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An Alternative Route for Coal to Liquids:
Methanol-to-Gasoline (MTG) Technology
Max Heinritz-Adrian / Uhde GmbH, Germany
Adrian Brandl / Uhde GmbH, Germany
Max Hooper / Uhde Corporation of America
Xinjin Zhao / EMRE, U.S.A.
Samuel A. Tabak / EMRE, U.S.A.
Presented at the Gasification Technologies Conference
17th October, 2007
Hyatt Regency Hotel, San Francisco, CA
An Alternative Route for Coal to Liquids:
Methanol-to-Gasoline (MTG) Technology
AGENDA
1. Introduction
2. MTG Principles
3. Fixed-Bed MTG
4. New Zealand Synfuels Plant
5. Coal to Gasoline Concept
6. Fluidized Bed MTG
7. Conclusion
Routes to Synthetic Transportation Fuels: FT, MTG
SynGasGeneration
Methanol toGasoline (MTG)Steam
Natural GasCoal
BioMass
• Both are 3 Step Process
• Thermal Efficiencies are Essentially Governed by ThermalEfficiencies of the Syngas Production Process and Feed
PrimarilyGasoline
FischerFischer
TropschTropsch
Methanol
Synthesis
ProductProduct
Work-upWork-upPrimarily
Diesel
100100100
0.151Oxygenates
-546Heavy Oil/Wax
-1622Gasoil/Distillate
82.33619C5 - 160C
10.911Butane
1.192Butylenes
4.321Propane
0.2112Propylene
0.431Ethane
-40Ethylene
0.785Methane
MTGCompound
Comparison of Fischer Tropsch with MTG
Low Temp FT*
Co Catalyst @428F
High Temp FT*
Fe Catalyst@644F
* Steyberg & Dry, “Fischer Tropsch Technology”, Elsevier, 2004 (All FT yields are prior to refining for gasoline octane ,and diesel pour point improvement)
** Final plant product with gasoline Octane 92 R+O
• Unique “Shape Selective” chemistry discovered in the early 1970’s
• Major Challenge – Make marketable gasoline
• Development by Mobil (now ExxonMobil) through the 70’s on a variety ofprocess options
– Pilot operations up to 4 bpd in the US
– Pilot operations up to 100 bpd in Germany (with Uhde): Fluidized-bed MTG
and MTO between 1982-1985
• Decision by New Zealand Government in 1979 to build commercial 14,500bpd
plant in Motunui, NZ. Plant ownership 75% NZ Government/25% ExxonMobil
• Plant started up 1985 and operated successfully for ~10 years till conversion to
chemical grade Methanol production
• Contract for 100,000 mtpa MTG plant for JAM, Shanxi, China awarded to Uhde in
2006 - start-up of the plant expected in late 2008
MTG Scale-up and Development
Shape Selective Dehydration/Condensation of Methanol to Gasoline
MTG ProcessReaction Principle
Product ProductionPer 1000 tonnes MeOH
Gasoline 387
LPG 46
Fuel gas 7
Methanol
Water
Gasoline
Water 560
Recycled as process water
Typical Fixed-Bed MTG Product Quality
2005
Summer
2005
Winter
MTG
Gasoline
US
Regulation
China
Regulation
Oxygen(Wt%) 0.95 1.08
API Gravity 58.4 61.9 61.8
Aromatics(%Vol) 27.7 24.7 26.5 40
Olefins(%Vol) 12 11.6 12.6 35
RVP(psi) 8.3 12.12 9
T50(F) 211.1 199.9 201
T90(F) 330.7 324.1 320
Sulfur(ppm) 106 97 0 30 800 (30)
Benzene(%Vol) 1.21 1.15 0.3 1 (0.62) 2.5 (1)
• MTG Gasoline is completely compatible with conventional gasolineinfrastructure.
• MTG Gasoline contains zero sulfur and low benzene contents.
Date Sources: US Average gasoline data from US EIA website.
New Zealand Synfuel Plant
75
80
85
90
95
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
ExpectedExpectedExpectedExpectedPlantPlantPlantPlant
New Zealand MTG Unit Gasoline Yield
Coal to Gasoline (CTG) via Fixed-Bed MTG
Gasification CO-Shift
Coal
Methanol Synthesis
Gas TurbineSteam Syst.
Gasoline
Power
Steam
Fuel Gas
MTGPlant
Acid GasRemoval
LPG
SulfurRec. Unit
Sulfur
Fuel Gas
Coal to Gasoline (CTG) via Fixed-Bed MTGOverall Mass Balance - 1,000,000 tpa Gasoline
CTG PlantCoal: ~420 t/hr
Gasoline: 3,000 t/d
27,570 bpd
LPG: 288 t/d
Sulfur(~10% ash)
CO2 (for EOR)
• JV MRDC, Uhde, URBK. Engineering by MRDC and Uhde
• Capacity 100 bpd gasoline
• Operated 1982/1984
• Heat removal systems :
- Catalysts circulated through an external cooler
- Internal heat exchanger pipes immersed in the dense bed
reactor
• Methanol conversion almost complete
• Gasoline yields reached 92%
Fluidized-Bed MTG Plant URBK Wesseling
Fluidized-Bed MTG Plant URBK WesselingFlow Scheme
Fluidized-Bed MTG Plant URBK WesselingMain Structure
− The continuous regeneration permits to hold the catalyst
activity constant at selected conditions
− The heat of reaction is removed efficiently by direct steamraising
− The lower pressure range reduces the power consumption butincreases the volume of the equipment
− MTO operation mode with downstream oligomerisation (OGD)allows for co-production of gasoline and diesel
Fluidized-Bed MTG TechnologyAdvantages
1. Methanol to Gasoline (MTG) is an effective route for coal toliquids processing
2. MTG is commercially fully proven and produces high qualitysynthetic transportation fuels
3. MTG is simple and robust in design and operation and allowshigh plant availabilities
4. MTG is available through license from ExxonMobil (EMRE) -Uhde co-operates closely as engineering partner with EMRE
Methanol-to-Gasoline (MTG) Technology
Conclusions