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FIELDS

  Coal to Liquid
   
 

Construction of large-scale coal-to-liquid industrial plants in China is from the beginning of twenty-first Century. Coal liquefaction process include two process routes of direct liquefaction and indirect liquefaction.

Shenhua coal direct liquefaction project obtained formal approval of the state in September 2002. The construction of the project is divided into two phases, of which the capacity of phase I construction is 3,200kt/a of oil product, it's composed of three production lines. The first production line of coal direct liquefaction project (Phase I) was started by Shenhua Group Co., Ltd. in August 2004, its design capacity was 1080kt/a of oil product. This is the first direct coal liquefaction commercial demonstration plant in the world. The plant was completed and put into production in 2009, coal liquefaction technology and catalyst researched and developed by Shenhua Group was used by this plant. The project achieved long-term stable operation in 2010.Now, Shenhua Group has started the construction of the second and the third direct liquefaction production lines (each line with production capacity of about 1000kt/a of oil product) of the project (Phase I),and the construction of the project (Phase II)(an indirect liquefaction production line of 1000kt/a of oil product) was also started synchronously.

The construction of a coal-to-oil industrial demonstration plant was started by Inner Mongolia Yitai Group in May 2006, the construction capacity of the plant is 160kt/a of oil. Qualified oil was produced by the plant on March 27 ,2009. This plant is the first completed and put-into-production indirect coal liquefaction demonstration plant in China, Integrated Technology of High Temperature Slurry FT Process (HTSFTP®) with proprietary intellectual property rights developed by Sinofuels China was adopted by the plant. This technology has been used for two 160kt/a demonstration plants of Inner Mongolia Yitai and Shanxi Luan to achieve the long-term stable operation. Now in China large-scale projects of coal indirect synthesis oil that are under construction by HTSFTP® technology are mainly:4000kt/a coal to oil project of Shenhua Ningxia Coal Industry Group, 1800kt/a coal to oil project of Shansi Luan Changzhi, 900kt/a coal to oil project of Yitai Yili Energy Co., Ltd., Yitai - Huadian Ganquanpu 2000kt/a Coal to Oil Project , 1200kt/a fine chemicals demonstration project of Inner Mongolia Yitai Hangjinqi, 2000kt/a coal indirect liquefaction demonstration project of Inner Mongolia Yitai Coal-to-Oil Co., Ltd. In addition, a 1100kt/a coal indirect liquefaction demonstration project is under construction by using coal to oil technology developed by Yanzhou Mining Group. By 2020,the total capacity of coal to oil projects is planned to reach 30,000kt/a in China.
 

 

Position of ECEC in the industry

ECEC participated in EPC general contract of partial units (including catalysts preparation unit, desulfurizing unit ,sour water stripping unit, oil residue forming unit and wastewater treatment unit) of the first production line of Shenhua Group Co., Ltd. coal direct liquefaction project.

ECEC was not only the overall design institute of Yitai - Huadian Ganquanpu 2000kt/a coal to oil project during engineering design stage, but also EPC general contractor of purification unit, exhaust gas conversion hydrogen production unit, wastewater treatment reclamation and evaporation crystallization unit as well as some utilities.

At present, ECEC is participating in basic engineering design of the second and the third production lines of coal direct liquefaction project (Phase I) and air separation unit and coal gasification unit of the project (Phase II) of Shenhua Group Co., Ltd.

Typical projects completed by ECEC include:
 

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The first production line of coal direct liquefaction project (Phase I) of Shenhua Group Co., Ltd., its design capacity is 1080kt/a of synthetic oil, mainly including catalysts preparation unit, coal liquefaction unit, hydrogenation stabilization unit, hydrogenation reformer, coal to hydrogen production unit, sulfur recovery facility, phenols recovery unit, coal preparation unit, light hydrocarbon recovery unit, desulfurizing unit, sour water stripping unit, oil residue forming unit, air separation unit, liquid storage and transport and handling facilities , etc. as well as necessary utilities and auxiliary facility.

Yitai-Huadian Ganquanpu 2000kt/a coal to oil project, mainly including air separation unit, raw coal pre-drying unit, fine coal gasifier, purification unit, oil product synthesis unit, oil processing unit, exhaust gases hydrogen production unit, solid material storage and transport system, liquid material storage and transport system, flare stack ,power center as well as associated utilities and auxiliary facility.
 

Source of technology

ECEC has accumulated more than 10 years of rich experience in coal to oil projects. To maintain its leading advantage in coal to oil industry, ECEC has kept long term cooperation with several domestic companies that are engaged in research of coal liquefaction technology. Meanwhile, ECEC has good cooperation with world famous licensors, such as TOPSOE of Denmark, Germany Lurgi, France Air Liquid Group, Germany Linde AG, Germany Siemens AG, etc.

In addition, ECEC was also involved in engineering, construction and pilot run of "kilotons Fischer Tropsch synthesis high-end wax pilot plant" of Yashen Technology R & D Center (Shanghai) Co., Ltd, and completed process design package of 80kt/a Fischer Tropsch synthetic wax project together with Yashen technology with Yashen technology R & D Center (Shanghai) Co., Ltd.

ECEC and TOPSøE of Danmark deeply discussed methanol to gasoline technology (MTG) and synthetic gas to gasoline technology (STG), expanded planning consulting and prepared feasibility study report for the Client by using the technology.

Sample project

Yitai - Huadian Ganquanpu 2000kt/a coal to oil project is a typical million tons coal to oil project. ECEC was general design institute of basic engineering design and detailed engineering design of the project, undertook engineering design of central control room, central laboratory ,purification unit, fire station / gas protection station, fire pump station, 110KV power transformation and distribution center, pipe gallery of the whole plant, emergency water basin of the whole plant, several circulating water stations. Moreover, ECEC was EPC general contractor of purification unit, exhaust gases conversion hydrogen production unit, wastewater treatment reclamation and evaporation crystallization unit and some utilities.

The basic engineering design of the project was started in May 2013, review of basic engineering design was completed in 2014 and site construction was started in August 2014. The plant is planned to be put into operation at the end of December, 2016.

The project is composed of the following main units:
 

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Gasification unit: including coal milling and drying unit, coal pressurization and feeding unit, gasification and crude synthetic gas scrubbing ,slag and grey water processing unit.
Operating pressure of gasification unit is 4.0MPa, 12 sets of home-made HTL gasifiers (daily coal handling capacity of a gasifier is 1800 tons) are provided, and 12 gasifiers are all in operation. China Aerospace Changzheng Chemical Engineering Co., Ltd. is responsible for supply of process package and key equipment, basic engineering design and detailed engineering design of the gasifiers.

Purification unit: including CO shift conversion unit, desulphurization/ decarbonization unit, fine desulfurization unit, refrigeration unit, CO2 compression unit, acid water steam stripping unit, sulfur recovery unit, they are all 2 series.
Domestic sulfur-resistant conversion catalysts is used for CO conversion, three-stage wide temperature sulfur-resistant conversion scheme is used, basic engineering design and detailed engineering design are completed independently by ECEC with its own technology.
For desulphurization/decarbonization section, cryogenic methanol wash process of Germany Lurgi is used for selective removal of CO2 and H2S from synthetic gas, plate type absorber is used, basic engineering design and detailed engineering design are completed independently by ECEC.
For fine desulphurization section, fine desulfurization catalyst developed by Hubei Chemical Industry Research Institute is used to reduce total sulfur content of purification synthetic gas below 0.5ppm. engineering design is completed independently by ECEC.
Refrigeration unit: propylene compression refrigeration technology is used to supply refrigeration for cryogenic methanol wash and synthetic oils units, home-make centrifugal type propylene compressor is used, engineering design is completed independently by ECEC.
Four-stage centrifugal compressor is used for CO2 compression to heat high concentration CO2 gas produced from cryogenic methanol wash respectively to 7.1MPa(G) and 5.6MPa(G) and send the gas to powder coal gasifier, 2 compressors are provided, normal handling ability of single set series compressor is 90750 Nm3/h; imported unit of Germany Simens is adopted, engineering design is completed independently by ECEC
Pure oxygen two-stage Claus + tail gas incineration technology of Hefeng Technology Co., Ltd. is used for sulfur recovery section, sulfur recovery tail gas is sent to thermoelectric unit along with boiler flue gas for desulphurization and then discharged after reaching the relevant standards. Process package of sulfur recovery section is provided by Hefeng Technology Co., Ltd. and engineering design is completed by ECEC.

Oil synthesis unit: including Fischer Tropsch synthesis unit, catalyst reduction unit, wax filtering unit and tail gas decarbonization unit; HTSFTP® proprietary technology developed by Synfuels China is used and Sinofuels Engineering Co., Ltd. is responsible for engineering design.

Oil processing unit: including hydrogenation refining unit, hydrogen cracking unit, processing unit and low temperature oil washing unit, one series is adopted, Sinofuels Engineering Co., Ltd. is responsible for engineering design.

ail gas hydrogen production unit: including membrane separation unit, tail gas conversion unit, reforming gas shift conversion unit, compression unit, PSA hydrogen extraction unit, engineering design is completed independently by ECEC with its own integration technology.
Membrane separation systems is used for separation of oil washing dry gas from oil processing unit and one series is adopted.
Exhaust gases conversion unit is used for handling of impermeable gas from membrane separation, by self-heating pure oxygen conversion process (ATR), hydrocarbon of impermeable gas is reformed into H2 and CO, in series with 1-stage shift reactor CO is reformed into H2, then they are sent to cryogenic methanol wash unit of purification plant for removal of CO2 and returned to PSA unit feedstock. Reformer burner is advanced ATR burner imported from Johnson Mattey of the U.K., at the same time pure oxygen conversion catalyst is also imported from Johnson Mattey of the U.K., one series is adopted.
Two sets of PSA hydrogen extraction units are designed, PSA1 is used for decarbonization gas purifying pure hydrogen gas, and PSA2 is used for membrane separation permeable gas purifying pure hydrogen gas.
Compression unit is provided with 2 centrifugal compressors, one compressor is used for repressurization of membrane separation permeable gas, another compressor is used for repressurization of resolving gas from 2 sets of PSA, repressurized resolving gas is sent to fuel gas pipeline network of the whole plant.

Raw coal predrying unit; it’s composed of 4 series, every production series including raw coal storage, drying, dry coal conveyance and air cooling. Raw coal predrying unit adopted internal heating fluidized bed coal drying process developed by Shandong Tianli Drying Technology and Equipment Co. Ltd., both basic engineering design and detailed engineering design is undertaken by Shandong Tianli Drying Technology and Equipment Co. Ltd.

Air separation unit: air separation unit is used to provide gas for coal gasification unit and supply necessary high purity N2 for the whole plant.
Air separation unit is planned to be constructed and operated by Air Liquid of France in the mode of BOT. Production Capacity of air separation unit is 4 ×115000Nm3/h of oxygen gas and necessary back-up system is set up (one liquid nitrogen storage tank of 1000Nm3, one liquid oxygen storage tank of 1500 Nm3, liquid nitrogen pump, liquid oxygen pump ,gasifier , etc.).Flow of liquid oxygen in-plane compression is used to directly produce high pressure oxygen gas.

Control system of the plant: imported DCS and SIS are used for the whole coal to oil production system to realize automation of production control and detection.

 

   
 

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