Cryogenics Lurgi

Technology Handbook 2 Technology Handbook

General: This Technology Handbook is intended for general information purposes only and is not intended as an offer, representation or warranty of any kind, or as a statement of any terms or conditions of sale. The information herein is believed to be correct, but is not warranted for correctness or completeness, or for applicability to any particular customer or situation.

Intellectual property: All the information contained in this document is the exclusive property of Air Liquide or one of its affiliates. Trademarks contained herein, including Yango™, HYOS™, Cryocap™, Phenosolvan™, Lurgi MPG™, Lurgi MegaMethanol™, Lurgi MTP™, MTP™, Rectisol™, Distapex™, G2G™, SMR-X™, Medal™, OxyClaus™, LTGT™, Omnisulf™, Purisol™, Sulfreen™, Degasulf™, Lurgi Biofuels™ and MPG™ belong to either L’AIR LIQUIDE, Société Anonyme pour l’Étude et l’Exploitation des Procédés Georges Claude or Air Liquide Global E&C Solutions Germany GmbH or Air Liquide Global E&C Solutions US Inc.

Economic hypothesis and definitions: Unless otherwise specified, OPEX calculations include variable operating costs (utilities, feedstock…) and fixed costs (labour…). Natural gas cost is assumed to be $4/mmBTU HHV. In addition, unless otherwise specified, CAPEX is calculated either: a) including all EPC costs (process units, offsite and utilities) but excluding owner’s costs for a plant built on the USGC; or, b) using 1.8xEP costs (process units, offsite and utilities). Price base is 2015. OPEX and CAPEX are indicative and can vary according to the basis of design, such as: product(s) yield and quality, site conditions, feedstock quality, utilities, project scope and plant capacity. Units are metric. Gallons (gal) are US Gallons (3.785 liters). Barrel (bbl) refers to oil barrel (42 gal). Heating value shall be understood as Lower Heating Value (LHV). Exchange rate used is: 1 Euro = 1.1 US Dollar.

Editor: Air Liquide Global E&C Solutions US Inc. Contact information for suggestions, improvements... email at [email protected]

January 2016, version 1.3

© 2015 Air Liquide Global E&C Solutions

Cryogenics 3 Lurgi This handbook is also availble in the following formats

PAPERBACK DIGITAL VERSION DIGITAL VERSION

ask any email address on pages 10/11 or any Air Liquide Global E&C Solutions representative)

Apps from Air Liquide:

GAS ENCYCLOPEDIA EASY GAS CONVERTER Allows users to quickly access a host of information Gives users the ability to instantly calculate volume on the physical and chemical properties of 64 gas conversions from gaseous to liquid state for 14 gas molecules (oxygen, nitrogen, hydrogen, etc.) in their molecules such as nitrogen, oxygen and hydrogen. solid, liquid and gaseous states. Available on Google Play and Appstore Available on Google Play and Appstore (for iPad only)

Cryogenics 4 Lurgi Value Through Technology

Dear Customer,

We are pleased to share with you our most recent Technology Handbook. This comprehensive overview of some 60 different advanced technologies was made possible thanks to the valuable input of the sought-after experts within our company.

We always strive to leverage our network and engage our experts, scientific and technical leads, solutions development teams and our own Air Liquide plant operators worldwide, so as to increase the value of our technologies and expand our knowledge in order to serve you better. As well, through our product line organization, we are able to be closer to the markets and customers we serve and this allows us to develop and continuously improve on our technological leadership.

Air Liquide Global E&C Solutions’ goal is to provide competitive solutions that are safe and reliable so that our customers can optimize their operations as well as their use of natural resources.

We encourage you to contact us through our regional offices or send an email to one of our technology groups. Our experts and project leaders will be at your disposal to answer your questions and offer additional information to help you move forward with your projects.

Thank you,

Domenico D’Elia Vice President and Chairman Air Liquide Global E&C Solutions

Air Liquide Global E&C Solutions’ Technology and Sales activity is organized into six product lines: Standard Plants, Cryogenics, Hydrogen, Downstream & Petrochemicals, Hydrocarbons and Oleochemicals; while operating in four regions: Americas, Asia, Europe and Middle-East & Africa. Such a worldwide set-up allows us to efficiently manage and develop our technology portfolio, be close to the markets we serve, in line with the needs of our customers.

Cryogenics 5 Lurgi Who We Are

Air Liquide Group Air Liquide Global E&C Solutions The World leader in gases, tech- nologies and services for Indus- A technology partner of choice try and Health Air Liquide Global E&C Solutions, the Air Liquide is present in 80 countries engineering and construction activity with approximately 68,000 employees of the Air Liquide Group, builds the and serves more than 3 million custom- Group’s production units (mainly air gas ers and patients*. Oxygen, nitrogen and separation and hydrogen production hydrogen are essential small molecules units) and also supplies external for life, matter and energy. ​They em- customers with its portfolio of body Air Liquide’s scientific territory and technologies. Its industrial gas, energy have been at the core of the company’s conversion and gas purification activities since its creation in 1902. solutions enable customers to optimize the use of natural resources. Air Liquide’s ambition is to lead its industry, deliver long-term performance Air Liquide Global E&C Solutions covers and contribute to sustainability. The the entire project life-cycle: license company’s customer-centric trans- engineering services / proprietary equip- formation strategy aims at profitable ment, high-end engineering & design growth over the long term. It relies on capabilities, as well as project manage- operational excellence, selective invest- ment & execution services. Its exclusive ments, open innovation and a network and innovative technologies are making organization implemented by the Group a contribution to the worldwide. Through the commitment transition of the energy sector. and inventiveness of its people, Air Liq- uide leverages energy and environment With more than 1,600 patents and transition, changes in healthcare and 3,500 employees, Air Liquide Global digitization, and delivers greater value E&C Solutions is at work connecting to all its stakeholders. people and ideas everywhere to create advanced technologies to solve * following the acquisition of Airgas on customer issues and position Air Liquide 23 May 2016 Group for growth over the long term.

Cryogenics 6 Lurgi Key Figures

engineering 15 centers 1,600 patents

3,500 proprietary employees 60 technologies

manufacturing 3 centers 6,000 plants built

Cryogenics 7 Lurgi Commitment to Safety

At Air Liquide Global E&C Solutions, Embodying a we have one goal with respect to safety-first culture Health, Safety, Environment and Security: To achieve zero accidents • Our safety commitment applies not and zero environmental incidents. only to our employees, but also to our contractors, customers, adjacent In pursuit of this goal, we strive to: facilities and local communities.

• Provide a secure work environment • We ensure that safety is the responsibility of everyone and is a • Prevent all injuries, damage to the part of the Air Liquide Global E&C environment and damage to property Solutions culture. In this way, we are all safety leaders, and all share a • Identify and reduce risks and exposure commitment to the golden rule of to hazards in a sustainable way safety first.

• Improve our Health, Safety, • We will not hesitate to stop an Environment and Security activity of whatever nature (design, performance continuously engineering, construction execution, or manufacturing) if it is not safe or if • Enforce Air Liquide Life Saving Rules there is any suspicion that it may end in an accident or incident, now or in the future.

Cryogenics 8 Lurgi Enabling Cleaner Solutions

Our solutions designed to protect life and the environment represent more than 40% of the company’s sales. As a responsible partner and technology provider, Air Liquide Global E&C Solutions is constantly seeking to reduce the environmental impact of the production facilities it builds for the Air Liquide Group but also offers its third-party customers the most environmentally-friendly technologies and applications available.

Cleaner Natural Gas Natural gas represents 15% of the world’s energy consumption and is the fastest growing energy source.

Our technologies enable efficient pollutants removal: Cleaner fuels • Amine wash Air Liquide Global E&C Solutions has multiple technologies • Membranes to remove pollutants from conventional fuels, as well as • CryocapTM technologies for the production of biofuels and alternative • Omnisulf clean fuels: • Hydrogen production for sulfur removal • Biodiesel Cleaner Power • Sulfur free fuels: LNG, Methanol or Gasoline (G2GTM) Air Liquide Global E&C Solutions pioneered the 61% development of oxycombustion as a way to capture CO 2 of our technologies in coal powered plants. Cleaner Water contribute to Industrial gases offer alternative solutions to conventional Key technologies are: Large Air Separation Units and water and waste treatment processes: CryocapTM Oxy. the protection • VSA for pure oxygen introduction into biological basins of the environment with in-house gas injectors, or oxygen for ozone production Cleaner Chemicals TM • CO2 for pH adjustment (such as Cryocap ) Everyday goods such as cosmetics and detergents are • Removal of chemical contaminants produced more and more using green chemicals. Air (Phenosolvan, GLS and CLL, part of the FBDB Liquide Global E&C Solutions’ suite of 13 oleochemicals technology package) technologies is a key contributor to the developement of such products with a share of more than 60% of the market.

Cryogenics 9 Lurgi How to reach us Beijing Hangzhou Shanghai Kobe Technology Groups

Standard plants Email: [email protected]

Cryogenics Email: [email protected] New Delhi

Hydrogen Email: [email protected]

Syngas Email: syngas@airliquide.com Singapore Kuala Lumpur Petrochemicals Calgary Email: [email protected] Montreal Houston G2G™ – Gas-to-Gasoline Email: [email protected]

Natural Gas Treatment Email: [email protected] Sao Paulo

Sulfur Email: [email protected] Doha LNG Ras Al Khaimah Email: [email protected] Abu Dhabi Dubai Oleochemicals Al Khobar Email: [email protected]

Services Johannesburg Email: [email protected] Our other locations’ contact information can be found at www.engineering-airliquide.com

Cryogenics 10 Lurgi Regions & Centers Vitry Champigny Africa Frankfurt Air Liquide Global E&C Solutions South Africa (Pty) Ltd. Krakow Beijing Lurgi Place, Turnberry Office Park Kiev Hangzhou 180 Cumberland Avenue Bryanston 2191 - SOUTH AFRICA Moscow Shanghai Tel: +27 11 2 44 46 00 Email: [email protected] Kobe Americas Air Liquide Global E&C Solutions US Inc. 9807 Katy Freeway, Suite 100 Houston TX 77024 - USA Tel: +1 713 624 80 03 Email: [email protected]

New Delhi Asia Air Liquide Global E&C Solutions Shanghai Co., Ltd. A3, Cao He Jing Modern Service High-Tech Park No. 1528 Gu Mei Road Shanghai 200233 - CHINA Tel: +86 21 60 91 90 00 Email: [email protected] Singapore Selangor Europe Calgary Air Liquide Global E&C Solutions France S.A. Montreal 57 avenue Carnot, BP 313 Houston 94503 Champigny-sur-Marne - FRANCE Tel: +33 1 49 83 55 55 Email: [email protected]

Air Liquide Global E&C Solutions Germany GmbH Olof-Palme-Str. 35 Sao Paulo 60439 Frankfurt am Main - GERMANY Tel: +49 69 580 80 Email: [email protected]

India Air Liquide Global E&C Solutions India Private Ltd. Ras Al Khaimah A24/10 Mohan Cooperative Abu Dhabi Industrial Estate Mathura Road Delhi 110 044 - INDIA Dubai Tel: +91 11 42 59 50 50 Email: [email protected] Al Khobar Middle-East Air Liquide Engineering Middle East Johannesburg Dubai Airport Free Zone, 5 East, Block A Suite 301, P.O. Box 54368 Dubai - UNITED ARAB EMIRATES Tel: +97 1 42 05 55 00 Email: [email protected]

Cryogenics 11 Lurgi Other Centers

Americas Kobe Moscow Calgary Air Liquide Global E&C Solutions Japan Ltd Air Liquide Global E&C Solutions ooo Air Liquide Global E&C Solutions Canada LP 7-1-15, Goko-dori, 17 Ulitsa Vorontsovskaya 140 - 4th Avenue SW - Suite 550 Chuo-ku, Kobe Moscow 109147 - RUSSIA Calgary, Alberta, T2P 3N3 - CANADA 651-0087 - JAPAN Tel: +7 49 56 41 28 94 Tel: +1 403 774 4300 Tel: +81 78 265 0201 Singapore Middle-East Montreal Ras-Al-Khaimah Air Liquide Global E&C Solutions Singapore Pte Ltd Air Liquide Global E&C Solutions Canada LP Air Liquide Middle East Manufacturing 3 HarbourFront Place 5125 du Trianon Maritime City Free Zone Company #09-04 HarbourFront Tower Two Suite 200 PO Box 29341 Singapore 099254 Montreal Quebec H1M2S5 - CANADA Ras-Al-Khaimah - UNITED ARAB EMIRATES Tel: +65 6373 7299 Tel: +1 514 798 5590 +97 1 42 05 55 00 Selangor Sao Paulo Abu Dhabi Air Liquide Global E&C Solutions Malaysia Sdn Bhd Air Liquide Global E&C Solutions Brazil Ltda Air Liquide Global E&C Solutions Germany GmbH - Abu Dhabi C-31-6, Jaya One, No 72 A, Jalan University, Av. das Nações Unidas Al Maryah Island, Abu Dhabi Global Market Square 46200, Petaling Jaya, Selangor, Malaysia 14º andar, Cep 04578-000 Al Maqam Tower, Office# 3506, 35th Floor Tel: +603 7947 5688 Brooklin Novo P.O. Box 62594 Sao Paulo-SP - BRAZIL Abu Dhabi - UNITED ARAB EMIRATES Tel: +55 11 55 09 84 36 Europe Tel: +971 2418 7554 / 56 Vitry Asia Air Liquide Global E&C Solutions France S.A. Al Khobar Beijing 18 Quai Jules Guesde Air Liquide Global E&C Solutions Arabia Engineering Consultancy Partnership Beijing Lurgi Engineering 94407 Vitry-sur-Seine - FRANCE 1st Floor, Office D-301, Al Salah Building Consulting Co. Ltd Tel: +33 1 48 82 66 64 Khalid bin Al Waleed Street Unit 0408, Landmark Tower 2 Air Liquide Global E&C Solutions France S.A. Al Rakah, Khobar - SAUDI ARABIA 8 North Dongsanhuan Road 4, rue des Fusillés Tel: +966 1 3857 7031 Chaoyang District 94781 Vitry-sur-Seine Cedex - FRANCE Beijing 100004 - CHINA Tel: +33 1 45 73 66 66 Tel: +86 10 65 90 67 97 Krakow Hangzhou Air Liquide Global E&C Solutions Poland S.A. Air Liquide Global E&C Solutions Hangzhou Co. Ltd Mogilska 41 Sanliyang, North Gongchen Bridge 31-545 Krakow - POLAND No. 398 Shixiang Road Gongshu District Tel: +48 12 6 27 22 0 Hangzhou 310015 - CHINA Tel: +86 571 89 01 91 18 Kiev Air Liquide Global E&C Solutions Ukraine Hangzhou Office 301 Air Liquide Global E&C Solutions Hangzhou Co. Ltd 8A, Ryzka Str. Floor 20~26, Tower 1, DELIXI Building 04112 Kiev - UKRAINE No. 28 Xueyuan Road Tel: +38 044 2255909 West Lake District, Hangzhou 310012 - CHINA Tel: +86 571 2816 6118

Cryogenics 12 Lurgi Table of Contents

STANDARD PLANTS PETROCHEMICALS OLEOCHEMICALS

16 Yango™ – Standard Air Separation Unit 44 Low Pressure (LP) Methanol 74 Sliding Cell Extractor – Seed Crushing and Extraction

17 Sigma – Standard Air Separation Unit 45 Lurgi MegaMethanol™ 75 Natural Oil Refining Vacuum Swing Adsorbtion (VSA) – On-Demand 46 Lurgi MTP™ – Methanol-to-Propylene 18 76 Lurgi Biodiesel Oxygen Generation 47 Butadiene Extraction (BASF NMP Licensed) 77 Fatty Acid Methyl Ester Distillation/Fractionation 19 Nitrogen Generation System 48 Lurgi / Nippon Kayaku Acrylic Acid 78 Glycerin Distillation and Bleaching 20 HYOS™ R – Hydrogen Generation System 49 Methyl Acrylate (Hexion Licensed) 79 Fatty Acid Production (Oil Splitting) CRYOGENICS 50 Ethyl Acrylate (Hexion Licensed) 80 Fatty Acid Distillation/Fractionation 22 Large Air Separation Unit 51 Butyl Acrylate (Hexion Licensed) 81 Fatty Acid Hydrogenation 23 CO Cold Box – Syngas Separation and Purification 52 2-Ethylhexyl Acrylate (Hexion Licensed) 82 Fatty Alcohol – Wax Ester Route 24 Liquid Nitrogen Wash 53 Distapex™ – Aromatics Extractive Distillation 83 Fatty Alcohol – Methyl Ester Route 25 Hydrogen and Argon Recovery 54 G2G™ – Gas-to-Gasoline 84 LP3 – Low Pressure Fatty Alcohol Production 26 Cryocap™ H2 – Cryogenic CO2 Separation NATURAL GAS TREATMENT 85 Bio Propylene Glycol (BASF Licensed) Cryocap™ Oxy – Cryogenic CO2 Separation for 27 56 Nitrogen Rejection Unit Oxycombustion 86 Sorbitol Production 57 Combined Natural Gas Liquids Recovery & NRU 28 Helium Extraction and Liquefaction ENGINEERING SERVICES 58 Amine Wash for Acid Gas Removal HYDROGEN 88 Conceptual and Feasibility Studies 59 Combined Membrane/Amine Wash for Acid Gas Removal 30 Small-Scale Steam Methane Reformer 89 Oil Refineries Optimization/Hydrogen Management 60 Omnisulf™ – Acid Gas Enrichment and Removal 31 Steam Methane Reforming (SMR) – Hydrogen Production 90 Project Execution 61 Cryocap™ for Acid Gas Removal 32 SMR-X™ – Zero Steam Hydrogen Production 91 Oil Refineries Engineering Design SULFUR 33 Pressure Swing Adsorption (PSA) – Hydrogen Purification 92 Customer Services 64 OxyClaus™ Sulfur Recovery Unit SYNGAS 93 Focus on: Engineering for Existing Plants 65 Sulfur Recovery Unit 36 Autothermal Reforming (ATR) – Syngas Generation 66 Claus – Emission-Free Sulfur Recovery Unit 94 Focus on: Customer Training LIST OF ABBREVIATIONS AND ACRONYMS 37 Lurgi MPG™ – Multi-Purpose Gasifier LNG 95

38 Lurgi FBDB™ – Fixed Bed Dry Bottom Coal Gasification 68 Small-scale LNG (Nitrogen Refrigeration Cycle) 39 Rectisol™ – Syngas Purification 69 Mid-scale LNG (Mixed Refrigerant Cycle) 40 Steam Methane Reforming (SMR) – Syngas Production 70 Boil-Off Gas Reliquefaction Unit 41 Gas POX – Natural Gas Partial Oxidation 71 Boil-Off Gas Reliquefaction (LIN)

Cryogenics 13 Lurgi

Standard Plants

Standard Plants

Cryogenics 15 Lurgi ™ Yango – Standard Air Separation Unit Standard Plants

Application Description Nitrogen vent Steel making (basic oxygen furnaces, YangoTM air separation unit is based on HP GAN Booster Air blast furnaces, electric arc furnaces), air compression, adsorption purification, HP GOX Main Air Compressor chemicals (ethylene oxide, ammonia, cryogenic distillation of main Compressor LP GAN etc.) components and internal compression Clean Dry Air of high pressure products. Feedstock Precooling & Air + Energy (electrical or steam) Yango is a standardized, highly Front End Purification packaged ASU solution to support Pumps Product short-time-to-start-up projects. Expander Oxygen from 99.6% to 99.8% purity and Booster up to 50 bar Several process schemes are available to optimize both CAPEX and OPEX LOX To Storage Co-Product depending on customer product Nitrogen, liquid oxygen, liquid nitrogen, requirements, energy cost and custom- LIN To Storage liquid argon, compressed dry air er process integration potential.

Capacity Air Liquide Global E&C Solutions offers optimized solutions in terms 330 to 770 tpd of construction strategy, operating philosophy and reliability.

Economics Specific energy: 400 to 600 kWh/t References >20 Capital intensity: Contact Yango [email protected]

mm USD 0 5 10 15 20 25 30

Sigma

mm USD Cryogenics 0 5 10 15 20 25 30 16 Lurgi

Vzcuum Swing Absorption

mm USD 0 5 10 15 20 25 30

Nitrogen Generation System

mm USD 0 5 10 15 20 25 30

HYOS

mm USD 0 5 10 15 20 25 30

Sigma – Standard Air Separation Unit Standard Plants

Application Description Nitrogen vent Steel making (oxygen boosting, electric Sigma units are based on air HP GAN Booster Air arc furnace), chemicals (ethylene oxide, separation with the following steps: HP GOX Main Air Compressor etc.), glass, non-ferrous metals, waste air compression, adsorption, Compressor LP GAN water treatment, pulp and paper purification, cryogenic distillation Clean Dry Air of main components, internal Feedstock compression. Precooling & Air + Energy (electrical) Front End Purification Several process schemes are available Pumps Product to optimize both CAPEX and OPEX Expander Oxygen up to 99.6% purity depending on customer product Booster requirements.

Co-product LOX To Storage Nitrogen, liquid oxygen, nitrogen The Sigma units are designed to reduce and argon, compressed dry air construction and time to production with LIN To Storage a highly packaged architecture. Capacity Some liquid co-production could be 150 to 350 tpd available to refill backup liquid storages.

Yango

Economics Specific energy: 280 to 460 kWh/t References mm USD 0 5 10 15 20 25 30 >40 Capital intensity: Latest projects: Baku Steel, Klondyke, Klabin, COP Sigma Contact [email protected]

mm USD 0 5 10 15 20 25 30

Vzcuum Swing Absorption

mm USD Cryogenics 0 5 10 15 20 25 30 17 Lurgi

Nitrogen Generation System

mm USD 0 5 10 15 20 25 30

HYOS

mm USD 0 5 10 15 20 25 30

Vacuum Swing Adsorption (VSA) – On-Demand Oxygen Generation Standard Plants

Application Description Air compression Adsorption Oxygen compression Steel making, glass, pulp and paper, VSA uses the process of air separation & Vacuum & Backup generation ➂ waste water treatment, mining by adsorption. The basic principle of air separation by adsorption relies on the ➆ Feedstock use of specific zeolite adsorbents for ➅ Air + Energy (electrical) the selective adsorption of nitrogen over ➀ ➁ Gaseous ➂ oxygen and argon. Oxygen Product Oxygen from 90% to 93% purity Main features are:

• Compact design layout ➇ Co-product • Fully packaged and pre-tested skids ➄ none • Minimized schedule, erection and ➃ start-up times YangoCapacity • Automatic and unattended operation 40 to 150 tpd Capitalization of more than 20 years of ➀ Air Filter ➄ Exhaust operating and maintenance experience. ➁ Air Blower ➅ Oxygen Booster mm USD ➂ Adsorber(s) ➆ Gas buffer 0 5 10 15 20 25 30 ➃ Vacuum Pump ➇ Liquid oxygentank

Sigma

Economics Specific energy: 265 kWh/t References mm USD 0 5 10 15 20 25 30 >100 Capital intensity:

Contact Vzcuum Swing Absorption [email protected]

mm USD 0 5 10 15 20 25 30

Nitrogen Generation System

mm USD Cryogenics 0 5 10 15 20 25 30 18 Lurgi

HYOS

mm USD 0 5 10 15 20 25 30

Nitrogen Generation System Standard Plants

Application Description Residual rich gas Gaseous N2 LIN to LNG terminal, crude oil refinery, This nitrogen generation system (>35% O2) Heat exchanger to Customer backup error electronics is based on air separation with the following steps: air compression, Feedstock adsorption, purification, cryogenic Air + Energy (electrical) distillation of main components. Yango Product Several process schemes are available Nitrogen (gaseous, liquid) with to optimize both CAPEX and OPEX 100 ppm to 1 ppb O2 depending on customer product mm USD requirements. R01 R02 Co-product0 5 10 15 20 25 30 none Some liquid co-production could be available to refill backup liquid storages. D01 Sigma Air Capacity inlet Systems often include backup 500 Nm3/h to 70,000 Nm3/h K01 vaporizers and storages designed as of nitrogen C01 per customer’s requirements mm USD (availability and reliability). 0 5 10 15 20 25 30

These systems are safe, reliable and Vzcuum Swing Absorption easy-to-operate and maintain. Compression Purification Cold Production Heat Exchange Distillation Economics Specific energy: 175 to 280 KWh/t References mm USD 0 5 10 15 20 25 30 >100 Capital intensity:

Latest projects: Gorgon LNG, South Hook LNG, Peru LNG, Moscow Refinery, Toshiba Nitrogen Generation System Contact [email protected]

mm USD 0 5 10 15 20 25 30

HYOS

mm USD Cryogenics 0 5 10 15 20 25 30 19 Lurgi

™ HYOS R – Hydrogen Generation System Standard Plants

Yango Application Description Glass manufacturing, steel making, HYOS™ R plants are skidded, modular Burner Hydrogen Air Feed Product food, chemicals, electronics, hydrogen hydrogen generators, that produce high NG Feed Air energy mm USD purity gaseous hydrogen from natural NG Compressor 0 5 10 15 20 25 30 gas (methane) and water. Compressor

Feedstock Hot NG SigmaNatural gas HYOS™ R uses the Steam Methane Module Preheat Reforming (SMR) process to generate Water Knockout the reformate (mixture of H , CO , Air Product 2 2 Drum Gaseous hydrogen of 99.999% purity water) and the Pressure Swing Preheat mm USD Adsorption (PSA) process to purify Co-product0 5 10 15 20 25 30 the reformate into pure hydrogen. Low Temp Water none PSA Turndown ratio can reach 50%. Gas Shift Vzcuum Swing Absorption Capacity The benefits of HYOS™ R are a small Hydrodesulfurization 270 Nm3/h footprint and low installation cost by skidded design, no steam import Waste Gas Tank mm USD required due to an integrated steam 0 5 10 15 20 25 30 generator.

Nitrogen Economics Generation System HYOS™ R is designed as a stand- Yield: 0.47 (Nm3 Natural gas/Nm3 alone plant which can be operated Hydrogen) unattended.

References mm USD 0 5 10 15 20 25 30 9 Capital intensity: Latest project: Ternium (2011), Sisecam (2012) HYOS Contact [email protected]

mm USD 0 5 10 15 20 25 30

Cryogenics 20 Lurgi Cryogenics

Cryogenics

Cryogenics 21 Lurgi Large Air Separation Unit Cryogenics

Application Description Nitrogen vent Steel making (basic oxygen furnaces, Large air separation units are based HP GAN Booster Air blast furnaces, electric arc furnaces), on adsorption purification, cryogenic HP GOX Main Air Compressor gas monetization (gas-to-methanol, distillation of main components and Compressor LP GAN -propylene, -liquids), coal gasification, internal compression of high pressure Clean Dry Air chemicals (ethylene and propylene products. oxide, etc.), clean power (IGCC, Precooling & oxycombustion) From the small standard of a few Front End Purification hundred tonnes per day to Mega ASU Pumps Feedstock complex (multi train) of more than Expander Air + Energy (electrical or steam) 15,000 tonnes per day, Air Liquide Booster Global E&C Solutions offers optimized solutions in terms of construction Product LOX To Storage Oxygen up to 99.8% purity and 100 bara strategy, operating philosophy and reliability. LIN To Storage Co-product Nitrogen, rare gases (Kr, Xe, He, Ne), liquid oxygen, nitrogen and argon, compressed dry air

Capacity Up to 6,000 tpd

Economics Specific energy: 160 to 500 kWh/t References >4000 Capital intensity: Latest project: Sasol: 5,800 tpd (at sea level) in construction in South Africa

Contact [email protected]

mm USD 0 Several 50 processes100 150 are available200 250 300

to optimize economics depending on product requirements, energy cost and process integration.

mm USD 0 50 100 150 200 250 300 Cryogenics 22 Lurgi

with LNG

mm USD 0 50 100 150 200 250 300

mm USD 0 50 100 150 200 250 300

mm USD 0 50 100 150 200 250 300

CO Cold Box – Syngas Separation and Purification Cryogenics

Application Description Heat Carbon monoxide (CO) production CO cold box process is based on Exchanger from synthesis gas and/or a ratio- cryogenic separation technology using Fuel adjusted synthesis gas stream for use the difference in boiling points of the H2 in chemical industry main components from the synthesis COCH4 Column gas. Feedstock Synthesis gas from natural gas/naphtha Feed gas is pretreated to remove Wash Stripping Column Column or coal/residue gasification impurities which will freeze at cryogenic temperatures encountered in the CH4 Product process. Every cryogenic process Pumps CO up to 99.99% purity is tailor-made to fit the customer’s specifications and other requirements Co-product on co-products. Hydrogen, oxogas, methane, LNG Available CO Cold Box processes: Capacity • “M”: Methane Wash Up to 2,400 tpd • “P”: Partial Condensation CO CO Expander • “C”: Carbon Monoxide Wash Compressor

Economics Specific energy: 18 to 600 kWh/tonne Syngas

mm USD 0 Capital 50 intensity: 100 150 200 250 300 References >40

Latest project in 2015 (Malaysia)

mm USD Contact 0 50 100 150 200 250 300 [email protected]

Economics are highly dependent on the type and quality of feedstock (coal gasificationwith LNG or natural gas), as well as of the required CO pressure (MDI/TDI, PC, AcAc, MEG, etc.).mm USD 0 50 100 150 200 250 300

Cryogenics 23 Lurgi

mm USD 0 50 100 150 200 250 300

mm USD 0 50 100 150 200 250 300

Liquid Nitrogen Wash Cryogenics

Application Description MP GAN Production of synthesis gas for Raw hydrogen and high pressure ammonia plants nitrogen are fed to the liquid nitrogen Synthesis gas Product wash unit. Both streams are cooled 3H2=N2 Feedstock down against product gas. Raw hydrogen (from shift/RectisolTM) LNW Offgas Raw hydrogen is fed to the bottom Product of the nitrogen wash column and Ammonia synthesis gas with a condensed nitrogen liquid is fed to the top. Trace impurities, like methane, stoechiometric N2/H2 ratio of 1:3 argon and carbon monoxide, are Co-product removed and recycled as fuel gas. GN Methane, LNG 2 To establish the desired H2/N2 ratio, Front End Capacity high pressure nitrogen is added to the Purification process stream. Up to 2,200 tpd Feed Synthesis gas

mm USD 0 50 100 150 200 250 300 LIN Economics Utilities: • LIN: 0 to 0.02 tonne/tonne of syngas • Power (if LNG co-production): 900 kWh/tonne (of LNG) References mm USD 17 Capital0 50 intensity: 100 150 200 250 300 Latest project in 2015 (China)

Contact with LNG [email protected]

mm USD 0 50 100 150 200 250 300

mm USD 0 50 100 150 200 250 300 Cryogenics 24 Lurgi

mm USD 0 50 100 150 200 250 300

Hydrogen and Argon Recovery Cryogenics

Application Description N2 expander Recover hydrogen, nitrogen, argon and Water is removed from ammonia plant methane from ammonia plant purge gas purge gas before it enters the cold N2 compressor N2 using the cryogenic process box. The feed is cooled and partially condensed in a two stage exchanger. Fuel Feedstock The hydrogen goes mainly in the vapor gas Ammonia plant purge gas phase while the condensed phase is Distillation columns sent to separation pots and distillation MP H2 HP H2 Product columns. Nitrogen, argon and methane HP Flash pot Liquid argon, H (> 97% recovery) are further separated. Purge gas LIN 2 Purification feed LAR A nitrogen cycle compressor and a Co-product mm USD LNG 0 50 100 150 200 250 300 nitrogen turbine ensure the necessary N , fuel gas, LNG, liquefied nitrogen MP Flash pot 2 cold production and duty for the

Capacity distillation. Up to 50 tpd of argon

mm USD 0 50 100 150 200 250 300

Economics Specificwith LNG energy: 85kW/tonne mm USD References 0 Capital 50 intensity: 100 150 200 250 300 13

Latest project: Shiraz (Iran)

Contact

mm USD [email protected] 0 50 100 150 200 250 300

Hydrogen and argon recovery plants are economically favored when there is a need for recovery argon in remote areas where the price of argon is high. mm USD 0 50 100 150 200 250 300

Cryogenics 25 Lurgi ™ Cryocap H2 – Cryogenic CO2 Separation Cryogenics

H product Application Description 2

CO2 capture from H2 production plants The offgas is compressed, dried and

sent to a cryogenic unit, where the CO2 Feedstock is separated from the other components Offgas from H plant by a combination of partial condensation Natural 2 SMR Shift H2 PSA and distillation. A pure and pressurized Gas

Product CO2 flow is produced from the cold box.

CO2 The non condensed gases are recycled Off gas Co-product through a membrane system to recover Fuel H and CO . Residual gas is sent to the Membranes H 2 2 2 burners of the reformer. Residue to fuel gas Capacity The CO2 product is compressed up to TM From 500 to 2,000 tpd CRYOCAP H2 supercritical pressure or liquefied and stored in liquid storage. Economics Food-grade quality can be achieved by CO Product Cold box OPEX+CAPEX: 45 USD/tonne of CO 2 2 an additional purification on a catalytic bed where all remaining hydrocarbons Increase H production by 13% to 20% 2 and alcohols are destroyed. Cyocap™ H offers the lowest costs 2 Cyocap™ H can be installed for for CO production from H plant 2 2 2 greenfield as well as brownfield H (20%less capex than amines) 2 plants. References France, Port Jérôme, 2015, 100 kt/year food-grade CO2

Contact [email protected]

Cryogenics 26 Lurgi ™ Cryocap Oxy – Cryogenic CO2 Separation for Oxycombustion Cryogenics

Application Description Non condensable to vent CO2 capture from power plants The flue gas issued from the boiler plant is first treated in a pre-treatment unit, Feedstock which aims to cool the gas and remove Oxycombustion flue gas the SOx, HF, HCl, most of the NOx, and the dust. Then the gas is compressed Product and dried before entering the cryogenic Flue Gas purification unit. CO2 Cold Box Low Pressure In the cold box, CO2 is recovered by Co-product Pre-Treatment none combination of partial condensation and distillations, which allow the removal of the heavy compounds such as NOx and Capacity CO Product the light elements such as O , Ar, N , 2 From 1,000 to 15,000 tpd 2 2 NO and CO.

The CO2 product is compressed, condensed and pumped up to supercritical pressure.

Economics

Cyocap™ Oxy allows very high CO2 recovery and near zero-emission to the atmosphere (SOx, particulate matters, NOx, Hg). References Australia, Callide, 2012, 75 tpd Capital intensity: Spain, Ciuden, 2012, 200 tpd (warm) and 10 tpd (cold box)

United States, FutureGen2.0, 2013, 3,200 tpd

Contact mm USD [email protected] 0 50 100 150 200 250 300

He Liq. only incl. He purif.

mm USD 0 50 100 150 200 250 300 Cryogenics 27 Lurgi Helium Extraction and Liquefaction Cryogenics

Application Description Helium Purification Helium Liquefaction

Pure liquid helium production and The impure helium feed gas is purified N2 purge Air loading into ISO containers in a first section, where N2, CH4, H2, HE Cycle CO, Ar, O2, water and CO2 are Compressor Helium Rich Cryogenic H2 Feedstock separated from helium. It is composed Feed Gas Compressor Upgrader Removal PSA Natural gas or impure helium gas of a cryogenic partial condensation unit, extracted as non-condensable a hydrogen removal system and a HE side-product from LNG units or impure Pressure Swing Adsorber (PSA) unit. Liquefier Offgas Dryers helium gas extracted from nitrogen Recycle rejection units Then, the pure gaseous helium is cooled and liquefied via a helium cycle Product and the use of cryogenic expanders with Helium Storage a highly optimized cryogenic exchanger and Loading Helium Liquid helium Storage arrangement. Expanders are based on Liquid Co-product a proprietary technology using static Nitrogen gas bearing, ensuring high reliability Vapor none Gasbag and efficiency. Recycle Loading Capacity Liquid helium is continuously Bays Up to 20 tpd (one train) produced and stored in tanks. The unit Vapor Recovery System is equipped with loading bays to fill ISO containers. All helium vapors from the Economics containers are collected and recycled Pure liquid helium The highly efficient process combined within the unit. with the vapor recovery system allows for a very high helium recovery (> 99%). References

mm USD Qatar, Ras Laffan, 2013, 20 tpd 0 Capital 50 intensity: 100 150 200 250 300 Qatar, Ras Laffan, 2005, 9 tpd

Contact He Liq. only incl. He purif. [email protected]

mm USD 0 50 100 150 200 250 300

Cryogenics 28 Lurgi Hydrogen

Hydrogen

Cryogenics 29 Lurgi Small-Scale Steam Methane Reformer Hydrogen

Application Description Flue Gas HP Steam Highly modularized and standardized The small-scale SMR product is a production of hydrogen hydrogen plant concept including four different plant sizes with pre-defined Process Steam Heat Feedstock equipment, piping arrangement and Recovery Flue Gas Natural gas, refinery offgas modules. Fuel Gas Tail Gas Product A steam ejector can be included to allow Hydrogen a wide range of feed pressures.

For export steam production of high Natural H2 Co-product Co Shift Gas Product Steam quality, the plant can include a process condensate vaporizer. Hydro- Reformer Capacity desulfurization OPEX can be optimized for high and Boiler Feed PSA 10,000 to 40,000 Nm3/h Hydrogen Pre-Treatment low export steam flow rates. Water Recycle Those units are highly modularized Hydrogen and standardized units with compact layout and short project execution time (<15 months FOB).

Economics Feed+fuel-steam: 12.5 to 13.2 MJ/Nm3 References >10 Capital intensity: Latest reference: Huafon H2 Plant in China

Contact [email protected]

mm USD 0 50 100 150 200

mm USD 0 50 100 150 200 Cryogenics 30 Lurgi

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Steam Methane Reforming (SMR) – Hydrogen Production Hydrogen

Application Description Flue Gas HP Steam Production of hydrogen by steam Desulfurized feed gas is mixed with methane reforming of hydrocarbon steam and pre-heated. feed in catalyst filled tubes heated in Process Steam Heat a top-fired furnace Feed and steam are reformed to H , Recovery 2 Flue Gas CO and CO2 in the proprietary top-fired Fuel Gas Feedstock steam reformer at pressures in the Tail Gas Natural gas, refinery offgas, LPG, range of 15-45 barg. naphtha Methane conversion requirements of Natural Pre- downstream steps are adjusted via the Co Shift H2 Product Gas Reformer Product Hydrogen main process parameters, reforming temperature and steam-to-carbon ratio. Hydro- Reformer Co-product desulfurization CO is shifted with steam to hydrogen Pre-Treatment Boiler Feed PSA Steam Water and CO . Hydrogen is separated in 2 a pressure swing adsorption and the Recycle Capacity Hydrogen remaining gas is used as fuel in 40,000 to 200,000 Nm3/h H 2 the reformer.

Economics Feed+fuel-steam: 12.3 to

13.2 MJ/Nm3 H2

Steam production: 0.4 to 1.2 kg/Nm3 H2 References mm USD 130 (all types of SMRs) 0 Capital intensity:50 100 150 200 Latest references: Yanbu K.S.A, Canada, Netherlands and USA

Contact [email protected]

mm USD 0 50 100 150 200

mm USD 0 50 100 150 200 Cryogenics 31 Lurgi

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™ SMR-X – Zero Steam Hydrogen Production Hydrogen

Application Description Flue Gas Production of hydrogen without co- Compared to conventional steam producing steam in a radiative heat reformers, the reformed gas at the exchange steam methane reformer outlet of the catalyst-filled reformer Process Steam Heat (SMR) tubes is cooled by heat exchange with Recovery Flue Gas process gas inside the tubes. Fuel Gas Feedstock Tail Gas Natural gas, naphtha The geometry and material of the internal heat exchange coils is optimized Product for reliability and high efficiency, so the Natural Pre- new generation SMR does not produce Co Shift H2 Hydrogen Gas Reformer export steam like conventional medium Product Co-product to large-sized ones. H2 Hydro- Reformer None desulfurization The plant’s steam system is simplified Pre-Treatment Boiler Feed PSA Water Capacity and fewer reformer tubes are required, because approximately 20% of the Up to 100,000 Nm3/h hydrogen process heat is supplied by internal heat exchange.

mm USD 0 50 100 150 200 Ecology: CO2 emissions are 5% lower than those of a conventional SMR.

Economics

Feed+fuel: 13.8 MJ/Nm3 H2 References mm USD Callisto Plant, Belgium 0 Capital intensity:50 100 150 200 Contact

[email protected]

mm USD 0 50 100 150 200

mm USD 0 50 100 150 200 Cryogenics 32 Lurgi Pressure Swing Adsorption (PSA) – Hydrogen Purification Hydrogen

Application Description PRODUCTION Recovery and purification of pure Pure H2 product is delivered at

hydrogen from different H2-rich streams a pressure close to feed pressure (pressure drop across PSA could be Feedstock as low as 0.5 bar) and impurities are Raw hydrogen from SMR, POX, removed at a lower pressure (typical cryogenic purification, methanol plant PSA offgas pressures range from 1.1 purge gases, ethylene off-gas, styrene to 10 bara). offgas, gasification, ammonia plant, CCR, and other offgases or any The PSA tail-gas, containing impurities, combination of the above. can be sent back to the fuel system (SMR burners or refinery fuel network) Product with or without the need of a tail-gas mm USD compressor. Operation is fully 0 Hydrogen 50 up to 99.9999%100 purity150 200 automatic. Co-product none PSA units use the most advanced adsorbents on the market and patented OFF FEED GAS Capacity high efficiency cycles to provide DRUM maximum recovery and productivity. OFF GAS 5,000 to 200,000 mm Nm3/h USD 0 50 100 150 200 Typical on-stream factors are >99.9%.

Turndown can be as low as 25%.

Economics PSA units are compact, fully skid- H2 recovery rate: 60 to 90% mounted and pre-tested units designed References mm USD for outdoor and unmanned operation. > 70 (in operation or under construction) Capital0 intensity:50 100 150 200 Contact

[email protected]

mm USD 0 50 100 150 200

Cryogenics 33 Lurgi

Syngas

Syngas

Cryogenics 35 Lurgi Autothermal Reforming (ATR) – Syngas Generation Syngas

Application Description Feed Production of syngas by partial Desulfurized feed gas is preheated and oxidation of hydrocarbon feed followed optionally pre-reformed prior to entering by a catalytic reforming conversion in the ATR reactor. The gas is fed via the Desulfurization a single refractory lined reactor proprietary burner into a refractory lined reactor operating at 30 to 100 barg, Feedstock where it reacts with oxygen and steam Natural gas, refinery offgas, pre- to form syngas. The syngas is further Fired Heater Stream reformed gas, Fischer-Tropsch tail-gas, reformed via a Ni-based catalyst bed LPG, Naphtha located in the same reactor. The syngas is cooled in a waste heat boiler Product producing high pressure steam. The Pre-Reforming syngas can then be used as feedstock Syngas (H2+CO) for different synthesis processes such as methanol or Fischer-Tropsch Co-product O2 none synthesis. Syngas components can be ATR also separated to pure products (H2, CO, CO ). Capacity 2 Up to 1,000,000 Nm3/h (dry) Depending on the needed syngas Heat Recovery Syngas properties of the downstream process Economics this technology can be applied as Yield: 2.5- 4.0 Nm3 syngas / Nm3 stand-alone ATR or as a combination natural gas (including fuel for fired of SMR and ATR known as Combined heater) Reforming. References Oxygen consumption: 0.15 - 0.25 kg >30

O2 / Nm3 syngas Recent references: Capital intensity: NatGasoline, USA, 550,000 Nm3/h, start up exp. 2017 YCI, USA, 550,000 Nm3/h, start up exp. 2017

Contact [email protected]

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Cryogenics 36 Lurgi mm USD 0 100 200 300 400 500 600 700

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™ Lurgi MPG – Multi-Purpose Gasifier Syngas

Application Description Residue Value Utilization of all kind of liquid residues The feedstock together with oxygen High BTU from refinery or chemical processes for and steam is fed via the proprietary Low Sulfur Steam LP-Steam Pure CO the production of syngas by non-catalytic MPG-burner into the refractory lined re- 2 Fuel Gas partial oxidation of hydrocarbon feed. actor operating at 30 to 100 barg, where Feedstock it reacts in a non-catalytic partial oxida- Hydrogen MPGTM Raw Gas Gas tion at typically 1,200 to 1500 °C to form RectisolTM PSA Feedstock (Quench) Shift Cooling O Typical feedstocks are high viscous, low syngas. The syngas leaving the bottom 2 H S+CO reactivity, heavy residue from oil refining of the reactor is cooled by quench or in 2 2 a waste heat boiler, depending on feed- Quench Sulfur like: asphalt, bitumen, tar, visbreaker water stock characteristics and downstream TM residue, hydrocracker residue, FCC OxyClaus Claus Off-Gas O residue, vacuum residue, coal tar, oil usage. 2 sand tar, etc. The proprietary MPG-burner design Soot Water ASU Product allows a wide variety of feedstock Filtration properties to be handled safely and Syngas (H2 + CO) reliably, covering high viscosity and Air Filter cake MPG based H Production Co-product even particles up to millimeter size. 2 none The pressurized water cooling of the burner insures safe operation under all Capacity conditions. Up to 200,000 Nm3/h dry syngas per The technology may also be adapted to gasifier the usage of slurries with solid content or bio-based syncrude. Economics References Individual costs vary significantly Pre-1997: 26 gasification plants with 76 reactors build as exclusive sub-licensor for depending on feedstock, size, location, Shell Gasification Process; integration in refinery, etc. 1997: acquisition of commercially proven technology SVZ and enhancements by Lurgi Oxygen consumption: 1 Nm3 O2/kg feed regarding operating pressure and lifetime of burner; mm USD since 2000: 3 gasifications (heavy residue) with MPG-technology 0 Capital100 intensity:200 300 400 500 600 700

Latest reference: 130,000 Nm3/h H2 from hydro-cracked residue/vacuum residue from oil sand upgrading in Canada; start up expected 2016

Contact [email protected] mm USD 0 100 200 300 400 500 600 700

Cryogenics 37 Lurgi

mm USD 0 100 200 300 400 500 600 700

mm USD 0 100 200 300 400 500 600 700

mm USD 0 100 200 300 400 500 600 700

™ Lurgi FBDB – Fixed Bed Dry Bottom Coal Gasification Syngas

Application Description Sulphur ASU Coal gasification process for the Coal is converted into syngas by Recovery Unit Elemental Sulphur

production of syngas reacting with oxygen and steam. The GOX FBDB raw syngas will be further processed CO2 Rich Gas Feedstock (CO-shift, RectisolTM) to meet the DRI Coal Gas Low-rank (high ash, high water) coals downstream requirements of the FBDBTM (CO Shift) & Syngas Purification Ammonia Gasification Gas Cooling processes. Internal streams (e.g. (RectisolTM) SNG Product gas-liquor etc.) will be further treated HP Steam Liquid Fuels using proprietary technologies Syngas (H +CO) particularly suited for Rectisol Naphtha 2 TM the production of SNG (synthetic natural (Phenosolvan , CLL) to reduce the Ash gas) or DRI (direct reduction of iron ore) environmental impact of the gasification process. Gas Liquor Phenosolvan® Co-Product Separation CLLTM ZLD / Water reuse TM Crude tar acids (phenols), sulfur, tar, oil, The key differentiator of this technology GLS Process WW Treatment naphtha, ammonia is its suitability for low-rank coals which Liquid Ammonia cannot be processed economically by Phenols Capacity entrained flow gasification. 40,000 to 120,000 Nm3/h dry syngas Tar / Oil Notes: per gasifier, typically more than Lurgi FBDBTM is a trademark of Sasol 5 reactors per plant, largest plant Lurgi Technology Company (Pty) Ltd 40 reactors at one site CLL process is also known as Chemie Linz Lurgi process. Economics mm USD 0 Individual 100 costs200 300 depend 400 strongly 500 on600 700 location, coal quality, etc. References > 100 gasifiers Yield: 2000 Nm3 dry syngas / ton dry coal Largest plant: Sasol, RSA, 3.3 mmNm3/h (2 x 40 gasifiers, start up 1977 / 1982) Most recent plant: JSPL Coal gasification island for DRI in India (225,000 Nm3/h, Capital intensity (costmm base: USD 7 Mk+ 6+1 Mk IV gasifiers), start up 2014 in0 China)100 200 300 400 500 600 700

Contact [email protected]

mm USD 0 100 200 300 400 500 600 700

Cryogenics 38 Lurgi

mm USD 0 100 200 300 400 500 600 700

mm USD 0 100 200 300 400 500 600 700

™ Rectisol – Syngas Purification Syngas

Application Description Lurgi Rectisol® - The “5 in 1” Solution: Feedstock Gasification 1 Trace contaminant removal Removal of acid gases (CO2, H2S, COS, Acid gases contained in raw gases are 2 Deep Desulfurization (total S < 80 ppb) mercaptans, NH3, HCN) and nearly all removed by absorption with a physi- 3 Bulk CO2 removal (up to 100%)

trace components from syngas typically cal solvent (cold methanol). The rich 4 CO2 purification (total S < 5 ppmv) produced by gasification of coal, solvent leaving the contactor is regener- COS Dry CO2 Capture Ready (> 98.5 vol%) Hydrolysys 5 Acid Gas Enrichment (S > 25 vol%) petcoke, residue or heavy oil ated by flashing and stripping. Different process configurations are available to Feedstock deliver a tailored solution optimised for Trace CAPEX and OPEX for a given syngas Removal Raw syngas deriving from gasification Acid gas suitable for of all carbon containing feedstocks specification. sulfur recovery processes RectisolTM is the leading process when it Product Sulfur Acid Gas H2S Sulfur comes to the purification of gasification- Removal Enrichment CO2 Recovery Clean/high purity syngas (H2+CO) mm USD based syngas for catalytic applications, 0 100 200 300 400 500 600 700 such as: SNG, methanol, ammonia and Syngas suitable for Co-product catalytic synthesis Fischer-Tropsch. CO CO CO CO2, H2S rich gas for SRU processes 2 2 CO 2 Removal Treatment 2 Compressor Using inexpensive solvent in CO2 suitable for Capacity compression, synthesis combination with optimized heat integra- 100,000 to 1,000,000 Nm3/h per train or venting tion, the Rectisol process has extremely mm USD 0 100 200 300 400 500 600 700 low operating costs and high availability. Economics Individual costs vary significantly depending on feedstock, size, purity request, etc. References

mm USD >110 (> 35 since 2005) 0 Capital 100 intensity:200 300 400 500 600 700 Largest reference: SNCG CTL project (4.2 mmNm3/h, 4 trains), start up expected 2016.

Contact [email protected]

mm USD 0 100 200 300 400 500 600 700

mm USD 0 100 200 300 400 500 600 700 Cryogenics 39 Lurgi

Steam Methane Reforming (SMR) – Syngas Production Syngas

Application Description Flue Gas HP Steam Production of carbon monoxide, Feed gas is desulfurized, mixed with

CO+H2 and syngas by steam methane steam and pre-heated. reforming of hydrocarbon feed in Process Steam catalyst filled tubes heated in a top-fired Feed and steam are reformed to H , Heat 2 Recovery furnace. CO and CO2 in the proprietary top-fired Flue Gas Fuel Gas mm USD steam reformer at pressures in the 0 Feedstock(s) 100 200 300 400 500 600 700 range of 15 - 45 barg. Tail Gas Natural gas Methane conversion requirements of Product(s) downstream conversion steps are adjusted via the main process Natural Carbon monoxide, oxogas, syngas Pre- Syngas (H2+CO) parameters, reforming temperature and Gas Reformer mm USD steam to carbon ratio. Syngas 0 100 200 300 400 500 600 700 Reformer Cooling Co-product Hydro- H2 desulfurization Steam, hydrogen Carbon dioxide can be recycled and/or Boiler Feed imported to save natural gas feed. Pre-Treatment Water Capacity Up to 40,000 Nm3/h carbon monoxide Up to 350,000 Nm3/hmm USD syngas, dry 0 100 200 300 400 500 600 700

Economics Feed+Fuel: 45.6 MJ/Nm3 CO Feed+Fuel+CO2: 19.3 MJ/Nm3 CO References

mm USD 130 (all types of SMRs) 0 Capital 100 intensity:200 300 400 500 600 700 Recent contracts:

2x H2+CO plant in Germany (Air Liquide and BASF) start-up in 2014 and 2015 3x Syngas plants for methanol in the US CO plant in the Netherlands

mm USD Contact 0 100 200 300 400 500 600 700 [email protected]

Cryogenics 40 Lurgi Gas POX – Natural Gas Partial Oxidation Syngas

Application Description Feedstock Production of CO, oxogas and syngas Feed gas is desulfurized, mixed with by partial oxidation of hydrocarbon feed steam and preheated in a fired heater. in a refractory lined reactor HP Steam Fired Heater / Feed, steam and oxygen are fed from HDS CO Feedstock the proprietary burner to a refrac- 2 Natural gas, refinery offgas tory lined reactor operating at 40 to

100 barg, where H2, CO and CO2 are PSA / produced via partial oxidation. Gas WHR / Gas Amine Product WHB CO Coldbox O POX Cooling Wash CO, syngas (H2+CO) 2 Membrane Product Reformed gas is cooled down producing high pressure steam. CO is removed Co-product 2 none from the syngas in an amine wash unit.

The required product ratio (H +CO) can Capacity 2 be adjusted by a membrane, PSA or CO Up to 150,000 Nm3/h syngas, dry coldbox. Waste ASU Waster

Air

Economics Feed+fuel: 1.1 Nm3 NG/Nm3 CO References 4 Capital intensity: Latest: Freiberg (2004), Confidential customer (Germany, 2013)

Contact [email protected]

mm USD 0 100 200 300 400 500 600 700

Cryogenics 41 Lurgi

Petrochemicals

Petrochemicals

Cryogenics 43 Lurgi Low Pressure (LP) Methanol Petrochemicals

Application Description Cooler Saturated Medium-scale production In the LP methanol unit (either with Steam Separator Steam Drum (< 1 million tpa) of methanol from integrated gas generation based on Interchanger BFW synthesis gas derived from all kinds of natural gas or downstream of a coal carbonaceous material (mainly natural gasification unit) syngas is converted 83 bar gas and coal) over a copper catalyst in water-cooled HP Steam reactor to produce raw methanol. Feedstock Recycles Gas Unconverted synthesis gas is recycled Compressor Natural gas or synthesis gas (H2+CO) back to the synthesis loop to enhance Synthesis Gas Product Final Compressor Product yield and carbon efficiency. Separator Cooler Synthesis Gas Methanol Methanol in the required specification 20 bar Reactor Raw methanol leaving the synthesis (AA, IMPCA, etc.) LP Steam loop is further distilled to meet the re- Sea Water Co-product quired specification. Purge Gas none Crude Methanol Blow Down

Capacity Note: scheme represents only the methanol synthesis unit Up to 3,500 tpd

Economics With combined reforming: Yield: Natural gas consumption: 29 MMBTU (LHV)/tonne References (this includes the energy for the oxygen 45 in operation production: 0.4-0.5 tonne oxygen/tonne) Key reference: Hainan Methanol (China), 2,000 tpd Capital intensity: Contact [email protected]

mm USD 0 500 1 000 1 500 2 000

Cryogenics mm USD 44 Lurgi 0 500 1 000 1 500 2 000

mm USD 0 500 1 000 1 500 2 000

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™ Lurgi MegaMethanol Petrochemicals

Application Description Gas Cooled Water Cooled Large scale production (> 1 million tpa) In the Lurgi MegaMethanolTM unit (either Reactor Reactor of methanol from synthesis gas derived with integrated gas generation based HP Steam from all kinds of carbonaceous material on natural gas or down-stream of a coal (mainly natural gas and coal) gasification unit) syngas is converted over a copper catalyst in a two-stage Feedstock reactor system (water-cooled followed Make Up Gas by gas-cooled) to produce raw Natural gas or synthesis gas (H2+CO) methanol. Unconverted synthesis gas Product is recycled back to the synthesis loop to Methanol in the required specification enhance yield and carbon efficiency. (AA, IMPCA, etc.) Raw methanol leaving the synthesis Co-product loop is further distilled to meet the re- none quired specification.

Capacity Due to high energy integration of the unit and the low recycle ratio in the 2,500 to 7,000 tpd synthesis loop, Lurgi MegaMethanolTM 10,000 tpd (GigaMethanol) Purge Crude Boiler Feed yields the lowest production cost. Gas Methanol Water Economics Our most recent design (GigaMethanol) With combined reforming: Note: scheme represents only the methanol synthesis unit can produce up to 10,000 tpd in one Yield: single train. 29 MMBTU (LHV)/tonne (this includes the energy for the oxygen References production: 0.4-0.5 tonne oxygen/tonne) 7 in operation (4 gas based, 3 coal based), 4 in construction (2 gas based, 2 coal based). mm USD 0 Capital intensity:500 1 000 1 500 2 000 Largest reference: 11,000 tonnes per day in two trains (coal based, under construction).

Contact [email protected]

mm USD 0 500 1 000 1 500 2 000

mm USD Cryogenics 0 500 1 000 1 500 2 000 45 Lurgi

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™ Lurgi MTP – Methanol-to-Propylene Petrochemicals

Application Description Fuel Gas The on-purpose production of In a first step, methanol is converted MTP Reactors Internal Use 2 Operating Ethylene propylene from methanol is a way to into dimethyl-ether (DME) which is, 1 Regeneration 60 t/d produce propylene independently from together with recycled hydrocarbon Propylene crude oil and/or natural gas liquids. streams, the feedstock for the fixed- Product 1410 t/d Hence it supports the utilization of land- bed MTP reactor filled with proprietary Conditioning DME Product locked coal or natural gas reserves as zeolite catalyst. The effluent from the Pre-Reactor Fractionation feedstock for petrochemical processes. MTP reactor is cooled and enters a separation sequence similar to the one Feedstock applied in steam-crackers. During this Methanol sequence, the effluent is separated into different hydrocarbon streams which are LPG 109 t/d Product partially recycled to the reactor in order Polymer-grade propylene to maximise the propylene yield. The last step of the separation sequence Co-product is the production of polymer-grade Gasoline and LPG propylene. Water Recycle Capacity Compared to crude-based processes Olefin Recycle (naphta cracking, metathesis, PDH) the Gasoline 500 to 1,500 tpd MTP process has the lowest cash cost. 540 t/d Process Water Economics Yield: 3.5 tonnes methanol/tonne propylene References 3 references in operation (all coal based), first natural gas based plant in engineering Capital intensity: stage.

Contact [email protected]

mm USD 0 500 1 000 1 500 2 000

mm USD 0 500 1 000 1 500 2 000 Cryogenics 46 Lurgi

mm USD 0 500 1 000 1 500 2 000

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Butadiene Extraction (BASF NMP Licensed) Petrochemicals

Application Description C3/C4 - HC Recovery of 1,3 butadiene from a In the pre-distillation tower methyl Rafinate crude C4 stream from olefins plants by acetylene, propadiene and other light C4 - Acetylene extractive distillation components are removed from the raw Water C4 cut feedstock which then enters Feedstock the bottom section of the main washer NMP Crude C4 column while NMP solvent enters at the NMP top. C4 raffinate consisting of butanes Product and butenes is drawn off as overhead Butadiene 1,3 butadiene product. The loaded solvent is sent to the C4 - HC rectifier. The divided wall arrangement Co-product in the upper part allows it to strip less none soluble butenes in the first compartment mm USD which are fed back to the main washer 0 500 1 000 1 500 2 000 Capacity and to separate C4 acetylenes in the second compartment. The solvent from 6 to 35 t/h the rectifier is sent to the degassing tower where hydrocarbons are removed. The solvent is the recycled to the rectifier C3/C4 - HC via compression. NMP to Heat mm USD Recovery 0 Economics 500 1 000 1 500 2 000 Predistillation Extractive Distil- Degasing BD Utility consumption (per tonne The side stream of the degassing tower lation Distillation butadiene) containing diluted C4 acetylenes is fed Steam 1.7 t/t into a scrubber to recover NMP solvent. Electricity 150 kWh/t After further dilution with raffinate Water, cooling 150 m3/t or other suitable materials, the References mm USD C4 acetylene stream is discharged to 36 units in operation 0 Capital intensity:500 1 000 1 500 2 000 battery limits for further processing. The

crude butadiene withdrawn as overhead Contact product from the rectifier is sent to the [email protected] butadiene column for final purification. The butadiene product is withdrawn as liquid side product. mm USD 0 100 200 300 400 500 Ecology: NMP biodegrades readily and has low toxicity to aquatic life. Compared to other technologies, this process is much more eco-friendly.

mm USD 0 100 200 300 400 500 Cryogenics 47 Lurgi Lurgi / Nippon Kayaku Acrylic Acid Petrochemicals

Application Quench: The AA is recovered from the The combined Lurgi/Nipponmm USD Kayaku reactor product gas in a quench tower. 0 500 1 000 1 500 2 000 technology produces ester-grade acrylic The AA solution is routed to an extractor. Solvent Crude AA acid (EAA). Main uses are adhesives, Uncondensed gases are sent to an Extraction Recovery paints and coatings (acrylic esters). offgas treater to recover the remaining Separation AA. A side draw from the offgas is sent Offgas Feedstock to incineration. Overhead gas is recycled Recycle to the first reactor. Propylene mm USD Propylene Offgas to 0 500 1 000 1 500 2 000 Solvent extraction: Liquid-liquid Air incinerator Rafinate Stripping Product extraction is used to separate water and Steam

Ester-grade acrylic acid AA. The solvent is recovered and recycled.In a first step, water and acetic Quench/ Offgas Treater Co-product acid are removed to achieve a crude AA Reaction none to be further purified in the next process mm USD steps. The extractor bottom is sent to the 0 500 1 000 1 500 2 000 Capacity raffinate stripper to recover remaining AA EAA Purification Product Up to 20 t/h (single train) solvents. Crude AA recovery: In this section, Economics solvent and acetic acid are removed Organic Utility costs: 7.7 USD/tonne from crude AA using two columns. Waste Wastewater mm USD Raffinate stripping: The raffinate stripper 0 Capital 100 intensity: 200 300 400 500 recovers solvents from the wastewater streams. The Lurgi/Nippon Kayaku technology References combines high performance catalysts One plant with a capacity of 140,000 tpa of EAA is operated in China; startup took place with highest acrylic acid yields and in 2012. mm USD outstanding catalyst longevity with an 0 100 200 300 400 500 optimized process. With low raw materi- Contact Description al and energy consumption, low [email protected] Reaction: Acrylic acid is produced by environmental impact and high onstream catalyzed oxidation of propylene time, this technology exhibits competi- in a two-stage tubular fixed-bed reactor tive production costs. system. The reactors are cooled by Acrylic acid purification: Crude AA is circulating molten heat transfer salt. purified in the Ester grade AA column. The heat of reaction is used to produce To maximize AA recovery dimer could be steam. converted to AA in a dedimerizer.

Cryogenics 48 Lurgi Methyl Acrylate (Hexion Licensed) Petrochemicals

Application Further purification of the crude meth- Production of methylacrylate (MA) by ylacrylate takes place in the alcohol the esterification reaction of acrylic acid extractor and the light ends with methanol. The methylacrylate is column where process water and used mainly for adhesives, paints and methanol as well as other light ends Extraction Distillation coatings. are removed. The final product column separates high boiling components to Feedstock be routed to the AA regeneration Fractionation Acrylic acid, methanol section and the purified MA product can be send to storage. MeOH Product Methylacrylate In the AA regeneration section acrylic AA acid is recovered to be recycled to the Co-product reactor. The high boiling components none are routed to the decomposer where they could partly be converted back to AA Regeneration methanol, methylacrylate and acrylic Decomposition Capacity Methylacrylate acid to be recycled. Remaining Up to 4 t/h unconverted components are Heavy Ends MeOH Waste Water discharged to battery limit for further Regeneration Economics treatment. Process configuration is optimized resulting in low raw material The bottom product of the alcohol consumption, optimized energy extractor is routed to the methanol integration and low utility requirements. regeneration section to recover Environmental impact minimized. methanol to be recycled to the reactor. References On stream times exceeding 8,000 hours The water is partly reused in the One plant with 12,000 tpa operated by Hexion in Czech Republic per year could be achieved. process as well as routed to battery limit for further treatment. Contact Description [email protected] The reaction is catalyzed in a fixed bed Methylacrylate is prone to reactor by means of a strong acid solid polymerization. In order to minimize catalyst (ion-exchange resin). polymerization effects, an inhibitor injection system is foreseen at critical The reactor effluents are routed to the locations in the plant. fractionation section to separate unre- acted acrylic acid from crude methy- lacrylate, process water and methanol.

Cryogenics 49 Lurgi Ethyl Acrylate (Hexion Licensed) Petrochemicals

Application ethanol. Further purification of the crude Production of ethylacrylate (EA) by ethylacrylate takes place in the alcohol the esterification reaction of acrylic acid extractor and in the light ends column with ethanol. The ethylacrylate is used where process water and ethanol as mainly for adhesives, paints and well as other light ends are removed. Extraction Distillation coatings. The final product column separates high boiling components to be routed to the Feedstock AA regeneration section and the purified Fractionation Acrylic acid, ethanol EA product can be sent to storage. EtOH Product In the AA regeneration section the Ethylacrylate acrylic acid is recovered and recycled AA to the reactor. The high boiling Co-product components are routed to the none decomposer where they are partly converted back to ethanol, ethylacrylate AA Regeneration and acrylic acid to be recycled. Capacity Ethylacrylates Remaining unconverted components Up to 4 t/h are discharged to battery limit for further Heavy Ends EtOH Waste Water treatment. Economics Regeneration Process configuration is optimized The bottom product of the alcohol ex- resulting in low raw material tractor is routed to the EtOH consumption, optimized energy regeneration section to recover ethanol integration and low utility requirements. to be recycled to the reactor. The water Environmental impact minimized. On is partly reused in the process as well as References stream times exceeding 8,000 hours routed to battery limit for further treat- One plant with 11,000 tpa operated by Hexion in Czech Republic per year could be achieved. ment. Contact Description Ethylacrylate is prone to polymerization. [email protected] The reaction is catalyzed in a fixed bed In order to minimize polymerization reactor by means of a strong acid solid effects, an inhibitor injection system is catalyst (ion-exchange resin). foreseen at critical locations in the plant.

The reactor effluents are routed to the fractionation section to separate unre- acted acrylic acid from crude ethylac- rylate, process water and

Cryogenics 50 Lurgi Butyl Acrylate (Hexion Licensed) Petrochemicals

Application reactor system are separated in the Production of butylacrylate (BA) by dehydration columns. The organic the esterification reaction of acrylic acid phase (mainly butanol and AA) is Waste Water (AA) with butanol. The butylacrylate is recycled. The liquid crude BA and used mainly for adhesives, paints and the catalyst are routed to the catalyst NaOH Solution coatings. extraction column where the catalyst is extracted by means of process water Feedstock and is recycled to the reactors. Acrylic acid, butanol Residual acrylic acid in the crude BA is neutralized in the neutralization column by means of a caustic soda solution. Product Purification Butyl Butylacrylate Section Acrylate In the purification section light ends Distillation Co-product are removed from the crude BA and none recycled back to the reactor system. BuOH In a second step high boiling Waste Water components are separated and the final AA Capacity Catalyst Acrylic Acid pure BA product is generated to be sent Recovery Neutralization Up to 20 t/h Extraction to storage. The high boiling components Decom- Organic are transferred to the decomposer position Waste Economics where they could partly be converted Process configuration is optimized back to mainly BA to be recycled to the Catalyst Reaction resulting in low raw material reactor section. Remaining unconverted consumption, optimized energy components are discharged to battery integration and low utility requirements. limit for further treatment. Environmental impact minimized. References On stream times exceeding 8,000 hours Butylacrylate is prone to polymerization. One plant with 16,500 tpa operated by Hexion in Czech Republic per year can be achieved. In order to minimize polymerization effects, an inhibitor injection system is Contact Description foreseen at critical locations in the plant. [email protected] The reaction is catalyzed by means of para-toluene sulphuric acid (PTSA). A four stage reactor system ensures the conversion. The process water generated by the reaction is continuously removed from the reactor system. Process water, unconverted butanol and acrylic acid leaving the

Cryogenics 51 Lurgi 2-Ethylhexyl Acrylate (Hexion Licensed) Petrochemicals

Application effluent which contains the reacted Catalyst Production of 2-ethylhexylacrylate 2EHA, non reacted 2EHOH and PTSA Regeneration (2EHA) by the esterification reaction is routed to the extraction section Distillation of acrylic acid with 2-ethylhexanol where the PTSA catalyst is extracted by 2EHOH (2EHOH). The 2EHA produced is means of process water and recycled used mainly for adhesives, paints and to the Catalyst Regeneration Column. coatings. Additional 2EHOH is introduced via this column into the process and the Feedstock extraction water is separated. The Acrylic acid, 2-ethylhexanol recovered PTSA catalyst and the preheated 2EHOH is routed to the first reactor. Product 2Ethyl-hexyl 2-ethylhexylacrylate Purification Acrylate Coalescence In the Coalescer Section water is Section Co-product removed from the extracted crude Reaction none 2EHA. The following Purification Extraction Section separates unreacted alcohol AA which is recycled to the Reaction Capacity Catalyst Waste Water Section. Furthermore, high boiling Up to 5 t/h components are removed and the final Organic Waste pure 2EHA product is generated to be Décom- position Economics sent to storage. The high boilers are Process configuration is optimized discharged to the Heavy End resulting in low raw material Decomposer where they are partly Tuolene consumption, optimized energy converted back to 2EHA and EHOH integration and low utility requirements. and recycled to the reactor section. Environmental impact minimized. Remaining unconverted components On stream times exceeding 8,000 hours are discharged to battery limit for further per year could be achieved. treatment. References Description 2EHA is prone to polymerization. One plant with 26,500 tpa operated by Hexion in Czech Republic The reaction is catalyzed by means In order to minimize polymerization of para-toluene sulphuric acid (PTSA). A effects, an inhibitor injection system is Contact three stage reactor system ensures the foreseen at critical locations in the plant. [email protected] conversion. The process water generat- ed by the reaction is removed continu- ously by an azeotropic distillation step with a carrier agent. The reactor

Cryogenics 52 Lurgi ™ Distapex – Aromatics Extractive Distillation Petrochemicals

Application Description Recovery of aromatics from a heart-cut The aromatics in the feedstock are feedstock by extractive distillation separated by extractive distillation CW

using N-methylpyrrolidone (NMP) as a Combinate Rafinate Feedstock solvent. The raffinate product containing Rafinate and Pyrolysis gasoline the non-aromatics leave the extractive ED-Culumn distillation column via the top. The Product loaded solvent is routed to a stripper CW CW Benzene column where the final aromatic product Benzene is recovered at the column top and Solvent Co-product routed to battery limit. The lean solvent Stripper is recycled to the extractive distillation none Aromatics column. Cut Capacity Ecology: Due to the unique properties Up to 40 t/h HP Steam HP Steam of NMP, the process has an excellent ecological footprint.

Economics The DistapexTM process requires Recovery rate: > 99.5% a minimum number of equipment items Rich Solvent Utility costs: 8.8 USD/tonne and is especially renowned for reliability Utilities (per tonne benzene) and availability as well as low operating Lean Solvent Steam, tonne 0.7 costs. Due to the low boiling point of the Electricity, kWh 8 solvent only medium-pressure steam is Water, cooling, m3 19 required. Solvent loss, kg 0.01 References > 27 Capital intensity: Contact [email protected]

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™ G2G – Gas-to-Gasoline Petrochemicals

Application Description Lurgi MegaMethanol™ and ExxonMobil G2G™ technology presents an Natural Gas Syngas Lurgi MTG ~ 16.100bpd Plant Methanol Plant MTG technologies licensed in an opportunity to monetize low cost 160 MMSCFD Gasoline integrated approach to monetize low feedstock into transportation fuels either cost feedstock, usually natural gas or for domestic use or for export markets. 5.000 mtpd Methanol coal, to high value oil products. Projects are driven by the spread Air Liquide Lurgi Technologies Air Liquide can also leverage its global between the price of feedstock and oil ASU network of ASUs and syngas facilities products. Low cost gas or stranded Exxon Mobil Technologies to provide synergistic solutions for gas can enhance profitability even at G2G™ projects. low-moderate oil price scenarios. The gasoline product from G2G™ is low in Feedstock benzene and has no sulfur compounds. Natural gas (NG), coal, heavy Product can be used as on-spec hydrocarbons, biomass gasoline that meets or exceeds any typical (stringent) environmental Product standards or as a refinery blending Sulfur free gasoline/petrol stock.

Co-product Profitability is driven by low feedstock LPG (optional) prices relative to market value of wholesale oil products. References Capacity Lurgi Methanol is well referenced with more than 50 units in service. 1,000 to 32,000 bpd Standardized design: 16,100 bpd ExxonMobil Zealand MTG plant operated from 1985 until 1997 with a high on-stream factor, plus new units underway in China. Economics Yield: 9,100 scf natural gas/barrel Contact Opex: 8.5 USD/barrel [email protected]

mm USD 0 Capital 100 intensity: 200 300 400 500

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Cryogenics 54 Lurgi

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Natural Gas Treatment

Natural Gas Treatment

Cryogenics 55 Lurgi Nitrogen Rejection Unit Natural Gas Treatment

Application Description Removal of nitrogen from natural gas, Natural gas feed is partially condensed, associated gases and unconventional then methane and nitrogen are gas sources separated into a system of distillation column(s). Depending on the feed Low Nitrogen Feedstock composition and pressure, the system Presure Natural gas with high nitrogen content can include one to three distillation columns. Product Natural gas, nitrogen The process scheme selection is done Methane according to project-specific parameters Co-product such as such as feed evolution with LNG, liquid nitrogen, crude helium time and and product specifications.

Capacity Air Liquide Global E&C Solutions offers a wide range of solutions, such as the Natural Gas Up to 1,000,000 Nm3/h High ability to treat any N2/CH4 mixtures Presure (5-90%), high efficiency, flexibility and Economics recovery (>99% methane), minimization Economics are highy dependent on of greenhouse gases emissions to the feedstock and requirements (high atmosphere (methane in N2 vent efficiency or low CAPEX). << 1%), CAPEX optimization, operation

flexibility thanks to proprietary design. Contact us for more information.

References Nitrogen Rejection from syngas: QIANXI COAL CHEMICAL (China), BASF ANTWERP (Belgium), YIMA CSU (China)

Nitrogen Rejection from natural gas: FEED major gas processing plant (Russia), Bayern Gas (Germany)

Contact [email protected]

Cryogenics 56 Lurgi Combined Natural Gas Liquids Recovery & NRU Natural Gas Treatment

Application Description Nitrogen NGL recovery associated with the Air Liquide Global E&C Solutions removal of nitrogen from natural gas, offers state-of-the art NGL technology Methane associated gases and unconventional with high efficiency C2 recovery gas sources (90% to >98%) and low energy consumption. NRU Cold Box Feedstock Natural gas with NGL Combined with Air Liquide’s know-how in nitrogen rejection and expertise in Product cryogenics, Air Liquide solutions differentiate through thermal integration NGL (C2+), natural gas and synergies to provide overall Co-product optimised NGL/ NRU plants. LNG, liquid nitrogen, crude helium

Feed Capacity Up to 1,000,000 Nm3/h Natural Gas Economics Liquids High NGL recovery with sales gas on specifications easily achieved with significant reduction in capital and operating costs when compared to conventional independent units. References Economics are highy dependent FEED major gas processing plant (Russia), many references of NGL separation on feedstock and requirements (high (NGL plants, Lurgi MTPTM columns) and nitrogen rejection (syngas and natural gas efficiency or low CAPEX). references)

Contact us for more information. Contact [email protected]

Cryogenics 57 Lurgi Amine Wash for Acid Gas Removal Natural Gas Treatment

Application Description Acid Gas ® Removal of acid gases (CO , H2S, Acid gases contained in raw gases are Clean Gas (to DMR) Absorption HP-Flash Regeneration (to LTGT ) 2 Flash Gas COS, light mercaptans RSH) from removed by absorption with a chemical (to CLS) natural gas, associated gases and or a mixture of chemical and physical unconventional gas sources solvent. The rich solvent leaving the contactor is regenerated by flashing. Feedstock Demin Natural gas with low acid gases content Different process configurations can be Water (typically <15%) combined to various solvent types and concentrations to meet requirements Product for individual applications. Air Liquide Natural gas Global E&C Solutions can offer very energy-efficient processes such as Co-product the BASF OASE purple, formulated Acid gases for pipeline or LNG specifications.

Capacity This process presents the advantage of very low hydrocarbon co-absorption. Up to 1,500,000 Nm3/h Feed Gas Economics Economics are highy dependent on feedstock and requirements (high efficiency or low CAPEX).

Contact us for more information. References > 50 (Implemented with BASF OASE purple, MEA, DEA, MDEA solvents)

Largest reference: QATARGAS LNG phases 2, 3 and 4 with each 1,500 MMSCFD –

Removal of CO2, COS and H2S from natural gas feedstock.

Contact [email protected]

Cryogenics 58 Lurgi Combined Membrane/Amine Wash for Acid Gas Removal Natural Gas Treatment

Application Description Acid Gases Acid Gases

Removal of CO2 and H2S from medium Acid gases contained in raw gases are acid gas fields removed in a 2-step separation:

Feedstock 1) CO bulk removal by CO -selective 2 2 Raw Gas Sweet Gas Natural gas with medium acid gas hollow fiber membrane (MEDALTM) Pretreatment Membrane Amine Wash content (typically 15-35%) reducing the CO2 content at the amine inlet to such content that the overall Product plant sizing exhibits optimum Natural gas economics.

2) CO and sulfur species are Co-product 2 Acid gases removed by absorption with an aqueous solution of amine. The rich amine Capacity solution leaving the contactor is regenerated by flashing or stripping. Up to 1,500,000 Nm3/h

Economics Economics are highy dependent on feedstock and requirements (high efficiency or low CAPEX).

Contact us for more information.

References > 10 in operation

Contact [email protected]

Cryogenics 59 Lurgi ™ Omnisulf – Acid Gas Enrichment and Removal Natural Gas Treatment

Application Description Liquid Tail Gas Offgas Sulfur S SO CO CO , H S CO SO , CO Sweetening and processing of natural The OmnisulfTM technology Aquisulf STU x Claus SRU 2 2 LTGT/HYDR 2 2 LTGT/ABS 2 Incineration 2 2 SRU SRU SRU gas by removing CO2, H2S, COS, encompasses the following proprietary mercaptans, water and mercury to key processes: pipeline or LNG specifications as well as production of liquid, elemental sulfur Acidic components are removed using ® H2S Lean Solution while minimizing SO2 emissions to the BASF’s OASE technology and the LTGT/REG atmosphere to meet most stringent cleaned gas is routed to a dehydration SRU Semi-Lean Solution environmental regulations and mercaptan removal unit (DMR) H2S that removes moisture and mercaptans Offgas Rich Solution CO H S Feedstock with special 13X zeolite technology. If 2 2 necessary, mercury is removed from the Raw natural gas, associated gas LTGT/AGE sweet gas with impregnated activated SRU

Product carbon. Mercaptans are recovered from CO2 PURISOL Fuel Gas the regeneration gas with the Lurgi H2S Natural gas, sulphur (99.9% purity) RSH MSRU PurisolTM technology. All gas streams containing sulfur are routed to a sulfur RSH, H O Co-product Raw Gas 2 recovery unit (SRU). Elemental sulfur CO , H S None 2 2 BASF is produced in the Claus process COS, RSH Chiller H2O+RSH Sweet Gas OASE DMR DMR Capacity (equipped with a Lurgi Multi-Purpose AGR Burner) followed by a Lurgi tail gas Up to 1,500,000 Nm3/h treatment (LTGTTM) unit combined Regeneration Gas with an acid gas enrichment system to Economics boost sulfur recovery and reduce SO Economics are highy dependent 2 emissions. The sulfur product is then on feedstock and requirements (high treated further by applying an AquisulfTM References efficiency or low CAPEX). Qatargas LNG phases 2, 3 and 4 are running with the OmnisulfTM process. Two trains degassing process that removes H2S concentrations below 10 ppm. are under construction in the Middle-East Contact us for more information Offgases are incinerated before being safely released to the atmosphere. Contact [email protected] The OmnisulfTM technology can be tailored for gas reinjection.

Cryogenics 60 Lurgi ™ Cryocap NG for Acid Gas Removal Natural Gas Treatment

Application Description NG to Pipeline

Removal of CO2 from natural gas, The CO2 rich natural gas is first dried associated gases and unconventional and sent to a cold box where it is cooled gas sources down and sent to a distillation column. Membrane Cold Box

Feedstock High CO2 partial pressure favors the CO partial condensation and thus Natural Gas with high CO2 content 2 CO to EOR (> 35%) makes its separation from natural gas 2 even easier. The non-condensable gas Product is enriched in methane and sent to a Natural Gas membrane for final purification. Raw NG

The CO purity of the product Co-product 2 Acid Gases corresponds to pipeline specifications, Simple Pre-treatment generally 1 to 10 mol%. The permeate Capacity stream of the membrane enriched in CO is sent back to the cold box. The Up to 1,000,000 Nm3/h 2 CO2 and heavy hydrocarbons condense in the cold box and are collected at high Economics pressure. NGL recovery is possible with Separation cost: less than almost no additional cost. 1 USD/MMBTU

Cryocap™ NG is tolerant to a few % Capex savings: > 50% vs. amine wash H2S. Cryocap NG also allows for H2S bulk removal fom NG. Contact us for more information.

References Cryocap™ H2 Port Jérôme, Cryocap™ Oxy CIUDEN, Cryocap™ Oxy Callide, FutureGen 2.0 Cryocap™ Oxy FEED

Contact [email protected]

Cryogenics 61 Lurgi

Sulfur

Sulfur

Cryogenics 63 Lurgi ™ OxyClaus Sulfur Recovery Unit Sulfur

Application Description SWS Gas Recovery of sulfur from acid gas In a conventional Claus plant ambient Acid Gas Claus Tail Gas streams containing hydrogen sulfide air is used to oxidise 1/3 of the Oxygen

(H2S) for new units or debottlenecking hydrogen sulfide (H2S) in the acid gases of existing units to sulfur dioxide (SO2). Up to 80% of the total oxygen demand can be covered TM Thermal Catalytic Catalytic Feedstock with pure oxygen in the OxyClaus unit Stage Stage I Stage II Acid gas from sweetening units and by using a proprietary burner design. sour-water strippers; oxygen Oxygen is injected into the acid gas resulting in an extremely hot flame. Product By introducing air around the outside Bright yellow sulfur with up to of this flame a zone with moderate 99.9% purity combustion temperatures are created and therefore conventional refractory Sulfur Co-product materials can be used in the thermal None stage.

Capacity In downstream catalytic stages of the Claus unit, including reactors, Up to 1,000 tpd condensers and heaters, no specialized equipment or changes in usual design Economics practice are required. OxyClausTM provides savings of approximately 30% of the total installed The unit can be operated with air only cost of a new sulfur recovery unit and or with air + oxygen. This allows for enables increased capacity of existing covering peak loads and flexible sulfur recovery units up to 200%. processing of feed gases with low or high content of H2S by automatic Contact us for more information. change-over from air to oxygen operation and vice versa.

References > 40 in operation

Contact [email protected]

Cryogenics 64 Lurgi Sulfur Recovery Unit Sulfur

Application Description Acid Gas Recovery of sulfur from acid gas The acid gases are burnt SWS Gas Flue Gas streams containing hydrogen sulfide sub-stoichiometrically with air in a Claus Tail Gas Offgas (H2S) refractory lined furnace. Resulting

mixture of H2S and SO2 reacts to form Feedstock elemental sulfur which is removed from Acid gases from sweetening units and the process through condensation. sour-water strippers In subsequent catalytic stages, typically TGT two or three, the conversion to sulfur is Claus (LTGTTM or SulfreenTM) Incineration Product promoted further yielding a sulfur Bright yellow sulfur with up to recovery of 94.5% – 97.5% for the 99.9% purity Claus unit. Offgas Co-product Two tail gas treatment (TGT) options None are available to boost the sulfur recovery further. Sulfur Degassing (Aquisulf or Degasulf) Capacity 1) SulfreenTM: A catalytic purification Up to 1,000 tpd of the Claus tail gas for an overall sulfur recovery of up to 99.5%. Economics Sulfur recovery: >95% 2) LTGTTM: Claus tail gas is purified Sulfur in a wet-scrubbing process. Due to the Operating costs can be considered recycling of the H2S rich stream to the negligible if credit is given for steam Claus unit, total sulfur recovery can be produced in SRU. increased to 99.9%. References > 170 Claus plants (4 to 1,000 tpd) Capital intensity: In the degassing section, the H2S content of the sulfur is decreased to > 60 tail gas treatment processes a maximum of 10 ppm. For this the catalytically promoted AquisulfTM > 50 AquisulfTM in operation technology (registered trademark of Elf Aquitaine) or the DegasulfTM technology mm USD can be employed. Offgas from tail gas Contact 0 50 100 150 200 250 treatment and degassing is incinerated [email protected]

and released to the atmosphere.

Cryogenics 65 Lurgi Claus – Emission-Free Sulfur Recovery Unit Sulfur

Application Description Recovery of sulfur from acid gas Raw gas is desulfurized in an AGR AGR streams containing hydrogen sulfide and acid gas is sent to the emission-free Raw Gas (PurisolTM or RectisolTM) Purified Gas (H2S) with 100% sulfur recovery SRU for sulfur recovery. The conventional Claus process is employed Feedstock to recover sulfur from the acid gas Acid gases from acid gas removal unit in elemental form. Gases containing Acid Gas Tail Gas Recycle and sour-water strippers hydrogen sulfide (H2S) from sour- water strippers can be fed to the Claus Claus Tail Gas Tail Gas Product unit in addition. The recovered sulfur Bright yellow sulfur with up to is degassed and is then available as a sellable product. 99.9% purity Hydrogenation Tail Gas Claus / OxyClausTM Quench Compression Co-product Claus tail gas is hydrogenated None and cooled before being compressed and routed to the AGR. Here it is Capacity desulfurized and recycled, together with the acid gas, back to the Claus unit. Up to 1,000 tpd Valuable components inside the tail gas, like H and CO end up in the purified Economics 2 Degassing Sulfur gas. With this recycle a sulfur recovery CAPEX: 25% less than conventional rate of 100% is achieved. The sulfur amine-wash tail gas treatment emissions to the atmosphere in overall complex are significantly reduced. Sulfur recovery: 100% It is recommended to install an References Contact us for more information. OxyClausTM in this concept because Three emission-free SRUs have been designed, one has been in operation for this reduces the process gas volume 25 years. and therefore lowers not only investment cost plus operating cost Contact but also the amount of inert gas sent [email protected] to AGR.

Cryogenics 66 Lurgi LNG

LNG

Cryogenics 67 Lurgi Small-scale LNG (Nitrogen Refrigeration Cycle) LNG

Application Description N2 Recycle Liquefaction of natural gas (NG) for The process consists of three main Compressor small scale plants serving for power modules: pre-treatment, liquefaction and N2 Turbo applications (peak shaving, remote LNG storage and loading (truck trailer, Expanders (x2) power) or fuel (marine, truck, rail, etc.) bunkering barge, etc.). Pretreatment Feedstock 1) Pre-treatment is a combination of Natural gas an amine system to remove acid gases

(typically CO2) contained in the feed gas Product and a drying unit to remove moisture Natural Gas LNG (typically Thermal Swing Adsorption). from pipeline LNG or field Storage Co-product 2) The liquefaction process is based on a nitrogen cycle (closed loop): N is first None 2 Main Heat Exchanger compressed and boosted. After being Capacity cooled down through a Brazed Aluminum Heat Exchanger, it is Up to 600 tpd Heavies (NGL) expanded releasing N2 at low pressure

and low temperature. Cold N2 (at T < –165oC) is then re-injected into the Main Heat Exchanger to cool down the natural gas and convert it to LNG,

which is sent to storage. Warm N2 is then recycled through the cycle Economics compressor. References Capital intensity: 3) Storage can be either pre-fabricated 15 peakshavers in operation (Canada, United States and Argentina). (vacuum insulated) for small volumes or Examples: Citizens Gas (United States), Gas Natural Fenosa (Argentina) flat bottom tanks for larger needs depending on the applications 90 nitrogen cycle liquefiers (for LIN or LNG) considered. The loading station can be adapted to truck trailer loading or Contact mm USD maritime. [email protected] 0 50 100 150 200 250

mm USD 0 50 100 150 200 250 Cryogenics 68 Lurgi

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Mid-scale LNG (Mixed Refrigerant Cycle) LNG

Application 1) NG pre-treatment is a combination of Liquid Separators Mixed Liquefaction of natural gas for mid-scale an amine system to remove acid gases Refrigerant plants serving for larger power or fuel (typically CO2) contained in the feed gas Compressor applications, possibly mid-sized LNG and a drying unit to remove moisture export terminal (typically Temperature Swing Main Heat Exchanger Adsorption). Feedstock Natural gas 2) The liquefaction process is a mixed refrigerant closed loop cycle Product consisting of a mixture of hydrocarbons LNG, NGLs and nitrogen. The refrigerant is compressed and separated in liquid and LNG gaseous streams. Lightest fractions of Co-product Storage the refrigerant are sent to the cold end None Natural Gas of the main heat exchanger, cooled from pipeline down and sent back to the compressors or field Capacity after being vaporized through the main 600 to 6,000 tpd Pretreatment HX. Heaviest fractions are let down and vaporized at an intermediate level in the Heavies (NGL) Economics main HX. The optimization of the mixed mm USD refrigerant cycle consists of taking Capital0 50 intensity: 100 150 200 250 advantage of the vaporization

temperature difference between generated refrigerant streams to optimize the NG liquefaction heat exchange profile. In addition, the heavy References hydrocarbons removed from the One 0.7 mtpa in design mm USD process can be recovered and sold as 0 50 100 150 200 250 15 peakshavers in operation (Canada, United States and Argentina). NGL. Examples: Citizens Gas (United States), Gas Natural Fenosa (Argentina) 3) Storage for mid scale LNG plants are usually large flat bottom tanks, Contact Description though tank farms composed of vacuum [email protected] The process consists of three main insulated tanks can also be a solution bricks: NG pre-treatment,mm USD NG 0 50 100 150 200 250 in some cases. The loading station can liquefaction, LNG storage and loading be adapted to truck trailer loading or (truck trailer, bunkering barge, etc.). maritime.

mm USD Cryogenics 0 50 100 150 200 250 69 Lurgi

Boil-Off Gas Reliquefaction Unit LNG

Application Description N2 make-up Recovery of Boil-Off Gas (BOG) for A BOG reliquefaction unit allows for

import & export terminals and during the recovery of boil-off gas emitted TO ATMOS

ship-to-ship transfer from LNG storage and its reliquefaction. C21

C21CE Feedstock The system is based on a nitrogen Boil-off gas + energy (electrical or fuel) reverse Brayton cycle with one or two Natural Gas + gaseous N2 make-up expanders scheme, depending on BOG available pressure. Product ET20CE LNG It allows for avoiding BOG flaring and debottlenecking of LNG export E20 terminals. Co-product ET20 None ET20C Capacity 50 to 500 tpd

mm USD 0 50 100 150 200 250

E21 V21 Economics Specific energy: 500 to 800 kWh/tonne LNG mm USD 0 Capital 50 intensity: 100 150 200 250

mm USD References 0 50 100 150 200 250 For bunkering applications (embarked on board)

Contact [email protected]

mm USD 0 50 100 150 200 250 Cryogenics 70 Lurgi Boil-Off Gas Reliquefaction (LIN) LNG

Application Description Recovery of boil-off gas (BOG) for LIN to LNG box unit allows for the GAN LIN import and export terminals and during recovery of large boil-off gas emitted Storage ship-to-ship transfer during ship loading or unloading GNG operations. Feedstock Boil-off gas + liquid nitrogen Liquid nitrogen is delivered and stored Natural Gas Purification continuously in a liquid nitrogen storage,

Product which delivers large liquid nitrogen flow LIN-LNG Heat Ex. LNG LNG to recover BOG flow emitted during the Storage few hours of ship loading or unloading. Co-product None It allows for avoiding BOG flaring and mm USD reduces the investment cost compared 0 50 100 150 200 250 with BOG reliquefaction solution. Capacity

50 to 500 tpd

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Economics LIN consumption: 1.3 to 1.5 mol/mol References mm USD >20 Capital0 50 intensity: 100 150 200 250 Contact

[email protected]

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Cryogenics 71 Lurgi

Oleochemicals

Oleochemicals

Cryogenics 73 Lurgi Sliding Cell Extractor – Seed Crushing and Extraction Oleochemicals

Application Description Cake/Flakes from Production of crude edible oils The oil content of different types of prepressing/preparation seeds ranges between 20-50 wt.%. Feedstock After feedstock specific preparation steps (cleaning, drying, etc.) the oil Cake Oil seeds (soybean, canola/ rapeseed, Extraction DTDC Meal sunflower, palm kernel...) is gained from the seeds by solvent extraction with hexane. For seeds Product with higher oil content (e.g. rapeseed, Gums Crude edible oils for use in food or sunflower) the extraction is typically (Lecithin) Miscella technical applications after refining combined with a prepressing step to reduce the load on the extraction. Miscella Oil Water Meal for animal feed Crude Oil Distillation Degumming The Lurgi sliding cell extractor is the

Co-product Solvent Recycle Crude lecithin core of the extraction plant. It provides high flexibility regarding feedstock Solvent Capacity changes, very reliable operation and optimum extraction conditions with Up to 5,000 tpd Solvent Absorption / Air Stripping complete counter-current flow of solvent Recovery Vent vs. flakes and large contact areas.

The miscella (oil/solvent mixture) Condensate from extraction is separated into its recovery components by distillation and water (Zero Waste option) Economics degumming. The solvent is re-used Economics are highly dependent in the extraction after removing the on the type of feedstock and required collected moisture. Gums can be References meal quality. purified to lecithin or recycled to the > 300 plants in China, Southeast Asia, Americas, Europe for different feedstocks meal. Capital intensity: Contact The desolventized, toasted, dried and [email protected] cooled (DTDC) meal can be used as protein rich animal feed.

The whole process is kept under slight vacuum so that emissions can be controlled by absorption to fulfill 0 50 100 150 200 250 mm USD environmental regulations.

Cryogenics 74 Lurgi

0 5 10 15 20 25 mm USD

0 5 10 15 20 25 mm USD Natural Oil Refining Oleochemicals

Typical Oil Refinery Application Description H – Multi Feedstock 2 Removal of impurities from crude oils Crude oils and fats contain different Produc- and fats contaminants like free fatty acids (FFA), tion phospholipids (gums), soaps, color, odor, etc. Their removal is called Hydro- Feedstock genation Crude oils and animal fats “Refining” for food purposes to reach Soybean oil, Soybean oil, crude degummed / RBD oil quality (refined, bleached, bleached Product deodorised) and “Pretreatment” to reach Pretreated and/or refined oils and fats quality for further processing, Degum- Bleach- Winteri- ming ing sation Tanks for e.g. for biodiesel production or oil hydrogenated (RBD oil) Sunflower Sunflower oil, oils Weigh- Deo- splitting. oil, crude degummed / doris- bleached ing Co-product ing Fatty acid distillate (FAD) Technologies are available for all appli- Tocopherol cations: FFA can be removed chemi- Margarine Plant cally by neutralisation or thermally by Rapeseed Rapeseed oil, degummed / Inter- deacidification. Waxes are separated oil, crude bleached Capacity esterifi- in winterisation. Color and polycyclic cation 100 tpd to 2,800 tpd aromatic hydrocarbons (PAHs) are removed in bleaching; odors and Economics Fish oil, pesticides during deodorisation (with degummed / Packing bleached Economics are highly dependent on Tanks for vitamin E as potential by-product). interesterified application of the refined oil (technical oils applications or edible oil), the required Refining also includes process steps process steps (e.g. degumming, for fat modification like hydrogenation Palm oil, Palm oil, bleaching, winterisation, deodorisation, crude degummed / (saturation of double bonds), bleached hydrogenation, fractionation and interesterification (to adjust the interesterification) and the type of melting point) or fractionation process (batch, semi-batch or (separation according to chain length) continuous). and side processes like soapstock splitting or gum drying. References > 400 plants in Southeast Asia, China, Americas and Europe based on different feedstocks

Latest reference in 2015

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Cryogenics 75 Lurgi Lurgi Biodiesel Oleochemicals

Application Description Oils and Fats Production of biodiesel Biodiesel is produced from triglycerides (Fatty Acid Methyl Ester, FAME) by transesterification with methanol under presence of an alkali catalyst Feedstock (sodium methylate) at ~65°C and Oil Refining Vegetable or animal oils and fats; major atmospheric pressure. NaOH feedstock for fuel applications are rapeseed, soya, tallow or palm oil Key features of Lurgi`s biodiesel technology are maximum yield Methanol Product (1 kg feedstock = 1 kg biodiesel), closed Glycerin Water Catalyst Biodiesel meeting all international quali- wash water loop (no waste water from Transesterification Pretreatment and ty standards, incl. EN 14214 and ASTM core process units) and sediment Evaporation D6751 removal for palm and soya oil to remove sterol glucosides far below limits given Co-Product by international quality standards. Crude glycerin (purity > 80%) Crude Glycerin Concentration >80% Only NaOH and HCl are used in the HCI Washing and Drying Capacity process. Resulting sodium chloride Sediment Removal ends up in the glycerin, can easily be Standard capacities 100 - 1100 tpd removed and does not cause fouling or side reactions during further processing (see glycerin distillation). Biodiesel Economics “ready-to-use”

Capital intensity: References > 50 plants since 2000 (Europe, Americas, Southeast Asia, India) 0 50 100 150 200 250 mm USD Contact [email protected]

0 5 10 15 20 25 mm USD

Cryogenics 76 Lurgi 0 5 10 15 20 25 mm USD Fatty Acid Methyl Ester Distillation/Fractionation Oleochemicals

Application Description Vacuum Quality improvement of biodiesel FAME is separated according to and/or production of fatty acid methyl molecular chain lengths to apply specific ester (FAME) fractions and metathised cuts in a fractionation column. A falling Steam FAME for chemical industry film evaporator and vacuum pressure Water reduce heat stress to FAME resulting Feedstock in superior product quality suitable for FAME from transesterification surfactant or personal care applications. (see Lurgi Biodiesel process) Distilled FAME can also be sold as Product top-quality water-clear biodiesel with improved cold flow properties and FAME fractions and/or distilled biodiesel Fraction 1 50-100 ppm residual water. Sterol Co-product glucosides and monoglycerides are None removed close to detection limits.

Capacity Heat recovery by steam generation Fraction 2 makes this process very energy 100 tpd to 1,000 tpd efficient. Economics Opex: 30-50 USD/tonne (feedstock)

(depending on number of fractions and their related purities) Fatty acid methyl ester

Residue

References > 10 plants since 2000 (Southeast Asia) with capacities up to 1,000 tpd.

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Cryogenics 77 Lurgi Glycerin Distillation and Bleaching Oleochemicals

Application Description Vacuum Purification of glycerin to pharma Vacuum distillation is used to separate and technical grade glycerin from organic components and Vacuum salts at temperatures up to 175°C. The Cold Feedstock residue from the column bottom is sent Condenser Cooler Crude glycerin from biodiesel or oil to a post distillation still (not shown) splitting (fatty acid) plants to increase glycerin yield. Salt can be separated from the residue by a Hot Cooler Product decanter to reduce the amount of waste Condenser Pharma grade glycerin (purity > 99.7%) and to increase glycerin recovery even Technical further. Grade Glycerin Co-product Technical grade glycerin Pharma grade glycerin as the main (purity 85-90%) product is polished by bleaching, i.e. Dryer / Distillation adsorption at fixed beds of activated Degasser Still Heat Exchanger Capacity carbon. Light impurities end up in the by-product, technical grade glycerin, 10 tpd to 600 tpd which is 3-5% of the feed. Cooler Economics Opex: 35 USD/tonne Heater Residue Crude Pharma Glycerin Grade Glycerin to bleaching

References 45 plants since 2000 (Europe, Southeast Asia, Americas, China, India) including World’s largest glycerin distillation (600 tpd with decanter technology, startup 2010)

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Cryogenics 78 Lurgi Fatty Acid Production (Oil Splitting) Oleochemicals

Application Description Splitting Tower Production of crude fatty acids Triglycerides are hydrolyzed catalyst-free to fatty acids and glycerin Feedstock by addition of water at elevated temper- Preconcentration Process Seed oils, tropical oils, animal fats atures (~250°C) and elevated pressure Vacuum water Flashing (~55 bar) with splitting degrees up to Product 99.5%. Crude fatty acids The fatty acids rise to the top of Co-product the splitting column and are dried by Glycerin water flashing before further processing (25-35% glycerin content) by distillation/fractionation or hydrogenation. 260°C Capacity Water and glycerin leave the column Fat 100 tpd to 1,000 tpd at the bottom and are also flashed. The flashing vapors are used for heat Economics recovery. Water Opex: 10 USD/tonne (feedstock) Glycerin Water Steam Treatment & Final concentration of crude glycerin is Evaporation 80-88% (almost salt-free), which can be sold or further processed to pharma grade glycerin.

Crude Fatty acid

Fat

Crude Glycerin concentration 80-88%

References > 25 plants since 2000 (Europe, Southeast Asia, China, India)

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Cryogenics 79 Lurgi Fatty Acid Distillation/Fractionation Oleochemicals

Application Description Vacuum Vacuum Water Steam Vacuum Purification and fractionation of crude Fatty acids are separated from non-vol- fatty acids atile components by vacuum distillation.

Feedstock Fractions of different fatty acid chain Dryer Degasser Crude fatty acids from oil splitting lengths with high purity can be obtained Low Boiling with our vacuum fractionation plants. components Product Distillation Still Fatty acids fractions/fatty acid distillate The use of structured packing and vacuum in the fractionation columns Fractionation Column Co-product reduces the thermal stress and ensures None high product qualities. Steam generation in the condensers makes the process Capacity highly energy efficient. 100 tpd to 1,000 tpd Each fatty acid fractionation plant will be tailor-made by our experts to ensure Economics best fit to the needs of our customers. Opex: 30-50 USD/tonne(feedstock) (depending on number of fractions and Residue Heavy Ends their related purities) Distillate Crude Fatty Acid

References > 50 plants (Europe, Southeast Asia, China, India, Saudi Arabia) with capacities up to 600 tpd.

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Cryogenics 80 Lurgi Fatty Acid Hydrogenation Oleochemicals

Application Batch hydrogenation Continous hydrogenation Saturation of fatty acid double bonds (hardening) Vacuum

Feedstock Catalyst Fatty acids from oil splitting Vacuum Hydrogenation Reactor H2 Product Partially or fully hydrogenated fatty Dryer acids down to an iodine value of 0.3 Degasser

Co-product Hydrogenation None Reactor

Capacity Batch: 50 tpd to 100 tpd Surge Vessel Continuous: 100 tpd to 600 tpd

Economics Catalyst Opex: Filter • Batch: 11 USD/tonne (feedstock) • Continuous: 10 USD/tonne Filter Press (feedstock) (depending on number of fractions and Heating and Cooling Circuit their related purities) Spent Catalyst Fatty Acid Description Spent Catalyst Saturation of fatty acid double bonds by Hydrogen Fatty Acid Hydrogenated addition of H (~ 99.9% by vol.) under Fatty Acid 2 Hydrogenated elevated temperatures and pressure (up Fatty Acid to 200°C @ ~25 bar) in the presence of a Ni catalyst. References Continuous (for full hydrogenation and 10 plants since 2000 in Southeast Asia up to 400 tpd large plants) and batch process variants (for full or partial hydrogenation) are Contact available. [email protected]

Cryogenics 81 Lurgi Fatty Alcohol – Wax Ester Route Oleochemicals

Application Description Oils & Fats Production of fatty alcohols via fatty Fatty acid fractions (see oil splitting and acids fatty acid fractionation) are esterified Glycerin Distillation & catalyst-free with fatty alcohol into wax Oil Splitting Pharma grade Bleaching Feedstock ester. Subsequent hydrogenation glycerin Depending on the desired product all produces fatty alcohol in a fixed bed kinds of vegetable oils and fats can be reactor in the presence of a Cu catalyst Fatty Acid Distillation / Fatty Acid Fractions used. Biggest market is C12/14 from (180-210 °C @ 250 bar). Traces of Fractionation (possible by-product) palm kernel and coconut oil. oxygenates are hydrogenated in a polishing section (carbonyl conversion). Fatty Acid Fatty Alcohol Product The resulting fatty alcohol cuts can Recycle Esterification Water Fatty acids (intermediate product) and further be fractionated into final fatty fatty alcohols as fractions of different alcohol products. Wax Ester chain lengths The wax ester route is normally chosen Fixed Bed Hydrogen Co-product if there is no integration required with a Hydrogenation Glycerin methyl ester plant because short chain fatty acids have a higher market price than the corresponding fatty alcohols Fatty Alcohol Distilla- Capacity tion / Fractionation & which would be produced via the methyl 90 tpd to 600 tpd Carbonyl Conversion ester route.

Economics Fatty Alcohols Opex: 120 USD/tonne

References 6 plants since 1990s up to 480 tpd (India, Indonesia, China, and Saudi Arabia) latest plant under construction

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Cryogenics 82 Lurgi Fatty Alcohol – Methyl Ester Route Oleochemicals

Application Description Oils & Fats Production of fatty alcohols from oils and After production of methyl ester (see fats via methyl ester (Lurgi Biodiesel) Lurgi Biodiesel), the resulting esters are hydrogenated in a fixed bed reactor Deacidification Fatty Acid Distillate Feedstock in the presence of a Cu catalyst Depending on the desired product all (180-210 °C @ 250 bar) to produce fatty Make-up alcohol. Methanol can be recycled to Methanol kinds of vegetable oils and fats can be Glycerin Distillation & Transesterification Pharma grade used. the transesterification step. Bleaching glycerin Product Traces of oxygenates are hydrogenated in a carbonyl conversion section as Methyl ester (intermediate product) and Methyl Ester Methyl Ester Fractions fatty alcohols as fractions of different polishing. Distillation /Fractionation (possible by-product) chain lengths The methyl ester route is preferred, Methyl Ester if a methyl ester plant exists at site or Co-product Fixed Bed Methanol Recovery Hydrogen Glycerin methyl ester will be a side product of the Hydrogenation facility. Capacity Fatty Alcohol Distillation 90 tpd to 600 tpd / Fractionation & Carbonyl Conversion Economics Opex: 115 USD/tonne Fatty Alcohols

References 2 plants (Indonesia), last plant 2015 (540 tpd)

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Cryogenics 83 Lurgi LP3 – Low Pressure Fatty Alcohol Production Oleochemicals

Application Description Wax Ester Feed Makeup & Recycle Hydrogen Improved hydrogenation process Hydrogenation of wax ester is improved for Fatty Alcohol - Wax Ester Route with LP3 features: Reactor A Reactor B Feedstock Liquid Phase: Proven liquid phase Wax ester hydrogenation in fixed bed reactors also suitable for long chain fatty alcohols in Catalyst Catalyst Products contrast to vapor phase hydrogenation. bed 1 bed 3 Fatty alcohol Low Pressure: Comparatively low Co-product pressure (reduced from 250 bar to None 100 bar) reduces energy requirements (OPEX savings approx. 5%) and Catalyst Catalyst bed 2 bed 4 Capacity CAPEX (savings approx. 15-20%). 90 tpd to 600 tpd Long Performance: Double reactor system for seamless catalyst Economics changeovers with no disruption to Opex: 100 USD/tonne operations and efficient catalyst Crude Fatty Alcohol utilization for more profitable lifecycles Contact us for more information. (see operation steps in diagram). Quench Hydrogen The temperature in the catalyst beds is controlled by hydrogen quenches Sequence of reactor operation to limit amount of side-products.

A B A B A B A B Step 1

Step 1: Step 2: Step 3: Step 4: Sequential operation Catalyst change A Sequential operation Operation A A-B Operation B B-A Catalyst change B

References Proven in laboratory scale, under implementation in commercial scale.

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Cryogenics 84 Lurgi Bio Propylene Glycol (BASF Licensed) Oleochemicals

Application Description Pharma Grade Production of bio propylene glycol In this process, licensed from BASF, Glycerin (1,2-propanediol, MPG) from glycerin glycerin is hydrogenated in liquid phase as alternative to petrochemical route using a copper catalyst. The reaction takes place in two serial fixed bed Feedstock reactors at a temperature between Pharma grade glycerin 175 to 195 °C and pressures between Hydrogen Hydrogenation 75 and 200 bar. Product Pharma grade propylene glycol The crude product is purified in a two-column distillation unit to yield pharma grade propylene glycol. Low Boiling Co-product (e.g. Methanol, Water) None Distillation High Boiling Capacity (e.g. Ethylene glycol, Glycerin) 50 to 100 tpd

Economics Contact us for more information Pharma Grade Propylene Glycol

References One pilot plant (Germany), one commercial demonstration plant (Belgium, 2012).

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Cryogenics 85 Lurgi Sorbitol Oleochemicals

Application Description Hydrogen Sorbitol is produced by batchwise The glucose solution is hydrogenated hydrogenation of aqueous glucose in a batch reactor using nickel or solution. ruthenium catalysts. Reaction takes place at 110 °C and 40 bar pressure. Glucose Hydrogenation Feedstock After reaction, the product slurry is 50% Sorbitol Slurry Reactor(s) Glucose from wet milling plants filtered to recover the catalyst. Makeup catalyst compensates catalyst loss and Product deactivation. The crude sorbitol solution Technical, food or pharma grade is purified by ion exchange and evapo- Makeup Waste rated to the final concentration. Option- Catalyst Recycle Catalyst Catalyst sorbitol Pressure ally, sorbitol powder can be Filter Co-product obtained by melt crystallisation. None

Ion Crude Sorbitol Capacity Exchange 100 to 200 tpd

Sorbitol 0 50 100 150 200 250 Purified Sorbitol Evaporator mm USD 70%

Economics OPEX: 130-165 USD/tonne w/o feedstock and fixed cost. References Capital intensity: > 10 plants (Germany, Finland, Thailand, India) 0 5 10 15 20 25 mm USD Latest project 2015 (Russia)

Contact [email protected]

0 5 10 15 20 25 mm USD

Cryogenics 86 Lurgi Services

ieei eices

Cryogenics 87 Lurgi Conceptual and Feasibility Studies Services

Description Our team of experts can assist owners in early phases of project development. Studies are customized to meet the Customer’s needs. Our typical packages are: • Screening/Pre-feasibility study comprising first CAPEX/OPEX estimates • Feasibility study for more detailed economic analysis: – class 4 or 5 cost estimate – mass and utility balance – BFD – footprint • Permitting study: This package is designed to provide the technical information required to apply for an air permit (title V and PSD) early on. It typically comprises: – process description – BFD – mass balance – emissions – fugitive emissions – start-up and shut-down scenarios.

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Cryogenics 88 Lurgi Oil Refineries Optimization/Hydrogen Management Services

Description H2 Producers Liquefied petroleum gas (LPG) Profitability enhancement services are the backbone of hydrogen optimization and Propane ➃ ➄ LPG Light naphta Butane management solutions. SPLITTER LIGHT NAPHTA 12 MBPD HYDROTREATING IZOMERI- Our customized, proprietary PIMS simulation software (“LP Modelling”) offers H2 Heavy naphta 30 MBPD ZATION Consumer Kerosene 29 MBPD industry-leading hydrogen optimization studies. UDE Propane

C R ➂ ATM ➇ LPG Butane CRUDE Light gasoil SPLITTER A typical study comprises the following steps: DIST. HEAVY NAPHTA CATALYTIC 8 MBPD SAHARA Heavy gasoil HYDROTREATING REFORMING G 95 MBPD 48 MBPD 20 MBPD A • Refinery audit ➆ S CRUDE O ATMOSPHERIC ➁ CATALYTIC L • Global Refinery Balance CRUDE Kerosene REFORMING I DISTILLATION 32 MBPD N KEROSENE 170 MBPD E - Include all hydrogen producers and consumers HYDROTREATING 40 MBPD - Close balance Light POLYMERIZATION gasoil 13 MBPD LPG • Unit balance D ➅ I Light Cat Naphta GASOLINE S - Calibrate make-up and recycle gas rates to have accurate gas/oil ratios Heavy CATALYTIC CRACKING DESULFURI- T gasoil Heavy Cat Naphta 65 MBPD ZATION I - Calculate hydrogen partial pressure Light 46 MBPD L gasoil➀ L - Calibrate instruments as required A T VACUUM Heavy gasoil DISTILLATE E DISTILLATION HYDROTREATING 48 MBPD 70 MBPD

Bunker

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Cryogenics 89 Lurgi Project Execution

Description Our team of experts can assist owners in early phases of project implementation.

The most popular packages are: • Process Design Package (PDP) • Modularization study and project execution strategy • Preliminary engineering (FEED) • Detailed engineering • Procurement services • Construction management • Assistance to commissioning and start-up

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Cryogenics 90 Lurgi Oil Refineries Engineering Design Services

Description Air Liquide utilizes its 25 years of experience in engineering design and refining technologies to provide refinery services such as: • Technology evaluation and licensor selection • Conceptual/feasibility studies • Basic engineering on the basis of third party PDP documentation • Front-end engineering design (FEED) • Detail engineering for revamps of existing units or for new refinery units • Procurement services • Construction Management • Assistance to commissioning and start-up

We have experience in designing the following units: • Crude Distillation Unit (CDU) • Vacuum Distillation Unit (VDU) • Hydrotreatment/ Desulfurization • Hydrocracking • Isomerization • SRU • Hydrogen plant

We have more than 170 references and experience working with many technology licensors, such as: Axens, UOP, Uhde, Criterion, BASF, ExxonMobil, Chevron...

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Cryogenics 91 Lurgi Customer Services Services

Air Liquide Global E&C Solutions’ Services make our customers’ businesses more reliable, competitive and cost-efficient, wherever they are in the world.

Traditionally, Air Liquide Global E&C Solutions offers support and long-term services to the Air Liquide Group. Today, we bring our many years of engineering and operational experience to third party customers through a growing range of services – from spare parts management to long term service agreements. These maximize the efficiency and reliability of our customers’ assets, either engineered by us or by other actors in the market.

Our aim is to be a one-stop service provider, so that customers can enjoy the reassurance of working with one reliable partner, have more visibility over operating costs and fully optimize each process in the short and longer term.

• Spare Parts Services: specific lists and supply for your asset management, safety stocks, interchangeability studies, compliance with updated regulations. • Site Services: sending our experts on-site to resolve issues, check performance, install new components, supervize planned or unplanned shut-down events. • Product Support Services: remote technical assistance, monitoring and diagnostics, customer training, EHS consulting. • Engineering Services: conversions, modifications, upgrades: from conceptual and feasibility studies to project execution for the improvement of existing plants, design for third parties and validation, performance improvement programs. • Long Term Service Agreements: extended performance guarantees, special rates on one or more services from the other categories in a single agreement of variable duration to keep plants running at maximum efficiency.

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Cryogenics 92 Lurgi Focus on: Engineering for Existing Plants Services

Description Air Liquide Global E&C Solutions in all facets of engineering: • Performance Improvement Programs (PIP) • Plant upgrades • Plant relocations • Environmental performance • Reliability improvements • Safety improvements • Obsolescence management / life extension • Site audits and reports

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Cryogenics 93 Lurgi Focus on: Customer Training Services

Description For more than 100 years, Air Liquide has been a recognized leader in the cryogenic industry and more specifically in the following areas: • Cryogenic and LNG plant design and operations • Safety when handling and transporting cryogenics liquids • Maintenance of cryogenic plants

Our offering includes: • Compressed Gas Association industry practice • Basic process training: 1-2 days theoretical classroom process technology overview • Detailed process training: 1-2 weeks hands on-training on the site • Maintenance of cryogenic assets • Safety in operating cryogenic assets • Safety in transporting and handling cryogenic liquids • Customized training

Our training offering varies in each region, as it depends on the availability of local experts and technical resources.

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Cryogenics 94 Lurgi List of abbreviations and acronyms

2EHA 2-ethylhexylacrylate DME Dimethyl ether HP High pressure NH3 Ammonia 2EHOH 2-ethylhexanol DMR Dehydration and mercaptan removal unit HT High temperature Ni Nickel AA Acrylic acid DRI Direct reduction of iron ore IGCC Integrated gasification combined cycle NMP N-methylpyrrolidone AA Methanol specification per US federal DTDC Desolventizer, toaster, dryer and cooler IMPCA International methanol producers and NO Nitrous oxide regulation O-M-232e E&C Engineering and construction consumers association NOx Nitrous oxides AcAc Acetic acid EA Ethylacrylate ISO International Organization NRU Nitrogen removal unit AGR Acid gas removal for Standardization EAA Ester-grade acrylic acid OpEx Operating expenditures APH Air pre-heater Kr Krypton EOR Enhanced oil recovery PAH Polycyclic aromatic hydrocarbon Ar Argon LAR Liquid argon EtOH Ethanol PC Polycarbonate ASU Air Separation Unit LIN Liquid nitrogen FAD Fatty acid distillate PDH Propane dehydrogenation ATR Autothermal reformer/reforming LNG Liquefied natural gas FAME Fatty acid methyl ester PDP Preliminary design package BA Butylacrylate LOX Liquid oxygen FBDB Fixed bed bry bottom gasifier PIMS Proprietary simulation software BFD Block flow diagram LP Low pressure FEED Front-end engineering design PIP Performance improvement program BFW Boiler feedwater LP3 Low pressure fatty alcohols production FFA Free fatty acid POX Partial oxidation BOG Boil-off gas LPG Liquefied petroleum gas FOB Free on board PSA Pressure swing adsorbtion BTU British thermal unit LTGT Lurgi tailgas treatment F-T Fischer-Tropsch PSD Prevention of significant deterioration BuOH Butanol Methylacrylate G2G Gas-to-Gasoline MA PTSA Para-toluene sulfuric acid C2+ Hydrocarbons with 2 or more carbons GAN Gaseous nitrogen MDEA Methyl diethanolamine RBD Refined, bleached and deodorized C4 Mixture of 4-carbon hydrocarbons MDI Methylene diphenyl diisocyanate (butane, butylenes and butadienes) GAR Gaseous argon RSH Carbon-bonded sulfhydryl or thiol MEA Monoethanolamine CapEx Capital expenditures GNG Gasesous natural gas SMR Steam methane reforming or reformer MEG Monoetylene glycol CCR Continuous catalytic reforming GOX Gaseous oxygen SNG Synthetic natural gas Methanol CDU Crude distillation unit H2 Hydrogen MeOH SO2 Sulfur dioxide CH4 Methane H2S hydrogen sulfide MP Medium pressure SOx Sulfur oxydes CLS Claus HC Hydrocarbon MPG Multi-purpose gasifier SRU Sulfur removal unit CO Carbon monoxide HCl Hydrochrloric acid Mono propylene glycol TDI Toluene diisocyanate CO2 Carbon dioxide HCN Hydrogen cyanide MTG Methanol-to-Gasoline USD United States dollar COS Carbonyl sulfide HDS Hydrodesulfurization MTP Methanol-to-Propylene VDU Vacuum distillation unit CSFT Cold soak filtration test He Helium NaOH Soda VSA Vacuum Swing Adsorbtion Cu Copper HF Hydrofluric acid Ne Neon WHRS Waste heat recovery system CW Cooling water Hg Mercury NG Natural gas Xe Xenon DEA Diethanolamine HHC Heavy hydrocarbon NGL Natural gas liquids

Cryogenics 95 Lurgi www.engineering-airliquide.com