ENHANCING METHANOL CAPACITY WITH TECHNOLOGY INNOVATION
Jim LoneyOctober 17, 2017Gasification & Syngas Technologies Conference
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One of the world’s largest engineering, procurement, fabrication, construction and maintenance companies
Providing innovative and integrated solutions for methanol facilities of varying sizes across the globe
More than 60,000 employees executing projects globally
Experience with all methanol licensors
Fluor has an extensive resume of major USGC Petrochemical projects
Delivering capital efficient solutions for today’s methanol projects
Integrated EPFC approach that drives to a lower TIC
Single point responsibility with financeable ‘wrap’
Zero Base ExecutionSM project delivery
Modularization ~ 15% reduction on TIC from stick built
Global Sourcing Strategies
Proprietary CO2 Technology solution for existing and new methanol facilities
ABOUT FLUOR
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AV2010348-001.pptx3
3rd Gen Modular
ExecutionSM
Zero Base
ExecutionSM
Integrated EPFC
tools
Revamp and new
build methanol
facilities
Experience with
all licensors
Performance
testing
Material
management
Supply and
procurement
capability
Commercial
Strategies Group
Global supplier
agreements
Supplier quality
surveillance
Capacity to self-
perform fabrication
of modules
SMFI - Edmonton,
Canada
ICA Fluor - Tampico,
Mexico
ANGS - Sakhalin
Island, Russia
COOEC-Fluor -
Zhuhai, China
Construction
equipment
Tool program
Equipment
planning and
forecasting
Scaffolding
Blast-resistant
air shelters
Start-up and
commissioning
Operations and
Maintenance (O&M)
Plant engineering
Inspection and integrity
Asset management
solutions
Turnarounds, outages,
and shutdowns
ENGINEERING PROCUREMENT FABRICATION ANDMODULARIZATION
DIRECT HIRECONSTRUCTION
O&M MODIFICATIONAND ASSET INTEGRITY
Fully Integrated Solutions
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NTS The Concept – Econamine FG PlusSM CO2 Enhancement
Steam methane reformer (SMR) based methanol plants have excess hydrogen compared to the ideal hydrogen-to-carbon oxides ratio
Without adjustment, the purge stream will be rich in hydrogen which is typically used as reformer fuel
This purge stream can be converted to additional methanol if there is a source of carbon oxides
The source of CO2 is Fluor’s Econamine FG+ process which captures CO2 from the reformer flue gas
Adding CO2 increases the plant methanol production capacity and improves plant efficiency
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NTS The Concept – Econamine FG PlusSM CO2 Enhancement
Three Options:
1. For existing plants, add a purge converter and combine the hydrogen-rich purge stream with CO2
2. Add CO2 to the existing process and debottleneck existing equipment
3. Incorporate into the design of new facilities
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NTS The Concept - Econamine CO2 FG PlusSM Enhancement
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Simplified Econamine FG PlusSM flowsheet
AV2010348-001.pptx7
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Prosint Methanol Plant, Brazil
Fluor demonstrated this concept at the Prosint methanol plant in Brazil starting in 1999 for over 15 years
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Addresses the need for an alternative to large scale new build Methanol facilities
Applicable to existing SMR based Methanol Plants which use natural gas feed stock
Divert existing purge stream from use as fuel to new purge converter
Replace diverted reformer fuel with natural gas
Use existing product storage tanks and shipping infrastructure
Methanol production increases 33% from 2800 MTPD to 3720 MTPD
Efficiency improves about 4%
Reformer stack CO2 Emissions per tonne of methanol are reduced by about 20%
Fluor Solution
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Additional equipment required:
Purge Converter/Loop
Distillation with Reboilers/Condensers
Econamine FG Plus Carbon Dioxide Capture – about 1200 tonne/day Direct Contact Cooler; Flue Gas Blower; Absorber; Stripper; CO2 Product Compressor
Plot space requirement: about 250’ by 400’
Natural Gas usage increases about 30%
Power usage increases by about 6 MW
Steam usage increases by about 135 tonne/hr
Cooling duty increases by about 600 x 106 BTU/hr
Implementation Considerations
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3D Rendering of Econamine FG PlusSM
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Summary Fluor capacity enhancement applicable to existing SMR based
Methanol Plants which use natural gas feed stock Can also be incorporated into new designs
Methanol production increases 33% from 2800 MTPD to 3720 MTPD
Incremental improvement in efficiency – about 4%
Additional benefit of reducing reformer carbon footprint by 20% - overall CO2 per tonne of methanol improves by about 4%
Alternative solution to a new large scale methanol facility
Fluor integrated EPFC execution model:
Safety in Design
Cost and Schedule Predictability
Assurance of Quality
Delivering Capital Efficiency
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NTS Using carbon dioxide recovery to increase methanol
productionContacts:
Technical : Jim Loney, Director, Process Engineering
[email protected] 001-949-349-7490
Sales: Sarah McKay, Director, Sales
[email protected] 001-949-349-5492
Econamine FG PlusSM process and licensing information: Satish Reddy, VP Process Technology
[email protected] 001-949-349-4959 or 001-281-263-1245
AV2010348-001.pptx13