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© Lurgi AG
Lurgi‘s HP-POX Pilot Plant:A Milestone to Improved Syngas Production
Gasification Technologies 2004Washington, DC, October 3 – 6, 2004
U. Wolf, H. SchlichtingLurgi AG
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 20042
Milestones to Improved Syngas Production
Syngas Production Technology…
Where do we come from ...
Where are we going to …
Where are we today ...
Why Syngas
Megammonia® as Example for the Benefits
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 20043
Milestones to Improved Syngas Production
General Gas to Chemicals Processing Routes
Fuel GasLPGNaphthaDieselWaxesAmmoniaFuel CellsChemicals (MTBE, Acetic Acid, Formaldehyde, ...)Diesel, transport. fuelsPropylene/PolypropyleneAcrylic Acid/AcrylatesEthylene/PropylenePower/Fuel/DME(Diesel)Hydrogen
MegaSyn®
Fischer Tropsch
Synthesis
Mega-Methanol®
Upgrading
MTO
MtPower
MTH
MtSynfuels®
Acrylic AcidMTP®
Natural Gas /Associated Gas
MTC
Lurgiproprietary process
Megammonia®
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 20044
Milestones to Improved Syngas Production
Lurgi-Casale MEGAMMONIA®Lurgi-Casale MEGAMMONIA®
Design Criteria for Megammonia® Process
Single line ammonia process for capacities in excess of1 000 000 t/y
Reasonable vessel sizes - if practicable < 5 m Ø
Pipe sizes in line with international standards
Ammonia production at lower capital and operating cost
Excellent bankability due to reference position and low scale-up
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 20045
Milestones to Improved Syngas Production
Conventional Ammonia ProcessConventional Ammonia Process
Steam Reform35 bar
CO-ShiftHT & LT31 bar
MDEAWash28 bar
Nat. gas
CO2
SecondReform33 bar
Methan.26 bar
Amm.Synth.
90 - 180bar
Liquid ammonia
AirPurge
gasrecovery
CH4
H2
Fuel gas
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 20046
Milestones to Improved Syngas Production
MEGAMMONIA® PROCESSMEGAMMONIA® PROCESS
ATR60 bar
Gas purif.RNWU52 bar
Nat. gas
Oxygen
CO-ShiftHTS
55 bar
Amm.Synth
200 bar Liquidammonia
NitrogenASU
CO2
Air
CH4, CO & ArFuel gas
RNWU = Rectisol ® + Liquid Nitrogen Wash Unit
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 20047
Milestones to Improved Syngas Production
MEGAMMONIA® INVESTMENT BENEFITMEGAMMONIA® INVESTMENT BENEFIT
Lower investment required
73
91
100
60
65
70
75
80
85
90
95
100
2 x 2 000 tpd conven.Plant
1 x 4 000 tpd conven.Plant
MEGAMMONIA
Rel
ativ
e ca
pex
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 20048
Milestones to Improved Syngas Production
MEGAMMONIA® OPERATING COST BENEFITMEGAMMONIA® OPERATING COST BENEFIT
Reduced operating cost
100
6860
50556065707580859095
100
Trinidad highestcash cost
Trinidad lowestcash cost
MEGAMMONIA
Rel
ativ
e ca
sh c
ost (
per
t NH 3
)
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 20049
Milestones to Improved Syngas Production
LURGI - CASALE EXPERIENCE RECORDLURGI - CASALE EXPERIENCE RECORD
Technology Installed capacity
Pox units 74 x 106 m3n syngas /day capacity
ATR units 107 x 106 m3n syngas /day capacity
CO-Shift units 133 plants built
Rectisol® Wash units 40 plants built
Ammonia synloops 23 units built /under construction
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 200410
Milestones to Improved Syngas Production
SCALE-UP REQUIRED FOR MEGAMMONIA®SCALE-UP REQUIRED FOR MEGAMMONIA®
Technology Factor Basis
Air Separation Unit 0,7 O2 production
CPox Unit 0,9 CO + H2 production
CO-Shift Unit 0,7 CO conversion
Rectisol® Wash Unit 0,6 CO2 removed
Nitrogen Wash Unit 1,2 CO removed
Syngas Compressor 1,1 Shaft power
NH3 Synthesis Unit 1,3 Gas recirculation
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 200411
Milestones to Improved Syngas ProductionStatus 1992:Example of Lurgi GTL-Plant based on Combined Reforming
Location: Rep. Of South AfricaTechnology: Combined Reforming, Synthol Fischer-Tropsch Synthesis, COD
(Conversion of Olefins to Destillates)Capacity: Syngas: 900,000 m³n/h (806 mm scf/d),
Products:350,000 tpa diesel fuel, 100,000 tpa gasoline
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 200412
Milestones to Improved Syngas Production
Lurgi Combined ReformingLurgi Combined Reforming
KMI, Indonesia
Methanol Plant
Capacity:
2000 mtpd
Start-up: 1998
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 200413
Milestones to Improved Syngas ProductionStatus 2004:Lurgi MegaMethanol Plant AtlasStatus 2004:Lurgi MegaMethanol Plant Atlas
400
m
600 m
100
mLocation: Trinidad
Technology: Megasyn Combined Reforming, Megamethanol Methanol Synthesis
Capacity: Syngas: 530,000 m³n/h (475 mm scf/d),Products: 5,000 tpd methanol
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 200414
Milestones to Improved Syngas Production
HP-POX Pilot Plant at TU-Freiberg, Saxonia
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 200415
Milestones to Improved Syngas Production
HP-POX Pilot Plant
Multi Process Test Facility:
ATR, Gas-Pox, MPG (liquid feedstock)
Feedstock:Liquid Feedstock 500 kg/h
Natural Gas 500 m3/h
Reactor:Operating Pressure 100 bar
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 200416
Milestones to Improved Syngas Production
HP-POX Pilot Plant
WaterTreatment
Storage
Compressor
Pump andVaporizier
Steam Generator
Soot Water Cooler
Fresh water
LiquidFeeds
NitrogenSupply
Instrument AirSupply
MeasuringStation
Power Supply AnalyticalArea
DesulphurisationReactor
Flar
e Sy
stemNatural
Gas
Liquid O2
Soot Water
Flue Gas
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 200417
Milestones to Improved Syngas Production
HP-POX Pilot Plant: Research ProgramHP-POX Pilot Plant: Research Program
ProcessesCatalytic Autothermal ReformingPartial Oxidation of Natural GasPartial Oxidation of Liquid Feedstock
Varied ParametersPressureOxygen/Carbon Ratio (Temperature) Steam/Carbon RatioResidence Time
New ResultsDemonstration of HP-Syngas ProductionTrace Components / Soot FormationCatalyst behaviour
10/14/2004 Gasification Technologies 2004, Washington , DC, Oct 3-6, 200418
Milestones to Improved Syngas Production
Dr. Holger SchlichtingProcess Manager MPGDept. A-TEEPhone +49 69 5808 1418Fax +49 69 5808 2645e-mail [email protected]
? Comments ?Contact :
Ulrich WolfDirector Syngas TechnologyDept. A-TMPhone +49 69 5808 3238Fax +49 69 5808 2645e-mail [email protected]
Lurgi AGD-60295 Frankfurt am MainGermanyInternet: www.lurgi.de
