AirLiquide Gasification 2016 PDF

Syn Gas Generation
Various Routes – Multiple Products

February 11, 2016 | Air Liquide Global E&C Solutions | New Delhi
June 14, 2012 l Siddhartha Mukherjee | Air Liquide Global E&C Solutions | New Delhi
New Delhi
Classification Level: PUBLIC
Business Owner: Global E&C Solutions Communications
Distribution List:
Syngas Generation - Various Routes, Multiple Products
Clean Conversion – Our Story

Coal Gasification and its Applications
SNG
Ammonia
Methanol
Methanol > Propylene
Hydrogen
Hydrogen and Carbon Monoxide
DRI Gas
Residue Gasification
Steam Methane Reforming
Associated Technologies
Wrap-up and Summary
2 Gasification India 2016 Air Liquide, world leader in gases for industry, health and the environment
AL Global E&C Solutions Perspective
Clean Conversion – Our Story
Drivers and our contribution
■ fluctuating price of oil & gas

in many locations Our value addition
■ Growing domestic demand for We know…

fuel and petrochemical products
Coal C
■ Reduction of dependency on
fuel and petrochemicals imports
O2 Oxygen
■ Abundance of coal
Syngas CO H2
Synfuel
CH3OH
and the
products.
Clean Conversion
C ■ NG, LPG, Naphtha

• SMR, ATR
• CO Shift, Amine Wash
• Coldbox, PSA
H 2O + O2 ■ Coal, Heavy Residue

• Gasification
• CO Shift, Rectisol™
• Coldbox, PSA
CO + H2 ■ Synthesis
• Methanol, DME
• MTP, Acrylic Acid
• Synfuels, Ammonia
Clean Conversion
Raw
Syngas Syngas Treating Synthesis Final Products
Material
Residue Methanol Methanol

Gasification AGR
PSA
Natural DME DME
Gas
CO
Cold Box MTP ™ Propylene
Coal
Acrylic Acid Acrylic Acid

Biomass
Amine
CO Shift
Wash Fischer
Reforming Syn fuels
Tropsch
Methanation SNG
Ammonia Ammonia
Sulfur DRI
Recovery
ASU
Technology and Design by Air Liquide
Raw
Syngas and Synthesis Final Products
Material
Lurgi
Residue Methanol
Gasification Methanol
Lurgi FBDB™ AL
Lurgi MPG™ PSA
Lurgi
Natural Lurgi DME
DME
Gas Rectisol ™
AL Lurgi
Cold Box Propylene
Coal MTP ™
Lurgi NK
Acrylic Acid
Biomass Acrylic Acid
Amine
CO Shift GTL.F1
Wash
Fischer Syn fuels
Lurgi SMR Tropsch
Lurgi ATR
Lurgi POX
Methanation SNG
Ammonia Ammonia
AL
ASU Lurgi
OxyClaus DRI
™
Coal Gasification and its Applications
Lurgi FBDB™ Coal-to-X Syngas
N2
(Fuel Gas)
Air Liquide Lurgi MPG® Lurgi OxyClaus®
Elemental Sulfur
ASU Gasification Sulfur Recovery
CO2
Coal Air Liquide Ammonia Syngas

Preparation LNW Unit
Syngas, DRI, Power
Lurgi Lurgi Rectisol®
HP Steam Gasification CO Shift / Gas SNG
Methanation
Gas Cooling Purification
Lurgi Methanol-Propylene
Ash
Methanol Synth.
CO
Air Liquide Air Liquide
CO Cold Box PSA Hydrogen
(Rectisol Naphtha)
Lurgi Lurgi Phenosolvan® & Lurgi CLL™

(Phenols)
GLS Process™ Gas Liquor Recovery and Water Treatment
(Clear Tar / Oil)
Liquid Ammonia
ZLD – Water Reuse
Coal to H2 and NH3: Fujian Gasification Project
Gasification Ammonia
ASU CO-Shift Nitrogen Wash
Lurgi
Rectisol™
&
OxyClaus™ PSA
78 000 Nm3/h H2 + 900 tpd NH3 NH3 H2

ASU, Gasification, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash,
Ammonia Synthesis, PSA, Integration/OSBL
Coal to Ammonia: TGI/SCJ
Gasification Ammonia
ASU Lurgi Nitrogen
Rectisol™ Wash
&
OxyClaus™
H2 N2
180 000 Nm3/h N2+H2
ASU, Rectisol™, SRU OxyClaus™, Liquid Nitrogen Wash
Coal to Propylene: Shenhua Ningxia
5000 tpd MeOH to each MTP™

ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™
Coal to Methanol and Propylene: Shenhua Ningxia
Gasification
ASU CO-Shift, Mega- MTP®
Rectisol® Methanol®
Oxy Claus™
Gasification train DME

Rectisol® Methanol
Methanol train
MTP®
Methanol
ASU Gasification
Rectisol®
(4 trains) Synfuels
ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™

Coal to DRI Gas: Jindal Steel and Power
ASU Lurgi Lurgi

FBDB™ Rectisol™
Gasification &
OxyClaus ™
Lurgi CLL™
Phenosolvan ™
CH4
CO
225 000 Nm3/h CO+H2+CH4
H2
ASU, Lurgi FBDB™ Gasification, Phenosolvan™, CLL™, Rectisol™, SRU OxyClaus™
Residue Gasification - MPG®
MPG® Summary
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
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
16
Residue Gasification References
2005 North West Upgrader

Purchases from SVZ
2002 HD POX
2001 Ultafertil
Multi
45 years experience
in residue gasification: Purpose
75 units
62.5 x 106 m3 N/d Gasification
Fixed Bed Grate Gasifier
1950 1960 1970 1980 1990 2000 2010

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, Methanol Synthesis Gas 800.000 Nm³/d MPG
Slurries and Power
2000 Brazil Asphalt, others Ammonia Synthesis Gas, 850.000 Nm³/d MPG
Burner Revamp
2002 Germany Natural Gas, Raw Synthesis Gas 36.000 Nm³/d MPG
Residue
2005 Canada Hydrocracked Hydrogen 3.500.000 Nm³/d MPG
17
Residue
Gasification India 2016 Air Liquide, world leader in gases for industry, health and the environment
17
()* MPG reference plant technology purchased by Lurgi, operated for more than 30 years
MPG® Residue-to-X Syngas
N2
(Fuel Gas)
Air Liquide Lurgi OxyClaus®
Elemental Sulfur
ASU Sulfur Recovery
CO2
Feed Air Liquide Ammonia Syngas

LNW Unit
Syngas, DRI, Power
Lurgi Lurgi Rectisol®
HP Steam MPG® CO Shift / Gas SNG
Methanation
Gas Cooling Purification
Lurgi Methanol-Propylene
Methanol Synth.
CO
Metal Ash Air Liquide Air Liquide

Recovery System CO Cold Box PSA Hydrogen
Metal Ash Waste Water
Steam Methane Reforming
World Map & References - Lurgi ReformerTM
Degussa Rheinfelden YARACO1 / YARACO 2

Messer Dormagen Location: Germany
Location: Germany Location: China
Product: 8.000 Nm³/h Hydrogen Product: 9.200Nm³/h CO
PRAXAIR Richmond Product: 7.000 Nm³/h CO Start-up: 1997
AIR LIQUIDE HERACLES Start-up: 1998 / 2005
Location: California Start-up: 2002
Location: Netherlands
Product: 204.000 Nm³/h Hydrogen Product: 130.000 Nm³/h Hydrogen
Start-up: 2010 (under construction) Start-up: 2011 (Project in Progress)
GLIMAR DALIAN
Location: Poland Location: China
Product: 10.000 Nm³/h Hydrogen Product: 72.000 Nm³/h Hydrogen
Start-up: - Start-up: 2006
AIR LIQUIDE Gulf Coast SMR H2

Location: Texas / USA
Product: 130.000 Nm³/h Hydrogen
Start-up: 2011 (Project in Progress) LOTOS HGU 2
Location: Poland
Product: 100.000 Nm³/h Hydrogen HAINAN Methanol
Start-up: 2009 (under construction) Location: China / Hainan
Product: 2.000 mtpd Methanol
Start-up: 2006
TITAN and ATLAS Methanol
Location: Trinidad
Product: 2.500/5.000 mtpd Methanol
Start-up: 1999 / 2004
PEMEX Cadereyta
Location: Mexico
Start-up: 2000 Batamas MEGAH
Location: Malaysia
Start-up: 1994
Cleveland-Cliffs ZAGROS 1 / ZAGROS 2

Location: Trinidad Location: Iran
Product: 41.500 Nm³/h Hydrogen Product: 5.000/5.000 mtpd Methanol
Start-up: 1998 Start-up: 2006 / 2009
National Petrochemical Co. (Kharg)
Location: Iran
PEMEX Madero Product: 2.000 mtpd Methanol
Location: Mexico Start-up: 1999
Start-up: 2001
P.T. Kaltim Methanol Industry
Location: Malaysia
Product: 2.000 mtpd Methanol
Start-up: 1998
SIPCHEM CO
Location: Saudi Arabia
Product: 30.520 Nm³/h CO BASF – BPC Kuantan
Start-up: 2009 Location: Malaysia
Product: 58.000 Nm³/h Syngas
Melaka HPU 2 Start-up: 2000
Location: Malaysia
Start-up: 2008
Repsol YPF
Location: Argentina PML
Product: 1.210 mtpd Methanol Location: Malaysia / Labuan
Start-up: 2002 Product: 5.000 mtpd Methanol
Start-up: 2009
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)
■ 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
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 H2 Lic.+ B.E. 2011
Middle East LPG, Naphtha, 339 300 H2 (2 EPC 2010
ROG, NG train + S/A PSA)
North America NG 130 000 H2 EPC 2009
Europe NG 130 000 H2 EPC 2009
Latest References – H2 and CO Plants
Region Feed Capacity (Nm3/h) Scope Award

Europe NG 8 500 CO EPC 2013
60 000 H2
24 100 H2
Asia NG 9 800 CO EPC 2010
35 600 H2
Largest H2 unit: 339 300 Nm3/h H2 (2 trains, S/A PSA)
Lurgi Reformer® - Isometric Arrangement
Process Gas
Combustion Air
Fuel Gas
Flue Gas
Arrangement Drawing
25
Lurgi SMR Feed-to-X Syngas
N2
Air Liquide
ASU
Ammonia Syngas
Feed
HP Steam
Air Liquide
SMR CO2 Removal Hydrogen
CO Cold Box PSA
CO
ATR CO Shift
Methanol
Synthesis Methanol-Propylene
Next Generation Coal Gasification Island
Associated Technologies
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
■ Methanol: > 50 plants; 9 coal based.

■ MTP™ : 2 running
■ Claus : >170 Claus Units

■ OxyClaus™ SRU: > 40 burners
Air Liquide: Air Gases
■ Operating >350 Air Separation Units
Total gaseous production
O2 > 120,000 tpd
N2 > 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)
Air Liquide’s Lurgi FBDBTM
■ Lurgi FBDBTM MK+TM: Proven Operation CO CH4
Innovative use of referenced technology for no scale-up risk H2
Safe & forgiving operation
Beneficial for low rank coal
Improved Capex and Opex
■ Financially Secure Investment
■ 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 H 2O
World bank standards
Best efficiency for high moisture & high ash coal

especially for SNG production.
Air Liquide’s Lurgi RectisolTM
■ > 60 Years of design expertise and operational feedback CO H2

■ Reference situation
21 references 2011 - today
42 references since 2000
Over 100 references in total
Complete CO2 and Sulfur removal.
■ 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
Air Liquide’s Cryogenic Gas Treating
■ > 90 Cold boxes referenced N2
CO H2
■ Syngas Final treating
Remove impurities in syngas e.g. CH4, N2… CH4
Produce pure syngas.
Composition ratio adjustment H2/N2=3:1…
■ 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!
Air Liquide’s Lurgi Methanol
> 40 Years of design expertise and operational
CH3OH
feedback
51 Plants with a total capacity of 33.5 MMTPY.
Extremely quick transfer of reaction heat:

Quasi isothermal operation
Overheating of catalyst impossible
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.
Food for Thought and Wrap-up
Air Liquide’s value addition
Value addition
■ Cutting-edge, commercially proven
We know… proprietary technologies
addressing the growing markets for
C CH4 coal-based & natural gas based

fuels and petrochemicals:
O2 Oxygen ■ Synfuels/Diesel
■ Methanol, DME
■ Propylene
Syngas CO H2 ■ Ammonia
■ Hydrogen
Synfuel
CH3OH
and the
products.
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,
4
naphtha, mixed feed
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
4,000 Air Liquide Global E&C Solutions Colleagues Thank You!
Lorton Montreal Ennery Krakow New Delhi Beijing

Moscow
Vitry Frankfurt
/Seine
Champigny
/Marne
Bussy-Saint-Georges Shanghai
Memphis
Harima
Houston
Hangzhou
Hyderabad
Singapore
Chennai
Sao Paulo
Johannesburg
Dubai
Riyadh
Engineering centers Manufacturing workshops Business offices Cryogenic equipment centers

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What are some of the technologies discussed for syngas generation and product synthesis?

What are some of the technologies discussed for syngas generation and product synthesis?

What are some of the applications mentioned for syngas and the products derived from it?

What are some of the applications mentioned for syngas and the products derived from it?

Syn Gas Generation

Various Routes – Multiple Products

Classification Level: PUBLIC

Business Owner: Global E&C Solutions Communications

Clean Conversion – Our Story

■ fluctuating price of oil & gas

■ Growing domestic demand for We know…

C ■ NG, LPG, Naphtha

H 2O + O2 ■ Coal, Heavy Residue

Residue Methanol Methanol

Acrylic Acid Acrylic Acid

Coal Air Liquide Ammonia Syngas

Lurgi Lurgi Phenosolvan® & Lurgi CLL™

(Clear Tar / Oil)

ZLD – Water Reuse

78 000 Nm3/h H2 + 900 tpd NH3 NH3 H2

5000 tpd MeOH to each MTP™

Gasification train DME

ASU, CO-Shift, Rectisol™, SRU OxyClaus™, LP Methanol & MegaMethanol™, MTP™

ASU Lurgi Lurgi

45 years prior operating experience with heavy

Existing Reference operating in Brazil (Fosfertil)

2005 North West Upgrader

1950 1960 1970 1980 1990 2000 2010

Feed Air Liquide Ammonia Syngas

Metal Ash Air Liquide Air Liquide

Metal Ash Waste Water

Degussa Rheinfelden YARACO1 / YARACO 2

AIR LIQUIDE Gulf Coast SMR H2

Cleveland-Cliffs ZAGROS 1 / ZAGROS 2

■ 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

■ 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

Region Feed Capacity (Nm3/h) Scope Award

Region Feed Capacity (Nm3/h) Scope Award

■ ASU: > 350 in the last 40 years

■ Lurgi FBDB™: > 120 reactors

■ Rectisol™ : > 100 Lurgi Rectisol

■ Methanol: > 50 plants; 9 coal based.

■ Claus : >170 Claus Units

Total gaseous production

O2 > 120,000 tpd

N2 > 95,000 tpd

■ The world leader in large scale air separation units

■ Financially Secure Investment

■ High Efficiency and reduced cost of SNG

Best efficiency for high moisture & high ash coal

■ > 60 Years of design expertise and operational feedback CO H2

Outstanding track record in a variety of applications!

■ Distillation packing: high efficiency & load variety.

Worldwide largest CO purifications

Extremely quick transfer of reaction heat: