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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
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Agenda
� Motivation
� Today´s methanol industry
� Towards larger capacities – a joint effort of R&D, catalyst
development and plant engineering
� Monomer and fuel from Methanol
� Conclusions
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02468
1 01 21 41 61 820222426283 0
1970 198 0 1990 2 001 2 02 0 2 05 0
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Increasing energy demand
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How will the future look like?
Sources:www.spiegel.de/fotostrecke/0,5538,16327,00.htmlhttp://www.pacificrenewables.com/fischer-tropsch.htm
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Spoilt for feedstock choices
1110 hits 754 hits
1380 hits
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Syngas & MeOH – the flexible dream team
CoalNatural GasBioMassTar Sands etc.
Syngas Methanol
ChemicalsPropyleneDMEFuels
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Chemical Methanol Market
� Today development
Formaldehyde 12 MM tpa up
MTBE 6 MM tpa down
Acetic Acid 3 MM tpa up
Miscellaneous Uses 11 MM tpa up
TOTAL 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 cost
to economic methanol production
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Ways 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
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H2/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
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Typical Single-Train Capacities
100 1.000 10.000 100.000 1.000.000
MeOH Reforming
MPG- PartialOxidation
AutothermalReforming
Steam Reforming
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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
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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, m3
eff. / hr
43713 20240 19433
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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
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Preferred route: Oxygen-based
ATR: homogeneous/heterogeneous formation of syngas
principle reactions:
combustion of methane
steam reforming of methane
Water gas shift reaction
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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
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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 αααα-Al2O3 Nickel catalyst→ high thermal stability
� multilayer refractory lining→ thermal protection
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Development steps towards MegaSyn™
Atlas Methanol - 5000 mt/d, commissioned 2004
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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)
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Development of Technology
Picture 1 – Towngas, Hamburg, 1954
Picture 2 – FT Syngas, Mosselbai, 1993
Picture 3 – MegaMethanol, ATLAS, 2004
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Towngas, Hamburg, 1954
Feedstock: Refinery Offgas
Product: Towngas
Capacity: 25.2 MMSCFD
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PetroSA, Mosselbay, 1993
Feedstock: Natural Gas
Product: Fischer-Tropsch Syngas
Capacity: 252 MMSCFD per train
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ATLAS, Trinidad, 2004
Feedstock: Natural gas
Product: Methanol Syngas
Capacity: 420 MMSCFD
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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
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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
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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
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Development of Synthesis Loop1. Conventional Synthesis Loop
Synthesis Gas16 bar
Cooling Water
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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
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240
245
250
255
260
265
270
275
280
0 0,2 0,4 0,6 0,8 1
Catalyst Height
Tem
pera
ture
°C
ReactionCooling Water
Development of Synthesis LoopTemperature Profile Steam Raising Reactor
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Development of Synthesis LoopSteam Raising Reactors
Steam Drum
Inter-changer
Reactors
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Development of Synthesis Loop2. Two-Step Methanol Synthesis
PurgeGas
RecycleCompressor
CrudeMethanol
Compressed Synthesis Gas
Boiler FeedWater
Gas-cooledReactor
Steam RaisingReactor
MP-Steam
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Development of Synthesis LoopLurgi‘s Two Reactor Concept (CMC)
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Large Single Train Capacity
Low Investment Cost
Operation at the Optimum Reaction Route
� High Equilibrium Driving Force
� High Conversion Rate
Lowest recycle/syngas ratio
High methanol content (11 %) at reactor outlet
Development of Synthesis LoopGas Cooled Reactor
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0
50
100
150
200
250
300
0 0,2 0,4 0,6 0,8 1
Catalyst Height
Tem
pera
ture
°C
ReactionCooling Gas
Development of Synthesis LoopTemperature Profile Gas Cooled Reactor
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Development of Synthesis LoopSummary of Highlights / Two-Step Methanol Synthesis
g Operation at the Optimum Reaction Route
� High Equilibrium Driving Force
� High Conversion Rate
g Elimination of Reactor Feed Preheater
g Elimination of Catalyst Poisoning
Thermodynamically controlled
Steam Raising Reactor
g Simple and Exact Reaction Control
g Quasi Isothermal Operation
g High Methanol Yield
g 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
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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 effort
comprising technology development and catalyst research (Süd-Chemie)
Two step synthesis
Conventional synthesis
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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
Tho
usan
d to
ns
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
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Steam cracker Propanedehydrogenation (PDH)
C2=:C3= = 3:1 selective C3= production
selected locations (rich NG)
Proven Routes for C3= production
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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
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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/a
Plantlocation
Various prospects are not listed
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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®
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Synfuels, Mossel Bay, RSA
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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
� �
�
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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!
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Thank you!
Methanol production
Conventional Outlets
Monomer Production (today)
Fuel Production (tomorrow)
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Comments?
Contact :
Dr. Thomas WurzelDirector Gas to Chemicals
Dept. L-TG
Phone +49 69 5808 2490Fax +49 69 5808 3032e-mail Dr.Thomas.Wurzel@lurgi.com
Lurgi AG Lurgiallee 5D-60295 Frankfurt am MainGermanyInternet: www.lurgi.com