Coal Gasification

Coal Gasication

Cleanly converting coal,

petroleum coke and biomass into

high-value products and power

Air Products Syngas Solutions™ formerly:

• Shell Coal Gasication Process (SCGP)

• GE Energy's gasication technology

What dierentiates us?

• Air Products Syngas Solutions oers

a Technology license, equipment and

engineering, and engineering service

as well as a “Sale of Gas” model

where Air Products builds, owns

and operates the syngas production

facility.

• Our coal gasication experience

dates back to the early 1970s; more

than 200 Air Products gasication

reactors have been developed or are

in the planning stage for both the

dry-feed and slurry-feed designs.

• We continuously improve our

technologies through research and

development and by incorporating

lessons learned into our master

designs.

• Air Products gasication units

successfully process a wide range of

solid fuels including various types

of coal (from lignite to anthracite),

petroleum coke (petcoke) and

biomass blends.

• Our designs oer performance

advantages by helping to minimize

oxygen and freshwater consumption

and enhance syngas yield.

• Because Air Products is both a

gasication technology owner and

an operator, we have extensive

experience in gasier start-up,

operation and maintenance.

Air Products Gasication Process (GP) at a glance

Customer driver

Access to coal, petcoke or biomass; lack of access to oil and gas along

with high or volatile prices; sustainable operations (emissions)

Solution

The Air Products Gasiﬁcation Process, which can convert a wide

range of coals, including petcoke and biomass, into syngas

Value delivered

High-value products or power with low emissions

Proof point

Dozens of gasiﬁers in operation and several more due to start up in

the near future

The world’s growing appetite for energy and chemicals is increasing the demand

for clean coal, particularly in countries with indigenous reserves or access to low

cost imports. However, depletion of the highest quality deposits and increasingly

restrictive emission regulations require operators to use lower quality coal in

environmentally acceptable ways.

We oer the Air Products Gasiﬁcation

Process (GP) in four product

conﬁgurations (shown below) that

can convert a wide range of coal types

to synthesis gas (syngas) for:

• Integrated gasiﬁcation combined

cycle (IGCC) power generation with

optional carbon dioxide capture

• High-value chemical production

• Synthetic hydrocarbon (fuels)

production

• Hydrogen production

The right process for

the right project

Dry-feed systems use an inert carrier

gas to transport dry, pulverized coal

into a multi-injector, water-walled

gasiﬁer. Our slurry-feed systems

generate a high-pressure, coal-

Air Products GP

Dry-Feed

Syngas Cooled

Gasier

Opposed

Multiple

Burners

Bottom

Water

Quench

Air Products GP

Dry-Feed

Bottom Quench

Air Products GP

Slurry-Feed

Syngas Cooled

Air Products GP

Slurry-Feed

Bottom Quench

This dry-feed gasiﬁer has a

convective syngas cooler that

oers heat recovery through

steam generation.

This dry-feed gasiﬁer

oers a robust quench

design and part of the

MP steam.

This slurry-feed gasiﬁer

has a radiant syngas cooler

that oers heat recovery

through steam generation.

This slurry-feed gasiﬁer

oers a robust quench

design.

Gasifier

Quench

Chamber

Quench Ring

Dip & Draft Tube

Refractory

Gasier

Syngas

Cooler

Air Products Syngas Solutions

provides operational support and

business and project-execution

services from design and engineering

to commissioning and start-up. We

can also help with master planning

and training.

water slurry to convey the coal to

a single injector, refractory lined

gasiﬁer, where oxygen is injected

with the slurry stream to produce

raw syngas. The raw syngas can be

cooled using either a quench design,

which rapidly cools the syngas, or

a radiant syngas cooler design to

generate high-quality steam from

the high-temperature syngas. A

full assortment of gasiﬁcation

technologies and knowledge of

downstream syngas processing is

our advantage. Let Air Products guide

you to choose what is right for your

project.

Performance advantages

Our options oer:

• Low coal and oxygen consumption, typically 510–615 kg coal and

310–350 Nm

oxygen per 1,000 Nm

of eective syngas respectively.

• High throughput and availability, and low maintenance costs by using

proven features of technologies such as reactor membrane wall, burner

technology, refractory-lined gasiﬁer with quench, and radiant syngas

cooler design conﬁguration.

The Air Products Gasication Process syngas cooler line-up:

Has a higher thermal eciency; produces less wastewater; and generates

high- and medium-pressure steam, which can help to reduce operating

costs.

Air Products gasiﬁcation with heat recovery through syngas cooler design

oers higher thermal eciency and generates high- to medium-pressure

steam. Plants with higher operating costs can bank on these design

conﬁgurations for optimum plant economics.

Our bottom water-quench line-up:

Requires up to 30-50% less capital expenditure and oers more stable

operation through its simpliﬁed conﬁguration—and widens coal

suitability.

Air Products Quench gasiﬁcation design oers lowest capital cost up

to 30-50% while oering wide feed and capacity operating range. Its

potential local fabrication and simple design enable quicker plant

construction and start-up duration.

Case Studies

Converting coal to chemicals

Air Products GP syngas cooler technology

has successfully supplied syngas

and steam to a Baling fertilizer plant

since 2006. Feeding 2,000 tons of dry

pulverized coal per day produces syngas

for urea/fertilizer and caprolactam (nylon)

manufacture.

An Air Products high-pressure gasication

system has been in successful operation

since 2015, and the 2,000 ton (coal) slurry-

feed gasier pressure is 87 bar resulting

in signicant operating cost and energy

saving for downstream chemical process.

An Air Products slurry-feed gasication

system has been running on 100% petcoke

since 2000, producing ammonia-based

fertilizers with all syngas CO

recovered

and sent to a CO

pipeline for enhanced oil

recovery. Syngas availability in this plant

has been as high as 99.7% on an annual

basis and averages over 98 % for the life

of the plant

Since 2016, Air Products has operated

high-capacity methanol plants fueled by

15,000 tons of coal per day.

Generating IGCC power

The rst coal-based IGCC operated in

1980. Across multiple plants we have

demonstrated feedstock exibility,

processing more than 20 dierent coal

types and blends running successfully

with up to 30 wt% biomass for dry feed.

In slurry-feed systems, more than 40

coal and petcoke blends with up to 100%

petcoke have been run in commercial

operation. Both systems had emissions

less than 30 ppm NOx and 15 ppm SOx.

The United States’ largest coal-based IGCC

produces 600 MW (net) using a slurry-feed

syngas cooler technology and has been in

commercial operation since 2012 on high

chloride Indiana subbituminous coal.

South Korea’s rst IGCC plant is now in

operation. This facility uses a dry-feed

syngas cooler to produce 300 MW (net) of

electric power from 2,670 tons per day of

bituminous and sub-bituminous coal.

tell me more

airproducts.com/syngassolutions

Have you

considered how

you can . . .

• Produce chemicals and

hydrocarbon liquids with-

out relying on oil and gas

imports?

• Generate power with lower

emission levels?

• Adapt to lower-quality coal?

• Reduce risk and save capital

by allowing Air Products to

nance/run the gasication

complex?

The information contained herein is based on data believed to be accurate as of the date compiled. No

representation, warranty, or other guarantee, express or implied, is made regarding the merchantability,

ﬁtness for a particular purpose, suitability, accuracy, reliability, or completeness of this information or the

products, materials, or processes described. Some services may not be available in certain countries, regions,

or provinces. The user is solely responsible for all determinations regarding any use of materials, products,

or processes in its territories of interest. Air Products expressly disclaims liability for any loss, damage, or

injury resulting from or related to the use of or reliance on any of the information contained herein.

For more information , please contact us at:

Air Products and Chemicals, Inc.

Mario Moniz

[email protected]om

Air Products Syngas Solutions™ is part of Air Products and Chemicals, Inc.

Value

Our coal gasiﬁcation technology can be tailored to meet dierent needs,

including:

• Providing an alternative feedstock for chemical manufacture

• Producing synthetic liquid fuels and lubricants

• Generating power with lower emissions than from burning coal

or even natural gas, with the option of high-pressure carbon capture

and storage.

Both dry- and slurry-feed technologies compliment their various key features

in oering an optimum solution for a speciﬁc type of feed and downstream

applications while considering customer economical and operational

objectives.

The multiple-burner designs can be easily scaled up, and high reliability

reduces or eliminates the need for a spare gasiﬁer. This enables construction

of fewer, larger units, which helps reduce capital and operational costs

by requiring fewer operators, less maintenance, and a smaller spare parts

inventory. Units with a dry coal intake capacity of 3,200 tons per day have

already been put into operation.

More than 100 types of coal have been processed. Using a blend of coal and

petcoke greatly increases gasiﬁer reliability and can signiﬁcantly improve

operational stability, eciency and syngas output, particularly for operators

using high-ash coal.