wurzel
TRANSCRIPT
-
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