Customizing Syngas Specifications with E-Gas Technology Gasifier Arnold Keller, David Breton, Chancelor Williams and Graham Poulter, ConocoPhillips, Houston, Texas Gasification Technology Conference San Francisco, CA October 16, 2007
Outline E-Gas Gasifier Features Multi Fuel, Multi Products Gasification Technology Major Reactions In the E-Gas Gasifier E-Gas Operations Customized to the Application Gasifier Operational Control Summary 2
E-Gas TM Gasifier KEY FEATURES Two Stage Design Slurry Fed Raw Syngas ~ 1900F ADVANTAGES Oxygen Blown Two Stage Design Enables Entrained Flow Continuous Slag Removal Refractory Lined Slurry Oxygen Slurry 2 nd Stage Char Recycle Operating Flexibility to Produce Syngas for Multiple Products First Stage 2600 F Slag Quench Water Slag Slurry Oxygen E-Gas TM two stage gasifier for carbon conversion and heat recovery 3
E-Gas TM Multi-Fuel, Multi-Product Gasification Technology Feedstock Options Low Methane Product Options Hydrogen Ammonia CO Methanol FT Products Coal Pet Coke E-Gas Clean Low-cost Syngas Intermediate Methane Power & Steam Gasification Products Slag Elemental Sulfur High Methane SNG 4
Major Reactions In the E-Gas Gasifier 2 nd Stage CO + H2O H2 + CO2 (Water Gas Shift) Slight Exothermic CO + 3H 2 CH 4 + H 2 O (Methanation) Exothermic COAL/COKE CHAR Endothermic Hot Gas To Be Quenched 1 st Stage CO + H 2 O H 2 + CO 2 (Water Gas Shift) Slight Exothermic C + H 2 O H 2 + CO (Water Gas) Endothermic C + CO 2 2CO (Boudouard) Endothermic C + O2 CO2 (Combustion) Very Exothermic Other Constituents are: H 2 S, COS, NH 3, HCN, N 2, Ar, Slag 5
E-Gas Operations Customized to the Application 2 nd Stage Temperature Control Quench hot gas from 1 st Stage in the 2 nd Stage Thermal heat from 1 st Stage converted to chemical energy Options 1. Add cooled recycle gas to the 2 nd Stage 2. Add quench water to the 2 nd Stage 3. Add quench steam to the 2 nd Stage 4. Partial or full slurry quench to the 2 nd stage 5. Adjust gasifier operating pressure 6
Gasifier Operational Control Steam Production Syngas Gasifier Operation Hydrogen CO Methane Recycle Syngas Quench Water/Steam Quench Second Stage Slurry Pressure First stage Slurry Char Oxygen Slag 7
IGCC Application with Maximum Carbon Capture (Add Just Enough Steam/Water to meet Carbon Capture Requirement) Carbon Capture Vs Methane Make 96% 94% Gasifier Operation Syngas Quench Steam/Water Quench Partial Slurry Quench Pressure First Stage Slurry Carbon Capture % 92% 90% 88% 86% 84% 82% 80% 78% 0 50 100 150 200 250 300 Oxygen Methane Make CO + 3H 2 CH 4 + H 2 O (Methanation) Very Exothermic 8
Chemical And FT Applications (Add More Steam/Water to drive WGS to Increase H2:CO Ratio ) H2:CO Ratio Vs Methane Make 1.6 Gasifier Operation Syngas Quench Steam/Water Quench Partial Slurry Quench Pressure H2:CO Ratio 1.4 1.2 1 0.8 0.6 0.4 First stage Slurry Oxygen 0.2 0 0 50 100 150 200 Methane Make CO + H 2 O H 2 + CO 2 (Water Gas Shift) Slight Exothermic 9
SNG Application CH 4 Range: 2%-7% (H2 + CO) Vs. Methane Make 2500 2000 Gasifier Operation Syngas Quench Steam/Water Quench Full Slurry Quench Pressure First stage Slurry H2 + CO 1500 1000 500 Oxygen 0 0 50 100 150 200 250 300 Methane Make CO + 3H 2 CH 4 + H 2 O (Methanation) Very Exothermic 10
SUMMARY 1. E-Gas gasifier operating flexibility E-Gas two-stage gasifier Is more flexible than single stage 2 nd stage allows customization to match the syngas application 2. E-Gas gasifier performance Exceed 90% carbon capture Control H 2 /CO ratio for CTL plants Increase CH 4 production in gasifier for SNG plants 3. E-Gas process performance modeling Independent study evaluations are typically incorrect E-Gas process proprietary empirical model required to accurately predict performance 11
Back Up Slides 12
Cold Gas Efficiency Varies With Methanation Efficiency Vs Methane Make 79.00% 78.00% 77.00% Effcy % 76.00% 75.00% 74.00% 73.00% 0 50 100 150 200 Methane Make 13
Cold Gas Efficiency Varies With H 2 :CO Ratio Cold Gas Effcy Vs H2:CO Ratio H2:CO Ratio Vs Efficy 79.00% 78.50% 78.00% 77.50% 77.00% Effcy 76.50% 76.00% 75.50% 75.00% 74.50% 74.00% 73.50% 0 0.5 1 1.5 H2:CO Ratio 14
Syngas For Chemicals Feedstock ASU Recycle Char High Pressure Steam CO 2 Syngas @ H2:CO ratio O 2 Gasification HTHR/ Dry Char CO- Shift LTHR/ AGR Slurry Prep Slag Water Gas Shift Reaction CO + H 2 O H 2 + CO 2 H 2 S Sulfur Removal Sulfur HTHR: High Temp Heat Recovery LTHR: Low Temp Heat Recovery 15
Syngas for IGCC Without Carbon Capture Power + Steam ASU Recycle Char High Pressure Steam Power Block O 2 Slurry Prep Gasification Slag HTHR/ Dry Char Power LTHR/ AGR H 2 S Sulfur Removal Sulfur HTHR: High Temp Heat Recovery LTHR: Low Temp Heat Recovery 16
Syngas for IGCC With Maximum Carbon Capture N 2 Power + Stream ASU O 2 Recycle Char High Pressure Steam H 2 H 2 +N 2 Power Block Slurry Prep Gasification Slag HTHR/ Dry Char CO- Shift Water Gas Shift Reaction CO + H 2 O H 2 + CO 2 LTHR/ AGR H 2 S Sulfur Removal Sulfur CO 2 HTHR: High Temp Heat Recovery LTHR: Low Temp Heat Recovery 17
Syngas for Substitute Natural Gas (SNG) ASU Recycle Char High Pressure Steam CO 2 SNG O 2 Gasification HTHR/ Dry Char CO- Shift LTHR/ AGR Methanation Slurry Prep Slag Water Gas Shift Reaction CO + H 2 O H 2 + CO 2 H 2 S Sulfur Removal Sulfur Methanation Reaction CO + 3H 2 CH 4 + H 2 O HTHR: High Temp Heat Recovery LTHR: Low Temp Heat Recovery 18