The Low Cost Gas Era Gasification versus Steam Reforming - a True Alternative? Karsten Radtke, Ines Wulcko ThyssenKrupp Industrial Solutions (USA/Germany)
ThyssenKrupp Group Sales: US$ ~46 bn Employees: 160,745 Components Technology Sales ( mill) 6,172 Elevator Technology Sales ( mill) 6,416 Industrial Solutions (TKIS) Sales ( mill) 6,271 Materials Services Sales ( mill) 13,660 Steel Americas Sales ( mill) 2,060 Steel Europe Sales ( mill) 8,857 EBIT ** ( mill) 268 EBIT** ( mill) 674 EBIT** ( mill) 420 EBIT ** ( mill) 212 EBIT ** ( mill) -68 EBIT ** ( mill) 206 Employees 28,941 Employees 50,282 Employees 18,546 Employees 30,289 Employees 3,466 Employees 26,231 ThyssenKrupp Group: - founded 204 years ago in Essen (Krupp) TKIS: - 100+ gasifiers designed, built, put into successful operation - world leader in syngas technologies: Gasification (PRENFLO, HTW), Steam Methane Reforming (SMR), Auto Thermal Reforming (ATR) *) Continuing operations (after reclassification of Steel Americas) before consolidation **) Adjusted before consolidation, after definition changes 1
Shale Gas: Challenge and Opportunity for Synthesis Gas Generation 2
Synthesis Gas is the central intermediate product: Nearly all hydrocarbons can be converted to syngas by very different means Feedstock Gas, Naphtha Hydrocarbon Conversion Steam Reformer / ATR Syngas Methanol Product Generation MTO Product Diesel, Plastics Oil/Residues Oil Gasification MTG Gasoline, LPG Petcoke Ammonia Urea Fertilisers Hard Coal PRENFLO Gasification Synthesis Gas CO + H2 Fischer- Tropsch Diesel, Naphtha Biomass Waxes, Lubes Biomass CO- Shift Hydrogen Lignite HTW Gasification Methanation Synthetic Natural Gas Wastes IGCC El. Power 3
ThyssenKrupp Industrial Solutions: Proprietary Syngas Technologies PSG PDQ PRENFLO HTW SMR ATR Entrained-Flow Gasification Fluidized Bed Gasification Steam Methane Reforming Autothermal Reforming 4
Entrained-Flow Gasification: PRENFLO PRENFLO is a slagging gasifier that operates above the ash melting point => high carbon conversion, high efficiency for coal and petcoke for biomass, if pre-treated Major Reference: Elcogas IGCC, Puertollano/Spain Selected and permitted for several projects around the world, including U.S.A. 5
Uhde PRENFLO gasification under construction: BioTfueL in France Biomass/Coal/Petcoke/Oil Gasification to Liquid Fuels Facility Construction ongoing Commissioning starts in 2016 Start-up beginning 2017 6
Fluidised-Bed Gasification: Uhde HTW Gasification HTW especially suited for biomass, wastes and low-rank, high ash coals with high ash melting points HTW has strong reference basis through full commercialisation over 3 decades New HTW Pilot Plant at University Darmstadt commissioned in 2015 Current main focus on China, India 7
Uhde Steam Reforming Technology More than 60 Uhde steam reformers built since 1966 Largest reformer has 960 tubes Commercial reformers operate over a wide range Ammonia @ 40 bar 780-820 C Methanol @ 20-25 bar 850-880 C Hydrogen @ 20-25 bar 880 C Oxogas @ 9-12 bar 900 C Olefins (STAR) @ 5-6 bar 570-590 C SINCOR C.A., Jose, Venezuela 2 x 98,000 m 3 /h (V norm ) Hydrogen 8
Principle Overview: Steam Reforming (SMR) Pressure bar(a) 5-50 Process steam % 100 ( base case ) Gas quality - H 2 surplus Steam NG Energy available - Excess Air separation - - Steam ratio - 2.5-3.4 H 2 -CO 2 /CO+CO 2-2.9-3.0 CH 4 slip % 3.0-5.0 O 2 required Mol/Mol - C in feed Prod. Gas 880 C 9
Uhde Steam Reforming (SMR) Technology Hydrogen Plants, St. Charles, LA & Port Arthur, TX Two plants with 135 mm SCFD each based on Uhde Steam Reforming technology 10
Uhde Auto-Thermal Reformer (ATR) Technology 11
Principle Overview: Autothermal Reforming (ATR) Pressure bar(a) 30-40 Process steam % 70 Gas quality - Carbon surplus Energy available - Energy import for drives Air separation - Required NG 580 C O 2 100 C Steam 300 C Steam ratio - 0.3-3.5 H2-CO2/CO+CO2-1.1-1.7 CH4 slip % 0.5-4.0 O2 required Mol/Mol 0.55-0.75 C in feed Prod. Gas 1,000 C 12
Combined Reforming (SMR plus ATR) Pressure bar(a) 40 Process steam % 60-65 Gas quality - Stoichiometric Energy available - Energy import for drives Air separation - Required Steam ratio - 1.5 Steam NG 510 C NG 370 C O 2 100 C H2-CO2/CO+CO2-2.02 CH4 slip % 1.0 O2 required Mol/Mol 0.445 C in feed 780 C Prod. Gas 880 C 13
Combined Autothermal Reforming (CAR ) Pressure bar(a) 40 Process steam % 100 Gas quality - Stoichiometric Energy available - Energy import for drives Air separation - Required Steam ratio - 2.5 H2-CO2/CO+CO2-1.98 Steam 300 C NG 370 C Prod. Gas 550 C CH4 slip % 1.0 O2 required Mol/Mol 0.49 C in feed O 2 100 C 14
Main chemical reactions for synthesis gas generation: Steam reforming CH4 + H2O CO + 3 H2 Partial oxidation: CH4 + 0.5 O2 CO + 2 H2 ΔHR = +206 kj/mol endothermal ΔHR = -35 kj/mol exothermal Synthesis gas composition requirements: ammonia: (H2 + CO) / N2 3.0 methanol: (H2 CO2) / (CO + CO2) 2.0 hydrogen: H2 = max. gas to liquids: H2 / CO 2.0 15
Syngas Technologies in Comparison: H2/CO Ratio 0 1.0 2.0 3.0 4.0 Note 1): H2/CO ratio adjustable via CO Shift SMR Combined Reforming Hydrogen production is favored by SMR, other technologies such as ATR/CAR/POX produce more CO or lower H 2 /CO ratios SMR has economical advantages in producing hydrogen for large capacities Syngas applications, which require more CO content, are favored by the non-smr routes, especially by Partial Oxidation/Gasification ATR Oil/Gas Gasification Coal Gasification 16
Steam Reformer Technologies: Summary Overview Steam 510 C Steam NG 300 C Steam NG NG 370 C NG 370 C O 2 100 C Prod. 550 C Gas 1 2 3 4 580 C 100 C 580 C NG O 2 Steam 880 C Prod. Gas 780 C 880 C Steam ref. ( 1 ) Combined ref. ( 2 ) CAR ( 3 ) Autoth. ref. ( 4 ) Pressure bar(a) 5-50 40 40 30-40 Process steam % 100 ( base case ) 60-65 100 70 Gas quality - H 2 surplus Stoichiometric Stoichiometric Carbon surplus Energy available - Excess *) Energy import Energy import Energy import for drives for drives for drives Air separation - - Required Required Required Steam ratio - 2.5-3.4 1.5 2.5 0.3-3.5 H 2 -CO 2 /CO+CO 2-2.9-3.0 2.02 1.98 1.1-1.7 CH 4 slip % 3.0-5.0 1.0 1.0 0.5-4.0 O2 required - - 0.445 0.49 0.55 0.75 (Mol/Mol C in feed) *) No excess in case of an additional pre-reformer Prod. Gas 100 C O 2 1,000 C Prod. Gas 17
Combination Gasification with Auto-Thermal Reforming Example 1: Coal-to-MeOH ATR 85% 15% to Aux. Boiler Offgas Gasification Partial CO Shift AGR MeOH synthesis MeOH Example 2: Coal-to-NH3 ATR 85% 15% to Aux. Boiler Offgas Gasification CO Shift AGR PSA NH3 synthesis NH3 18
Characteristics of Gas Generation Technologies Key Performance Parameters SMR ATR HTW Gasification HTW with ATR PRENFLO Steam ratio (volume based) 2.5-3.4 0.3-3.5 - - - H 2 /CO-ratio 3.0-5.0 2.0-5.0 0.76 1.13** 0.58 Syngas ratio (H 2 -CO 2 )/(CO+CO 2 ) 2.9-3.0 1.1-1.7 0.15 0.37** 0.36 CH 4 slip (% of water and N 2 free raw gas) 3.0-5.0 0.5-4.0 5.68 4.45** 0.01 Feed consumption (MW Feed/1000 Nm³/h Syngas)* 3.0-4.0 3.6-4.2 5.00 3.71 4.26 Steam consumption (kg Steam/Nm³/h Syngas) * 0.756 *** 0.1-1.0 0.27 0.30 0.02 O 2 consumption kg O 2 /Nm³ Syngas * - 0.3-0.5 0.38 0.32 0.43 * Syngas = CO + H 2 ** Values after merging the syngas originating from HTW and ATR, before CO-shift) *** Steam input, SMR: actual net steam consumption: 0.276 kg steam/nm³ syngas 19
Syngas Technologies: Summary Solid or liquid feedstocks require Gasification Technology to generate syngas. Steam Reforming, Auto Thermal Reforming or Combined Autothermal Reforming are only applicable for gaseous feestocks. For gas feedstocks, the desired product influences the technology decision: Hydrogen production prefers the application of SMR technology High CO containing gas applications prefer gasification/partial oxidation SMR has economical advantages in producing hydrogen for large capacities The combination of Gasification (HTW) with Reforming (ATR) provides higher product yield from the same amount of coal feedstock, higher H2/CO ratio, and reduces the consumption figures, and increases the feedstock flexibility (solid/gas) Gasification has a broad feedstock flexibility. Once the plant is installed, only gasification allows the later application or variation of alternative feedstocks if properly foreseen during the design stage (e.g.: BioTfueL) The oil & gas price volatility over the life-time of a chemical plant (typically 25+ years) is far less predictable than the coal price stability 20
Steam Reforming PDH/PP Complex Port Said, Egypt October 2015 Gasification IGCC Plant Puertollano, Spain October 2015 Thank you for your attention 21