LURGI FBDB MK+ Gasification Technology 6 th International Freiberg Conference Dresden / Radebeul May 19 22 nd, 2014 Air Liquide Global E&C Solutions Germany l Lurgi FBDB technology
Outline Mk+ Gasification Module Benefits for Coal to SNG Projects Update on SNG Projects in China Highlights on Key Innovations Purification of the gas liquor for ZLD solution Dry ash handling Status JSPL Coal to DRI Project in India 2 6 th IFC - May 21 st 2014 - Germany
Basis of Lurgi FBDB TM Mk Plus TM Development Step 1: Starting point: Mark 4 from Jindal Steel & Power Ltd. (JSPL) Angul project Lessons learnt from 30 years of operation of Sasol (Secunda, RSA) and DGC (North Dakota, USA) plants Latest project: JSPL Angul, India, 40 barg design pressure Step 2: Increase of the diameter Reason: Gain in terms of capacity Definition point: Lurgi Mark 5 (Sasolburg 1985 to 2004) Rich references of Mk 4 101 gasifiers globally Continuous technology improvement 1970s-2010) Quant ify influence of diameter increase Latest MK4 (Design pressure: 40barg) Design improvement based on experience from Mk 5 Continuous technology improvement of MK 4 Step 3: Increase of the operating pressure Gain in capacity, efficiency, environmental footprint and methane yield Optimum pressure: 60 barg for Capex and scale-up risk Validation of the gasification process calculations with the Ruhr 100 pilot plant test results and data MK4 MK5 Quantify benefits of high pressure gasification Ruhr-100 pilot plant maximum operation pressure : 100bar) Gasification database under high pressure and some special design features MK+ - Lurgi new FBDB Gasifier 3 6 th IFC - May 21 st 2014 - Germany
The Lurgi FBDB Gasifier LURGI FBDB Mark4 Gasifier Outside diameter: 4.13 m Height: 12.5 m Design pressure: 40 barg Raw Gas Loading, dry: up to 60000 Nm³/h LURGI FBDB Mark+ Gasifier Outside diameter: 5.05 m Height:17.0 m Design pressure: :60 barg Raw Gas Loading, dry: up to 120000 Nm³/h 1950s - 2010 2011-2500 t/d coal feed 500 MWth 4 6 th IFC - May 21 st 2014 - Germany
Benefits for Coal to SNG projects MK+ : innovative use of referenced technology for no scale up risks Improved Opex and lower Capex compared to Mk4 Higher direct production of CH4 Reduced coal, O2 and HP Steam consumption Higher thermal efficiency O2 O2 10 to 15% decrease of the SNG cost versus Mk4 Coarse Coal 50% to 75% FBDB MK+ Rectisol Methanation SNG Part of the SNG is produced by ETF gasification for coal fines. (ETF: 50% higher SNG cost) Fine coal ETF Rectisol Methanation SNG 5 6 th IFC - May 21 st 2014 - Germany
Update on SNG projects in China 2 plants started-up with a total capacity of 2.7 BCMY of SNG Datang Keqi phase 1 Qinghua Yili phase 1 More than 20 new projects got the NDRC Lutiao in 2013 2 main locations for SNG projects Inner Mongolia province Xinjiang province Challenges Magnitude of the Capex (large projects) Management of the project risks Highest standards for emissions and effluents Scarcity of the water 6 6 th IFC - May 21 st 2014 - Germany
From Gas Liquor to Zero Liquid Discharge Full chain of purification of the water Unique offer from Air Liquide Solution based on fully referenced technologies Recycle of the purified water as make-up to cooling water circuit Coal O2 Steam Lurgi FBDB Gasification CO Shift & Gas Cooling Acid Gas CO2, H2S, HCN Dephenolized Gas Liquor Gas Liquor Organics Raw syngas Stripped Gas Liquor Recycle of the water is a must for CtSNG projects (<5 twater /knm3) Gas Liquor Separation Phenosolvan Phenols Recovery CLL NH 3 Recovery Waste Water Treatment Cooling water Make-up Mud liquor CO2, H2S, solvent Clear Tar / Oil Crude Phenols Liquid Ammonia 7 6 th IFC - May 21 st 2014 - Germany
Phenosolvan / CLL / WWT: Economics Make-up water for the cooling water system produced by WWT WWT consists of advanced biotreatment followed by high efficiency RO and evaporation / crystallization units Impact WWT on SNG cost: 2.5% Large credit coming from co-products Spec Unit RMB/unit CW 30 C T 0.2 TW 45 C T 0.57 Demin water 30 C T 8 LP Steam 4.5 bar T 70 MP Steam 8.5 bar T 85 N2 7 bar Nm³ 0.165 Power kwh 0.42 Caustic As pure Kg 3.1 solvent (DIPE) Kg 11.5 CTA T 2800 Ammonia T 2500 Flow 550 t/h of GL Phenosolvan CLL WWT Total CAPEX M 48 32 41 121 OPEX RMB/t 4.1 35.2 5.8 45.1 CAPEX + OPEX RMB/t 21.6 46.9 20.2 88.7 Credit co-products RMB/t 13 22 0 35 Net TCO RMB/t 8.6 24.9 20.2 53.7 % Total TCO 16% 46% 38% 100% % of SNG cost 1.1% 3.2% 2.5% 6.8% Ref 1.7 for 2 BCMY 8 6 th IFC - May 21 st 2014 - Germany
Evaluation of dry ash handling for FBDB Incentives for dry ash handling No water consumption No effluent water to treat Lower operating costs Broader opportunities to sell the ash Wet sluice way system Most commonly applied worldwide Very reliable Wet ash to be disposed off or sold Loss of water with the ash ~ 3 / t of ash (handling / separation) 9 6 th IFC - May 21 st 2014 - Germany
Optimized dry ash handling solution Interesting competitive solution of the ash management for FBDB Ash disposal cost reduced by by 5% (no ash sold) by 11% (10% of the ash sold) Footprint reduced by 65% Referenced and proven equipment (power plants) Easy operation and maintenance Solution with high availability (> 99.5%) 10 6 th IFC - May 21 st 2014 - Germany
Magaldi group: dependable by innovation since 1929 The Magaldi Group, founded in 1929, World leader in mechanical transportation of hot and abrasive bulk materials for coal-fired power plants, cement manufacturers, steel mills, foundries, mines etc. Magaldi develops and provides technologies for the safe and environmental friendly handling of raw materials and ash in the coal fired power plants 11 6 th IFC - May 21 st 2014 - Germany
Magaldi group: dependable by innovation since 1929 The Superbelt ensures the safest and most reliable transportation of abrasive and hot bulk material, associated with maximum life time. The Magaldi ECOBELT is a steel belt conveyor completely enclosed in a dustproof steel casing, unique in its design and able to transport materials with aggressive properties, both chemical and physical, without any release to the external environment. Hundreds of successful installations in Power Industry (hot bottom ash, mill rejects, Eco ash); Foundries (hot castings, sand, molds, scraps); Cement Industry (hot clinkers); Metallurgical plants (hot DRI, metal sinter etc.). 12 6 th IFC - May 21 st 2014 - Germany
JSPL Coal to DRI Gasification Project Commissioning completed Mk4 Gasifiers Start-up on-going CLL Phenosolvan Photos site Jan 2014 Courtesy JSPL Customer: JSPL Location: Orissa, India Key Process data: Sub. Coal 35% ash 7 MK4 gasifiers 225,000 Nm3/h DRI SG LHV: 3,500 kcal/nm3 H2/CO ratio: 1.7 Scope for complete gas island - gasification, Rectisol, SRU PDP / BE / DE Prop Equipt supply Operators training Start-up assistance 13 6 th IFC - May 21 st 2014 - Germany
JSPL Coal to DRI Gasification Project 14 6 th IFC - May 21 st 2014 - Germany
Contact information Mr Frederic Judas, Director Technology Coal to Gas Product Line Air Liquide Global E&C Solutions Germany GmbH frederic.judas@airliquide.com Tel: + 49 69 5808 2081
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