Professional Documents
Culture Documents
Gasification
Technologies
2
Table of contents
Gasification 04
Feedstocks 06
Syngas applications 08
ThyssenKrupp Uhde's experience in gasification 09
The PRENFLO
process (PSG) 10
The PRENFLO
process (PDQ) 12
The HTW process 14
Major Projects 16
Range of Services
- Technologies 20
- Serving our Customers 22
Contacts 23
3
Company profle
With its highly specialised workforce of more than 5,600 employees
and its international network of subsidiaries and branch offces,
ThyssenKrupp Uhde, a Dortmund-based engineering contractor,
has, to date, successfully completed over 2,000 projects throughout
the world. ThyssenKrupp Uhdes international reputation has been
built on the successful application of its philosophy Engineering with
ideas to yield cost-effective, high-tech solutions for its customers.
The ever-increasing demands placed upon process and application
technology in the felds of chemical processing, energy and envi-
ronmental protection are met through a combination of specialist
know-how, comprehensive service packages, topquality engineering
and deadline reliability. The extensive international experience in the
design and construction of chemical plants makes ThyssenKrupp
Uhde the ideal licensor and engineering contractor for gasifcation
plants.
ThyssenKrupp Uhdes head
office Dortmund, Germany
4
Gasification
Why gasifcation? Gasifcation processes offer a number of upstream and
downstream advantages to customers faced with rising oil prices and
dwindling energy reserves as well as a need to meet increasingly stringent
environmental requirements. With proper preparation a variety of carbon-
based materials can be easily gasifed to produce synthesis gas (syngas)
for the subsequent production of chemicals, liquid fuels, electricity or direct
reduction gas (DRI). Gasifcation is particularly clean and effcient.
5
Gasification is also flexible with respect to feedstock quality and
the use of mixed feedstocks. The gasification of low-value or waste
materials is an attractive option. Even otherwise problematic ma-
terials can be gasified together with the main feedstock.
As coal is much more abundant than oil and gas and global avail-
ability ensures security of supply and relative price stability for the
foreseeable future, coal will play an ever greater role in power gen-
eration, the chemical industry (e.g. in India, China and Africa) and
in the production of liquid fuels (gasoline, diesel, etc.).
Gasification technology offers environment-friendly, efficient solu-
tions for these applications. In power generation, for example, gasi-
fication can achieve high thermal efficiencies and also forms a basis
for Carbon Capture and Storage (CCS).
ThyssenKrupp Uhdes proprietary HTW and PRENFLO
technology
provide tailor-made gasification solutions optimised for the respec-
tive project-specific application:
HTW: fluidised-bed gasification
PRENFLO
7
8
Syngas applications
There are various process routes available for obtaining the desired
syngas composition, which may be a mixture of carbon monoxide
and hydrogen or either pure hydrogen or carbon monoxide alone.
Hydrogen, for example, can be used in the refinery industry to
achieve lighter and cleaner liquid fuels or for new applications such
as fuel cells for power generation or cars.
Hydrogen-rich syngas can be produced via the sour CO shift pro-
cess. In this case, the CO in the raw gas produced by gasification is
shifted with steam to form hydrogen and carbon dioxide before the
sour gas components are removed.
A number of processes are available for desulphurisation and car-
bon dioxide removal, such as: MDEA, aMDEA, Genosorb, Selexol,
Sulfinol, Rectisol.
For the production of ammonia synthesis gas, a liquid nitrogen pro-
cess can be used for the final cleaning and to obtain the correct
mixture of hydrogen and nitrogen.
ThyssenKrupp Uhde offers all of these process stages and can pro-
vide optimised solutions for complete production plants for e.g. fer-
tilisers or liquid fuels as well as for combined hydrogen and electric
power generation with or without carbon dioxide capture, or for direct
reduction in the steel industry (DRI).
The raw gas produced by gasifcation needs to be treated before it can be
used for the production of downstream products, such as hydrogen, SNG,
ammonia, methanol, liquid fuels, electricity or direct reduction gas (DRI).
Methanol
MTO
MTG
Ammonia
H
2
SNG
Reduction
Gas
IGCC/
Power
Urea
ThyssenKrupp Uhde
Steam Reformer
Fischer-
Tropsch
Diesel
Naphtha
Diesel
Naphtha
Gasoline
LPG
Waxes
Lubes
PRENFLO
Gasification
HTW
Gasification
Gas
Naphtha
Oil
Orimulsion
Residues
Petcoke
Hard Coal
Lignite
Biomass
Brown Coal
Waste
9
ThyssenKrupp Uhde's experience in gasification
ThyssenKrupp Uhde's gasification history
Different technologies for different applications
10
The PRENFLO
Process
with Steam Generation (PSG)
The PRENFLO
(PSG)
process
Main process data:
Gasification pressure:
40 bar and higher
Gasification temperature:
> 2,000 C
Gas temperature at
outlet of gasifier:
1,350 - 1,600 C
Carbon conversion:
> 99 %
Typical raw gas
composition:
CO + H
2
> 85 vol. %
CO
2
2-4 vol. %
CH
4
< 0.1 vol. %
11
Process description
First, the feed dust is prepared in the feed preparation unit.
Approximately 80% of the dust is smaller than 0.1 mm and has
a water content of approx. 1-2 wt.% in the case of hard coals and
approx. 8-10 wt.% in the case of lignite. This feed dust is then
gasified in the PRENFLO
gasifier/boiler (PSG)
ppmv
Raw gas analysis PDQ
ppmv
Raw gas analysis PSG Main features of the PSG process:
Entrained-flow
Dry dust feed for high efficiency
Multiple burners with high availability and
long lifetime
Horizontally arranged burners for high
carbon conversion
Membrane wall with long lifetime
Waste heat boiler for efficient heat recovery
Operates above ash melting point
12
The PRENFLO
Process
with Direct Quench (PDQ)
The PRENFLO
(PDQ)
process
Main process data:
Gasification pressure:
40 bar and higher
Gasification temperature:
> 2,000 C
Gas temperature at outlet
of gasifier/quench:
200 - 250 C
Carbon conversion:
> 99 %
Typical raw gas
composition:
CO + H
2
> 85 vol. %
CO
2
6 - 8 vol. %
CH
4
< 0.1 vol. %
13
Oxygen
Feed
Slag
Raw gas
PRENFLO
gasifier/
Direct Quench (PDQ)
Main features of the PDQ process:
Entrained-flow
Dry dust feed for high efficiency
Multiple burners with high availability and
long lifetime
Horizontally arranged burners for high
carbon conversion
Membrane wall with long lifetime
Full water quench for syngas saturation
Shorter supply and construction schedule
Lower investment cost
Operates above ash melting point
Layout comparison of
PRENFLO
PDQ
ppmv
Raw gas analysis PDQ
ppmv
Raw gas analysis PDQ
Process description
First, the feed dust is prepared in the feed preparation unit.
Approximately 80% of the dust is smaller than 0.1 mm and has a
water content of approx. 1-2 wt.% in the case of hard coals and
approx. 8-10 wt.% in the case of lignite. This feed dust is then
gasified in the PRENFLO
gasification)
17
Coal-to-Liquids (MTG)
Jincheng Anthracite Coal Mining, Shanxi, China
Capacity: 2,600 barrels per day
Gasification plant for the production of oxo gas
Oberhausen, Germany
Capacity: 83,000 m
3
(Vn)/h (dry) CO + H
2
Gasification plant for the production of ammonia and methanol
Modderfontein, South Africa
Capacity: 90,000 m
3
(Vn)/h (dry) CO + H
2
PRENFLO
demonstration plant
Frstenhausen, Germany
Capacity: 4,200 m
3
(Vn)/h (dry) CO + H
2
18
Major Projects
Methanol-to-Gasoline (MTG)
In combination with ThyssenKrupp Uhdes gasification technolo-
gies, different process routes for the production of liquids from coal
or other carbonaceous feedstocks, i.e. the Methanol-to-Gasoline
(MTG) route or the Fischer-Tropsch synthesis route, can be supplied.
Elcogas IGCC Plant
This IGCC plant is based on a highly integrated system in which
the total air for the air separation unit is taken from the gas turbine
compressor. The plant can be divided into three main parts:
the gasification island, comprising the feed preparation unit,
the PRENFLO
)
Synthesis gas products
Ammonia
Nitrogenous fertilisers
Urea
Hydrogen & Nitrates
Synthesis gas generation
Steam reforming
Autothermal reforming
Combined autothermal
reforming (CAR
)
Synthesis gas products
Hydrogen
Carbon monoxide
Oxo synthesis gas
Methanol
Mineral acids
Nitric acid
N
2
O / NOx abatement
(DeNOx, De-N
2
O
, EnviNOx
)
Nitrogenous fertilisers
Ammonium nitrate
(HDAN, LDAN),
CAN, UAN, ASN, AS
Phosphate Fertiliser
DAP, NP, NPK
Electrolysis
Electrolysis
Chlor-alkali electrolysis
HCI electrolysis
Chlorate electrolysis
Bleaching chemicals / Others
Chlorine dioxide (CIO
2
)
Ferric Chloride (FeCI
2
)
Organic chemicals /
Polymers
Organic chemicals
Ethylene dichloride (EDC)
Vinyl chloride (VCM)
Vinyl acetate monomer (VAM)
Ethylene oxide
Ethylene glycol
Oxo alcohols
Propylene oxide
Polypropylene
Homopolymers
Copolymers
Polyethylene
HDPE
LDPE
LLDPE
Copolymers
Polyvinyl chloride
S-PVC
Others
Styrene plastics
(ABS, EPS, GPPS/HIPS)
Carboxymethylcellulose (CMC)
Engineering plastics
21
Gas Technologies
Gasification
(PRENFLO
& HTW)
Coal / petcoke gasification
(PRENFLO
)
Oil / residue gasification
Biomass gasification
Partial oxidation
Synthesis gas applications
Gas treatment for synthesis
gas, hydrogen
Sulphur recovery
Coal-to-liquids (methanol-to-
gasoline, Fischer-Tropsch)
Ammonia, methanol
Olefins
Propane dehydrogenation
(STAR process
)
Coke Plant Technologies
Coke oven batteries
Gas treatment plants
Coke quenching facilities
Coal / coke handling
Heat-recovery coke plants
Emission control systems
Refining Technologies
Oil refining
Crude oil processing
Atmospheric distillation
Vacuum distillation
Catalytic processing
Hydrotreating,
hydrodesulphurisation,
hydrocracking
Catalytic reforming
Fluid catalytic cracking (FCC)
Isomerisation
Alkylation, dimerisation
Ethers
Methyl / ethyl tertiary butyl
ether (MTBE, ETBE)
Selective hydrogenation
Oxygenate removal
Tertiary amyl methyl ether
(TAME)
Dimethyl ether (DME)
Ohter processes and offsites
Gas-to-liquids
(product upgrading)
Hydrogen / synthesis gas
Gas / LPG separation
Thermal cracking
Visbreaking
Bitumen and asphalt
Offsite facilities
Lube oil, waxes and white oil
Solvent extraction
Propane de asphalting
Solvent dewaxing
Wax deoiling
Lube oil hydrofinishing
Lube oil hydrocracking
Wax hydroisomerisation
Catalytic dewaxing
Wax / white oil hydrogenation
Lube oil blending
Aromatics and derivates
Extractive distillation (BTX)
using the Morphylane
process
Reformate hydrogenation
Pyrolysis gasoline hydrogenation
Coke-oven light oil hydrorefining
Catalytic reforming
Xylene isomerisation
Disproportionation
Toluene dealkylation
Divided wall column fractionation
Styrene extraction
Olefins and solvents
Alcohols
Isopropanol (IPA)
Secondary butanol (SBA)
Ketones
Methyl isobutyl ketone (MIBK)
Methyl ethyl ketone (DMK)
C4 olefins
Butene concentration
(Butenex
, Molsieve)
22
Range of Services
Serving our Customers
ThyssenKrupp Uhde is dedicated to providing its customers with
a wide range of services and to supporting them in their efforts
to succeed in their line of business. With our worldwide network
of subsidiaries, associated companies and experienced local rep-
resentatives, as well as first-class backing from our head office,
ThyssenKrupp Uhde has the ideal qualifications to achieve this goal.
We at ThyssenKrupp Uhde place particular importance on interact-
ing with our customers at an early stage to combine their ambition
and expertise with our experience.
Whenever we can, we give potential customers the opportunity to
visit operating plants and to personally evaluate such matters as
process operability, maintenance and on-stream time.
We aim to build our future business on the confidence our cus-
tomers place in us.
ThyssenKrupp Uhde provides the entire spectrum of services asso-
ciated with a process-oriented EPC contractor from a single source.
Our large portfolio includes:
Licensing of gasification and down-stream technologies,
incl. the basic engineering package (BEP)
Front-end engineering design (FEED)
Feasibility studies
Cost estimates
Engineering, procurement, construction
Commissioning and start-up support
Training of operating personnel
After-sales services.
The policy of the ThyssenKrupp Uhde group and its subsidiaries is
to ensure utmost quality in the implementation of our projects. Our
head office and subsidiaries worldwide work to the same quality
standard, certified according to: DIN/ISO 9001/EN29001.
We remain in contact with our customers even after project com-
pletion. Partnering is our byword.
By organising and supporting technical symposia, we promote active
communication between customers, licensors, partners, operators
and our specialists. This enables our customers to benefit from the
development of new technologies and the exchange of experience
as well as troubleshooting information.
We like to cultivate our business relationships and learn more about
the future goals of our customers. Our after-sales services include
regular consultancy visits which keep the owner informed about the
latest developments or revamping options.
ThyssenKrupp Uhde stands for tailor-made concepts and interna-
tional competence.
For more information contact one of the ThyssenKrupp Uhde offices
near you, visit:
www.Uhde.eu
or contact:
E-mail: gasification.Uhde@thyssenkrupp.com
Phone: +49 231 547-3973
Fax: +49 231 547-3382
Engineering, Project Management, Procurement, Construction Management,
Quality, Health Environment Safety (HES) and Technologies
23
Contacts ThyssenKrupp Uhde Worldwide
WESTERN EUROPE
ThyssenKrupp Uhde GmbH
Friedrich-Uhde-Strasse 15
44141 Dortmund
Germany
Tel.: +49 231 5 47-0
Fax: +49 231 5 47-30 32
www.uhde.eu
ThyssenKrupp Uhde GmbH
Friedrich-Uhde-Strasse 2
65812 Bad Soden/Taunus
Germany
Tel.: +49 6196 2 05-0
Fax: +49 6196 2 05-14 20
ThyssenKrupp Uhde GmbH
(R & D centre)
Neubeckumer Str. 127
59320 Ennigerloh
Germany
Tel.: +49 2525 99 32 21
Fax: +49 2525 99 32 22
Uhde High Pressure
Technologies GmbH
Buschmhlenstrasse 20
58093 Hagen
Germany
Tel.: +49 2331 96 7-0
Fax: +49 2331 96 73 70
ThyssenKrupp
Uhde Engineering Services GmbH
Annabergstrasse 43-51
45721 Haltern am See
Germany
Tel.: +49 2364 927 8-0
Fax: +49 2364 927 8-9 11
Uhde Fertilizer Technology B.V.
Noordhoven 19
6042 NW Roermond
The Netherlands
Tel.: +31 475 399 770
Fax: +31 475 399 777
Uhde Inventa-Fischer GmbH
Holzhauser Strasse 157-159
13509 Berlin
Germany
Tel.: +49 30 435 67-5
Fax: +49 30 435 67-699
Uhde Inventa-Fischer AG
Via Innovativa 31
7013 Domat/Ems
Switzerland
Tel.: +41 81 632 63 11
Fax: +41 81 632 74 03
Uhdenora S.p.A.
Via Bistolf, 35
20134 Milan
Italy
Tel.: +39 02 21 29 1
Fax: +39 02 21 54 87 3
CENTRAL AND EASTERN EUROPE
OOO Uhde
pr. Lenina 48
606023 Dzerzhinsk
Russia
Tel.: +7 8313 35 03 30
Fax: +7 8313 35 03 34
OOO Uhde
Branch Offce Moscow
Usacheova Str. 33/2
119048 Moscow
Russia
Tel.: +7 499 940 03 12
Fax: +7 499 940 03 10
OOO Uhde
Branch Offce Nizhny Novgorod
Malaya Pokrovskaya st. 6/2
603000 Nizhny Novgorod
Russia
Tel.: +7 831 299 96 80
Fax: +7 831 299 96 81
Uhde Edeleanu s.r.o.
Pekarsk 7
60200 Brno
Czech Republic
Tel.: +420 5 4342 39 11
Fax: +420 5 4323 71 14
AMERICAS
Uhde
Corporation of America
1370 Washington Pike
Bridgeville, Pennsylvania 15017
USA
Tel.: +1 412 25 78 27 7
Fax: +1 412 25 78 34 4
Uhde Engineering de
Mxico S.A. de C.V.
Av. Sierra Gamn 120, Piso 7
Colonia Lomas de Chapultepec
CP 11000
Mxico D.F.
Mexico
Tel.: +52 55 52 84 02 00
Fax: +52 55 52 84 02 72
Uhde Corporation - Canada Offce
1177 - 11th Ave SW, Suite 405
Calgary, Alberta
Canada, T2R 0G5
Tel.: +1 403 209 44 13
Fax: +1 403 245 56 25
Uhde do Brasil Ltda.
Rua Victor Civita, 77, n 77, bloco 1
Edifcio 6.2, Sala 502 parte
Jacarepagu, Rio de Janeiro/RJ,
Brazil
Tel.: +55 21 3311 62 01
Fax: +55 21 3311 62 23
SOUTH-EAST ASIA, PACIFIC
REGION AND AUSTRALIA
Uhde India Private Ltd.
Uhde House
L.B. Shastri Marg
Vikhroli (West)
Mumbai 400 083
India
Tel.: +91 22 67 96 80 00
Fax: +91 22 25 78 43 27
ThyssenKrupp Otto
Ginza Ohno Bldg. 1 - 17
Tsukiji 4-chome, Chuo-ku
Tokyo - 104-0045
Japan
Tel.: +81 3 35 45 36 61
Fax: +81 3 35 45 55 59
KEPCO-Uhde Inc.
M-Tower Bldg. 4F
154-11 Samseong-dong
Gangnam-gu
135-791 Seoul
South Korea
+82 70 7862 18 02
+82 70 7862 18 10
Uhde
Beijing Representative Offce
Unit 4A, 22/F, China Life Tower
No.16 Chaoyangmenwai Avenue
Chaoyang District
Beijing 100020
P.R. China
Tel.: +86 10 85 25 29 99
Fax: +86 10 85 25 21 79
Uhde Engineering
Consulting (Shanghai) Co. Ltd.
4/F Building No.10,
Pujiang Intelligence Valley,
No.1188 Lianhang Road, Shanghai,
201112, P.R.China
Tel.: +86 21 6128 69 99
Fax: +86 21 6128 69 00
Uhde Representative c/o
ThyssenKrupp AG Representative
Offce Vietnam
Unit 01, 21st Floor, Vincom Tower B
191 Ba Trieu St.
Hai Ba Trung Dist.
Hanoi
Vietnam
Tel.: +84 4 974 25 52 - 61
Fax: +84 4 974 25 63
Uhde Shedden (Australia) Pty. Ltd.
Level 2,
355 Spencer Street
West Melbourne Vic 3003
Australia
Tel.: +61 3 92 07 57 77
Fax: +61 3 92 07 58 88
Uhde (Thailand) Ltd.
Empire Tower 3, 30th Floor
195 South Sathorn Road
Yannawa/Sathorn
Bangkok - 10120
Thailand
Tel.: +66 2 612 82 00
Fax: +66 2 612 82 90
MIDDLE EAST AND NORTH AFRICA
Uhde Arabia Ltd.
Al-Raja Building, 3rd Floor,
Khobar Dammam Highway
Al-Khobar 31952
Saudi Arabia
Tel.: +966 3 887 24 14
Fax: +966 3 887 66 52
ThyssenKrupp Technologies
Tech Center Middle East
Dubai Festival City
Festival Tower, Offce 2101
P.O. Box 36774
Dubai
United Arab Emirates
Tel.: +971 4 705 93 00
Fax: +971 4 705 93 01
Uhde Engineering Egypt Co. S.A.E.
6A Mostafa Refeat Street
Sheraton Heliopolis Area
UEE Building
Cairo
Egypt
Tel.: +20 2 2266 28 85
Fax: +20 2 2266 28 81
CENTRAL AND SOUTHERN AFRICA
Uhde
A Division of ThyssenKrupp PDNA
Engineering (Pty) Ltd.
71 Nanyuki Road
Sunninghill, 2191
South Africa
Tel.: +27 11 236 10 00
Fax: +27 11 236 11 25
ThyssenKrupp Uhde
Friedrich-Uhde-Str. 15 44141 Dortmund
Phone +49 231 5 47-0 Fax +49 231 5 47-30 32
www.uhde.eu info.uhde@thyssenkrupp.com
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