A syngas network for reducing industrial carbon footprint and energy use

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1 A syngas network for reducing industrial carbon footprint and energy use Professor Dermot J Roddy Newcastle University Sustainable Thermal Energy Management in the Process Industries International Conference (SusTEM2011)

2 The basic proposition There is a case for building syngas (or synthesis gas) networks as a means of contributing to the reduction of industrial carbon footprints.

3 What is syngas? To a chemist: H 2 + CO Usually also contains CO 2 Often contains methane Contaminants: H 2 S, COS, particulates, tars, nitrogen compounds Composition depends on feedstock, gasification conditions, choice of gasification technology, choice of oxidant, extent of clean-up

4 Outline of presentation Syngas from fossil fuels Syngas from sustainable sources Syngas for power, heat, fuels & chemical feedstocks/products CO 2 capture & storage? Pathways that reduce net energy footprint or CO 2 emissions The case for building a syngas network Syngas network development the issues.

5 Syngas from fossil fuels Eston Grange 850MW IGCC plant with CCS

6 Syngas from fossil fuels Composition % v/v Contaminants g/m 3 Hydrogen 61 Dust Nil Methane 25 Ammonia 0.1 Carbon monoxide 5 Naphthalene 0.5 Carbon dioxide 2 Benzole 4 15 Ethane 1 Hydrogen Sulphide 1 5 Ethylene 2 Hydrogen Cyanide Nitrogen 4 Oxygen 0.2 UCG Coke oven gas

7 Syngas from sustainable sources

8 Syngas from sustainable sources Gussing plant, Austria

9 Syngas for power, heat, fuels & chemical feedstocks/products E4Tech, Review of technologies for gasification of biomass and wastes, 2009, NNFCC project 09/008, available via Fischer-Tropsch synthesis Iron or cobalt catalyst C 20-40bar Heavy waxes for diesel, or light olefins for gasoline Methanol synthesis Copper-zinc catalyst C bar Methanol Mixed alcohols synthesis Alkali-FT or Alkalimethanol catalyst C bar Mixed alcohols: methanol, ethanol and higher alcohols Syngas fermentation Biological: anaerobic microbes C Atmospheric Ethanol and/or other alcohols

10 Abbreviations: AN: Abbreviations: Acrylonitrile ADN: Adiponitrile HMDA: Hexamethylenediamine ACN: LPG: Liquid Acetonitrile Petroleum Gas ACH: Acetone Cyanohydrin HCN: Hydrogen Cyanide EO/EG: Ethylene Oxide/ Ethylene Glycols EOD: MMA: Methyl Ethylene Methacrylate Oxide Derivatives PET: Polyethylene Terephthalate PTA: Purified Pure Terephthalic Acid Acid KA: Ketone Alcohol AA: Adipic Acid Key: PTA DuPontSA Teesside Chemicals Cluster North Sea Crude Oil Imported Naphtha Imported Feeds Petroplus Distillation Teesside Petroplus Chemicals Cluster Product Company LPG & Naphtha Olefins (cracker) Sabic Aromatics Sabic Olefins (cracker) Huntsman Aromatics Huntsman Adiponitrile Propylene Propylene Natural Gas Ethylene Ethylene Ethylene Propylene Paraxylene Cyclohexane Cyclohexane Cyclohexane ADN EO/EG Dow Ethylene Glycol Hydrofining Acrylonitrile AN BASF HCN BASF EO/EG Dow Olefin exports PTA Artenius Paraxylene Higher Alcohols KA 4) DuPont Invista HMDA 5) DuPont Invista Ethylene Oxide Adiponitrile ADN BASF Byproduct Export ACN 1) HCN BP Imported Acetone EO EO EO EG Diesel blending Petroplus ACH ACH 2) Lucite By Product 3) HCN BASF Ethoxylates Croda Uniqema & Shell Ethoxylates Ethylene Shell Oxide Derivatives EOD Dow Dow PET PTA DuPontSA Artenius Adipic AA Acid DuPont Invista HMDA BASF MMA Lucite Surfactants Croda PET DuPontSA Nylon 6,6 DuPont Invista Olefins Chain Acrylics Aromatics Chain Polyester Nylon North Sea Crude Natural Gas Refinery 6) Petroplus Feedstock, inputs various Natural gas various Ammonia Terra Ammonia Terra Benzene Benzene Nitric Acid Terra Acrylics Lucite Nitrobenzene Huntsman Nitram Terra Aniline Aniline Huntsman Huntsman Polyurethanes Ammonia Chain Fertiliser

11 How pure does syngas need to be? Sulphur (mg/nm 3 ) Halides (mg/nm 3 ) Particulates (mg/nm 3 ) Raw syngas Engine Chemical synthesis Adapted from: ] Roddy, DJ and Manson-Whitton, C, Biomass gasification and pyrolysis. In Comprehensive Renewable Energy, Volume 5: Biomass and Biofuels, Elsevier, March 2012 (in press)

12 S CO 2 capture from syngas S ASU Gasification Heater Gas Treatment Sulphur and CO 2 Removal Plant Feedstock Oxygen Steam CO 2 gas Air Nitrogen Entrained Flow Quench Gasifier Frit Boiler Feedwater Heat Recovery Steam Generator Gas Turbine Sulphur Steam Turbine Boiler Feedwater Combined Cycle Gas Turbine

13 Technologies for CO 2 separation Chemical absorption eg mono-ethanolamine Developed in 1940s Physical absorption eg pressure swing absorption Mature technology Membranes eg cellulose acetate, polydimethylsiloxane, polyvinyl alcohol Compact, simple, low maintenance & energy efficient. Working on selectivity, permeability & cost. Size Technology of choice today Very small <5 million scfd Membrane units Small 5-40 million scfd Amine and membrane units compete Medium/large >40 million scfd Amine units are cheaper Basile, A, Gallucci, F and Morrone, P, Advanced carbon dioxide (CO 2 ) separation membrane development for power plants, in Advanced power plant materials, design and technology, 2010, DJ Roddy (ed), Woodhead Publishing.

14 CO 2 capture & storage?

15 Pathways that reduce net energy footprint or CO 2 emissions Where the original source of the syngas is sustainably grown biomass Where the original source of the syngas is waste oils, flare gases or other carbonaceous industrial wastes Where syngas is decarbonised and used for power generation or hydrogen displacement Where CO 2 is captured during syngas conversion (eg to ammonia) Where syngas is converted into long-life polymers Carbon-negative combinations?

16 The case for building a syngas network Carbon floor price is coming Energy-intensive industries in the UK are struggling to secure Government support (except possibly for the electricity-intensive industries) There are options for reducing energy footprint & CO 2 emissions using syngas Relevant plants are spatially distributed in regional clusters so a network is needed The same concept applies to other process industry clusters around the world with the same or similar drivers.

17 Buffer storage Condensate Brine Heater Steam F Condensate Hydrogen out Brine Reservoir m Heat exchanger Steam F Hydrogen in F: Duplicated product flow meter Hydrogen Brine Not shown: Emergency shutdown system Knockout pots Filters

18 Syngas network development the issues Sizing the network Timing its growth Determining ownership & access arrangements Planning & regulatory hurdles Wide range of syngas compositions.

19 Questions? Professor Dermot J Roddy Newcastle University dermot.roddy@ncl.ac.uk Funding from the Regional Development Agency for North East England (One Northeast) and the Tees Valley Industrial Programme for exploring the regional implications of this work is acknowledged.

The commercialisation of UCG

The commercialisation of UCG Dr Dermot Roddy Chief Technology Officer Five-Quarter Energy Holdings Ltd droddy@five-quarter.com www.five-quarter.com 1 Scale of the UK opportunity c. 10,000 billion tonnes