CO2 UTILISATIONIN MeOH

AND NH3/UREA PLANTS

Casale is a Swiss global supplier oftechnologies & engineering solutions

CASALE TECHNOLOGIES

Ammonia

Nitric Acid

Urea

Ammonium Nitrate

Solution UAN

Solid ANPRIL/GRAN/C

AN

Syngas generation

Melamine

SuperPhosphateSSP/TSP/USP

DAP / NP / NPK

Methanol

NitrogenFertilizer

PhosphateFertilizer

ComplexFertilizer

NG

Most of Methanol and NH3/Urea is produced from natural gas

These plants utilise the ‘Steam Reforming’ (SMR) for the syngas generation.

CO2 0.5 t/t MeOH0.25 t/t Urea

This process is based on the reaction between methane and steam.

CH4+H2O=CO+3H2 (very endothermic)

CO+H2O=CO2+H2 (slightly exothermic)

T=800/850 C P=25/35 bar

The reaction heat is supplied by burning fuel (NG)

A standard MeOH plant has a capacity of 3’000 MTD and the CO2 emissions from the SMR are ab. 1’500 MTD

A standard NH3/Urea plant has a capacity of 2’000/3’200 MTD and the CO2 emissions from the SMR are ab.1’100 MTD

Urea is the key to nitrogen fertilization

Urea

World production is ab. 200 Million TY

Without nitrogen fertilization, the earth could sustain a maximum of 4 billion people… but we are 7 billion!

NO UREANO PARTY

NH3/UreaThe syngas produced, is converted into NH3, and then Urea,

3H2+ N2=2NH3

2NH3+CO2=(NH2)2CO+H2O

The CO2 comes from the SMR reaction and from the shift reaction

Primary Reformer

Secondary Reformer CO shift CO2 removal Ammonia

synthesisUrea

synthesis

Fuel

SteamNatural gas

Flue gas

Air

H2, N2

NH3 Urea

CO2

CO2

The amount of CO2 available in the syngas is 10 % short of the necessary to convert all ammonia into urea

The CO2 necessary is available in the stack gas of the steam reformer

NH3/Urea

Primary Reformer

CO2recovery

Secondary Reformer CO shift CO2 removal Ammonia

synthesisUrea

synthesis

Fuel

SteamNatural gas

Flue gas

Air

H2, N2

NH3 Urea

CO2

CO2

MeOH Demand By Use and Region (2012)

MeOH

MeOHThe syngas produced, is converted into methanol, at about 80 bar, on a catalyst,

CO+2H2=CH3OH

CO2+3H2=CH3OH+H2O

The synthesis gas produced in the SMR is short of H2

Primary Reformer

Compression MeOHSynthesis Distillation

Fuel

SteamNatural gas

Flue gas

MeOH

CO2

H2

H2, CO

If CO2 can be provided in addition, then the plant capacity can be increased by 20 % with minimal modifications.

The CO2 necessary is available in the stack gas of the steam reformer

MeOH

Primary Reformer

CO2recovery

Compression MeOHSynthesis Distillation

Fuel

SteamNatural gas

Flue gas

MeOH

CO2

CO2

H2, CO

CDR Economics

CAPEX

Add

ition

al

$/T

ME

OH

DEPRECIATION. YEARS

OPEX

$/T

ME

OH

NG COST $/MBTU

• The use of a CDR allows to upgrade easily Methanol and NH3/Urea plants, utilizing CO2 presently vented

• The key to its success is the capital cost and the operability

• The research project Casale/ETH is focused on developing a new CDR concept to

• reduce the investement cost and the energy consumption

• Improve the operability

CONCLUSIONS

…THANK YOU….