Lurgi’s MegaMethanol® Process Atlas and Beyond
Jim Aiello
Houston - January 19, 2005 1
Agenda
MegaMethanol® Concept Atlas Execution MegaMethanol® Status Technology Improvements Downstream Technologies Conclusions
2
MegaMethanol® Concept
MegaMethanol® –
> 1 million t/a methanol single train capacity
Technical Features – – –
3
Oxygen-blown synthesis gas production Two-step methanol synthesis Hydrogen recovery
Atlas Methanol: World’s largest operating MeOH Plant at 5000 mtpd
Low investment and very competitive production cost
4
Atlas Execution
First of its kind MegaMethanol® Plant Single train process Largest Methanol Plant at 5,000 mt/d Energy consumption of less than 30 million BTU per mt methanol Lurgi executed lump sum turn-key project Consideration of Client´s input / optimization throughout the entire project execution period
5
Atlas Execution Proven process concept (Lurgi MegaMethanol® by Combined Reforming) Natural Gas
Air
6
PreReforming
Steam Reforming
Desulphurization
Autothermal Reforming
Oxygen AirSeparation
Fired Heater
Fuel
Steam System
Two-Step Synthesis
Methanol Distillation
PSA
Pure Methanol
Intermediate Tank Farm
Water Treatment
Desalination
Sweet Water Cooling
Sea Water Cooling
Emergency Power Gen.
Instument& Plant Air
Flare System
Methanol Tank Farm
Fire Fighting System
Auxiliary Boiler
Rain Water System
Atlas Execution Competitive Engineering - Lurgi home office and Lurgi subsidiaries A. Design
2 water cooled methanol reactors and 1 gas cooled methanol reactor (new development)
largest Autothermal Reformer worldwide with a new burner design (new development)
Process optimization and combination / selection of individual process steps in order to realize the scale-up of the plant
large equipment due to scale-up e.g.fired heater / atmospheric column / waste heat boiler system
7
Atlas Execution
Autothermal Reformer 8
Atlas Execution
9
Methanol Synthesis
Atlas Execution
B. Procurement
World-wide procurement of equipment Bankruptcy of some equipment suppliers Quality: comprehensive expediting & inspection to ensure high quality standards
10
Atlas Execution
C. Construction
4 million man-hours without lost time accident 8.5 million construction man-hours in total peak 150 Lurgi construction personnel peak 2,200 people from construction subcontractors
11
Atlas Execution D. Quantities
Largest equipment: atmospheric column, 80m long, 500 tons auxiliary boiler, 480 tons gas cooled methanol reactor, 460 tons
12
4,500 piles 20,000 m³ concrete 4,100 t steel structure 4,100 t piping incl. PU 5,500 m FRP piping 230,000 m cable 3,000 instruments 50,000 m² painting 60,000 m² insulation
Atlas Execution Time schedule
13
Pre-Engineering
Dec. 2000 - May 2001
Contract effective date
Sept. 1st, 2001
Construction
Sept. 2001 - May 2004
Pre-Commissioning
Sept. 2003 - March 2004
Commissioning
Nov. 2003 - May 2004
1st Methanol Production
June 2nd, 2004
Commercial Production (85%)
July 24th, 2004
Performance Test passed
Oct. 5th, 2004
Lurgi MegaMethanol® Status Contract status: On stream:
Atlas Methanol, Trinidad
5,000 t/d
Under construction:
14
Zagros I, Iran
5,000 t/d
Zagros II, Iran
5,000 t/d
Chile IV, Chile
2,400 t/d
Lurgi MegaMethanol® Status Lurgi Contract status Under design:
15
Hainan, China
2,000 t/d
Acetex / Tasnee, Saudi Arabia
5,400 t/d
Qafac, Qatar
6,750 t/d
Technology improvements… Period
Plant Capacity
Net Production Cost per t of methanol *
1995 - 1999
approx. 2.000 tpd
US$ 100,00 - 120,00
1999 - 2000
approx. 2.500 tpd
US$ 80,00 - 90,00
2000 - 2003
approx. 5.000 tpd
US$ 50,00 - 60,00
Future synthesis gas production using highpressure process
approx. 10.000 tpd
US$ <40,00
(HP Pox Freiberg)
… are the driving force to lower production costs of methanol * gas prices in the range between US$ 0.5 and 1.00 per MMBTU 16
Technology Improvements: Synthesis gas production has strong impact on plant cost
Air AirSeparation Separation Unit Unit
Oxygen Associated Gas Natural Gas
Synthesis SynthesisGas Gas Production Production
60% of the plant cost *)
Methanol Methanol Synthesis Synthesis
Methanol
40% of the plant cost*)
approx. 30 bar operating pressure in conventional plants approx. 70 - 100 bar operating pressure in new development (HP-POX) 17
Technology Improvements: Combined Reforming at PetroSA (Mossgas) Fischer-Tropsch Plant Ö The largest synthesis gas plant in the world
Capacity: 3 x 268 MMSCFD syngas Start-up: 1992
¾ ATR is the key for large-scale syngas plants and the only way to benefit from economy of scale 18
Technology improvements Vision for future / new developments
Further increase of one train capacity - Lurgi pilot plant HP POX Freiberg - Pure Autothermal Reforming at higher pressure without syngas compressor
Further development of downstream applications (MTO, MTP®, MTC, MtPower®)
19
Downsteam Technologies Diesel Gasoline Fischer Tropsch Synthesis
Upgrading
LPG Fuel Gas Waxes/Lube Oil
MtPower
Power
MegaSyn®
Natural Gas / Associated Gas
Fuel Cells Chemicals (MTBE, Acetic Acid, Formaldehyde)
MtSynfuels
MegaMethanol®
Diesel/Gasoline MTP® MTO
Propylene/Polypropylene Acrylic Acid
Acrylic Acid/Acrylates Ethylene/Propylene
MTD MTH
Megammonia®
Fuel (DME) Hydrogen Ammonia/Urea/Fertilizer
MegaSyn® & MegaMethanol® “open the door” for Gas-to-Chemicals 20
Downstream Technologies:
MTP® - Current Status Ö More than 7000 operating hours of pilot plant in Frankfurt Ö ~ 11000 operating hours in Demo Unit at Statoil TBO plant -
results confirm expectations for selectivities, conversion, lifetime
-
results exceed expectations for cycle lengths
Ö Catalyst is commercially manufactured and available Ö Process Design of Commercial Plant is completed
Ö First Commercial Plant (100,000 tpa) is signed
Ö Several LOI signed for world-scale capacities
21
Downstream Technologies:
Beyond Mega-Plants: The “Hub” Concept Air
Natural Gas
Stand Alone Concept
GOX ASU
SN=2.05 MeOH Synloop Gas Generation & distillation
Natural Gas H2/N2 Air
The “Hub” Concept
Air
Gas Generation
NH3 Synloop
NH3 4000 MTPD
Natural Gas SN=2.05
GOX ASU
Gas Generation
GAN 22
MeOH 5000 MTPD
MeOH Synloop & distillation
MeOH 5000 MTPD
NH3 Synloop
NH3 4000 MTPD
H2/N2
Downstream Technologies:
“Hub Concept” / “Gas Based Refinery” Dimethylether
Fuels Kerosene DME Plant
COD Plant
ASU
Syngas
MeOH Plant
Plant
Methanol
MTP Plant
Polypropylene
Pipes Films Packaging
Acrylic Acid
SAP Diapers
Acrylates
Dispersions Paints
Acrylonitrile
Fibres ABS/SAN
Acetates
Adhesives Solvents Films
CO O2
O2 N2
Air
H2
H2
CO/H2
OxoAlcoho l Plant
O2
Ammonia Plant
Ammonia
MeOH Acetic Acid Plant 23
Fuel Additives
Gasoline
Propylene
Natural Gas Associated Gas
Diesel
CO
Conclusions Lurgi MegaMethanol® is a very competitive plant concept Lurgi R&D is actively developing further plant capacity increases Lurgi´s gas conversion technologies (MegaSyn® and MegaMethanol®) “open the door” for downstream methane based petrochemical applications MTP® converts methane to Propylene and is being commercially implemented Methanol is a commercially viable fuel for power generation and acceptable to turbine manufacturers The economics of MtSynfuels are comparable to those of Fischer Tropsch The “Hub” concept / “gas-based refinery” is ready for implementation 24
Thank You!
!
!
!
Contact: James G. Aiello Director Business Development Lurgi 333 N. Sam Houston Pkwy E., Suite 400 Houston, Texas
25
Phone Fax e-mail
Questions? 281-582-8892 281-582-8894
[email protected]
