Methanol and Derivatives from NG and Coal. Norbert Ringer BU Catalysts - Syngas

Transcription

1 Methanol and Derivatives from NG and Coal Norbert Ringer BU Catalysts - Syngas

2 2 Table of Contents Clariant at a glance Market Drivers Syngas an Universal Platform Coal Based Syngas Methanol Synthesis Technology Methanol Derivatives Conclusions

3 Clariant at a glance Norbert Ringer BU Catalysts - Syngas

4 4 Clariant at a glance A GLOBALLY LEADING COMPANY IN SPECIALTY CHEMICALS Sales 2015 (CHF m) from continuing operations Net result 2015 (CHF m) from continuing operations Business Areas 110 in companies countries Employees 2015

5 5 GSTC conference, Vancouver, Four Business Areas Care Chemicals Catalysis Natural Resources Plastics & Coatings

6 6 Clariant Syngas Catalysts Ammonia Methanol and MTProp Adsorbents and Catalysts for Syngas Hydrogen for Refineries Steel production Fuel Cells Fuels from Coal / Alternative Feedstocks Synthetic Natural Gas (SNG) Coal to Liquid (CTL) Gas to Liquid (GTL) Biomass to Liquid (BTL) Methanol to Gasoline (MTG) Syngas to Higher Alcohols ActiSorb ReforMax ShiftMax MegaMax AmoMax FTMax HyProGen Adsorbents for Feed Purification (S, Cl, As, COS, CO, heavy metals, ) Reforming Catalysts Water Gas Shift Methanol Production Ammonia Production Fischer-Tropsch Processes Hydrogen for Fuel Cells

7 Market Drivers Norbert Ringer BU Catalysts - Syngas

8 8 Top 5 Countries Adding Base Chemical Capacity More than 200 Million Tons from 2010 to 2020 China is adding more than 120 million metric Investment tons of base capital chemical has shifted capacity to from North 2010 America, to however, 2020 to meet the vast demand majority growth of new and investment maintain a continues high degree to accelerate of self-sufficiency in Asia/Pacific, dominated by China Million Metric Tons China United States Top five will add nearly 75% of all base chemical capacity Saudi Arabia South Korea Ammonia Methanol Paraxylene Benzene Chlorine Propylene Ethylene India Source: IHS, Fertilizer Outlook

9 9 Global Syngas Markets End Use Market Size 2014 [million t/a] AAGR, [%] Ammonia Methanol Hydrogen* Fischer-Tropsch liquids (XTL) Syngas to power (IGCC) Synthetic Natural Gas (SNG) ~25 n/a ~8 n/a Source: Nitrogen+Syngas, BCInsight; 82nd IFA Annual Conference, Fertilizer Outlook * Excludes other uses on the table

10 10 Methanol Driver: Fuel Blending China s Provinces in the Driver s Seat Source: Methanol Institute Province Local Methanol Gasoline Standards Implemented Since Gansu M15 & M Guizhou M Hebei M15 & M Heilongjiang M Jiangsu M Liaoning M Shaanxi M15 & M Shandong M Shanghai M Shanxi M5, M15, M85 & M Sichuan M Xinjiang M15 & M Zhejiang M15, M30 & M Ningxia M15 & M Estimated 10 million tons of methanol blended with gasoline as M15 in 2014, against total gasoline consumption of 105 million tons China adopted national standards for M85 and M100 issued in 2009

11 11 Methanol Driver: Methanol-to-Olefins China Light Olefins Capacity (Million Metric Tons) % of Unconventional Light Olefins Capacity Unconventional light olefins production expected to reach 40% of China supply 75% 50% 40 25% Olefin-Conventional CTO MTO PDH % of Unconventional 0% Source: IHS

12 Syngas Universal Platform Norbert Ringer BU Catalysts - Syngas

13 13 Syngas and Methanol Universal Platforms Non-conventional Hydrocarbons: Tar sands Shale gas Coal-bed methane Flare gas Raw materials: Coal Natural Gas Heavy Oil Peat Oil residues Wood Biomass Syngas CO + H 2 Generation Conditioning CH 3 OH CO 2 H 2 Technical Photosynthesis Fuel XTL H2 SNG NH3 chemicals Methanol Chemistry: MTP (propylene) MTO (olefins) MTG (gasoline) MTA (aromatics) Formaldehyde Na-methylate Acetic Acid Ethylene Glycol Methyl Amines Vinyl Acetate Methyl formate MMA MTBE Chloromethanes DMT Dimethyl carbonate Ethanol Methyl mercaptan DMS DMSO

14 14 USA and China are driving the Syngas Markets North American Shale Gas China Coal

15 17 Methanol from Natural Gas Natural Gas Purge Gas Desulphurisation Pre- Reforming Steam Reforming Hydrogen Recovery Autothermal Reforming Methanol Synthesis Methanol Distillation Oxygen Air Air Separation Pure Methanol

16 17 Methanol from Coal Purge Gas Coal Purge gas recycle Gasification Sour Gas Shift Syngas Purification Methanol Synthesis Methanol Distillation Oxygen Air Separation Air Pure Methanol

17 Coal Gasification Norbert Ringer BU Catalysts - Syngas

18 18 Coal Gasification MeOH H 2 /CO= H 2 /CO= 2 O 2 H 2 O Sour Gas Shift Electricity (IGCC) Feed Rectisol or Selexsol Fuel Slag H 2 S, RSH H 2 /CO= Hydrogen, NH 3 Water-Gas-Shift (WGS): CO + H 2 O CO 2 + H 2 SNG Sour-Gas-Shift (SGS): H 2 S > 100ppm H 2 /CO= 3

19 19 Public, Sustainability as Driver for Syngas Innovation Process Optimization Clairant/Siemens Case Study: Coal-to-H2, Clariant/Siemens Technology BFW BFW CO: 60.5 mol% H 2 : 29.6 mol% CO: 1.3 mol% H 2 : 55.8 mol% ShiftMax m 3 ShiftMax m 3 ShiftMax m 3 Intrinsicly Safe catalyst Risk of run-away (> 700 C) Steam Export, less water 44% higher efficiency 20% reduced CAPEX, 25% lower catalyst volume

20 20 Public, Sustainability as Driver for Syngas Innovation Traditional and Pre-sulfided SGS comparison 1 IN-SITU Sulfidation, State-of-the-Art Loading: 1-2 days Sulfidation: up to 1 week sulfur emission People No handling of toxic and flammable sulfur compounds such as DMDS or CS 2 Loading: 1-2 days DMDS CS 2 2 EX-SITU Sulfidation by Clariant Plug & Play Planet Significantly reduced emission during start-up ShiftMax 820-S Performance Ex-Situ sulfiding results in 10-20% better Performance Start-up time savings result in up to 0.5 m$ product sales per day Up to 1.0 m$ reduced CAPEX

21 21 Public, Sustainability as Driver for Syngas Innovation Innovations contribute to a sustainable future PEOPLE SAFETY- SHIFTMAX 820S Pre-sulfided ShiftMax 820S series Catalysts avoids the use of flammable toxic agents such as CS2 and reduces the risk of high temperature excursions during plant start-up. SAFE AND HEALTHY OPERATION FOR 1,000,000 EMPLOYEES IN ALL COAL CHEMICAL PLANTS IN CHINA

22 Methanol Synthesis Norbert Ringer BU Catalysts - Syngas

23 MegaMethanol Two-step Synthesis Methanol Recycle Compressor Gas-cooled Reactor Water-cooled Reactor HP-Steam Make Up Gas MEGAMAX 800 Purge Gas Crude Methanol Boiler Feed Water

24 weight time yield / kg MeOH kg -1 catalyst h-1 Superior MegaMax 800 performance with higher activity and productivity Long time test in bench-scale unit using coal gas Test at high-stress conditions: 60 bar, 270 C MM700 MM800 Competitor A time on stream / h MM800 shows superior activity at 270 C SUSTAINABILITY AS DRIVER FOR SYNGAS INNOVATION AT CLARIANT

25 MegaGuard 700 as bodyguard for MegaMax catalyst SAFEGUARD PERFORMANCE, EFFICIENCY AND RELIABILITY OF YOUR CRITICAL PROCESS MEGAGUARD 700 Superior guard catalyst in China market Highly effective in trapping and decomposing the incoming carbonyls of iron and nickel Protects reliably the downstream methanol synthesis catalyst MegaMax series from catalyst poisoning by iron and nickel compounds Maintains outstanding high activity and selectivity of MegaMax series over the long life of the catalyst SUSTAINABILITY AS DRIVER FOR SYNGAS INNOVATION AT CLARIANT

26 Value creation from MegaMax 800 Value creation (NPV basis) compared to Standard catalyst in K RMB 70,000 60,000 8,427 1,546 50,000 40,000 30,000 55,602 65,575 20,000 10,000 0 Increased methanol production due to higher yield (same SynGas input) Lower energy consumption due to reduced amount of impurities in crude methanol Longer catalyst life, due to reduced hydrothermal ageing Total value creation SUSTAINABILITY AS DRIVER FOR SYNGAS INNOVATION AT CLARIANT

27 Innovations contribute to a sustainable future VALUE CREATION- MEGAMAX MegaMax series help to increase the capacity of methanol plants. 10% CAPACITY INCREASE = INCREASE 6 MIO TONS METHANOL ANNUALLY = FUEL 16 MIO CARS WITH SULFUR-FREE AND HIGH OCTANE M15 FUEL SUSTAINABILITY AS DRIVER FOR SYNGAS INNOVATION AT CLARIANT

28 Methanol Derivatives Norbert Ringer BU Catalysts - Syngas

29 DME A Valuable Product DME Dehydration of methanol in the presence of SC catalysts Distillation to yield pure DME Mega- Methanol MeOH- Recycle Energy- Production Liquids Alternative to conventional diesel fuel and LPG Feed gas turbines (Power DME Reaction DME Distillation DME product generation) Syngas Production H 2 O Recycle Water

30 Methanol-to-Propylene: MTP Process MeOH Methanol, Grade A 1.7 * 10 6 t/a = 5000 t/d Fuel Gas 15 kt/a (internal use) Propylene DME Pre- Reactor Product Conditioning Propylene 500,000 t/a LPG 54 kt/a MTP Reactor(s) (2 operating + 1 regenerating) Olefin Recycle Water Recycle Product Fractionation Process Water 930 kt/a Gasoline 140 kt/a Source: Lurgi

31 MTP / PP Complex Projects in China Datang Power, Duolun, Inner Mongolia Shenhua Ningxia Coal Group (Ningmei), Yinchuan, Ningxia Province (2 Units) 12.3 Mio Nm³/d Syngas 1,700,000 t/a Methanol 500,000 t/a Propylene Feed Syngas Plant Methanol Plant MTP Plant Polypropylene Plant 900,000 t/a Water 140,000 t/a Gasoline 500,000 t/a Polypropylene Source: Lurgi

32 Conclusion Norbert Ringer BU Catalysts - Syngas

33 33 Conclusions Syngas is a universal platform able to convert any kind of carbon containing feedstock into Chemicals, Fuels or Energy Clariant has an extremely broad Syngas portfolio with catalytic solutions covering all major Syngas applications Syngas markets, especially for key products Methanol and Ammonia are growing China, US and Iran are adding significant Syngas capacity due to advantaged feedstocks and new technologies for Olefin production Clariant s R&D efforts are focused on incorporating sustainability and responsible care into the design of our products addressing resource and process efficiency, energy savings and employee safety Besides the use of NG and Coal as feedstock, our engagement in CO 2 based technologies is a further commitment to sustainability and long-term innovation

34 34 Public, Sustainability as Driver for Syngas Innovation Clariant s Involvement = Commitment to Sustainability At present Potential future involvement CO 2 to Methane / Methanol / Fuel AUDI / ETOGAS: Conversion of CO 2 from biogas to CH 4 on commercial scale for use in Audi methane powered car fleet Sunfire: Conversion of CO 2 to Fischer Tropsch Liquids utilizing Clariant s RWGS (reverse-water-gas-shift) and FT catalysts ic4: Academia and industry consortium, demonstration and further characterization of methanation technology for future improvements BioMeOH: Decarbonisation of mobility adding Biomethanol as fuel additive / Biomethanol to improve CO2 balance/economics of BioGas/Bioethanol plants Carbon2Chem : Large consortium led by ThyssenKrupp for conversion of steel manufacturing off-gas to methanol (methane and ammonia also considered)

35 35 Thanks! Questions?