PdVSA - EFI Seminarchem.engr.utc.edu/ench430/2006/Teams/TOPS/FT vs MM ppt.pdf · 1 GTC - Process Options for Venezuela PdVSA - EFI Seminar Caracas, 6 March 2002 GTC - Gas to Chemicals

1

GTC - Process Options for Venezuela

PdVSA - EFI SeminarPdVSA - EFI SeminarCaracas, 6 March 2002Caracas, 6 March 2002

GTC - Gas to Chemicals - Process Options for VenezuelaGTC - Gas to Chemicals - Process Options for VenezuelaDr.-Ing. Waldemar LiebnerDr.-Ing. Waldemar Liebner

2

GTC - Process Options for VenezuelaContents

• Introduction• Lurgi’s Syngas Production Technologies• Natural Gas: abundance and challenge• Fischer-Tropsch: classic route to synfuel• Lurgi’s MegaMethanol®-Technology• MegaMethanol® to Dimethyl Ether• MegaMethanol® to Propylene• Propylene to Synfuels• Conclusion


Gaseous andLight LiquidHydrocarbons


Heavy O ilHeavy O il M ethanolM ethanol CoalCoal W aterW ater

Steam &Autotherm alReform ing


PartialOxidation

PartialOxidation Reform ingReform ing GasificationGasification ElectrolysisElectrolysis

Hydrogenand Syngas

Hydrogenand Syngas

Hydrogen and Syngas Technologies

HydrogenHydrogenM ethanolDM EOlefins

M ethanolDM EOlefins

Am m oniaAm m onia Oxo alcoholsAcetic Acid

Oxo alcoholsAcetic Acid Ore ReductionOre Reduction

UreaFischer Tropsch

UreaFischer Tropsch Fine Chem icalsFine Chem icals M iscellaneousM iscellaneous

Lurgi’s Syngas Production Technologies




Heavy O ilHeavy O il M ethanolM ethanol CoalCoal W aterW ater



PartialOxidation

PartialOxidation Reform ingReform ing GasificationGasification ElectrolysisElectrolysis

Hydrogenand Syngas

Hydrogenand Syngas

Hydrogen and Syngas Technologies

HydrogenHydrogenM ethanolDM EOlefins

M ethanolDM EOlefins

Am m oniaAm m onia Oxo alcoholsAcetic Acid

Oxo alcoholsAcetic Acid Ore ReductionOre Reduction

Urea Urea

Fine Chem icalsFine Chem icalsM iscellaneousM iscellaneous

Lurgi‘s

FischerTropsch Fischer Tropsch



Gas Gas Production Plants Designed by LurgiProduction Plants Designed by Lurgi

Steam Reform ing 74 Plants / 96 Units Total Capacity 140 000 000 m ³/dwith Pre-Reform ing Largest Plant Capacity 440 000 m ³/h*37 Plants / 47 Units

Autotherm al Catalytic Reform ing11 Plants / 29 Units Total Capacity 37 000 000 m ³/d

Largest Plant Capacity 637 000 m ³/h

Noncatalytic Partial Oxidation35 Plants / 75 Units Total Capacity 62 500 000 m ³/d

Largest Plant Capacity 424 000 m ³/h

Com bined Reform ing (Steam Reform ing/Catalytic Autotherm alReform ing)8 Plants / 10 Units Total Capacity 69 000 000 m ³/d

Largest Plant Capacity 900 000 m ³/h *** Four Trains** Three Trains


6


North America16,7%

Middle East

14,7%

Africa39,3%

Far East & Oceania

7,7%

West. Europe

3,1%

E.Europe&FSU6,8%

C&S America11,6%

Flared Natural Gas (1998)

better use:make 130 Mt/a of methanol!build 74 MegaMethanol (and

MTP) plants!

total amount flared worldwide:100 billion m³ per year

Source:Energy Information Administration (EIA): ”International Natural Gas Information” 14 Feb 2001, http://www.eia.doe.gov

7

GTC - Process Options for VenezuelaUses of Natural Gas

Natural Gas

Hydrogen Fischer-TropschProducts Ammonia Methanol

Gas Sales

Power GenerationLNG

Re-injection

RefineriesFuelEdib.Oil/Fat

Clean FuelsClean FuelsLubricantsLubricantsWaxWaxAlpha OlefinsAlpha Olefins

UreaAcrylonitrileFertilisers

DME, FormaldehydeSolvents, MTBEClean Fuels, FuelCells PowerGeneration

Acetic Acid

Olefins

Syngas (CO, H2)

5%5%

8

GTC - Process Options for VenezuelaFischer-Tropsch Technology (FT)

Converts Synthesis Gas to Liquid Hydrocarbons

Product Spectrum Depends On:Temperature, Catalyst, Pressure, Gas Composition

High Temperature Fischer-Tropsch:350 °C: Gasoline and Light Olefins

Low Temperature Fischer-Tropsch:250 °C: Distillate and Waxes

Generalised Reaction:2n H2 + n CO ( CH 2 ) n + n H2O

FT - The classic route from NG to synfuels

9

GTC - Process Options for VenezuelaHistory of Lurgi‘s FT Process Development

Commercialisation of ARGE-synthesis in 1952location: Sasolburg / South Africastart up: 1955no. of reactors: 5

All original reactors still in operation today;extension of capacity in 1987 (+ 1 reactor)

10

GTC - Process Options for VenezuelaModern FT Reactor Technology

Slurry phase reactor (by far preferred)

Tubular reactor

Fluidised bed reactor

Lurgi has commercial experience in all thesereactor technologies

11

GTC - Process Options for VenezuelaLurgi Combined Reforming

Mossgas Fischer-Tropsch PlantCapacity: 3 x 300 000 Nm3/h syngasStart-up: 1992

12

GTC - Process Options for VenezuelaFT Syngas Production

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)

13

GTC - Process Options for VenezuelaComparative Economics1) - Cost of Production Estimate

A B C D E FTotal CapitalInvestment [MM$]Total PlantCapital [$/bpd]

1.423

23,710

1.744

29,066

1.237

20,612

1.671

27,856

1.350

22,498

1.291

21,520

NG to Process- [$/bbl]- [MMBtu/bbl]Cat & Chemicals- [$/bbl]Utilities- [$/bbl]

4.108.20

0.76

(0.00)

4.699.39

1.52

3.06

4.298.58

1.50

0.39

4.228.44

1.53

0.80

4.889.76

1.61

2.57

5.1010.20

1.52

3.06

Cost ofProduction- [$/bbl]

23.10 31.71 22.63 28.68 26.79 26.73

Market Price 2)

- Gasoline [$/bbl]- Diesel [$/bbl]

Western Europe34.7528.88

US Gulf Coast31.4226.51

Japan29.7033.21

1) Chem Systems, January 2001 2) Corresponding Crude Oil Price: ca. 21 $/bbl

14

GTC - Process Options for VenezuelaMegaMethanol® Concept

MegaMethanol®: > 1 million t/a methanol single train capacity

Technical Features:Oxygen-blown synthesis gas production

Two-step methanol synthesis

Hydrogen Recovery

The basis for even more value from natural gas:

15

GTC - Process Options for VenezuelaMegaMethanol® Process

Desulphur-isation

Pre-Reforming

NaturalGas

MethanolSynthesis

MethanolDistillation

PureMethanol

AutothermalReforming

AirSeparationAir

Oxygen

HydrogenRecovery

16


• Methanex, USA 1700 MTPD 1992• Statoil, Norway 2400 MTPD 1992• SINOPEC, 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 2000 Mega MeOH• Zagros, Iran 5000 MTPD 2000 Mega MeOH

Latest Methanol Project References

17


Economics of MegaMethanol®

SteamReforming

CombinedReforming

Mega-Methanol

Capacity mtpd 2500 2500 5000Natural GasDemand MBtu / mt 30 28.5 28.5

NOx Emission kg / mt 0.8 0.2 0.1

Total Fixed Cost(EPC) Million US$ 225 215 300Product Value(EPC) US$ / mt 113 108 79

Assumptions:• Investment and energy cost for O2 production and power generation included• NG Feedstock: 0.5 US$ / MMBtu; Depreciation: 10 % per year, ROI before taxes: 20 %

MegaMethanol® Process

18

GTC - Process Options for VenezuelaDimethyl Ether (DME)

Alternative to Conventional Diesel Fuel

Transportation

Very low Emission Levels

Clean and efficient Power Generation

Similar Properties as LPG (Storage, Transport)

DME: Energy Carrier of the Future!

19

GTC - Process Options for VenezuelaComparison of DME Synthesis / Alternatives

DME Direct Synthesis

Gas/water shift reaction*

*carbon loss by CO2 formation

CO + H2O CO 2 + H 2

Methanol synthesis CO + 2 H 2 CH 3OH

Methanol dehydration 2 CH 3 OH CH 3-O-CH 3 + H2O

DME direct synthesis 4 H2 + 2 CO CH 3-O-CH 3 + H2O

DME Synthesis via Methanol

20

GTC - Process Options for VenezuelaDME Production by Methanol Dehydration

DMEReaction

DMEDistillation

DMEProduct

Stabilised MeOH

H2ORecycle

MeOHRecycle

WasteWater

Off-gas

SyngasProduction

21


Reactor: Adiabatic Fixed Bed Reactor

High Conversion Rate

Purity: According to Requirement

Highly efficient Heat Integration Systems,resulting in low Utility RequirementLow Utility Consumption

Zero Emission

DME Process Features

22

GTC - Process Options for VenezuelaEconomics of the Lurgi DME process

MegaMethanol® & Dehydration Plant

DME production 5000 t/d

Natural gas demand 42.9 MMBtu/t

Total fixed cost (EPC) 406 MMUS$

Product value (EPC) 83.3 US$/t

based on natural gas price = 0.5 US$ per MMBtu anddepreciation 10% of total fixed cost

23

GTC - Process Options for VenezuelaPropylene: Uses and Demand

4,3

2,7

4,4

4,3

4,5

5,8

0 2 4 6 8

P olypropylene

A crylonitrile

O xo-A lcohols

C um ene

P ropyleneO xide

A crylic A cid

Av. Growth Rate, %(Capacity by 2005)

Oxo-Alcohols8%

Others

7%

Polypropylene58%

Cumene6%

PropyleneOxide 7%

Acrylonitrile10%

AcrylicAcid

4%

2000 World Propylene Supply/Demand53.5 Million Tons

24

GTC - Process Options for VenezuelaMTP: Simplified Process Flow Diagram

MTP 1 MTP 2 MTP 3

Gasoline

Light EndPurge

ProcessWater

DMEPre-Reactor

ProductConditioning

Propylene

Regeneration

C4/C5Purge

Water Recycle

Olefin Recycle

Crude Methanol

Reactor Stages

25

GTC - Process Options for VenezuelaMTP Reactor System

propylene production onlymore complicated set-up to controlreaction temperaturelow risk of scale-uplow coking tendency of catalystdiscontinuous in-situ regenerationat reaction temperature (no stresson the catalyst)defined residence time formaximum selectivity

ethylene/propylene co-productiongood temperature control

complicated multi-step scale-uphigh coking tendency of catalystcontinuous regeneration at elevatedtemperatures; oxygen breakthroughinto process possiblebroad residence time distribution

Fixed-Bed Fluidised-Bed

26

GTC - Process Options for VenezuelaMTP Technology Status

PROCESS>8000 operating hours of pilot plantdemo unit started 01/ 2002on-going optimisation of process design forcommercial plant

CATALYSTcatalyst development completed by suppliercatalyst is commercially manufactured

27

GTC - Process Options for VenezuelaMTP Production Figures

Methanol1.667 Mio tpy

5000 tpd

Propylene519,000 tpy

Gasoline143,000 tpy

Fuel Gas, LPG 69,000 tpy

Regeneration

Discontinuous

In-situ Catalyst

Methanol toPropylene

Conversion

Water (product)936,000 tpy

ProductSeparation

28


MethanolToPropylene - Economics

Comparison Naphtha Gas to Methanol Cracker to Propylene Plant

Plant Investment, $MM 580 620Product Sales, $MM/Year 376 303Cost of Production, $MM/Year 293 126Sales-Cost Difference, $MM/Year 83 177

Return on Investment, % 14.3 28.5

MTP Economics

29

GTC - Process Options for VenezuelaMTP Economics

0

5

10

15

20

25

30

35

60 70 80 90 100 110

M ethanol Feed , $/m t

Intern

al Rate of Return

*, %

* Equity: 20%, Depreciation/Year: 10%

380 $/t Propylene

400 $/t Propylene

Mega-

Methanol TM

30

GTC - Process Options for VenezuelaSynfuels, Mossel Bay, RSA

31

GTC - Process Options for VenezuelaGas Refinery via Methanol - Lurgi’s MTS Route

DiscontinousIn-situ CatalystRegeneration

MTP MTS ProductSeparation

Distillate4.290 t/d

Gasoline1860 t/d

Light Ends420 t/d

Gasoline

Water Recycle

Hydrocarbon Recycle

Hydrocarbon Recycle

Methanol15.000 t/d

32

GTC - Process Options for VenezuelaComparison Lurgi MTS Route - FT SynthesisProduct Slate and Properties

Product Slate Lurgi Route FT SynthesisNaphtha : 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

33

GTC - Process Options for VenezuelaComparative Economics1): Lurgi Route vs. FT

Basis

Plant Location: Middle EastPlant Capacity: 50,000 barrels per day productsNatural Gas Price: 0.50 US$ / MMBtuDepreciation: 10 % for ISBL / 5 % for OSBLReturn on Investment: 10 %Total Capital Investment: Includes Total Plant Capital (ISBL+OSBL) plus 20 %

for Other Project Cost, year 2000Cost of Production: Includes depreciation and 10 % ROIProduct Market Prices: Year 2000, adjusted to shipping costs from Middle

East and applicable tariffs for the considered regions

1) Chem Systems, 2001

34

GTC - Process Options for VenezuelaComparative Economics: Lurgi Route vs. FTCost of Production Estimate

Lurgi MTS Route 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]

3.767.511.450.28

4.228.441.530.8

Cost of Production + ROI [$/bbl] 24.88 28.68Market 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

35

GTC - Process Options for VenezuelaConclusions

Lurgi’s syngas production technologiesfor all feedstocks and for all capacities:

• Gasification (non-catalytic partial oxidation) of heavy residue/asphalt/Orimulsion®

• ATR (catalytic partial oxidation) of natural gasspecifically for large capacities: MegaSyn®

• LurgiReformer® (SMR - steam methane reforming) and Combined Reforming of natural gas, for “normal” capacities

Lurgi’s MegaMethanol® opens new routes of gas monetisation:• Dimethyl ether (DME) can be produced at attractive costs

to 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 synfuels via MegaMethanol® and propylene

are comparable to FT routes

36


ThankYou!!!!

Questions?

37


Back-up slides

38

GTC - Process Options for VenezuelaGas To Chemicals - Gas To Liquids

Light Ends

Distillate

MTS ProductSeparation GasolineMegaMethanol® MTPNatural Gas

Methanol PropylenePolypropyleneAcrylic Acid

Propyleneoxide

GTC

GTL

39

GTC - Process Options for VenezuelaTypical GTL Synfuel Product Slates1)

A B C D E F

Naphtha [wt.%] 30 14 15 20 20

Gasoline [wt.%]

M-Distillate [wt.%] 20 18 25 15 30

Diesel [wt.%] 50 68 60 65 50

Naphtha : MD+Diesel 1 : 2.3 1 : 5.4 1 : 5 1 : 4 1 : 41) Chem Systems, 2001

40


Quality Aspects of Diesel Fuel

IgnitionCharacteristics of the ComponentsCetane Number

Density, Effect on Engine Performance

Exhaust Gas Emissions, Sulfur, Particulates, Nox

Viscosity, narrow Limits

Cold Flow Properties, substitutes Kerosene

Dimethyl Ether (DME)

41


Properties of DME and other Fuels

Chemical formula CH3OCH3 C3H8 CH4 CH3OHMolecular weight 46.07 44.1 16.04 32.04Boiling point at 0.1MPa, °C -24.8 -42.1 -161.5 64.7 150-370Liquid density, kg/m³ (20°C) 666 501 - 792 <845Relative 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 0.6-6.5Cetane number 55-60 5 0 5 40-55Net calorific value (MJ/kg) 28.84 ~42.519.946.3 50

Name DME Propane Methane Methanol Diesel

Dimethyl Ether (DME)

Documents

PdVSA - EFI Seminarchem.engr.utc.edu/ench430/2006/Teams/TOPS/FT vs MM ppt.pdf · 1 GTC - Process Options for Venezuela PdVSA - EFI Seminar Caracas, 6 March 2002 GTC - Gas to Chemicals