Minimizing associated gas flaring with smaller scale methanol production
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1 Minimizing associated gas flaring with smaller scale methanol production Esben Sorensen, Haldor Topsoe Inc. EFI Gas Flare Reduction & Monetization Forum; Denver Marriott City Center Denver, Colorado; June June 2015
2 Haldor Topsoe Company Established in 1940 by Dr. Haldor Topsoe. Private 100% family owned company Global market leader in heterogeneous catalysis with a 75 year long track record 2,700 employees (2015) in 11 countries across five continents. HQ in Lyngby, Denmark, with regional offices in Houston TX, India, China, Russia, Bahrain, Malaysia, South Africa, Brazil and Argentina Three key operating business units: Chemicals, Environmental, and Refinery. A fourth unit, New Business Unit, focused on developing new technologies Revenue about $1 billion (2014). Services: Catalysts Technology/licensing Engineering Hardware Catalyst manufacturing plants: Frederikssund, Denmark Houston, Texas Future: China, Brazil Founded on the belief that applied fundamental research is key to build and retain a leading position in catalysis Close to 10% of revenues annually applied to support R&D efforts Basic research and catalyst development done by 300+ world class scientists Active phase Pore structure Catalyst Reactor
3 The Topsoe Philosophy Catalysts Research and development Technology Licensing Catalyst & HW sale Technology Client ~10% of revenue spent on R&D 3
4 NG flaring world wide and in North Dakota ND Flaring rate in August 2014: 28% or 375 MM SCFD ( 18,000 MTPD MeOH) World wide flaring rate 2011: 14,300 MM SCFD (World Bank Estimate)
5 The Challenge How do we preserve the value of the NG in a transportable form at lowest cost? Produce a valuable commodity product Match available resources Proven technology Low OPEX and CAPEX The corporate world in itself means nothing unless it improves the lives of people and the conditions in poor countries. Haldor Topsøe
6 If we can reduce gas flaring in North Dakota, we may be able to use the same approach world wide
7 Gas flaring in ND Time period: Jan 2012 July 2014 No. of registered wells: 9,395 GPS coordinates Monthly flaring data: SCFM + number of days in operation Twenty most promising wells analyzed Average production: 0.9 MM SCFD 45 STPD MeOH per well (conservative estimate)
8 Typical Methanol production cost (OPEX+CAPEX) Natural Gas as feed stock Minimum continuous rate to ensure profitability: 40 MM SCFD NG 25 MM SCFD associated gas due to lower cost and higher LHV
9 Nm3/h flared gas Typical Flare Rates large wells in N.D Well no. 1 Well no. 2 Well no. 3 Well no /09/ /04/ /10/ /05/ /11/ /06/ /12/2014 Date
10 Conversion of associated gas to methanol or gasoline Time period: Jan 2012 July 2014 No. of registered wells: 9,395 GPS coordinates Monthly flaring data: SCFM + number of days in operation Twenty most promising wells analyzed Average production: 0.9 MM SCFD 45 STPD MeOH per well (conservative estimate) Stable assoc. gas supply required Minimum 15 years About 25 MM SCFD (1400 STPD MeOH or 4,000 bpd gasoline) Combining of gas sources is required
11 Options available Pipe-line for transportation of associated gas Expensive, does not match NG-specifications and risk of liquid drop-out LNG Very expensive in small scale, transportation issues (cost & efficiency) Petrochemicals production NH 3 (complicated) Methanol (possibly as intermediate product) Diesel (complicated) DME (not yet a commodity product, requires pressurized transportation) Gasoline (complicated but with good market fit) High levels of sulfur in gas may necessitate presulfurization option for WSA production
12 Options available Pipe-line for transportation of associated gas Expensive, does not match NG-specifications and risk of liquid drop-out LNG Very expensive in small scale, transportation issues (cost & efficiency) Petrochemicals production NH 3 (complicated) Methanol (possibly as intermediate product) Precursor for gasoline, formaldehyde, acetic acid, DME a.o. Minimize scope at gas site 3 x 8 MMSCFD sites instead of 1 x 25 MM SCFD site Diesel (complicated) DME (not yet a commodity product, requires pressurized transporation) Gasoline (complicated but with good market fit)
13 Topsoe s methanol strategy The attractiveness of upgrading syngas into methanol for use as a transportation fuel or in chemical production is increasing around the world. Our methanol solutions can be integrated with other processes to enable feedstock and co-production flexibility. Ensure reliable operation, extremely high energy efficiency, and superior conversion levels. Help achieve the best economic performance for customers, in both the short and long term.
14 Haldor Topsoe methanol products timeline 1 st methanol plant Technology ATR One-step reforming Boiling water reactor Two-step reforming Standard coproduction. 3,000 MTPD plant 5000 MTPD plant Flexible coproduction SMK MK-101 MK-121 MK-151 FENCE TM Catalyst
15 Syngas for methanol production Key specification of syngas M=(H 2 CO 2 )/(CO+CO 2 ) must be close to 2 High CO/CO 2 ratio desirable Low CH 4 content
16 Selection of syngas technology for methanol NG as feed stock S/C H 2 /CO CO 2 CH 4 SMR (one-step reforming) Conventional tubular reforming High Medium Two-step reforming Combined tubular and oxygen-blown secondary reforming ~3 Medium Low ATR reforming Stand-alone oxygen-blown reformer Low Low Conclusion: SMR is today not attractive for methanol production from NG
17 Technology comparison NG as feed stock 5,000 MTPD MeOH plant Two-step reforming ATR Energy consumption, including oxygen, MM BTU/MT MeOH ISBL cost including ASU Catalyst cost Oxygen consumption Reforming section duty S/C ratio CO/CO 2 in synthesis gas
18 Methanol production by ATR Oxygen/steam Autothermal reformer Methanol reactor Hydrogenator Sulfur removal Prereformer Steam Steam Natural gas Make-up comp. Rec. comp. Hydrogen recovery Purge gas Raw methanol
19 ATR vs. SMR for associated gas Autothermal reforming of associated gas with AGR T ref =1880 o F, P ref =470 psi, S/C=0.6 M=1.97; CO/CO 2 =9.6, CH 4 =1.0% Steam reforming of associated gas T ref =1560 o F, P ref =350 psi, S/C=2.5 M=2.4; CO/CO 2 =1.6, CH 4 =4.9% Autothermal reforming of associated gas with AGR Steam reforming of associated gas
20 Economic Analysis of a specific case Autothermal reforming of associated gas: Procedure Detailed PFD s One-line specifications for all process equipment US Gulf coast ISBL cost estimate (+/- 30%) OSBL cost from empiric data CAPEX from amortization of TIC Benchmarking towards MeOH from NG using ATR-based methanol production
21 Impact of feed stock and scale on production price Typical methanol production costs Feed stock / Process Capacity CAPEX 1) USD/ST OPEX USD/ST Sum USD/ST Natural Gas / ATR 5,000 MTPD ) 129 Associated Gas / ATR 430 STPD Associated Gas / ATR 1400 STPD 140 3) ) Incl. insurance & utilities etc. and assuming OSBL-cost = ISBL-cost and ROI=12%. Exchange rate: 1 Euro = 1.10 USD 2) Assuming 2.5$/MM BTU as NG cost 3) Assuming a cost scaling factor of 0.72 Cost estimates are from 2013; actual costs depend on S-content in gas (max 100 ppm)
22 Conclusions Conversion of associated gas to petrochemicals is an attractive way to reduce gas flaring Combining of gas sources is required to reach an attractive production scale minimum 25 MMSCFD for 15 years A company such as Haldor Topsoe can provide all the required technology Infra-structure must be built to support this initiative
23 Thank you for your attention Our values: Business: We go the extra mile to create lasting value for our customers. Science: Our passion for science and innovation strengthens our business. People: Topsoe is a great place to work and to have worked. Society: We create sustainable solutions that make a difference to the world of today and tomorrow.
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