5% 6.8%Ref 1.7 for 2 BCMY
6th IFC - May 21st 2014 - Germany
■ Large credit coming from co-products
Evaluation of dry ash handling for FBDB■ Wet sluice way system
■ Most commonly applied worldwide■ Very reliable■ Wet ash to be disposed off or sold■ Loss of water with the ash■ ~ 3€ / t of ash (handling / separation)
■ Incentives for dry ash
Air Liquide, world leader in gases for industry, he alth and the environment9 6th IFC - May 21st 2014 - Germany
■ Incentives for dry ash handling■ No water consumption■ No effluent water to treat■ Lower operating costs■ Broader opportunities to
sell the ash
Optimized dry ash handling solution
■ Ash disposal cost reduced by ■ by 5% (no ash
sold)■ by 11% (10% of
the ash sold)
Interesting competitive solution of the ash
management for FBDB
Air Liquide, world leader in gases for industry, he alth and the environment
■ Referenced and proven equipment (power plants) ■ Easy operation and maintenance■ Solution with high availability (> 99.5%)
■ Footprint reduced by 65%
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Magaldi group: dependable by innovation since 1929
The Magaldi Group, founded in 1929,
World leader in mechanical transportation of hot and abrasive bulk materials
for coal-fired power plants, cement manufacturers, steel mills, foundries, mines etc.
Air Liquide, world leader in gases for industry, he alth and the environment11 6th IFC - May 21st 2014 - Germany
Magaldi develops and provides technologies for the safe and environmental friendly handling of raw materials and ash in the coal fired power plants
Magaldi group: dependable by innovation since 1929
■ The Superbelt ® ensures the safest and most reliable transportation of abrasive and hot bulk material, associated with maximum life time.
Air Liquide, world leader in gases for industry, he alth and the environment12 6th IFC - May 21st 2014 - Germany
■ Hundreds of successful installations in Power Industry (hot bottom ash, mill rejects, Eco ash); Foundries (hot castings, sand, molds, scraps); Cement Industry (hot clinkers); Metallurgical plants (hot DRI, metal sinter etc.).
■ The Magaldi ECOBELT ®®®® is a steel belt conveyor completely enclosed in a dust-proof steel casing, unique in its design and able to transport materials with aggressive properties, both chemical and physical, without any release to the external environment.
JSPL Coal to DRI Gasification Project
Commissioning completedStart-up on-going
■ Customer: JSPL■ Location: Orissa, India■ Key Process data:
■ Sub. Coal 35% ash■ 7 MK4 gasifiers■ 225,000 Nm3/h DRI SG■ LHV: 3,500 kcal/Nm3
Mk4 Gasifiers CLL
Air Liquide, world leader in gases for industry, he alth and the environment13 6th IFC - May 21st 2014 - Germany
■ H2/CO ratio: 1.7 ■ Scope for complete gas
island - gasification, Rectisol , SRU■ PDP / BE / DE■ Prop Equipt supply■ Operators training■ Start-up assistance
Photos site Jan 2014 – Courtesy JSPL
Phenosolvan
JSPL Coal to DRI Gasification Project
Air Liquide, world leader in gases for industry, he alth and the environment14 6th IFC - May 21st 2014 - Germany
Contact informationMr Frederic Judas, Director TechnologyCoal to Gas Product LineAir Liquide Global E&C Solutions Germany [email protected]: + 49 69 5808 2081Tel: + 49 69 5808 2081
4,000 Air Liquide Global E&C Solutions Colleagues Thank You!
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