The R&D Center - gcg-es.com

1 The R&D Center The aerial view shows the impressive extension of the R & D Center How is Research and Introduction Development defined at Lurgi? Since the company's founding in the year 1897, Lurgi has For Lurgi, Research and Development means the definition actively supported research and development. The establish- and implementation of R&D projects, which are derived ment of the company s own R&D Center in 1937 bears evi- from the corporate objectives through a holistic strategic dence to the importance attached to the development of approach. The R&D tasks are chiefly driven by the market. proprietary technologies as an essential element of the international plant engineering and contracting business. Consequently, R&D projects have the following objectives: Located to the East of Frankfurt, on premises covering more Develop new products/processes that are technically and than 50,000 square meters, this is where Lurgi pooled its commercially mature just in time (applied research).

2 Research facilities. The necessary test equipment was Preserve/boost the market attractiveness of existing prod- installed, laboratories and pilot facilities were erected and a ucts/processes in a continuous improvement process comprehensive infrastructure set up. Today, many services (development). at the workshop level for example are no longer rendered Support the marketing efforts for existing products/. by own Lurgi staff but are outsourced. This arrangement processes by specific testing and analysis of feedstocks, permits the company to focus on its research activities. intermediates, end products, catalysts, etc. (technical improvement and service). In July 2007, a strong partnership also in the field of R&D. led to the acquisition of Lurgi by Air Liquide. Air Liquide These clearly defined tasks determine the structure and operates its own R&D centers around the world, in equipment of the research laboratory that will be presented France, Japan, USA, etc.

3 They command an excellent knowl- below. The core activities of Lurgi have been focused edge of the respective fields of expertise. The shared target on 50 product groups from the areas petrochemicals, gas is to develop energy-efficient processes, invent clean production and treatment, gas-to-chemicals technologies as processes by limiting nitrogen oxide and CO2 emissions, and well as renewable resources. As a result, virtually all ongo- develop new energy solutions such as hydrogen, gasifica- ing R&D projects handled by the research laboratory derive tion, biomass, clean coal, etc. for a sustainable environ- from these business segments. Experimental work at the ment. research laboratory is supported by the development activi- ties of the associated process and engineering disciplines The Lurgi R&D Center now forms part of the worldwide from the relevant technology group. An important element Engineering & Construction operations of Air Liquide.

4 Of Lurgi strategy is to execute R&D projects together with partners and customers, or to commission universities or institutes with such tasks. This strategy is designed to allo- cate competences and resources appropriately and timely to the corresponding research and development targets. 2. Structure and Organization Current R&D Projects Providing R&D services at an optimized cost/benefit ratio Following, some typical R&D projects are presented for is a challenge for every company. To this end it is essential the business segments in order to illustrate the diversity of not only to make available the necessary resources in terms subjects handled, and provide at the same time an overview of labor, equipment and budget but also to implement of the technical capabilities of the research laboratory. an efficient organization and structure. R&D at Lurgi is assigned to the technology business segment and, hence, subordinated to the Board of Management member respon- sible for technology.

5 By meshing R&D with process engi- neering, experimental work at lab scale is directly tested against the planned commercial scale implementation. This translates into a shortening of development times and HP-POX. avoids technical as well as commercial risks early on. A. discipline-specific university training as a chemist, physicist Gas Generation MPG. or process engineer is therefore the best starting point for a career in R&D. The highly qualified staff of our research Purification laboratory ensures competent assistance to the business segments of Lurgi. Methanol Process development always implies an efficient analytical laboratory, which will be presented below. It is also essential MTP . to organize round-the-clock shift operation to feed the test R&D Gas-to-Chemicals equipment as required and monitor operational safety and MtSynfuels . reliability. DME. Petrochemistry Geminox . BtL. Renewable Biodiesel Ressources Fatty Alcohols 3.

6 HP-POX Freiberg Gas Generation and Purification Lurgi Syngas Technologies Test units are available at the Lurgi R&D Center to test the The efficient production of synthesis gas is the key process high-pressure and high-temperature reforming of gas and for an economical conversion of various inexpensive feed- naphtha. These units are used to support catalyst develop- stocks to valuable products such as transport fuels, metha- ments and to test new process conditions arising from nol and ammonia. Large syngas capacities are required new gas production concepts for optimum heat integration. to economically convert natural gas in remote locations to A demonstration unit for high-pressure partial oxidation transportable products on the Gas to Liquids (GTL) and Gas processes (HP-POX Plant) was built at the Institute of Energy to Chemicals (GTC) routes. Synthesis gas as well as hydro- Process Technology and Chemical Engineering of the Tech- gen and carbon monoxide are primarily obtained by reform- nical University and Mining Academy of Freiberg.

7 This joint ing natural gas. In addition, the high-temperature gasifica- research project is backed by the German Ministry of Eco- tion of inexpensive refinery residues is economical. nomics and Technology (BMWi) and by the Saxon Ministry of State for Science and Art (SMWK). The processes available for this purpose are This pilot unit is designed as multi-process test facility. Tests Steam reforming (Lurgi reformer) have been performed for catalytic autothermal reforming Autothermal reforming (catalytic partial oxidation) (ATR) and non-catalytic partial oxidation of natural gas Non-catalytic partial oxidation (Gas) (Gas-POX) as well as gasification of liquid feedstock (MPG). Multi Purpose Gasification (MPG) (partial oxidation The maximum operating pressure is 100 bar and the through- of liquid feedstock) put is 500 kg/h of liquid feedstock and 500 m3n /h for natural gas, respectively. The processes, which have been established for decades, are continually developed further, prompted by progress achieved in catalysts, construction material and the need for larger single train capacities.

8 4. Wax Ester Hydrogenation, VVF-India Rectisol Ultra Pure Syngas Natural Gas Turbine Gas Purisol . Pipeline Gas Raw Syngas aMDEA Pure Off-Gas MDEA/DEA. Pure CO2 By-Product Off-Gas Sulfur Tail Gas Sulfur Others Recovery Treating Own Technology Specific Expertise Gas Purification clients are performed. They complement the existing data- Lurgi commands the full range of gas purification tech- base and improve the scale-up procedure. A specialized nologies, partly as proprietary technologies and with out- laboratory is operated for the quantitative analysis of sulfur standing know-how for open-art technologies like amine components as well as trace components prevailing typically treating. The design basis of these technologies was devel- in raw gases from the gasification of oil, coal and natural gas. oped at the R&D Center in the pilot plants available and by determining solvent properties with specially designed labo- Sulfur Management ratory equipment.

9 Refineries and gas producers have to cope with increasingly The gas purification test unit is designed as multi-process more stringent environmental protection and emission test facility. Removal of hydrogen sulfide, carbon dioxide control regulations. Lurgi's well-known sulfur recovery tech- and other typical trace components has been tested exten- nologies, such as OxyClaus , Sulfreen , Lurgi Tail Gas sively with physical as well as chemical solvents. The pilot Treating and Omnisulf , are continually optimized at the plant comprises several columns designed for pressures up R&D Center . to 100 bar. When employing a wide range of structured and random packings as well as trays, gas loads of 12,000 and In this field, Lurgi cooperates with research partners like the solvent loads of up to 20 ln per hour can be applied. University of Strasbourg and with industrial partners, The different columns and the process equipment the oil and gas producer Total Fina Elf and the catalyst sup- can be connected according to the process requirements plier S d-Chemie.

10 The resulting combination of the most and parameters to be tested. Operation of the plant is current research results, experience in catalyst development fully automatic. A state-of-the-art DCS and safety system and production as well as in-depth knowledge of the is employed for process control and data acquisition. process and our customers' needs enables Lurgi to offer The pilot plant is used to determine the selectivity and optimized process solutions to reduce industrial emissions capacity of various solvents as well as their interaction with and meet or exceed the environmental regulations. trace components and construction materials. Measure- ment campaigns in the commercial-scale plants of Lurgi's 5. Methanol Reactor Gas-to-Chemicals MTP Methanol to Propylene identical gas velocities, identical temperature profiles and During initial pilot plant tests at the Lurgi R&D Center , the identical residence times.