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Presentation on Coal Gasification based Urea plant of Talcher Fertilizers Ltd. Panel Discussion – Gasification India 2017

07th December, 2017

India’s First Clean Coal Technology Plant

Game Changer for India

• Alternative avenue for vast consumption of high

ash Indian coal

• Clean Coal Technology
• Reduced dependence on LNG
• Alternative

route for production

• f

NG equivalent syngas

Talcher Fertilizers Ltd.

• Category of Project
• Revival, categorized with green field project of closed units of FCIL
• Project Location

:Talcher, Odisha (140 km from Bhubaneswar)

Project Location

• Syngas

:189,000 Nm3/day

• Ammonia

:2200 TPD (0.73 MMTPA)

• Urea

:3850 TPD (1.27 MMTPA)

• Gasification by – products
• Sulphur

: 95 TPD

• Slag

:1342 TPD (56 TPH)

• Fly ash

:112 TPD (4.7 TPH)

Production Capabilities

• Technology which can handle high ash content

(up to 47%) of Indian coal

• Proximate Coal Analysis:
• Moisture, % wt.

:5.00

• Ash, % wt.

:43.50 (max. 47%)

• Volatile, % wt.

:25.75

• Fixed Carbon, % wt.

:25.75

• Fluidity point, ºC

:>1400

• HHV MJ/kg

:16.81

• Plant can handle pure coal feed and petcoke

blend up to 25%

Challenges for Talcher Fertilizers

Clean Coal Technology

Gasification Coal + Petcoke Syngas Future Uses Feed Preparation Shift Gas Clean-up CO2

*

H2 Ammonia Synthesis Urea Production N2 Urea Sulphur Recovery N2 O2 Air To market Air Separation Slag to market

Coal Gasification Process of Talcher Fertilizer

90% 10% Fly Ash

* Balance CO2 shall be captured

• Shell Coal Gasification Technology (SCGP) – entrained bed

technology

Gasification Technology

• Coal
• Source

:50% North Arkhapal Srirampur Mine

• Consumption :
• Total

:7572 MTPD (2.5 MMTPA)

• Gasification

:3331 MTPD (1.09 MMTPA)

• CPP

:4241 MTPD (1.40 MMTPA)

• Transportation to Plant: via 10 km long conveyor
• Petcoke
• Source

:IOCL Paradip Refinery (200 km from Talcher)

• Consumption

:1000 MTPD (0.32 MMTPA)

• Transportation to plant

: Railway and Road

Raw Material & Sources

Concept of Petcoke Blending

• Petcoke: Low Ash, high heating value: Ash 0.1%, C 90%, 8500

kcal

• On mixing with Coal, improves stability of operation
• Largely mitigates problems of high Ash content of Talcher Coal
• Petcoke blend reduces overall Ash content
• Worldwide proven plants are available and operated upto 35%

Ash

• Blending gives plant flexibility of processing different proportions
• f Coal and Petcoke

Coal Quality (Ash%) Petcoke % in Blend Resultant Ash % 43 10 38.7 43 15 36.6 43 25 32.3 40 (Bhubneshwari coal) 25 <30

Project Schedule

Package NIT Date Status Boundary wall and approach road Work 25.08.2017 (award date) Work under progress Site Grading tender 27.10.2017 (Bid opening) 30.12.17 (award) Coal Gasification LSTK tender 18.05.2017 10.01.18 (Bid open) Urea Ammonia LSTK tender 9.10.2017 8.1.18 (Bid open) CPP & Offsite tenders 30.01.2018 (expected)

• Tendering & Awarding of Major Packages:

Sl. Description Timelines 1 Duration of project 41 months 2 Construction start / Zero Date

• Feb. 18 / Apr. 18

3 Mechanical completion (MC) (36 months) Feb., 2021 4 Commissioning (5 months from MC) Jul., 2021 5 COD Sep., 2021

Strategy Document for Technology Expansion

• Strategy for technology expansion
• Clue

from China coal gasification technology

• expansion. 121 operating plants and 57 under

construction coal gasification plants

• Total 400 gasifiers (322 in China). 11 built by L&T
• About 300 mmscmd equivalent NG production in

China

• China coal consumption 10 MTPD, India is 2 MTPD
• China consumption in gasification is 1.6 MTPD
• Additional 11 Gasifiers proposed, 13.2 mmscmd NG

equivalent

Timelines for Technology Expansion elsewhere in India

Plant /Mine Location

• No. of

Gasifiers NG equiv. (mmscmd) Timelines DFR/ Planning Product Talcher/ Talcher mine 02 2.40 Jul., 21 Ready NH3/Urea Talcher/ Talcher mine 01 1.20 2023 Execution by GAIL Methanol/other chemicals Jharsuguda/ Mahanadi coal mine 04 4.80 2025 Mar., 18 As per DFR Asansol/Durgapur Raniganj mines 03 3.60 Sindri/ Jharia mines 03 3.60 Total 13 15.6

• Approx. annual saving of Rs. 10k cr.
• Target: 50 gasifiers, 16MMTPA

LNG equiv.

• Rs. 50,000 cr.

import bill

• Ultimate Target: To minimize

India’s dependency on LNG imports

• By 2035

North Arkhapal Srirampur Mine

• Tentative Geological reserves

: 920 million ton

• Block area

: 11.7 sq. km

• Tentative grade of coal

: G 9 to G 14

• Coal field

: Talcher, Angul Odisha

• Status of mine

: GR report for DFR by M/s CMPDI in Jan., 19

• Bridge Linkage for start up

: Bhubneswari coal mine

• Ash content

: 35 to 47% (avg. 40%)

Value Addition Plans (Future)

• Provision of conversion of excess Syngas (100,000 Nm3/d) into

methanol and other chemicals

• Provision of additional gasifier for natural gas production
• Sulphur enhancing purification unit – lumps to granules
• Conversion of excess CO2 to dry ice and sale of liquid N2
• Production of melamine from urea

Thank You

Location of additional Gasifiers