Engineers India Limited Multi product generation from Coal via gasification

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1 Engineers India Limited Multi product generation from Coal via gasification 16 th February, 2017, New Delhi

2 Future Energy Scenario - India Energy Hungry Nation (a) Growth Vs Energy Demand Trend India Imports 77 % of its oil, 30 % of its gas, & even 34% of Coal Source: India: Towards Energy Independence 2030 (b) Energy Demand and Supply International Oil & Gas Price, Shortage of Resources are bottlenecks for India s Economic Growth Fossil Resource Starving Source: ExxonMobil 2014 Outlook for Energy

3 Outline Gasification Technologies Applications Polygeneration Summary 3

4 Outline Gasification Technologies Applications Polygeneration Summary 4

5 Coal vs. other fuels SNG CTL - Add hydrogen or reject carbon GTL - Reject hydrogen or add carbon. Volatility CTG - Add more hydrogen or reject more carbon. Coal- Low hydrogen, carbon rich source 5

6 Coal Gasification Technologies Technology selection mainly depends on feed properties : Ash content Reactivity Rank 6

7 Challenges for Gasification Technologies - Indian coal The high ash content means a high ash output rising CAPEX due to needed enlargement of ash handling system necessary storage of ash may also cause problems Increasing efforts for gas treatment (raw gas cleaning etc.) lowers the total plant efficiency Necessary high gasification temperature due to the feedstock/ ash composition requires special gasifier reactor design e.g. material selection, ash handling High ash content and high ash melting point above 1400 C means higher oxygen consumption rising OPEX availability 7

8 Technology Comparison Fixed/moving bed Lower operating temperature - lower carbon conversion efficiencies Non-uniform temperature profile - promotes the generation of tars, oils, and other undesirable by-products Cannot handle fine material - large piles of waste coal fines material Handling of caking coal Fluidized Bed Moderate Temperature Limited by Ash Fusion Temperature (AFT) High conversion at moderate temperature Suited for low rank, high AFT reactive coals (Typical INDIAN Coal) Entrained bed Slagging conditions highest oxygen consumption/ton coal for melting high ash and high AFT Indian coals (energy intensive) High capital intensity Slag penetration in refractory Indian coal (mostly high ash) Lurgi Moving Bed (Moisture + Ash)~ 55% 8

9 Outline Gasification Technologies Applications Polygeneration Summary 9

10 Applications of Coal Gasification Gasifiers once solved energy problems - they might, yet again.

11 Syn Gas and Polygeneration Acetic Acid Polyurethanes Speciality Chemicals DMF, Polyketones, Formic Acid DMC, polycarbonates Pure CO CO and H2/CO Syn gas / CO+H2 Methanol H2-CO2 = 2 CO+CO2 SNG H2-CO2 = 3 CO+CO2 Ammonia H2/N2=3 Oxo-alcohols H2/CO =1 Synfuels H2/CO=2 FT synthesis

12 Outline Gasification Technologies Applications Polygeneration Summary 12

13 CTL Yields & Hybrid Coal Conversion Coal Gasification Coal Water/Gas Shift Hydrogen Recovery H 2 DCL Bottoms Indirect conversion Direct Coal Conversion FT Tail Gas Raw ICL Products H 2 Raw DCL Products Product Refining & Blending Final Products ICL product slate ~ 80% Diesel, 20 % Naphtha Diesel : Cetane : 70-75, Sulfur:<1 ppm Aromatics < 4 %, Sp. gravity : Naphtha: RON: 45-75, Sulfur : Nil Aromatics:2%, Sp. gravity :0.673 DCL product slate ~ 65% Diesel, 35 % Naphtha Diesel : Cetane : 42-47, Sulfur:< 5 ppm Aromatics: 4.8 %, Sp. gravity : Naphtha: Octane (RON): >100, Sulfur: <0.5 ppm Aromatics:5%, Sp. Gravity :0.765 Hybrid concept Integrated products complement each other balance between process efficiency and final fuel quality by blending improve process flexibility and maximize targeted product slate 13

14 Coal to Hydrogen Estimated world hydrogen production and use (2008). Source: various Generalised process flow for industrial hydrogen and syngas production Note: SMR = Steam methane reforming; ATR = Auto thermal reforming; POX = Partial oxidation 14

15 Coal to SNG (1) (Source- ExxonMobil 2014 Outlook for Energy) India s Natural Gas Demand Natural gas consumption is significant - Demand outpacing production - India - fourth largest LNG importer - Imports expected to rise ~30% in National coal reserves is the key Costly LNG import substitution - Country s economic potential Easy to implement - Technology well developed Conventional fuel - Infrastructure already in place MMSCMD Domestic sources LNG Imports Gas Imports (Crossborder pipeline) Total Source wise supply of Natural Gas Expected growth at an average of 6.8% /year (Source- Vision 2030 Natural Gas Infrastructure in India) 15

16 SNG From Coal 5 MMSCMD ASU O 2 = TPH Steam TPH Gasification Unit N2 Utility Block Nm3/hr CO =20-24% CO 2 =24-28% H2=35-38% CH4=8-12% H2O=30-35% H2S= % CO Shift Technology Nm3/hr CO =12-15% CO2=28-32% H2=40-44% CH4=8-12% Inert+H2S= H2S Removal Sulfur to storage SRU CO2 rich stream Nm3/hr CO =20.28% CO 2 =1.02% H2 = 62% CH4 =15% Inert =0.43 H 2 /CO ~ 3 CO2 Removal SNG SNG (Methanation) 5 MMSCMD Coal ~ 4.5 MMTPA Ash = upto 35 % Coal Washery Feed Coal = 6.2 MMTPA Ash % VM=20-25% FC=20-30% Sulfur ~ % Nm3/hr Nm3/hr SHIFTED AGR Power Block UN-SHIFTED AGR H2S Removal CO2 rich stream CO2 Removal Nm3/hr 16

17 Coal to Chemicals (CTC) - Methanol Methanol - is starting point for the synthesis of a wide range of industrial Chemicals - Directly as an alternative fuel - India imports large amount of methanol (about 80% of domestic demand in 2009), Methanolbased fuel production TIGAS Topsøe Integrated Gasoline Synthesis MtG Methanol-to Gasoline e.g.. ExxonMobil (Uhde) DtG Dimethyl ether-to-gasoline (e.g.. Karlsruhe Institut fürtechnology) DtO Dimethyl ether-to -Olefins (e.g.. Karlsruhe Institut für Technology) MtO Methanol-to -Olefins (e.g.. UOP, MtP by Lurgi/ Air Liquide) StF Syngas -to -Fuel (CAC, TU Freiberg) MtD Methanol-to -Dimethyl ether (eg. Lurgi/ Air Liquide) StD Syngas -to -Dimethyl ether (eg JFE) COD Conversion of Olefins to Distillates (e.g. Lurgi/ Air Liquide) MtS MtSynfuels by Lurgi/ Air Liquide 17

18 METHANOL MATERIAL BALANCE 5000 MTPD ASU O 2 = TPH Steam TPH Gasification Unit Coal = MMTPA Ash = upto 35 % Coal Washery N2 Feed Coal = 9-12 MMTPA Ash= % VM=20-25% FC=20-30% Sulfur ~ % Utility Block Nm3/hr CO =24% CO 2 =27% H2=37% CH4=11% H2O=32% H2S= CO Shift Technology Nm3/hr CO =15-20% CO2=27-34% H2=38-42% CH4=10-12% Inert+H2S= H2S Removal SHIFTED AGR Power Block UN-SHIFTED AGR H2S Removal Sulfur SRU CO2 CO2 Removal CO2 rich stream Nm3/hr CO =24-28% CO 2 =18-22% H2 = 55-60% CH4 =14-16% Inert = CO2 Removal SNG CO Cold Box Nm3/hr CO =20.28% CO 2 =1.02% H2 = 62% CH4 =15% Inert =0.43 H 2 -CO2 =3 CO+CO2 CO 2 Purge gas CO H2 Methanol Unit 5000 TPD 18

19 Coal to Chemical (CTC) Ammonia/Urea 92 % of Ammonia in China is produced through Coal against 0 % in India Commercial technology Johnson Matthey Linde Kellogg Brown and Root Haldor Topsøe Ammonia Casale Uhde World ammonia production by feedstock type. Source: IFA, 2010b Global demand for ammonia, exceeded 170 million metric tonnes in 2013 IHS report NG Naphtha Fuel Oil Coal Relative investment Relative sp. Energy requirement (based on LHV) Relative ammonia plant investment and relative energy requirement for 1800 t/d NH 3 19

20 AMMONIA MATERIAL BALANCE 2200 MTPD N2 ASU O 2 ~30-35 TPH Gasification Unit Coal Washery Steam TPH Coal ~ 2 MMTPA Ash = upto 35 % Utility Block ~ Nm3/hr CO =20-25% CO 2 =22-28% H2=35-40% CH4=5-11% Inert+H2S=25-35% CO Shift Technology CO = % CO 2 =35-40% H2=45-50% CH4=8-10% Inert+H2S=0.27% H2S Removal SHIFTED AGR Sulfur to storage SRU CO2 CO2 Removal Nm3/hr CO =0.59 % CO 2 =1.02% H2 = 83% CH4 =16% Inert =0.45 SNG Liq. N2 wash Nm3/hr N2 ~ 25% H2 ~ 75% Feed Coal = 2.0~2.4 MMTPA Ash % VM=20-25% FC=20-30% Sulfur ~ % Power Block UREA CO2 Ammonia Unit 2200 TPD 20

21 Coal Captive Power Plant Coal Washe ry Urea Urea Unit Methanol Methanol Unit POLYGENERATION C O H 2 CO Cold Box CH4 Recovery SNG Unit Methanation Substitute Natural Gas Liquid Nitrogen Wash Ammonia Unit Ammoni a 21

22 Polygeneration Cost Comparison (million US$, NG price at 8.59$/MMBTU, *2014 ) Description` Clean Syngas SNG (5MM SCMD) Methanol 5000(MTPD) Ammonia/Urea 3850(MTPD) Project Cost ( Billion USD) Total Production ~1.8MM Cost of Production, USD 9.5/MMBTU 8.5/MMBTU 19,000Rs/MT 190/MT 22

23 Outline Gasification Technologies Applications Polygeneration Summary 23

24 Summary Gasification is a proven technology, a vast number of gasifiers are operating since decades successfully on commercial basis Gasification allows flexibility in feedstock and polygeneration of products, Gasification is environmental friendly Technologies like gasification are able to help India to meet the rising demands for power and chemicals 24

25 THANK YOU