Air Liquide Presentation (Siddhartha Mukherjee) Rev 0

The Lurgi FBDBTM Gasification Island
Value Added Products
April 10 , 2014 | Air Liquide Global E&C Solutions India Pvt Ltd | New Delhi
June 14, 2012 l Siddhartha Mukherjee | Air Liquide Global E&C Solutions | New Delhi
New Delhi
Classification Level: PUBLIC
Business Owner: Global E&C Solutions Communications
Distribution List:
Lurgi FBDBTM Gasification Island
Contents
Gasification Technologies
to Offer
The Lurgi FBDBTM Gasifier
Coal Gasification for Different
Products
Other Technologies to Offer
Rectisol
Sulphur Recovery
Air Separation Unit
CO Cold Box
PSA
Liquid Co-Products
References
Wrap-Up
2 Coal Gas 2014 Air Liquide, world leader in gases, technologies and services for Industry and Health
Air Liquide Global E&C Solutions Perspective
One-Stop-Shop
3 Air Liquide, world leader in gases, technologies and services for Industry and Health
Technologies to Offer A One-Stop-Shop
Air Liquide Global E&C Solutions offers not only the

Gasification Block but
The Complete Gasification Island
Lurgi FBDBTM Gasification CO Cold Box

Air Separation Unit PSA
Lurgi Rectisol Unit Lurgi Phenosolvan Unit
OxyClaus Unit Lurgi CLLTM Technology
Methanation Unit GTL.F1
Liquid Nitrogen Wash Fischer-Tropsch Technology
Lurgi MPG
Lurgi FBDB Coal-to-X Syngas
N2
(Fuel Gas)
Air Liquide Lurgi MPG Lurgi OxyClaus

Elemental Sulfur
ASU Gasification Sulfur Recovery
CO2
Coal Air Liquide Ammonia Syngas

Preparation LNW Unit
Syngas
Lurgi FBDB Lurgi Lurgi Rectisol
HP Steam Gasification CO Shift / Gas Lurgi SNG
Gas Cooling Purification Methanation
HP Steam
Ash
CO
Air Liquide Air Liquide
CO Cold Box PSA Hydrogen
(Rectisol Naphtha)
Lurgi Lurgi Phenosolvan & Lurgi CLL

(Phenols)
GLS Process Gas Liquor Recovery and Water Treatment
(Clear Tar / Oil)
Liquid Ammonia
ZLD Water Reuse
Lurgi FBDBTM Gasifier
Golden Rules in Coal Gasification
One never knows enough about the coal
Understanding of the coal is essential for the design
Get control over the coal quality during operating is a must
Lurgi FBDBTM Coal Gasification
Lurgi FBDBTM Gasification Technology
Lurgi Fixed Bed Dry Bottom Gasification Technology
Highlights of Lurgi FBDBTM
The Lurgi FBDBTM Process accounts for more than 25% of all
feedstock gasification based synthesis gas generated worldwide
The process was initially developed in the 1930s
The process, has a long track record of optimum performance
featuring high gasification efficiency and low oxygen consumption
over many years of operation
Proven in the world for all ranks of coal
Proven in the world for various applications :
Syngas for liquid fuels in Sasol, Secunda, South Africa
SNG on Dakota Gasification Company, Canada
Ammonia syngas for Tianji Coal Chemical Company, China
Methanol for Yima (Henan), China
DRI Gas for JSPL, Angul, India
The gasifiers at Sasol, Secunda form the largest Coal Gasification
Plant in the World
Lurgi FBDB Gasification
Gasifier
1
top
Coal
0.9
Drying
Gas
0.8
0.7
0.6 Devolatilization
0.5
Gasification
0.4
0.3 Combustion
0.2
Ash
0.1
Gasifier 0
bottom
0 300 600 900 1200 1500
Temperature [C]
The Lurgi FBDBTM Gasifier Operating Range
Coal suitability, complex function of

Particle Size Distribution: Lump coal
typically 5 50 mm with size fractions
above and below top and bottom sizes
limited to less than 5%
Ash Fusion Temperature: Ash fluid
temperature, at oxidizing conditions
above 1,200C
Combined total ash and moisture upto 55%
Good thermal and mechanical strength
Caking coal accommodated by inclusion
of proven proprietary internals into the
gasifier vessel
Green highlighted area shows proven operating range for Lurgi
FBDBTM Gasifier
All ranks of coal proven in operation
Lignite, Sub-bituminous, bituminous, anthracite
The Lurgi FBDBTM Gasifier Sketch
Twin Coal Lock
Reactor
Gas Off-take
Wash Cooler
Rotating Grate
Ash Lock
Coal Gasification for Different Products
Production of Syngas for DRI and SNG for Fuel
N2
Coal Air Separation Sulfur Recovery

Elemental Sulfur
Preparation Unit Unit
CO2
CO Shift
(depending on Acid Gas Syngas for DRI
HP Steam Gasification
raw gas Removal
composition)
Ash Methanation SNG
Production of Ammonia Syngas
N2

Elemental Sulfur
CO2
Acid Gas Liquid Ammonia Syngas

HP Steam Gasification CO Shift
Removal Nitrogen Wash
Ash
Production of Hydrogen
N2

Elemental Sulfur
CO2
Acid Gas Pressure Hydrogen

HP Steam Gasification CO Shift
Removal Swing Adsorption
Ash
Production of Hydrogen and Carbon Monoxide
N2

Elemental Sulfur
CO2
CO Shift
(depending on Acid Gas CO CO
HP Steam Gasification
the Removal Cold Box
split required)
Ash Pressure Hydrogen

Swing Adsorption
Production of Methanol
N2

Elemental Sulfur
CO2
CO Shift
(depending on Acid Gas Methanol
HP Steam Gasification Methanol
raw gas Removal Synthesis
composition)
Ash
The Air Separation Unit
The Air Liquide Air Separation Unit - Highlights
Long and thorough experience in air separation plants

Over 3500 plants built not only for 3rd party Buyers but also for direct
operation by AL
550 production and distribution centers all over the world
The engineering and construction activity has thus available a large
amount of data on industrial operation that it can benefit from
Being both a supplier and an operator of plants, Air Liquide selects the
most suitable solution for a project taking into account :
The type and characteristics of product utilization
The compression system
The automation needs
The availability of utilities
The plant layout
The Rectisol Process
Rectisol Process - Highlights
The Rectisol syngas purification technology has an outstanding

position in the world
Especially in the case of coal gasification
Also feed gas generated from oil or petcoke gasification
The Rectisol process was invented over 60 years ago and still today
purifies 75% of the syngas produced worldwide.
Rectisol is still the only process that deals with all raw gas
contaminants.
More than 85 Lurgi Rectisol plants were built within the last 60 years.
The Rectisol gas purification technology is a purely physical
absorption process.
Rectisol Process Highlights
1. Trace contaminant removal COS, CS2, NH3, HCN, mercaptans,

mercury, Fe and Ni carbonyls and BTX
2. As the COS is removed together with the H2S, there is no need for a
COS hydrolysis reactor upstream of a Rectisol unit
3. Desulfurization to synthesis feed quality

total S < 0.1 ppmv
4. Bulk CO2 removal bulk CO2 can be removed

(10ppm in syngas)
5. CO2 purification CO2 can be purified

total S < 5 ppmv
CO2 does not contain water
6. Acid Gas Enrichment Claus-suited acid gas
The OxyClaus Process
Claus Section
Oxygen
MP-Stream HP-Stream
Acid Gas
Claus
Combustion
Chamber
SWS Gas
Reactor
BFW
LP-
Fuel Gas
Stream Reactor
BFW
Air
Tailgas
Sulpur
Lurgi OxyClaus Burner
H2S Acid Gas Process Air
Oxygen
Pilot
Fuel Gas
Steam
SWS Gas
Combustion Air
Oxygen
Lurgi OxyClaus - Highlights
Significant reduction in Capital Investment when building new SRUs.
Processing of feed gases with both high and low H2S contents.
Almost complete combustion of ammonia contained in SWS offgases
Processing of Claus gases with elevated hydrocarbon contents,
Flexible processing when handling temporarily high or low amounts of

H2S by automatic changeover from air to oxygen operation and
vice versa
Capacity boosting of existing Claus unit by replacing burner.
The CO Cold Box
Air Liquide CO Cold Box - Highlights
CH4
CO
Flash Gas
H2
Adsorbers
(H2O & CO2
removal)
Methane Wash Column Impure Flash Column CO-CH4 Column

Syn Gas (H2 Removal) (Trace H2 removal)
Air Liquide CO Cold Box - Highlights
Around 75 plants built out of which around 25 are operated by AL.

The activated alumina bed, located upstream, very effectively protects
the bed of the molecular sieve. There is no case in the plants of the
AIR LIQUIDE Group where it had to be replaced.
AIR LIQUIDE patented AST Advanced Sieve Trays has wide operating
range, very low pressure drops on columns and consequently energy
savings
Easier process control
The Fin Plate Heat Exchangers, made in Aluminium, are a critical
component for the performance, reliability and safety of the Plant.
Flanged connections, which are potential leakage points, are avoided.
Because of the high level of automation proposed, the efficiency of the
plant is improved.
The Pressure Swing Adsorption
Air Liquide PSA Highlights
Air Liquide has large feed experience as a Hydrogen PSA Operator

and extensive references for building PSAs
Air Liquide has designed and manufactured 70 PSAs for Third Party
and Group
Very well known with designing PSAs operating on CO Cold Box H2
rich gas
Air Liquide as a Hydrogen PSA Operator operates 69 PSAs world
wide
High toughness Steel of for adsorber vessels (very low P, S and C
content) for high lifetime under cycling and hydrogen environment
More stringent than any code or other manufacturers standard
PWHT on adsorber vessels and skid piping
Carefully selected Valves and Accessoires,
Liquid Co-Products
Lurgi FBDBTM Gasification Island - Valuable Co-products
Full chain of purification of the water

Coal
Lurgi FBDB CO Shift &
Raw syngas
Gasification Gas Cooling
Steam
Dephenolized gas liquor with less than 20 ppm Mono-

Phenols
Acid Gas Extraction of Poly-Phenols as saleable product
CO2, H2S, HCN Organics
Dephenolized Stripped
Gas Liquor Gas Liquor Gas Liquor
Phenosolvan
Gas Liquor Lurgi CLLTM Waste Water Zero Liquid
Phenols
Separation NH3 Recovery Treatment Discharge
Recovery
Mud liquor CO2, H2S, solvent
Clear Tar / Oil Crude Phenols Liquid Ammonia

Coal
Raw syngas
Steam
Stripped Gas Liquor < 50 ppm NH3 for biological

treatment
Acid Gas Liquid anhydrous ammonia as saleable product
Phenosolvan
Phenols
Recovery

Coal
Raw syngas
Steam
Biotreatment followed by reverse osmosis technology

Complete re-use of waste water in the process ZLD
Acid Gas
Phenosolvan
Phenols
Recovery
Coal Oxygen Sulphur

Sulphur
1260 t/h (ar) 347 t/h Recovery Unit
HP Steam FBDBTM Syngas

Gas Cooling Rectisol
1000 t/h Gasification 1800,000 Nm3/h
Naphtha
Dry Ash Gas Liquor 11 t/h
250 t/h Separation
Gas Liquor Lurgi CLLTM Wastewater

Phenosolvan NH3 Recovery Treatment
Separation
Tar / Oil Phenols Liquid NH3 Reuse

42 t/h 9 t/h 11 t/h 990 m3/h
FBDB Gasification Island - Valuable Co-products
Chinese market conditions
Co-Product Market Price Case Study Case Study Case Study

RMB/t t/h 103 RMB/h USD/h
Clear Tar + Oil 3,800 42 159.6 26000
Rectisol Naphtha 3,800 11 41.8 6810
Liquid NH3 2,300 11 25.3 4130
Crude Phenols 2,400 9 21.6 3520
40,500 USD/h
Together with the value of the recovered Sulphur, this accounts to 25 % of the
feedstock and utilities cost !!!
1 RMB = 0.163 USD
References
The Lurgi FBDBTM Gasifier References
Reference List Lurgi FBDB Coal Gasification
No. of
Start-up Plant name, Client City Country Gasifiers/ Feedstock Product
Modules
2014 Jindal Steel & Angul,Orissa India 7 Coal, High Ash 225,000 Nm/hr Reduction Gas for DRI
Power Ltd.
2000 Yima Yima (Henan) China 2 Sub-bituminous Coal 80,000 TPA (tons per annum) Methanol
1987 Tianji Coal Lucheng China 5 Semi-Anthracite NH3: 300 kTPA

Chemical Company (Shanxi) HNO3: 540 kTPA
Nitro Phosphate: 900 kTPA
Ammonium Nitrate (explosive grade): 200
kTPA
6
1985 Dakota Gasification North Dakota, United 14 Lignite 1450 x 10 Nm/annum SNG
Company Beluah States
6
1982 Sasol Synfuels Secunda South 40 Sub-bituminous Coal Fischer-Tropsch Products, 40 x 10 Nm/day
Africa syngas for liquid fuels and chemicals
6
1979 Sasol Synfuels Secunda South 40 Sub-bituminous Coal Fischer-Tropsch Products, 40 x 10 Nm/day
Africa syngas for liquid fuels and chemicals
6
1955 Sasol Chemical Sasolburg South 17 Bituminous Coal Fischer-Tropsch Products, 17 x 10 Nm/day
Industries Africa syngas for liquid fuels and chemicals
Lignite Reference Lurgi FBDBTM
Dakota Gasification Company Beulah, North Dakota, USA

14 x LURGI FBDBTM units Start-up: 1985 Coal: Lignite coal
Products: Synthetic Natural Gas (SNG) and CO2
Sub-bituminous Reference Lurgi FBDBTM
SASOL Synfuels, Secunda, South Africa

80 x LURGI FBDBTM units Start-up: 1979 Coal: Sub-bituminous coal
Products: Syngas to FT fuels
Sub-bituminous Reference Lurgi FBDBTM
Yima Coal Gasification, Henan Province, PRC

2 x LURGI FBDBTM units Start-up: 2000 Coal: Sub-bituminous coal
Product: Methanol
Anthracite Reference Lurgi FBDBTM
Tianji Coal Chemical Company, Shanxi Province, PRC

5 x LURGI FBDBTM units Start-up: 1987 Coal: Anthracite coal
Product: NH3
High Ash Reference Lurgi FBDBTM
Jindal Steel & Power Ltd., Odisha Province, India

7 x LURGI FBDBTM units Start-up: ongoing Coal: High ash Indian coal
Product: Reduction gas for DRI
Wrap-Up
Wrap-Up
Excellent Technology for Low Rank Coals

Appropriate Technology for following applications:
Substitute Natural Gas SNG
Direct Reduction of Iron DRI
Coal to Liquids CTL
NH3 with CH4 co-production
Based on a long industrial operation experience

Significant Improvements achieved by the Lurgi FBDBTM Mk PlusTM
Improved Environmental Footprint
A New Waste Water Treatment Unit:
Complete Process Water Re-Use Zero Liquid Discharge
Recovered Co-products are adding significantly to the plant economy

A Real One-Stop-Shop
Proven technologies integrated into a single package
4,000 Air Liquide Global E&C Solutions Colleagues Thank You!
Lorton Montreal Ennery Krakow New Delhi Beijing

Moscow
Vitry Frankfurt
/Seine
Champigny
/Marne
Bussy-Saint-Georges Shanghai
Memphis
Harima
Houston
Hangzhou
Hyderabad
Singapore
Chennai
Sao Paulo
Johannesburg
Dubai
Riyadh
Engineering centers Manufacturing workshops Business offices Cryogenic equipment centers

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The Lurgi FBDBTM Gasification Island

Value Added Products

Classification Level: PUBLIC

Business Owner: Global E&C Solutions Communications

Air Liquide Global E&C Solutions offers not only the

Lurgi FBDBTM Gasification CO Cold Box

Air Liquide Lurgi MPG Lurgi OxyClaus

Coal Air Liquide Ammonia Syngas

Lurgi Lurgi Phenosolvan & Lurgi CLL

(Clear Tar / Oil)

ZLD Water Reuse

One never knows enough about the coal

Understanding of the coal is essential for the design

Get control over the coal quality during operating is a must

Lurgi FBDBTM Gasification Technology

Lurgi Fixed Bed Dry Bottom Gasification Technology

Coal suitability, complex function of

Twin Coal Lock

Coal Air Separation Sulfur Recovery

Ash Methanation SNG

Coal Air Separation Sulfur Recovery

Acid Gas Liquid Ammonia Syngas

Coal Air Separation Sulfur Recovery

Acid Gas Pressure Hydrogen

Coal Air Separation Sulfur Recovery

Ash Pressure Hydrogen

Coal Air Separation Sulfur Recovery

Long and thorough experience in air separation plants

The Rectisol syngas purification technology has an outstanding

1. Trace contaminant removal COS, CS2, NH3, HCN, mercaptans,

3. Desulfurization to synthesis feed quality

4. Bulk CO2 removal bulk CO2 can be removed

5. CO2 purification CO2 can be purified

6. Acid Gas Enrichment Claus-suited acid gas

H2S Acid Gas Process Air

Significant reduction in Capital Investment when building new SRUs.

Almost complete combustion of ammonia contained in SWS offgases

Processing of Claus gases with elevated hydrocarbon contents,

Flexible processing when handling temporarily high or low amounts of

Capacity boosting of existing Claus unit by replacing burner.

Methane Wash Column Impure Flash Column CO-CH4 Column

Around 75 plants built out of which around 25 are operated by AL.

Air Liquide has large feed experience as a Hydrogen PSA Operator

Full chain of purification of the water

Dephenolized gas liquor with less than 20 ppm Mono-

Mud liquor CO2, H2S, solvent

Clear Tar / Oil Crude Phenols Liquid Ammonia

Full chain of purification of the water

Stripped Gas Liquor < 50 ppm NH3 for biological

Mud liquor CO2, H2S, solvent

Clear Tar / Oil Crude Phenols Liquid Ammonia

Full chain of purification of the water

Biotreatment followed by reverse osmosis technology

Mud liquor CO2, H2S, solvent

Clear Tar / Oil Crude Phenols Liquid Ammonia

Coal Oxygen Sulphur

HP Steam FBDBTM Syngas

Gas Liquor Lurgi CLLTM Wastewater

Tar / Oil Phenols Liquid NH3 Reuse

Co-Product Market Price Case Study Case Study Case Study

Clear Tar + Oil 3,800 42 159.6 26000

Rectisol Naphtha 3,800 11 41.8 6810

Liquid NH3 2,300 11 25.3 4130

Crude Phenols 2,400 9 21.6 3520