Jim Powers Worleyparsons Coal Gasification

Gasification Products & Technologies forGasification Products & Technologies for Pakistan’s CoalPakistan Coal Forum – 18 November 2010Presented by Jim Powers and Joanne Hilton

1818--NovNov--10101818 NovNov 1010

Gasification

Why Gasification?

C l R & P d tiCoal Reserves & Production

Gasifier Types and Selection for Pakistan’s Lignite

Power Generation via Gasification

Chemicals and Fuel Production from GasificationH d• Hydrogen

• Carbon Monoxide• Ammonia and Fertilizers• Methanol• Synthetic Natural Gas• Fischer-Tropsch Liquid FuelsFischer Tropsch Liquid Fuels

2 18-Nov-10

Why Gasification?

1818--NovNov--10101818 NovNov 1010

Gasification

Gasification is Transformation

Using Gasification Technologies, you can transform

COAL

into Valuable Products

4 18-Nov-10

Gasification

TRANSFORMATION

FEEDS PRODUCTSGasification Syngas

• Coal (all types)• Electricity

• Hydrogen

Technologies Cleaning and Conversion

Technologies

• Pet coke

• Oil (includingheavy residues)

• Ammonia

• Fertilizer heavy residues)

• Natural Gas

• Biomass

SYNGAS

H2 + CO

• Methanol

• SNG• Biomass

• Wastes•Liquid Fuels

•Gasoline

5 18-Nov-10

•Diesel

Gasification

Gasification is TransformationIt allows:

the conversion of a carbon-containing feedi h t d ifi ti tusing heat, pressure and a gasification agent

(steam/water, air/oxygen)into a gaseous product (syngas) with a useableinto a gaseous product (syngas) with a useable heating value

Gasification is NOT combustion because it creates a valuable product (syngas) instead of flue gasinstead of flue gas

6 18-Nov-10

Gasification

This Transformation is due to the various Gasification Reactions that occur:Gasification Reactions that occur:

The chemistry of gasification is very complexMultiple reactions occur in the GasifierMultiple reactions occur in the Gasifier

The partial oxidation reaction is shown along with combustion:CnHm + n/2 O2 => n CO + m/2 H2 (partial oxidation)

CnHm + (n+m/4) O2 => n CO2 + m/2 H2O (combustion)

As an example, the simplest hydrocarbon, Methane, is used below: CH4 + ½ O2 => CO + 2 H2 (partial oxidation – CH4)

CH4 + 2 O2 => CO2 + 2 H2O (combustion – CH4)CH4 2 O2 CO2 2 H2O (combustion CH4)

7 18-Nov-10

Emissions and Solids fromAlternativeCoal-fired Power Technologies

Emission/Solid

Existing US Recent Generic Subcritical Coal

Plant IGCC

PC – New Conventional Supercritical with

FGD/SCR SO2 lb per MMBtu (HHV) 1 1 0 05 0 15lb per MMBtu (HHV) lb per MWh

1.111

0.050.42

0.151.28

NOx lb per MMBtu (HHV) lb per MWh

0.3 3

0.02 0.18

0.11 0.94

PM10 Ib per MMBtu (HHV) lb per MWh

0.03 0.3

0.003 0.02

0.020.12

CO lb per MMBtu (HHV) lb per MWh

0.18 1.8

0.02 – 0.04* 0.15 – 0.34*

0.16 1.6

AshAsh lb per MMBtu (HHV) lb per MWh

12 120

0 0

10 85

Slag lb per MMBtu (HHV) lb per MWh

0 0

15 127.5

0 0

FGD Sl dFGD Sludge lb per MMBtu (HHV) lb per MWh

15 150

0 0

13 110.5

Elemental Sulfur lb per MMBtu (HHV) lb per MWh

0 0

1 – 2 8.5 – 17.0

0 0

8 18-Nov-10

Heat Rate (Btu per kWh) 10,000 8,600 8,600 Source: Cambridge Energy Research Associates. *Assumes recovery or sequestering of pure carbon dioxide stream.

Mercury Removal Costs from IGCC versus Conventional Pulverized Coal Boilers

Factor IGCC ConventionalFactor IGCC Conventional Boiler

Process removal location

Syngas ahead of acid gas recovery

Stack gas g y

Ratio of gas flow volumes

1 150

Cost of removal 0.25 2.5—3.5(dollars per MWh) Cost of removal (dollars per lb)

3,500 25,000—35,000

Source: Cambridge Energy Research Associates.

9 18-Nov-10

Coal Reserves & Production

1818--NovNov--10101818 NovNov 1010

Coal Reserves

Total Coal Reserves – 826 billion tonnes (Proved Recoverable)Pakistan ranks 20th in the World with 2.1 billion tonnes

Lignite Reserves – 150 billion tonnes (Proved Recoverable)Pakistan ranks 15th in the World with 1.8 billion tonnes

Total Coal Production – 6,372 million tonnesPakistan ranks 35th in the World with 3.9 million tonnes

Total Lignite Production – 882 million tonnesPakistan ranks 25th in the World with 1.0 million tonnes

Data Source: World Energy Council; Survey of Energy Resources Interim Update 2009

Data is for year end 2007

11 18-Nov-10

Coal Reserves

World Coal Reserves – Ranked By Country (for 2007)

250,000

200,000

,

100,000

150,000

mill

ion

tonn

es

LigniteSub-bitBit+An

50,000

m

0

12 18-Nov-10


Lignite Reserves

World Lignite Reserves – Ranked By Country (for 2007)

25 000

30,000

35,000

s

15,000

20,000

25,000

mill

ion

tonn

es

0

5,000

10,000

0

13 18-Nov-10


Coal Reserves

Pakistan’s Total Potential Coal Reserves200 3.5

140

160

180

2.5

3

80

100

120

billi

on to

nnes Hypothetical Reserves

Inferred Reserves

Indicated Reserves

Measured Reserves1.5

2

billi

on to

nnes

Proved Amount in PlaceProved Recoverable

20

40

60

80 Measured Reserves

0.5

1

0

20

Total Coal Reserves0

Measured Total Coal Reserves

14 18-Nov-10

Data Source: World Energy Council; Survey of Energy Resources 2007

Coal for Electrical Power

Electricity Generation by Source for Selected Countries

World Pakistan Australia China Germany India USA

C l 40 8% 0 1% 76 8% 79 1% 45 6% 68 6% 48 8%Coal 40.8% 0.1% 76.8% 79.1% 45.6% 68.6% 48.8%

Oil 5.5% 35.4% 1.1% 0.7% 1.5% 4.1% 1.3%

Gas 21 2% 32 4% 15 0% 0 9% 13 8% 9 9% 20 8%Gas 21.2% 32.4% 15.0% 0.9% 13.8% 9.9% 20.8%

Nuclear 13.5% 1.8% 0.0% 2.0% 23.3% 1.8% 19.2%

Hydro 16.2% 30.3% 4.7% 16.9% 4.2% 13.8% 6.5%y

Other 2.8% 0.0% 2.5% 0.5% 11.6% 1.9% 3.4%

Total 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%

15 18-Nov-10

Data Source: International Energy Agency (IEA) website; Statistics for 2008


For some countries, coal represents an even higher percent of Electricity Generationof Electricity Generation

South Africa 93% Israel 63%Poland 92% Czech Rep 60%

PR China 79% Morocco 55%

Australia 77% Greece 52%

Kazakhstan 70% USA 49%

I di 69% G 46%India 69% Germany 46%

Source IEA 2010

16 18-Nov-10


Coal is dominant fuel for the generation of electrical powerWorld Electricity Generation by Fuel Type y y yp

40.8%

16.2%2.8% Other

Hydro

13.5%

CoalOilGas

NuclearCoal

GasNuclearHydroOtherGas

Oil

5.5%21.2%

Oil

17 18-Nov-10

Data Source: International Energy Agency website; 2008 Statistics*Other includes solar, wind, combustible renewables, geothermal and waste

Gasification

Pakistan uses less coal forless coal for Power Generation than most countries thatcountries that have significant coal reserves

18 18-Nov-10

Gasifier Types and Selection ypfor Pakistan’s Lignite

1818--NovNov--10101818 NovNov 1010

Gasification

Gasification Technologies are typically classified by the type of reactorof reactor• The main reactor types are:

− Moving Bed− Entrained Flow− Entrained Flow− Fluidized Bed

There is another type of Gasification under development; in-situ or Underground Coal Gasification (UCG). In this case the “reactor” is the cavity in the coal seam itselfcase, the reactor is the cavity in the coal seam itself.

20 18-Nov-10

Gasification

Moving Bed – the coal enters from the top and the oxidant

COAL SYNGASp

and steam enters from the bottom. The syngas flows upwards through the coal.

Gasifier

upwards through the coal. As it reacts, the coal is moving downwards (i.e. a “moving bed”) The syngas

Gasifier Reactor Bed

moving bed ). The syngas then exits out the top. The ash or slag exits out the bottom

OXIDANT & STEAM

ASH or SLAGbottom. STEAM

21 18-Nov-10

Gasification

Entrained Flow – the coal enters with the oxidant and steam and flow

OXIDANT & STEAM

COAL

together.

In a downflow reactor (shown left), the coal and oxidant enter in the top and Gasifiercoal and oxidant enter in the top and flow downwards as the coal reacts to become syngas. The syngas then exits out the bottom with the slag

Gasifier

Reactor

out the bottom with the slag.

In an upflow reactor, the coal and oxidant enter on the side and flow upwards as the coal reacts to become syngas. The syngas then exits out the top and the slag exits out the bottom.

SLAGSYNGAS

22 18-Nov-10

Gasification

Fluidized Bed – the coal enters with the oxidant and

SYNGAS

steam at the bottom and flow together. The oxidant carries the coal particles upwards Gasifierthe coal particles upwards “fluidizing the bed” as the coal reacts to become syngas. The syngas then exits out the top

Gasifier

Reactor

Bed

syngas then exits out the top. The ash is removed out the bottom.

OXIDANT &

ASH

OXIDANT & STEAM COAL

23 18-Nov-10

Gasifier Types

Gasifier Type Entrained Flow Fluidized Bed Moving Bed

Technologies CoP E-Gas, GE E MHI Sh ll

HTW, TRIG, BGL, LurgiEnergy, MHI, Shell, Siemens, Udhe Prenflow

SES U-GAS

Outlet Temperature High Moderate Low1250 – 1600°C (2300 – 2900°F)

900 – 1050°C(1650 – 1900°F)

425 – 650°C (800 – 1100°F)

Oxygen Demand High Moderate LowOxygen Demand High Moderate Low

Ash Conditions Slagging Dry ash or agglomerating

Dry Ash or Slagging

Size of Coal Feed <0.2mm 6 – 10mm 6 - 50mm

Acceptability of Fines Unlimited Good Limited

Carbon Conversion High Low High

Other Characteristics Methane, tars, and oils in syngas

24 18-Nov-10

Gasification Selection for Lignite

High coal ash content is bad for all types of gasifiers as well as for coal fired boilersas for coal fired boilers

The high ash coal is less efficient as all of the ash must be heated to the reaction temperature. This tends to favor eated to t e eact o te pe atu e s te ds to a ofluidized bed or dry ash moving bed Gasifier.

The high ash coal is even less efficient for slagging g gg gentrained flow Gasifiers as the reaction temperature is higher (so that the ash melts to become a liquid slag).

25 18-Nov-10


High coal moisture content is bad for all types of gasifiers as well as for coal fired boilerswell as for coal fired boilers

The high moisture coal is less efficient as all of the moisture must be heated to the reaction temperature.

It is even less efficient for the slurry-feed Gasifiers as the high moisture coals typically do not slurry well i.e. the slurry h l lid t tihas a low solids concentration

For dry-feed, entrained flow Gasifiers, the coal must be pre-dried before it can be fed into the Gasifierdried before it can be fed into the Gasifier.

For other dry-feed Gasifiers, either moving or fluid bed, the coal must also be pre-dried but typically to a lesser amount.coal must also be pre dried but typically to a lesser amount.

26 18-Nov-10


For moving bed Gasifiers, the amount of fines fed must be controlled. The rejected fine material can be burned in acontrolled. The rejected fine material can be burned in a boiler on-site.

Most of the existing Gasifiers that operate using lignite are ofMost of the existing Gasifiers that operate using lignite are of the moving bed type.• 3 CTL plants (97 gasifiers) operating at Sasol in South Africa • Dakota Gasification had 14 gasifiers operating on lignite in North

Dakota

27 18-Nov-10

Power Generation via Gasification

1818--NovNov--10101818 NovNov 1010


For the generation of electrical power from coal, the coal is ground and burned in a boiler to make steam. The steam ggoes to a steam turbine generator to produce the electricity.

A pulverised coal fired power plant is a single

l l t (A lcycle plant (As only a steam turbine is used to generate electricity)

29 18-Nov-10


To increase the efficiency of the power plant, a gas turbine generator can be addedgenerator can be added• This is known as a combined cycle plant• Most combined cycle plants burn natural gas in the gas turbine

Thi i ll d t l bi d l (NGCC) l t• This is called a natural gas combined cycle (NGCC) plant

Syngas from coal gasification can also be used instead of y g gnatural gas in the gas turbine• This type of plant is called an Integrated Combined Cycle Gasification

(IGCC) power plant(IGCC) power plant

30 18-Nov-10

Block Flow Diagram – Basic IGCC

OxygenAir Separation

(ASU)

Coal Handling Gasification Syngas Cooling

Raw Syngas

Clean SyngasAcid Gas

Electrical Power

Acid G

SyngasRemoval

(AGR) Flue GasGas

TurbineHRSG

Power

Electrical Po er

Sulfur Recovery

Gas

Steam Turbine

PowerSteam

Combined Cycle Block

31 18-Nov-10

y

SulfurProduct

Cycle Block


Advantages of Integrated Combined Cycle Gasification (IGCC)(IGCC)• Is a cleaner coal technology

• Impurities can be removed from the syngas before it is burned in the p y ggas turbine (i.e. pre-combustion) resulting in lower emissions of SOx, particulates, mercury, etc

• The plant can be designed to produce other products• The plant can be designed to produce other products (polygeneration)

32 18-Nov-10


Advantages of Integrated Combined Cycle Gasification (IGCC)(IGCC)• The IGCC plant can also be designed to remove carbon dioxide

(CO2) pre-combustion.

• The syngas to the gas turbine will consist mostly of hydrogen (H2)

• The CO2 is then available for use in enhanced oil recovery (EOR) or for storage as part of a carbon capture and storage system (CCS)for storage as part of a carbon capture and storage system (CCS)

33 18-Nov-10

Block Flow Diagram – IGCC with CCS


(ASU)For CCS, Add CO

Shift

Coal Handling Gasification Syngas CoolingCO Shift

Raw Syngas

Raw H2 + CO2 Hydrogen (H2)

to TurbineAcid Gas Electrical

Power

CO2Acid G

to TurbineRemoval

(AGR) Flue GasGas

TurbineHRSG

Power

Electrical Po er

For CCS, Add CO2

Compression

For CCS, Modify AGR

CO2 Compressor

Sulfur Recovery

Gas

CO2

Steam Turbine

PowerSteam

Combined Cycle Block

Compression

34 18-Nov-10

y 2Product

SulfurProduct

Cycle Block


Disadvantages of IGCCAdds complexity and cost to the power plant• Adds complexity and cost to the power plant

• Advances are being made in post-combustion CO2 removal

• Can still be difficult to permit (US and Europe) as coal is perceived to• Can still be difficult to permit (US and Europe) as coal is perceived to be a “dirty” fuel

35 18-Nov-10

Chemicals and Fuel Production from Gasification

1818--NovNov--10101818 NovNov 1010

Chemicals from Gasification

Gasification can be used to generate a wide range of chemical and fuel productschemical and fuel products• Carbon monoxide (CO) and hydrogen (H2) are the building blocks

• Various syngas processing steps are used to remove contaminants y g p g p(i.e. syngas cleaning) and to create the required chemicals (i.e. syngas conversion)

• Carbon Dioxide can easily be captured and removed for use or• Carbon Dioxide can easily be captured and removed for use or storage (CCS)

37 18-Nov-10


Hydrogen from Gasification• One of the simplest plant configurations is used to generate a high• One of the simplest plant configurations is used to generate a high

purity hydrogen product

• Hydrogen can be used:− For Refinery hydrotreating and hydrocracking

− For Oil Sands Syncrude upgrading

− As a decarbonized fuel – to gas turbines, fuel cells and hydrogenAs a decarbonized fuel to gas turbines, fuel cells and hydrogen powered vehicles

− Converted to other products such as Ammonia

38 18-Nov-10

Block Flow Diagram - Hydrogen


(ASU)


Raw Syngas

H d

Raw H2 + CO2 Raw HAcid Gas

CO2Acid G

Final Purification

Hydrogen Product

Raw H2c d Gas

Removal(AGR)

CO2 CompressorSulfur

Recovery

GasCO2

Product

39 18-Nov-10

SulfurProduct

Optional


Carbon Monoxide from GasificationAnother simple plant configuration is used to generate a high purity• Another simple plant configuration is used to generate a high purity carbon monoxide product

• Carbon monoxide is a starting point for:− Phosgene for polyurethane

− Acetic Acid

Oxo alcohols− Oxo-alcohols

• Hydrogen is also available as a product

40 18-Nov-10

Block Flow Diagram – Carbon Monoxide


(ASU)

Coal Handling Gasification Syngas Cooling

Raw Syngas

Fi l Carbon

Raw CO + H2+ CO

CO + H2Acid Gas HYCO

CO2Acid G

Final Purification

Carbon MonoxideProduct

+ CO2c d Gas

Removal(AGR)

HYCO Separation

CO2 Compressor

Sulfur Recovery

GasCO2

Product

PSA HydrogenProduct

41 18-Nov-10

y

SulfurProduct

OptionalOff-Gas


Ammonia from GasificationAmmonia is one of most widely produced basic chemical and is• Ammonia is one of most widely produced basic chemical and is mostly used to produce nitrogen-containing fertilizers

• Approximately 10% of the world wide ammonia production is from gasification (the rest is from natural gas reforming)

• Hydrogen and nitrogen (from the ASU) are reacted in the Ammonia Synthesis sectiony

N2 + 3 H2 => NH3

42 18-Nov-10


Ammonia and Urea from GasificationTypically urea is also produced using the carbon dioxide from the• Typically, urea is also produced using the carbon dioxide from the gasification section

2 NH3 + CO2 => NH2CONH2 + H2O

• Other ammonia-based chemicals that can be produced are nitric acid, ammonium nitrate and also ammonium sulfate

43 18-Nov-10

Block Flow Diagram - Ammonia


(ASU)


Raw Syngas

Fi l A i

Raw H2 + CO2 Raw H2Acid Gas

CO2Acid G

Final Purification

Ammonia Product

Removal(AGR)

Ammonia Synthesis

N from ASU

CO2 Compressor

Sulfur Recovery

GasCO2

Product

N2 from ASU

44 18-Nov-10

y

SulfurProduct

Optional


Methanol is another widely used chemical that can be produced from Gasificationproduced from Gasification • Hydrogen and carbon monoxide are reacted in the Methanol

Synthesis section2 H CO CH OH2 H2 + CO => CH3OH

• Methanol itself is the starting point for a wide array of chemical products such as:− Acetic Acid− Acetic Anhydride− MTBE− DME− Formaldehyde− Olefins− Gasoline

45 18-Nov-10

Block Flow Diagram - Methanol


(ASU)


Raw Syngas

Fi l M th l

Raw H2 + CO + CO

Raw H + COAcid Gas Methanol

CO2Acid G

Final Purification

Methanol Product

+ CO2 H2 + CORemoval

(AGR)

Methanol Synthesis & Distillation

CO2 Compressor

Sulfur Recovery

GasCO2

Product

46 18-Nov-10

y

SulfurProduct

Optional


Synthetic Natural Gas (SNG) from GasificationCarbon Monoxide and Hydrogen are reacted in the Methanation• Carbon Monoxide and Hydrogen are reacted in the Methanationsection

CO + 3 H2 => CH4 + H2O

• Carbon Dioxide is also reacted with hydrogenCO2 + 4 H2 => CH4 + 2 H2O

• The remaining carbon dioxide can also be captured for CCS• The remaining carbon dioxide can also be captured for CCS

47 18-Nov-10

Block Flow Diagram - SNG


(ASU)


Raw Syngas

Fi l SNG

Raw H2 + CO + CO

Raw H + COAcid Gas

CO2Acid G

Final Purification

SNG Product

+ CO2 H2 + CORemoval

(AGR)Methanation

CO2 Compressor

Sulfur Recovery

GasCO2

Product

48 10-Nov-10

y

SulfurProduct

Optional

18-Nov-1048


Fischer-Tropsch (FT) Liquid Fuels from GasificationCarbon Monoxide and Hydrogen are reacted in the FT synthesis• Carbon Monoxide and Hydrogen are reacted in the FT synthesis section

CO + 2 H2 => -[CH2 ]- + H2O

where -[CH2 ]- represents the basic building block of the hydrocarbon chain

• The FT liquids are upgraded using conventional refinery hydrotreating processeshydrotreating processes

49 18-Nov-10

Block Flow Diagram – FT Liquid Fuels


(ASU)


Raw Syngas

Fi lFT

Gasoline

Raw CO + H2+ CO

CO + H2Acid Gas Li id

CO2Acid G

Final Purification

Gasoline + CO2c d Gas

Removal(AGR)

FT Synthesis

H slipstream

Liquids Upgrading FT

Diesel

CO2 Compressor

Sulfur Recovery

GasCO2

Product

H2 slipstream

50 18-Nov-10

y

SulfurProduct

Optional

Gasification Products

GasificationGasification

FischerTropsch

CarbonMonoxide

OxoAlcohols SNG Carbon

DioxideGas

Turbines Hydrogen Ammonia Methanol

ElectricalPower

TransFuels,Waxes

Urea Formal-dehyde MTBE Acetic

Acid PhosgeneDetergents,Plasticizers

51 18-Nov-10

Poly-Urethane

Questions?Thank YouThank You

52 18-Nov-10

WorleyParsons

1818--NovNov--10101818 NovNov 1010

What Differentiates WorleyParsons

Comprehensive geographic presence

Committed empowered and technically capable people

Industry leadershipOutstanding operational in health, safetyand environmentalperformance

and corporate performance

Success in project delivery –large and small

Focus on long-termcontracts and gasset-based services

EcoNomics™ –delivering profitable sustainability

54 18-Nov-10

Experience Covering all Phases of the Asset Lifecycle

55 18-Nov-10

Company Overview

Leading professional services provider to the energy, resource, and complex process industriesresource, and complex process industries

Organized into Customer Sector Groups:

UpstreamHydrocarbons

DownstreamHydrocarbons

PowerC l Fi d Pl t

Minerals & MetalsB M t l

Infrastructure &EnvironmentHydrocarbons

Fixed Offshore FacilitiesFloating Production SystemsDeepwater Solutions Subsea Systems

HydrocarbonsRefining PetrochemicalsChemicalsPolymers

Coal-Fired PlantsAdvanced CoalNuclearGas Turbine/Combined Cycle

Base MetalsCoalChemicalsFerrous MetalsAlumina

EnvironmentCoastal and MarineWater and WastewaterTransportEnvironment

Offshore PipelinesOnshore PipelinesOnshore Production FacilitiesHeavy Oil and Oil SandsLNG

GasificationSulphur Management

Air Quality ControlIntegrated Gasification Combined Cycle (IGCC)Transmission NetworksOperations & Maintenance

AluminumIron OreGas Cleaning

LNGTerminals

Renewable Energy

56 18-Nov-10

Global Reach

40 countries | 30,000 personnel

Canada6,500

Europe1,800

Asia5,300

Middle East3,200

United States5,300

Australia &New Zealand

Latin America/Caribbean

1,100

Africa1,000

5,800

57 18-Nov-10

Addendum

1818--NovNov--10101818 NovNov 1010

Coal Production

World Lignite Production – Ranked By Country (for 2007)

160.0180.0200.0

s

40 060.080.0

100.0120.0140.0

mill

ion

tonn

es

Lignite

0.020.040.0

German

yRuss

iaTurk

eyite

d States

ChinaAus

tralia

Greece

Poland

Serbia

India

RomaniaBulg

aria

Thaila

ndCana

daerz

ogov

inaHung

aryMon

golia

Maced

onia

Spain

Slovenia

Unite

Bosnia-

He M

59 18-Nov-10


Coal Production

World Coal Production – Ranked By Country (for 2007)

Total

2,500.0

3,000.0

1,000.0

1,500.0

2,000.0

mill

ion

tonn

es

Total

0.0

500.0

ChinaUnite

d States

India

Austra

liaRuss

iaSou

th Afric

aGerm

any

Indon

esia

Poland

Kazakh

stan

Turkey

Ukraine

Columbia

Canada

Greece

ech R

epubli

cViet

namSerb

iaKore

a, North

Romania

Un S K

Czec K


60 18-Nov-10


Coal Production

World Coal & Lignite Production – Ranked By Country (for 2007)

2,500.0

3,000.0

1,000.0

1,500.0

2,000.0

mill

ion

tonn

es

LigniteTotal

0.0

500.0

Chinad Stat

esInd

iaAus

tralia

Russia

h Africa

German

ydo

nesia

Poland

akhsta

nTurk

eyUkra

ineolum

biaCana

daGreec

eRep

ublic

Vietnam

Serbia

aNorth

Romania

United S Aus R

South GerInd

o PKaz

ak T U Col Ca GCze

ch R

ep Vie SKore

a, Ro

61 18-Nov-10


Coal Classification

1818--NovNov--10101818 NovNov 1010

Coal Ranks

Higher Rank Coals• Anthracite contains 86-97 percent carbon and has a heating value• Anthracite contains 86 97 percent carbon, and has a heating value

slightly lower than bituminous coal. • Bituminous coal contains 45-86 percent carbon, and has two to three

times the heating value of lignite Bituminous coal was formed undertimes the heating value of lignite. Bituminous coal was formed under high heat and pressure.

Lower Rank Coals• Sub-bituminous coal has a higher heating value than lignite. Sub-

bituminous coal typically contains 35-45 percent carbon, compared to 25-35 percent for lignite.

• Lignite is the lowest rank of coal with the lowest energy content. Lignite coal deposits tend to be relatively young coal deposits that were not subjected to extreme heat or pressure. Lignite is crumbly and has high moisture content.

63 18-Nov-10

Coal Ranks

Material Wood Peat Lignite Sub- Bituminous Anthracitebituminous

Moisture (as found)

30 – 60 90+ 20-40 10 – 20 13 – 1 2 – 3.5

Moisture (air-dried)

10 – 15 20 – 25 15 – 25 10 – 20 13 – 1 2 – 3.5

Carbon 50 55 – 65 65 – 73 73 – 78 78 – 92 92 – 96Carbon 50 55 65 65 73 73 78 78 92 92 96

Hydrogen 6.0 5.5 4.5 6.0 5.3 2.5

Oxygen 4.3 3.2 21 16 8 4

64 10-Nov-1018-Nov-1064

Coal Ranks

Material Lignite Sub- Bituminous Anthracitebituminous

Volatile Matter 27 – 35 22 – 27 8 – 22 < 8Volatile Matter 27 35 22 27 8 22 < 8

Fixed Carbon 65 – 73 73 – 78 78 – 92 > 92

Heating ValueHHV, MJ/kg

26 – 28 28 – 32 32 – 36 36 – 37

65 10-Nov-1018-Nov-1065

Coal Ranks

100%

70%

80%

90%

Moisture

50%

60%Volatile matterFixed carbon

us C

us B

usA

s

20%

30%

40%

min

ous

C

min

ous

B

min

ous

A

atile

bitu

min

ou

atile

bitu

min

ou

atile

bitu

min

ou

vola

tile

tile

bitu

min

ous

hrac

itic

e hrac

itic

0%

10%

Lign

ite

Subb

itum

Subb

itum

Subb

itum

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Syngas Treatment (Contaminant Removal)

1818--NovNov--10101818 NovNov 1010

Syngas Treating

Before the Syngas from Gasification can be used to make a final chemical product or burned in a gas turbine,final chemical product or burned in a gas turbine, contaminants must be removed.

The main contaminants include Sulfur compounds, Carbon Dioxide and coal trace elements such as Mercury• H2S and COS (from feed sulfur)

A id G R l (AGR) P th idAcid Gas Removal (AGR) Processes remove the acid gases (CO2 and H2S) from the syngas• The most common AGRs are Amine, Selexol and Rectisol.

Sulfur Recovery Processes capture the H2S and recover the sulfur as either elemental S in a Claus unit or by converting h lf S lf i A idthe sulfur to Sulfuric Acid

68 18-Nov-10

Syngas Treating

Pressure Swing Adsorption (PSA) produces purified a hydrogen stream from the syngas. All other components exithydrogen stream from the syngas. All other components exit in the PSA off-gas stream.

Mercury can be removed from syngas using activated e cu y ca be e o ed o sy gas us g act atedcarbon adsorbent.

CO Shift (also called water gas shift)( g )• Clean or sweet shift (H2S removed before and CO2 after shift)• Raw or sour shift (H2S and CO2 removed after shift)

COS Hydrolysis reacts the COS with water to produce H2S and CO2. COS can not be removed by all AGRs while H2S is easy to removeis easy to remove.

69 18-Nov-10

Oxygen Supply

1818--NovNov--10101818 NovNov 1010

Oxygen Supply

The oxygen needed for Gasification is separated out of atmospheric Air

High Purity OAir from the

AtmosphereAir

Separation Unit

Oxygen

High Purity

78.1 % Nitrogen78.1 % Nitrogen

20.9 % Oxygen20.9 % Oxygen

Unit

(ASU)

High Purity Nitrogen

ygyg

0.9 % Argon0.9 % Argon Optional: Argon,

Helium, Neon

71 18-Nov-10

And smaller amounts of Neon, Helium and other

rare components

Oxygen Supply

Advantages of using high purity Oxygen instead of atmospheric air include:atmospheric air include:• Lower compression cost as the atmospheric nitrogen does not need

to be compressed to full supply pressure• Lower volumetric flows through the gasification and downstream• Lower volumetric flows through the gasification and downstream

processes (no atm. Nitrogen)• Allows higher purity syngas for use in chemical synthesis

All d ti f hi h it it f th• Allows production of high purity nitrogen for other uses• Allows production of high value byproducts such as Argon and rare

gases

Disadvantages of using Oxygen• Capital and Operating cost of the ASU• Capital and Operating cost of the ASU

72 18-Nov-10

Oxygen Supply

There are two main types of commercially offered technologies for air separation unitsfor air separation units

Cryogenic Distillation• Uses the different boiling points of oxygen and nitrogen to separate g p yg g p

the oxygen from the nitrogen• Operates at very low temperatures

O b il t 183 C d Nit b il 196 C• Oxygen boils at -183 C and Nitrogen boils -196 C • Oxygen gas becomes liquid first and is separated from the nitrogen in

the distillation column

Vacuum Pressure Swing Adsorption (VPSA)• Uses the differences in adsorption of oxygen and nitrogen on a solid

adsorbent material to separate the oxygen from the nitrogenadsorbent material to separate the oxygen from the nitrogen

73 18-Nov-10

Oxygen Supply

Cryogenic Air Separation • A typical commercial air separation unit uses a multi-column• A typical commercial air separation unit uses a multi column

cryogenic distillation process for high purity oxygen production. Oxygen purities of 99.8% can be achieved.

• Cryogenic ASU can supply very large flow rates (up to 5 000Cryogenic ASU can supply very large flow rates (up to 5,000 tonne/day of oxygen in a single train).

• High purity nitrogen can also be produced. High purity argon production is another option.production is another option.

74 18-Nov-10

Oxygen Supply

Vacuum Pressure Swing Adsorption (VPSA) • Oxygen VPSA systems use high efficiency molecular sieve adsorbent• Oxygen VPSA systems use high efficiency molecular sieve adsorbent

to selectively recover oxygen from the inlet air.• VPSA systems are typically used for small flow rates (generally 150

tonnes or less)tonnes or less)• The oxygen product purity is limited to about 93-94%.

75 18-Nov-10

Gasification

WorleyParsons has provided engineering, procurement, and construction services for major gasification projects, including Valero (formerly Motiva) at Delaware City, Delaware and ExxonMobil at Baytown, Texas. WorleyParsons has also conducted multiple process design packages, feasibility studies, and front-end design for global power and chemical gasification applications.

Motiva added a petroleum-coke integrated gasification combined cycle (IGCC) facility to their existing refinery, using GE Gasification Technology (formerly Chevron/Texaco technology). This plant was a dual-train unit designed to gasify the fluid petroleum coke generated at the plant to produce primarily steam and electricity. The plant upgrade included an acid gas removal unit, dual-advanced combustion turbine generators, and two heat recovery steam generators. WorleyParsons provided EPC services for the 235 MW IGCC repowering project.

WorleyParsons is one of the world's prominent international project delivery organizations. In the most recent Engineering News-Record survey we placed 12th among International Design Firms, 3rd in Power, 10th in Industrial/Petroleum, and 10th in the United States.

Global Experience

WorleyParsons has extensive experience in the design, procurement, and construction of gasification process units. We provide full engineering services to all types of gas, coal, oil, and nuclear power plants and transmission and distribution systems, and have been instrumental in supplying over 115,000 MW of generating capacity worldwide.

WorleyParsons can assist owner’s in evaluating technology options.


Services

Project managementFeasibility and optimization studiesProcess simulation and selectionProcess design packagesTechnology developmentFront-end engineering and designDetailed designConstruction managementMaterials managementWorldwide procurement and logisticsSource inspectionRepowering servicesReference plant designOwner’s engineerRegulatory compliancePermittingCommissioning and start-up Operations and maintenanceQuality assuranceSafety programs

The ExxonMobil Baytown Complex also used GE Gasification Technology for producing syngas from deasphalter rock. The gasification unit utilizes two trains to generate raw syngas that is used for 1) fuel gas, 2) hydrogen production, and 3) feedstock sold for the production of other end-use products.

Advanced Technology

In addition to GE Gasification Technology, WorleyParsons has worked with other major gasification technologies such as Shell, E-Gas, British Gas/Lurgi, KBR Transport Reactor, and Foster Wheeler fluidized beds. WorleyParsons uses in-house proprietary process models to conduct feasibility, performance, and design studies for clients.

Reference Plant Design

WorleyParsons has shifted the paradigm of engineering design with our reference plant design approach. Our approach virtually eliminates rework during the construction and installation phases of a power design project. Reference plant designs are more than replications. They reuse the design framework as the basis, and they contain flexible applications to facilitate and expedite subsequent design modifications.

Acid Gas Removal

WorleyParsons has extensive experience in the design and construction of acid gas removal units. We have designed over 120 amine units using a variety of amine solutions such as MEA, DEA, and MDEA. These units are located across North America, Europe, the Middle East, Japan, Taiwan, and the Philippines.

Sulfur Recovery

WorleyParsons is a global leader in sulfur recovery technology. We have designed and built over 500 sulfur recovery plants, representing over 60 percent of worldwide production of recovered sulfur. These facilities include some of the world's largest single-train units and apply proprietary WorleyParsons processes.

Construction Management

WorleyParsons can provide you the flexibility needed to meet your project staffing requirements. We offer a comprehensive range of cost-effective construction management services in new construction, modification, and maintenance. We can mobilize a team to manage your construction project or provide specific individuals to supplement your staff.

Overall Project Design

WorleyParsons can act as sole contractor to engineer, procure, and construction manage all facets of the project. This capability together with the know-how gained from extensive experience makes WorleyParsons the right choice as your contractor.

Owner’s Engineering

WorleyParsons can help you reach your financial, operating, and technical goals. As Owner’s Engineer, we focus on integrating our team with our client’s team, promoting a seamless flow of communication and progress.


For more information on how WorleyParsons can help you, please contact: Doug Eberhart 6330 West Loop South Bellaire, TX 77401+1 713 350 [email protected] Michael DeLallo2675 Morgantown Rd.Reading, PA 19607+1 610 855 [email protected]

ExxonMobil Syngas Project,Baytown, Texas

Jim Powers Worleyparsons Coal Gasification

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