gas to chemicals
DESCRIPTION
Gas to chemicalsTRANSCRIPT
India Chem 2002: Gas To Chemicals
Gas To ChemicalsGas To Chemicals
New Delhi, September 18-21, 2002New Delhi, September 18-21, 2002
Jens WagnerJens Wagner Technologically Advanced Natural Gas Monetization:
Opportunities for Chemicals & Petrochemicals
India Chem 2002: Gas To Chemicals
Agenda
Gas To Chemicals - Drivers
MegaSyn®-Technology
MegaMethanol®-Technology
Gas-Based Petrochemistry
Gas-Based Refinery
India Chem 2002: Gas To Chemicals
We are the leading engineering contractor
in the field of oil/gas/chemicals,
customer oriented
and focussed on proprietary technologies
and exclusive licenses for growth markets
like gas-to-chemicals,
and their global, professional realisation
from a single source.
Vision Lurgi Oel · Gas· Chemie
India Chem 2002: Gas To Chemicals
10
68
16
78
263
98
41
61
0 50 100 150 200 250 300
North America
S&C America
Western Europe
Eastern Europe & FSU
Middle East
Africa
Far East & Oceania
World
years
7,1%
7,8%
34,6%
38,1%
3,0%
4,3%
5,0%
% of globalreserves
Source: Energy Information Administration (EAI): ”International Natural Gas Information” 14 Feb 2001, http://www.eia.doe.gov
Driver INatural Gas: Reserves-To-Production Ratio
India Chem 2002: Gas To Chemicals
3,700 billion ft³ of natural gas are flared per year
World production of ammonia
4x World production of methanol
Source: Energy Information Administration (EIA): ”International Natural Gas Information” 14 Feb 2001, http://www.eia.doe.gov
Driver II
India Chem 2002: Gas To Chemicals
Driver III
India Chem 2002: Gas To Chemicals
WORLD POLYPROPYLENE PRICE COMPARISONCurrent Dollars
0
200
400
600
800
1000
1200
1990 1993 1996 1999 2002 2005 2008 2011 2014 2017 2020
USGC-Contract USGC-Spot
West Europe-Contract SEA ContractSEA Spot
Forecast
Dollar per Ton
Source: CMAI
Driver III
India Chem 2002: Gas To Chemicals
For years Lurgi Oel · Gas · Chemie GmbH is one of the mayor players in the field of Syngas Generation and Synthesis Technologies. Based on our
huge experience,
expertise, and
success
the Gas-to-Chemicals (GTC) route is a consequent further development and application of our core technologies and know-how.
Driver IV
Mossgas Fischer-Tropsch Plant
India Chem 2002: Gas To Chemicals
Lurgi Mega Concept -
SYNGASCO + H2
MethanolFT-
Fischer TropschProducts
DME
Hydrogen Olefins
PolypropyleneAcrylonitrilPolyethylene
Ethylene-Glycol-Olefins
Diesel-Additives
Formaldehyd
MTBE
Acetic Acid
Fuel
Diesel
LiquidsEnergy-Production
Fuel Cell,“GreenFuels“
Clean Fuels,Lubricants, -Olefins
„Stranded“Gas
Production of many high-value products
Urea
Ammonia
Basis of a gas-based Chemicals- and Refinery Industry
India Chem 2002: Gas To Chemicals
How do You want to produce Your Syngas?
ASU
5 x 1000 Tubes
1.5 Mio Nm³/h =560 Mio SCF/d
Syngas
1.5 Mio Nm³/h =560 Mio SCF/d
Syngas
1.5 Mio Nm³/h =560 Mio SCF/d
Syngas
ASU
India Chem 2002: Gas To Chemicals
0
100
200
300
400
500
0 0,3 0,6 0,9 1,2 1,5 1,8
SR
CR
ATR
relativecost
106 Nm3/h syngas
Gas to Syngas (MegaSynTM) - Investment Cost Comparison
India Chem 2002: Gas To Chemicals
Process Characteristics:
low S/C ratio 1.5 - 0.5 mol/mol high CO selectivity low CO2 emission
outlet temperature 900 - 1050 °C low methane slip close approach to equilibrium
pressure: 40 bar commercially proven(up to 70 bar possible)
single train capacity500,000 m3 syngas /hr under construction
Autothermal Reformer
India Chem 2002: Gas To Chemicals
Combined Reformer, Mossgas, South Africa
India Chem 2002: Gas To Chemicals
Gas to Chemicals Processing Routes
MegaSyn®
Fischer Tropsch
Synthesis
Mega-Methanol®
Upgrading
MTO
MTD
MTH
MtSynfuels
Acrylic Acid
Diesel
Gasoline
LPG
Fuel Gas
Waxes/Lube Oil
Power
Fuel Cells
Chemicals (MTBE, Acetic Acid, Formaldehyde)
Diesel/Gasoline
Propylene/Polypropylene
Acrylic Acid/Acrylates
Ethylene/Propylene
Fuel (DME)
Hydrogen
MTP®
Natural Gas /
Associated Gas
Megammonia® Ammonia/Urea/Fertilizer
MtPower
India Chem 2002: Gas To Chemicals
Lurgi’s LP-Methanol Technology Milestones
1969 First LP-Methanol Catalyst Test
1970 Cooperation with Süd-Chemie for Catalyst Manufacturer
1970 Operation of a 100 Tubes-Reactor Demonstration Unit
1972 First 3 LP-Methanol Plants in Operation
1997 MegaMethanolTM Concept Published
2001 37 LP-Methanol Plants including two awarded contracts for
MegaMethanolTM plants
India Chem 2002: Gas To Chemicals
Simplified Diagram of Lurgi‘s MegaMethanol® Technology
Desulphur-ization
Pre-Reforming
AutothermalReforming
MethanolDistillation
Air-Separation
PureMethanol
Oxygen
NaturalGas
PSA
MethanolSynthesis
Air
• improved gasification
• high energy efficiency for MeOH synthesis
• low investment costs
• large single-train capacity
methanol production cost of less than 50 $/t !
Syngas
Purge Gas
Crude Methanol
Steam
BoilerFeedWater
Gas-CooledReactor
Water-CooledReactor
India Chem 2002: Gas To Chemicals
Methanol Technology Competitive Situation
Market Share
Lurgi 27%
MGC,Other12%
ICI 61%
1969 - 1992 1992 - 2001
Lurgi 55%
MGC,Other20%ICI 25%
India Chem 2002: Gas To Chemicals
Dimethyl Ether (DME) -Alternative to Conventional Diesel Fuel
Excellent transportation fuel (“better diesel”)
Very low emission levels
Clean and efficient power generation Similar properties as LPG (storage, transport)
DME: Energy Carrier of the Future!(see www.aboutdme.org)
India Chem 2002: Gas To Chemicals
DME Production by Methanol Dehydration
DMEReaction
DMEDistillation
DMEProduct
Stabilised MeOH
H2ORecycle
MeOHRecycle
WasteWater
Off-gas
SyngasProduction
India Chem 2002: Gas To Chemicals
Reactor: Adiabatic Fixed Bed Reactor
High Conversion Rate
Purity: According to Requirement
Highly efficient Heat Integration Systems,resulting in low Utility Requirement
Low Utility Consumption
Zero Emission
Lurgi DME Process Features
India Chem 2002: Gas To Chemicals
Lurgi DME - Economics
MegaMethanol® & Dehydration Plant
DME production 5000 t/d
Natural gas demand 42.9 MMBtu/tDME28.5
MMBtu/tMeOH
Total fixed cost (EPC) 415 MMUS$
Production Cost 93.0 US$/tDME
= 3.4 $/MMBtu
Diesel fuel (for comparison) 4.8 - 6.1 $/MMBtu
based on NG price = 0.5 US$/MMBtu and both, depreciation & ROI 10% of total fixed cost
India Chem 2002: Gas To Chemicals
MTP 1 MTP 2 MTP 3
Gasoline
Fuel Gas
ProcessWater
DMEPre-Reactor
ProductConditioning
Propylene
LPG
Water Recycle
Olefin Recycle
Methanol
Reactor Stages
MTP® - Simplified Process Flow Diagram
India Chem 2002: Gas To Chemicals
Propylene production only
tailor-made, proprietary zeolite catalyst
Fixed-bed reactors
Low coking of catalyst results in low number of regeneration cycles
Discontinuous in-situ regeneration at reaction temperature
Proven process elements
Catalyst commercially available
MTP® - Technical Highlights
India Chem 2002: Gas To Chemicals
PROCESS More than 4000 operating hours of pilot plant in Frankfurt Demo unit in Norway started 01/ 2002, today about 3000
operating hours, more than 8000 scheduled Optimisation of process flow sheet for commercial plant
finished
CATALYST catalyst development completed by catalyst supplier catalyst is commercially manufactured and available
MTP® Technology Status
India Chem 2002: Gas To Chemicals
SyngasPlant
Poly-propylene
Plant
Propylene Plant (MTP)
Methanol Plant
Natural
Gas
1.7 Mio t/aMethanol
3.8 Mio Nm³/d 520 000 t/aPropylene
520 000 t/aPolypropylen
e
12.3 Mio Nm³/dSyngas
Case Study B, Blockflow Diagram
143 000 t/aGasoline
936 000 t/aWater
MTP Economics I
India Chem 2002: Gas To Chemicals
MTP Economics II
Methanol MTP PP Capacity MTY 1,700,000 520,000 520,000
Investment Cost EPC Mio US$ 350 215 165Owner‘s Cost incl. Capitalised Interest Mio US$ 70 43 33
Feed Cost US$ Natural Gas Methanol Propylene 0,5 $/MMBtu 43 $/t 174 $/t
Production Cost US$/t 42.9 210.1 261.0- Raw Materials US$/t 14.4 150.3 212.8- Utilities US$/t 1.6 5.6 6.8- Operation & Maintenance US$/t 5.6 11.3 8.6- Plant OVDH & Insurance US$/t 6.0 12.1 9.2- Depreciation US$/t 15.3 30.8 23.6
Credit for by-product Naphtha US$/t - - 35.7 - Cost of Product US$/t 43 174 261
Production Cost, Case Study B: Integrated MegaMeOH/MTP/PP Complex
India Chem 2002: Gas To Chemicals
MTP Economics III
ROI, Case Study B: Integrated MegaMeOH / MTP / PP Complex
Methanol - MTP - PP
Investment Cost EPC Mio US$ 730 Owner‘s Cost incl. Capitalised Interest Mio US$ 146
Feed Stock Cost US$ Natural Gas 0,5 $/MMBtu
Production Cost US$/t 154.3- Raw Materials US$/t 49.7- Utilities US$/t 9.1- Operation & Maintenance US$/t 19.9- Plant OVHD & Insurance US$/t 21.2- Depreciation US$/t 54.4
Revenues Mio US$ 356.6- Methanol (90 US$/t) US$/t - - Naphtha (130 US$/t) US$/t 18.6- Polypropylene (650 US$/t) US$/t 338.0
Return on Investment , ROI1) % 23.1
1) ROI Estimate based on Chem Systems Methodology
India Chem 2002: Gas To Chemicals
MeOH-Plant
PP-Plant
Natural Gas“Methane”
SyngasCO + H2
Methanol Propylene Polypropylene
Oxoalcohol-Plant
Acrylic AcidAcrylic AcidPlant
2-EHOH Acryl. Plant
Bu-Acryl. Plant
2EHAC BuAc
Acrylic Acid
BuOH
Propylene Propylene
Acrylic Acid2-EHOH
Butylacrylate2-Ethylhexylacrylate
Gas-based Petrochemistry
MTP® Plant
India Chem 2002: Gas To Chemicals
Gas Refinery via Methanol - Lurgi’s MtSynfuel® (MTS)
DiscontinousIn-situ CatalystRegeneration
MTP COD ProductSeparation
Distillate4.290 t/d
Gasoline1860 t/d
Light Ends420 t/d
Gasoline
Water Recycle
Hydrocarbon Recycle
Hydrocarbon Recycle
Methanol15.000 t/d
India Chem 2002: Gas To Chemicals
Comparison Lurgi MTS Route - FT Synthesis I
Product Slate Lurgi Route FT Synthesis
Naphtha : Diesel (max.) 1 : 4 1 : 2.3 – 1 : 5.4
Product Properties Lurgi Route3) FT Synthesis3)
Spec (Europe from 2005)Gasoline-Aromatics-Benzene-Sulphur-Olefins-RON 2)
-MON 2)
vol.%vol.%wppmvol.%
max.max.max.max.
351
50/10 1)
1891/95/98
82.5/85/88
3<< 1
0448075
< 1<< 1
0> 30< 40< 40
Diesel-Polyaromatics-Sulphur-Cetane No.
vol.%wppm
max.max.min.
1150/10 1)
51
< 1< 155
< 1< 5
> 70
1) Diesel with 10 wppm sulphur has to be available on the market2) RON / MON for Regular Gasoline / Euro-Super / Super-Plus3) Properties before naphtha upgrading
India Chem 2002: Gas To Chemicals
Comparison Lurgi MTS Route - FT Synthesis II
Cost of Production Estimate1)
Plant Location: Middle East
Plant Capacity: 50,000 barrels per day products
Natural Gas Price: 0.50 US$ / MMBtu
Depreciation: 10 % for ISBL / 5 % for OSBL
Return on Investment: 10 %
Total Capital Investment: Includes Total Plant Capital (ISBL+OSBL) plus 20 %for Other Project Cost, year 2000
Cost of Production: Includes depreciation and 10 % ROI
Product Market Prices: Year 2000, adjusted to shipping costs from Middle East and applicable tariffs for the considered
regions
1) Basis: Chem Systems, 2001
India Chem 2002: Gas To Chemicals
Comparison Lurgi MTS Route - FT Synthesis IIICost of Production Estimate
Lurgi MtSynfuels existing FT1)
Total Capital Investment [MM $]-Total Plant Capital [$/bpd]
1.45224,192
1.67127,856
NG to Process (LHV) [$/bbl][MMBtu/bbl]
Cat. & Chemicals [$/bbl]
Utilities [$/bbl]
3.767.51
1.45
0.28
4.228.44
1.53
0.8
Cost of Production + ROI [$/bbl] 24.88 28.68
Market Prices 2)
- Gasoline [$/bbl]- Diesel [$/bbl]
Western Europe34.7528.88
US Gulf Coast31.4226.51
Japan29.7033.21
1) Chem Systems, 20012) Corresponding Crude Oil Price: about 21 $/bbl
India Chem 2002: Gas To Chemicals
Conclusions - Future PerspectivesThe challenge of abundant NG is answered.
MegaSyn® and MegaMethanol® - Lurgi’s Mega Concept opens
new routes of gas monetisation:
• Dimethyl ether (DME) can be produced at attractive coststo become an economical fuel
• Propylene is a high-demand, high value product. It can be pro-duced cheaper than by conventional processes
• The economics of MtSynfuels® are comparable to FT routes
• A “gas-based petrochemistry/refinery” is developed by Lurgi
India Chem 2002: Gas To Chemicals
Back-up slides
India Chem 2002: Gas To Chemicals
Latest Methanol Project References
Methanex, USA 1700 mtpd 1992
Statoil, Norway 2400 mtpd 1992
CINOPEC, China 340 mtpd 1993
KMI, Indonesia 2000 mtpd 1994
NPC, Iran 2000 mtpd 1995
Sastech, RSA 400 mtpd 1996
Titan, Trinidad 2500 mtpd 1997
PIC, Kuwait 2000 mtpd 1998
YPF, Argentina 1200 mtpd 1999
Atlas, Trinidad 5000 mtpd 1999
NPC, 4th Methanol, Iran 5000 mtpd 2000
India Chem 2002: Gas To Chemicals
Operation at the
Optimum Reaction Route
High Equilibrium Driving Force
High Conversion Rate
Elimination of Reactor Feed Preheater
Elimination of Catalyst Poisoning
Two-Step Methanol Synthesis
Gas Cooled ReactorWater Cooled Reactor
Simple and Exact Reaction
Control
Quasi Isothermal Operation
High Methanol Yield
High Reliability
High Energy Efficiency
India Chem 2002: Gas To Chemicals
Ignition Characteristics of the Components Cetane Number
Density, Effect on Engine Performance
Exhaust Gas Emissions, Sulfur, Particulates, Nox
Viscosity, narrow Limits
Cold Flow Properties, substitutes Kerosene
Dimethyl Ether (DME) -Quality Aspects of Diesel Fuel
India Chem 2002: Gas To Chemicals
Chemical formula CH3OCH3 C3H8 CH4 CH3OH
Molecular weight 46.07 44.1 16.04 32.04
Boiling point at 0.1MPa, °C -24.8 -42.1 -161.5 64.7 150-370
Liquid density, kg/m³ (20°C) 666 501 - 792 <845
Relative density (gaseous, air=1) 1.59 1.52 0.55 - -
Vapor pressure, MPa (20°C) 0.51 0.85 - - -
Explosive limits (vol% in air) 3-17 2.1-9.4 5-15 5.5-44 0.6-6.5
Cetane number 55-60 5 0 5 40-55
Net calorific value (MJ/kg) 28.84 ~42.519.946.3 50
Properties of DME and other Fuel
Name DME Propane Methane Methanol Diesel
India Chem 2002: Gas To Chemicals
DME Synthesis: Alternatives
Methanol dehydration 2 CH3 OH CH3 OCH3 + + H2O
Water gas shift reaction*
*carbon loss by CO2 formation
CO + H2O CO2 + H2
DME Direct Synthesis
DME direct synthesis 4 H2 + 2 CO CH3 OCH3 + H2O
MegaMethanol® synthesis** CO + CO2 + 5 H2 2 CH3 OH + H2O
DME Synthesis via MegaMethanol®
**CO2 consumption = “sequestration”!
India Chem 2002: Gas To Chemicals
Lurgi DME - Process
HeatIntegration 2
DMEReactor
Methanol Recycle
DMEColumn
MethanolWaterColumn
ProcessWater
OffgasScrubber
CrudeMethanol
Offgas
DME Product
Light Ends
HeatIntegration 1
CoolingSystem
India Chem 2002: Gas To Chemicals
Synfuels, Mossel Bay, RSA
India Chem 2002: Gas To Chemicals
MTP® - Product Slate
India Chem 2002: Gas To Chemicals
tests for catalyst optimization
optimization of reaction conditions in 1st, 2nd and 3rd stage
testing & optimization of “simulated“ recycle streams
optimization of steam dilution
test of regeneration conditions
optimization of DME pre-reactor
Three-Stage PDU (Pilot Plant)1
st stage
2n
d stage
3rd stag
e
DME pre-reactors
MTP® R&D Development Strategy
India Chem 2002: Gas To Chemicals
Demo Plant, Norway, 2002
MTP® R&D - Objective of Demo Unit
Demo Unit is the next step of scale-up allowing final scale-up to industrial size in one last step
Compare Demo Unit results with Pilot Plant (successful)
confirm operating conditions and process performance in long time operation
test of catalyst life, deactivation and regeneration, demonstrate catalyst lifetime greater than 1 year
test influence of “real“ hydrocarbon recycle on product yield and catalyst activity
India Chem 2002: Gas To Chemicals
MTP® - Process Design of Commercial Plant
Create initial commercial design based on pilot plant data
Improve thermodynamic property set in process simulator (e.g. evaluation & regression of VLE data)
Optimize process flow sheet (e.g. sequence of component separation, heat integration study) MTP Plant, 3D PDS Model
Produce all engineering documents requ. for investment cost estimate
Icarus based investment cost model
Incorporate demo plant results Value Engineering
India Chem 2002: Gas To Chemicals
MTP Economics
40 50 60 70 80 90
380 $/t Propylene
400 $/t Propylene
0
5
10
15
20
25
30
35
40
Methanol Feed, $/t
Inte
rnal
Rat
e o
f R
etu
rn*,
%
Mega Methanol®
deliveredon site“integrated”
* Equity: 20%, Depreciation/Year: 10%
India Chem 2002: Gas To Chemicals
MTP Reactor System
propylene production only
more complicated set-up to control reaction temperature
low risk of scale-up
low coking tendency of catalyst
discontinuous in-situ regeneration at reaction temperature (no stress on the catalyst)
defined residence time for maximum selectivity
ethylene/propylene co-production
good temperature control
complicated multi-step scale-up
high coking tendency of catalyst
continuous regeneration at elevated temperatures; oxygen breakthrough into process possible
broad residence time distribution
Fixed-Bed Fluidised-Bed
India Chem 2002: Gas To Chemicals
Lurgi‘s FT Experience I Commercialisation of ARGE-synthesis in 1952
location: Sasolburg / South Africa start up: 1955 no. of reactors: 5
All original reactors still in operation today;extension of capacity in 1987 (+ 1 reactor)
Modern FT Reactor Technology
Slurry phase reactor (by far preferred)
Tubular reactor
Fluidised bed reactor
Lurgi has commercial experience in all these reactor technologies
India Chem 2002: Gas To Chemicals
Lurgi‘s FT Experience II
Lurgi designed the syngas production unitsof all FT-plants currently in commercial
operation
Sasol/Secunda (coal gasification)
Mossgas (combined reforming of NG)
SMDS/Bintulu (partial oxidation of NG)Today, Lurgi MegaSyn® is available for FT Synthesesas well as for MtSynfuel®
Lurgi’s route through methanol to transportation fuels
India Chem 2002: Gas To Chemicals
Gas-based Petrochemistry
OILconventional route
Natural GasAssociated Gas“Stranded Gas”emerging route
COALfuture route ?
Feedstock
AromaticsBenzeneTolueneXylenes
„Oxidates“Alcohols, Ethers,
Esters, Acids,Aldehydes
Intermediates PetrochemicalProducts
OlefinsEthylene
Propylene
PolyolefinsPE, PP
Acrylates
PolycondensatesPC, PET,
PBT
Solvents
FuelsFuel additives
Syngas Methanol
Cracker
MTO
Lurgi‘sMegaSyn
Lurgi‘sMTP®
Lurgi‘sMTC
LurgiMegaMethanol®