Wurzel

Lurgi MegaMethanol Technology Delivering the building blocks for future fuel and monomer demand

Presented at the DGMK Conference Synthesis Gas Chemistry, October, 4. 6., 2006

Dr. Thomas Wurzel, Lurgi AG

2Agenda

Motivation

Todays methanol industry

Towards larger capacities a joint effort of R&D, catalyst development and plant engineering

Monomer and fuel from Methanol

Conclusions

302468

1 01 21 41 61 820222426283 0

1970 198 0 1990 2 001 2 02 0 2 05 0

Billion tons of coal equivalent

Increasing energy demand

4How will the future look like?

Sources:www.spiegel.de/fotostrecke/0,5538,16327,00.htmlhttp://www.pacificrenewables.com/fischer-tropsch.htm

5Spoilt for feedstock choices

1110 hits 754 hits

1380 hits

6Syngas & MeOH the flexible dream team

CoalNatural GasBioMassTar Sands etc.

Syngas Methanol

ChemicalsPropyleneDMEFuels

7Chemical Methanol Market

Today developmentFormaldehyde 12 MM tpa upMTBE 6 MM tpa down Acetic Acid 3 MM tpa up Miscellaneous Uses 11 MM tpa upTOTAL 32 MM tpa

annual increase 3 % i. e. 1 MM tpa

pre-dominant feedstock: natural gas

close the gap in low cost methanol supply: MegaPlants (> 1 million tpy) selection of syngas technology is key 60 65 % of ISBL costto economic methanol production

8Ways to produce Syngas

TubularReforming

Tubular Reforming

Pre-reforming

H2SRectisol

MPG

H2SRectisol

Gasification

TubularReforming

Cold BoxPSA

CO2Removal

Autotherm.Reforming

CO ShiftConversion

MPG

Pre-reforming

Secondary Reforming

PSA

Coal NaphthaHeavyResidue

Synthesis Gas

Natural GasRefinery

Off-gasesLPG

H2 H2 CO

9H2/CO Ratios for Syngas Generation

CMR= Co m b i n e d Me t h a n e Re f o r m i n g

1 2 3 4 5

MPG

A T R

C MR

S MR

H2/CO ratioF e e d N atu ral G as

10

Typical Single-Train Capacities

100 1.000 10.000 100.000 1.000.000

MeOH Reforming

MPG- PartialOxidation

AutothermalReforming

Steam Reforming

11

Lurgi Highlights for Syngas Production

Lurgi offers all gas-b ased sy n gas t ec h n ologies W orld largest sin gle t rain sy n gas un it ( A T LA S ) W orld largest m ult ip le t rain sy n gas un it ( M osselb ai) H igh est out let t em p erat ure for a st eam reform er ( B P

S ic h uan p lan t ) V ast ex p erien c e in h an d lin g ox y gen ( sin c e 1 9 2 8 ) 5 0 + y ears ex p erien c e in A T R ( sin c e 1 9 5 4 ) M ore t h an 1 0 0 , 0 0 0 , 0 0 0 N m 3 / d ay c ap ac it y in st alled P ilot p lan t t o t est m ore sev ere op erat in g c on d it ion s

12

Syngas Benchmarks for MeOH

Parameter Steam Reforming

Autothermal Reforming

Combined Reforming

Stoechiometric number, SN

2.95 2.05 2.05

CO/CO2 ratio 2.3 2.5 2.8

Methane slip, % (dry)

3.28 1.76 2.10

Steam reformer duty, GJ/hr

1740 - 460

Syngas flow at compressor suction, m3eff. / hr

43713 20240 19433

13

Syngas Benchmarks for MeOH

Parameter Conventional Technology

MegaMethanol Technology

Capacity, MTPD 2500 5000

Natural gas consumption (MMBTU/ton MeOH)

30 28.5

Investment1), % 100 130

Operating cost, % 100 97

Production cost, % 100 79

1) Oxygen supply over the fence

14

Preferred route: Oxygen-based

ATR: homogeneous/heterogeneous formation of syngas

principle reactions:

combustion of methane

steam reforming of methane

Water gas shift reaction

15

Features of Autothermal Reformer

Low S/C ratio 1.5 - 0.5 mol/mol

high CO selectivity

low CO2 emission

Outlet temperature 950 - 1050 C

Low methane slip

Close approach to equilibrium

Pressure: 40 bar realised (large scale)

70 bar realised Demoplant

High gas throughput possible

Up to 1,000,000 Nm3 gas /hr

16

Reactor Design

uncooled burner (no CW circuit) proper mixing and combustion free of vibration

Burner and Reactor as one unit

no start-up burner

low SiO2 -Al2O3 Nickel catalyst high thermal stability

multilayer refractory lining thermal protection

17

Development steps towards MegaSyn

Atlas Methanol - 5000 mt/d, commissioned 2004

18

Milestones in ATR History

1922 Autothermal Reforming(recuperative mode)

1928 Lurgi introduces oxygen-based gas production (coal gasification)

1954 First Lurgi ATR (Towngas production)

1979 First application of combined reforming

2004 First MegaSyn Application in operation(ATLAS plant)

19

Development of Technology

Picture 1 Towngas, Hamburg, 1954

Picture 2 FT Syngas, Mosselbai, 1993

Picture 3 MegaMethanol, ATLAS, 2004

20

Towngas, Hamburg, 1954

Feedstock: Refinery OffgasProduct: TowngasCapacity: 25.2 MMSCFD

21

PetroSA, Mosselbay, 1993

Feedstock: Natural GasProduct: Fischer-Tropsch SyngasCapacity: 252 MMSCFD per train

22

ATLAS, Trinidad, 2004

Feedstock: Natural gasProduct: Methanol SyngasCapacity: 420 MMSCFD

23

Base of Fluid Dynamical Simulation

Thermo-chemicalModel

Navier-StokesEquations

Reactor/Burner

Geometry

Velocitytemperature pattern

CFD was introduced approx. 15 years ago in-house expert group established and growing standard tool for design work intensive model validation performed

24

Advantages of Oxygen-based Syngas Generation

Reduced investment (20 30 %) compared to conventional steam reforming

Higher energy efficiency (less CO2 emissions)

Higher flexibility towards feedstock fluctuation

Availability of one single train plant is higher than of two smaller trains

25

The next generation:HP POX Pilot Plant

Demonstrationplant for production of Syngas from Natural Gas, Liquid Hydrocarbons/Slurries at pressures up to 100 bar sponsored by BMWA, SMWK, mg technologies

26

Development of Synthesis Loop1. Conventional Synthesis Loop

Synthesis Gas16 bar

Cooling Water

27

Development of Synthesis LoopLurgi Steam Raising Reactor

Quasi isothermal Operation Extremely quick transfer of Reaction Heat Methanol Yield up to 1.8 kg MeOH/l Catalyst Long Catalyst Operation Life 80 % of Reaction Heat converted to MP steam Safe and uniform Temperature Control Overheating of Catalyst impossible Thermosyphon Circulation - no Pumps Easy Start-up by direct Steam Heating Fast Load Changes possible Easy and fast Load/Discharge of Catalyst

28

240

245

250

255

260

265

270

275

280

0 0,2 0,4 0,6 0,8 1Catalyst Height

T

e

m

p

e

r

a

t

u

r

e

C

ReactionCooling Water

Development of Synthesis LoopTemperature Profile Steam Raising Reactor

29

Development of Synthesis LoopSteam Raising Reactors

Steam Drum

Inter-changer

Reactors

30

Development of Synthesis Loop2. Two-Step Methanol Synthesis

PurgeGas

RecycleCompressor

CrudeMethanol

Compressed Synthesis Gas

Boiler FeedWater

Gas-cooledReactor

Steam RaisingReactor

MP-Steam

31

Development of Synthesis LoopLurgis Two Reactor Concept (CMC)

32

Large Single Train CapacityLow Investment CostOperation at the Optimum Reaction Route

High Equilibrium Driving Force High Conversion Rate

Lowest recycle/syngas ratioHigh methanol content (11 %) at reactor outlet

Development of Synthesis LoopGas Cooled Reactor

33

0

50

100

150

200

250

300

0 0,2 0,4 0,6 0,8 1Catalyst Height

T

e

m

p

e

r

a

t

u

r

e

C

ReactionCooling Gas

Development of Synthesis LoopTemperature Profile Gas Cooled Reactor

34

Development of Synthesis LoopSummary of Highlights / Two-Step Methanol Synthesis

g Operation at the Optimum Reaction Route

High Equilibrium Driving Force

High Conversion Rateg Elimination of Reactor Feed Preheater

g Elimination of Catalyst PoisoningThermodynamically controlled

Steam Raising Reactor

g Simple and Exact Reaction Control

g Quasi Isothermal Operationg High Methanol Yieldg High Energy Efficiency

Gas Cooled Reactor

High Syngas Conversion Efficiency Extended Catalyst Life (almost unlimited) Large Single Train Capacity Low Investment

g Heat of Reaction converted to MP steam(80 %)Kinetically controlled gg

35

Development of Synthesis LoopSynthesis Design Parameters

Syngas Flow m3N/t MeOH 2580 2550

Recycle Flow m3N/t MeOH 8500 5100

Synthesis Loop Pressure bar 80 75

Methanol Content mol% 7 11Reactor Outlet

The implementation of the MegaMethanol technology represents a unique joint effortcomprising technology development and catalyst research (Sd-Chemie)

Two step synthesis

Conventional synthesis

36

Propylene Demand by Derivative 1990 - 2025

Main growth by PP!

0

20000

40000

60000

80000

100000

120000

140000

160000

1990 1995 2000 2005 2010 2015 2020 2025

T

h

o

u

s

a

n

d

t

o

n

s

PP ACN Cumene Oxos PO Others

Demand growth 1990Demand growth 1990--2001 = 8.3% p.a.2001 = 8.3% p.a.Demand growth 2001Demand growth 2001--2025 = 4.5% p.a.2025 = 4.5% p.a.

World

source: ChemSystems

37

Steam cracker Propanedehydrogenation (PDH)C2=:C3= = 3:1 selective C3= production

selected locations (rich NG)

Proven Routes for C3= production

38

MTP: Simplified Process Flow Diagram

Propylene474 kt/a 1)

Gasoline 185 kt/a

Fuel Gas internal use

Process Water 935 kt/afor internal use

DMEPre-Reactor

ProductConditioning LPG

41 kt/a

Water Recycle

Olefin Recycle

Methanol1.667 Mt/a = 5000 t/d

Product Fractionation

MTP Reactors(2 operating + 1 regenerating)

Ethylene

1) Polymer grade

20 kt/a

optional

39

MTP Projects gas- and coal-based

2009Order, Dec.05474China I (coal based)2009Order, June. 06474China II (coal based)

2010BE in progress100Iran

exp.s-u

StatusproductionP/PP, kt/aPlantlocation

Various prospects are not listed

40

Olefin Production

Olefin Oligo-merisation

Gasoline877 t/d

LPG741 t/d

Kero/Diesel6,961 t/d

H2,70 t/d,from Methanol

synthesisWaterrecycle

Hydrocarbon Recycle

Methanol19,200 t/d

Productseparation

+ MD Hydrogenation

Hydrocarbon Recycle

Process water, 10,115 t/d,can replace raw water maximum diesel case

64,000 bpd total products

Gas-based Refinery via Methanol: Lurgis MtSynfuels

41

Synfuels, Mossel Bay, RSA

42

Natural GasC o al

R e si d ueB i o m ass

SyngasP l ant

P o l y-p r o p yl e ne

P l ant

O l e f i n P r o d u c t i o n

M e t h ano l P l ant

Block Flow Diagram Routes to Fuel & Monomer

P r o p yl e ne b o o st i ng

O l i go m e r -i sat i o n D i e se l p o o l

43

Conclusions

Syngas/MeOH are the key intermediate to convert any carbon containing feedstock into value added products

Lurgi offers the whole technological chain (syngas, MeOH and monomer/fuel)

Down-stream methanol is not a vision, it is reality!

44

Thank you!

Methanol production

Conventional Outlets

Monomer Production (today)

Fuel Production (tomorrow)

45

Comments?

Contact :

Dr. Thomas WurzelDirector Gas to ChemicalsDept. L-TGPhone +49 69 5808 2490Fax +49 69 5808 3032e-mail [email protected]

Lurgi AG Lurgiallee 5D-60295 Frankfurt am MainGermanyInternet: www.lurgi.com