Integrated processes for converting coal to chemicals and fuels - - PowerPoint PPT Presentation

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Integrated processes for converting coal to chemicals and fuels - - PowerPoint PPT Presentation

Nov 06, 2023 211 likes •508 views

Integrated processes for converting coal to chemicals and fuels Maninder J it Singh Haldor Topse Converting coal to chemicals and fuels Sulfuric acid SNG Coal Coal Syngas Ammonia DME gasification conditioning Methanol Formaldehyde

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SLIDE 1

Integrated processes for converting coal to chemicals and fuels

Maninder J it Singh Haldor Topsøe

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SLIDE 2

Coal Syngas conditioning Coal gasification Sulfuric acid SNG Ammonia Methanol DME Formaldehyde Gasoline

Converting coal to chemicals and fuels

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SLIDE 3

Integrated production

Maximize utilization of H2 and CO2

  • Combined production
  • Hydrogen, TREMPTM
  • Ammonia, urea, methanol
  • TIGAS
  • Minimizing sulfur emissions
  • Sulfur removal unit
  • Commercial grade sulfuric acid
  • Integrated steam system
  • Overall benefit on energy efficiency
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SLIDE 4

Process steps in an integrated CTX plant

Sulfuric acid Air Coal Syngas Steam Steam N2 CO2 MeOH DME product MeOH product Urea product NH3 product O2 NH3 Gasifier Final purification NH3 synthesis WSA™ Urea synthesis MeOH synthesis DME synthesis ASU Sour shift Acid gas removal H2S

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SLIDE 5

Typical Topsoe sour shift section

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SLIDE 6

Features of sour shift catalyst SSK-10

  • Active at low temperatures
  • Allows high CO conversion at low steam/dry gas
  • High selectivity at low steam to dry gas ratio
  • Methanation reaction is limited
  • Proprietary kinetics for the CH4 formation
  • Sour shift can be designed for minimum S/DG ratio
  • No risk of temperature run away
  • Specialised guard catalyst
  • Dust protection
  • Carbonyl protection
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SLIDE 7

Sulfur removal downstream the sour shift

  • Both H2S and COS will typically be present
  • Sour shift will hydrolyze the COS to equilibrium
  • Methanol plants with by-pass across the shift section
  • Possibility to install hydrolysis reactor on the by-pass stream
  • CKA-3 catalyst from Topsoe
  • Selective hydrolysis of COS to equilibrium
  • No change in the H2/CO ratio
  • HTZ-31 promoted absorbent from Topsoe
  • Remove equilibrium COS before the synthesis units
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SLIDE 8

What to do with H2S?

H2S

Sulfuric acid Claus plant Sulfur Uses of sulfuric acid Sulfuric acid plant WSA Plant

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SLIDE 9

What is WSA?

Wet gasS

ulfuric Acid A catalytic process for purification of sulfur- containing streams while producing concentrated sulfuric acid Sulfuric acid Cleaned gas Energy (HP Steam) S H2S RSH COS CS2 SO2 SO3 H2SO4

H2S gas SO2 converter Acid cooler Product acid Combustion air Stack gas Blower WSA condenser Interbed cooler Gas cooler Combust

  • r

Air Blower

BFW

Steam drum

WHB CW Superheated steam

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SLIDE 10

Value addition by WSA!

CAPEX & Environment:

  • More than 99.9% of the sulfur content can be recovered
  • Without need of tail gas treatment unit
  • Simple lay-out
  • Relatively few components and small plot space gives low investment

OPEX:

  • Excellent heat management
  • Producing large amount of valuable HP superheated steam
  • Sulfur is recovered as concentrated sulfuric acid of commercial grade
  • Valuable product of extensive use in India
  • Ease of operation
  • High plant availability (no fouling S-condensers/catalyst or HC and NH3 feed issues)
  • No waste products or chemicals added
  • Minimal impact on OSBL utilities
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SLIDE 11

Comparison WSA vs. Claus

Production

Production figures WSA Claus + TGTU $/t tph $/yr tph $/yr Sulfuric acid 32 3.56 978,939

  • Sulfur

100

  • 1.16

999,974 HP steam 17 9.50 1,388,965

  • LP steam

13

  • 2.70

301,874 Total production value 2,367,903 1,301,848

= 0

1,388,964

$ = USD

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SLIDE 12

Comparison WSA vs. Claus

Consumption

Consumption figures WSA Claus + TGTU unit $/unit

tph/kWh

$/yr

tph/kWh

$/yr Fuel gas t 130

  • 0.23

257,152 Oxygen t 47

  • 0.56

226,363 HP steam t 17

  • 1.33

194,455 BFW t 0.34 11.2 32,750 3.70 10,819 CW t 0.03 30.8 7,947

  • El. Power

kWh 0.08 205 141,047 400 275,213

$ = USD

Total consumption cost 181,744 964,002 Net production income 2,186,160 337,846 Sulfuic acid at zero value 1,207,221

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WSA references

2 1 3 4 1 2 6 1 13 14 15 11 5 4 9 10 3 5 6 7 8 1 2 4 5 6 8 9 5 6 2 3 5 2 1 3 7 8 12 4 3 7 4 2 19 9 10

Oil refining Coking Gasification Metallurgy Viscose Sundry applications

18 4 1 7 3 17 16 11 8 9 20 10 11 13 12 10 5 11 17 15 12 14 24 23 22 12 26 25 27 16 21 15 16 19 18 6 14 13 17 20 21 19 18 22 7 28 20 23 8 29 13 31 23 28 25 27 26 30 6 25 32 33 24 24 21 34 29 31 9 30 35 14 26 36 37 38 28 29

Acid production :4 – 1,140 MTPD 130+ references 30 within gasification

Korean Western Power Taean IGCC plant Start-up 2015 Mississippi Power Company Kemper County IGCC plant Start-up 2015 Sasol Synfuels (Pty.) Ltd. Secunda, RSA Start-up 2009

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Uncoupling India from LNG import

  • by utilisation of national coal resources for SNG
  • India is the fourth largest LNG importer in the world
  • Imports are expected to rise ~30% in 2015
  • National coal reserves and pet coke is the key
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SLIDE 15

Schematic TREMP™layout (Topsoe Recycle Energy Efficient Methanation Process)

Feed

Inlet temp. down to 230°C

SNG Sulphur guard Bulk methanation Trim methantion

High exit temp., typically 675°C

  • Robust process
  • Low operating cost
  • Excellent catalysts

Special features of TREMP™

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SLIDE 16

MCR catalyst developed for Topsoe TREMP™ methanation

  • MCR Catalyst – the heart of the TREMP ™unit
  • High thermal stability, demonstrated up to 800°C
  • Active at low temperature (300°C)
  • High resistance to carbon formation
  • High mechanical strength
  • The catalyst is delivered prereduced
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Industrial case – Coal to SNG

  • Qinghua SNG plant
  • Two step desulfurization of raw syngas
  • High surface HTZ-5 absorbent
  • Copper-Zinc based ST-101 for final absorption
  • Services rendered
  • Process and basic design
  • Detailed engineering of high pressure equipment
  • Supply of catalyst
  • Assistance during commissioning and start-up

Customer

Qinghua, China

Start up 2013 Capacity, SNG 172,000 Nm 3/h

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Industrial case – Coal to LNG

Huineng Coal Chemical Co. Ltd. , China

  • SNG to LNG requires high product purity
  • Reached 105% load
  • Services rendered
  • Process and basic design
  • Detailed engineering of high pressure equipment
  • Supply of catalyst
  • Assistance during commissioning and start-up

Customer

Huineng Coal Chemical Co.Ltd., China

Start up 2014 Capacity, SNG 50,000 Nm 3/h

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SLIDE 19

Topsoe synthesis loop

S-300 Converter Make-up gas Boiler BFW CW Product ammonia NH3(l)

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SLIDE 20

S-300 Converter Make-up gas Boiler BFW CW Product ammonia NH3(l)

Special features of Topsoe ammonia loop

  • Topsoe 3 bed ammonia converter
  • Well proven radial flow converter with about 50 references
  • Easy to operate
  • Highly reliable
  • High efficiency
  • No purge
  • KM ammonia synthesis catalyst
  • High activity
  • Small particles
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SLIDE 21
  • Optimized for lower beds
  • Higher NH3 concentration
  • Lower temperatures
  • Favorable equilibrium

KM1 KM 111 KM 111 S-300

KM 111 – New Topsoe ammonia synthesis catalyst

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SLIDE 22

Industrial case – Coal to ammonia

Customer

Zhongyan Kunshan, China

Start up 2015 Capacity 900 MTPD Ammonia

  • Zhongyan Kunshan Co. Ltd ammonia plant
  • Single S-300 ammonia converter
  • Bayonet u-tube loop boiler
  • Services rendered
  • Process and basic design
  • Detailed engineering of high pressure equipment
  • Supply of proprietary equipment and catalyst
  • Assistance during commissioning and start-up
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SLIDE 23

Topsoe methanol synthesis loop

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MK-151 Topsoe methanol synthesis catalyst

  • The FENCE™technology inhibits sintering
  • Cu crystals separated by picket fence of metal oxides
  • Very high activity
  • Long lasting stability
  • Low by-products formation

Cu ZnO Al2O3

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SLIDE 25

Industrial case – Coal to methanol

Customer

Xianyang Shaanxi, China

Start up 2010 Capacity 2000 MTPD Methanol

  • Xianyang methanol plant
  • One step desulfurization of raw syngas
  • Single boiling water methanol reactor
  • Operating at 108% capacity
  • 1% better carbon efficiency compared to design
  • Services rendered
  • Process and basic design
  • Detailed engineering of high pressure equipment
  • Supply of proprietary equipment and catalyst
  • Assistance during commissioning and start-up
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SLIDE 26

Industrial case – Integrated process

Customer

Tianfu Chemical, China

Start up 2009 Capacity

  • 910 MTPD

Ammonia

  • 750 MTPD

Methanol

  • 550 MTPD

DME

  • Tianfu ammonia and DME plant
  • Single S-300 ammonia converter
  • Single boiling water methanol reactor
  • Single adiabatic DME
  • Product flexibility
  • Services rendered
  • Process and basic design
  • Detailed engineering of high pressure equipment
  • Supply of proprietary equipment and catalyst
  • Assistance during commissioning and start-up
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SLIDE 27

Conclusion

  • Coal can be used to produce a variety of products
  • Added value to the plant owner
  • Integration of the process units creates synergies
  • Improves overall energy efficiency
  • Economy of scale
  • Product diversity
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SLIDE 28

To find out more

  • r get in contact

www.topsoe.com sing@topsoe.com

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