Syngas to Liquids (SGTL) Plant Alex Magarychev -Team leader- Kamal Tbakhi John Elzaibak Roy Kim Team Mentor Bill Keesom Dennis O’Brien 9/21/2018 Team Hotel

Agenda Process objectives Commercial uses and prices of products Our Mission Process objectives Commercial uses and prices of products Block Flow Diagram Chemistry of Syngas to Olefins Competing processes for methanol and olefin production Decisions on process and products Future steps Spin Straw into Gold 9/21/2018 Team Hotel

Context for Group Hotel Project 9/21/2018 Team Hotel

Processing Objectives Processing routes Syngas to methanol Methanol to products Methanol DME Gasoline Olefins Decision criteria for choosing product to focus on Market size Market growth Product prices Competing routes to products 9/21/2018 Team Hotel

Product prices $/Ton Source Propylene 1200 Methanol 482 Dimethyl Ether http://www.fibre2fashion.com/textile-market-watch/propylene-price-trends-industry-reports.asp   Methanol 482 Methanex: http://www.methanex.com/products/methanolprice.html Dimethyl Ether ?? Gasoline 600 Platt's Oilgram Price Report - October 11, 2012 - Based on $3.04/gal Diesel 738 Platt's Oilgram Price Report - October 11, 2012 - Based pm $3.30/gal Prices of propylene in the last 3 years -high percentage of the profit are made from proplyene -price of the propylene in 2011 reaced 1500 because of a big shortage in propylene industry (outage of plant) -demand rise 5% per year 3.13$/gal * 1gal/3.78l * 0.82kg/l = 9/21/2018 Team Hotel

Commercial Uses of Propylene picture from http://www.dow.com/productsafety/finder/pro.htm#ProdUses Polypropylene surgical mesh Polypropylene thermal clothing Polypropylene Chair 9/21/2018 Team Hotel

Major Sources of Propylene Ethylene steam crackers – propylene yield is highly dependent on the type of feed Most US steam crackers process ethane, which makes little or no propylene European and Asian steam crackers process naphtha which produces propylene together with ethylene Petroleum refineries – primarily from the Fluid Catalytic Cracking (FCC) unit Dehydrogenation of propane Methanol to olefins 9/21/2018 Team Hotel

Transportation 9/21/2018 Team Hotel

Block Flow Diagram Methanol Methanol to Olefins (MTO) Synthesis Syngas Propylene + byproducts Syngas Methanol 9/21/2018 Team Hotel

Chemistry: Syngas to Methanol Specifications/Conditions Temperature: 250-290 C Pressure: 50-100 atm Feedstock: Synthesis Gas Syngas Ratio: 2.0-2.1 Catalyst: Copper based (>99.9% selectivity) Byproducts: Possible traces of Water and Carbon Dioxide One-stage column to reach desired methanol purity (for MTO) Lurgi recommends 2-2.1 9/21/2018 Team Hotel

Syngas to Propylene Processes Syngas to Methanol Methanol to Propylene Lurgi Johnson Matthey Devey Methanol Process Technology UOP Lurgi SYN Energy Technology Co. Ltd. and Lummus Technology 9/21/2018 Team Hotel

Johnson Matthey and Linde Methanol Processes Johnson Matthey successor to Imperial Chemical Industry (ICI) The Linde isothermal reactor uses JM catalyst technology Pioneer of the LPM process Almost 50% market share Catalyst: Cu/ZnO/Al2O3, but different adjustments are constantly made Temperature: 250-300 C Pressure: 100 atm Uses a fixed bed reactor Steam production Licencess their technology to other companies Capacity:100 mt/day to over 1,000 mt/day 9/21/2018 Team Hotel

Davy Methanol Process Technology designs using JM(ICI) Catalysts Radial Flow Steam Raising Converter Tube Cooled Converter Axial Flow Catalyst in Tubes Capacity: 3500 t/day Capacity: 2500 t/day Capacity: 1500 t/day 9/21/2018 Team Hotel

Lurgi Methanol Processes Lurgi Process Capacity: 5000 mt/day Catalyst: CuO/ZnO, Cu/ZnO/Cr2O3 + promoters Temperature: 250-260C Pressure: 50-60 bar Shell and tube reactor (Two step process) Energy efficient, creates high pressure steam High conversion efficiency Low investment cost 9/21/2018 Team Hotel

Chemistry: MTO MTO Catalysts 9/21/2018 Team Hotel

Methanol to Olefins Background The Methanol to Hydrocarbons process was discovered at Mobil Oil in 1977. Hydrocarbons production from methanol over a zeolite catalyst has been known Since the 1980s. However not possible on commercial scale due to high price of methanol and complexity of process. Propylene production from methanol started to become technically feasible in 1999. A demonstration unit was then built in 2001 at StatoilHydro's plant, a Norwegian oil and gas company, in Tjeldbergodden, Norway and proven successful. 9/21/2018 Team Hotel

UOP MTO Process SAPO catalyst -> high selectivity Conversion: around 80% Low catalyst consumption High P/E ratios –> 1.3-1.8 9/21/2018 Team Hotel

SYN Energy Technology Co. Ltd. DMTO Technology DICP – DMTO II Major products ethylene & propylene (almost 50/50) 1 ton olefins produced/2.95 tons methanol 99.18% conversion rate Currently running in China – successful 10kta-scale plant ($2.75bln project) 9/21/2018 Team Hotel

Lurgi MTP Process Methanol Coversion > 99% Propylene Conversion: around 71% Can be achieved at <$400/ton Simple and stable zeolite catalyst Commercially proven Two units being built in China Will produce 519,000 tons/yr 9/21/2018 Team Hotel

Product and Process and Decisions Product decision: methanol to propylene Processing decisions Syngas to methanol – Lurgi process Methanol to olefins – Lurgi process Next Steps Creating Flow Sheets Material and Energy Balances Reaction Kinetics Data Hand Calculations Rough Economics 9/21/2018 Team Hotel

9/21/2018 Team Hotel