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Gas To Chemicals
Agenda
Gas To Chemicals - Drivers
MegaSyn-Technology
MegaMethanol-Technology
Gas-Based Petrochemistry
Gas-Based Refinery
Driver I
Natural Gas: Reserves-To-Production Ratio
World
% of global
reserves
61
7,1%
41
Africa
7,8%
98
263
Middle East
Eastern Europe & FSU
Western Europe
38,1%
78
3,0%
16
4,3%
68
S&C America
North America
5,0%
10
34,6%
50
100
150
200
250
300
years
Source:
Energy Information Administration (EAI): International Natural Gas Information 14 Feb 2001, http://www.eia.doe.gov
Driver II
4x World production
of methanol
World production
of ammonia
Driver III
Driver III
WORLD POLYPROPYLENE PRICE COMPARISON
Current Dollars
1200
Forecast
1000
800
600
400
200
0
1990
1993
1996
1999
2002
USGC-Contract
West Europe-Contract
SEA Spot
Source: CMAI
2005
2008
2011
2014
USGC-Spot
SEA Contract
2017
2020
Driver IV
For years Lurgi Oel Gas Chemie GmbH is one of the mayor players
in the field of Syngas Generation and Synthesis Technologies. Based
on our
huge experience,
expertise, and
success
the Gas-to-Chemicals (GTC) route is a
consequent further development and
application of our core technologies
and know-how.
Stranded
Gas
Formaldehyd
MTBE
SYNGAS
CO + H2
Methanol
FT-
DieselAdditives
Fischer Tropsch
Products
Fuel
Hydrogen
Olefins
DME
Clean Fuels,
Lubricants, Fuel Cell,
-Olefins
Green
Fuels
Ammonia
Diesel
Urea
EnergyProduction
Polyethylene
Ethylene-Glycol
-Olefins
Liquids
Polypropylene
Acrylonitril
ASU
5 x 1000 Tubes
500
400
SR
CR
ATR
300
200
100
0
0
0,3
0,6
0,9
1,2
1,5
1,8
Autothermal Reformer
Process Characteristics:
LPG
Upgrading
Fuel Gas
Waxes/Lube Oil
MtPower
Power
MegaSyn
Fuel Cells
Natural Gas /
Associated
Gas
MtSynfuels
MegaMethanol
MTP
Propylene/Polypropylene
Acrylic Acid
MTO
MTD
MTH
Megammonia
Diesel/Gasoline
Acrylic Acid/Acrylates
Ethylene/Propylene
Fuel (DME)
Hydrogen
Ammonia/Urea/Fertilizer
Gas-Cooled Water-Cooled
Reactor
Reactor
improved gasification
high energy efficiency for
MeOH synthesis
low investment costs
Purge
Gas
Natural
Gas
Desulphurization
Air
Boiler
Feed
Water
Syngas
Crude Methanol
PreReforming
Autothermal
Reforming
AirOxygen
Separation
Steam
Methanol
Synthesis
Methanol
Distillation
PSA
Pure
Methanol
1992 - 2001
Lurgi 27%
Lurgi 55%
MGC,
Other
12%
ICI 61%
ICI 25%
MGC,
Other
20%
MeOH
Recycle
Off-gas
Stabilised
MeOH
Syngas
Production
DME
Reaction
DME
Distillation
H2O
Recycle
DME
Product
Waste
Water
Zero Emission
5000
t/d
42.9
28.5
MMBtu/tDME
MMBtu/tMeOH
415
MMUS$
Production Cost
Diesel fuel (for comparison)
93.0
= 3.4
4.8 - 6.1
US$/tDME
$/MMBtu
$/MMBtu
based on NG price = 0.5 US$/MMBtu and both, depreciation & ROI 10% of total fixed cost
Fuel Gas
DME
Pre-Reactor
Product
Conditioning
Propylene
LPG
MTP 1
MTP 2
MTP 3
Reactor Stages
Water Recycle
Gasoline
Olefin Recycle
Process
Water
Fixed-bed reactors
CATALYST
MTP Economics I
Case Study B, Blockflow Diagram
Natura
l
Gas
Syngas
Plant
1.7 Mio
t/a
Methanol
Methanol
Plant
Propylene
Plant
(MTP)
936 000 t/a
Water
Polypropylene
Plant
MTP Economics II
Production Cost, Case Study B: Integrated MegaMeOH/MTP/PP Complex
Methanol
MTP
PP
1,700,000
520,000
520,000
Capacity
MTY
Mio US$
350
215
165
Mio US$
70
43
33
Feed Cost
US$
Methanol
43 $/t
Propylene
174 $/t
Production Cost
42.9
210.1
261.0
- Raw Materials
- Utilities
- Operation & Maintenance
- Plant OVDH & Insurance
- Depreciation
US$/t
US$/t
US$/t
US$/t
US$/t
US$/t
14.4
1.6
5.6
6.0
15.3
150.3
5.6
11.3
12.1
30.8
212.8
6.8
8.6
9.2
23.6
US$/t
- 35.7
Cost of Product
US$/t
43
174
261
Natural Gas
0,5 $/MMBtu
Mio US$
Mio US$
US$
Production Cost
US$/t
US$/t
US$/t
US$/t
US$/t
US$/t
154.3
Revenues
Mio US$
US$/t
US$/t
US$/t
356.6
- Raw Materials
- Utilities
- Operation & Maintenance
- Plant OVHD & Insurance
- Depreciation
- Methanol (90 US$/t)
- Naphtha (130 US$/t)
- Polypropylene (650 US$/t)
730
146
Natural Gas
0,5 $/MMBtu
49.7
9.1
19.9
21.2
54.4
18.6
338.0
23.1
Gas-based Petrochemistry
Natural
Gas
Methane
Syngas
CO + H2
MeOHPlant
Methanol
MTP
Propylene
Plant
Propylene
PPPlant
Polypropylene
Propylene
OxoalcoholPlant
Acrylic Acid
Plant
Acrylic Acid
2-EHOH
Acrylic Acid
BuOH
2-EHOH
Acryl. Plant
Bu-Acryl.
Plant
2EHAC
BuAc
2-Ethylhexylacrylate
Butylacrylate
Acrylic Acid
Hydrocarbon Recycle
4.290 t/d
Hydrocarbon Recycle
Methanol
15.000 t/d
MTP
COD
Product
Separation
Gasoline
1860 t/d
Gasoline
Water Recycle
Discontinous
In-situ Catalyst
Regeneration
Light Ends
420 t/d
Lurgi Route
FT Synthesis
1:4
1 : 2.3 1 : 5.4
Lurgi Route3)
FT Synthesis3)
35
1
50/10 1)
18
91/95/98
82.5/85/88
3
<< 1
0
44
80
75
<1
<< 1
0
> 30
< 40
< 40
11
50/10 1)
51
<1
<1
55
<1
<5
> 70
Middle East
Plant Capacity:
Depreciation:
Return on Investment:
10 %
1)
Lurgi MtSynfuels
existing FT1)
1.452
24,192
1.671
27,856
NG to Process (LHV)
[$/bbl]
[MMBtu/bbl]
3.76
7.51
4.22
8.44
[$/bbl]
1.45
1.53
Utilities
[$/bbl]
0.28
0.8
24.88
28.68
[$/bbl]
[$/bbl]
[$/bbl]
Japan
29.70
33.21
Propylene is a high-demand, high value product. It can be produced cheaper than by conventional processes
Back-up slides
1700 mtpd
1992
Statoil, Norway
2400 mtpd
1992
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
1999
2000
CINOPEC, China
Operation at the
Optimum Reaction Route
High Reliability
Ignition
Characteristics of the Components
Cetane Number
Name
DME
Chemical formula
CH3OCH3
C3H8
CH4
CH3OH
Molecularweight
46.07
44.1
16.04
32.04
-24.8
-42.1
64.7
150-370
666
501
-161.5
-
792
<845
1.52
0.55
0.51
0.85
Explosive limitsvol%
(
in air)
3-17
2.1-9.4
5-15
Cetane number
55-60
28.84
46.3
50
19.9
5.5-44 0.6-6.5
40-55
~42.5
4 H2 + 2 CO
CO + H2O
CO2 + H2
2 CH3 OH + H2O
Methanol dehydration
2 CH3 OH
Cooling
System
DME Product
DME
Column
Offgas
Scrubber
Crude
Methanol
Heat
Integration 2
Heat
Integration 1
Methanol Recycle
Methanol
Water
Column
Process
Water
MTP R&D
Development Strategy
Three-Stage PDU (Pilot Plant)
DME prereactors
recycle streams
3rd stage
2nd stage
1st stage
Improve thermodynamic
property set in process
simulator (e.g. evaluation
& regression of VLE data)
Value Engineering
MTP Economics
Mega Methanol
on site
integrated
40
delivered
35
30
25
20
15
10
5
0
40
50
60
70
80
90
production only
more
complicated set-up to
control reaction temperature
low
risk of scale-up
low
in-situ
regeneration at reaction
temperature (no stress on the
catalyst)
Fluidised-Bed
ethylene/propylene co-production
discontinuous
defined
Lurgis FT Experience I
Tubular
reactor
Fluidised
bed reactor
Lurgis FT Experience II
(coal gasification)
SMDS/Bintulu
Today,
Lurgi MegaSyn is
available
for FT Syntheses
(partial
oxidation
of NG)
Gas-based Petrochemistry
Feedstock
Intermediates
OIL
conventional route
Natural Gas
Associated Gas
Stranded Gas
emerging route
Aromatics
Cracker
Olefins
MTO
Lurgis
MegaSyn
Syngas
COAL
future route ?
Benzene
Toluene
Xylenes
Lurgis
MTP
Ethylene
Propylene
Petrochemical
Products
Polyolefins
PE, PP
Acrylates
Polycondensates
PC, PET,
PBT
Solvents
Methanol
Oxidates
Lurgi
MegaMethanol
Lurgis
MTC
Alcohols, Ethers,
Esters, Acids,
Aldehydes
Fuels
Fuel additives