Converting Methanol to Propylene (MTP) M. Daftari Gh. Joukar; NPC-RT General Manager S. Sahebdelfar;...
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Transcript of Converting Methanol to Propylene (MTP) M. Daftari Gh. Joukar; NPC-RT General Manager S. Sahebdelfar;...
Converting Methanol to Propylene(MTP )
M. Daftari
Gh. Joukar; NPC-RT General ManagerS. Sahebdelfar; Head of NPC-RT Catalyst GroupA. Firouzi; Head of NPC-RT Process GroupM. Asadi; NPC-RT Catalyst GroupH. Alaiee; NPC-RT Engineering GroupS. Zeinali; NPC-RT Process Group
Outline
•Natural Gas, Methanol and Propylene Chain
•Joint MTP® Technology
•Process
•Catalyst
•NPCRT’s new PVM® Technology
•Economy
• Methanol to Propylene
•Gas to Propylene
•Process Integrations
Natural Gas
•Huge resources of NG in Iran )world’s second resources(
•Constant developing markets in:
• Direct usage as less carbon-intensive fuel )distribution
networks(
• Power generation )power plants(
• Transport to international markets )pipelines, LNG
shipping(
• Added value chemicals production )petrochemical
complexes(
Methanol, domestic supply & demand
•Several domestic plants in operation•Shiraz Petrochemical Complex )200,000 T/A(•Khark Petrochemical Complex )660,000 T/A(•Fanavaran Petrochemical Complex )1,000,000 T/A(•Zagros Petrochemical Complex )2×1,650,000 T/A(
•Ongoing domestic plants•Khark Petrochemical Complex )1,300,000 T/A(•Kaveh Petrochemical Complex )2,100,000 T/A(•Marjan Petrochemical Complex )1,650,000 T/A(•Bushehr Petrochemical Complex )1,650,000 T/A(•Veniran Petrochemical Complex )1,650,000 T/A(•Petrochem Petrochemical Complex )1,650,000 T/A(•Kimia Pars Khavarmianeh Petrochemical Complex )1,650,000 T/A(•Farsa Shimi Petrochemical Complex )1,650,000 T/A(•Dipolymer Arian Petrochemical Complex )1,650,000 T/A•…
Supply is more than domestic demand, and major part of product are being exported
Methanol, worldwide supply & demand
Thousands of metric tones
Propylene, worldwide supply & demand
Thousands of metric tones
olefinsparaffinsaromatics
methanol Catalyst
Methanol to Olefin
What is Special about Zeolites?
• Pores with molecular dimensions leads to shape selectivity
• Narrow range of pores sizes in the solid because of
crystalline giving better selectivity than non-crystalline
materials
Shapes Selectivity
Conversion of MeOH to Olefin
MeOH(CH3OH)
NG(CH4)
DME(CH3OCH3)
C3=(C3H6)
C2=(C2H4)
Other C=series
ParaffinsLPG,
Gasoline
Water(H2O)
Water(H2O)
Narrow pore Zeolites•SAPO- 34•SAPO- 18•Chabazite
Medium pore Zeolites•ZSM -5•ZSM- 11
Wide pore ZeolitesMordeniteZSM-4Faujasite )X and Y(
Acidic Behavior
ɣ-Alumina
Converting MeOH to Propylene
MeOH(CH3OH)
NG(CH4)
DME(CH3OCH3)
C3=(C3H6)
C2=(C2H4)
Other C=series
ParaffinsLPG,
Gasoline
Water(H2O)
SynGas Processes
CO, H2
Natural Gas
CH4, Pure
Methanol
Grade AA
CH3OH
)100 Kg/Hr(
Di-methyl Ether
CH3OCH3 )40% Mole(
Water
H2O )40% Mole(
Methanol
CH3OH )20% Mole(
No Oxygenate
C3=
)32 Kg/Hr(
LPG
)4 Kg/Hr(
Gasoline
)8 Kg/Hr(
Water
)56 Kg/Hr(
C2=*
)~ 2 Kg/Hr(
* By default, recycles back to reaction
Joint MTP® Project with Lurgi Oel.Gas.Chemie
• Started at 2003
• Joint development of a commercial scale of MTP® process
• Research studies on pilot plant scales
• Design, construction and startup of the first semi-commercial
MTP Demo Plant in the world
• Basic engineering of the first commercial MTP plant in the
world
C3=
MeOH
Unit 300 Gas Separation
Unit 100 Reaction
Unit 400 Compression
Unit 500 Purification
LPG
Gasoline
MeOH, DMEHC
Unit 1100 Cold Water System
Unit 1000 Steam System
Unit 1200 Refr. System
Unit 200 Regeneration
Nitrogen, Plant Air, Instrument Air, Electrical Power, Fuel, LPG for startup, etc.
FlareDM WaterHP Steam HP Condensate
MTP, Block Flow Diagram
MTP Key Features
• High propylene yield )more than 65% mole, on C basis(
• Simple process )low-cost propylene production(
• Simple fixed-bed adiabatic reactor system
• Simple well-known purification section
• Low pressure operation
• Added value by-products )LPG, Pyrolysis Gasoline(
NPC-RT Facilities
• Several microrecator setups with online analyzers
• Lab and pilot scale catalyst production setups
• 4×100 gr catatest setup )parallel beds(
• 1500 gr catalyst pilot plant with main separation units
• Semi-comercial catalyst production setup
• MTP demo plant with complete comercial features )worlds
first semi-comercial MTP plant(
• Complete analytical facilities
• Expert research and engineering team
NPCRT activities
• More than 8000 hours pilot plant run
• Development of a new catalyst with great performance, and
• Commercializing NPCRT‘s PVM® catalyst )patented(
• Process integration studies with focus on GTP, and
combinition to existing olefin plants
• New separation concepts
• New innovative reactor )patent preparation(
Scale-up History
Extruded NPC-RT catalyst
NPCRT proprietary catalyst
• Developed by NPC-RT )issued as patent(
• Zeolite type
• Promoted and improved formulation
• Confirmed in lab, bench and pilot scale performance tests
• Flexibility of catalyst for gasoline production )MTG(
• Low methane production
• Lower heavy hydrocarbon and higher light olefins production
versus commercial sample under MTP process conditions
• Increased selectivity to propylene by using some specific
promoters
Highlights of NPCRT catalyst
• Competitive performance )propylene selectivity, methanol
conversion & lifetime( versus commercial counterparts
• Mild processes conditions for catalyst manufacturing )100 ºC,
1 barg and non-corrosive starting materials(
• Economic manufacturing unit for mass catalyst production
• High mechanical strength )top & side(
Chemical composition of NPC-RT catalyst
Reaction: T= 480˚C, WHSV=0.9h-1, P=atm, MeOH/ H2O=1/1wt%,
Once-through pilot test results
MTP Combination with other Processes
• MTP as reaction section of a conventional naphtha based olefin
plant• Better C3= to C2= ratio, better economies• Moderate process condition )lower P and T( vs. olefin furnaces• Not to much changes to existing plant
• Complete natural gas to propylene chain; GTP or GTPP• Possibility for lower MeOH purification, better economies• Possibility for using MTP process water for Syngas generation,
better economies
• MTP integrated with power plant• Possibility for using MTP process water for power generation, better
economies
• DME with MTP• Bigger DME section, more plant production flexibility
MTP Economies
GTP Economies
Sensitiviuty Of IRR to NG Price
0
5
10
15
20
25
30
35
40
0 5 10 15 20
NG Price )cent/m3(
IRR
)%
(
1150 USD/ton
1100 USD/ton
1000 USD/ton
900 USD/ton
800 USD/ton
700 USD/ton
600 USD/ton
500 USD/ton
Propylene Price
Much better economy
Conclusions
• Methanol could have a key position in natural gas value chain in natural-gas based petrochemical industries
• Methanol can be effectively used as a supplement or alternative to naphtha
• NPC-RT has developed effective catalysts and technology to convert methanol to value added higher hydrocarbons
• The technology has demonstrated in pilot and demo scales
Conclusions )cont’d(
• The technology could be integrated with a number of conventional petrochemical and refining technologies
Thanks
M. Daftari