Air Products’ coal gasification technology: An advanced solution for efficient coal-to-products value chains

Rob van den BergTechnology Manager Coal Gasification

Air Products Syngas Solutions

November 29, 2018

1Air Products Internal Use Only

Gasification potential

2

Gas/Residue/Coal/Biomass

Oxygen, Steam

Chemicals

Power Generation

Methanation

Liquefaction(F-T)

Enhanced Oil Recovery

Steam/Electricity

Hydrogen, Ammonia, Methanol,

Oxo-alcohols

Synthetic Natural Gas

(SNG)

Transportation Fuels

Sulphur CO2

Gasification&

Gas Treating

Clean syngas(CO + H2)

3

with residue feedstock e.g. for refineries(hydrogen, steam and power) in

partnership with Shell

with solid feedstock (coal/petcoke and biomass) e.g. for chemicals, hydrogen,

steam and power

APSS Gasification technology portfolio

COAL GASIFICATION PROCESS

Syngas cooler

Bottom waterquench

“One proven technology, two line-ups”

RESIDUE GASIFICATION PROCESS

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APSS licensing reference in Asia Pacific region

Almost 20 years of commercialization 27 license projects, 31 gasifiers in operation, 6 gasifiers

under construction

22 gasifiers with >2000 t/d coal intake capacities Largest gasifier delivered 3,200 t/d, started-up mid 2018

Pulverized coal intake capacity

> 3,000 t/d> 2,000 t/d< 2,000 t/d

2526

27

1 Lu’an 4x3,200 t/d

2 Datang International Power 3x2,800 t/d

3 Henan Hebi 2,700 t/d

4 YTH Tianan 2,700 t/d

5 Yunnan Zhanhua 2,700 t/d

6 Datong Coal Mine Group 2,400 t/d

7 Shenhua DCL 2x2,200 t/d

8 Henan Longyu 2,100 t/d

9 Henan Zhongyuan Dahua 2,100 t/d

10 Guizhou Tianfu 2,000 t/d

11 Tianjin Soda 2x2,000 t/d

12 Sinopec Anqing 2,000 t/d

13 Sinopec Hubei 2,000 t/d

14 Sinopec Dongting 2,000 t/d

15 Guangxi Liuzhou 1,200 t/d

16 Changqing Baoji 3x1,800 t/d

17 Jiutai 2x1,800 t/d

18 YTH Shuifu 1,100 t/d

19 Henan Kaixiang I 1,100 t/d

20 Dalian Dahua 1,100 t/d

21 Henan Kaixiang II 1,100 t/d

22 Wison Nanjing 1,000 t/d

23 YTH Jinxin 1,000 t/d

24 Hubei Shuanghuan 1,000 t/d

25 Vinachem (VIETNAM) 1,400 t/d

26 Hanichemco (VIETNAM) 1,400 t/d

27 Taean IGCC (KOREA) 2,670 t/d

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Mature core of the technology:reactor and burners

BOILER FEED

WATER TUBE

(50-60 bar270-300oC)

solid slag on tube wall

molten slagflows downwards

GASIFIERSPACE

(1500-1600oC40-45 barg)Membrane wall

protected by slag layer

Multiple (4-6) opposed

burners

Slag leaves at the

bottom

Syngas and flyash leave at the top

Protection against high operating temperatures via a slag layer on a membrane (water) wall

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Syngas cooler process line-up

Process line-up with Syngas Cooler (SGC) offers high efficiency and small environmental footprint

WETSCRUBBING

COAL FEEDING

MILLING/DRYING

FLYASH TO STORAGE

HP STEAM

MP STEAM

SLAG

COAL/PETCOKE QUENCH GAS (200oC)

Gasifier

SALTS

RAWSYNGAS

WATER TREATMENT

900oC

FLYASH SYSTEM

1,600°C HPHT FILTER

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Broad operating experience on many different kinds of coal

FEED FLEXIBILITY

Handled over >200 different kinds of coal covering the whole reactivity spectrum from lignite to anthracite, ash contents from 6-37%

Four projects successfully used petcoke blended with coal, with excellent operational results

DEEP INSIGHT IN PROCESS

Based on extensive operating experience, several modelling tools were developed to confidently assess novel coals, optimise coal blends and provide reliable guarantees

Property range of feedstocks operated on

Petcoke

Ash (MF) wt%

Moisture wt%

FT, oC

35.0%-

3.8%

2000℃ 100%100%

Anthracite

Bituminous

Sub-bituminous

Lignite

Feedstock

36.4%36.4%--

5.9%5.9%

>1500℃-

1140℃

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Lu’an Coal-to-liquids project is the flagship coal chemical project of Shanxi province.JV between Luan and Air Products to own and operate ASU, gasification and gas treating plants

Shanxi Luan

APSS - SGC Lu’an CTL project

Excellent operational track record:

- JV project closed in April 2018- Three gasifiers on stream July 2018- Milestone reached on September 26, 2018 with all four gasifiers in operation

Lu’an CTL Project dimensions:

Location: Changzhi city, Shanxi ProvinceScale: - 825 kNm3/hr (CO+H2)

- 4x3,200 ton/d AP coal gasifiers- 4x3,000 ton/d AP ASUs

…producing 1.8 Mton/yr of high-quality oil products (Fischer-Tropsch liquids)

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Chinese project management in Jinxin(Inner Mongolia)

Contract signed

Construction kick-off Erection MCI Handover Start-up

June 2014 March 2015 Nov. 2015Jan-Feb 2014 April 2016 18 June 2016

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5

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10/5/2007 10/10/2007 10/15/2007 10/20/2007 10/25/2007 10/30/2007 11/4/2007 11/9/2007

Ash

cont

ent,

%

Gasification of high-ash coals

0

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40

2-Feb-08 12-Feb-08 22-Feb-08 3-Mar-08 13-Mar-08 23-Mar-08 2-Apr-08

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2/24/2008 2/26/2008 2/28/2008 3/1/2008 3/3/2008 3/5/2008 3/7/2008

Ash

cont

ent,

%

Dongting Liuzhou

LiuzhouYunzhanhua

Myth: Because of their high ash content and high Ash Fluid Temperature Indian coals are extremely difficult to gasify

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Gasified 100% petcoke in a demonstration plantin Houston

Petcoke blending gives good operational performance and reliability: long, continuous operating runs (of up to 291 days) and longest number of running days in a year (341 days).

1987 2010 NOW

Rich operating experience with petcoke gasification

Tianfu was the first dry-feed gasification plant in China that successfully demonstrated petcoke/ coal blending

Now four APSS plants in China have operational experience on petcoke

Excellent way to improve a high-ash feedstock and run more economically!

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Overall reliability figures for 2016/2017: Overall APSS plant reliability 98.6%/98.4%. Longest A run (continuous run without stop): 242 days/248 days Longest B run (run with short stop < 24 hours): 254 days/296 days 14 sites/18 sites achieved >300 on-stream days per year, with a

maximum of 348 days/340 days in operation Several months of 100% technology reliability

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20

40

60

80

100

Aver

age

Tech

nolo

gy R

elia

bilit

y Rt[%

]

month-year

Average Technology Reliability Rt for SCGP clients

Actual ave 2012: 91Actual ave 2011: 90

Actual ave 2010: 85

2010

20112012

2009

2013

Actual ave 2013: 94Actual ave 2014: 96

2014

2015

Actual ave 2015: 96.3

2016

Actual Ave 2016: 98.6

2017

Ave YTD 2017: 98.4

Top-quartile operating performance 2012-2017

EARLY STAGE CONSULTING

FEED AND EPC STAGE

UNIT OPTIMISATION AND TEST RUN

LONG-TERM. STABLE

OPERATION

(PRE-) COMMISSIONING AND START-UP

SUPPORT

Full technical support from design to stable operation

14`

Looking to the future

With the acquisition of world-class gasification technologies Air products aims to contribute to a cleaner energy future.

Continuous improvement has seen the reliability of Air Products’ technologies steadily improve in recent years.

Air Products has a strong reference list in coal gasification and offers proven technology in different line-ups: dry feed and slurry feed, syngas cooler and quench, it all depends on the economic requirements of a project.

Our dedicated gasification teams offer comprehensive and experienced support in all phases of a project.

Thank you…tell me more

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Back-up slides

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Simplification and standardization of technology

Over the last several years the APSS design has gone through a rigorous simplification and standardization effort

- Key equipment unchanged: reactors, burners, membrane wall => efficiency/carbon conversion are NOT affected

- Overall line-up was scrutinized and simplified, strongly reducing the equipment count

- Standard ‘off-the-shelf’ capacities/designs are now available => cost AND schedule advantage

- All equipment can be manufactured and purchased from local, yet proven authorized vendors

This has resulted in a >20% CAPEX reduction compared to an existing design (cost basis 2008-2009), as independently determined by a Chinese Design Institute

On APSS coal gasification technology: “Dry feed with high efficiency, low oxygen consumption, steam recovery, and much less black water treatment”

Yong Wang Li, Synfuels China (Freiberg Conference 2015)

Gasification of high-ash coals

21 Jun 5 Jul 19 Jul 2 Aug 16 Aug 30 Aug

Typical ash content design window

45

40

35

30

25

20

15

10

0

Ash

cont

ent,

%

Operational data from a Chinese customer

DESIGN WINDOW

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Myth: Because of their high ash content Indian coals are extremely difficult to gasify