Engineers India Limited 16 th February , 2017, New Delhi Multi product generation from Coal via gasification
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Engineers India Limited
16th February , 2017, New Delhi
Multi product generation from Coal via gasification
Future Energy Scenario - India
(b) Energy Demand and Supply (a) Growth Vs Energy Demand Trend
Source: ExxonMobil 2014 Outlook for Energy
2
International Oil & Gas Price, Shortage of
Resources are bottlenecks for India’s Economic
Growth
Energy Hungry
Nation
Fossil Resource
Starving
India Imports –
77 % of its oil,
30 % of its gas, &
even 34% of Coal Source: India: Towards Energy Independence 2030
3
•Gasification Technologies
•Applications
•Polygeneration
•Summary
Outline
4
•Gasification Technologies
•Applications
•Polygeneration
•Summary
Outline
SNG
5
CTL - Add hydrogen or
reject carbon
GTL - Reject hydrogen or
add carbon.
CTG - Add more hydrogen or
reject more carbon.
Coal vs. other fuels
Coal- Low hydrogen, carbon rich source
Volatility
6
Coal Gasification Technologies
• Technology selection mainly depends
on feed properties :
Ash content
Reactivity
Rank
Challenges for Gasification Technologies - Indian coal
7
The high ash content
• means a high ash output
• rising CAPEX due to needed enlargement of ash handling system
• necessary storage of ash may also cause problems
Increasing efforts for gas treatment (raw gas cleaning etc.)
• lowers the total plant efficiency
Necessary high gasification temperature due to the feedstock/ ash
composition
requires special gasifier reactor design
e.g. material selection, ash handling
High ash content and high ash melting point above 1400°C means higher
oxygen consumption
• rising OPEX
• availability
8
Fixed/moving bed
• Lower operating temperature - lower carbon
conversion efficiencies
• Non-uniform temperature profile - promotes
the generation of tars, oils, and other
undesirable by-products
• Cannot handle fine material - large piles of
waste coal fines material
• Handling of caking coal
Entrained bed
• Slagging conditions – highest oxygen
consumption/ton coal for melting high ash and
high AFT Indian coals (energy intensive)
• High capital intensity
• Slag penetration in refractory
Fluidized Bed
Moderate Temperature – Limited by Ash
Fusion Temperature (AFT)
• High conversion at moderate temperature
• Suited for low rank, high AFT reactive coals
– (Typical INDIAN Coal)
Technology Comparison
Indian coal (mostly high ash)
Lurgi Moving Bed (Moisture + Ash)~ 55%
9
•Gasification Technologies
•Applications
•Polygeneration
•Summary
Outline
Applications of Coal Gasification
Gasifiers once solved energy problems - they might, yet again.
Syn Gas and Polygeneration
CO and H2/CO
Pure CO
Acetic Acid
Polyurethanes
Speciality Chemicals
DMF, Polyketones,
Formic Acid
DMC, polycarbonates
Syn gas / CO+H2
Methanol
H2-CO2 = 2
CO+CO2
Oxo-alcohols
H2/CO =1
Ammonia
H2/N2=3
Synfuels H2/CO=2
FT synthesis
SNG
H2-CO2 = 3
CO+CO2
12
•Gasification Technologies
•Applications
•Polygeneration
•Summary
Outline
CTL Yields & Hybrid Coal Conversion
13
Coal
Gasification
Water/Gas Shift
Hydrogen Recovery
Product
Refining
& Blending
Direct Coal
Conversion
Coal
Raw DCL
Products
Final
Products
Raw ICL
Products
FT Tail Gas
H2
H2
DCL product slate
~ 65% Diesel, 35 % Naphtha
Diesel : Cetane : 42-47, Sulfur:< 5 ppm
Aromatics: 4.8 %, Sp. gravity : 0.865
Naphtha: Octane (RON): >100, Sulfur: <0.5 ppm
Aromatics:5%, Sp. Gravity :0.765
Indirect
conversion
DCL
Bottoms
ICL product slate
~ 80% Diesel, 20 % Naphtha
Diesel : Cetane : 70-75, Sulfur:<1 ppm
Aromatics < 4 %, Sp. gravity : 0.780
Naphtha: RON: 45-75, Sulfur : Nil
Aromatics:2%, Sp. gravity :0.673
Hybrid concept
• Integrated
• products complement
each other
• balance between
process efficiency and
final fuel quality by
blending
• improve process
flexibility and maximize
targeted product slate
Coal to Hydrogen
14
Estimated world hydrogen production and use (2008). Source: various
Generalised process flow for industrial hydrogen and syngas production
Note: SMR = Steam methane reforming; ATR = Auto thermal reforming; POX =
Partial oxidation
Coal to SNG (1)
15
India’s Natural
Gas Demand Natural gas consumption is significant
- Demand outpacing production
- India - fourth largest LNG importer
- Imports expected to rise ~30% in 2017
- National coal reserves is the key
Costly LNG import substitution
- Country’s economic potential
Easy to implement
- Technology well developed
Conventional fuel
- Infrastructure already in place (Source- ExxonMobil 2014 Outlook for Energy)
MMSCMD 2012-13 2016-17 2021-22 2026-27 2029-30
Domestic sources 101.1 156.7 182 211 230
LNG Imports 44.6 143.0 188 214 214
Gas Imports (Cross-
border pipeline) 0.0 0.0 30 30 30
Total 145.7 299.7 400 454 474
Source wise supply of
Natural Gas
Expected growth at an
average of 6.8% /year
(Source- Vision 2030 Natural Gas
Infrastructure in India)
SNG From Coal – 5 MMSCMD
16 16
Coal
Washery
Gasification
Unit
H2S
Removal
CO2
Removal
SNG (Methanation)
5 MMSCMD
Feed Coal = 6.2 MMTPA
Ash 40-45 %
VM=20-25%
FC=20-30%
Sulfur ~ 0.3 – 0.5 %
SHIFTED AGR Coal ~ 4.5 MMTPA
Ash = upto 35 %
CO Shift
Technology
ASU Utility Block
H2S
Removal
CO2
Removal
UN-SHIFTED AGR
SRU
CO2 rich
stream
Sulfur to storage
O2 =72-768 TPH
Steam
N2
Power Block
670000 Nm3/hr
CO =20-24%
CO2=24-28%
H2=35-38%
CH4=8-12%
H2O=30-35%
H2S=0.2-0.3%
SNG
CO2 rich
stream
140-150 TPH
502500 Nm3/hr
186008 Nm3/hr
504545 Nm3/hr
CO =20.28%
CO2 =1.02%
H2 = 62%
CH4 =15%
Inert =0.43
H2/CO ~ 3
167500 Nm3/hr
542700 Nm3/hr
CO =12-15%
CO2=28-32%
H2=40-44%
CH4=8-12%
Inert+H2S=0.2-0.4
Coal to Chemicals (CTC) - Methanol
17
Methanol
- is starting point for the synthesis of a wide range of industrial Chemicals
- Directly as an alternative fuel
- “India imports large amount of methanol (about 80% of domestic demand in 2009),
TIGAS Topsøe Integrated Gasoline Synthesis
MtG Methanol-to –Gasoline e.g.. ExxonMobil (Uhde)
DtG Dimethyl ether-to-Gasoline (e.g.. Karlsruhe Institut fürTechnology)
DtO Dimethyl ether-to -Olefins (e.g.. Karlsruhe Institut für Technology)
MtO Methanol-to -Olefins (e.g.. UOP, MtP by Lurgi/ Air Liquide)
StF Syngas -to -Fuel (CAC, TU Freiberg)
MtD Methanol-to -Dimethyl ether (eg. Lurgi/ Air Liquide)
StD Syngas -to -Dimethyl ether (eg JFE)
COD Conversion of Olefins to Distillates (e.g. Lurgi/ Air Liquide)
MtS MtSynfuels ® by Lurgi/ Air Liquide
Methanol-
based fuel
production
METHANOL MATERIAL BALANCE – 5000 MTPD
18 18
Coal
Washery
Gasification
Unit
H2S
Removal
CO2
Removal
Feed Coal = 9-12 MMTPA
Ash= 40-45 %
VM=20-25%
FC=20-30%
Sulfur ~ 0.3 – 0.5 %
SHIFTED AGR Coal = 12-15 MMTPA
Ash = upto 35 %
CO Shift
Technology
ASU Utility Block
H2S
Removal
CO2
Removal
UN-SHIFTED AGR
SRU
CO2
Sulfur
O2 =150-170 TPH
Steam
N2
Power Block
753143 Nm3/hr
CO =24%
CO2=27%
H2=37%
CH4=11%
H2O=32%
H2S=0.2-0.3
CO2 rich
stream
300-325 TPH
567038 Nm3/hr
CO =24-28%
CO2 =18-22%
H2 = 55-60%
CH4 =14-16%
Inert =0.3-0.5
786367 Nm3/hr
CO =15-20%
CO2=27-34%
H2=38-42%
CH4=10-12%
Inert+H2S= 0.2-0.35
Methanol
Unit
5000 TPD
SNG
CO
Cold
Box
474585 Nm3/hr
CO =20.28%
CO2 =1.02%
H2 = 62%
CH4 =15%
Inert =0.43
H2-CO2
CO+CO2
CO2
CO
H2
=3
Purge
gas
Coal to Chemical (CTC) – Ammonia/Urea
19
Global demand for ammonia, exceeded 170 million metric
tonnes in 2013………IHS report
Relative ammonia plant investment and relative energy requirement for
1800 t/d NH3
World ammonia production by feedstock type. Source: IFA, 2010b
92 % of Ammonia in China
is produced through Coal
against 0 % in India
NG Naphtha Fuel
Oil
Coal
Relative investment 1.0 1.15 1.5 2.5
Relative sp. Energy
requirement (based on
LHV)
1.0 1.1 1.3 1.7
Commercial technology
• Johnson Matthey
• Linde
• Kellogg Brown and Root
• Haldor Topsøe
• Ammonia Casale
• Uhde
AMMONIA MATERIAL BALANCE – 2200 MTPD
20 20
Coal
Washery
Gasification
Unit H2S
Removal
CO2
Removal
Feed Coal = 2.0~2.4 MMTPA
Ash 40-45 %
VM=20-25%
FC=20-30%
Sulfur ~ 0.3 – 0.5 %
SHIFTED AGR Coal ~ 2 MMTPA
Ash = upto 35 %
CO Shift
Technology
ASU Utility Block
SRU
CO2
Sulfur to storage
O2 ~30-35 TPH
Steam N2
Power Block
~ 299496 Nm3/hr
CO =20-25%
CO2=22-28%
H2=35-40%
CH4=5-11%
Inert+H2S=25-35%
CO2
60-65 TPH
369225 Nm3/hr
CO =0.59 %
CO2 =1.02%
H2 = 83%
CH4 =16%
Inert =0.45
SNG
Liq.
N2
wash
241837 Nm3/hr
N2 ~ 25%
H2 ~ 75%
Ammonia
Unit
2200 TPD
CO =0.2-0.35%
CO2=35-40%
H2=45-50%
CH4=8-10%
Inert+H2S=0.27%
UREA
POLYGENERATION 21
Liquid Nitrogen
Wash
Methanol Unit CO Cold Box
CH4
Recovery
SNG Unit
Methanation
Urea
Unit
Coal
Coal
Washe
ry
Captive
Power
Plant
Ammoni
a
Substitute
Natural
Gas
Methanol Ammonia
Unit
Urea
H
2
C
O
Polygeneration Cost Comparison
22
Description` Clean Syngas
SNG (5MM
SCMD)
Methanol
5000(MTPD)
Ammonia/Urea
3850(MTPD)
Project Cost ( Billion
USD) 9.5 0.183 0.476 0.464
Total Production ~1.8MM 5 5000 3850
Cost of Production,
USD 9.5/MMBTU 8.5/MMBTU 19,000Rs/MT 190/MT
(million US$, NG price at 8.59$/MMBTU , *2014 )
23
•Gasification Technologies
•Applications
•Polygeneration
•Summary
Outline
Summary
24
Gasification is a proven technology, a vast number of gasifiers
are operating since decades successfully on commercial basis
Gasification allows flexibility in feedstock and polygeneration of
products,
Gasification is environmental friendly
Technologies like gasification are able to help India to meet
the rising
demands for power and chemicals
THANK YOU
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