Workshop on Gasification Technologies March 2-3, 2006 Tampa, Florida
Getting off the Natural Gas Habit Coal to Nitrogen Fertilizers Neal Barkley, P.E. Plant Manager
Coolwater Demonstration Project
Coffeyville Nitrogen Plant
Block Flow Diagram NH 3 Product ASU Nitrogen Ammonia Synthesis UAN Plant UAN Product Hydrogen Oxygen Quench Gasifier Pressure Swing Absorption (PSA) Syn-gas Scrubbing Recycle Raw H 2 CO Shift/ Gas Cooling CO 2 Purification Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Sulfur Recovery H 2 S
Block Flow Diagram BOC Gases ASU Nitrogen Ammonia Synthesis Hydrogen UAN Plant NH 3 Product UAN Product Oxygen Quench Gasifier Pressure Swing Absorption (PSA) Syn-gas Scrubbing Recycle Raw H 2 CO Shift/ Gas Cooling CO 2 Purification Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Sulfur Recovery H 2 S
BOC Gases Air Separation Unit
Block Flow Diagram NH 3 Product ASU Nitrogen Ammonia Synthesis UAN Plant UAN Product Hydrogen Oxygen Quench Gasifier Pressure Swing Absorption (PSA) Syn-gas Scrubbing Recycle Raw H 2 CO Shift/ Gas Cooling CO 2 Purification Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Slag Sulfur Recovery H 2 S
Refinery Cokers
Coke Handling
Coke Conveyor and Rod Mill Structure
Main and Spare Gasifier Structures
Main Gasifier Vessel
Slag
Block Flow Diagram NH 3 Product ASU Nitrogen Ammonia Synthesis UAN Plant UAN Product Hydrogen Oxygen Quench Gasifier Pressure Swing Absorption (PSA) Syn-gas Scrubbing Recycle Raw H 2 CO Shift/ Gas Cooling CO 2 Purification Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Sulfur Recovery H 2 S
Block Flow Diagram NH 3 Product ASU Nitrogen Ammonia Synthesis UAN Plant UAN Product Hydrogen Oxygen Quench Gasifier Pressure Swing Absorption (PSA) Syn-gas Scrubbing Recycle CO Shift/ Gas Cooling Raw H 2 CO 2 Purification CO 2 Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Sulfur Recovery H 2 S
CO 2 Absorber
H2S Concentrator and Stripper
Block Flow Diagram NH 3 Product ASU Nitrogen Ammonia Synthesis UAN Plant UAN Product Hydrogen Oxygen Quench Gasifier Pressure Swing Absorption (PSA) Syn-gas Scrubbing Recycle Raw H 2 CO Shift/ Gas Cooling CO 2 Purification Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Tessenderlo Kerley Sulfur Recovery H 2 S
Block Flow Diagram NH 3 Product ASU Nitrogen Ammonia Synthesis UAN Plant UAN Product Hydrogen CO2 Oxygen Quench Gasifier Pressure Swing Absorption (PSA) Syn-gas Scrubbing Recycle Raw H 2 CO Shift/ Gas Cooling CO 2 Purification CO2 Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Sulfur Recovery H 2 S
Block Flow Diagram NH 3 Product ASU Nitrogen Ammonia Synthesis UAN Plant UAN Product Hydrogen Oxygen Quench Gasifier Pressure Swing Absorption (PSA) Syn-gas Scrubbing Recycle CO Shift/ Gas Cooling Raw H 2 CO 2 Purification Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Sulfur Recovery H 2 S
PSA Vessels
Block Flow Diagram NH 3 Product ASU Nitrogen Ammonia Synthesis UAN Plant UAN Product Hydrogen Oxygen Quench Gasifier Pressure Swing Absorption (PSA) Syn-gas Scrubbing Recycle Raw H 2 CO Shift/ Gas Cooling CO 2 Purification Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Sulfur Recovery H 2 S
Ammonia Synthesis and Refrigeration
Syn-gas and Refrigeration Compressors
Ammonia Storage Tank
Block Flow Diagram NH 3 Product ASU Nitrogen Ammonia Synthesis Ammonia UAN Plant UAN Product Oxygen Quench Gasifier Syn-gas Scrubbing Hydrogen Pressure Swing Absorption (PSA) Recycle Raw H 2 CO Shift/ Gas Cooling CO 2 CO 2 Purification Acid Gas Removal (Selexol) CO 2 Vent Coke Grinding Slurry Preparation Sulfur Recovery H 2 S
UAN Plant
UAN Rail Loading Facility
Operators at work in the control room
Nitrogen Fertilizer 101 Nitrogen is a basic nutrient for all plants. It does not build up in the soil, so it needs to be applied each growing season. Ammonia is the basic building block for nearly all fertilizers that contain nitrogen. In 2005, the US produced 8.7 million tons of ammonia. In 2005, the US consumed 14.7 million tons of ammonia. Nearly all was produced using natural gas!
Nitrogen Fertilizer 102 Ammonia cash cost build-up (example) Gas Cost $ 6 per mmbtu x Gas consumption 33 mmbtu per short ton = Gas cost $198 per short ton + other production costs $20 per ton = Total Cash Cost $218 per ton
Natural Gas Cost Since 1985 16 14 12 10 8 6 4 2 0
Nitrogen Fertilizer Market Global market Ammonia and urea are imported into the US US Production is in decline primarily due to low cost gas overseas Due to infrastructure limitations (pipelines, rail cars), domestic plants continue to operate when the demand (and price) support it. US Demand is set by acres of corn (primarily) and wheat (to a lesser extent).
US Coal Reserves
US Coal Prices 1985-2004 30 25 20 15 10 5 0
Coal or Coke to Ammonia Ammonia cash cost build-up (example) Coke or coal 1.1 tons per ton x Delivered cost $30 per ton coke Raw material cost $33 per ton Electricity 1,250 kwh per ton x Electricity cost $0.05 per kwh Total electricity $62.27 per ton
Coal or Coke to Ammonia Ammonia cash cost build-up (example) Raw material cost $33 per ton Total electricity $62.27 per ton Other direct costs $70 per ton Debt (SWAG) $50 per ton Total cost $215.27 per ton Equivalent of $5.90 per mmbtu natural gas
The future looks bright for Gasification!