Coal Gasification Related...

Vice CTO: Mr. Pi JinlinVice CTO: Mr. Pi Jinlin

WuhuanWuhuan Engineering Co., Ltd.Engineering Co., Ltd.

3030thth Nov, 2018Nov, 2018

Coal Gasification Related IndustriesCoal Gasification Related Industriesandand

Economic & Environmental Economic & Environmental Sustainability AnalysisSustainability Analysis

Background of MCGI111

Notes: MCGI means Modern Coal Gasification related Industries3E means Environment, Economy & Energy Efficiency

Application of MCG Technologies222

3E Analysis of MCGI333

Tips & Suggestions444

Coal

Ammonia Route

MethanolRoute

PurificationGasification

Liquif.Route

Fuel GasRoute Town gas/SNG/IGCC

Urea/Melamine/AN/ Other fertilizers

• Olefin/DME• Formaldehyde/Acetic Acid• MTBE/ DMMn• Medicine/Solvents

Gasoline/Diesel/LPG

1. Background of MCGI 1. Background of MCGI

EGRoute

Polyesters/Surfactants/Solvents

1.1 Main Commercialized Production Chains of MCGI1.1 Main Commercialized Production Chains of MCGI

(1) Ammonia/Urea China NH3 capacity is ~70 MTPA, ~30% of the world China Urea capacity is ~82 MTPA, ~40% of the world ~76% of China NH3/Urea is produced from coal

(2) Methanol China capacity is ~80 MTPA, ~60% of the world ~70% of China methanol is produced from coal

1. Background of MCGI1. Background of MCGI

1.2 MCGI plays an important role in China1.2 MCGI plays an important role in China

(3) EG China capacity is ~8.1mt/a, ~25% of the world Capacity of coal-based EG is ~2.45 mt/a, ~30% of China total 3.15 MTPA Coal-based EG projects are under construction

(4) Direct Coal Liquefaction China’s capacity is ~1 mt/a; it has largest and the only one commercial plant in the world in operation Direct Coal Liquefaction projects with a total capacity of 2 mt/a are under construction


(5) Indirect Coal Liquefaction China’s capacity is ~6 mt/a Projects with a total capacity of 20mt/a are planned to be constructed

(6) MTO/MTP China’s capacity of olefin is ~50mt/a Capacity of coal-based olefin is ~13mt/a, ~25% of China’s total Coal-based olefin projects with a total capacity of ~20mt/a are under construction

(7) SNG China’s capacity is ~5 billion Nm3/a. SNG projects with a total capacity of 70 billion Nm3/a are under construction


Drivers of coal gasification related industries(1) Higher Self-Reliance in Energy Supply(2) Lower Risk of Oil and NG Supply from Abroad (3) Less Pressure of CO2 Emission China is the only country in the world, where large-scale coal-gasification-related industries play a significant role in economy development. China’s coal-gasification-related plants have the world’s largest single-train capacity, and advanced and reliable performance.


1.3 MCGI is a valuable sector in China1.3 MCGI is a valuable sector in China

(1) Capacity of Ammonia/Urea The largest single-train ammonia capacity: ~700 kt/a

Urea: ~1.2mt/a.(2) Capacity of Methanol The largest single-train methanol capacity: ~2mt/a(3) Capacity of EG The largest single-train EG capacity: ~100 kt/a(4) Direct Coal Liquefaction : ~1 mt/a(5) Indirect Coal Liquefaction: ~ 1 mt/a(6) MTO: ~833 kt/a(7) SNG: ~2 billion Nm3/a


We are very glad to share with you ourexperience on how to develop Coal Chemicalprojects that suit local conditions and applylocal feeds.


Gasifi-cation

Fixed Bed Gasf.

Entr. Flow Gasf.

Fluid Gasf.

LurgiBGLU.G.I. GE-Texaco

E-GasMulti-Nozzle

HTWKRWU-gasTRIGSCCR

Coal Slurry

Dry Pulverised CoalShellPrenfloGSPHT-L

2. Application of MCG Technologies2. Application of MCG Technologies

2.1 Modern Coal Gasification Technologies2.1 Modern Coal Gasification Technologies

Inherent safety

Environment-friendly

High energy efficiency

High feed flexibility

High single-train capacity

High reliability and easy maintenance


2.2 Features of Advanced MCG2.2 Features of Advanced MCG

Matching coal properties Matching final products Advanced technology

• Inherent safety• Environment-friendly• High energy efficiency

Reliable and profitable• High reliability and commercial proven• High single-train capacity• Cost effective


2.3 Principles in Coal Gasification Technology Selection2.3 Principles in Coal Gasification Technology Selection

The selection of coal gasification process iscrucial to the success of a project.


Entrained flow gasification technology (the dominating technology in the market)


2.4 Introduction of Main Coal Gasification Technologies2.4 Introduction of Main Coal Gasification Technologies

Reference List

ItemsFeedstock scale

for Single Gasifier

Number of Gasifiers

Syngasx106 Nm3/d Remarks

Multi-Nozzle Gasification (Coal Slurry Entr. Flow Gasification)

<1,000 t/d 5

- Total feedstock amount is 110,000 t/d1,000~2,000 t/d 76

~3,000 t/d 12

SHELL Gasification (Dry Pulverised Coal side fired Entr.

Flow Gasfication)

<1,000 t/d 8

113.5 Including 2 trains of SHELL bottom quench gasifiers1,000~3,000 t/d 19

>3,000 t/d 6GSP Gasification

(Dry Pulverised Coal top fired Entr. Flow Gasfication)

200 MW (1,000 t/d) 298 -

500 MW(2,000 t/d) 31

HT-L Gasification(Dry Pulverised Coal top fired Entr.

Flow Gasification)

1,000 t/d 27

- -2,000 t/d 61

3,000 t/d 1



Schematic flow diagram of Multi-Nozzle gasification


Schematic flow diagram of shell gasification with syngas cooler


Schematic flow diagram of Siemens GSP gasification

NO. Pollutant Stack, m max. allowed vent rate, kg/h

max. allowed vent concentration, mg/Nm3

1 Particles - - 10

2 SO2 - - 50

3 NOx - - 100

4 H2S 80 9.3 -

3. Analysis of 3E on MCGI3. Analysis of 3E on MCGI

3.1 Mandatory Pollutant Limits3.1 Mandatory Pollutant Limits in Chinain China Gaseous Emission, the highest emission standards in the world

No. Pollutant Limitation, mg/L1 PH 6.0-9.02 TSS 503 CODCr 504 BOD5 105 NH3-N 5.06 total N 307 total P 0.58 total organic carbon 159 oil 3.0

10 total cyanide 0.3


Effluents: The highest discharge standards in the world, andpracticed “Zero discharge” principle in NW China.

Waste Solids: slag, flyash and filter cake are recycled asconstruction materials and catalysts are recycled by vendors.

Items

Coal DirectLiquefaction

Coal Indirect Liquefaction MTO SNG

Baseline AdvancedValue Baseline Advanced

Value Baseline AdvancedValue Baseline Advanced

Value

Energy consumption(t coal eq/t or /kNm3) ≤1.9 ≤1.6 ≤2.2 ≤1.8 ≤4.0 ≤3.0 ≤1.4 ≤1.3

Coal consumption

(t coal eq/t or /kNm3)≤3.5 ≤3.0 ≤3.3 ≤2.8 ≤5.1 ≤4.6 ≤2.0 ≤1.6

Water Consumption(t /t or /kNm3) ≤7.5 ≤6.0 ≤7.5 ≤6.0 ≤16.0 ≤12.0 ≤6.0 ≤5.5

Energy Efficiency (%) ≥55.0 ≥57.0 ≥42.0 ≥44.0 - - ≥51.0 ≥57.0


3.2 Mandatory Energy Efficiency Requirements in China3.2 Mandatory Energy Efficiency Requirements in China

Gasifi-cation

Purifi-cation

NH3Synth.

UreaSynth.

O2/Steam

Gasification and purification NH3 Synth. and Urea Synth.

Typical Simplified Process Scheme

Urea

CO2

Pre-drying

Lignite


3.3 Typical Economic Indexes of lignite3.3 Typical Economic Indexes of lignite--basedbased NH3/Ur. ProjectNH3/Ur. Project

No. Items Unit Data Price

1 Main Product

1.1 Urea Kt/a 1,047 241USD/t

1.2 Ammonia Kt/a 600 Immediate product

2 Main feedstock

2.1 Feedstock coal (lignite, LHV ~ 3,000kcal /kg, as received) Kt/a 1,202 15 USD/t

2.2 Fuel coal (lignite, LHV ~ 3,000kcal/kg, as received) Kt/a 1,297 15 USD/t

2.3 Fresh water Kt/a 12,200 1.5 USD/t

2.4 Electricity kwh/a Balance


Note:1. Annual operating time 8,000 hrs.2. Construction time: 3 years, Running time: 17 years

No. Items Unit Data

3 Main financial evaluation indicators

3.1 Construction investment MM USD 847

3.2 Annual average sales income MM USD 249

3.3 FIRR before income tax ％ 13.88

3.4 FIRR after income tax ％ 11.89

3.5 Investment recovery period before income tax(including construction period) years 8.72

3.6 The cost of urea USD/t 147



Gasifi-cation

Purifi-cation

MethanolSynth.

MethanolDistill.

O2/Steam

Gasification and purification Methanol Processing

MOHPre-drying

Lignite


3.4 Typical Economic Indexes of Lignite3.4 Typical Economic Indexes of Lignite--based Methanol Projectbased Methanol Project


1 Main Product

1.1 Methanol Kt/a 600 346USD/t

2 Main feedstock

2.1 Feedstock coal (lignite, LHV ~ 3,000kcal/kg, as received) Kt/a 1,271.7 15USD/t

2.2 Fuel coal (lignite, LHV ~ 3,000kcal/kg, as received) Kt/a 792 15USD/t

2.3 Fresh water Kt/a 9,100 1.5USD/t



No. Items Unit Data


3.1 Construction investment MM USD 712





3.6 The cost of liquid methanol USD/t 212




Gasifi-cation

Purifi-cation

PSA EGSynthesis

O2/Steam

Gasification and Purification Gas Sep. and EG Synth.

EGPre-drying

Lignite

CO Cryogen. Sep.


3.5 Typical Economic Indexes of Lignite3.5 Typical Economic Indexes of Lignite--based EG Projectbased EG Project


1 Product

1.1 EG Kt/a 400 902 USD/t

2 Main feedstock

2.1 Feedstock coal (lignite, LHV ~3,000 kcal/kg, as received) Kt/a 1,128 15 USD/t

2.2 Fuel coal (lignite, LHV ~ 3,000kcal/kg, as received) Kt/a 1,344 15 USD/t

2.3 Fresh water Kt/a 12,848 1.5 USD/t



No. Items Unit Data


3.1 Construction investment MM USD 1,011





3.6 The cost of liquid EG USD/t 426



Typical Economic Data of Urea Project in Indonesia

No. Feed and Fuel Coal Price USD/t

FIRR before Income tax %

Eq. Price of NG Based Chemicals USD/MM Btu

1 15 13.88 3.5

2 20 12.63 4.5

3 30 9.95 5.4

Note:1. Annual operating time 8,000 hrs, Annual urea capacity 1,047 Kt /a, annual ammonia (immediate product) capacity 600 Kt/a. 2. Construction time: 3 years, Running time: 17 years. 3. Assumed feed and fuel Coal are lignite coal, LHV ~ 3,000 kcal/kg as received.4. Assumed urea price is 241 USD/t.5. The data are preliminary at feasibility stage and estimated based on engineering experience in China and Indonesia.


3.6 Economic competitiveness against NG 3.6 Economic competitiveness against NG

-- A good report of coal properties and coal reserve-- A good report of final product scheme-- A good FSR covering

-- Construction conditions and site information (site location, material supply, utility and infrastructures, transportation, climate)

-- Market survey and study-- Technical sketch and utility/off-site requirements-- High level construction schedule-- Estimate -- Financial analysis-- Conclusion

4. Tips & Suggestions4. Tips & Suggestions

-- A good FEED with perfect project definition:-- Basic engineering design-- Project management strategy-- Precise investment estimate

-- Award EPC contract to a professional and experienced EPC contractor

4. Tips & Suggestions4. Tips & Suggestions

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