Thermochemical Upgrading Workshop Coal to Liquids (F-T) Via Gasification Newark, DE Oct. 8/9, 2013 l Pietro Di Zanno I Program Manager - Synfuels l Air Liquide GE&CS
Presentation Agenda Acknowledgement Mr. Max Michael Weiss, Director Innovation, Frankfurt, Germany and Mr. Denis Cieutat, Managing Director, GTL.F1 Air Liquide Global E&C Solutions Perspective One Stop Shop Next Generation Lurgi FBDB TM Coal Gasification GTL.F1 Technology Conclusions 2
Technologies Offered A One-Stop-Shop Concept Air Liquide Lurgi Can Offer a Complete One Stop Shop!!! Main Technologies FBDB TM Gasification Air Separation Unit Rectisol Unit GTL.F1 : Fischer-Tropsch Supporting Technologies Liquid Nitrogen Wash Phenosolvan Unit CLL TM Technology OxyClaus Unit Optional Technologies Methanation CO ColdBox 3
Thermochemical Upgrading Workshop Coal to Liquids Via Gasification Gasification Technology 4
Coal to Liquids GZN Processes Required : Before Fischer-Tropsch N2 (Fuel Gas) Air Liquide ASU Lurgi MPG Gasification Lurgi OxyClaus Sulfur Recovery Elemental Sulfur CO2 Coal Preparation HP Steam Lurgi FBDB Gasification Lurgi CO Shift / Gas Cooling Lurgi Rectisol Gas Purification Syngas Ash HP Steam (Rectisol Naphtha) Lurgi GLS Process 2 Operation Modes Possible: Co-products Recovered Co-products Gasified Lurgi Phenosolvan & Lurgi CLL Gas Liquor Recovery and Water Treatment (Phenols) (Clear Tar / Oil) Liquid Ammonia ZLD Water Reuse 5
Lurgi FBDB TM Mk Plus TM Gasifier Countercurrent Operation: Coal Moving Down Gas Moving Up Gasifier top 1 0.9 0.8 Drying Coal Gas 0.7 0.6 Devolatilization 0.5 0.4 0.3 Gasification Combustion 0.2 0.1 Gasifier 0 bottom Ash 0 300 600 900 1200 1500 Temperature [ C] Temperature Profiles and Operating Zones 6
The Lurgi FBDB TM Gasifier Operating Range Coal Suitability, Complex Function of: Lump Coal Typically 5 50 mm PSD Ash Fusion Temperature > 1200 C Under Oxidizing Conditions Combined Total Ash and Moisture < 55% Thermal and Mechanical Strength Caking In Range of Proven Proprietary Internals Green Area Shows Proven Operating Range for the Lurgi FBDB TM Gasifier All Ranks of Coal Proven in Operation Lignite, Sub-bituminous, Bituminous, Anthracite 7
Basis of Lurgi FBDB TM Mk Plus TM Development of the Present Gen Drivers Lower Environmental Footprint Competitiveness Starting Point: Mark 4 From Jindal Steel & Power Ltd. (JSPL) Angul Project Lessons Learnt From 30 Years Of Operation of Sasol s (Secunda, RSA) And DGC (North Dakota, USA) Plants Latest Project: JSPL Angul, India, 40 Barg Design Pressure Increase of the Diameter Reason: Gain In Terms of Capacity Increase of the Operating Pressure Gain In Capacity, Efficiency, Environmental Footprint / Methane Slip Optimum Pressure: 60 Barg for Capex and Scale-up Risk Name Mark 4 Mark + Nomenclature Mk4-HP40 Mk5E-HP60 Gas Loading knnm3/h 100% 60,000 200% 120,000 Outside dia (m) 4.13 5.05 Overall Height (m) 12.5 17 DP (Barg) 40 60 Other Important Results Less Fugitive Emissions Ash Lock and Other Tightening Treated Water 80 % Recovery Lowered Overall Capex Acros Whole Process Chain 8
Thermochemical Upgrading Workshop Coal to Liquids Via Gasification F-T Technology 9
Coal to Liquids Fischer-Tropsch Technology GTL.F1 AG The Company A Limited Company Under Swiss Jurisdiction Founded in 2005 Shareholders PetroSA and Lurgi GmbH Works With Air Liquide Global Engineering & Construction Solutions The Technologies GTL.F1 Owns the Fisher-Tropsch Slurry Bubble Column Technology and Catalyst IP An Advanced Slurry Bubble Column Reactor Concept With Proprietary Cobalt Catalyst Focus To Market The Entire F-T Concept Based on: All Syngas Production Technologies (Gas or Coal or Biomass Based) Proprietary F-T Technology Integrating Upgrading Technology From a Third Party Link to Air Liquide Global E&C Solutions Technologies Air Separation Units, Hydrogen Units and Purification Technologies Such as Cold Boxes, Membranes, PSAs and Tail Gas Recovery
Coal to Liquids GTL.F1 AG Services Offered Studies Usually the First Stage of an Project Development Process Licensing of Technology (i.e.) Licensor Design Package Supply of Proprietary Equipment Supply of Proprietary Cobalt Catalyst Engineering Plant Commissioning, Training, Start-Up Support Technology Support Dissemination of Improvements Development of Processes World s Largest Demomstration Plant for Cobalt Slurry Bubble Column Reactor Operation Plant Operations Support Services (Through PetroSA)
Coal to Liquids Product Slate Dictates Technology Choice! Technology Choice is Dictated by the Product Slate What Market is Desired? Regional Product Demand and Pricing? What Are the Product Specifications for the Product Slate? Company Focus? Low Temperature Process Benchmark - Cobalt or Iron Catalyst Based Three Reactor Configurations Exist - Fixed Bed, Slurry Bubble Column and Micro-channel LPG ~ 5% Naphtha 15 20% Middle Distillates 75 80% 12
Coal to Liquids Reactor Technologies GTL.F1 (Slurry Bubble Column) Tubular Fixed Bed Reactor Small Maximum Capacity Lower Productivity / Volume Construction PoorerHeat Transfer / Temp. Gradients Pressure Drop Scale Up Slurry Bubble Column Reactor Higher Maximum Capacity Higher Productivity / Volume Easier Construction Good Heat Transfer Pressure Drop Scale Up Catalyst / Wax Separation Espinoza 13
Fischer-Tropsch Development Activities - Invested Largest Semi-Commercial Unit in the World Mossel Bay, South Africa, With PetroSA and Statoil Semi-Commercial Operational Between 2004 and 2008 12 Testing Programs With Six Month Runs Obtained Reactor Diameter Structural Height Foot Print Operation 2.7 Meters 40 Meters 25 X 40 Meters Up to 1000 B/D What Was Developed Development of SU and SD Procedures Handling of Catalyst Slurry Determination of Hydrodynamic Parameters Verification of Product Yields Verification of Long Term Catalyst Activity Optimization of the Product Recovery System (Oil and Water)
Coal to Liquids Process Scheme With GTL.F1 ATR TGR Gasification Rectisol SRU
Coal to Liquids Process Integration Benefits Process Integration is Important for Optimizing Plant CAPEX, OPEX and Product Slate Most Capital Intensive Process Gasification and Syngas Treatment Required to Deal With Feedstock. Considerable Integration Potential Between Units Reduces CAPEX Improved Reliability / Availability Can be Designed With Appropriate Buffers and Storage Units Product Slate Can Also Include: Power, Steam, CO2, Sulphur, and Industrial Gases CTL Plant % of Total CAPEX Gasification Gas Treat F-T Upgrading 20 30% 10 15% 15 25% Offsites and Utilities 30 40% 10 15%
Coal to Liquids Project and Market Issues Unknowns? Technology Application Operations? Customer(s) Environmental CO2 and Water Pollution Execution High Crude & Product Pricing Low Feedstock Cost (Coal) CAPEX Significant Project Uncertainties Financing Terms & Conditions Feedstock / Natural Gas Competition Government Support Energy Diversification Feedstock Reserves Uncertainty Syndication, Pricing 17
Coal to Liquids F-T Overview F-T Technology Based on Slurry Reactor and Cobalt Catalyst is the Benchmark Suitable for GTL, BTL, and CTL Based Projects Slurry Bubble Column Technology Demonstration in a Large Scale is Essential Air Liquide Global Engineering & Construction Solutions and GTL.F1 Can Provide Performance Guarantees, Facilitating Bankability Our Semi-Commercial Demonstration Plant Many Challenges Solved During Testing Programs Lessons Learned Incorporated Within Commercial Designs Process Suitable for Medium and Large Projects Modularization - To Meet Project Constraints Usually a Construction Issue Optimization of Different Processes Required CAPEX and OPEX Reduction Results Air Liquide Global Engineering & Construction Solutions With GTL.F1 : Provides One Interface for All Required Technologies - Improving Design, Process Guarantees and Ensuring Project Viability 18
Coal to Liquids Conclusion Coal to Liquids Projects Are Technologically Feasible. Are Complex Require Significant CAPEX Operational Experience is Needed on the Whole Plant and. We Have Not Discussed Carbon Dioxide Emission Issues Fixed Bed Dry Bottom Gasification is Proven and Operating Fischer Tropsch Slurry Bubble Bed Technology Is Available Integration Within the Units and Within the Gasification Process is a Top Priority Will Work With FBDB Technology and With All Other Gasification Processes Air Liquide Can Provide a One Stop Shop for All Technologies Required Integration of Processes and Utilities and Offsites (Water, Etc.) Important. CTL Projects Can be Strategic and Profitable - Opportunities Exist, Especially for Medium to Large Capacities 19
Thermochemical Upgrading Workshop Thank You for Your Kind Attention Questions? Pietro Di Zanno International Senior Expert Program Manager Synfuels Pietro.dizanno@airliquide.com Tel: 49 69 5808 1729 Mob: 49 172 653 1053 Denis Cieutat International Fellow Managing Director GTL.F1 Denis.Cieutat@airliquide.com Tel: 49 69 5808 2333 Max Weiss International Senior Expert Director Innovation Max-Michael.Weiss@airliquide.com Tel: 49 69 5808 3452