Envirotherm GmbH. - P r o f e s s i o n a l C o m p e t e n c e -

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1 Envirotherm GmbH

2 Allied Group Structure ATG Group Aloe Environment Fund Paris, France Dongfang Boiler Group Co. Ltd. Zigong, Sichuan, China Allied Resource Corp. Wayne, PA, USA 70 % 30 % Allied Technologies GmbH Frankfurt a. M. G. Daradimos (Chairman) J. Kremer Chengdu Huilian Property Management Stock Co. Ltd. Allied Syngas (ASC) Wayne, PA, USA Envirotherm GmbH Essen / Germany G. Daradimos (Chairman) J. Ladenthin H. Hirschfelder DKC SCR Catalyst Production Chengdu, Sichuan, China Puralube Inc. Wayne, PA, USA BAMAG Environment GmbH Butzbach / Germany W.-Fr. Staab BAMAG International GmbH Essen / Germany G. Daradimos J. Ladenthin BAMAG Mena LLC Cairo, Egypt Th. Winckler (Chairman) I. Schmittmann H. A. Ghaffar 2

3 Allied Technologies Group (ATG) ATG Group Allied Technologies is a member of the Allied Group ( is a strategic holding company with offices in Frankfurt/Main, Germany, and controls Allied s engineering entities o o o o BAMAG Environment GmbH Envirotherm GmbH BAMAG International GmbH and BAMAG Mena LLC Allied Technologies Group employs in Germany and in Egypt over 170 total staff, including about 150 skilled professionals (primarily engineers) is able to perform 150,000 (plus) engineering hours annually 3

4 ATG: Technologies ATG Group Technologies within the ATG Group: Combustion of fossil fuels, biomass and residues in the Circulating Fluidized Bed (CFB) Gasification of fossil fuels, biomass and residues in the Circulating Fluidized Bed (CFB) and in the Fixed Bed Gasifier (BGL) Incineration of hazardous waste in the rotary kiln Destruction of chemical weapons in the bogie hearth furnace (highly toxic waste) Flue gas dedusting (dry and wet ESPs, bag houses) Flue gas denitrification (SNCR und SCR) Wet and dry flue gas scrubbing Water purification / waste water treatment Thermal treatment of sludges in the bubbling fluidized bed 4

5 Business Segments your experienced and qualified engineering partner with an extensive list of references and strong growth based on a portfolio of proprietary technologies acquired from Lurgi CLEAN ENERGY CLEAN AIR (Air Pollution Control - APC) Modern Gasification Technologies Highly Efficient Flue Gas Cleaning Technologies Multi-Purpose Combustion Technologies Production and Distribution of Honeycomb SCR Catalysts 5

6 Clean Air Clean Energy Cooperation and License Agreements FB/CFB Power Plants Gasification Cooperation with the Slovak Boiler Manufacturer SES, Tlmače DEDINI, Brazil, for fluid bed technologies Shriram epc, India, fluid bed (CFB) and fixed bed (BGL) gasification Collaboration with CEMEX on CFB gasification in the Cement Industry (industrial know-how from Ruedersdorf facility) University of Clausthal-Zellerfeld, Germany, CUTEC Institute R&D in CFB gasification TU Bergakademie Freiberg BGL Pilot Plant and BGL modelling SCR Catalysts Production SCR-Process Clean Air Activities Joint Venture with Dongfang Boiler Group, Chengdu, Sichuan, China Dongfang, SSEP for SCR process in China Cooperation with ERC GmbH, Germany Jeongwoo, for ESP in Korea Longking, TFEN, DATANG Group, Londian Hongtai for fabric filter in China VT Corp, ISGEC for ESP in India 6

7 Clean Energy - Combustion Technologies - 7

8 Combustion Technologies Fluid Bed Stationary and Circulating Fluid Bed Technologies have a high acceptance and are a base technology in the utility and other industries for combustion of coal, (high/low rank), biomass and various residual materials (sludges, RDF). Envirotherm s portfolio includes the stationary (FB) as well as the circulating (CFB) fluid bed technologies Fluid Beds offer a proven and reliable technology with numerous reference plants and excellent emission values Downstream flue gas treatment technologies are available and designed in accordance with the latest environmental laws/directives 8

9 Combustion Technologies Fluid Bed Selected References Stadtwerke Flensburg, Germany (combined heat and power plant) Existing 3 trains of CFB steam generators (150t steam/h, 535 C, 90 bar) Original design for subbituminous hard coal (15t/h) Engineering for a re-fuelling project to co-fire up to 25% (energy) of biomass and RdF (high CV and high Cl content) 9

10 Combustion Technologies Fluid Bed Selected References Cottbus, Germany (combined heat and power plant) Pressurized lignite fired fluidized bed combustor (82 MW el, live steam 200 t/h, 540 C, 160 bar and reheat 540 C, 44 bar) Heavy fouling in cyclones, in-bed bundles and gas turbine inlet vanes limiting substantially running time and full load capability Envirotherm redesigned and refurbished cyclones, and reengineered in-bed bundles to minimize fouling and increase availability after modifications full load and longer runs were achieved Illustration of CHP plant Cottbus (Germany) 10

11 Combustion Technologies Fluid Bed Selected References Grovehurst, England Largest FB-combustor built by Lurgi (nozzle grate area 32 m²) Feedstock 16.6 t/h deinking sludge, 6.2 t/h rejects from paper industry, two feeding points Heat Recovery Section to produce 31.3 t/h of 30 bar, 345 C steam Gas cleaning with bag filter and SNCR, addition of Zeolite to remove dioxins and furanes. High content of calcium components in paper sludge helps to remove acidic pollutants from flue gas and are removed in bag filter 11

12 Combustion Technologies Fluid Bed Selected References 12

13 Combustion Technologies Bogie Hearth Furnace Base technology for incineration of toxic and hazardous waste Feedstock includes but is not limited to toxic activated carbon, contaminated waste, hazardous process waste, wood High temperature post incineration and extensive flue gas cleaning Process applied to thermally destroy residual materials from chemical weapons destruction Contaminated solid materials 13

14 Combustion Technologies Bogie Hearth Furnace Selected References Bogie Heart Furnace Technology Base technology for incineration of toxic and hazardous waste High temperature post incineration and extensive flue gas cleaning Process applied to thermally destroy residual materials from chemical weapons destruction one plant in Germany, four plants in Russia Exit of bogie hearth furnace Plant arrangement Potschep 14

15 Combustion Technologies Rotary Kiln (under license of Doosan Lentjes GmbH) Rotary kiln incineration technology is the most secure method to eliminate and to dispose of hazardous waste, such as industrial and chemical as well as hospital waste, in an ecologically compatible manner Incineration at high temperatures (around 1,200 C), i.e. toxic components are thermally destroyed Waste volume is significantly reduced Energy from waste is recovered and utilized Ash is recovered as non-leachable slag and can easily be disposed of or utilized Capacities up to 50,000 t/a have been realized in 25 installations worldwide 15

16 Combustion Technologies Rotary Kiln Selected References Izmit, Turkey Hazardous Waste Treatment Plant Start-up in 1996; solid and liquid waste incineration, capacity t/a Process chain Waste reception and pre-treatment Waste charging Rotary kiln incineration Post combustion Heat recovery section with steam production (27 t/h, 40 bar, 350 C) and generation of electricity (5.2 MW) Flue gas cleaning Scrubber effluent and waste water treatment 16

17 Combustion Technologies Rotary Kiln Selected References Izmit, Turkey: Hazardous Waste Treatment Plant 17

18 Clean Energy - Modern Gasification Technologies - 18

19 Modern Gasification Technologies The BGL Slagging Gasifier: Development Developed by British Gas and Lurgi (hence BGL) to improve Lurgi s dry bottom fixed bed gasification process Demonstrated with various feedstock in Westfield, Scotland Highest efficiency, lowest oxygen consumption First commercial installation at Schwarze Pumpe Site (East Germany) in 2000 Technology acquired from Lurgi in BGL under engineering/construction (12 in China, 2 in India), commissioning planned from 2011 onwards 19

20 Modern Gasification Technologies The BGL Slagging Gasifier: Process Applications Input Gasification Additional Processing Conversion Products Air Separation Unit CO 2 IGCC Power Oxygen Methanol Synthesis Chemicals/ Gasoline Coal BGL Gasifier Shift Reactor Gas Clean-Up Methanation Synthetic natural gas Alternative Feedstock Fischer Tropsch Synthesis Fuels Ammonia Synthesis Fertilizers Typical BGL Gas Composition for bituminous coal H 2 33 % CO 56 % CO 2 4 % CH 4 7 % BGL Process has clear investment and operational advantages in a wide range of application. According to gas composition BGL is well suited to SNG production because of its high efficiency and the presence of CH 4 in product gas 20

21 Modern Gasification Technologies BGL Slagging Gasification Commercial plant for the gasification of mixtures of coal and waste as feedstock to generate electricity and to produce methanol Site location: Secondary Raw Materials Utilization Centre, SVZ Schwarze Pumpe, Germany Start-up in 2000, commercial operation until mid 2007 Modular pressurized fixed bed gasification, gas output equivalent to MW el Currently 14 BGL gasifiers are under engineering/construction in China and India 21

22 Gasifier inner diameter in m BGL Gasifier Current Development Increase in reactor diameter to 4m higher throughput Increase in operation pressure (up to 40bar) higher CH 4 content, less tar and oil Stirrer implementation for caking coals 5 4 BGL 3 Yituo BGL 3 SVZ BGL 3 China Nat. BGL 3 Hulunbeier BGL 3 Shriram BGL BGL 1 BGL 2 Plant Start up Feedstock BGL Coal BGL Coal BGL 3 SVZ 2000 Waste & up to 80% waste BGL 3 Hulunbeier 2011 Lignite 1 BGL 3 Yituo 2012 Hard coal BGL 3 Shriram 2013 High ash hard coal BGL 3 China National 2013 Bituminous coal 22 BGL 4 Project Lignite Fuel throughput in t/d

23 Modern Gasification Technologies BGL Selected References: China National Coal Client Location of facility Application Feedstock Features Scope of Supply China National Coal Development Co. Ltd., Beijing, PRC China National Coal Corp., Beijing, PRC Ordos Tuke, Inner Mongolia, PRC Syngas for the production of 1,000,000 t/a Ammonia (1,750,000 t/a urea) Weakly caking bituminous coal (210 t/h, 5,000 t/d as received) Five (5) + two (2) BGL gasifiers (40 bar operating pressure) with stirrers Synthesis gas production 295,000 Nm³/h Process Design Package for gasification and gas liquor separation Process performance guarantees Plant erection and commissioning assistance Start-up 2013 Progress Process Design Package finished October

24 Modern Gasification Technologies BGL Selected References: Hulunbeier, China Client Location of facility Application Feedstock Features Scope of Supply Yuntianhua United Commerce Co., Ltd. Kunming, Yunnan, PRC Hulunbeier New Gold Chemical Co., Ltd., Hailaer, Hulunbeier, Inner Mongolia, PRC Hulunbeier, Inner Mongolia, PRC Syngas for the production of 500,000 t/a ammonia (800,000 t/a urea) Domestic dried and briquetted lignite (130 t/h, 3,100 t/d as received) Two (2) + one (1) BGL gasifiers (40 bar operating pressure) Raw gas production (CO+ H 2 ) 119,000 m N ³/h PDP (Process Design Package) for gasification island including tar/oil separation Proprietary equipment supply Process performance guarantees Plant erection and commissioning assistance Start-up Summer

25 Courtesy of Hulunbeier New Gold Chemical Co. Ltd. Modern Gasification Technologies BGL Selected References: Hulunbeier, China Progress May 2008 site clearance and civil work commenced Process Design Package delivered 4 th Quarter 2008 Detailed Design completed 3 rd Quarter 2009 Gasifier installations on site Class room staff training, August

26 Modern Gasification Technologies BGL Selected References: Hulunbeier, China Yuntianhua: Gasifier Reactor Transport over more than 1,000 km Distance 26

27 Modern Gasification Technologies BGL Selected References: Yituo, China Client China Yituo Group Co. Ltd., Luoyang, Henan Province, PRC Location of Facility Luoyang, Henan Province, PRC Application Feedstock Features Scope of Supply Fuel gas Local hard coal (30t/h, 720 t/d) One (1) + one (1) BGL gasifiers Raw gas production 43,000 m N ³/h PDP for gasification, gas cooling and tar/oil separation Proprietary equipment supply Process performance guarantees Plant erection and commissioning assistance Start-up Mid

28 Modern Gasification Technologies BGL Selected References: Shriram EPC, India Client Shriram EPC Ltd., Chennai, India Location of Facility Paradeep, Orissa, India Application Feedstock Features Scope of Supply Syngas for the production of synthetic ammonia High ash domestic hard coal (132 t/h, 3,200 t/d) Two (2) BGL gasifiers, one relocated from Germany, the second built identical to the relocated one Raw syngas production 150,000 m N ³/h Relocation and reengineering as far as required for gasification, gas cooling, tar/oil separation and phenol recovery Basic engineering for new BGL Plant erection and commissioning assistance on request Start-up 1 st Quarter

29 Modern Gasification Technologies The CFB Gasification Process: Development and References Fluid bed technology was developed in the early 1920s (original Winkler fluid process) Lurgi developed the circulating fluid bed (CFB) applying high slip velocity, introduced CFB to power plants and applied the process to gasification of various feedstock Fluid beds are operated at temperatures below ash softening point (i.e C) with an even temperature profile in the reactor and excellent heat and mass transport Proven technology with numberless references Envirotherm acquired the CFB gasification process from Lurgi/Lentjes in 2003 Envirotherm s commercial reference plants include - first CFB gasification in the cement industry Ruedersdorf, Germany - CFB gasification of demolition wood Geertruidenberg, The Netherlands - CFB gasification of high ash Indian coal Barbil, India 29

30 Modern Gasification Technologies CFB Selected References: Geertruidenberg, The Netherlands Client N.V. Elektriciteits-Produktiemaatschappij, Zuid-Nederland (EPZ), Eindhoven, The Netherlands (today RWE-essent) Location of Facility Amercentrale, Geertruidenberg, The Netherlands Application Feedstock Features Scope of Supply Gasification of demolition wood, gas is dedusted and injected into coal fired boiler for the generation of electricity (CO 2 -neutral) Crushed demolition wood (21 t/h, 500 t/d) One (1) CFB gasifier Raw gas production 50,000 m N ³/h EPC contract Start-up

31 Modern Gasification Technologies CFB Selected References: Geertruidenberg, The Netherlands EPZ, Amercentrale: Process Scheme 31

32 Modern Gasification Technologies CFB Selected References: Geertruidenberg, The Netherlands EPZ, Amercentrale: Plant View 32

33 Modern Gasification Technologies CFB Selected References: Ruedersdorf, Germany First industrial application of the near atmospheric circulating fluidized bed (CFB) gasification process in the cement industry, Ruedersdorf, Germany Start-up and in full commercial operation since 1996 Two follow-up CFB gasifiers in early commissioning for the Indian steel industry Key Data Thermal Capacity 100 MW Fuels: Carbon containing ash 5-15 t/h Pulverised coal max. 6 t/h or Secondary fuels t/h Produced Gas: Flow rate 50,000 m 3 N/h Heating value 3,000 5,000 kj/m 3 N Gas exit temperature 950 C 33

34 Modern Gasification Technologies CFB Selected References: Jindal Steel, India Client Jindal Steel and Power Co. Ltd., New Delhi, India Location of Facility Barbil, Orissa, India Application Feedstock Features Scope of Supply Production of clean fuel gas for the steel industry Domestic Indian high ash (27%) coal (23 t/h, 550 t/d per gasifier) Two (2) CFB gasifiers Raw fuel gas production 50,000 m N ³/h per gasifier Basic engineering Plant erection and commissioning assistance Start-up First Quarter

35 Modern Gasification Technologies CFB Selected References: Jindal Steel, India Barbil / Orissa, India: two CFB gasifiers in parallel fuel: domestic Indian coal with 27% ash, 8% moisture per gasifier: 23t/h coal, 50,000 m³ n /h syngas 35

36 Superheater Evaporator Modern Gasification Technologies CFB Selected References: Jindal Steel, India Barbil / Orissa, India: Process Flow Diagram Turbine / Generator C.W. Steam Drum Solid Fuel Bed Material Deaerator CFB Gasifier Cyclone Quench Clean Fuel Gas Air Air Air Sec. Air Prim. Air C.W. Seal Pot Radiation Pass Wet ESP Recirculation Pump Air C.W. Bed Ash Ash Water Tar Dust Water 36

37 Clean Air - Air Pollution Control Technologies - 37

38 APC - Technologies Dust removal SCR-Process Production and distribution of honeycomb catalysts 38

39 APC Technologies Dust Removal Dust removal Wet & dry electrostatic precipitators Fabric filters (standard design) Proprietary low pressure fabric filters Tar filters Ceramic filters (high temperature application) More than 13,000 reference plants worldwide 39 Retrofit 350 MW Powerplant Fynsvaerket, Denmark ESP Wachtberg 200 MW CFB Powerplant

40 APC Technologies SCR Process NO x reduction (DeNO x ) process, based on Selective Catalytic Reduction (SCR) Manufacture of honeycomb SCR catalysts in China (joint venture with Dongfang Boiler Group) Power Plant Hoosier, 2x540 MW 40

41 APC Technologies SCR Catalyst Production in China Chengdu Dongfang KWH Environmental Protection Catalysts Co., Ltd. (DKC) Since the 60 s Envirotherm (former KWH) developed honeycomb SCR catalysts and their application for NO x reduction. Envirotherm/KWH became one of the top five manufacturers worldwide. The former German catalyst production plant was relocated in 2006 from Marl to China for cost reasons and forms part of the joint venture company between Envirotherm and Dongfang Boiler Group. This plant is in commercial operation and delivers low-cost, high quality honeycomb catalysts accepted by reputed utilities. A second plant with a capacity twice as high as the relocated plant has been put into operation in July

42 APC Technologies SCR Catalyst Production in China DKC: 2nd Plant 42

43 Contact Envirotherm GmbH Ruhrallee 185 D Essen info@envirotherm.de Tel: +49 / 201 /