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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
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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
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Context for Group Hotel Project
9/21/2018 Team Hotel
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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
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Product prices $/Ton Source Propylene 1200 Methanol 482 Dimethyl Ether
Methanol 482 Methanex: Dimethyl Ether ?? Gasoline 600 Platt's Oilgram Price Report - October 11, Based on $3.04/gal Diesel 738 Platt's Oilgram Price Report - October 11, 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
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Commercial Uses of Propylene
picture from Polypropylene surgical mesh Polypropylene thermal clothing Polypropylene Chair 9/21/2018 Team Hotel
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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
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Transportation 9/21/2018 Team Hotel
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Block Flow Diagram Methanol Methanol to Olefins (MTO) Synthesis Syngas
Propylene + byproducts Syngas Methanol 9/21/2018 Team Hotel
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Chemistry: Syngas to Methanol
Specifications/Conditions Temperature: C Pressure: atm Feedstock: Synthesis Gas Syngas Ratio: 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
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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
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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: 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
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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
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Lurgi Methanol Processes
Lurgi Process Capacity: 5000 mt/day Catalyst: CuO/ZnO, Cu/ZnO/Cr2O3 + promoters Temperature: C Pressure: 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
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Chemistry: MTO MTO Catalysts 9/21/2018 Team Hotel
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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
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UOP MTO Process SAPO catalyst -> high selectivity
Conversion: around 80% Low catalyst consumption High P/E ratios –> 9/21/2018 Team Hotel
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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
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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
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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
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9/21/2018 Team Hotel
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