steam reformers

8/12/2019 Steam Reformers

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SELAS-LINDE GmbHThe Furnace Company

Furnace Technology MeetSteam ReformersTuesday, 23 April 2013 MumbaiThursday, 25 April 2013 New Delhi


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SL _ PS / Dziurdza219thto 20thOctober 2010

General

Process Design

Mechanical Design

Control and Safety Philosophy

References

Competing Reformer Technologies

Linde Reformer Technology


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Gas Generation by Steam Reformingis applied for the production of

Hydrogen

Carbon Monoxide

Synthesis Gas

Reducing Gas

Ammonia

Methanol

Hydrocarbons



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Basic Chemistry:

CnHm+ mH2O

CH4+ H2O

CO + H2

O

nCO + (n+m/2) H2

CO + 3 H2

CO2

+ H2

endothermic

endothermic

exothermic

Internal Heat Supplyby partial combustion of feedstock

External Heat Supply

Overall endothermic

Reformer Design Application- Fundamental Reforming Chemistry


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Top-FiredReformer

Side-FiredReformer

Terraced-WallReformer

Bottom-FiredReformer

Linde Reformer TechnologyTubular Reformer Types


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General

Process Design

Mechanical Design


References



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Steam/ Carbon Ratio

Pressure

Tube Exit Temperature

Tube Inlet Temperature

Air Preheat Temperature

Excess Air

Process Design Variables

Heat Flux

Tube Inner Diameter

Heated Tube Length

Tube Material

Overall Arrangement

Mechanical Design Variables

Unit Cost of Feed/Fuel/Power

Export Steam Flow Rate

Desired Payback

Owner Design Criteria




feedstock catalyst type demand of downstream units

downstream process units (e.g. PSA) feed supply pressure tube material

Reformer application tube material

type of feedstock material limits

export steam demand NOxlimitations

forced or induced draught fuel type quality of distribution export steam demand

Steam / Carbon Ratio

Pressure

Tube Exit Temperature

Tube Inlet Temperature

Air Preheat Temperature

Excess Air

Linde Reformer TechnologyProcess Design Variables



Low Steam / Carbon Ratio

High Pressure

High Tube Exit Temperature

High Tube Inlet Temperature

High Air Preheat Temperature

Low Excess Air

High Heat Flux

To cope with the more stringent request on the process variables like

Design limits are approached

Design margins have to be reduced More sophisticated design tools have to be used Environmental limits have to be considered

Linde Reformer TechnologyChallenges in Reformer Design



Co-current flow permits

The highest flue gas temperature when the tube process gas temperature is

lowest

The lowest flue gas temperature when the tube process gas temperature is

highest

This is accomplished by

Supplying the upper portion of the catalyst tubes with the most heat

(where a maximum heat flux is desired)

Limiting the supply of heat at the bottom portion (where most of the

reforming reaction has already taken place) where the heat flux is low

Linde Reformer TechnologyTop Fired Reformer Principle



Radiation from two sides Radiation from one side

T

T

DT

Circumference Temperature Distribution

D

irectionofmaximumFlux

Dir

ectionofmaximumFlux

D

irectionofmaximumFlux

TubePitch

Linde Reformer TechnologyCatalyst Tube Design

DT



Tubewall Temperature Profiles

770

780

790

800

810

820

830

840

850

860

870

880

0,0 2,0 4,0 6,0 8,0 10,0 12,0

Heated Tube Length

Temperature

Calc.average TWT




Tubewall Temperature Profiles

820

840

860

880

900

920

940

960

0,0 2,0 4,0 6,0 8,0 10,0 12,0

Heated Tube Length

Temperature

Calc.average TWT

Calc. max TWT

Calc.max TWT with maldistribution allowance





General

Process Design

Mechanical Design


References




Typical Basic Dimensions:

Spacing row to row: 2100 - 2300 mmSpacing wall to row: 1600 - 1800 mmSpacing tube to tube: 260 - 300 mm

Tube inside diameter: 4 - 4.5 inch

Ratio Tube spacing: 1.8 - 2.0

max. tubes/burner 4 - 5max. No. of tubes/row 54

Linde Reformer TechnologyMechanical Design Variables



Linde Reformer TechnologyTop Fired Reformer - General Arrangement



Inlet Section

Radiant Section

Outlet Section

Linde Reformer TechnologyRadiant Box Sectional View


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Inlet Main Header

Inlet Sub Header

Inlet Pigtail

Reformer Tube

Outlet Pigtail

Hot outlet Header

Cold outlet Header

Feed Line

Linde Reformer TechnologyHot System


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Fuel and Combustion AirDistribution System

Feed Distribution System

Penthouse Ventilation

Tube Suspension System

Key Design Elements

Linde Reformer TechnologyTop Fired Reformer - Inlet Section


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Linde Reformer TechnologyTube Suspension System


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Linde Reformer TechnologyRow Wise Modular Burner Design


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Linde Reformer TechnologyRow Wise Modular Burner Design


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Linde Reformer TechnologyRow Wise Modular Burner Design Concept


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Linde Reformer TechnologyBurners


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Linde Reformer TechnologyHarped Catalyst Tube Design


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Linde Reformer TechnologyInstalled Catalyst Tube Harps


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Cold Collecting System

Fluegas Collecting System

Hot Collecting System

Key Design Elements

Linde Reformer TechnologyTop Fired Reformer - Outlet Section


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Linde Reformer TechnologyCold Collecting System


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Completely Insulated/Painted

Modular Components

Integrated SCR Design

Key Design Elements

Linde Reformer TechnologyWaste Heat Recovery Unit Modular Design


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Overview of technologies: DeNOx System

Nitrogen compounds

NOx

DeNOx

+ High NOx reduction rates

+ Lower operating temperature

- High investment costs- Catalyst has to be replaced- Sensitivity of catalyst

Selective Catalytic Reduction (SCR)

+ Low investment costs

+ Easy maintenance

+ No major replacement parts

- Lower reduction rates

- Higher operating temperature- Potential problems with WHR

Selective Non-Catalytic Reduction (SNCR)


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Overview of technologies: DeNOx - Chemistry

Organic Nitrogen compounds in waste streams

NOx-formation

Injection of NH3 or urea solution:

CO(NH2)2+ 2 NO + O2 => 2 N2+ CO2+ 2 H2O

4 NH3+ 4 NO + O2 => 4 N2+ 6 H2O

Injection controlled by downstream NOx-analyser

Minimisation of ammonia slip

DeNOx


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Linde Reformer TechnologyWaste Heat Recovery Unit Modular Design


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General

Process Design

Mechanical Design


References



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TRIP

Reformer FuelPressureLOW

CombustionAir Flow

LOW

ReformerFurnacePressure

HIGH

Fluegas FanTRIPCombustionAir Fan

TRIP

Steam/Carbon Ratio

LOW

Steam DrumLevelLOW

ProcessFeed FlowLOW

Local andPanel HandTRIPS

Reformer exittemperature

HIGH

FurnaceFlame

DetectorFAILURE

Instrument Air Failure Power Failure

Closes ProcessSteam to a

minimum stop

Stops PSAProgram

Isolates ProcessFeed to Reformer

Opens Ventbetween Fuel

Valves

Isolates ReformerFuel

Stops HydrogenCompressor

Closes Valve inletPSA

Linde Reformer TechnologyEmergency Shut-Down System


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General

Process Design

Mechanical Design


References



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Application Ranges of Top Fired Reformers and Lindes Experience

1000

No. of Catalyst Tubes436

No. of Tube Rows16

9

Pressure (bar)

45

41

Exit Temperature (C)1000

945

Linde Reformer TechnologyApplication Ranges


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Reformer Design Data very large

Inner Tube Diameter mm 127

Outer Tube Diameter mm 151

Tube Length (heated) mm 13750

Absorbed Heat MW 356.00

Average Flux density (inside) W/m 84495

Selected Number of Tubes - 768

Number of Rows - 16

Tubes per Row - 48

Distance Tube/Tube (Center) mm 290

Distance Row/Wall (Long Side) mm 1850

Distance Row/Wall (Short Side) mm 400

Distance Row/Row mm 2300

Fire Box Width (inside) mm 38200

Fire Box Length (inside) mm 14850

Process Pressure bar 20

Design Pressure barg 22.7

Process Temperature C 875

Design Temperature C 975

Total Heat Release MW 672.00

Number of Burners (100%) 180

Number of Burners (60%) 24

Burner Capacity (100%) MW 3.05 + 10 %

Burner Capacity (60%) MW 1.83 + 10 %

Total Burner Capacity MW 592.80

Combustion Air Excess 10%

Combustion Air Temperature C 360


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Reformer Plot Plan Side View


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Reformer Plot Plan Top View


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SMR Process Flow Scheme


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Reformer Section View


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Reformer Side View


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Reformer penthouse insight


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Reformer Process Gas Piping


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Feed Distribution System


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Linde Catalyst tube design

Gas inlet through

Top Flange

Thermal Plug

Catalyst Grid

Catalyst Tube

Material: 2535 CrNiNbTi Microalloy RInner diameter: 4 to 4.5 inches

Heated Length: 12 to 14 metres

Top Flange

Outlet Pigtail

Material: Incoloy 800H

Inner diameter: 30 mm

Length: 600 to 800 mm


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Linde Catalyst tube design


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Burner Design

204 forced draft Low-NOx arch burners in total

Callidus, Zeeco, Bloom

17 rows 12 burners

15 rows with 100% burners 3.05MW

2 rows with 60% burners 1.83MW

One burner per row equipped with UV flame supervision

(Fire-Eye Phoenix 85UV kompakt, with vortex cooling box)

air pressure at 110% duty: 20 mbar

Fuel gas pressure at 110% duty: max. 1.75 bar-g

Firebox temperature 1060C

Staged combustion air headers


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Computational Fluid Dynamics

Fluid dynamics optimization

Software: FLUENT

SL is equipped with 4 Workstations

Radiant Zone Optimization - optional


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Flue Gas ducting

Heat input in upper

section of furnace

Uniform flue gas flowover length and width of

furnace

Flue Gas ductingdesigned for < 3%

maldistribution

Li d R f T h l


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Linde Reformer TechnologyTop Fired Reformer in Italy - 4 rows -

Li d R f T h l


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Linde Reformer TechnologyTop-Fired Reformer in USA - 7 rows -

Li d R f T h l


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Linde Reformer TechnologyTop-Fired Reformer in India - 8 rows -

Linde Reformer Technolog


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Use of sophisticated design tools

Use of most advanced metallurgy

Constant hanger support for inlet system and catalyst tubes

Outlet header system installed in radiant floor coffin to minimize heat loss

Flexibility with regard to top or side entry of reformer tubes

Use of short outlet pigtails to minimize elevation

Modular penthouse and WHR design for cost effective construction

Penthouse cooling for operator safety

Flexibility with regard to convection section arrangements

Single lance combination fuel burner system

Balanced draft for high system efficiencies

Linde Reformer TechnologySummary

COST EFFECTIVE,RELIABLE AND MECHANICALLY ADVANCED DESIGN


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General

Process Design

Mechanical Design


References



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SIDE FIRED STEAM REFORMER


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Top Fired Side-/Terraced Fired

Shape Rectangular Box Long & Narrow Box

No. of Cells Single Single or Multiple

Tube

ArrangementSeveral Parallel Rows One Row per Cell

Process Flow Down Down

Flue Gas Flow Co-Current Counter-Current

Convection

Section

Horizontal at grade

Vertical along side box

Elevated above Radiant

Vertical Down

Draft Balanced or inducedBalanced, Induced or

Natural

Reformer Design Application


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Top Side Terraced

Maintenance Cost

Control Complexity

No. of Burners

Burner Access

Piping mass

Surface Area (box)

Natural Draft Operation

Heat input Control along tubeInvestment Cost

Ease of expansion

high low

no yes yes

noyes yes

Reformer Design ApplicationSMR Configuration Comparisons


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Steam Reformer

STEAM REFORMER

Urea/Ammonia

Key Data

- No. 336 tubes

- No. 7 rows of tubes

- inner tube id. 4,5

- Heated tube length 12,5m- tube spacing 260 mm


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Steam Reformer for a Urea/Ammonia Project(2050MTPD)

Reformer:- 723 to steel

- 160 to catalyst tube system

- 55 to piping

- 480 to Inner lining andrefractory

WHR-System:

-320 to ducts & steel casing

-250 to coil


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Steam Reformer for 7000 MTPD Methanol Plant

STEAM REFORMERKey Data:- No. 396 tubes- No. 9 rows of tubes- inner tube id. 127mm- Heated tube length11 5m- tube spacing 290 mm

d l d l d f


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Modularization drivers Quality and Safety

Quality increases under which construction is accomplished

Well-rehearsed assembly process in workshop

Established quality control system in place

No weather impact

Safety

With prework, workers face less exposure due to weather, heights,harzadous operation and neighboring construction activities

Less workers at onsite translate into reduced craft congestion and exposureto ongoing operations

h i l f d l i i


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Further potential for modularization

Increase the modularization in the reformer section by: modularize entire Penthouse section with entire inlet system components modularize radiant box panels with ceramic fibre pre-installed convection coils can be pre-assembled and shop hydrotested The inlet manifold and outlet system can be harped into shippableassemblies

the refractory lined transfer line can be shop fabricated sectional pre-fabrication of ladders, platforms and stair towers


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Linde Ammonia Concept

Linde Ammonia Concept (LAC)


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Linde Ammonia Concept (LAC)Simplified Block Diagram

AmmoniaProduct

AtmosphericAir

HydrocarbonFeed

H2 Unitwith

PSA Purification

N2 Unit

AmmoniaSynthesisLoop



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Linde Ammonia Concept (LAC)Possible valuable By-Products

H2 Unitwith

PSA Purification

N2 Unit

AmmoniaSynthesis

Loop

HydrocarbonFeed

AtmosphericAir

AmmoniaProduct

CO2 CO H2

N2O2ArRareGases

Methanol

CO Recovery

MEOH Unit



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Linde Ammonia Concept (LAC)A combination of proven technologies

50 units, up to 125.000 Nm3/h

Casale: 125 converters +loopsLinde: 6 complete Ammonia Plants

2.400 units,up to 340.000 Nm3/h


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Linde Ammonia Concept (LAC)Comparison of LAC process with conventional scheme

Desulfu-rization

Desulfu-

rization

PrimaryReformer

Isotherma

l

Shift

Conventional Ammonia Plant

HTShift

LTShift

CO2Removal

Methan-nation

AmmoniaSynthesis

PurgegasSeparation

Feed

Air


Primary

ReformerPSA

Nitrogen

Unit

Ammonia

Synthesis

NH3

CO2

NH3

Feed

Air

SecondaryReformer

Downstream this pointthe flowrate of a conventionalplant is 30 to 80% highercompared to the LAC-process

0

Purgegas Separation

Cost related facts: number of temperature changes temperture levels flowrate number of equipment and catalyst

Efficiency related facts:

heat exchange losses pressure drops

LAC-Process

Conventional Plant

Figure 1



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p ( )Linde Isothermal Reactor

Figure 4Steam

CirculatingWaterBoiler Feed Water

Gas Entry

GasExit

CirculatingWater



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p ( )Comparision of Equipment Items

ExchangersVesselsColumnsReactorsBig Machines

(Compressors,TurbinesGenerator)PumpsOther MachinesAir Separation UnitInert Gas UnitPurge gas separatorPSA Unit

Totals

Conventional

Plant

LAC

Plant6025886

3511-11-

155

3419454

25121--1

105

Common for both plants, and not included in above count, are:Refrigeration Unit, Ammonia storage, Cooling Water System, Flare System, Effluent Collection, Instrument Air Unit



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p ( )Comparision of Catalyst volumes 1350 MTPD NH3

ConventionalPlant

LACPlant

Desulphurisation

Primary Reformer

Secondary Reformer

HT Shift

LT Shift

Methanation

Ammonia Synthesis

24.8 m3 28.0 m3

36.0 m3

35,1 m370.5 m3

96.5 m3

27.0 m3

92.3 m3

37.0 m3

----

52.0 m3

--

83.9 m3

Total 382.2 m3 200.9 m3

Linde 12-Bed PSA System Top View


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y p110.000 Nm3/h H2

Linde Air Separation Plant


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pConventional Cryogenic Process

cold generationair compression air purification heat exchange rectification

AIR

GAN

GOX

filter

air compressor

expansions-turbine with

booster-compressor

heat-exchanger

pressure-column

low pressure-column

evaporator/condenser

direct-contactcooler

evaporationcooler

molecularsieveadsorber

Impure GAN

coldbox


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Section View


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Reformer + Isothermal Shift


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Ammonia Synthesis


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Vadodara / Indien


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Lindes HyCO offeringsBOO / Over the Fence Supply

Agenda


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Agenda

1. BOCI

2. Typical commercial model for BOO / over-the-fence gas supply

3. Over the Fence (BOO) supply advantages

4. Linde Gas HyCO Experience

5. LindesOperational Excellence

6. Overall value that Linde can bring to IOCL/BP

Linde Hydrogen Technology


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DESIGNS

BUILDS

OPERATES

LINDE IS ONE OF THE FEW COMPANY IN THE WORLD THAT

ASU, HYDROGEN, SYNGAS & CO FACILITIES

USING THEIR OWN IN-HOUSE TECHNOLOGY

Linde Hydrogen Technology

Plant Operation


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LINDE GASOPERATES AND MAINTAINSLINDE ENGINEERINGDESIGNS & BUILDS

EXPERIENCE

Plant Operation

Hydrogen and Synthesis Gas technologies of thei d i i i i i


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Linde Engineering Division

Product Line

Hydrogen & Synthesis

Gas

Hydrogen Plants

H2/CO Plants

CO-Plants

Syngas Plants

Ammonia Plants

Methanol Plants

Gas Removal Processes

Gas Separation Processes

The Best in the Business Trust Us


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The Best in the Business Trust Us

Linde Gas - Worldwide market share and position 1


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Linde Gas Worldwide market share and position

#3 North America

15%

#2 Europe

32%

#2 South America

24%

#1Africa

42%

#1Asia/Pacific 2

19%

1 Total market share subject to potential disposals2 Includes all of Asia and Australia, including captive market ChinaSource: Annual Reports, Broker Reports, Spiritus Consulting, Linde Analysis

Linde Group in IndiaBOC I di Li it d


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- BOC India Limited

BOC India Limited (A member of The Linde Group), is Indias leading Industrial

Gas Company which is established over 75 years in India with headquarters inKolkata.

BOCI has around 700 employees in India

Linde Gas On-site / BOO Plants Worldwide


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Linde Gas On site / BOO Plants Worldwide

HYCO Tonnage Air Tonnage ECOVAR (standard plants)

H2, CO, CO2, Synthesis gas O2, N2, Ar, Kr, Xe O2, N2, H2

100 200.000 Nm3/h 3.000 50.000 Nm3/h 50 3.000 Nm3/h

> 65 plants > 300 plants > 800 plants

In total Linde is operating more than 1000 plants producing

industrial gases in all continents with strong focus in Asia

Overview of the major syngas (H2/ CO) production facilitiesd d t d b th Li d G


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owned and operated by the Linde Group

La Porte

Concon

Singapore

Caojing

Leuna

Milazzo

H2/CO-plantH2-plant

POX-plant

Toledo

Lima

LemontSalt Lake

Bulwer

Clear Lake

Paraguana

Concepcion

Daesan

Murrin-

Murrin

Teesside

Map Tha Phut

Aurangabad

BOO or On-site Supply Typical Commercial Model


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pp y yp

Feedstock/Air &Utilities

Customer Production

Fixed Fee for Capital

Recovery and FixedOperational Cost

Unit Charge formolecules (adjustedwith actual price of

Feedstock & Utilities)

15 year contract

Supply of H2,CO, Syngas, CO2

,O2, N2

molecules

HYCO Plant

Or ASU

HYCO Plant

Or ASU

Summary of Benefits of over the fence supply schemeImproved Gas Economics


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Improved Gas Economics

FINANCIAL Capital Avoidance.

Payments only begin whengas is delivered.

Level and predictable gascosts.

Turnaround peaks avoided.

No major $MM surprises

SHIFT OF RISKS Capital Accuracy

Construction

Maint. & Operations

Accuracy

Volatility

On-Stream Reliability Labor Relations, Cost, &

Legacy.

Changing Safety & Maint.Standards & Policies.

IMPROVED ALIGNMENT

15+ Year, not 2 3 as for LSTKLow gas cost, not cheap equipment

Alignment of gas delivery / needschedule.

Mechanical completion inappropriatetarget.

Collaborate on cost/benefit

analysis decisions. Continuous innovation

Maintain Competitiveness

Improve Reliability

Improved Safety Practice

Obvious

Project development costs such as initial capital, utilities etc

Less obv ious

Future major equipment repair capital

Ownership costs such as overheads, insurance, debt impact, & labor legacy

H2 for Refinery Toledo, USASteam Reformer supplying H2 to 2 Refineries


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Steam Reformer supplying H2 to 2 Refineries

H2: 144,000 Nm3/h

Steam: 67.8 t/h

Feed: Natural Gas / ROG / RFG

Fuel: Natural Gas / ROG / RFG

Average Reliability of each train

>>99,5%

2 x Top-fired Selas Reformer Trains

12 bed Linde PSA


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Hans Dziurdza


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Manager Sales and Marketing

SELAS-LINDE GmbH

Wolfratshauser Str. 138

82049 PullachPhone +49 89 7447 47 12

Fax +49 89 7447 47 81

[email protected]

www.selas-linde.com

Thank you for your attention.
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