co2 utilisation in meoh and nh3/urea · pdf filecasale technologies ammonia nitric acid urea...
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CO2 UTILISATIONIN MeOH
AND NH3/UREA PLANTS
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CASALE TECHNOLOGIES
Ammonia
Nitric Acid
Urea
Ammonium Nitrate
Solution UAN
Solid ANPRIL/GRAN/C
AN
Syngas generation
Melamine
SuperPhosphateSSP/TSP/USP
DAP / NP / NPK
Methanol
NitrogenFertilizer
PhosphateFertilizer
ComplexFertilizer
NG
Most of Methanol and NH3/Urea is produced from natural gas
These plants utilise the ‘Steam Reforming’ (SMR) for the syngas generation.
CO2 0.5 t/t MeOH0.25 t/t Urea
This process is based on the reaction between methane and steam.
CH4+H2O=CO+3H2 (very endothermic)
CO+H2O=CO2+H2 (slightly exothermic)
T=800/850 C P=25/35 bar
The reaction heat is supplied by burning fuel (NG)
A standard MeOH plant has a capacity of 3’000 MTD and the CO2 emissions from the SMR are ab. 1’500 MTD
A standard NH3/Urea plant has a capacity of 2’000/3’200 MTD and the CO2 emissions from the SMR are ab.1’100 MTD
Urea is the key to nitrogen fertilization
Urea
World production is ab. 200 Million TY
Without nitrogen fertilization, the earth could sustain a maximum of 4 billion people… but we are 7 billion!
NO UREANO PARTY
NH3/UreaThe syngas produced, is converted into NH3, and then Urea,
3H2+ N2=2NH3
2NH3+CO2=(NH2)2CO+H2O
The CO2 comes from the SMR reaction and from the shift reaction
Primary Reformer
Secondary Reformer CO shift CO2 removal Ammonia
synthesisUrea
synthesis
Fuel
SteamNatural gas
Flue gas
Air
H2, N2
NH3 Urea
CO2
CO2
The amount of CO2 available in the syngas is 10 % short of the necessary to convert all ammonia into urea
The CO2 necessary is available in the stack gas of the steam reformer
NH3/Urea
Primary Reformer
CO2recovery
Secondary Reformer CO shift CO2 removal Ammonia
synthesisUrea
synthesis
Fuel
SteamNatural gas
Flue gas
Air
H2, N2
NH3 Urea
CO2
CO2
MeOH Demand By Use and Region (2012)
MeOH
MeOHThe syngas produced, is converted into methanol, at about 80 bar, on a catalyst,
CO+2H2=CH3OH
CO2+3H2=CH3OH+H2O
The synthesis gas produced in the SMR is short of H2
Primary Reformer
Compression MeOHSynthesis Distillation
Fuel
SteamNatural gas
Flue gas
MeOH
CO2
H2
H2, CO
If CO2 can be provided in addition, then the plant capacity can be increased by 20 % with minimal modifications.
The CO2 necessary is available in the stack gas of the steam reformer
MeOH
Primary Reformer
CO2recovery
Compression MeOHSynthesis Distillation
Fuel
SteamNatural gas
Flue gas
MeOH
CO2
CO2
H2, CO
CDR Economics
CAPEX
Add
ition
al
$/T
ME
OH
DEPRECIATION. YEARS
OPEX
$/T
ME
OH
NG COST $/MBTU
• The use of a CDR allows to upgrade easily Methanol and NH3/Urea plants, utilizing CO2 presently vented
• The key to its success is the capital cost and the operability
• The research project Casale/ETH is focused on developing a new CDR concept to
• reduce the investement cost and the energy consumption
• Improve the operability
CONCLUSIONS
…THANK YOU….