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Modeling and Analysis of Coal-Based Lurgi Gasification for LNG and Methanol Coproduction Process

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Modeling and Analysis of Coal-Based Lurgi Gasification for LNG and Methanol Coproduction Process processes Article Modeling and Analysis of Coal-Based Lurgi Gasification for LNG and Methanol Coproduction Process Jingfang Gu 1, Siyu Yang 1,* and Antonis Kokossis 2,* 1 School of Chemical Engineering, South China University of Technology, Guangzhou 510641, China; [email protected] 2 School of Chemical Engineering, National Technical University of Athens, GR-15780 Athens, Greece * Correspondence: [email protected] (S.Y.); [email protected] (A.K.); Tel.: +86-20-8711-2056 (S.Y.); +30-2-10-772-4275 (A.K.) Received: 23 May 2019; Accepted: 30 September 2019; Published: 2 October 2019 Abstract: A coal-based coproduction process of liquefied natural gas (LNG) and methanol (CTLNG-M) is developed and key units are simulated in this paper. The goal is to find improvements of the low-earning coal to synthesis natural gas (CTSNG) process using the same raw material but producing a low-margin, single synthesis natural gas (SNG) product. In the CTLNG-M process, there are two innovative aspects. Firstly, the process can co-generate high value-added products of LNG and methanol, in which CH4 is separated from the syngas to obtain liquefied natural gas (LNG) through a cryogenic separation unit, while the remaining lean-methane syngas is then used for methanol synthesis. Secondly, CO2 separated from the acid gas removal unit is partially reused for methanol synthesis reaction, which consequently increases the carbon element utilization efficiency and reduces the CO2 emission. In this paper, the process is designed with the output products of 642,000 tons/a LNG and 1,367,800 tons/a methanol. The simulation results show that the CTLNG-M process can obtain a carbon utilization efficiency of 39.6%, bringing about a reduction of CO2 emission by 130,000 tons/a compared to the CTSNG process. However, the energy consumption of the new process is increased by 9.3% after detailed analysis of energy consumption. The results indicate that although electricity consumption is higher than that of the conventional CTSNG process, the new CTLNG-M process is still economically feasible. In terms of the economic benefits, the investment is remarkably decreased by 17.8% and an increase in internal rate of return (IRR) by 6% is also achieved, contrasting to the standalone CTSNG process. It is; therefore, considered as a feasible scheme for the efficient utilization of coal by Lurgi gasification technology and production planning for existing CTSNG plants. Keywords: coproduction; Lurgi syngas; cryogenic separation; methanol synthesis; LNG 1. Introduction China is the main source of global energy growth as well as the largest energy consumer in the past 20 years [1]. In 2016, China’s natural gas production was 148.7 billion Nm3, with a yearly rate increase of 8.5%. Meanwhile, the total imports are 92 billion m3, with an annual growth rate of 27.6%. However, the total yearly gas consumption is 237.3 billion m3, which is 15.3% higher than that of 2015 [2]. If keeping with the same growth rates, the natural gas will be in insufficient supply in the near future. To alleviate such an energy shortage, the Chinese government encourages the build and operate (B&O) development of coal to conduct synthetic natural gas (CTSNG) projects. Therefore, many CTSNG projects have been launched recently and are being run successfully all over the country, as shown in Table1. Processes 2019, 7, 688; doi:10.3390/pr7100688 www.mdpi.com/journal/processes Processes 2019, 7, 688 2 of 20 Processes 2019, 7, 688 2 of 21 TableTable 1. 1.B&O B&O CTSNG CTSNG projects projects in in China China (2018). (2018). Capacity Capacity ProjectProject StatusStatus Company Company 9 3 LocationLocation (10 Nm /a)(109 Nm3/a) KeqiKeqi Coal-based Coal-based Gas Gas Project Datang InternationalDatang International Power Power Chifeng, Inner OperatingOperating 1.331.33 Chifeng, Inner Mongolia Project PhasePhase I I GenerationGeneration Company Company Mongolia XinjiangXinjiang Kingho Kingho SNG SNG Project XinjiangXinjiang Kingho EnergyKingho GroupEnergy Group Co., OperatingOperating 1.381.38 Yili, XinjiangYili, Xinjiang Project PhasePhase I I Co., Ltd. Ltd. HuinengHuineng Ordos Ordos SNG SNG projects Inner MongoliaInner HuinengMongolia Coal Huineng Coal Ordos, Inner OperatingOperating 44 Ordos, Inner Mongolia projects PhasePhase I I Chemical IndustryChemical Co., Industry Ltd. Co., Ltd. Mongolia Yili Xintian SNG Project OperatingYili XintianYili Xintian Coal Chemical Coal Chemical Co., Co., Ltd. 2 Yili, Xinjiang Yili Xintian SNG Project Operating 2 Yili, Xinjiang Keqi Coal-based Gas Project DatangLtd. International Power Chifeng, Inner Building 2.67 Keqi Coal-basedPhase II/III Gas Datang InternationalGeneration Power Company Mongolia Building 2.67 Chifeng, Inner Mongolia Project Phase II/III GenerationDatang Company International Power Datang Fuxin SNG Project Building 4 Fuxin, Liaoning Datang Fuxin SNG Datang InternationalGeneration Power Company Building 4 Fuxin, Liaoning XinjiangProject Kingho’s SNG Project GenerationXinjiang CompanyKingho Energy Group Co., Building 4.13 Yili, Xinjiang Xinjiang Kingho’sPhase SNG II Xinjiang Kingho EnergyLtd. Group Building 4.13 Yili, Xinjiang HuinengProject PhaseOrdos II SNG Projects InnerCo., Ltd. Mongolia Huineng Coal Ordos, Inner Building 1.6 Huineng OrdosPhase SNG II Inner MongoliaChemical Huineng Industry Coal Co., Ltd. Mongolia Building 1.6 Ordos, Inner Mongolia ProjectsXinjiang Phase Zhundong II SNG Chemical Industry Co., Ltd. Changji, Building Suxin Energy Hefeng Co., Ltd. 4 XinjiangDemonstration Zhundong SNG Project Xinjiang Building Suxin Energy Hefeng Co., Ltd. 4 Changji, Xinjiang DemonstrationBeijing Enterprises Project JT Ordos Inner Mongolia Beijing Enterprises Ordos, Inner Building 4 SNG Project InnerJT Mongolia Energy Development Beijing Co., Ltd. Mongolia Beijing Enterprises JT Building Enterprises JT Energy 4 Ordos, Inner Mongolia Ordos SNG Project However, CTSNG projects face someDevelopment challenges. Co., Ltd. Firstly, the market price of synthetic natural gas (SNG) products is not based on its cost structure, nor according to the guidance from a market mechanism.However, Departments CTSNG projects of China face offer some a challenges. rather lower Firstly, price theto the market public, price and of priority synthetic is naturalgiven to gascivil (SNG) use, transportation products is not field, based etc. on Thus, its cost lower structure, economic nor returns according are tocommon the guidance to all CTSNG from a projects. market mechanism.The price of Departmentsnatural gas has of Chinafallen osharplyffer a rather since lowerNovember price 2015 to the in public, the country and priority after the is givenNational to civilDevelopment use, transportation and Reform field, Commission etc. Thus, lower issued economic a report returns about price are common adjustment to all [2]. CTSNG In Figure projects. 1, it Theshows price that, of during natural 2015 gas hasto 2018, fallen the sharply price of since SNG November is reduced 2015from in2.75 the to country 1.82 CNY/Nm after the3. After National 2018, Developmentthe price further and decreased Reform Commission to 1.78 CNY/Nm issued3. a In report such aboutcase, the price market adjustment price of [2 ].SNG In Figure is 0.971 CNY/, it shows Nm3 that,lower during than 2015that toof 2018, 2015. the Taking price ofKeqi SNG Coal-Based is reduced fromGas Project 2.75 to 1.82Phase CNY I for/Nm an3. Afterexample, 2018, in the 2017, price it furtherproduced decreased 1.03 billion to 1.78 Nm CNY3 SNG/Nm products,3. In such yet case, with thea big market deficit price of 650 of million SNG is CNY. 0.97 CNY It can/ Nm be seen3 lower that thanif natural that of gas 2015. price Taking keeps Keqi fluctuating Coal-Based at Gasa low-price Project Phase level, I forthese an CTSNG example, projects in 2017, are it produced likely to 1.03face billionsevere Nm losses.3 SNG products, yet with a big deficit of 650 million CNY. It can be seen that if natural gas price keeps fluctuating at a low-price level, these CTSNG projects are likely to face severe losses. 3.0 2.5 2.0 ) 3 1.5 Price(CNY/m 1.0 0.5 0.0 2014 2015 2016 2017 2018 Time Figure 1. China’s synthesis natural gas (SNG) market price recording (2014–2018). Figure 1. China’s synthesis natural gas (SNG) market price recording (2014–2018). Secondly, the SNG product is mainly supplied for civil use like urban heating in the winter. Thus, there is a peak–valley difference of natural gas demand between winter and summer. In most of the Processes 2019, 7, 688 3 of 20 Processes 2019, 7, 688 3 of 21 Secondly, the SNG product is mainly supplied for civil use like urban heating in the winter. Thus, northernthere is a cities peak–valley of China, di fftheerence top ofdemand natural of gas natura demandl gas betweenin the heating winter period and summer. is from InNovember most ofthe to Marchnorthern of the cities following of China, year. the topIn contrast, demand the of naturaldemand gas in inthe the non-heating heating period period is remains from November at a lower to levelMarch from of the April following to October. year. According In contrast, to the statistics demand from in the Ji non-heating[3], the consumption period remains in the heating at a lower period level isfrom up to April 10 times to October. of that According in the non-heating to statistics period. from Taking Ji [3], the the consumption winter of 2018 in theas an heating example, period theis gap up betweento 10 times supply of that and in thedemand non-heating of natural period. gas is Taking about the 24 winterbillion ofm3 2018. Since as natural an example, gas cannot the gap be between stored forsupply a long and time, demand coal-based of natural gas gas projects is about are 24 facing billion production m3. Since naturalcuts during gas cannot the non-heating be stored for period, a long whichtime, coal-based brings huge gas economic projects arelosses.
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