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Praxair’s OTM Solid State Combined
Reformer – A Modular Syngas Generator
PIOGA Technical Conference
Seven Springs Mountain Resort,
Champion, PA
August 23 – 24, 2016
OTM
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OTM – How it works:
Solid State Combustion Driven Air Separation and Compression
Dual phase
dense layer
Cross Section High
Pressure
Fuel
Porous support Active layers
Electrons
Pure
Oxygen
Low
Pressure
Air
950-1000oC
Oxy-
combustion
Product
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Step Change OTM Syngas Technology
Combined reforming in a single integrated efficient package
Primary Steam
Methane Reformer (SMR) Air Separation
Unit (ASU)
Secondary AutoThermal
Reformer (ATR)
Multi-Process
Combined
Reforming
O2
Heat OTM tube
ASU + ATR
Air
NG + Steam Syngas
Partially Reformed Syngas
(H2, CO, CO2, CH4, H2O)
Primary
reformer (SMR)
O2
O2
Benefits of OTM Lower capex
• 3 unit ops in 1 (SMR
+ ASU+ATR)
• Modular design
Lower opex / NG • High quality syngas
• Utilizes tail gas
Significantly reduced
GHG emissions
Optimal fit with scale
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Integrated Combined Reformer Panel Array
Combined reforming in a single pass
ceramic membranes
reformer
OTMs
Reformers
NG + Steam
to reformers
Product
Syngas
Thermal integration
Multiple Panels Back to Back
Facilitate Thermal Integration
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Panel Array Scale-up
Single Panel
Double Panel
Quad Panel
0.5 bpd
5000 scfd NG
2 bpd
20,000 scfd NG
8 bpd
80,000 scfd NG
Panels number-up to meet target capacity
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Modular System Scale-Up
Scale-up simplified by numbering up repeatable modular elements
Modular System
Design
Furnace “Pack”
Single Furnace “Train”
Ceramic and Reformer
Panel Array
ceramic membranes
reformer
Repeating elements facilitate mass
manufacturing Panels number-up to meet
target capacity 10 – 20 panels per pack
Wide range of train capacities (200 – 800 BBL/d)
by varying panel design and number of packs Entire plant arrives in prefabricated skids & modules
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Robust System Operation
No ceramics failures through 44 week torture test!
Site
power
failure
Month 1 2 3 4
Stand-by
Operating
OT
M
Process
Trips
Process Starts
Deep
thermal
cycles
■ 44 Week operating campaign
■ Site NGSyngas
■ 50,000 scfd Syngas
■ +150 on/off syngas cycles
■ Multiple deep thermal cycles
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Technology Readiness
Achieved commercial ceramic performance targets
– Extraordinary progress on flux, strength, creep life, degradation
– Robust glass-ceramic seals
Proved unique combined reforming process
– Demonstrated at single and multi-panel levels
– Robust to system-start up, shut-down, trips, and transients
On-Track with Supply Chain and Cost Reduction
– Tube manufacturing capacity increased to 8 MM scfd syngas/yr
– Qualifying external parties for high volume substrate manufacturing
– Shops qualified to manufacture panel array modules
– Delivering on key capital cost reduction targets
Ready for industrial scale demonstration
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Large Methanol Economics with OTM
Joint evaluations with major licensor and producer
Greenfield methanol plants: 1000 – 3000 metric tons/day
But world scale methanol (280 MMSCFD) too large for OTM today …
SMR + ATR + ASU (CR)
SMR
CO2 emissions Base +16% NG Consumption Base +13% Operating cost Base +7% Capital investment Base -9%
15 yr IRR, % 14.1% 14.9% Net income*, $MM/yr 82 84
OTM CR
-29% (142,000 t/yr) Base
-4% ($5 MM/yr) -18% ($175 MM)
18.4% 113
Conventional IRR’s within 1%
OTM achieves efficiency of a combined reformer without an O2 plant
Enhances project returns by 4% and net income by $30 MM/yr
*3000 mT/d; MeOH @ $350/mT
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Small GTL Prospectus
OTM provides step change economics
– $20/bbl lower production cost
– Lower “oil price threshold” for GTL projects based on gas – liquid spread
– Projects viable when SMR and ATR are not
Projects are manageable scale, cost and risk but….
Small GTL market is developing slowly
– First projects are nearing completion
– Low oil prices, high capital cost and technology risk have slowed project
development
– Expect improved market conditions as these headwinds abate
Meanwhile…Establishing channels to market with stakeholders
– “Back end” technology licensors and equipment suppliers
– Engineering and fabrication companies
– Companies that are already developing projects, working with end customers
Small GTL is right sized for early term commercialization
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OTM Economics for GTL
Flare gas and stranded gas – compelling early opportunities
SMR
OTM*
$4/MMBtu
$20/bbl ∆ confirmed by GTL stakeholders
40
60
80
100
120
140
160
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Equ
iv. c
rud
e o
il, $
/BB
L
BBL/d
$0 Flare gas
$2 Stranded gas
$4 Pipeline gas
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Next Milestone - Commercial Reference Plant
Modular shop fabricated syngas Generator for a range of applications
8 MM scfd syngas at a
Praxair HYCO facility
Platform for….
80 mtpd MeOH
5 MM scfd H2
200 bpd GTL
Demonstrates key
technology elements at scale
Design and operational data
Exercises ceramic and
system supply chain
Engaged specialty equipment
suppliers, fabricators,
technology and engineering
firms
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Mid Term Ambitions…
60 MM scfd syngas
Platform for….
600 mtpd MeOH
40 MM scfd H2
1500 bpd GTL
Maximize shop fabricated
modular content
Mass manufactured ceramic
components identical to
smaller scale systems
Benefits of modular membrane systems extends to larger scales
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Acknowledgements
This material is based upon work supported by the Department of Energy under Award Number DE-FE26-07NT43088. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and options of authors expressed herein do not necessarily state or reflect those of the United States government or any Agency thereof.