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

2

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

3

02468

1 01 21 41 61 820222426283 0

1970 198 0 1990 2 001 2 02 0 2 05 0

�� � �� �� � � � � � � � � �� � � �� � � � � � � � � � �� � � � � �� �� � � � � � � � � � � � � �� � � � � � �� �Billion tons of coal equivalent

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

5

Spoilt for feedstock choices

1110 hits 754 hits

1380 hits

6

Syngas & MeOH – the flexible dream team

CoalNatural GasBioMassTar Sands etc.

Syngas Methanol

ChemicalsPropyleneDMEFuels

7

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

8

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