Lurgi s MPG Gasification plus Rectisol Gas Purification Advanced Process Combination for Reliable Syngas Production

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1 Lurgi s MPG Gasification plus Rectisol Gas Purification Advanced Process Combination for Reliable Syngas Production Ulrich Koss, Holger Schlichting Gasification Technologies 2005 San Francisco, October 2005 Lurgi AG

2 Content Multi Purpose Gasification History of Lurgi Gasification Know-How Features of MPG HP-Pox Demonstration Plant Application in Ammonia Plant Gas Purification Technology Advantages of Rectisol for a Hydrogen Plant 2

3 3 MPG - Multi Purpose Gasification Lurgi s Gasification Technologies 75% of Syngas from Coal World Wide produced in this type Gasifier Operates since 5 years with feedstock mixture of coal, petcoke and municipal waste 30 years operation with slurry feedstock

4 Special Features of MPG Feed O 2 + Steam Feed A O 2 Feed B Steam Cooling Water Quench Water Gas-offtake Soot Slurry 4

5 Advantages of MPG Feedstock Flexibility No limitations on Flash Point of Feedstock Viscosity up to 300 cst Particles up to 1 mm Life Time of Burner Higher Reliability and Availability Restart without Inspection Inherent Safety by pressurized Cooling Water System Client did not inspect burner even during 2 weeks general turnaround Low Feedstock Pressure Drop allows for cheaper Oil-Pumps Simultaneous feeding of immiscible Feedstock Integrated Heat-up Burner 5

6 Comparison Quench/Boiler Feed Oxidant (O 2 Air) Steam Burner Feed Oxidant (O 2 Air) Steam Sat. HP-steam Syngas Quench Water Syngas Heat Recovery Boiler Soot Slurry Quench Configuration Boiler Configuration 6

7 Comparison Quench versus Boiler Configuration Boiler Configuration Feedstock limitations due to possible Boiler fouling HP-Steam available highest thermal efficiency 2 step gas cleaning strong Claus gas Higher costs for boiler (normally payback < 2 years) Quench Configuration Feedstock flexibility MP-steam available trade off efficiency versus costs Fastest route to hydrogen but weak Claus gas Lowest cost for hydrogen production unit 7

8 HP-POX Demonstration Plant at Technical University of Freiberg, Saxonia, Germany 8

9 HP-POX Demonstration Plant Multi Process Test Facility: ATR, Gas-Pox, MPG (liquid feedstock) Feedstock: Liquid Feedstock Natural Gas 500 kg/h 500 m3/h (0.5 MMSCFD) Reactor: Operating Pressure 100 bar 9

10 HP-POX Demonstration Plant Fresh water Water Treatment Steam Generator Flue Gas Liquid Feeds Storage Natural Gas Liquid O 2 Compressor Pump and Vaporizier Desulphurisation Reactor Flare System Soot Water Cooler Soot Water Nitrogen Supply Instrument Air Supply Measuring Station Power Supply Analytical Area 10

11 MPG-Reactor in Asphalt based NH 3 -Plant 11

12 Feedstock and Product Feedstock: Residue Asphalt C/H-Ratio Ash Content Viscosity at 180 C Viscosity at 290 C 970 t/d 8.8 kg/kg 0.04 wt% 360 cst 20 cst Flash Point 170 C Products: Ammonia Equivalent H 2 Urea 1350 t/d Nm3/h (100 MMSCFD) 2000 t/d 12

13 Fertilizer Plant Based on Residue Asphalt Air Air Separation HP-Steam Boiler Refrigeration Unit O 2 HP-Steam Pure Hydrogen Liquid Ammonia Feed Gasification + WHB Rectisol H 2 S Removal CO-Shift Rectisol CO 2 Removal Liquid N 2 Wash NH 3 Synthesis Carbon Recovery Claus Unit Pure CO 2 Urea Synthesis Urea Soot and Ash Pellets Sulfur 13

14 Lurgi s Gas PurificationTechnology Ownership Own Technology Specific Expertise Natural Gas Raw Syngas Rectisol Purisol amdea Ultra Pure Syngas Turbine Gas Pipeline Gas Pure Off-Gas Off-Gas MDEA / DEA Pure CO 2 By-Product Others Sulphur Recovery Tail Gas Treating Sulphur 14

15 Selection of Appropriate Gas Purification Process Product Gas Purity Rectisol ppm H 2 S + COS ppm CO 2 Purisol 5-50 ppm H 2 S, no COS removal MDEA 3-50 ppm H 2 S; no COS removal amdea 1-50 ppm H 2 S 5-50 ppm CO 2 15

16 MPG based H 2 Plant Feedstock LP-Steam Pure Impure CO 2 CO 2 Low High BTU BTU S > Low 100 Sulfur ppm Fuel Fuel Gas Gas Steam MPG Quench Raw Gas Shift Gas Cooling Selective Rectisol AGR Methanation PSA 97% Hydrogen O 2 H 2 S+CO 2 Sulphur Carbon Slurry O 2 OxyClaus ASU MARS Waste Water Treatment Process Water Air Metals/Ash 16

17 Rectisol - A costly technology? Five-in-one : 1. Trace contaminant removal COS, CS 2, NH 3, HCN, Hg. 2. Deep Desulfurization directly to synthesis feed quality (Total S < 0.1 ppmv) only with Rectisol! 3. Bulk CO 2 removal 100 % CO 2 can be recovered 4. CO 2 purification Total S < 5 ppmv in CO 2 Stream 5. Acid Gas Enrichment Claus-suited acid gas even at a CO 2 /H 2 S ratio of > 500 one Rectisol compares with five tasks to be performed in five processes steps So, set up the right B.L. when comparing costs! 17

18 Trace Contaminants It s the small bugs that can bother you most! COS Hg VOC s NH 3 Carbonyls HCN CS 2 Wilhelm Busch Mercaptans 18

19 : The Rectisol Story Mio Nm3/day ex Gasifiers Capacity Installed & Operating Pure IGCC Others Rectisol Source: GTC Gasification Data Base Today, Rectisol purifies 75 % of the world s synthetic gas produced from oil residue, coal, & wastes 90 % of synthesis gas produced by gasification (non-igcc use) 19

20 Summary A Gasification Plant consists not only of the gasifier Consider optimum integration of the required process steps Gasification CO-Shift Conversion Gas Purification Soot Water Handling Claus Process Advantages of Rectisol Gas Purification are worldwide recognized 6 new Rectisol plants in the last 2 years 20

21 Contact :? Comments? Ulrich Koss Head Syngas Technology Dept. A-TE Phone Fax Dr. Holger Schlichting Process Manager MPG Dept. A-TEE Phone Fax Lurgi AG D Frankfurt am Main Germany Internet: 21

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