Methanol Plant Expansion for Increased Profitability

Transcription

1 Plant Expansion for Increased Profitability Andrew Board October worldwide

2 120 Years of Syngas Experience The First 100 Years 1892 Humphreys & Glasgow founded First Hydrogen Plant 1944 First Producer Gas Plant 1951 First Onia Geigy Plant 1956 Underground Coal Gasification 1957 First Syngas Plant for Fischer-Tropsch 1958 First Gasification Plant 1962 First Reformer 1963 First Ammonia Plant 1965 First Plant 1971 First Refinery Plant First SNG Plant 1972 First Offshore Design 1992 Jacobs Acquires H&G 2

3 Experience Global Client Location Scope Togliattiazot Salalah Company (SMC) Saudi International Petrochemical Company (SIPC) QAFAC Saudi Company Ar-Razi 3 & Ar-Razi 4 National Company Ibn Sina Samara, Russia Salalah, Oman Al Jubail, Saudi Arabia Qatar Al Jubail, Saudi Arabia Al Jubail, Saudi Arabia Basic Engineering Package & Reformer Detailed Design for 2 x 3,300 TPD methanol plants to be located on Togliattiazot s existing complex. Loop design included JM s tube cooled converter. FEED package and an ITB for LSTK EPCC bids for a grass roots 3,000 TPD methanol plant. OSBL design included docks and seawater intake / outfall. FEED package for a 2,900 TPD methanol plant. Jacobs monitored the turnkey contractor and provided operator training, plant commissioning for SIPC. FEED package, commissioning and start-up assistance for a 2,500 TPD methanol plant. Basic and Detailed Engineering for SMR for 2,500 TPD methanol plant. Detailed engineering of the reformer furnace, convection heat recovery section, and ancillary equipment for a 2,100 TPD methanol plant. Also provided construction and commissioning advisory services.

4 Experience North America Client Location Scope Methanex Geismar, LA PDP, FEED, permitting and EPCm for relocation of 2 X 2,860 TPD plants from Punta Arenas, Chile to Geismar, LA. Methanex LyondellBasell Celanese Medicine Hat Channelview, TX Edmonton, Canada Basic Engineering for distillation upgrade and integration. NOx emission reduction study. Provide basic engineering support and EPCm services for the 2,125 TPD Channelview Restart and Emission Reduction Project. Basic Engineering for methanol plant and Detailed Engineering for SMR for 2,100 TPD methanol plant. 4

5 Conventional SMR based Plant - 1 NG to SMR Fuel Steam Purge gas to SMR Fuel Natural Gas NG Compression Purification and Saturation Steam Methane Reforming (SMR) Heat Recovery and Syngas Compressor (SGC) Synthesis Loop Distillation Product CH 4 + H 2 O CO + 3H 2 CO + H 2 O CO 2 + H 2 CO 2 + 3H 2 CH 3 OH + H 2 O CO + H 2 O CO 2 + H 2 Combing to give overall reaction: CO + 2H 2 CH 3 OH Water 5

6 Conventional SMR based Plant - 2 Conventional Natural Gas SMR based methanol plants provide good reliable low cost operation for methanol production Not the most efficient in terms of energy consumption, typically between 33 and 36 MMBtu/MT (HHV) Plant operation leads to an excess of hydrogen in the methanol synthesis loop, which is purged and burnt as fuel in SMR Is there a better use for this hydrogen? 6

7 CO 2 injection Option 1 NG to SMR Fuel Steam Purge gas to SMR Fuel Natural Gas NG Compression Purification and Saturation Steam Methane Reforming (SMR) Heat Recovery and Syngas Compressor (SGC) Synthesis Loop Distillation Product CO 2 injection CO 2 injection Water CO 2 injection up to stoichiometry level However, as CO 2 injection increases, rate of production increase and efficiency improvement decreases Distillation impacts needs assessment due to increase load and greater water produced in synthesis reactions 7

8 CO 2 injection Option 1 Total Natural Gas Units Base Case Current operation Option 1a CO2 injection to SGC Option 1b CO2 injection to SMR MMBtu/day 105, , , ,712 CO 2 Injected TPD Option 1c CO2 injection to SGC with increased NG Production Natural Gas Utilization MTPD 3,000 3,083 3,098 3,299 MMBtu/MT

9 Purge Loop Option 2 Purge gas to SMR Fuel PSA tailgas to SMR Fuel High Pressure PSA Purge Loop NG to SMR Fuel Steam CO 2 injection Natural Gas NG Compression Purification and Saturation Steam Methane Reforming (SMR) Heat Recovery and Syngas Compressor (SGC) Synthesis Loop Distillation Product Water 9

10 Purge Loop Option 2 Units Base Case Current operation Option 2a Purge Loop with fixed NG Total Natural Gas MMBtu/day 105, , ,555 CO 2 Injected TPD ,209 Production MTPD 3,000 3,180 3,825 Option 2b Purge Loop with increased NG Natural Gas Utilization MMBtu/MT

11 ATR and OTR Option 3 Oxygen Natural Gas Auto Thermal Reforming (ATR) and Reformed Gas Boilers Once-Through Reactor (OTR) NG to SMR Fuel Steam Purge gas to SMR Fuel Natural Gas NG Compression Purification and Saturation Steam Methane Reforming (SMR) Heat Recovery and Syngas Compressor (SGC) Synthesis Loop Distillation Product CO 2 injection Water 11

12 ATR and OTR Option 3 Units Base Case Current operation Total Natural Gas MMBtu/day 105, ,626 CO 2 Injected TPD O 2 Consumed TPD Production MTPD 3,000 4,173 Natural Gas Utilization MMBtu/MT Option 3 ATR and OTR 12

13 TIC/annualized production ($/TPA) Additional Production (TPD) Financial impact Option 1a CO2 injection to SGC Option 1b CO2 injection to SMR Option 1c CO2 injection to SGC with increased NG Option 2a Purge loop with fixed NG Option 2b Purge loop with increased NG Option 3 ATR and OTR 0 TIC/Annualized Production Additional Production 13

14 Case Study Implementation of Option 3 plant implementing parallel ATR and OTR with ~20% increase in Natural Gas and CO 2 addition Oxygen Natural Gas Auto Thermal Reforming (ATR) and Reformed Gas Boilers Once-Through Reactor (OTR) NG to SMR Fuel Steam Purge gas to SMR Fuel Natural Gas NG Compression Purification and Saturation Steam Methane Reforming (SMR) Heat Recovery and Syngas Compressor (SGC) Synthesis Loop Distillation Product CO 2 injection Water 14

15 Case Study Implementation of Option 3 Plant Capacity increased from 3,300 TPD to 4,400 TPD Natural Gas increase approximately 20%, maximum CO 2 injection plant improvement in Natural Gas utilization from 36 to 32.7 MMBtu/day plant now an exporter of steam to other users Project status FEED Completed by Jacobs EPC awarded 15

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