UMATAC Industrial Processes€¦ · FMG is in the final stages of constructing an oil shale...
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The Alberta Taciuk P - The FMG P UMATAC In The Fushun Mining Group (F processing, and manufacturi final stages of constructing a Process (ATP) Technology un ATP Systems, a Division of A FMG is famous in China for i world measuring 6 km long, 2 capacity of this facility is 8.4 above the coal deposit and is FMG produces oil from a por but the vertical retorts can no The fines are currently being rejected fines will be redirect (Above) The ATP Processor for the FMG Project is similar in size to the Processor for the Stuart Oil Shale Research and Development Project, built in Gladstone, Australia in 1999. 1) Introduction 2) Project Development UMATAC, in cooperation with Polysius AG, a ThyssenKrupp company based in Germany, began discussions with FMG in 2002 to explore use of the ATP Technology with Fushun oil shale. UMATAC obtained small oil shale samples from FMG in 2003 for testing at UMATAC’s pilot plant facility. Based on the test results, the parties held technical discussions and review meetings in China in 2003, 2004, and 2005. In 2004, FMG shipped 100 tonnes of oil shale to Calgary. This material was tested in 2005 in UMATAC’s 5 tonne/hour pilot plant. Following the test program, the parties held further technical discussions UMATAC’s 5 tonne/hour pilot plant. Following the test program, the parties held further technical discussions and negotiations culminating in the contract for design and construction of the first ATP System for FMG. Project Highlight ¾ First application of Chinese oil shale. ¾ Design teams locate China. ¾ Leading edge field m proven. This has ov size restrictions. ¾ Environmental perfo and greenhouse ga A) Project Construction The FMG plant site is located inland and approximately 450 km from the nearest deep water port. Many of the large diameter components of the ATP Processor had to be shipped in sections then welded and field machined to meet the required tolerances. These erection procedures include field welding and leading edge field machining process that has overcome previous machine size restrictions. ATP Processor Mechanical Summary: • Rotating length = 63 m (206 ft) • Outer shell diameter = 8.5 m (28 ft) • Support tyre diameter = 11 m (36 ft). • Operating weight = 2,800 tonnes (3,100 tons) • Operating speed = 4.0 rpm • Installed drive power = 2800 kW (3750 hp) B T p e • • • • • • (Left and Below) The “ATP Center Support” section of the outer shell – manufactured in Malaysia. Shipping weight was 164 tonnes. (Above) The ATP Center Support with Preheat Tube connections. (Above) View inside the ATP Processor Combustion Zone. (Above) View of Combustion End and Hydrocarbon Vapour Cyclones. (Above) View of Cooling Zone (Feed and Discharge End). Process (ATP) Technology Project in China - ndustrial Processes FMG) is a large state owned coal mining, coal ing company based in Fushun, China. FMG is in the an oil shale processing plant using the Alberta Taciuk nder license from UMATAC Industrial Processes – AECOM Canada. its West Open Pit coal mine, one of the largest in the 2.2 km wide, and 400 m deep. Coal production million tonnes/year. The oil shale at the mine lies s mined as over-burden. rtion of the oil shale using a vertical retort technology, ot process the fine portion of the crushed oil shale. g discarded. Once the ATP System is in operation, the ted to the ATP plant. (Above and Left) Assembly of the ATP Processor on the plant site in Fushun, China. (Left) Field machining of the 11 m (36’) diameter support tyres on-site. This was a leading edge field- machining operation successfully completed under challenging Design and construction of the first FMG ATP plant commenced in early 2006 and was originally scheduled for completion in late 2008. A combination of equipment delivery delays, high demand for commodities world wide, pressures within China due to the Olympic preparations and limited Chinese engineering availability resulted in delay of the plant completion date to early 2010. 3) The FMG Project, Fushun, China (Below) View of assembled ATP Processor. challenging conditions in China. 2010. ts the ATP Technology to ed in Canada, Germany, and machining technique was vercome previous equipment ormance has been enhanced as emissions reduced. B) Environmental Performance The first ATP System being constructed at FMG will be used to confirm and demonstrate the plant’s ability to achieve the targets set for the project. The design teams have implemented new equipment configurations and design changes to improve environmental performance, including: Installing equipment to recover heat from the hot flue gas and spent shale leaving the ATP Processor. This equipment reduced greenhouse gases by 15%. A preheat gas thermal oxidizer to destroy potentially odorous compounds. Wet scrubbing of sulphur dioxide and ammonia from the flue gas to reduce pollutant emissions. Use of high efficiency baghouse dust collectors to minimize particulate emissions. Improving resource utilization by making use of the 20% of the shale that is currently discarded. Achieving fuel self sufficiency – no imported fuel (such as natural gas) is required to operate the ATP Processor. (Right) High efficiency baghouse dust collectors and flue gas fan. (Left) Off Gas Heater. (Above) Feed and Ash Handling Systems. (Above) Hydrocarbon Vapour Scrubber and Fractionator (Oil Recovery). (Above) Oil Recovery plant. The FMG ATP facility has a rated oil shale processing capacity of 1,750,000 tonnes/year (230 t/h). If operating results from the first unit meet expectations, FMG will install three to five additional ATP System trains, and opportunities for expansion into other locations in China are opened.
Transcript of UMATAC Industrial Processes€¦ · FMG is in the final stages of constructing an oil shale...
The Alberta Taciuk Process (ATP) Technology- The FMG Project in China
UMATAC Industrial Processes
The Fushun Mining Group (FMG) is a large state owned coal mining, coalprocessing, and manufacturing company based in Fushun, China. FMG is in thefinal stages of constructing an oil shale processing plant using the Alberta TaciukProcess (ATP) Technology under license from UMATAC Industrial ProcessesATP Systems, a Division of AECOM Canada.
FMG is famous in China for its West Open Pit coal mine, one of the largest in theworld measuring 6 km long, 2.2 km wide, and 400 m deep. Coal productioncapacity of this facility is 8.4 million tonnes/year. The oil shale at the mine liesabove the coal deposit and is mined as over
FMG produces oil from a portion of the oil shale using a vertical retort technology,but the vertical retorts can not process the fine portion of the crushed oil shale.The fines are currently being discarded. Once the ATP System is in operation, therejected fines will be redirected to the ATP plant.
(Above) The ATP Processor for the FMG Project is similar in size to the Processor for the Stuart Oil Shale Research andDevelopment Project, built in Gladstone, Australia in 1999.
1) Introduction
2) Project Development
UMATAC, in cooperation with Polysius AG, a ThyssenKrupp company based in Germany, began discussionswith FMG in 2002 to explore use of the ATP Technology with Fushun oil shale. UMATAC obtained small oil shalesamples from FMG in 2003 for testing at UMATAC’s pilot plant facility.
Based on the test results, the parties held technical discussions and review meetings in China in 2003, 2004,and 2005. In 2004, FMG shipped 100 tonnes of oil shale to Calgary. This material was tested in 2005 inUMATAC’s 5 tonne/hour pilot plant. Following the test program, the parties held further technical discussionsUMATAC’s 5 tonne/hour pilot plant. Following the test program, the parties held further technical discussionsand negotiations culminating in the contract for design and construction of the first ATP System for FMG.
Project HighlightsFirst application of the ATP Technology toChinese oil shale.Design teams located in Canada, Germany, andChina.Leading edge field machining technique wasproven. This has overcome previous equipmentsize restrictions.Environmental performance has been enhancedand greenhouse gas emissions reduced.
A) Project ConstructionThe FMG plant site is located inland and approximately450 km from the nearest deep water port. Many of thelarge diameter components of the ATP Processor had tobe shipped in sections then welded and field machined tomeet the required tolerances.
These erection procedures include field welding andleading edge field machining process that hasovercome previous machine size restrictions.
ATP Processor Mechanical Summary:
• Rotating length = 63 m (206 ft)
• Outer shell diameter = 8.5 m (28 ft)
• Support tyre diameter = 11 m (36 ft).
• Operating weight = 2,800 tonnes (3,100 tons)
• Operating speed = 4.0 rpm
• Installed drive power = 2800 kW (3750 hp)
B) Environmental PerformanceThe first ATP System being constructed at FMG will be used to confirm and demonstrate theplant’s ability to achieve the targets set for the project. The design teams have implemented newequipment configurations and design changes to improve environmental performance, including:
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(Left and Below) The “ATPCenter Support” section ofthe outer shell –manufactured in Malaysia.Shipping weight was 164tonnes.
(Above) The ATPCenter Support withPreheat Tubeconnections.
(Above) View inside the ATP ProcessorCombustion Zone.
(Above) View of Combustion End andHydrocarbon Vapour Cyclones.
(Above) View of Cooling Zone (Feedand Discharge End).
The Alberta Taciuk Process (ATP) TechnologyThe FMG Project in China -
UMATAC Industrial Processes
The Fushun Mining Group (FMG) is a large state owned coal mining, coalprocessing, and manufacturing company based in Fushun, China. FMG is in thefinal stages of constructing an oil shale processing plant using the Alberta TaciukProcess (ATP) Technology under license from UMATAC Industrial Processes –ATP Systems, a Division of AECOM Canada.
FMG is famous in China for its West Open Pit coal mine, one of the largest in theworld measuring 6 km long, 2.2 km wide, and 400 m deep. Coal productioncapacity of this facility is 8.4 million tonnes/year. The oil shale at the mine liesabove the coal deposit and is mined as over-burden.
FMG produces oil from a portion of the oil shale using a vertical retort technology,but the vertical retorts can not process the fine portion of the crushed oil shale.The fines are currently being discarded. Once the ATP System is in operation, therejected fines will be redirected to the ATP plant.
(Above and Left) Assembly of theATP Processor on the plant site inFushun, China.
(Left) Fieldmachining ofthe 11 m (36’)diametersupport tyreson-site. Thiswas a leadingedge field-machiningoperationsuccessfullycompletedunderchallenging
Design and construction of the first FMG ATPplant commenced in early 2006 and wasoriginally scheduled for completion in late 2008. Acombination of equipment delivery delays, highdemand for commodities world wide, pressureswithin China due to the Olympic preparations andlimited Chinese engineering availability resultedin delay of the plant completion date to early2010.
3) The FMG Project, Fushun, China
(Below) View of assembled ATPProcessor.
challengingconditions inChina.
2010.
Project HighlightsFirst application of the ATP Technology to
Design teams located in Canada, Germany, and
Leading edge field machining technique wasproven. This has overcome previous equipment
Environmental performance has been enhancedand greenhouse gas emissions reduced.
B) Environmental PerformanceThe first ATP System being constructed at FMG will be used to confirm and demonstrate theplant’s ability to achieve the targets set for the project. The design teams have implemented newequipment configurations and design changes to improve environmental performance, including:
Installing equipment to recover heat from the hot flue gas and spent shale leaving the ATPProcessor. This equipment reduced greenhouse gases by 15%.
A preheat gas thermal oxidizer to destroy potentially odorous compounds.
Wet scrubbing of sulphur dioxide and ammonia from the flue gas to reduce pollutantemissions.
Use of high efficiency baghouse dust collectors to minimize particulate emissions.
Improving resource utilization by making use of the 20% of the shale that is currentlydiscarded.
Achieving fuel self sufficiency – no imported fuel (such as natural gas) is required to operatethe ATP Processor.
(Right)High efficiency baghouse
dust collectors and fluegas fan.
(Left)Off Gas Heater.
(Above) Feed and Ash Handling Systems. (Above) HydrocarbonVapour Scrubber andFractionator (Oil Recovery).
(Above) Oil Recovery plant.
The FMG ATP facility has a rated oil shale processing capacity of 1,750,000 tonnes/year (230 t/h).
If operating results from the first unit meet expectations, FMG will install three to five additional ATPSystem trains, and opportunities for expansion into other locations in China are opened.
