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SELAS-LINDE GmbHThe Furnace Company
Furnace Technology MeetSteam ReformersTuesday, 23 April 2013 MumbaiThursday, 25 April 2013 New Delhi
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General
Process Design
Mechanical Design
Control and Safety Philosophy
References
Competing Reformer Technologies
Linde Reformer Technology
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Gas Generation by Steam Reformingis applied for the production of
Hydrogen
Carbon Monoxide
Synthesis Gas
Reducing Gas
Ammonia
Methanol
Hydrocarbons
Linde Reformer Technology
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Basic Chemistry:
CnHm+ mH2O
CH4+ H2O
CO + H2
O
nCO + (n+m/2) H2
CO + 3 H2
CO2
+ H2
endothermic
endothermic
exothermic
Internal Heat Supplyby partial combustion of feedstock
External Heat Supply
Overall endothermic
Reformer Design Application- Fundamental Reforming Chemistry
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Top-FiredReformer
Side-FiredReformer
Terraced-WallReformer
Bottom-FiredReformer
Linde Reformer TechnologyTubular Reformer Types
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Linde Reformer Technology
General
Process Design
Mechanical Design
Control and Safety Philosophy
References
Competing Reformer Technologies
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Steam/ Carbon Ratio
Pressure
Tube Exit Temperature
Tube Inlet Temperature
Air Preheat Temperature
Excess Air
Process Design Variables
Heat Flux
Tube Inner Diameter
Heated Tube Length
Tube Material
Overall Arrangement
Mechanical Design Variables
Unit Cost of Feed/Fuel/Power
Export Steam Flow Rate
Desired Payback
Owner Design Criteria
Linde Reformer Technology
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feedstock catalyst type demand of downstream units
downstream process units (e.g. PSA) feed supply pressure tube material
Reformer application tube material
type of feedstock material limits
export steam demand NOxlimitations
forced or induced draught fuel type quality of distribution export steam demand
Steam / Carbon Ratio
Pressure
Tube Exit Temperature
Tube Inlet Temperature
Air Preheat Temperature
Excess Air
Linde Reformer TechnologyProcess Design Variables
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Low Steam / Carbon Ratio
High Pressure
High Tube Exit Temperature
High Tube Inlet Temperature
High Air Preheat Temperature
Low Excess Air
High Heat Flux
To cope with the more stringent request on the process variables like
Design limits are approached
Design margins have to be reduced More sophisticated design tools have to be used Environmental limits have to be considered
Linde Reformer TechnologyChallenges in Reformer Design
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Co-current flow permits
The highest flue gas temperature when the tube process gas temperature is
lowest
The lowest flue gas temperature when the tube process gas temperature is
highest
This is accomplished by
Supplying the upper portion of the catalyst tubes with the most heat
(where a maximum heat flux is desired)
Limiting the supply of heat at the bottom portion (where most of the
reforming reaction has already taken place) where the heat flux is low
Linde Reformer TechnologyTop Fired Reformer Principle
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Radiation from two sides Radiation from one side
T
T
DT
Circumference Temperature Distribution
D
irectionofmaximumFlux
Dir
ectionofmaximumFlux
D
irectionofmaximumFlux
TubePitch
Linde Reformer TechnologyCatalyst Tube Design
DT
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Tubewall Temperature Profiles
770
780
790
800
810
820
830
840
850
860
870
880
0,0 2,0 4,0 6,0 8,0 10,0 12,0
Heated Tube Length
Temperature
Calc.average TWT
Linde Reformer TechnologyCatalyst Tube Design
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Tubewall Temperature Profiles
820
840
860
880
900
920
940
960
0,0 2,0 4,0 6,0 8,0 10,0 12,0
Heated Tube Length
Temperature
Calc.average TWT
Calc. max TWT
Calc.max TWT with maldistribution allowance
Linde Reformer TechnologyCatalyst Tube Design
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Linde Reformer Technology
General
Process Design
Mechanical Design
Control and Safety Philosophy
References
Competing Reformer Technologies
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Typical Basic Dimensions:
Spacing row to row: 2100 - 2300 mmSpacing wall to row: 1600 - 1800 mmSpacing tube to tube: 260 - 300 mm
Tube inside diameter: 4 - 4.5 inch
Ratio Tube spacing: 1.8 - 2.0
max. tubes/burner 4 - 5max. No. of tubes/row 54
Linde Reformer TechnologyMechanical Design Variables
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Linde Reformer TechnologyTop Fired Reformer - General Arrangement
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Inlet Section
Radiant Section
Outlet Section
Linde Reformer TechnologyRadiant Box Sectional View
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Inlet Main Header
Inlet Sub Header
Inlet Pigtail
Reformer Tube
Outlet Pigtail
Hot outlet Header
Cold outlet Header
Feed Line
Linde Reformer TechnologyHot System
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Fuel and Combustion AirDistribution System
Feed Distribution System
Penthouse Ventilation
Tube Suspension System
Key Design Elements
Linde Reformer TechnologyTop Fired Reformer - Inlet Section
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Linde Reformer TechnologyTube Suspension System
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Linde Reformer TechnologyRow Wise Modular Burner Design
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Linde Reformer TechnologyRow Wise Modular Burner Design
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Linde Reformer TechnologyRow Wise Modular Burner Design Concept
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Linde Reformer TechnologyBurners
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Linde Reformer TechnologyHarped Catalyst Tube Design
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Linde Reformer TechnologyInstalled Catalyst Tube Harps
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Cold Collecting System
Fluegas Collecting System
Hot Collecting System
Key Design Elements
Linde Reformer TechnologyTop Fired Reformer - Outlet Section
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Linde Reformer TechnologyCold Collecting System
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Completely Insulated/Painted
Modular Components
Integrated SCR Design
Key Design Elements
Linde Reformer TechnologyWaste Heat Recovery Unit Modular Design
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Overview of technologies: DeNOx System
Nitrogen compounds
NOx
DeNOx
+ High NOx reduction rates
+ Lower operating temperature
- High investment costs- Catalyst has to be replaced- Sensitivity of catalyst
Selective Catalytic Reduction (SCR)
+ Low investment costs
+ Easy maintenance
+ No major replacement parts
- Lower reduction rates
- Higher operating temperature- Potential problems with WHR
Selective Non-Catalytic Reduction (SNCR)
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Overview of technologies: DeNOx - Chemistry
Organic Nitrogen compounds in waste streams
NOx-formation
Injection of NH3 or urea solution:
CO(NH2)2+ 2 NO + O2 => 2 N2+ CO2+ 2 H2O
4 NH3+ 4 NO + O2 => 4 N2+ 6 H2O
Injection controlled by downstream NOx-analyser
Minimisation of ammonia slip
DeNOx
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Linde Reformer TechnologyWaste Heat Recovery Unit Modular Design
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Linde Reformer Technology
General
Process Design
Mechanical Design
Control and Safety Philosophy
References
Competing Reformer Technologies
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TRIP
Reformer FuelPressureLOW
CombustionAir Flow
LOW
ReformerFurnacePressure
HIGH
Fluegas FanTRIPCombustionAir Fan
TRIP
Steam/Carbon Ratio
LOW
Steam DrumLevelLOW
ProcessFeed FlowLOW
Local andPanel HandTRIPS
Reformer exittemperature
HIGH
FurnaceFlame
DetectorFAILURE
Instrument Air Failure Power Failure
Closes ProcessSteam to a
minimum stop
Stops PSAProgram
Isolates ProcessFeed to Reformer
Opens Ventbetween Fuel
Valves
Isolates ReformerFuel
Stops HydrogenCompressor
Closes Valve inletPSA
Linde Reformer TechnologyEmergency Shut-Down System
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Linde Reformer Technology
General
Process Design
Mechanical Design
Control and Safety Philosophy
References
Competing Reformer Technologies
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Application Ranges of Top Fired Reformers and Lindes Experience
1000
No. of Catalyst Tubes436
No. of Tube Rows16
9
Pressure (bar)
45
41
Exit Temperature (C)1000
945
Linde Reformer TechnologyApplication Ranges
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Reformer Design Data very large
Inner Tube Diameter mm 127
Outer Tube Diameter mm 151
Tube Length (heated) mm 13750
Absorbed Heat MW 356.00
Average Flux density (inside) W/m 84495
Selected Number of Tubes - 768
Number of Rows - 16
Tubes per Row - 48
Distance Tube/Tube (Center) mm 290
Distance Row/Wall (Long Side) mm 1850
Distance Row/Wall (Short Side) mm 400
Distance Row/Row mm 2300
Fire Box Width (inside) mm 38200
Fire Box Length (inside) mm 14850
Process Pressure bar 20
Design Pressure barg 22.7
Process Temperature C 875
Design Temperature C 975
Total Heat Release MW 672.00
Number of Burners (100%) 180
Number of Burners (60%) 24
Burner Capacity (100%) MW 3.05 + 10 %
Burner Capacity (60%) MW 1.83 + 10 %
Total Burner Capacity MW 592.80
Combustion Air Excess 10%
Combustion Air Temperature C 360
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Reformer Plot Plan Side View
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Reformer Plot Plan Top View
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SMR Process Flow Scheme
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Reformer Section View
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Reformer Side View
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Reformer penthouse insight
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Reformer Process Gas Piping
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Feed Distribution System
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Linde Catalyst tube design
Gas inlet through
Top Flange
Thermal Plug
Catalyst Grid
Catalyst Tube
Material: 2535 CrNiNbTi Microalloy RInner diameter: 4 to 4.5 inches
Heated Length: 12 to 14 metres
Top Flange
Outlet Pigtail
Material: Incoloy 800H
Inner diameter: 30 mm
Length: 600 to 800 mm
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Linde Catalyst tube design
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Burner Design
204 forced draft Low-NOx arch burners in total
Callidus, Zeeco, Bloom
17 rows 12 burners
15 rows with 100% burners 3.05MW
2 rows with 60% burners 1.83MW
One burner per row equipped with UV flame supervision
(Fire-Eye Phoenix 85UV kompakt, with vortex cooling box)
air pressure at 110% duty: 20 mbar
Fuel gas pressure at 110% duty: max. 1.75 bar-g
Firebox temperature 1060C
Staged combustion air headers
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Computational Fluid Dynamics
Fluid dynamics optimization
Software: FLUENT
SL is equipped with 4 Workstations
Radiant Zone Optimization - optional
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Flue Gas ducting
Heat input in upper
section of furnace
Uniform flue gas flowover length and width of
furnace
Flue Gas ductingdesigned for < 3%
maldistribution
Li d R f T h l
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Linde Reformer TechnologyTop Fired Reformer in Italy - 4 rows -
Li d R f T h l
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Linde Reformer TechnologyTop-Fired Reformer in USA - 7 rows -
Li d R f T h l
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Linde Reformer TechnologyTop-Fired Reformer in India - 8 rows -
Linde Reformer Technolog
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Use of sophisticated design tools
Use of most advanced metallurgy
Constant hanger support for inlet system and catalyst tubes
Outlet header system installed in radiant floor coffin to minimize heat loss
Flexibility with regard to top or side entry of reformer tubes
Use of short outlet pigtails to minimize elevation
Modular penthouse and WHR design for cost effective construction
Penthouse cooling for operator safety
Flexibility with regard to convection section arrangements
Single lance combination fuel burner system
Balanced draft for high system efficiencies
Linde Reformer TechnologySummary
COST EFFECTIVE,RELIABLE AND MECHANICALLY ADVANCED DESIGN
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General
Process Design
Mechanical Design
Control and Safety Philosophy
References
Competing Reformer Technologies
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SIDE FIRED STEAM REFORMER
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Competing Reformer Technologies
Top Fired Side-/Terraced Fired
Shape Rectangular Box Long & Narrow Box
No. of Cells Single Single or Multiple
Tube
ArrangementSeveral Parallel Rows One Row per Cell
Process Flow Down Down
Flue Gas Flow Co-Current Counter-Current
Convection
Section
Horizontal at grade
Vertical along side box
Elevated above Radiant
Vertical Down
Draft Balanced or inducedBalanced, Induced or
Natural
Reformer Design Application
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Top Side Terraced
Maintenance Cost
Control Complexity
No. of Burners
Burner Access
Piping mass
Surface Area (box)
Natural Draft Operation
Heat input Control along tubeInvestment Cost
Ease of expansion
high low
no yes yes
noyes yes
Reformer Design ApplicationSMR Configuration Comparisons
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Steam Reformer
STEAM REFORMER
Urea/Ammonia
Key Data
- No. 336 tubes
- No. 7 rows of tubes
- inner tube id. 4,5
- Heated tube length 12,5m- tube spacing 260 mm
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Steam Reformer for a Urea/Ammonia Project(2050MTPD)
Reformer:- 723 to steel
- 160 to catalyst tube system
- 55 to piping
- 480 to Inner lining andrefractory
WHR-System:
-320 to ducts & steel casing
-250 to coil
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Steam Reformer for 7000 MTPD Methanol Plant
STEAM REFORMERKey Data:- No. 396 tubes- No. 9 rows of tubes- inner tube id. 127mm- Heated tube length11 5m- tube spacing 290 mm
d l d l d f
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Modularization drivers Quality and Safety
Quality increases under which construction is accomplished
Well-rehearsed assembly process in workshop
Established quality control system in place
No weather impact
Safety
With prework, workers face less exposure due to weather, heights,harzadous operation and neighboring construction activities
Less workers at onsite translate into reduced craft congestion and exposureto ongoing operations
h i l f d l i i
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Further potential for modularization
Increase the modularization in the reformer section by: modularize entire Penthouse section with entire inlet system components modularize radiant box panels with ceramic fibre pre-installed convection coils can be pre-assembled and shop hydrotested The inlet manifold and outlet system can be harped into shippableassemblies
the refractory lined transfer line can be shop fabricated sectional pre-fabrication of ladders, platforms and stair towers
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Linde Ammonia Concept
Linde Ammonia Concept (LAC)
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Linde Ammonia Concept (LAC)Simplified Block Diagram
AmmoniaProduct
AtmosphericAir
HydrocarbonFeed
H2 Unitwith
PSA Purification
N2 Unit
AmmoniaSynthesisLoop
Linde Ammonia Concept (LAC)
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Linde Ammonia Concept (LAC)Possible valuable By-Products
H2 Unitwith
PSA Purification
N2 Unit
AmmoniaSynthesis
Loop
HydrocarbonFeed
AtmosphericAir
AmmoniaProduct
CO2 CO H2
N2O2ArRareGases
Methanol
CO Recovery
MEOH Unit
Linde Ammonia Concept (LAC)
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Linde Ammonia Concept (LAC)A combination of proven technologies
50 units, up to 125.000 Nm3/h
Casale: 125 converters +loopsLinde: 6 complete Ammonia Plants
2.400 units,up to 340.000 Nm3/h
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Linde Ammonia Concept (LAC)
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Linde Ammonia Concept (LAC)Comparison of LAC process with conventional scheme
Desulfu-rization
Desulfu-
rization
PrimaryReformer
Isotherma
l
Shift
Conventional Ammonia Plant
HTShift
LTShift
CO2Removal
Methan-nation
AmmoniaSynthesis
PurgegasSeparation
Feed
Air
Linde Ammonia Concept (LAC)
Primary
ReformerPSA
Nitrogen
Unit
Ammonia
Synthesis
NH3
CO2
NH3
Feed
Air
SecondaryReformer
Downstream this pointthe flowrate of a conventionalplant is 30 to 80% highercompared to the LAC-process
0
Purgegas Separation
Cost related facts: number of temperature changes temperture levels flowrate number of equipment and catalyst
Efficiency related facts:
heat exchange losses pressure drops
LAC-Process
Conventional Plant
Figure 1
Linde Ammonia Concept (LAC)
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p ( )Linde Isothermal Reactor
Figure 4Steam
CirculatingWaterBoiler Feed Water
Gas Entry
GasExit
CirculatingWater
Linde Ammonia Concept (LAC)
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p ( )Comparision of Equipment Items
ExchangersVesselsColumnsReactorsBig Machines
(Compressors,TurbinesGenerator)PumpsOther MachinesAir Separation UnitInert Gas UnitPurge gas separatorPSA Unit
Totals
Conventional
Plant
LAC
Plant6025886
3511-11-
155
3419454
25121--1
105
Common for both plants, and not included in above count, are:Refrigeration Unit, Ammonia storage, Cooling Water System, Flare System, Effluent Collection, Instrument Air Unit
Linde Ammonia Concept (LAC)
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p ( )Comparision of Catalyst volumes 1350 MTPD NH3
ConventionalPlant
LACPlant
Desulphurisation
Primary Reformer
Secondary Reformer
HT Shift
LT Shift
Methanation
Ammonia Synthesis
24.8 m3 28.0 m3
36.0 m3
35,1 m370.5 m3
96.5 m3
27.0 m3
92.3 m3
37.0 m3
----
52.0 m3
--
83.9 m3
Total 382.2 m3 200.9 m3
Linde 12-Bed PSA System Top View
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y p110.000 Nm3/h H2
Linde Air Separation Plant
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pConventional Cryogenic Process
cold generationair compression air purification heat exchange rectification
AIR
GAN
GOX
filter
air compressor
expansions-turbine with
booster-compressor
heat-exchanger
pressure-column
low pressure-column
evaporator/condenser
direct-contactcooler
evaporationcooler
molecularsieveadsorber
Impure GAN
coldbox
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Section View
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Reformer + Isothermal Shift
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Ammonia Synthesis
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Vadodara / Indien
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Thank youfor your attention
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Lindes HyCO offeringsBOO / Over the Fence Supply
Agenda
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Agenda
1. BOCI
2. Typical commercial model for BOO / over-the-fence gas supply
3. Over the Fence (BOO) supply advantages
4. Linde Gas HyCO Experience
5. LindesOperational Excellence
6. Overall value that Linde can bring to IOCL/BP
Linde Hydrogen Technology
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DESIGNS
BUILDS
OPERATES
LINDE IS ONE OF THE FEW COMPANY IN THE WORLD THAT
ASU, HYDROGEN, SYNGAS & CO FACILITIES
USING THEIR OWN IN-HOUSE TECHNOLOGY
Linde Hydrogen Technology
Plant Operation
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LINDE GASOPERATES AND MAINTAINSLINDE ENGINEERINGDESIGNS & BUILDS
EXPERIENCE
Plant Operation
Hydrogen and Synthesis Gas technologies of thei d i i i i i
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Linde Engineering Division
Product Line
Hydrogen & Synthesis
Gas
Hydrogen Plants
H2/CO Plants
CO-Plants
Syngas Plants
Ammonia Plants
Methanol Plants
Gas Removal Processes
Gas Separation Processes
The Best in the Business Trust Us
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The Best in the Business Trust Us
Linde Gas - Worldwide market share and position 1
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Linde Gas Worldwide market share and position
#3 North America
15%
#2 Europe
32%
#2 South America
24%
#1Africa
42%
#1Asia/Pacific 2
19%
1 Total market share subject to potential disposals2 Includes all of Asia and Australia, including captive market ChinaSource: Annual Reports, Broker Reports, Spiritus Consulting, Linde Analysis
Linde Group in IndiaBOC I di Li it d
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- BOC India Limited
BOC India Limited (A member of The Linde Group), is Indias leading Industrial
Gas Company which is established over 75 years in India with headquarters inKolkata.
BOCI has around 700 employees in India
Linde Gas On-site / BOO Plants Worldwide
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Linde Gas On site / BOO Plants Worldwide
HYCO Tonnage Air Tonnage ECOVAR (standard plants)
H2, CO, CO2, Synthesis gas O2, N2, Ar, Kr, Xe O2, N2, H2
100 200.000 Nm3/h 3.000 50.000 Nm3/h 50 3.000 Nm3/h
> 65 plants > 300 plants > 800 plants
In total Linde is operating more than 1000 plants producing
industrial gases in all continents with strong focus in Asia
Overview of the major syngas (H2/ CO) production facilitiesd d t d b th Li d G
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owned and operated by the Linde Group
La Porte
Concon
Singapore
Caojing
Leuna
Milazzo
H2/CO-plantH2-plant
POX-plant
Toledo
Lima
LemontSalt Lake
Bulwer
Clear Lake
Paraguana
Concepcion
Daesan
Murrin-
Murrin
Teesside
Map Tha Phut
Aurangabad
BOO or On-site Supply Typical Commercial Model
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pp y yp
Feedstock/Air &Utilities
Customer Production
Fixed Fee for Capital
Recovery and FixedOperational Cost
Unit Charge formolecules (adjustedwith actual price of
Feedstock & Utilities)
15 year contract
Supply of H2,CO, Syngas, CO2
,O2, N2
molecules
HYCO Plant
Or ASU
HYCO Plant
Or ASU
Summary of Benefits of over the fence supply schemeImproved Gas Economics
8/12/2019 Steam Reformers
92/95
SL _ PS / Dziurdza
Improved Gas Economics
FINANCIAL Capital Avoidance.
Payments only begin whengas is delivered.
Level and predictable gascosts.
Turnaround peaks avoided.
No major $MM surprises
SHIFT OF RISKS Capital Accuracy
Construction
Maint. & Operations
Accuracy
Volatility
On-Stream Reliability Labor Relations, Cost, &
Legacy.
Changing Safety & Maint.Standards & Policies.
IMPROVED ALIGNMENT
15+ Year, not 2 3 as for LSTKLow gas cost, not cheap equipment
Alignment of gas delivery / needschedule.
Mechanical completion inappropriatetarget.
Collaborate on cost/benefit
analysis decisions. Continuous innovation
Maintain Competitiveness
Improve Reliability
Improved Safety Practice
Obvious
Project development costs such as initial capital, utilities etc
Less obv ious
Future major equipment repair capital
Ownership costs such as overheads, insurance, debt impact, & labor legacy
H2 for Refinery Toledo, USASteam Reformer supplying H2 to 2 Refineries
8/12/2019 Steam Reformers
93/95
SL _ PS / Dziurdza
Steam Reformer supplying H2 to 2 Refineries
H2: 144,000 Nm3/h
Steam: 67.8 t/h
Feed: Natural Gas / ROG / RFG
Fuel: Natural Gas / ROG / RFG
Average Reliability of each train
>>99,5%
2 x Top-fired Selas Reformer Trains
12 bed Linde PSA
8/12/2019 Steam Reformers
94/95
SL _ PS / Dziurdza
Thank youfor your attention
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Hans Dziurdza
8/12/2019 Steam Reformers
95/95
Manager Sales and Marketing
SELAS-LINDE GmbH
Wolfratshauser Str. 138
82049 PullachPhone +49 89 7447 47 12
Fax +49 89 7447 47 81
www.selas-linde.com
Thank you for your attention.
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