Gasification India 2017 Synthesis Gas to Chemicals and Fuel Atul - - PowerPoint PPT Presentation

Gasification India 2017 Synthesis Gas to Chemicals and Fuel

Atul Shah

Syngas to Chemicals and Fuel - JM Technologies and Catalysts

2

syngas DME

• xo

Gasoline / Diesel methane ammonia methanol polyolefins 2EH/butanol 2PH MEG FT SNG NH 3

MTO

By others

MEG

C3= C4=

formaldehyde methanol

• xo

methylamines

Global Methanol Demand and Uses

3 Source: MMSA Methanol and Derivatives Analysis (MDA) Fuel, additives Plastics Wood resin boards Paints

Coal to Methanol

Entrained flow gasifiers preferred

• High exit temperature
• Low CH4 in syngas

Shift converts CO + H2O to H2 + CO2 Acid Gas Removal (AGR) removes excess CO2 and H2S Most recent methanol projects in China use syngas produced from low/medium ash coal AGR MeOH Unit Shift Gasifier Coal Oxygen CO2 & H2S Purge (Steam) SMR Optional Natural gas Methanol

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Typical syngas compositions

Syngas technology R ratio CO/CO2 % CH4 Steam Methane Reformer (SMR) 2.9 2 3 SMR+CO2 2.1 2 3 SMR+ Auto Thermal Reformer 2.1 3 1 SMR+ Gas Heated Reformer 2.1 2 1 Gasifier – coal1 2.05 10 0.5 Gasifier - biomass 2.05 5 5

• R ratio

– Excess H2 R = ([H2]-[CO2])/([CO]+[CO2])

• CO/CO2

– Heat of reaction/ reactivity

• CH4

– Loop efficiency

1 Entrained flow gasifier

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Tube Cooled Converter (TCC) Radial Steam Raising Converter (R-SRC) Axial Steam Raising Converter (A-SRC)

Methanol Synthesis – Reactor options

• Three Converter Types used for different applications
• Reactor configuration is optimised for feedstock and plant capacity
• Single reactor can produce 2000tpd (A-SRC) to 3000tpd (R-SRC)
• Plant capacity >6500tpd in commercial operation

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steam methane reforming distillation methanol synthesis

methanol

synthesis gas

JM Global Methanol Experience

JM’s technology and catalyst provides the world’s premier process for production of methanol from syngas

• JM have for > 60 years supplied

the methanol industry with leading technology and catalysts.

• Licensed into 92 Plants in 35

countries.

• 32% of all global methanol

capacity is JM technology

• 66% of all plants >2000 MTPD
• perating or being built in P

.R. China are JM technology

• >15 coal based projects ranging

from 600kta to >2,000 kta since 2006

Shenhua Baotou: Coal to Chemical complex

• China’s drive into self sufficiency, utilise domestic feedstock and

reduce dependency on imported oil for petrochemicals production

• First large scale coal to chemicals complex in China, produces

polyethylene, polypropylene and oxo alcohol

• 3 million tons of coal converted to ~700kta chemical products
• JM designed 5500 tpd Methanol to Olefin (MTO) grade methanol
• Successful start-up in 2010 has led to >20 CTC complexes

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FORMOX™

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formaldehyde oxide process

formaldehyde reaction

methanol

formaldehyde

system

• xidation
• Used in over 160 plants in 36

countries

• Total sold capacity is >20MMTPA
• FORMOX is the world’s largest

supplier of molybdenum oxide catalyst, used in ~70% of all oxide plants.

air

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Monoethylene Glycol (MEG)

• MEG is the most widely used industrial diol with global

consumption >26 million tpa

• MEG + PTA PET (polyester)

air

MEG

product

formaldehyde plant

methanol formaldehyde

DEG

co-product

MEG plant

CO H2

Methylamines and derivatives

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ChCl

ChCl synthesis

HCl ethylene

• xide

NMP

NMP synthesis

GBL

ammonia lights

purge

amination

waste

water

MMA DMA TMA

recycle methanol , MMA, TMA methanol

distillation

DMF

NMP synthesis

Carbon Monoxide

Downstream of the Methanol to Olefin (MTO) unit

The MTO unit produces a mixture of:

• Ethylene, used mainly for polyethylene
• Propylene, used mainly for polypropylene
• Mixed Butenes, recycled to increase conversion to propylene or used

as fuel However higher value can be generated by converting the propylene and/or the mixed butenes to alcohols via the LP OxoSM Alcohols process.

• xo

methanol polyethylene & polypropylene 2EH/butanol 2PH

MTO

By others

C3= C4=

• xo

Oxo Alcohols

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n-butyraldehyde iso + n-butyraldehyde

2-ethylhexanol iso-butanol n-butanol

propylene syngas

LP OxoSM

hydroformylation

hydrogen hydrogen

hydrogenation aldolisation refining refining hydrogenation

• LP Oxo Technology is a low pressure oxo process utilizing

rhodium catalyst systems

• Licensed into 53 projects, at 41 plants in 15 countries.

2-Propylheptanol (2PH) – Value Creation

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C4 stream raffinate III syngas

2PH 2PH plant

butene-1 CC4= TC4= IC4= MTBE butene-1

MTBE & butene-1 unit

methanol CC4= TC4= hydrogen

• 2PH is produced from essentially fuel value feedstock
• Above scheme operates on an integrated Coal to Chemical

facility in China

Dimethyl ether (DME)

Process

• Dehydration of methanol

Uses

• Fuel as LPG blend stock
• Aerosol as an alternative to

propane and butane Global Market

• Fuel grade ~6 million tpa
• Aerosol grade ~500,000 tpa

Substitute Natural Gas (SNG)

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Coal to syngas to SNG

• Large plants producing gas

for pipeline export to major cities

• Mostly in China to meet

environmental and energy security needs

SNG Plant in Inner Mongolia, 1.33 Billion Nm³/y

By others

Substitute Natural Gas (SNG)

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JM licensed SNG plants produce >50% of global SNG production JM has >100 years’ experience in methanation research and CRGTM methanation catalyst is the world’s most widely-used for this application

LNG

product

coal COG

coke

SNG

coke

• ven

COG

purification methanation

liquefaction

(optional )

Coke Oven Gas to LNG

• Smaller plants extracting value from by-product gas streams

Petcoke to Refinery Fuel Gas

• Upgrade low value coke via gasification and methanation
• Large project for Reliance at Jamnagar under implementation

Gas-to-Liquids

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natural gas

naphtha diesel

upgrading Fischer Tropsch conversion

• r

reforming

(compact reformer)

• r

biomass petcoke coal

• r
• r
• ther syngas

generation

Fixed-bed FT technology

reforming

(ATR, SMR, GHR)

• Fixed bed technology proven at

commercial scale producing 300 bbl/day of synthetic crude

• Recent development has focused
• n new catalyst and reactor

technology to improve performance and economics

Gas-to-Liquids - Reactor Improvement

Gas flows from CAN above passing down a porous central channel. Flows radially through the catalyst bed where reaction occurs and heats up by absorbing reaction heat Gas exits via porous outer wall and flows to the top of the inner side of the CAN Body Gas flows down a narrow annulus between the CAN Body and the inside wall of the tube where it cools by transferring heat to boiling water on the shellside A seal prevents the gas bypassing the next CAN and the gas enters the CAN below to repeat the process. Catalyst Carrier or “CAN” – How it works

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Multiple CANS in tubes

Commercial Demonstration of Reactor Improvement

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• Radial flow through each of

multiple CANS in a large diameter tube delivers very low pressure drop even with small catalyst particles

• Allows the use of 300 - 500

micron catalyst particles in a fixed bed tube giving high productivity and improved selectivity

• Commercial scale demonstrated in

a JM Mini Plant with Commercial size CAN’s and tube

• CAN unit operation sees same

flows and conditions as in a commercial reactor CANs Mini Plant

Ammonia

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Together, adding value to chemical processes

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Feedstock

Ammonia GTL Hydrogen SNG

Formaldehyde Fertilizers Clean fuels Adhesives Construction Shampoo

Natural gas

Syngas Building blocks Intermediates End use products

Edible oils and other oleochemicals

Biorenewables Detergents and soaps Food Biochemicals

Biomass and natural oils

Oleo / bio

Propylene

Butanediol Films, fibres and bottles Packaging Films and cables Engineering polymers

Natural gas liquids Petroleum

Petrochemicals

Mono ethylene glycol

Ethylene Aromatics Butane Methanol

Natural detergent alcohols PTA

Catalyst Licensing JM covered technology / products / service

Coal

Vinyl chloride monomer Oxo alcohols

Speciality

Agrochemicals & solvents Methylamines Nylon

Ethyl acetate Hexanediol

Solvent Acrylics Nitric acid UFC

MTO

Custom catalyst solutions

Plastics

Thank-you!

atulshah@matthey.com