NOVEL ROUTES IN CO2 UTILIZATION: A SUSTAINABLE APPROACH · • Broaden the utilization of CO 2 as a...
Transcript of NOVEL ROUTES IN CO2 UTILIZATION: A SUSTAINABLE APPROACH · • Broaden the utilization of CO 2 as a...
NOVEL ROUTES IN CO2 UTILIZATION: A SUSTAINABLE APPROACH
Dr. Khalid Albahily
SABIC CRD at KAUST
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Classification: General Business Use
SABIC AT-A-GLANCE
*Forbes 2018 **Billion
1976
Company established
34,000
Employeesaround the world
50
Countries of operations
3rd
Largest globalchemical company*
120th
Largest publiccompany in the world*
4
Corebusinesses
64
World-classplants worldwide
11,534
Global patentfilings
≈ 150
New productseach year
US$ B**
Total assets
86US$ B**
Net income
4.9US$ B**
Annual revenue
39.9
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OUR BUSINESSES
* Supplied under SABIC brand through Hadeed, a fully-owned SABIC Affiliate
Polyolefins, Polycarbonates and Blends, PVC , Polyester and Polystyrene
Synthetic Rubbers
Specialty Polymers & Polymer Additives
Glycols, Olefins, Oxygenates and Aromatics
Chemical Intermediates & Industrial Gases
Long SteelRebarWire RodRebar in Coil
Flat SteelHot Rolled CoilsCold Rolled CoilsGalvanized Rolled CoilsPre-painted Rolled Coils
• NitrogenPrilled UreaGranular UreaAmmonia
• PhosphateDAP and Dark DAPMAP
• Specialty NPKTGU
• Engineered Thermoplastics
• Specialty Compounds• Sheet & Film• Composites• Additive Manufacturing• Fluids• Thermosets and
Additives
BUSINESS PORTFOLIO
METALS*AGRI-NUTRIENTSPETROCHEMICALS SPECIALTIES
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OUR SUSTAINABILITY STRATEGY:MAIN FOCUS AREAS AND ACHIEVEMENTS IN 2017
* Assured by KPMG
- We are currently refreshing our materiality priorities and have linked SDG’s to the current sustainability priorities
Sustainability Report 2017
Learn more about SABIC’s sustainability facts and figures.
► Access Report here
Innovation and Sustainability Solutions
82Total Sustainability Solutions
Human Capital Development
+24,900Training program participants
Supply Chain
93%solids 100%liquids
Safety and Quality Assessment System (SQAS)
EHSS and Product Safety
14%Decrease in Total Recordable Incident Rate
Resource and Energy Efficiency*
9.3%GHG Emissions Intensity
35.2%Material-loss Intensity
8.8%Water Intensity
7.6%Energy Intensity
43%Reduction in Flaring Emissions
3.5 million MT
Total Current CO2
Utilization
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SABIC T&I Global NetworkSABIC GLOBAL T&I NETWORK
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Geleen
Bangalore
Houston
Riyadh
Jubail
Shanghai
Cartagena
BoZ
Moka
Thuwal
Research CentersApplication CentersSABIC Plastic Application Center at KSU, RiyadhSABIC Corporate Research & Development Center at KAUST
Five key geographies with innovation hubs in Middle East, USA, Europe, South East Asia, North East Asia
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SABIC GOALS FOR CO2 EMISSION REDUCTION
In KSA, SABIC plants vent a total volume of 5.2 Million Tons/year of “High Concentration” CO2 as waste streams from all MEGs, ammonia and steel plants. From this total vented CO2, around 3.4 Million tons/year will be utilized by 2025.
TECHNICAL OPTIONS FOR CONTROLLING CO2 EMISSIONS:
• Energy efficiency
• CO2 purification
• CO2 utilization
CURRENT FOCUS
• Broaden the utilization of CO2 as a feedstock for chemicals and polymers production, which includes methanol, acrylic acid, MEG, aromatics and special grades of polymers
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CO2 TO CHEMICALS: OVERVIEW OF PATENTS ALONG VARIOUS DIMENSIONS
• The top three assignees are, Sabic, BASF and Covestro .
• Other assignees active in this field include, Sinopec, Shell, Casale, LG etc.
• Sabic, Casale, Bayer, Ekokap found active and make entry to the top assignee list in this
quarter; whereas Chinese Academy of science found as less active player in this quarter.
Key Contributing Assignees Products obtained
22
13 12
86 6 6 5 5 4 4
0
5
10
15
20
25
No
. of
Pat
ents
Assignee
48
42 42
31 30 28
22 2118 17
106 6 5
2 2 2 10
10
20
30
40
50
60
No
of
Pat
ents
Products
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HP METHANOL CATALYST DEVELOPMENT
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TECHNOLOGY DEVELOPMENTCO2 UTILIZATION IN METHANOL PRODUCTION
SABIC is developing a catalytic technologyto reduce the poisoning effect of CO2 on the methanol catalyst, thereby increasing the potential use of CO2 as feedstock in the process
17% less CH4 intake
3 times higher CO2
captivated per ton of Methanol
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DRIVE AND VALUE PROPOSITION
TECHNOLOGY GAP/ BUSINESS DRIVE
• Development of high performance catalyst for methanol production
• Enhancement of catalyst stability under CO2-rich syngas feed (up to 14%)
Cu
Zn Zr
M Al
LaMActivity Stability Selectivit
y
Assembling
Preparation method
High dispersion of active metals (Cu) to increase activity
Enhance the interaction of metals and support to increase selectivity of methanol
APPROACH
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CO2 INJECTION INTO H2/CO
Feed gas: 55% H2/11% CO/x% CO2/ Ar Reaction conditions: 240 oC, 40 bar, and 5000 h-1
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• Feed gas: 55% H2/11% CO/x% CO2/ Ar• Reaction conditions: 220 oC, 40 bar, and 5000 h-1
700600500400300
0.7
0.6
0.5
0.4
0.3
0.2
0.1
TOS [h]
ST
Y (
Kg
-Me
OH
/L-c
at.
h)
SABIC
Reference
300280260240220200180
0.9
0.8
0.7
0.6
0.5
0.4
TOS [h]
STY
(Kg
-MeO
H/L
-cat
.h)
8% 9% 10 to 18%
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PRODUCTION OF HYDROGEN FROM
S, CO2 / H2O
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CO2 REDUCTION BY ELEMENTAL SULPHUR
SABIC developed a process for hydrogen and CO production from Sulphur, water and CO2. Catalyst development for ‘S2+CO2’ chemistry was demonstrated in a labscale reactor. The performance and stability of the catalyst were demonstrated up to 250 hours. Several catalyst found to be able to split CO2 to produce CO in presence of elemental sulfur
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• Both Sulphur and CO2 are inexpensive raw materials and easily available
• Energy intensity = 25 MMBTU/ton H2
BENEFITS
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Classification: General Business Use
PROJECT HIGHLIGHTS
• Syngas is an important feedstock for Petrochemicals
• Fossil sources are depleting around the world• Explore alternative feedstock's for future need• Non-hydrocarbon based technology
Reduce CO2 using ‘S’ to produce CO and SO2.
Produce H2 / syngas by water gas shift reaction.
Utilize SO2 in H2SO4 production.
S
CO2
CO/H2
H2O
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OBJECTIVES
TECHNOLOGY GAP/DRIVE
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PROCESS SCHEME
S + CO2
(>1000 °C)SO2 + CO
H2 + CO2
xH2 + yCO +zCO2
CO
SO3
SO2
0.5 O2 H2O H2SO4
(Sulfuric Acid)
H2
- CO2
H2O
H2O
xH2 + yCO(Synthesis Gas)
- CO2
APPLICATIONS
• Fertilizers
• Chemicals
• Performance Chemicals
• Metals
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PROCESS FLOWCHART
Sulfur Melter Reactor QuenchCO2
Scrubber
SO3
Reactor
Water-Gas Shift Reactor
CO2
Sulfur
CO2 recycle
SO2 removal(Absorption Column)
Compressor
Sulfuric Acid Process
CO-rich gasCO2+H2 CO/COS Separation
Oxidation
PSAH2
Feed heater
purge
CO
350 oC
400 oC
500 oC
1100 oC
30 oC
COS
CO2 SO2
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Two main criteria have been selected to drive
formulation of potential catalyst:
• Thermal stability of material (either oxide and
sulfide)
MOx + S2(g) → MSy + SO2
MSy+ CO2 → MOx + CO + SO2
• An material that exhibit ability to switch easily
from oxide to sulfide and vice-versa
Catalyst formulation
TECHNICAL APPROACH
Reaction Pathways
ReactionsΔH
kcal/mol
4CO2 + 1.325 S2 => 3.35CO + 0.65COS + 2SO2 82.2
3.35CO + 3.35H2O => 3.35CO2 +3.35H2 -29.9
0.65COS + 0.975 O2 => 0.65CO2 + 0.65SO2 -85.4
2.65SO2 + 1.325O2 => 2.65SO3 -62.2
Net -95.3
Overall1.34S2 + 2.28O2 + 3.356H2O => 3.35H2 + 2.64SO3
or
OverallS2 + 1.7O2 + 2.5H2O => 2.5H2 + 2SO3
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CONVERSION VS. SELECTIVITY
0 10 20 3060
65
70
75
80
85
90
95
100
CO
sel
ectiv
ity (%
)
CO2 conversion (%)
Total control over CO and COS selectivity by controlling the CO2 conversion
Catalyst maintained CO2 conversion however, selectivity varied over 10 days due to transformation in catalyst composition, which could be overcome to better catalyst design with higher temperature and mechanical stability
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WE HAVE A CLEAR AMBITION
To be successful in CO2 emission reduction and achieve our targets
We believe that innovation is our roadmap to success and leadership
Bring state of the art material solutions
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THANK YOU