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Dominant Technology for the Propylene Production(DTP )Process N. CHIKAMATSU 1 , K. HONDA 1 , A.OKITA 1 , J. TAKAHASHI 1 , K. OYAMA 1 , and M. NAKAMURA 2 1:JGC Corporation 2:Mitsubishi Chemical Corporation 7th Asian DME Conference Nov. 2011 Niigata, Japan
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Page 1: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

Dominant Technology for the

Propylene Production(DTPⓇ)Process

N. CHIKAMATSU1 , K. HONDA1, A.OKITA1, J. TAKAHASHI1,

K. OYAMA1, and M. NAKAMURA2

1:JGC Corporation

2:Mitsubishi Chemical Corporation

7th Asian DME Conference

Nov. 2011

Niigata, Japan

Page 2: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

2

Why propylene?

DTPⓇ Process Features

DTP Ⓡ Demonstration Plant Running

Development Schedule

Contents

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3

Polypropylene

Acrylic acid

Propylene is an important intermediate product.

Oxo alcohol

Propylene oxide

Acrylonitrile

Cumene Others

World Production

77 million ton-PPY/year

Applications of Propylene

Reference:Economy of Chemical Industry ”Kagaku Keizai”(Mar. 2011)

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0

20

40

60

80

100

120

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014

4

Unit:×106 ton

‘08-’14 Increase 4.2%/year

Reference: METI News Release (2010)

World Demand for Propylene W

orl

d D

em

an

d f

or

Pro

pyle

ne

Page 5: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

5

Conventional Propylene Production Process

Process

Cracking FCC

(Fluid Catalytic Cracking)

Dehydro-

genation Metathesis

Naphtha

Cracker FCC

DCC

[S&W]

OLEFLEX

[UOP]

OCT

[ABB Lummus]

Feedstock Light

Naphtha VGO

85%VGO+

15%VR C3

C2= &

2-C4=

Yield

[wt%]

C2= 29.0 1.0 3.6 - -

C3= 18.0 4.7 22.9 85.0 >90.0

C3=/C2

=

ratio 0.6 4.7 6.4 - -

Production

Ratio[%] 66 32 2

Reference: Journal of Japan Institute of Energy, Inomata (2005)

Almost all propylene is produced from cracking and FCC.

Propylene is by-product of cracking and FCC.

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Ethane Crackers in the Middle East

Country Owner Capacity

[104 ton/year]

Iran

Kharg Petrochemical 50

Amir Kabir Petrochemical 52

Maroon Petrochemical 110

Arvand Petrochemical 100

Arya Sasol Polymer 100

Jam Petrochemical 132

NPC/VPC(No.11) 120

NPC/VPC(No.12) 100

Ilam Petrochemical 32

Saudi

Arabia

Rabigh Refining Petrochemical 130

Tasnee Petrochemical 100

Eastern Petrochemical 130

Yansab 130

Qatar Ras Laffan Ethylene 130

UAE BOUROUGE-Ⅱ 140

Kuwait Equate-Ⅱ 85

Total capacity

for ethylene production:

16 million ton/year

Reference: ENN (2005)

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Product Yield for Feedstock of Cracker

Reference: Journal of Catalysis society of Japan, Suwa(2004)

0

10

20

30

40

50

60

Pro

duct Y

ield

[w

t%]

C2 Naphtha VGO

C3=

C2=

Feedstock Ethane Propane Butane Naphtha VGO

C2= Yield 53 40 33 32 22

C3= Yield 1 14 18 16 12

C3 C4

[wt%]

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8

By-product from naphtha cracking and FCC

Increasing demand (300 million ton/year)

Boom in the construction of ethane crackers

Wild fluctuations in oil prices

Propylene Situation

Expanding of propylene demand-and-supply gap

Diversification of raw materials

Dominant Technology for Propylene production(DTPⓇ)

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+ H2O

+ O2

Natural Gas

Lower Olefins Production from Natural Gas

CH4

C2H6

C3H8

Synthesis

Gas DME

Methanol

Olefins

C2H4

C3H6

DME to

Propylene

Dehydrogenation

Cracking

Methanol to

Olefins

- H2O

- H2

- H2

Page 10: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

CH3OCH3

10

Main product: Propylene

By-products: Water,

Ethylene, C4-C6 Olefins,

C1-C4 Paraffins,

C7+ Hydrocarbons

etc.

DTP Reaction

Zeolite catalyst

CH3OH

Methanol DME

C3H6

Propylene

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Advantages of DTPⓇ Catalyst

Typical

MFI

Catalyst

DTPⓇ

Catalyst

Proprietary MFI type Zeolite (ZSM-5) Catalyst

High Propylene Selectivity

Stable Performance at High Temperature

Feed : DME

Feature

of DTPⓇ

Catalyst

Page 12: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

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Hydrocarbon

Recycle

DTP

Reactor

Dehydration

Reactor

Feed:

Methanol

Water Gasoline

LPG

Propylene

Separation

Unit

Water

Separator

Compressor

C1-C2

C4-C6

Light gas

DME

+Steam

2,500 t/d 760 t/d (254,000 t/y)

DTPⓇ Process Flow

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Joint Development of JGC Corporation and

Mitsubishi Chemical Corporation

Simple Fixed-bed Adiabatic Reactor

Catalyst Regeneration by Combustion of Coke

High Propylene Yield (70%) by Recycling

By-Products

Optional Co-Feed of C4 Olefins from

Naphtha Cracker / FCC

DTPⓇ Process Features

Page 14: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

14

Constructed in Mitsubishi Chemical’s Mizushima Plant

Operation Started in August 2010

DTPⓇ Demonstration Plant

This demonstration is subsidized by NEDO.

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DTPⓇ Demonstration Plant Features

Identical Reaction Conditions to Those of

Commercial Scale Design

Actual C4-C6 By-Products Recycling to

DTP Ⓡ Reactor

Reactor Switching for Regeneration

Optional Co-Feed of C4 Olefins from

Naphtha Cracker

Confirmation of State of Products

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Hydrocarbon

Recycle Feed:

Methanol

Water Gasoline

LPG

Propylene

C4-C6

Light gas

DME

+Steam

70 %

Example of Running Data of the Demonstration Plant

Feed:

C4 Olefin

3 %

3 %

16 %

8 % Purge

Selectivity = Total Carbons of each effluent / Total carbons of methanol and C4 olefins as feed

High Selectivity for Propylene

Page 17: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

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Example of Running Data of the Demonstration Plant

Propylene Yield = Total Carbons of propylene product / Total carbons of methanol and C4 olefin as feed

0

10

20

30

40

50

60

70

80

90

100

Pro

pyl

en

e Y

ield

[%]

Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7

Propylene Yield: approximately 70%

Page 18: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

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Example of Running Data of the Demonstration Plant

Repeat of Reaction and Regeneration Successfully

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60

Days

Pro

pyle

ne Y

ield

[%

]

React. Reg. React. Reg. React. Reg.

Propylene Yield : Calculated according to

products from reactor A

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Confirmation of State of Products

Products from Demonstration Plant

Propylene mixture Water Gasoline

Analyzed and evaluated each product

Page 20: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

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Confirmation of State of Catalyst

Fresh

Catalyst

Degraded

Catalyst

Regenerated

Catalyst

Coke on Degraded Catalyst Eliminated Sufficiently

Catalysts from DTP Reactor of Demonstration Plant

Page 21: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

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Propylene Production via Methanol Derived from Natural Gas

in Gas-Producing Countries

Propylene Production with the Use of Both Methanol and

Ineffectively Utilized C4 Olefins from Naphtha Cracker

DTPⓇ Process Applications

Natural Gas Propylene

MeOH / DME

C4 Olefins

Propylene

Ethylene

MeOH / DME

Naphtha

Cracker

DTPⓇ

DTPⓇ

Page 22: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

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Process MTO MTP DTP

Company UOP /

Hydro Lurgi

JGC /

Mitsubishi Chemical

Catalyst modified SAPO-34 modified ZSM-5 modified ZSM-5

Process description

Reactor system Fluidized bed Fixed bed Fixed bed

Regeneration Continuous Batch mode Batch mode

Recycle no Olefin and Water Olefin and Paraffin

Conversion [%] 99.6 >99 >99.9

Operation Conditions

Temp. [deg-C] 350-550 425 450-550

Pressure[bar-G] 1-3 1.5 2.0

Olefin Yields[wt%] - - -

Ethylene 48-31 - -

Propylene 34-45 65 >70

Comparison with Competitive Processes

Page 23: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

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2007 2008 2009 2010 2011 2012 2013 2014

R&D activity

Equipment Scale

Marketing

Catalyst Improvement

Labo. Reactor(2 g/d)

Bench Plant (5 kg/d)

Demonstration Plant

License Promotion

Commercialization Planning

DTPⓇ Process Development Schedule

Process Improvement

Catalyst Development

Process Development

Page 24: Dominant Technology for the Propylene Production DTP …aboutdme.org/aboutdme/files/ccLibraryFiles/Filename/000000001973/7... · Cumene Others World Production ... UOP / JGC / Hydro

24

Thank You

for

Your Attention !

Contact:

Dr. Nobuyasu Chikamatsu

JGC Corporation

e-mail: [email protected]


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