FT vs MM ppt

8/10/2019 FT vs MM ppt

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GTC - Process Options for Venezuela

PdVSA - EFI SeminarPdVSA - EFI SeminarCaracas, 6 March 2002Caracas, 6 March 2002

GTC - Gas to Chemicals - Process Options for VenezuelaGTC - Gas to Chemicals - Process Options for VenezuelaDr.-Ing. Waldemar LiebnerDr.-Ing. Waldemar Liebner


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Contents

Introduction

Lurgis Syngas Production Technologies Natural Gas: abundance and challenge

Fischer-Tropsch: classic route to synfuel

Lurgis MegaMethanol-Technology MegaMethanolto Dimethyl Ether

MegaMethanolto Propylene

Propylene to Synfuels

Conclusion


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G aseous and

Light Liquid

Hydrocarbons

G aseous and

Light Liquid

Hydrocarbons

Heavy O il

Heavy OilM ethanol

M ethanol Coal

Coal W ater

W ater

Steam &

Autotherm al

Reform ing

Steam &

Autotherm al

Reform ing

Partial

Oxidation

Partial

Oxidation Reform ing

Reform ingGasification

Gasification Electrolysis

Electrolysis

Hydrogen

and Syngas

Hydrogen

and Syngas

Hydrogen and Syngas Technologies

Hydrogen

Hydrogen

M ethanol

DM EOlefins

M ethanol

DM E

Olefins

Am m onia

Am m onia Oxo alcohols

Acetic Acid

Oxo alcohols

Acetic Acid

Ore Reduction

Ore Reduction

Urea

Fischer Tropsch

UreaFischer Tropsch Fine Chem icals

Fine Chem icals M iscellaneous

M iscellaneous

Lurgis Syngas Production Technologies


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G aseous and

Light Liquid

Hydrocarbons

G aseous and

Light Liquid

Hydrocarbons

Heavy O ilHeavy Oil M ethanolM ethanol CoalCoal W aterW ater

Steam &

Autotherm al

Reform ing

Steam &

Autotherm al

Reform ing

Partial

Oxidation

Partial

Oxidation Reform ingReform ing GasificationGasification Electrolysis

Electrolysis

Hydrogen

and Syngas

Hydrogen

and Syngas

Hydrogen and Syngas Technologies

HydrogenHydrogen

M ethanol

DM EOlefins

M ethanol

DM E

Olefins

Am m oniaAm m onia Oxo alcohols

Acetic Acid

Oxo alcohols

Acetic Acid Ore ReductionOre Reduction

UreaUrea

Fine Chem icalsFine Chem icals

M iscellaneousM iscellaneous

Lurgis

Fischer Tropsch



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GasGas Production Plants Designed by LurgiProduction Plants Designed by Lurgi

Steam Reform ing74 Plants / 96 Units Total Capacity 140 000 000 m /d

with Pre-Reform ing Largest Plant Capacity 440 000 m /h*

37 Plants / 47 Units

Autotherm al Catalytic Reform ing

11 Plants / 29 Units Total Capacity 37 000 000 m /dLargest Plant Capacity 637 000 m /h

Noncatalytic Partial Oxidation

35 Plants / 75 Units Total Capacity 62 500 000 m /dLargest Plant Capacity 424 000 m /h

Com bined Reform ing (Steam Reform ing/Catalytic Autotherm al

Reform ing)8Plants / 10 Units Total Capacity 69 000 000 m /dLargest Plant Capacity 900 000 m /h **

* Four Trains

** Three Trains



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North

America

16,7%

MiddleEast

14,7%

Africa

39,3%

Far East &

Oceania

7,7%

West.

Europe

3,1%

E.Europe

&FSU

6,8%

C&SAmerica

11,6%

Flared Natural Gas (1998)

better use:make 130 Mt/a of methanol!build 74 MegaMethanol (andMTP)plants!

total amount flared worldwide:

100 billion m per year

Source:Energy Information Administration (EIA): International Natural Gas Information 14 Feb 2001, http://www.eia.doe.gov


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Uses of Natural Gas

Natural Gas

Hydrogen

Fischer-Tropsch

Products Ammonia Methanol

Gas Sales

Power GenerationLNG

Re-injection

RefineriesFuelEdib.Oil/Fat

Clean FuelsClean Fuels

LubricantsLubricants

WaxWax

Alpha OlefinsAlpha Olefins

UreaAcrylonitrileFertilisers

DME, FormaldehydeSolvents, MTBE

Clean Fuels, FuelCells PowerGeneration

AceticAcid

Olefins

Syngas (CO, H2)

5%5%


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Fischer-Tropsch Technology (FT)

Converts Synthesis Gas to Liquid Hydrocarbons

Product Spectrum Depends On: Temperature, Catalyst, Pressure, Gas Composition

High Temperature Fischer-Tropsch: 350 C: Gasoline and Light Olefins

Low Temperature Fischer-Tropsch:

250 C: Distillate and Waxes

Generalised Reaction:

2n H2+ n CO ( CH 2 ) n + n H2O

FT - The classic route from NG to synfuels


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History of Lurgis FT Process Development

Commercialisation of ARGE-synthesis in 1952 location: Sasolburg / South Africa start up: 1955 no. of reactors: 5

All original reactors still in operation today;extension of capacity in 1987 (+ 1 reactor)


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Modern FT Reactor Technology

Slurry phase reactor (by far preferred)

Tubular reactor

Fluidised bed reactor

Lurgi has commercial experience in all these

reactor technologies


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GTC - Process Options for VenezuelaLurgi Combined Reforming

Mossgas Fischer-Tropsch Plant

Capacity: 3 x 300 000 Nm3/h syngas

Start-up: 1992


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FT Syngas Production

Lurgi designed the syngas production unitsof all FT-plants currently in commercial operation

Sasol/Secunda (coal gasification)

Mossgas (combined reforming of NG)

SMDS/Bintulu (partial oxidation of NG)


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Comparative Economics1)- Cost of Production Estimate

A B C D E F

Total CapitalInvestment [MM$]Total Plant

Capital [$/bpd]

1.423

23,710

1.744

29,066

1.237

20,612

1.671

27,856

1.350

22,498

1.291

21,520

NG to Process- [$/bbl]- [MMBtu/bbl]

Cat & Chemicals- [$/bbl]

Utilities- [$/bbl]

4.108.20

0.76

(0.00)

4.699.39

1.52

3.06

4.298.58

1.50

0.39

4.228.44

1.53

0.80

4.889.76

1.61

2.57

5.1010.20

1.52

3.06

Cost of

Production- [$/bbl]

23.10 31.71 22.63 28.68 26.79 26.73

Market Price 2)

- Gasoline [$/bbl]- Diesel [$/bbl]

Western Europe34.7528.88

US Gulf Coast31.4226.51

Japan29.7033.21

1)Chem Systems, January 2001 2) Corresponding Crude Oil Price: ca. 21 $/bbl


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MegaMethanol Concept

MegaMethanol:

> 1 million t/a methanol single train capacity

Technical Features:

Oxygen-blown synthesis gas production

Two-step methanol synthesis

Hydrogen Recovery

The basis for even morevalue from natural gas:


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MegaMethanolProcess

Desulphur-isation

Pre-Reforming

NaturalGas

MethanolSynthesis

MethanolDistillation

PureMethanol

AutothermalReforming

AirSeparationAir

Oxygen

Hydrogen

Recovery

GTC P O ti f V l


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Methanex, USA 1700 MTPD 1992

Statoil, Norway 2400 MTPD 1992

SINOPEC, China 340 MTPD 1993

KMI, Indonesia 2000 MTPD 1994

NPC, Iran 2000 MTPD 1995

Sastech, RSA 400 MTPD 1996 Titan, Trinidad 2500 MTPD 1997

PIC, Kuwait 2000 MTPD 1998

YPF, Argentina 1200 MTPD 1999 Atlas, Trinidad 5000 MTPD 2000 Mega MeOH

Zagros, Iran 5000 MTPD 2000 Mega MeOH

Latest Methanol Project References

GTC P O ti f V l


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Economics of MegaMethanol

SteamReforming

CombinedReforming

Mega-Methanol

Capacity mtpd 2500 2500 5000Natural GasDemand

MBtu / mt 30 28.5 28.5

NOxEmission kg / mt 0.8 0.2 0.1

Total Fixed Cost(EPC)

Million US$ 225 215 300

Product Value(EPC)

US$ / mt 113 108 79

Assumptions:

Investment and energy cost for O2production and power generation included

NG Feedstock: 0.5 US$ / MMBtu; Depreciation: 10 % per year, ROI before taxes: 20 %

MegaMethanolProcess

GTC Process Options for Vene ela


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Dimethyl Ether (DME)

Alternative to Conventional Diesel Fuel

Transportation

Very low Emission Levels

Clean and efficient Power Generation

Similar Properties as LPG (Storage, Transport)

DME: Energy Carrier of the Future!

GTC Process Options for Venezuela


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Comparison of DME Synthesis / Alternatives

DME Direct Synthesis

Gas/water shift reaction*

*carbon loss by CO2formation

CO + H 2O CO 2+ H 2

Methanol synthesis CO + 2 H 2 CH 3OH

Methanol dehydration 2 CH 3 OH CH 3-O-CH 3+ H2O

DME direct synthesis 4 H2+ 2 CO CH 3-O-CH 3+ H2O

DME Synthesis via Methanol



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DME Production by Methanol Dehydration

DMEReaction

DMEDistillation

DMEProduct

StabilisedMeOH

H2ORecycle

MeOHRecycle

WasteWater

Off-gas

SyngasProduction



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Reactor: Adiabatic Fixed Bed Reactor

High Conversion Rate

Purity: According to Requirement

Highly efficient Heat Integration Systems,resulting in low Utility Requirement

Low Utility Consumption Zero Emission

DME Process Features



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Economics of the Lurgi DME process

MegaMethanol & Dehydration Plant

DME production 5000 t/d

Natural gas demand 42.9 MMBtu/t

Total fixed cost (EPC) 406 MMUS$

Product value (EPC) 83.3 US$/t

based on natural gas price = 0.5 US$ per MMBtu and

depreciation 10% of total fixed cost



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Propylene: Uses and Demand

4,3

2,7

4,4

4,3

4,5

5,8

0 2 4 6 8

P olypropylen e

A crylonitrile

O xo-A lco hols

C um en e

P ropylen e

O xide

A crylic A cid

Av. Growth Rate, %(Capacity by 2005)

Oxo-Alcohols

8%

Others

7%

Polypropylene

58%

Cumene

6%

PropyleneOxide 7%

Acrylonitrile

10%

AcrylicAcid

4%

2000 World Propylene Supply/Demand53.5 Million Tons



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MTP: Simplified Process Flow Diagram

MTP 1 MTP 2 MTP 3

Gasoline

Light EndPurge

ProcessWater

DMEPre-ReactorProductConditioning Propylene

Regeneration

C4/C5

Purge

Water Recycle

Olefin Recycle

Crude Methanol

Reactor Stages



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p

MTP Reactor System

propylene production only

more complicated set-up to controlreaction temperature

low risk of scale-up low coking tendency of catalyst

discontinuous in-situ regenerationat reaction temperature (no stress

on the catalyst)

defined residence time formaximum selectivity

ethylene/propylene co-production

good temperature control

complicated multi-step scale-up high coking tendency of catalyst

continuous regeneration at elevatedtemperatures; oxygen breakthrough

into process possible

broad residence time distribution

Fixed-Bed Fluidised-Bed



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p

MTP Technology Status

PROCESS

>8000 operating hours of pilot plant

demo unit started 01/ 2002

on-going optimisation of process design for

commercial plant

CATALYST

catalyst development completed by supplier

catalyst is commercially manufactured



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MTP Production Figures

Methanol

1.667 Mio tpy

5000 tpd

Propylene519,000 tpy

Gasoline

143,000 tpy

Fuel Gas, LPG

69,000 tpy

Regeneration

Discontinuous

In-situ Catalyst

Methanol toPropylene

Conversion

Water (product)

936,000 tpy

ProductSeparation



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MethanolToPropylene - Economics

Comparison Naphtha Gas to Methanol

Cracker to Propylene Plant

Plant Investment, $MM 580 620

Product Sales, $MM/Year 376 303

Cost of Production, $MM/Year 293 126

Sales-Cost Difference, $MM/Year 83 177

Return on Investment, % 14.3 28.5

MTP Economics



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MTP Economics

0

5

1 0

1 5

2 0

2 5

3 0

3 5

6 0 7 0 8 0 9 0 1 0 0 1 1 0

M ethanol Feed, $/m t

In

te

rna

lR

ate

of

R

eturn

*,

%

* Equity: 20%,Depreciation/Year: 10%

380 $/t Propylene

400 $/t Propylene

Mega-

M

ethanolTM



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Synfuels, Mossel Bay, RSA



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Gas Refinery via Methanol - Lurgis MTS Route

DiscontinousIn-situ CatalystRegeneration

MTP MTSProduct

Separation

Distillate4.290 t/d

Gasoline1860 t/d

Light Ends420 t/d

Gasoline

Water Recycle

Hydrocarbon Recycle

Hydrocarbon Recycle

Methanol15.000 t/d


Comparison Lurgi MTS Route FT Synthesis


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Comparison Lurgi MTS Route - FT SynthesisProduct Slate and Properties

Product Slate Lurgi Route FT Synthesis

Naphtha : Diesel (max.) 1 : 4 1 : 2.3 1 : 5.4

Product Properties Lurgi Route3) FT Synthesis3)

Spec (Europe from 2005)Gasoline-Aromatics-Benzene

-Sulphur-Olefins-RON 2)

-MON 2)

vol.%vol.%

wppmvol.%

max.max.

max.max.

351

50/101)

1891/95/98

82.5/85/88

3 70

1)Diesel with 10 wppm sulphur has to be available on the market2)RON / MON for Regular Gasoline / Euro-Super / Super-Plus3)

Properties before naphtha upgrading



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Comparative Economics1): Lurgi Route vs. FT

Basis

Plant Location: Middle East

Plant Capacity: 50,000 barrels per day products

Natural Gas Price: 0.50 US$ / MMBtu

Depreciation: 10 % for ISBL / 5 % for OSBL

Return on Investment: 10 %

Total Capital Investment:Includes Total Plant Capital (ISBL+OSBL) plus 20 %for Other Project Cost, year 2000

Cost of Production: Includes depreciation and 10 % ROI

Product Market Prices: Year 2000, adjusted to shipping costs from Middle East and applicable tariffs for the considered regions

1) Chem Systems, 2001


C ti E i L i R t FT


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Comparative Economics: Lurgi Route vs. FTCost of Production Estimate

Lurgi MTS Route existing FT1)

Total Capital Investment [MM $]-Total Plant Capital [$/bpd]

1.45224,192

1.67127,856

NG to Process (LHV) [$/bbl][MMBtu/bbl]

Cat. & Chemicals [$/bbl]

Utilities [$/bbl]

3.767.51

1.45

0.28

4.228.44

1.53

0.8

Cost of Production + ROI [$/bbl] 24.88 28.68

Market Prices 2)

- Gasoline [$/bbl]

- Diesel [$/bbl]

Western Europe34.75

28.88

US Gulf Coast31.42

26.51

Japan29.70

33.21

1)Chem Systems, 20012)Corresponding Crude Oil Price: about 21 $/bbl


C l i


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Conclusions

Lurgis syngas production technologiesfor all feedstocks and for all capacities:

Gasification (non-catalytic partial oxidation)of heavy residue/asphalt/Orimulsion

ATR (catalytic partial oxidation) of natural gasspecifically for large capacities: MegaSyn

LurgiReformer(SMR - steam methane reforming) andCombined Reforming of natural gas, for normal capacities

Lurgis MegaMethanolopens new routes of gas monetisation:

Dimethyl ether (DME) can be produced at attractive costs

to become an economical fuel Propylene is a high-demand, high value product. It can be pro-

duced cheaper than by conventional processes

The economics of synfuels via MegaMethanoland propyleneare comparable to FT routes



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Thank

You!

!

!

!

Questions?



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Back-up slides


Gas To Chemicals - Gas To Liquids


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Gas To Chemicals - Gas To Liquids

Light Ends

Distillate

MTSProduct

SeparationGasolineMegaMethanol MTPNatural Gas

Methanol Propylene

PolypropyleneAcrylic Acid

Propyleneoxide

GTC

GTL


Typical GTL Synfuel Product Slates1)


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Typical GTL Synfuel Product Slates1)

A B C D E F

Naphtha [wt.%] 30 14 15 20 20

Gasoline [wt.%]

M-Distillate [wt.%] 20 18 25 15 30

Diesel [wt.%] 50 68 60 65 50

Naphtha : MD+Diesel 1 : 2.3 1 : 5.4 1 : 5 1 : 4 1 : 4

1) Chem Systems, 2001




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Quality Aspects of Diesel Fuel

Ignition

Characteristics of the Components Cetane Number

Density, Effect on Engine Performance

Exhaust Gas Emissions, Sulfur, Particulates, Nox

Viscosity, narrow Limits

Cold Flow Properties, substitutes Kerosene



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FT vs MM ppt

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