Latest Development of Lurgi s MPG-technology Update on Hydrogen Unit for NWU Project

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1 Latest Development of Lurgi s MPG-technology Update on Unit for NWU Project U. Wolf, H. Schlichting, S. Walter, Lurgi AG J. Quinn, North West Upgrading Inc. Gasification Technologies Conference 2007 October 14-17, 2007

2 Table of Contents World Oil Reserves Products from Syngas from Gasification Gasification of Liquid Feedstocks CO-Shift Concepts Technology Selection for NWU Project Selection of Acid Gas Removal Concept Latest Modifications to Unit 2

3 World Reserves Currently, 90% of production is from conventional oil Production of heavy oil and bitumen are growing rapidly Canada and Venezuela together have >35% of the nonconventional oil reserves in sands Source: SPE International Conventional Oil - 30% Heavy Oil 15% Extra Heavy and Bitumen 55% World Oil in Place Conventional <100 cp Heavy Oil cp Bitumen >10,000 cp 3

4 Process routes from gasification Fuel Gas Fischer Tropsch Synthesis Upgrading LPG Naphtha Diesel Waxes Gasification Mega- Methanol Lurgi proprietary process MTC MtSynfuels MTP MTO MtPower MTH Acrylic Acid Fuel Cells Chemicals (MTBE, Acetic Acid, Formaldehyde,...) Diesel, transport. fuels Propylene/Polypropylene Acrylic Acid/Acrylates Ethylene/Propylene Power/Fuel/DME(Diesel) 4

5 MPG: Waste Heat Boiler Configuration Feedstock O 2 / Steam Syngas HP steam CO2 H2S Rectisol Sweet Shift CO2 Rectisol Crude Quench & Scrubbing Metal Ash Recovery System Metals Ash Excess Water Excess Water 5

6 MPG: Quench Configuration Feedstock O 2 / Steam HP steam MP steam CO2 Raw Gas Shift Gas Cooling Rectisol Crude Gas Scrubbing Raw Gas to AGR Metal Ash Recovery System Metals Ash Metals Process Water Ash Excess Water 6

7 Clean Shift vs. Raw Gas Shift Raw Gas Shift Quench mode of Gasifier Complete Gas Stream converted Steam Generation and low grade Heat Supply Process Condensate recycled back to front Limited by Sulphur Content Clean Shift WHB downstream of Gasification Split of Syngas Internal Reaction Heat Recovery Almost no Waste Water Higher Capital Costs 7

8 Soot water handling Lurgi s Metal Ash Recover System (MARS) 8

9 The North West Upgrader Diluent Recycle to Wellhead Fuel Gas / LPG Bitumen Feed Atmospheric Distillation Light End Recovery Acid Gas Removal Vacuum Distillation Hydrotreating Unit Product Stabilization SynCrude to Pipeline Hydrocracker Unit Claus Unit Sulfur Hydrocracked Heavy Residue Unit Carbon Dioxide 9

10 Objectives of Unit Maximize Production Minimize Investment Cost Maximize Flexibility in Feedstock Minimize HP-Steam Production (No Consumers in Upgrader) Avoid Fuel Gas Production (Low Value) Vent CO 2 to Atmosphere Keep Open Options for CO 2 Usage 10

11 Licensor Selection Criteria All Required Technologies from One Licensor Gasification, Acid Gas Removal, CO-Shift, H 2 -Purification Single Line Responsibility for Unit Multi Purpose Gasification (MPG) Lurgi s Experience and Commercial References of MPG Large Feedstock Flexibility} High Availability and Robust Burner Reliability Quick Restart Option Acid Gas Removal (AGR) Lurgi s Know-How to select most suitable process 11

12 AGR Process Selection Diluent Recycle to Wellhead Fuel Gas / LPG Bitumen Feed Sulfur = 15 t/h Atmospheric Distillation Vacuum Distillation Hydrocracker Unit Sulfur = 2 t/h Carbon = 44 t/h Light End Recovery Hydrotreating Unit Unit Product Stabilization Acid Gas Removal Claus Unit SynCrude to Pipeline Sulfur = 13 t/h Feed to Claus H 2 S < 12% Carbon Dioxide CO 2 = 155 t/h Sulfur 12

13 Selection of Gas Purification Process Product Gas Purity Rectisol ppm H 2 S + COS ppm CO 2 Selective AGR 5 50 ppm H 2 S, no COS removal Purisol / Selexol Selective Amine Treating MDEA 3 50 ppm H 2 S, no COS removal Bulk Amine Treating amdea 1 50 ppm H 2 S 5 50 ppm CO 2 13

14 MPG based H 2 Plant Feedstock LP-Steam Pure CO 2 High BTU Low Sulfur Fuel Gas Steam MPG Quench Raw Gas Shift Gas Cooling Rectisol Methanation PSA 97% O 2 H 2 S+CO 2 Sulfur Carbon Slurry O 2 OxyClaus Claus Off-Gas ASU MARS Waste Water Treatment Process Water Air Metals/Ash 14

15 Latest modifications to H 2 Unit New feedstock due to new hydrocracking technology Reduction of waste water by approx. 75% MP-steam production instead of LP-steam Optimization of interaction with Sour Water Stripper Soot-ash filter cake will be disposed to land-fill Optimization of plant layout 15

16 Comments Contact : Ulrich Wolf Director Syngas Technology Phone ulrich.wolf@lurgi.com Jim Quinn Vice President Engineering North West Upgrading Inc. Calgary, Alberta, Canada Stefan Walter Process Manager MPG Phone stefan.walter@lurgi.com Lurgi AG Frankfurt am Main, Germany Internet: 16

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