Advanced MTO: Breakthrough Technology for the Profitable Production of Light Olefins

Transcription

1 Advanced MTO: Breakthrough Technology for the Profitable Production of Light Olefins Rick Kempf UOP LLC, A Honeywell Company 2013 Middle East Downstream Week May 12-15, 2013 Abu Dhabi, United Arab Emirates 2013 UOP LLC. All rights reserved. UOP 6054A-1

2 Million MTA World Light Olefin Supply & Demand Propylene Ethylene Light Olefin Demand* * Source: IHS Chemical World demand for ethylene and propylene growing (about 4%/yr) More than 100M MTA of additional capacity will be needed by 2025 Consumption being driven by growing middle class in developing regions Propylene is mainly supplied as a by-product from stream cracking and FCC Propylene gap developing Increased use of lighter feedstocks for steam crackers Slow gasoline growth Several options for on-purpose propylene production Growing demand supply gap developing for propylene UOP 6054A-2

3 UOP Light Olefin Solutions UOP PetroFCC Process MaxEne VGO PetroFCC Unit Ethylene Propylene Gasoline Heavy Products Naphtha Normal Paraffins MaxEne Non-Normals Naphtha Cracker Catalytic Reformer Propane Dehydrogenation Methanol to Olefins Propane Oleflex Unit Hydrogen Propylene Methanol (From coal or gas) Advanced MTO Propylene Ethylene Multiple solutions to meet the increased demand for light olefins UOP 6054A-3

4 Advanced MTO Technology Regen Gas MTO Process Integrated with Olefin Cracking Process (OCP) MTO DME Recovery Light Olefin Recovery C 4 + Ethylene Propylene n-butenes (optional) Air Water OCP Methanol Sep Section By-products UOP 6054A-4

5 Discovery of a New Material 3.8 Ă Scientists at Union Carbide (UCC) discovered a new molecular sieve family, silicoaluminophosphates (SAPO) 5.5 Ă during early 1980 s SAPO-34 has a more narrow product distribution but faster coke formation compared to ZSM-5 MTO development transferred from UCC to UOP in 1988 UOP 6054A-5

6 Yield Benefits from OCP Integration 2.6 tons of Methanol consumed per ton of light olefin produced A little more ethylene, a lot more propylene, and a lot less C 4 + by-product OCP integration increases light olefin yields by >15% UOP 6054A-6

7 Benefits of Higher Light Olefin Yields Greater value created from raw materials Lower operating costs Less methanol/coal consumption Less energy consumed upstream of MTO Smaller upstream process units for syngas/methanol production Most of the capital required for coal-to-olefins is attributable to units upstream of MTO Less impact on the environment Most of the CO 2 emissions for coal-to-olefins are attributable to units upstream of MTO Water consumption is minimized UOP 6054A-7

8 $/MT Lt. Olefins Olefin Cost of Production Comparisons 2,000 Capital Charges (Depreciation + Return) Cash Cost of Production 1,000 0 Technology: Feedstock: Location: Propylene: Ethylene: Feed Price: Cracker Ethane Middle East KMTA $62/MT GTO Natural Gas Middle East 600 KMTA 400 KMTA $1.25/MMBtu PDH Propane USGC 750 KMTA --- $600/MT PDH Propane Middle East 750 KMTA --- $600/MT MTO Methanol Middle East 600 KMTA 400 KMTA $350/MT PDH Propane China 750 KMTA --- $800/MT Cracker Naphtha China 345 KMTA 655 KMTA $956/MT 8 MTO costs include the production of synthesis gas, methanol, and conversion to polymer-grade ethylene & propylene Cracker yields, utilities, and CAPEX from various sources On-Purpose Light Olefin Technologies Are Competitive

9 Cracker Feed Slate Changes Cracker Feeds Ethane E/P Mix LPG Light Naphtha FBR Naphtha Gas Oil Steam Cracker Cracker Products Ethylene Propylene C 4 By-products Pygas Shift to low cost ethane puts pressure on CCOP position of naphtha crackers UOP 6054A-9

10 Development History of UOP Advanced MTO Process ~1 kg/day of MeOH feed Multiple grades/sources of feed Reactor and regenerator configuration ~1,000 kg/day (maximum) of MeOH feed Multiple grades/sources of feed Reactor and regenerator configuration ~10,000 kg/day (10t/d) of MeOH feed Fully integrated Advanced MTO Process Configuration 1988 UOP Pilot Plant Operation 1995 INEOS Demo Unit (at the time Hydro) 2009 Total Petrochemicals Process Demonstration Unit UOP 6054A-10

11 Commercialization Status The following projects in China have disclosed the selection of the UOP / HYDRO MTO TM Process: Owner Location Scope LO Capacity MTA Expected On-Stream Wison (Nanjing) Clean Energy Company, Ltd. Nanjing, Jiangsu MTO / OCP 295, Jiutai Energy (Zhungeer) Company, Ltd. Ordos, Inner Mongolia MTO 600, Shandong Yangmei Hengtong Chemicals Company, Ltd. Linyi, Shandong MTO / OCP 295, Jiangsu-Sailboat Lianyungang, Jiangsu MTO / OCP 833, Strong global interest additional licenses expected in 2013 UOP 6054A-11

12 MTO Plant Construction as of Q Wison Engineering Ltd. UOP 6054A-12

13 Top Ten Reserves, Coal and Gas Location Coal Reserves US 27.6% Russian Federation 18.2% China 13.3% Australia 8.9% India 7.0% Germany 4.7% Ukraine 3.9% Kazakhstan 3.9% South Africa 3.5% Other Europe & Eurasia 2.6% Location Gas Reserves Russian Federation 21.4% Iran 15.9% Qatar 12.0% Turkmenistan 11.7% US 4.1% Saudi Arabia 3.9% United Arab Emirates 2.9% Venezuela 2.7% Nigeria 2.5% Algeria 2.2% 30.0% Coal Reserves 25.0% Gas Reserves 25.0% 20.0% 20.0% 15.0% 15.0% 10.0% 10.0% 5.0% 5.0% 0.0% 0.0% UOP 6054A-13

14 MTO Summary Strong demand growth for ethylene and propylene MTO opens a new path to ethylene and propylene starting from cost advantaged gas and coal Lower cost of production compared to oil derived feed High yield of ethylene and propylene (> 89%) Flexible product ratio (P/E range 1.25 to 1.8) Byproduct C 4 olefins available for B1, B2, and BD production Single train capacity up to 1.8 million MTA of light olefin Fully commercialized in 2013 by Wison Clean Energy Nanjing, China Three additional units operating by the end of 2015 UOP 6054A-14

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