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GASIFICATION AS AN ALTERNATE SOLUTION FOR INDIA’S GROWING ENERGY AND PETROCHEMICALS DEMAND
Sunil Singhal Kakul Singh Nandkishor V Bhongale Ravi Ravikumar
© 2016 Fluor. All Rights Reserved.Fluor is a registered service mark of Fluor Corporation.ML20160700-001.ppt
Gasification India 2018 , Nov 29-30, 2018, New Delhi, India
AGENDA
Gasification Overview
Type of Gasification Technologies
Commercial Gasification Technology Options
Gasification Feedstocks
Gasification Product Options
Relative Value Addition For Various Gasification Products
Pre-screening of various Gasification feeds, products and technology options
Gasification Drivers in India
Gasification to Chemicals/Petrochemicals- Process Configurations
Fluor Gasification Experience
Conclusions2
GASIFICATION OVERVIEW
Reaction of low value fuels such as coal, petroleum residues, biomass, industrial wastes, MSW, etc. with oxygen and steam at high temperature to produce H2 + CO synthesis gas
Primary Gasification Reactions:Partial Oxidation 2 C + O2 → 2 COSteam Gasification (Reforming) C + H2O → CO + H2
Water Gas Shift CO + H2O → CO2 + H2
Methanation 3 H2 + CO → CH4 + H2O
Operating Conditions: 900 – 2000°C / 0.3 – 85 barg
Heteroatoms: N converted primarily to N2, NH3, HCN S converted primarily to H2S, COS, CS2
Many trace components (e.g. formic acid, chlorides, sulphur & nitrogen compounds, cyanides, soot, metal carbonyls and others)
3
Contd..
GASIFICATION OVERVIEW
Water gas shift to adjust H2/CO ratio as required for end product CO + H2O H2 + CO2
Syngas clean up and acid gas removal to condition gas for downstream catalysts and to meet environmental regulations
Sulphur recovery as elemental sulphur or sulphuric acid
Potential for CO2 capture and use for Coal Bed Methane / Enhanced Oil Recovery or Sequestration
Gasification is a complex and challenging process Project execution requires integration of technologies from several parties Attention to trace components, corrosion, catalyst life and process control Special attention to CAPEX and OPEX from the early stages of project development Requires a highly qualified team with gasification experience
4
TYPE OF GASIFICATION TECHNOLOGIES
5
COMMERCIAL GASIFICATION TECHNOLOGY OPTIONS
6
TechnologyTechnology Features
No. of Stages Oxidant Feed Reactor Wall Syngas Cooling Flow Regime
Lurgi 1 Oxygen DryDouble Walled w/
Water JacketQuench &
ConvectiveFixed or Moving Bed
(Non-slagging)Sedin 1 Oxygen Dry
Double Walled w/ Water Jacket
Quench & Convective
Zemag 1 Oxygen DryDouble Walled
Refractory LinedQuench Fixed Bed (Slagging)
Uhde HTW 1Air /
OxygenDry Refractory Convective
Fluidized Bed (Non-slagging)SES (U-Gas) 1
Air / Oxygen
Dry Refractory Convective
Air Products (Formerly GE) 1 Oxygen Slurry Refractory Quench or Radiant
Entrained Flow (Slagging)
ECUST 1 Oxygen Slurry Refractory Quench
MDR (E-Gas) 2 Oxygen Slurry Refractory Convective
NWRICI (MCSG) 1 Oxygen Slurry Refractory Quench
Tsinghua (OSEF) 2 Oxygen SlurryWater Cooling Wall
TechnologyQuench
Contd..
COMMERCIAL GASIFICATION TECHNOLOGY OPTIONS
7
Technology
Technology Features
No. of Stages Oxidant Feed Reactor Wall Syngas Cooling Flow Regime
Air Products (Formerly Shell) 1 Oxygen Dry Membrane Wall Convective or Quench
Entrained Flow (Slagging)
Uhde Prenflo 1 Oxygen Dry Membrane Wall Convective or Quench
MHI 2 Air / Oxygen Dry Membrane Wall Convective
Siemens 1 Oxygen Dry Cooling Screen Quench
TPRI 2 Air / Oxygen Dry Membrane Wall Convective
GTI (R-Gas) 1 Oxygen Dry Liner wall Partial Quench
HT-L (CECO) 1 Oxygen Dry Water Wall Quench
KBR 1 Air / Oxygen Dry Refractory Convective TRIG (Non-slagging)
GASIFICATION FEEDSTOCKS
8
High Ash Indian Coal High ash content, up to 60 wt% High ash fusion temperature Presence of chlorides and fluorides
Petcoke Low volatile matter High sulphur content Low ash content Presence of metals such as vanadium, nickel and iron Requires gasification at high temperatures with entrained flow (slagging)
gasifiers
Others - Various processed and straight vacuum bottoms, Asphaltenes, Acid soluble oils Wood / plant waste, Municipal solid waste, Agriculture wastes (such as rice
hulls, nut shells, mushroom compost and others) Coal washery reject
COAL SCENARIO IN INDIA
9
0100200300400500600700800
2013-14 2014-15 2015-16 2016-17
Coal Production in India, MMTPA
Estimated coal reserves in India are 315 billion tonnes (as on 01.04.2017) - majority of this coal contain high ash
Coal production in India
Price of domestic coal is determined by the level of supply and demand and does not show direct relation with crude oil price trend/outlook
Source: Ministry of Coal Annual Report 2016-17
More heavy crudes more residues more petroleum coke
Current Indian petcoke production capacity is ~ 16 MMTPA
PETCOKE SCENARIO IN INDIA
10
02468
10121416
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
Petcoke Production in India, MMTPA
Source: Indian Petroleum and Natural Gas Statistics 2016-17
GASIFICATION PRODUCT OPTIONS
11
Low Value Fuels
MeOH & Derivatives
Fertilizers Clean Syngas Hydrogen & Energy
FT Products SNG
Olefins (C2=, C3=)Acetic AcidAldehydesAnhydridesDMEMEGMTBEEthanol GasolineMMADMTMethylaminesMethyl Halides
AmmoniaUreaAmmonium NitrateAmmonium SulphateAmmonium PhosphateUrea Ammonium Nitrate
Power & SteamDRIOxo GasGasoline
RefineryOil SandsFuel Cell Vehicles
Fuel GasC2-C3LPGNaphthaJet FuelDieselLubes, Waxes
12
RELATIVE VALUE ADDITION FOR VARIOUS GASIFICATION PRODUCTS
1. Indicative market prices in India in 2018.
2. Manufacturer gate price
3. Refinery gate price
4. If hydrogen is used in fuel cell vehicles, $/MMBtu price is 120 - 150 based on current price of 12 - 15 $/kg in USA
Product / Commodity Price, $/MMBtu Market Price(1)
Petcoke 2.7 - 3.0 $ 80 - 90 / MTHigh Ash Indian Coal 1.3 – 1.7 $ 18 - 25 / MTMethanol 21 - 22 $ 400 - 420 / MTEthanol 31.3 $ 797 / MT(2)
Ethylene 29 $ 1320 / MTPropylene 26 $ 1125 / MTAcetic Acid 42 $ 515 / MTMTBE 25 $ 825 / MT Ammonia 23 - 25 $ 400 - 440 / MTUrea 35 - 38 $ 300 - 330 / MTNaphtha 12 $ 530 / MTPetrol (Gasoline) 13.8 INR 31.8 / Ltr(3)
Diesel 14.3 INR 31.9 / Ltr(3)
SNG 8 / 12 LNG Landed / Gate PriceHydrogen(4) 16 Based on $8 natural gas price
PRE-SCREENING OF VARIOUS GASIFICATION FEEDS, PRODUCTS AND TECHNOLOGY OPTIONS
$/ MMBtu is an innovative approach for pre-screening of various gasification product value chains
Fluor has developed a proprietary process called IP-SET for assisting clients develop project concepts based on the most cost effective feed/process/ products taking into account all the pluses and minuses
This technique has proven to be a very effective approach to screening a large number of feed/ process/ products options in a relatively short duration.
IP-SET has been applied on many projects – many now operating and other’s in the design phase
This method accounts for all major items that impact the selection of a feed or a process or desired feed by assigning weightings to them and scores for various systems under consideration and totaling the composite score to establish relative ranking
IP-SET allows clients to vary the weightings and individual scores to perform a sensitivity analysis to assess if the relative ranking of the systems under consideration remain the same
13
GASIFICATION DRIVERS IN INDIA
Growing national and global energy demands
Heavy rely upon petroleum and natural gas import
Use of domestic resources will provide immunity to price fluctuations due to volatile prices and geopolitical instability in global energy market
Abundant coal reserves in India
Less costly vs Petroleum and NG derived feedstocks
Low feedstock cost high value added products mitigates higher CAPEX
Higher value added improved margin certainty
Tightening marine fuel sulphur specifications will result in more cokers increased global and Indian supply of petcoke
14
Contd..
GASIFICATION DRIVERS IN INDIA
Byproduct ‘S’ or H2SO4, CO2, Slag, N2,Ar can fetch additional revenue
Recovery of metals such as vanadium and nickel from petcokegasification derived slag
Ammonia recovery from sour/acid gases as ammonium phosphate , anhydrous ammonia or ammonium sulphate
Syngas cost of production more economical than imported LNG
Clean fuels/products from gasification offer reduced air emissions
15
INTEGRATION WITH REFINERY TO PRODUCE H2 ,STEAM/POWER & PETROCHEMICALS
16
LP O
2TO
S
RU
HP
O2
LP N
2FO
R
INE
RTI
NG
HP
N2
TO
PO
WE
R
PLA
NT
CO
2
CO
2
STANDALONE GASIFICATION PLANT TO PRODUCE METHANOL AND DERIVATIVES
17
GASIFICATION TO PRODUCE UREA
18
FLUOR GASIFICATION EXPERIENCE
19
Client Location Scope Feed Products Technology Completed
Confidential Indonesia Pre-FEED Coal Polypropylene, DME and Urea Confidential Ongoing
Lake Charles Methanol Louisiana FEED Petcoke Methanol GE Ongoing
Celanese / IOCL India Pre-FEED Petcoke, Coal Ethanol, Power Confidential 2015
Reliance Industries India E, P and PM
Support Petcoke, Coal Hydrogen, SNG, Power MDR E-Gas Ongoing
Pertamina Indonesia Pre-FEED MSW Power Solena 2014
Confidential Indonesia Pre-FEED High Moisture Indonesian Coal SNG, Urea, CO2 Confidential 2012
Jindal SynFuels India Pre-FEED High Ash Indian Coal FT Liquids, Ammonia Confidential 2012
Reliance ADAG India Pre-FEED High Moisture Indonesian Coal SNG, Power Confidential 2012
MAK Mongolia Pre-FEED High Moisture Brown Coal MTG, Power Confidential 2012
Fulcrum Sierra BioFuels Nevada FEED Refresh,
EPC MSW Ethanol, Power InEnTech (IET) 2012
OPTI Canada Phase II Alberta FEED Residue Hydrogen, Power, CO2 Shell 2012
Rentech California FEED Woody Waste FT Liquids, Power RentechSilvaGas 2011
Contd..
FLUOR GASIFICATION EXPERIENCE
20
Client Location Scope Feed Products Technology CompletedSummit Texas FEED Coal Urea, Power, CO2 Siemens 2011
Swan Hills Alberta Pre-FEED, FEED Deep
Unmineable Coal
Power, CO2
Swan HillsIn-situ Coal Gasification
2011
MSEZL India Pre-FEED Petcoke Acetic Acid, Hydrogen, Power Confidential 2010
Eastman Texas FEED Petcoke Hydrogen, Methanol, Ammonia, CO2 GE 2009
Confidential Montana Pre-FEED Coal Urea, Power, CO2 Siemens 2009
Valero Texas Pre-FEED Petcoke Hydrogen, Power, CO2 ECUST 2009
OPTI Canada Alberta FEED, EP Residue Hydrogen, Power Shell 2008
Steelhead Illinois FEED Coal SNG CoP E-Gas 2006
Total France FEED Residue Hydrogen, Power GE 2004
ISAB Italy Owner’s Eng. Residue Hydrogen, Power GE 1999
Great Plains North Dakota Owner’s Eng. Coal SNG Lurgi 1988
Shell Netherlands FEED, EPCM Residue Hydrogen, Power Shell 1997
Motiva Louisiana EP Residue Hydrogen GE 1985
Eastman Tennessee C Coal Chemicals GE 1986
Sasol South Africa EPCM Coal FT Liquids, Chemicals Lurgi 1980
CONCLUSIONS
21
Gasification is a complex and challenging process but – Offers a cost effective option to convert low value fuels such as coal and
petcoke into high value added products Petcoke/coal availability in India places gasification in a strategically important
position with anticipated positive downstream product slate demand Petrochemicals industry in India is based on naphtha / natural gas feedstocks.
Syngas from petcoke/coal gasification offers excellent domestically available feedstock option compared to the imports
Syngas cost of production is more economical than imported LNG in India. Byproducts ‘S’ or H2SO4, CO2, Slag, N2, Ar, V & Ni from slag can fetch
additional revenue Clean fuels/ products from gasification offer reduced air emissions, a key
concern in the wake of new stricter emissions norms worldwide Gasification can play a vital role in India’s long term petrochemical sector plans
eyeing self-reliance and maximum utilization of available resources in the country
While challenging, several gasification projects have been successful. Must employ best technologies and employ gasification experienced design engineers
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22
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Nandkishor V Bhongale
+91.124.457.0700 Extn. 3295
Sunil Singhal
+91.124.457.0700 Extn. 1649
Ravi Ravikumar
+1.949.349.7481
Kakul Singh
+91.124.457.0700 Extn. 2294