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 NH 3 ammonia methylamines methanol methanol MTO polyolefins DME formaldehyde By others syngas C3= oxo 2EH/butanol C4= oxo 2PH MEG MEG FT Gasoline / Diesel SNG methane 2

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

Coal to Methanol Entrained flow gasifiers preferred High exit temperature • Low CH 4 in syngas • Shift converts CO + H 2 O to H 2 + CO 2 Acid Gas Removal (AGR) removes excess CO 2 and H 2 S Most recent methanol projects in China use syngas produced from low/medium ash coal (Steam) CO 2 & H 2 S Purge Oxygen Coal Methanol Gasifier Shift AGR MeOH Unit Natural SMR gas Optional 4

Typical syngas compositions Syngas technology R ratio CO/CO 2 % CH 4 Steam Methane Reformer (SMR) 2.9 2 3 SMR+CO 2 2.1 2 3 SMR+ Auto Thermal Reformer 2.1 3 1 SMR+ Gas Heated Reformer 2.1 2 1 Gasifier – coal 1 2.05 10 0.5 Gasifier - biomass 2.05 5 5 • R ratio – Excess H 2 R = ([H 2 ]-[CO 2 ])/([CO]+[CO 2 ]) • CO/CO 2 – Heat of reaction/ reactivity • CH 4 – Loop efficiency 1 Entrained flow gasifier 5

Methanol Synthesis – Reactor options steam methane methanol methanol distillation synthesis reforming synthesis gas Axial Radial Steam Tube Steam Raising Cooled Raising Converter Converter Converter (A-SRC) (TCC) (R-SRC) 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 • 6

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 • operating 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 • 8

oxidation FORMOX™ form aldehyde ox ide process formaldehyde air formaldehyde reaction system methanol 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. 9

Monoethylene Glycol (MEG) CO H 2 MEG air formaldehyde product MEG plant plant methanol formaldehyde DEG co-product • MEG is the most widely used industrial diol with global consumption >26 million tpa • MEG + PTA PET (polyester) 10

Methylamines and derivatives GBL MMA NMP NMP synthesis Carbon recycle methanol , lights purge Monoxide MMA, TMA methanol NMP amination distillation DMF ammonia synthesis DMA waste water ethylene HCl oxide ChCl ChCl synthesis TMA 11

Downstream of the Methanol to Olefin (MTO) unit methanol MTO polyethylene & polypropylene By others C3= oxo 2EH/butanol C4= oxo 2PH 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 Oxo SM Alcohols process.

Oxo Alcohols hydrogen aldolisation hydrogenation refining 2-ethylhexanol n-butyraldehyde propylene LP Oxo SM syngas hydroformylation iso-butanol iso + n-butyraldehyde hydrogenation refining hydrogen n-butanol LP Oxo Technology is a low pressure oxo process utilizing • rhodium catalyst systems Licensed into 53 projects, at 41 plants in 15 countries. • 13

2-Propylheptanol (2PH) – Value Creation MTBE butene-1 raffinate III MTBE & butene-1 2PH C4 stream 2PH unit plant CC4 = butene-1 TC4 = CC4 = TC4 = IC4 = methanol syngas hydrogen • 2PH is produced from essentially fuel value feedstock • Above scheme operates on an integrated Coal to Chemical facility in China 14

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) By others 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 16

Substitute Natural Gas (SNG) coal SNG COG coke COG liquefaction methanation LNG oven purification (optional ) product coke 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 • JM licensed SNG plants produce >50% of global SNG production JM has >100 years’ experience in methanation research and CRG TM methanation catalyst is the world’s most widely -used for this application 17

Gas-to-Liquids Fixed-bed FT technology reforming (ATR, SMR, GHR) naphtha or natural gas reforming Fischer Tropsch upgrading conversion (compact reformer) or diesel biomass or other syngas petcoke generation or coal Fixed bed technology proven at • commercial scale producing 300 bbl/day of synthetic crude Recent development has focused • on new catalyst and reactor technology to improve performance and economics 18

Gas-to-Liquids - Reactor Improvement Catalyst Carrier or “CAN” – How it works Gas flows from CAN above passing down a porous central channel. Multiple CANS in tubes 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. 19

Commercial Demonstration of Reactor Improvement • 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 20

Ammonia 21

Together, adding value to chemical processes Feedstock Building blocks Intermediates Speciality End use products UFC Fertilizers Natural gas Ammonia Nitric acid Nylon SNG Methylamines Agrochemicals & solvents Syngas GTL Clean fuels Hydrogen Formaldehyde Adhesives Custom catalyst solutions Methanol Mono ethylene glycol Construction Vinyl chloride monomer Coal Plastics MTO Petrochemicals Petroleum Ethylene Packaging Films, fibres and Aromatics PTA bottles Films and cables Oxo alcohols Propylene Engineering Natural gas polymers Butanediol liquids Butane Acrylics Hexanediol Shampoo Oleo / bio Natural detergent alcohols Detergents and soaps Biomass and Edible oils and other oleochemicals Food natural oils Biorenewables Biochemicals Ethyl acetate Solvent Catalyst Licensing JM covered technology / products / service 22

Thank-you! atulshah@matthey.com