up-date on lurgi syngas technologies24/10/2003 gtc2003, san francisco up-date on lurgi syngas...
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24/10/2003 GTC2003, San Francisco
Up-Date on Lurgi Syngas Technologies
Up-Date on Lurgi Syngas Technologies
Gasification Technologies 2003, San Francisco H. Schlichting
Lurgi Oel.Gas.Chemie GmbH
24/10/2003 GTC2003, San Francisco
Up-Date on Lurgi Syngas Technologies
! Overview on World Gas Market
! Comparison of Syngas Production Technologies
! Application of MPG
! HP-POX-Pilot Plant
The Presentation will cover…….
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Up-Date on Lurgi Syngas Technologies
World Oil and Gas Reserves
0
20
40
60
80
100
120
140
160
World OilReserves
World GasReserves
Source: Erdöl Erdgas Kohle, July/August 2001
[years]
known today (proven)
including new discoveries
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Flared Natural Gas
better use:make 130 Mt/a of methanol!build 74 MegaMethanol (and MTP)plants!
total amount flared worldwide:100 *109 m³ per year(250.000 MMSCFD)
North America16,7%
Middle East
14,7%
Africa39,3%
Far East & Oceania
7,7%
West. Europe
3,1%
E.Europe&FSU6,8%
C&S America11,6%
Source: Energy Information Administration (EIA): ”International Natural Gas Information” 14 Feb 2001, http://www.eia.doe.gov
monetizing flared gas by producing
valuable products using the Lurgi‘s
Gas-to-Chemicals (GTC) technologies
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General Gas to Chemicals Processing Routes
Fuel GasLPGNaphthaDieselWaxesAmmoniaFuel CellsChemicals (MTBE, Acetic Acid, Formaldehyde, ...)Diesel, transport. fuelsPropylene/PolypropyleneAcrylic Acid/AcrylatesEthylene/PropylenePower/Fuel/DME(Diesel)Hydrogen
MegaSyn®
Fischer Tropsch
SynthesisUpgrading
Mega-Methanol®
MTO
MtPower
MTH
MtSynfuels®
Acrylic AcidMTP®
Natural Gas /Associated Gas
MTC
Lurgiproprietary process
Megammonia®
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Typical Single-Train Capacities of Various Syngas Technologies
100 1,000 10,000 100,000 1,000,000
MeOHReforming
MPG- Part ialOxidat ion
AutothermalReforming
SteamReforming
Capacity [Nm³ dry syngas/h]
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H2/CO Ratios of Syngas Generated from Natural Gas
1 2 3 4 5
M PG
ATR
CM R
SM R
H2/CO Ratio of Syngas
SMR = Steam Methane ReformingCMR= Combined Methane ReformingATR = Autothermal ReformingMPG = Multi Purpose Gasification
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Development of Lurgi‘s Gasification Related Process Know How
1950 1960 1970 1980 1990 2000
Fixed Bed Grate Gasifier
Multi
Purpose
Gasification
45 years experiencein residue gasification:! 75 units! 62.5 x 106 m3
N/d Syngas
year
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Special Features of MPG
Feed "
QuenchWater
O2 Steam
Gas-offtake
#
#
#
#
Soot Slurry
Feed A " Feed B"
SteamCooling Water
O2
"""
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Comparison Quench/Boiler
Feed "
Soot Slurry
QuenchWater
Oxidant(O2 Air)Steam
#
#
#
#
Feed
Oxidant(O2 Air)Steam
#
Syngas
# Syngas
Burner
Boiler Mode
Sat. HP-steam
"
HeatRecovery
Boiler
"
Quench Mode
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Application of MPG in a Fertilizer Plant Based on Asphalt Gasification
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Fertilizer Plant Based on Residue Asphalt
GasificationUnit
RectisolH2S Removal
Unit
CO-ShiftUnit
RectisolCO2 Removal
Unit
LiquidN2 Wash
Unit
NH3Synthesis
Unit
CarbonRecovery
UnitClaus Unit Urea
Synthesis
Air Separation
Unit
HP-SteamBoiler
Air
Feed
HP-Steam
SulfurSoot and AshPellets
Pure CO2 Urea
LiquidAmmonia
O2
RefigerationUnit
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Feedstock and Product
Feedstock:Residue Asphalt 970 t/dC/H-Ratio 8.8 kg/kgAsh Content 0.04 wt%Viscosity at 180°C 360 cStViscosity at 290°C 20 cStFlash Point 170 °C
Products:Ammonia 1350 t/dUrea 2000 t/d
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Project Driving Forces
$ Fluctuating feedstock properties $ Reliability proven commercially for slurry feeds
$ Reduce Load of HP-steam $ Atomizing of oil with steam
Operational Problems in Plant
$ Safety requires laborious procedure after each shut-down
Features of MPG Burner
$ Design of burner with inherent safety
system by stop of oil preheater allows high viscous feedstock
$ Burner lifetime limited due to safety causes high maintenance effort
$ Long burner lifetime reduces maintenance effort
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Gasifier Operation
$ Smooth start-up with automatic start-up system
$ Start directly with residue asphalt at 100 % load
$ Operation with oil viscosity above 100 cSt
$ Start with cold oil of high viscosity
$ Quick take over of gas to production
$ Lower reactor wall temperatures
$ Load changes easy controllable
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0
3
6
9
1100 1200 1300 1400
Temperature, °C
Rea
ctor
Hei
ght
MPG BurnerMPG Burner: AverageMPG Burner: CFD-SimulationOriginal BurnerOriginal Burner: Average
Reactor Temperature Profile
+ Lower maximum wall temperature reduces thermal stress of refractory
MPG - Lurgi Multi Purpose Gasification
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HP-POX Pilot Plant
Feedstock:Liquid Feedstock 500 kg/h
Natural Gas 500 m3/h
Reactor:Design Pressure 100 bar
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HP-POX Pilot Plant
Flue GasFresh water
WaterTreatment
Steam Generator
Storage
Compressor
Pump andVaporizier
Soot Water Cooler
LiquidFeeds
NitrogenSupply
Instument AirSupply
MeasuringStation
Power Supply AnalyticalArea
DesulphurisationReactor
Flar
e Sy
stemNatural
Gas
Liquid O2
Soot Water
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Contact :
Dr. Holger SchlichtingProcess ManagerLurgi Oel·Gas·Chemie GmbH
Dept. A-GPGG Phone +49 69 5808 1418Lurgiallee 5 Fax +49 69 5808 2639D-60295 Frankfurt am MainGermany e-mail [email protected]
Internet: www.lurgi.de
? Comments ?
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24/10/2003 GTC2003, San Francisco
Up-Date on Lurgi Syngas TechnologiesMPG - Lurgi Multi Purpose Gasification
Reaction to Load Changes
88
90
92
94
96
98
100
102
14:30 15:00 15:30 16:00 16:30 17:00Time
O2-
Flow
, % ;
Oil-
Flow
, % Oil-FlowO2-Flow
1160
1200
1240
1280
1320
14:30 15:00 15:30 16:00 16:30 17:00Time
Rea
ctor
Tem
pera
ture
s, °
C
T-TopT-MiddleT-Bottom
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World Oil and Gas Reserves II
10.3
56.7
49.5
11.2
5.16.37.3 38
106
282
215
12
68
100
10
20
30
40
50
60
NorthAmerica
S & CAmerica
Europe Africa MiddleEast
Russia AsiaPacific
Gas
Res
erve
s, T
rillio
n m
³
0
100
200
300
Life
time,
yea
rs
Source: Shell / EFI Conference 2000, Oil & Gas Journal
24/10/2003 GTC2003, San Francisco
Up-Date on Lurgi Syngas TechnologiesUses of Natural Gas
Gas SalesRe-injectionNatural Gas
Power Generation
Fischer-TropschProducts Methanol
RefineriesFuel
Clean FuelsClean FuelsLubricantsLubricantsWaxWaxAlpha OlefinsAlpha Olefins
UreaAcrylonitrileFertilisers
DME, FormaldehydeSolvents, MTBEClean Fuels, Fuel Cells Power Generation
Acetic Acid
Propylene
Syngas (CO, H2)
Hydrogen Ammonia
LNG5%5%
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Autothermal Reforming
Feed+steam#O2
"Combustion
Catalytic reactions
Temperature: 950–1050 °C1740 –1920 °F
Pressure: 30–40 bar435–580 psi
#SYNGAS
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MPG- Multi Purpose Gasification
SYNGAS#
Feed (Natural gas, heavy oil, chemical residues)
#O2/ Steam"
Partial oxidation
Steam reactions
Temperature: 1200–1450 °C2190–2640 °F
Pressure: 30–70 bar435–1015 psi
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Reactor Heat-Up$ Integrated heat-up burner
provides pilot flame up to self-ignition temperature of fuel gas
$ Fuel gas and air fed via product lances
+ Controlled temperature increase
+ Replacement of pilot burner by dummy tube in less than 15 min.
+ No handling at open hot reactor flange
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Scope of Project
$ New Burner Cooling Water Circuit
$ Modification of Oxygen Line
$ Installation of New Steam Line
$ Modification of Control System