VESTA a Novel SNG Technology
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1 VESTA a Novel SNG Technology Bressan Luigi Director of Process and Technologies Foster Wheeler Page - 1 -
2 Agenda Introducing Foster Wheeler Coal to Gas: Available SNG Technologies Coal to Gas: VESTA SNG Technology Status of the Technology Development Experience transfer Catalyst for VESTA SNG technology Application Conclusions Page - 2 -
3 Foster Wheeler An Introduction Tracing our roots to 1884 A leading international EPC contractor and power equipment supplier Successfully executed full life-cycle projects from concept to commissioning and operation including the Upstream, Midstream and Downstream hydrocarbon processing sectors $4 bn operating revenues in 2010 NASDAQ-listed company with operating HQ in Switzerland Permanent offices in 28 countries Page - 3 -
4 Foster Wheeler Delivering EPC excellence Upstream oil & gas LNG, gas-to-products, coal-to-products Refining Gasification Carbon capture & storage Chemicals & petrochemicals Pharmaceuticals, biotechnology & healthcare Power Metals & mining Environmental Page - 4 -
5 Foster Wheeler and Sud-Chemie jointly developed d the novel VESTA process to solve your SNG problem Page - 5 -
6 Coal to Gas Available SNG Technologies COAL Gasification Block Adjustment of H2/CO Ratio 3:1 CO2 Removal H2S Removal SNG Process SNG Gasification CO Conversion Purification SNG Process Different Technologies Differences in H2/CO Differences in CH4 Sour Gas Shift Physical Solvent Complex scheme to separate H2S from CO2 Exothermic Reaction Expensive Reactors Material High temperature Superheater Recycle at high temperature Recycle Compressor Page - 6 -
7 Coal to Gas Available SNG Technologies COAL Gasification Block Adjustment of H2/CO Ratio 3:1 CO2 Removal H2S Removal SNG Process SNG SNG Process Criticalities Exothermic Reaction Expensive Reactors Material High temperature Superheater Recycle at high temperature Recycle Compressor H2/CO Ratio Coke formation Recycle mandatory Temperature runaway Brick lined reactors Unsafe Operation Metal dusting risk Limitation in train size Page - 7 -
8 Coal to Gas VESTA SNG Technology Can Foster Wheeler and Sud-Chemie do more for you? Can we avoid high temperatures? Can we avoid recycle compressors? Can we avoid high temperature superheaters? Can we avoid brick lined vessels? Can we avoid high h alloyed steel? Can we avoid metal dusting? Can we avoid isothermal reactors? Page - 8 -
9 Coal to Gas VESTA SNG Technology Foster Wheeler and Sud-Chemie s Novel Vesta Process! Page - 9 -
10 Coal to Gas VESTA SNG Technology Available Technologies COAL Gasification Block Adjustment of H2/CO Ratio 3:1 CO2 Removal H2S Removal SNG Process SNG Novel Process COAL Gasification Block H2S Removal SNG Process CO2 Removal SNG Page
11 Coal to Gas VESTA SNG Technology Novel Process COAL Gasification Block H2S Removal SNG Process / CO2 removal SNG Gasification Purification SNG Process / CO2 removal All gasification technlogies are compatible with the Novel VESTA Process High efficiency / WHB / dry type are more beneficial H2S removal Carbonyl removal Fine Purification No H2/CO ratio adjustment No limitations of H2/CO ratio Neither coke formation nor metal dusting risk Low alloyed steel reactors Low severity WHB No Recycle Compressor Final CO2 removal (high quality) Page
12 Coal to Gas VESTA SNG Technology The novel VESTA process benefits Low temperature process: MAXIMUM 550 C No coke formation No metal dusting risk Once-through operation: NO RECYCLE COMPRESSOR Low severity steam boiler No brick-lined vessel No high alloyed steel No isothermal reactor High quality CO 2 recovery Page
13 Coal to Gas VESTA SNG Technology Economics Investment no recycle compressor no HT superheater all equipment sourced locally all equipment easy to transport on road smaller foot print Operation easy to operate start-up and shut-down procedures fast and simple high turn-down rate Safe to operate no temperature runaway possible Page
14 Status of the Technology Development The SNG novel process has been developed by FW with Sud-Chemie for the catalyst required for the methanation reactors The process has been simulated and the relevant optimum parameters defined Reactions have been tested at equilibrium and kinetics simulations have been completed The catalyst has been tested in the laboratory both for performance and resistance and all theoretical calculations have been confirmed Page
15 Experience Transfer FW has a great deal of experience in hydrogen plants where syngas is produced, shifted and cleaned up FW has a great deal of experience in power generation following a gasification unit (designed, engineered, constructed and started-up one of the largest IGCC in the world) FW have a great deal of experience in Acid Gas Removal systems from all available licensors FW has the capabilities to engineer complex control systems for the simultaneous operation of multi-unit complexes Page
16 Catalyst for VESTA SNG Technology Sud-Chemie Catalyst Nickel-based Stabilized matrix Continuous operation up to 560 C Stability demonstrated Page
17 Application Foster Wheeler and Sud-Chemie are investigating for opportunities in Chinese market On the basis of the information collected have tried to fix a typical study case Application The followings have been calculated: The specific consumption of clean syngas for 1000 NM 3 of SNG produced. Analysis and heating value of syngas Utility requirement/production for/from the process The information shall be considered preliminary and may be subject to further optimization on the basis of specific data that customers would like to give us Page
18 Application Design Basis Syngas composition At gasification outlet downstream AGR Syngas composition mol% CO H CO H 2 S + COS < 4 ppm N 2 Traces CH NH Ar Traces H 2 O 0.31 (sat) Syngas condition Value Pressure, Bar g 30.0 Temperature, 0 C 40.0 Page
19 Application Design Basis Utilities characteristics Steam Pressure (Bar g) Temperature (deg C) HP MP LP 1.8 Sat. Page
20 Application Conceptual Block Scheme CO2 Clean Shift Methanation reactors Finishing reactor 1 Syngas AGR CO2 Remov. Scrubber SNG 2 Page
21 Application 3 Methanation reactors Performances for a 250,000 Nm 3 /h (2.1 bn/y) Feed consumption 3433 kg/h of syngas for the production of 1,000 Nm 3 /h of SNG SNG quality CH H CO CO H 2 O Inerts traces traces LHV(kCal/Nm 3 ) after drying 1 2 Real production Nm 3 /h 272, ,656 Page
22 Application 3 Methanation reactors Performances for a 250, Nm 3 /h (2.1 bn/y) Performances (based on 3 methanation reactors) Utilities AGR inclusive (CO 2 removal) HP steam (40) 276 t/h MP steam (12) LP steam (1.8) Heat import 124 Gcal/h Demi water 448 t/h Electric Power (no recirculation compressor) Page
23 Application 3 Methanation reactors Catalyst volumes (based on 3 methanation reactors) Shift reactor CLEAN 160 m m diam. 1 Methanation 150 m m diam. 2 Methanation 160 m 3 4.7m diam. 3 Methanation 160 m 3 4.7m diam. Finishing Methanation 45 m 3 Total Shift 160 m 3 Total Methanation 470 m 3 Total finishing 45 m 3 Total 675 m 3 Page
24 Application 4 Methanation reactors Performances for a 250,000 Nm 3 /h (2.1 bn/y) Feed consumption 3433 kg/h of syngas for the production of 1,000 Nm 3 /h of SNG SNG quality CH H CO CO H 2 O Inerts traces traces traces traces LHV(kCal/Nm 3 ) after drying after drying Real production Nm 3 /h 272, , , , Page
25 Application 4 Methanation reactors Performances for a 250, Nm 3 /h (2.1 bn/y) Performances (based on 3 methanation reactors) Utilities AGR inclusive (CO 2 removal) HP steam (40) 276 t/h 419 t/h MP steam (12) LP steam (1.8) Heat import 124 Gcal/h 209 Gcal/h Demi water 448 t/h 589 t/h Electric Power (no recirculation compressor) Page
26 Application 4 Methanation reactors Catalyst volumes (based on 3 methanation reactors) Shift reactor CLEAN 160 m m 3. 1 Methanation 150 m m 3 2 Methanation 160 m m 3 3 Methanation 160 m m 3 4 Methanation m 3 Finishing Methanation 45 m 3 45 m 3 Total Shift 160 m m 3 Total Methanation 470 m m 3 Total finishing 45 m 3 45 m 3 Total 675 m m 3 Page
27 Conclusion Foster Wheeler and Sud-Chemie can tailor the VESTA process for your specific SNG project requirements Page
28 Thank you. Any questions? Page
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