Coal to Olefins Processes

Transcription

1 Coal to Olefins Processes Table of Contents A Report by NexantThinking Process Evaluation/Research Planning (PERP) Program PERP Report 2017S1 Published December Section Page 1 Executive Summary INTRODUCTION PROCESS OVERVIEW TECHNOLOGY LICENSORS Coal Gasification Methanol Synthesis Methanol to Olefins PROJECT DEVELOPMENTS PROJECT ECONOMICS Ethylene Cost of Production Propylene Cost of Production OLEFINS COMMERCIAL APPLICATIONS Ethylene Propylene OLEFINS GLOBAL MARKETS Ethylene Propylene Introduction PROCESS OVERVIEW CHEMISTRY Coal Gasification Methanol Synthesis Methanol to Olefins and Methanol to Propylene TECHNOLOGY LICENSORS Coal Gasification Methanol Synthesis Methanol to Olefins BUSINESS DEVELOPMENTS Policy and Regulation Project Developments

2 2.5 OLEFINS PROPERTIES Ethylene Propylene OLEFINS SPECIFICATIONS Ethylene Propylene HEALTH HAZARDS Ethylene Propylene STORAGE AND TRANSPORTATION Ethylene Propylene Commercial Technology INTRODUCTION COAL GASIFICATION Types of Coal Coal Gasification Reactors Commercial Gasification Technologies Air Separation Unit Syngas Cooler/Heat Recovery Particulates Removal Water Gas Shift Acid Gas Removal/Sulfur Recovery Hydrogen Gas Separation Water Treatment and Recycle METHANOL SYNTHESIS Introduction Methanol Licensors Johnson Matthey Process Technologies METHANOL TO OLEFINS Honeywell UOP Advanced MTO SYN Energy DMTO Sinopec SMTO Air Liquide/Lurgi MTP Tsinghua University FMTP Developing Technologies INTRODUCTION JGC AND MITSUBISHI DTP WO 2016/ A1 AN OXYGENATE CONVERSION PROCESS U.S PROCESS FOR PRODUCING ETHYLENE AND PROPYLENE FROM SYNGAS U.S. 2017/ A1 CATALYST AND PROCESS FOR SELECTIVE PRODUCTION OF LOWER HYDROCARBONS

3 4.6 U.S. 2015/ PROCESS AND PLANT FOR PRODUCING OLEFINS FROM OXYGENATES U.S. 2016/ A1 PROCESS FOR PRODUCING SHORT CHAIN OLEFINS FROM OXYGENATES Process Economics COSTING BASIS Investment Basis Pricing Basis Cost of Production Basis ETHYLENE COST OF PRODUCTION Naphtha Steam Cracker MTO Market Methanol Light Olefins Basis MTO Market Methanol Ethylene Basis MTO Integrated Light Olefins Basis MTO Integrated Ethylene Basis PROPYLENE COST OF PRODUCTION Propane Dehydrogenation MTO Market Methanol Propylene Basis MTP Market Methanol MTO Integrated Propylene Basis MTP Integrated SENSITIVITY CASES Ethylene Propylene Commercial Applications ETHYLENE PROPYLENE Regional Markets OVERVIEW ETHYLENE Global North America Western Europe Middle East Asia Pacific PROPYLENE Global North America Western Europe Middle East Asia Pacific Glossary References

4 Appendix Page A COP Tables... A-1 B Definitions of Capital Cost Terms Used in Process Economics... B-1 C Definitions of Operating Cost Terms Used in Process Economics... C-1 D PERP Program Title Index ( )... D-1 Figure Page 1.1 Methanol-Based Light Olefins in China Coal to Chemicals Process Ethylene Cost of Production Summary Propylene Cost of Production Summary - China Propylene Cost of Production Summary - China and Other Regions Global Ethylene Demand, Global Ethylene Capacity Regional Ethylene Exports/Imports Global Propylene Demand, Regional Propylene Capacity Regional Propylene Net Exports/(Imports) Methanol-Based Light Olefins in China Coal to Chemicals Process Major Gasification Reactions MTO Cocatalysts MB and HMB Hydrocarbon Pool Catalytic Cycle Coal Gasification and Syngas Recovery Types of Coal ECUST Entrained-Flow Gasifier E-Gas Two-Stage Gasifier E-Gas Technology Simplified Process Flow GE Energy Gasifier Shell Gasification Process KBR Gasifier BGL Gasifier Lurgi Dry-Ash Gasifier Methanol Licensor Market Share, Typical Two-Column Distillation Simplified Process Flow Diagram Typical Three Column Distillation Simplified Process Flow Diagram Johnson Matthey Steam Reforming Simplified Process Flow Diagram Johnson Matthey Radial Steam Raising Converter Johnson Matthey Combined Reforming Arrangement Johnson Matthey Combined Reforming Simplified Process Flow Diagram Johnson Matthey Autothermal Reformer Johnson Matthey Tube Cooled Converter

5 3.20 Johnson Matthey GHR + ATR Arrangement Johnson Matthey GHR + ATR Simplified Process Flow Diagram Johnson Matthey GHR + ATR Configuration Johnson Matthey Series Loop Simplified Process Flow Diagram Johnson Matthey Syngas to Methanol Simplified Process Flow Diagram UOP Advanced MTO Process: Reaction and Olefins Recovery UOP Advanced MTO Process: Olefins Cracking Process SYN Energy's DMTO with OCT and Ethylene Dimerization SYN Energy DMTO Process: Reaction and Light Olefins Recovery SYN Energy DMTO Process: OCT and Dimerization Section Diagram Sinopec SMTO Process Reaction and Olefins Recovery Air Liquide Lurgi MTP Process Simplified Process Flow Diagram Tsinghua University FMTP Process Simplified Process Flow Diagram DTP Simplified Flow Diagram Shell Oxygenate Conversion Process SABIC Light Olefins from Syngas Air Liquide Olefins Interconversion Ethylene Cost of Production Summary Propylene Cost of Production Summary - China Propylene Cost of Production Summary - China and Other Regions Ethylene Cost of Production - Capital Sensitivity Ethylene Cost of Production - Raw Material Sensitivity Propylene Cost of Production - Capital Sensitivity Propylene Cost of Production - Raw Material Sensitivity Global Olefins Demand Global Ethylene Demand, Global Ethylene Capacity Regional Ethylene Exports/Imports North America Ethylene Consumption, Western Europe Ethylene Consumption, Middle East Ethylene Consumption, Asia Pacific Ethylene Consumption, Global Propylene Demand, Regional Propylene Capacity Regional Propylene Net Exports/(Imports) North America Combined Propylene Consumption, Western Europe Propylene Consumption, Middle East Propylene Consumption, Asia Pacific Combined Propylene Consumption,

6 Table Page 1.1 Ethylene Cost of Production Summary Propylene Cost of Production Summary - China Propylene Cost of Production Summary - Other Regions Global Ethylene Consumption by Derivative Global Ethylene Consumption by Region Global Ethylene Supply, Demand, and Trade Global Propylene Consumption by Derivative Global Propylene Consumption by Region Global Propylene Supply and Demand Minimum Threshold Capacity for Coal to Chemical Projects Technical Standards for Coal-Based Projects Summary of MTO and MTP Plants Installed Capacity Key Physical and Thermodynamic Properties - Ethylene Key Physical and Thermodynamic Properties - Propylene Commercial Specification for Polymer Grade Ethylene Propylene Product Specifications Characteristics of Each Coal Type Licensor and Gasifier Types Gasifier Typical Characteristics Major Methanol Technology Licensors Syngas Composition for Different Reforming Processes Typical Syngas Compositions Including Coal Gasification Typical Syngas Composition for Methanol Synthesis Plant UOP Advanced MTO Process Material Balance UOP Advanced MTO Process Utilities Consumption Overall Material Balance MTP Process Catalyst Performance Lurgi MTP Process LPG Composition - Lurgi MTP Process Gasoline Composition - Lurgi MTP Process Prices of Raw Materials, Utilities, and Labor Ethylene Cost of Production Summary Cost of Production Estimate: Ethylene Process: Steam Cracking of Naphtha (High Severity + Butadiene Extraction), Coastal China Cost of Production Estimate: Ethylene Process: UOP Advanced MTO (Light Olefins, Market Methanol), Coastal China Cost of Production Estimate: Ethylene Process: UOP Advanced MTO (Ethylene, Market Methanol), Coastal China Cost of Production Estimate: Ethylene Process: UOP Advanced MTO (Light Olefins, Integrated Coal), Inland China Cost of Production Estimate: Ethylene Process: UOP Advanced MTO (Ethylene, Integrated Coal), Inland China Propylene Cost of Production Summary - China

7 5.9 Propylene Cost of Production Summary - Other Regions Cost of Production Estimate: Propylene Process: Propane Dehydrogenation via UOP Oleflex, Coastal China Cost of Production Estimate: Propylene Process: UOP Advanced MTO (Propylene, Market Methanol), Coastal China Cost of Production Estimate: Propylene Process: Air Liquid Lurgi MTP (Market Methanol), Coastal China Cost of Production Estimate: Propylene Process: UOP Advanced MTO (Propylene, Integrated Coal), Inland China Cost of Production Estimate: Propylene Process: Air Liquide Lurgi MTP (Integrated Coal), Inland China Global Ethylene Consumption by Derivative Global Ethylene Consumption by Region Global Ethylene Supply, Demand, and Trade North America Ethylene Consumption by Derivative North America Ethylene Consumption by Country North America Ethylene Supply, Demand, and Trade United States Ethylene Supply, Demand, and Trade Western Europe Ethylene Consumption by Derivative Western Europe Supply, Demand, and Trade Middle East Ethylene Consumption by Derivative Middle East Ethylene Consumption by Country Middle East Ethylene Supply, Demand, and Trade Asia Pacific Ethylene Consumption by Derivative Asia Pacific Ethylene Consumption by Country Asia Pacific Ethylene Supply, Demand, and Trade China Ethylene Supply, Demand, and Trade Global Propylene Consumption by Derivative Global Propylene Consumption by Region Global Propylene Supply and Demand North America Combined Propylene by Derivative North America Combined Propylene by Country North America Combined Propylene Supply, Demand, and Trade United States Combined Propylene Supply, Demand, and Trade Western Europe Propylene Consumption by Derivative Western Europe Combined Propylene Supply, Demand, and Trade Middle East Propylene Consumption by Derivative Middle East Propylene Consumption by Country Middle East Propylene Supply, Demand, and Trade Asia Pacific Combined Propylene Consumption by Derivative Asia Pacific Combined Propylene Consumption by Country Asia Pacific Propylene Supply, Demand, and Trade China Propylene Supply, Demand, and Trade

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