Application of MCG Technologies

Transcription

1 Coal Gasification Related Industries and Economic & Environmental Sustainability Analysis Vice CTO: Mr. Pi Jinlin Wuhuan Engineering Co., Ltd. 30th Nov, 2018

2 1 Background of MCGI 2 Application of MCG Technologies 3 3E Analysis of MCGI 4 Tips & Suggestions Notes: MCGI means Modern Coal Gasification related Industries 3E means Environment, Economy & Energy Efficiency

3 1. Background of MCGI 1.1 Main Commercialized Production Chains of MCGI Coal Gasification Purification Ammonia Route Urea/Melamine/AN/ Other fertilizers Methanol Route Olefin/DME Formaldehyde/Acetic Acid MTBE/ DMMn Medicine/Solvents EG Route Polyesters/Surfactants /Solvents Liquif. Route Gasoline/Diesel/LPG Fuel Gas Route Town gas/sng/igcc

4 1. Background of MCGI 1.2 MCGI plays an important role in China (1) Ammonia/Urea China NH3 capacity is ~70 MTPA, ~30% of the world China Urea capacity is ~82 MTPA, ~40% of the world ~76% of China NH3/Urea is produced from coal (2) Methanol China capacity is ~80 MTPA, ~60% of the world ~70% of China methanol is produced from coal

5 1. Background of MCGI (3) EG China capacity is ~8.1mt/a, ~25% of the world Capacity of coal-based EG is ~2.45 mt/a, ~30% of China total 3.15 MTPA Coal-based EG projects are under construction (4) Direct Coal Liquefaction China s capacity is ~1 mt/a; it has largest and the only one commercial plant in the world in operation Direct Coal Liquefaction projects with a total capacity of 2 mt/a are under construction

6 1. Background of MCGI (5) Indirect Coal Liquefaction China s capacity is ~6 mt/a Projects with a total capacity of 20mt/a are planned to be constructed (6) MTO/MTP China s capacity of olefin is ~50mt/a Capacity of coal-based olefin is ~13mt/a, ~25% of China s total Coal-based olefin projects with a total capacity of ~20mt/a are under construction (7) SNG China s capacity is ~5 billion Nm3/a. SNG projects with a total capacity of 70 billion Nm3/a are under construction

7 1. Background of MCGI 1.3 MCGI is a valuable sector in China Drivers of coal gasification related industries (1) Higher Self-Reliance in Energy Supply (2) Lower Risk of Oil and NG Supply from Abroad (3) Less Pressure of CO2 Emission China is the only country in the world, where large-scale coalgasification-related industries play a significant role in economy development. China s coal-gasification-related plants have the world s largest singletrain capacity, and advanced and reliable performance.

8 1. Background of MCGI (1) Capacity of Ammonia/Urea The largest single-train ammonia capacity: ~700 kt/a Urea: ~1.2mt/a. (2) Capacity of Methanol The largest single-train methanol capacity: ~2mt/a (3) Capacity of EG The largest single-train EG capacity: ~100 kt/a (4) Direct Coal Liquefaction : ~1 mt/a (5) Indirect Coal Liquefaction: ~ 1 mt/a (6) MTO: ~833 kt/a (7) SNG: ~2 billion Nm3/a

9 1. Background of MCGI We are very glad to share with you our experience on how to develop Coal Chemical projects that suit local conditions and apply local feeds.

10 2. Application of MCG Technologies 2.1 Modern Coal Gasification Technologies Fixed Bed Gasf. Lurgi BGL U.G.I. Coal Slurry Gasifi -cation GE-Texaco E-Gas Multi-Nozzle Entr. Flow Gasf. Dry Pulverised Coal Fluid Gasf. HTW KRW U-gas TRIG SCCR Shell Prenflo GSP HT-L

11 2. Application of MCG Technologies 2.2 Features of Advanced MCG Inherent safety Environment-friendly High energy efficiency High feed flexibility High single-train capacity High reliability and easy maintenance

12 2. Application of MCG Technologies 2.3 Principles in Coal Gasification Technology Selection Matching coal properties Matching final products Advanced technology Inherent safety Environment-friendly High energy efficiency Reliable and profitable High reliability and commercial proven High single-train capacity Cost effective

13 2. Application of MCG Technologies The selection of coal gasification process is crucial to the success of a project.

14 2. Application of MCG Technologies 2.4 Introduction of Main Coal Gasification Technologies Entrained flow gasification technology (the dominating technology in the market)

15 2. Application of MCG Technologies Reference List Items Multi-Nozzle Gasification Feedstock scale Syngas Number of for Single Gasifiers x106 Nm3/d Gasifier <1,000 t/d 5 1,000~2,000 t/d 76 ~3,000 t/d 12 <1,000 t/d 8 (Dry Pulverised Coal side fired Entr. Flow Gasfication) 1,000~3,000 t/d 19 >3,000 t/d 6 GSP Gasification 200 MW (1,000 t/d) 2 (Dry Pulverised Coal top fired Entr. Flow Gasfication) 500 MW(2,000 t/d) 31 1,000 t/d 27 2,000 t/d 61 3,000 t/d 1 (Coal Slurry Entr. Flow Gasification) SHELL Gasification HT-L Gasification (Dry Pulverised Coal top fired Entr. Flow Gasification) Remarks - Total feedstock amount is 110,000 t/d Including 2 trains of SHELL bottom quench gasifiers

16 2. Application of MCG Technologies Schematic flow diagram of Multi-Nozzle gasification

17 2. Application of MCG Technologies Schematic flow diagram of shell gasification with syngas cooler

18 2. Application of MCG Technologies Schematic flow diagram of Siemens GSP gasification

19 3. Analysis of 3E on MCGI 3.1 Mandatory Pollutant Limits in China Gaseous Emission, the highest emission standards in the world NO. Pollutant Stack, m max. allowed vent rate, kg/h max. allowed vent concentration, mg/nm3 1 Particles SO NOx H2S

20 3. Analysis of 3E on MCGI Effluents: The highest discharge standards in the world, and practiced Zero discharge principle in NW China. No. Pollutant Limitation, mg/l PH TSS CODCr BOD5 NH3-N total N total P total organic carbon oil total cyanide Waste Solids: slag, flyash and filter cake are recycled as construction materials and catalysts are recycled by vendors.

21 3. Analysis of 3E on MCGI 3.2 Mandatory Energy Efficiency Requirements in China Coal Direct Liquefaction Items Coal Indirect Liquefaction MTO SNG Baseline Advanced Value Baseline Advanced Value Baseline Advanced Value Baseline Advanced Value Water Consumption (t /t or /knm3) Energy Efficiency (%) Energy consumption (t coal eq/t or /knm3) Coal consumption (t coal eq/t or /knm3)

22 3. Analysis of 3E on MCGI 3.3 Typical Economic Indexes of lignitelignite-based NH3/Ur. Project O2/Steam CO2 Lignite Pre -drying Gasifi -cation Purifi -cation Gasification and purification NH3 Synth. Urea Synth. NH3 Synth. and Urea Synth. Typical Simplified Process Scheme Urea

23 3. Analysis of 3E on MCGI No. 1 Items Unit Data Price Main Product 1.1 Urea Kt/a 1, USD/t 1.2 Ammonia Kt/a 600 Immediate product 2 Main feedstock 2.1 Feedstock coal (lignite, LHV ~ 3,000 kcal /kg, as received) Kt/a 1, USD/t 2.2 Fuel coal (lignite, LHV ~ 3,000 kcal/kg, as received) Kt/a 1, USD/t 2.3 Fresh water Kt/a 12, USD/t 2.4 Electricity kwh/a Balance

24 3. Analysis of 3E on MCGI No. 3 Items Unit Data Main financial evaluation indicators 3.1 Construction investment MM USD Annual average sales income MM USD FIRR before income tax FIRR after income tax Investment recovery period before income tax (including construction period) years The cost of urea USD/t 147 Note: 1. Annual operating time 8,000 hrs. 2. Construction time: 3 years, Running time: 17 years

25 3. Analysis of 3E on MCGI 3.4 Typical Economic Indexes of LigniteLignite-based Methanol Project O2/Steam Lignite Pre -drying Gasifi -cation Purifi -cation Gasification and purification Methanol Synth. Methanol Distill. Methanol Processing Typical Simplified Process Scheme MOH

26 3. Analysis of 3E on MCGI No Items Unit Data Price Kt/a USD/t Main Product Methanol Main feedstock 2.1 Feedstock coal (lignite, LHV ~ 3,000 kcal/kg, as received) Kt/a 1, USD/t 2.2 Fuel coal (lignite, LHV ~ 3,000 kcal/kg, as received) Kt/a USD/t 2.3 Fresh water Kt/a 9, USD/t 2.4 Electricity kwh/a Balance

27 3. Analysis of 3E on MCGI No. 3 Items Unit Data Main financial evaluation indicators 3.1 Construction investment MM USD Annual average sales income MM USD FIRR before income tax FIRR after income tax Investment recovery period before income tax (including construction period) years The cost of liquid methanol USD/t 212 Note: 1. Annual operating time 8,000 hrs. 2. Construction time: 3 years, Running time: 17 years

28 3. Analysis of 3E on MCGI 3.5 Typical Economic Indexes of LigniteLignite-based EG Project O2/Steam Lignite Pre -drying Gasifi -cation Purifi -cation Gasification and Purification PSA EG Synthesis CO Cryogen. Sep. Gas Sep. and EG Synth. Typical Simplified Process Scheme EG

29 3. Analysis of 3E on MCGI No Items Unit Data Price Kt/a USD/t Product EG Main feedstock 2.1 Feedstock coal (lignite, LHV ~ 3,000 kcal/kg, as received) Kt/a 1, USD/t 2.2 Fuel coal (lignite, LHV ~ 3,000 kcal/kg, as received) Kt/a 1, USD/t 2.3 Fresh water Kt/a 12, USD/t 2.4 Electricity kwh/a Balance

30 3. Analysis of 3E on MCGI No. 3 Items Unit Data Main financial evaluation indicators 3.1 Construction investment MM USD 1, Annual average sales income MM USD FIRR before income tax FIRR after income tax Investment recovery period before income tax (including construction period) years The cost of liquid EG USD/t 426 Note: 1. Annual operating time 8,000 hrs. 2. Construction time: 3 years, Running time: 17 years

31 3. Analysis of 3E on MCGI 3.6 Economic competitiveness against NG Typical Economic Data of Urea Project in Indonesia No. Feed and Fuel Coal Price FIRR before Income tax USD/t % Eq. Price of NG Based Chemicals USD/MM Btu Note: 1. Annual operating time 8,000 hrs, Annual urea capacity 1,047 Kt /a, annual ammonia (immediate product) capacity 600 Kt/a. 2. Construction time: 3 years, Running time: 17 years. 3. Assumed feed and fuel Coal are lignite coal, LHV ~ 3,000 kcal/kg as received. 4. Assumed urea price is 241 USD/t. 5. The data are preliminary at feasibility stage and estimated based on engineering experience in China and Indonesia.

32 4. Tips & Suggestions -- A good report of coal properties and coal reserve -- A good report of final product scheme -- A good FSR covering -- Construction conditions and site information (site location, material supply, utility and infrastructures, transportation, climate) -- Market survey and study -- Technical sketch and utility/off-site requirements -- High level construction schedule -- Estimate -- Financial analysis -- Conclusion

33 4. Tips & Suggestions -- A good FEED with perfect project definition: -- Basic engineering design -- Project management strategy -- Precise investment estimate -- Award EPC contract to a professional and experienced EPC contractor

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