Recent Technical Advances in the Production of Syngas at Sasol Presentation by: EG van de Venter

Transcription

1 Recent Technical Advances in the Production of Syngas at Sasol Presentation by: EG van de Venter Contributions by : Sasol Syngas Gas Production Technical and Operational Members GASIFICATION TECHNOLOGIES COUNCIL, SAN FRANCISCO CALIFORNIA, OCTOBER 28-30, 2002

2 Recent Technical Advances in the Production of Syngas at Sasol 1. Overview of Sasol and Syngas Production 1.1 South African Syngas Operations 1.2 Financial Performance, FY 2001/ Sasol Process and Sasol-Lurgi FBDB Gasifier 2. Syngas Production Facilities Performance, FY 2001/02 3. Enablers 3.1 People 3.2 Plant 3.3 Technology 4. Future

3 1.1 South African Operations USA South America Africa China Middle East India Tokyo Asia Pacific Hong Kong India Singapore Australia Namibia Cape Town Zimbabwe Mozambique Botswana Pretoria Johannesburg Sasolburg Secunda Richards Bay South Africa Durban Mossel Bay Port Elizabeth Refineries South Africa Synfuels and Chemical Plants Coal used as main feedstock to produce Syngas via Sasol-Lurgi FBDB Gasification. South African plants gasify ±30 M tons of coal to Syngas. 97 FBDB Gasifiers 17 Sasolburg and 80 in Secunda. Production rates in excess of design capacity

4 1.1 South African Operations (cont) From humble beginnings to world-class facilities

5 1.2 Sasol Financial Performance, FY 2001/2 Another year of outstanding performance Record earnings despite tough market conditions. All key divisions contributed to earnings growth. 40% of earnings contributable to management actions (volumes, Sasol Chemie, cost reduction). 13% increase in sales to $6.1 billion. 4% increase in operating profit to $1.5 billion. Gearing within target of 20-40%. Capital projects of $3.3 billion committed.

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7 1.3 Sasol-Lurgi FBDB Gasifier Bunker Feeder Coal lock Coal Quench liquor Quench cooler Advantages Lump coal and limited grinding High ash content Coal with high ash flow temperature High cold gas thermal efficiency Rotating grate Ash lock Ash to sluiceway Steam & oxygen Low oxidant requirements Valuable co-products (e.g. tars) H 2 /CO = 1.7 to 2.0 (suitable for FT)

8 2.1 Syngas Production Facilities Performance FY2001/02 Synfuels GP, Secunda SynFuels Pure Syngas Production July 02: 3131 km3n/h Aug 02: 3113 km3n/h Sept 02: 3107 km3n/h Pure Symgas Load km3n/h Budget Avg 95/6 Avg 96/7 Avg 97/8 Avg 98/9 Avg 99/0 Avg 00/01 Jul-01 Aug-01 Sep-01 Oct-01 Nov-01 Dec-01 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Ytd 01/02 Actual Budget Steady increase to record volumes: stability and availability

9 2.2 Syngas Production Facilities Performance FY2001/02 Infrachem GP, Sasolburg Pure Gas Production Sasolburg, Infrachem, Pure Syngas Production /64 64/65 65/66 66/67 67/68 68/69 69/70 70/71 71/72 72/73 73/74 74/75 75/76 76/77 77/78 78/79 79/80 80/81 81/82 82/83 83/84 84/85 85/86 86/87 87/88 88/89 89/90 90/91 91/92 92/93 93/94 94/95 95/96 96/97 97/98 98/99 99/00 00/01 01/02 Pure Syngas vol (km3n/h) 02/03 Impressive track record to end year at near record levels: availability and feedstock preparation, blending and QA

10 3.1 Enablers People: Employees, Leadership and Strategy Years of operational and maintenance experience is employed to maintain the high level of plant availability, and each year increase the through put and efficiency of the facilities. Continuous training and development of employees lays the foundation for technology development and implementation. Building the right work place climate is driven through motivated leadership, strategy implementation and founded and on Sasol s five shared values: Customer Focus Winning with People Excellence in all we do Continuous improvement Integrity

11 3.2 Enablers - Plant Installed asset base of 97 gasifiers Sasol 1 Infrachem, Sasolburg: 1954/66-13 MK III gasifiers - 47 % scale up of org FBDB design bottom driven MK IV s added - 54% scale up MK V added of 88% scale up Sasol 2&3 Synfuels, Secunda : 80 MK IV s at Secunda De-bottlenecking key to realising inherent capacity Capacity per gasifier increased Peripheral assets: utility suppliers, downstream gas processing equipment, control systems etc Reliability and Availability: asset management and preventative maintenance.

12 3.3 Enablers - Technology Technology Development Architectural: new ways in which known units, inventions, etc. interact Incremental: improvements to existing unit operations Radical: new technology, new applications Technology Tools Process design tools (HTFS, Bjac, Aspen, steady state and dynamic etc.) Mechanical design tools (Autocad, CFD etc) Other (Piloting, Statistical software, ATP) Technology Support Groups Sasol Technology (Design, R&D and Project Execution) Operational support engineers and technicians Maintenance and Asset Management (reliability engineering

13 3.3 Enablers - Technology Architectural: New ways in which known units, inventions, etc. interact Feedstock Tests / Evaluations Evaluations of various size fractions. Elimination of Segregation in feed PSD. Other technology developments Improved tar solids processing. Dry coal screening Economic evaluations of alternative production routes.

14 R&D - coal mineralogy 3.3 Enablers - Technology Incremental: Improvements to existing unit operations Control and Instrumentation Advanced Process/Predictive Control (APC) Auto Start Up Gasifier Training Simulator Neural Networks Application Mechanical / Material Fifth generation jacket installation Mechanical modifications: shrink-fit pinions and stellite bearings Improved Gas Cooling - helical baffles for crude syngas coolers

15 3.3 Technology, Incremental: helical baffles Replace current baffle arrangement Prevents build up of deposits in Dead Zones Benefits: improved heat transfer and less on-line cleaning required Flow pattern in helical baffle heat exchanger Construction of helical baffle heat exchanger Increased heat transfer and/or lower shell side pressure drop

16 3.3 Enablers - Technology Radical: New technology, new applications Mechanical / Material New generation gasifier jacket Continuous Operation Feedstock Tests Biomass testing Environmental Open Impellor Aeration Units for Sulphur recovery Other New Generation Mark VI Gasifier

17 4 Future Further growth at Secunda syngas facilities Gasifier and technology development

18 4.1 Future: further growth at Secunda Increase saleable products Improve yields, efficiencies, effectiveness Reduce unit costs Goal: TO CLOSE THE GAP!!! - I.e. our common ultimate goal! GAP Business and Technical Support Growth target Business: technical strategy & medium & long term plans Sweat the assets Lift the baseline Optimise design base; short term, stability focus Baseline

19 4.2 Future: Gasifier development Gasifier development continues Coal Bunker Feeder Coal lock Feed Advanced Control Rotating grate Ash lock Ash to sluiceway Quench liquor Quench cooler Steam & oxygen Jacket Cooling Ash Extraction Focused drive to develop and implement technology

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