2013 Instituto Petroquímico Argentino (IPA) Conference 09 October 2013 Buenos Aires, Argentina

Transcription

1 The UOP Selexol Process: Efficient Acid Gas Removal in Gasification Value Chain Henry Traylor UOP LLC, A Honeywell Company 2013 Instituto Petroquímico Argentino (IPA) Conference 09 October 2013 Buenos Aires, Argentina 2013 UOP LLC. All rights reserved. UOP

2 Honeywell s Businesses $37.6 billion in revenues in 2012, 50% outside of U.S. Nearly 125,000 employees operating in 100 countries 19,000 engineers and scientists Morristown, NJ global corporate headquarters Aerospace Automation & Control Solutions Performance Materials & Technologies Transportation Systems UOP

3 UOP Company Profile Serving the Gas Processing, Refining & Petrochemical Industries Profile Significant Technology Position Sales: Breakdown Business Units: Gas Processing and Hydrogen (GP&H) Process Technology & Equipment (PT&E) Catalysts, Adsorbents & Specialties (CA&S) Renewable Energy and Chemicals (RE&C) Offering: Technology, catalyst & services to the refining, petrochemical and gas processing industries Supplier of molecular sieve adsorbents to process and manufacturing industries Equipment Products Services Licensing Equipment 45% Products 35% Licensing 7% Services 13% UOP Facilities Global Footprint Sales: Geographic Worldwide Headquarters Des Plaines, Illinois (suburban Chicago) 3,500+ Employees 20 Offices 17 Countries 12 Manufacturing Facilities 5 Engineering Centers UOP Offices UOP Manufacturing Sites Global Customers Asia Pacific 19% North America 32% China 12% India 5% Middle East 9% South America 9% E&A 9% CIS 5% UOP

4 UOP s Solution in Syngas Cleanup Acid Gas Removal PSA Sulfur Recovery Our technologies og es and products are designed ed to deliver e superior performance, safety and value when combined in an integrated system: High availability and reliability of processes and products Lower capital expenditure and operating costs resulting in lower cost of production of hydrogen UOP

5 Syngas Treating with Selexol Process UOP Polysep Membrane Sulfur Recovery Tail Gas Treating Power Hydrogen Synthesis Gas COS Hydrolysis CO Shift UOP Selexol Process UOP MTO Chemicals UOP Polybed PSA Methanation Substitute Natural Gas FT Synthesis UOP Liquids Upgrading Liquid Fuels UOP

6 Commercial Excellence & Experience Invented by AlliedSignal in 50s Acquired by Union Carbide in 90 Transferred to Dow in 01 Over 110 units in operations Global presence in syngas & natural gas applications Unique characteristics for syngas applications: Power (IGCC) SNG Chemicals Hydrogen Synfuels Natural gas applications: Hydrocarbon Gas Dewpoint Control EOR High CO 2 Content Gas LNG Peak Shaving CO 2 Removal Landfill Gas Treating Biogas Selexol process growing footprint in gas cleanup UOP

7 Selexol Process Applications Worldwide Recent Selexol Applications in Operation Sarlux: IGCC power and H 2 API: IGCC power Coffeyville Energy Resources: H 2 and CO 2 capture SandRidge: Natural gas CO 2 removal for EOR Nexen: H 2, fuel and future CO 2 capture Projects in Construction Duke Energy: IGCC power and future CO 2 capture Southern Company: IGCC power and CO 2 capture UOP

8 Commercial Experience in Gasification Plant Start-up Application Production Selexol Unit Duty Syngas Flow Feedstock Sarlux IGCC Italy 2000 Power H 2 Production 550 MW net Nm³/h Sulfur 404 psia Visbreaker Residue API IGCC Italy 1999 Power 250 MW net Sulfur 169 psia Visbreaker Residue Coffeyville Resources USA 2000 Ammonia Urea 21 T/h 62 T/h Sulfur & CO psia Petcoke Nexen Canada 2008 H 2 Production & Fuel Gas 337,000 Nm³/h syngas Sulfur psia Asphaltene Residue UOP

9 Key Characteristics of Selexol Process Feature Benefit Low Vapor Pressure Non -fouling High on-stream efficiency Low equipment count Low cooling requirements Low power requirements Non-toxic Low solvent loss Clean service High availability Lower CAPEX Lower OPEX Lower OPEX Safe Operation Selexol Process cost effective solution for H 2 S & CO 2 removal UOP

10 Selexol Process Overview Absorption/regeneration process for selective removal of H 2 S, COS, RSH & CO 2 Uses SELEXOL TM physical solvent from Dow Chemical Uses a typical solvent-extraction flow scheme Loading directly proportional to partial pressure Has unique selectivity characteristics that make it attractive for syngas and natural gas applications Product Quality Can be essentially sulfur free Project specific CO 2 capture and quality Project specific acid gas H 2S concentration UOP

11 Selexol Process in Syngas Applications Typical Gasification Complex Typical Raw Syngas H % CO 30-50% Ar 0.5-1% N % CO % H 2 S 0.5-2% COS ppmv Ni & Fe Carbonyls HCN, NH 3... No Shift, Full Shift or Partial Shift CO 2 Coal or PetCoke, Biomass Gasifier O 2 Air Separation Raw Syngas Sour Shift Tail Gas Selexol Unit H 2 S Sulfur Recovery Treated Syngas Sulfur Applications: Power SNG Chemicals Hydrogen Liquid Fuels etc UOP

12 What is the SELEXOL Process? Absorption/regeneration process for selective removal of H 2 S, COS, & CO 2 Uses a physical solvent Uses a typical solvent-extraction flow-scheme Loading directly proportional to partial pressure Treated Gas Feed Gas Acid Gas Solven nt Loading Physical vs Chemical Chemical Solvent Physical Solvent Typical Gasification Application Partial Pressure High Pressure is advantageous UOP

13 What is the SELEXOL Process? A physical solvent Polyethylene Glycol Dimethyl Ether Chemical formula: CH 3 O(C 2 H 4 O)nCH 3 where n has a specific distribution A clear fluid that looks like tinted water Regenerated by changing pressure, temperature t or applying a stripping gas Unique selectivity characteristics desirable for gasification syngas treating: ti H 2 ~ 1 :Relative Solubility Data CO ~ 2.2 CO 2 ~ 76 COS ~ 175 H 2 S ~ 680 Selexol = Selective UOP

14 Flow-scheme Applications Two Basic Flow-schemes Sulfur removal only Typically for power applications Can reduce treated gas any desired sulfur level One solvent absorber b with solvent regeneration Sulfur removal with separate CO 2 removal Typically for applications producing hydrogen, chemicals, SNG or coal-to-liquids Typically involves more stringent t product specifications Independent solvent absorbers with integrated solvent regeneration UOP

15 Two Basic Flow Schemes 1. Selexol for Sulfur Removal Only Power applications typically require sulfur removal only to 10 to 20 ppmv. Less than 1 ppmv can be achieved One solvent absorber with solvent regeneration Treated Gas Lean Solution Filter H 2 S Stripper Acid Gas Reflux Accumulator Feed Gas Sulfur Absorber H 2 S Concentrator Reflux Pump Makeup Water Export Water Packinox Exchanger Stripper Reboiler UOP

16 Two Basic Flow Schemes 2. Sulfur Removal & CO 2 Capture Treated Gas CO 2 Absorber CO 2 Tailored Design Sulfur in treated gas as low as 0.1 ppmv Sulfur in CO 2 as low as 2 ppmv CO 2 purity as high as 99.7 mol% Tuned acid gas composition Lean Solution Filter H 2 S Stripper Acid Gas Reflux Accumulator Shifted Feed Gas Sulfur Absorber H 2 S Concentrator Reflux Pump Makeup Water Export Water Packinox Exchanger Stripper Reboiler UOP

17 Reliability / Availability/ Maintainability Scheduled Outage Hrs Forced Outage Hrs Availability% Period Hours On stream availability >99% No scheduled maintenance requirement Reliability is >99% Failure rate ~1.97 failures/year Overall Plant availability dependent on gasification block ~80-90% Outage to on-line within 2-3 hours Selexol plant can still be operated with loss of refrigeration at ~50% reduced capacity UOP

18 Experience with Refinery Feedstock UOP

19 Sarlux S.r.l Italy Visbreaker Tar High Purity H 2 to Hydrocracker Air Electric Power Steam for Export Polybed TM PSA Raw H 2 O 2 Air Separation Unit Combined Cycle Power Plant Polysep TM Membrane Purified Syngas Feed Gasifier with Quench & Scrubbing Gas Cooling & COS Hydrolysis Selexol Claus Plant Elemental Sulfur Tail Gas UOP Technologies UOP

20 API Energia Asphalt Electric Power Combined Cycle Power Plant Steam for Export Air O 2 Air Separation Unit N 2 Syngas Expander Feedstock Gasifier with Quench & Scrubbing Gas Cooling & COS Hydrolysis Selexol Claus Plant Elemental Sulfur Tail Gas Treatment & Incinerator UOP Technologies UOP

21 Coffeyville, US Petcoke Air Air Separation Unit NH 3 Product N 2 Ammonia Synthesis UAN Plant UAN Product O 2 High Purity H 2 Purified CO 2 Raw H Polybed 2 CO 2 PSA Purification CO 2 Vent Tail Gas Raw CO 2 Quench Gasification Syngas Scrubbing CO Shift & Gas Cooling Selexol 2-stage Petroleum Coke Acid Gas Claus Plant UOP Technologies UOP

22 Summary Proven technology, enhanced reliability and availability Efficient and high overall sulfur recovery Simple flow schemes & limited number of equipment Enhanced safety and reduced maintenance Selexol unit designed to operate even with loss of refrigeration at reduced capacity Treat gases that other technologies cannot tolerate Low CAPEX and OPEX Customizable units Facilitates high pressure CO 2 capture System Integration (CO Shift/COS hydrolysis, Methanol synthesis/ Methanation etc.,) World-Class Technical Support from UOP and Dow Chemical Lower cost option for gasification UOP

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