Presentation on Coal Gasification based Urea plant of Talcher Fertilizers Ltd. Panel Discussion – Gasification India 2017 India’s First Clean Coal Technology Plant 07 th December, 2017
Talcher Fertilizers Ltd. Game Changer for India Alternative avenue for vast consumption of high ash Indian coal Clean Coal Technology Reduced dependence on LNG Alternative route for production of NG equivalent syngas
Project Location Category of Project Revival, categorized with green field project of closed units of FCIL • Project Location :Talcher, Odisha (140 km from Bhubaneswar)
Production Capabilities Syngas :189,000 Nm 3 /day Ammonia :2200 TPD (0.73 MMTPA) Urea :3850 TPD (1.27 MMTPA) Gasification by – products • Sulphur : 95 TPD • Slag :1342 TPD (56 TPH) • Fly ash :112 TPD (4.7 TPH)
Challenges for Talcher Fertilizers Technology which can handle high ash content (up to 47%) of Indian coal Proximate Coal Analysis: • Moisture, % wt. :5.00 • Ash, % wt. :43.50 (max. 47%) • Volatile, % wt. :25.75 • Fixed Carbon, % wt. :25.75 • Fluidity point, ºC :>1400 • HHV MJ/kg :16.81 Plant can handle pure coal feed and petcoke blend up to 25%
Clean Coal Technology Future Uses Coal + Petcoke * CO 2 Feed Syngas Preparation 10% Fly Ash H 2 Gas Ammonia Urea Gasification Shift Clean-up Synthesis Production O 2 90% Air N 2 Urea Separation N 2 Slag to Sulphur To market market Recovery Air Coal Gasification Process of Talcher Fertilizer * Balance CO2 shall be captured
Gasification Technology Shell Coal Gasification Technology (SCGP) – entrained bed technology
Raw Material & Sources Coal • Source :50% North Arkhapal Srirampur Mine • Consumption : - Total :7572 MTPD (2.5 MMTPA) - Gasification :3331 MTPD (1.09 MMTPA) - CPP :4241 MTPD (1.40 MMTPA) • Transportation to Plant: via 10 km long conveyor Petcoke Source :IOCL Paradip Refinery • (200 km from Talcher) Consumption :1000 MTPD (0.32 MMTPA) • Transportation to plant : Railway and Road •
Concept of Petcoke Blending Petcoke: Low Ash, high heating value: Ash 0.1%, C 90%, 8500 kcal On mixing with Coal, improves stability of operation Largely mitigates problems of high Ash content of Talcher Coal Petcoke blend reduces overall Ash content Coal Quality (Ash%) Petcoke % in Blend Resultant Ash % 43 10 38.7 43 15 36.6 43 25 32.3 40 (Bhubneshwari coal) 25 <30 Worldwide proven plants are available and operated upto 35% Ash Blending gives plant flexibility of processing different proportions of Coal and Petcoke
Project Schedule Tendering & Awarding of Major Packages: Package NIT Date Status Boundary wall and approach 25.08.2017 (award date) Work under road Work progress Site Grading tender 27.10.2017 (Bid opening) 30.12.17 (award) Coal Gasification LSTK tender 18.05.2017 10.01.18 (Bid open) Urea Ammonia LSTK tender 9.10.2017 8.1.18 (Bid open) CPP & Offsite tenders 30.01.2018 (expected) Sl. Description Timelines 1 Duration of project 41 months 2 Construction start / Zero Date Feb. 18 / Apr. 18 3 Mechanical completion (MC) (36 months) Feb., 2021 4 Commissioning (5 months from MC) Jul., 2021 5 COD Sep., 2021
Strategy Document for Technology Expansion Strategy for technology expansion Clue from China coal gasification technology • expansion. 121 operating plants and 57 under construction coal gasification plants Total 400 gasifiers (322 in China). 11 built by L&T • About 300 mmscmd equivalent NG production in • China China coal consumption 10 MTPD, India is 2 MTPD • China consumption in gasification is 1.6 MTPD • Additional 11 Gasifiers proposed, 13.2 mmscmd NG • equivalent
Timelines for Technology Expansion elsewhere in India Plant /Mine No. of NG equiv. Timelines DFR/ Product Location Gasifiers (mmscmd) Planning Talcher/ 02 2.40 Jul., 21 Ready NH3/Urea Talcher mine Talcher/ 01 1.20 2023 Execution Methanol/other Talcher mine by GAIL chemicals Jharsuguda/ 04 4.80 Mahanadi coal mine Asansol/Durgapur 03 3.60 Mar., 18 2025 As per DFR Raniganj mines Sindri/ 03 3.60 Jharia mines Total 13 15.6 Approx. annual saving of Rs. 10k cr. By 2035 • Target: 50 gasifiers, 16MMTPA LNG equiv. Rs. 50,000 cr. import bill • Ultimate Target: To minimize India’s dependency on LNG imports
North Arkhapal Srirampur Mine Tentative Geological reserves : 920 million ton Block area : 11.7 sq. km Tentative grade of coal : G 9 to G 14 Coal field : Talcher, Angul Odisha Status of mine : GR report for DFR by M/s CMPDI in Jan., 19 Bridge Linkage for start up : Bhubneswari coal mine Ash content : 35 to 47% (avg. 40%)
Value Addition Plans (Future) Provision of conversion of excess Syngas (100,000 Nm3/d) into methanol and other chemicals Provision of additional gasifier for natural gas production Sulphur enhancing purification unit – lumps to granules Conversion of excess CO2 to dry ice and sale of liquid N2 Production of melamine from urea
Thank You
Location of additional Gasifiers
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