Lurgi

Gas To Chemicals (GTC)
Lurgis Gas To Chemicals (GTC):
Advanced technologies for natural gas monetisation GASTECH 2005

Bilbao, Spain, March 14 - 17, 2005 Harald Kmpel, Waldemar Liebner, Matthias Wagner
1
DrLb / GTC_Gastech05_pres / 25.02.05
Contents
Introduction Natural Gas: abundance and challenge Lurgis MegaMethanol-Technology MegaMethanol to Dimethyl Ether MegaMethanol to Propylene = MTP MtSynfuels versus Fischer Tropsch Near future: gas-based petrochemistry Conclusion
2
Flared Natural Gas
E.Europe &FSU 6,3% West. Europe C&S 2,2% America 11,6%
Middle East 13,7%
total amount flared world-wide: 81 *109 m per year
Africa 43,3%
North America 15,7%
Far East & Oceania 7,2%
better use: make 102 Mt/a of methanol! build 60 MegaMethanol (and MTP) plants!
Source: Cedigaz, 2003
3
Gas to Chemicals Processing Routes
Fuel Gas LPG

Fischer Tropsch Synthesis Natural Gas / Associated Gas Upgrading
Naphtha Diesel Waxes Ammonia Fuel Cells Chemicals (MTBE, Acetic Acid, Formaldehyde, ...) Diesel, transport. fuels Propylene/Polypropylene
Acrylic Acid
Megammonia
MegaSyn
MTC MtSynfuels
MegaMethanol
MTP
Acrylic Acid/Acrylates Ethylene/Propylene Power/Fuel/DME(Diesel) Hydrogen
MTO
Lurgi proprietary process
MtPower MTH
4
The Lurgi MegaMethanol Concept
The basis for even more value from natural gas: MegaMethanol: > 1.7 million t/a methanol single train capacity Technical Features: Oxygen-blown synthesis gas production Two-step methanol synthesis Hydrogen Recovery
5
Simplified Diagram of Lurgis MegaMethanol Technology

Optimised reforming: high flexibility in stoichiometric number high energy efficiency for MeOH synthesis low investment costs large single-train capacity
Syngas
Purge Gas
Gas-Cooled Water-Cooled Reactor Reactor
Steam
Boiler Feed Water
methanol production cost: 65 $/t

Natural Gas
Crude Methanol
PreReforming
Desulphurization
Autothermal Reforming
Methanol Synthesis
Methanol Distillation
Air
AirOxygen Separation
PSA
Pure Methanol
Latest LurgiMethanol Project References
METHANEX, USA STATOIL, Norway SINOPEC, China KMI, Indonesia NPC, Iran SASTECH, RSA TITAN, Trinidad YPF, Argentina ATLAS, Trinidad NPC, 4th Methanol, Iran METHANEX, Chile 4 NPC, 5th Methanol, Iran Hainan, China Qafac, Qatar IAC Acetex (+730 t/d CO)
1700 mtpd 2400 mtpd 340 mtpd 2000 mtpd 2000 mtpd 400 mtpd 2500 mtpd 1200 mtpd 5000 mtpd 5000 mtpd 2400 mtpd 5000 mtpd 2000 mtpd 6750 mtpd 5400 mtpd
1992 1992 1993 1994 1995 1996 1997 1999 2000 2000 2002 2004 2004 2004 2004
7
Dimethyl Ether (DME) Alternative to Conventional Diesel Fuel
Excellent transportation fuel (better diesel) Very low emission levels Clean and efficient power generation Similar properties as LPG (storage, transport) DME: Energy Carrier of the Future!
(see www.aboutdme.org)
8
Lurgi MegaDME Dimethyl Ether Production by Methanol Dehydration
MeOH Recycle Off-gas Methanol DME Reaction DME Distillation DME Product
Syngas Production
H2O Recycle
Water Treatment
9
Lurgi DME - Economics
MegaMethanol & Dehydration Plant = MegaDME

Single-train production capacities: 5000 t/d (1.7 Mt/a) and more Available on order Incremental investment cost increase on MegaMethanol plant: < 10% Delivered cost (trans-ocean): same as for methanol (on energy basis)
10
DME projects in a sense
Lurgi will build several large DME plants, however

Plant location Iran Latin America Middle East Middle East production DME, kt/a 269 690 1180 1180 exp. s-u 2008 2008
Status contract signed LOI, financing
contract (pre-)BE 2009 LOI, financing 2009
11
MTP: Simplified Process Flow Diagram with production figures
Methanol, Grade AA 1.667 x 106 t/a = 5000 t/d
Fuel Gas 15,000 t/a internal use
DME PreReactor
Product Conditioning
Propylene 519,000 t/a

LPG 54,000 t/a
MTP Reactors
(2 operating + 1 reg.)
Gasoline 143,000 t/a
Olefin Recycle Water Recycle
Product Fractionation Process Water 936,000 t/a

for internal use and/or irrigation
12
Block Flow Diagram - PP Complex
3.8 Mio Nm/d
12.3 Mio Nm/d Syngas
1,700,000 t/a Methanol
520,000 t/a Propylene
Natural Gas
Syngas Plant
Methanol Plant
MTP Plant
900,000 t/a Water 140,000 t/a Gasoline
Polypropylene Plant
520,000 t/a Polypropylene
13
Block Flow Diagram - PP Complex
3.8 Mio Nm/d Natural Gas
0.52 Mt/a Propylene
GTP Plant
0.9 Mt/a Water 0.14 Mt/a Gasoline
Polypropylene Plant
0.52 Mt/a Polypropylene
14
Polypropylene Pricing
WORLD POLYPROPYLENE PRICE COMPARISON

Dollar per Ton
Current Dollars
1200
Forecast
1000
800
600
400
200
0 1990 1993 1996 1999 2002 2005 2008 2011 2014 2017 2020
USGC-Contract West Europe-Contract SEA Spot

Source: CMAI
USGC-Spot SEA Contract
15
GTP Economics
ROI - Case B: low propylene / high gasoline Integrated GTP / PP Complex GTP - PP
Investment Cost EPC Owners Cost incl. Capitalised Interest Feed Stock Cost Production Cost
- Raw Materials - Utilities - Operation & Maintenance - Plant OVHD & Insurance - Depreciation
Mio $/ Mio $/ US$ Mio $/ Mio $/ Mio $/ Mio $/ Mio $/ Mio $/ Mio $/
Mio $/ Mio $/
730 146 Natural Gas 0.5 $/MMBtu 150.7

46.6 8.6 19.9 21.2 54.4
Revenues
- Gasoline (130 $/t) - Polypropylene (650 $/t)
317.2
31.6 285.6
Return on Investment Internal Rate of Return (before Tax)
ROI % IRR2) %
19 20.6
16
1) ROI estimate based on Chem Systems Methodology 2) IRR estimate based on COMFAR
MTP Technology Status
PROCESS >9000 operating hours of pilot plant demo unit has logged >11,000 hours (March 04) proof of polymer grade propylene process design for commercial plant completed CATALYST catalyst development completed by supplier catalyst is commercially manufactured In short: The technology is on the market at fully commercial terms
17
MTP Projects
MTP projects gas-based

Plant location Iran Latin America Middle East Middle East production PP, kt/a 100 256 441 441 Status contract signed LOI, financing exp. s-u 2008 2008
contract (pre-)BE 2009 LOI, financing 2009
18
Gas-based Refinery via Methanol: Lurgis MtSynfuels
Hydrocarbon Recycle Hydrocarbon Recycle
Kero/Diesel
5.438 t/d
Methanol
15.000 t/d
Olefin Production
Olefin Oligomerisation
Product separation
+ MD Hydrogenation
Gasoline
685 t/d
Water recycle Process water, 7.902 t/d, can replace raw water
H2,55 t/d, from Methanol synthesis
LPG
579 t/d
19
Synfuels, Mossel Bay, RSA
20
Lurgis FT Experience Commercialisation of ARGE-synthesis in 1952

location: Sasolburg / South Africa start up: 1955 no. of reactors: 5
All original reactors still in operation today;

extension of capacity in 1987 (+ 1 reactor)
Modern FT Reactor Technology

Slurry phase reactor (by far preferred); tubular reactor; fluidised bed reactor
Lurgi has commercial experience in all these reactor technologies Lurgi designed the syngas production units of all FT-plants currently in commercial operation Sasol/Secunda (coal gasification) Mossgas (combined reforming of NG) SMDS/Bintulu (partial oxidation of NG)
21
Lurgis FT Experience II
Today, Lurgi MegaSyn is available for FT Syntheses as well as for MtSynfuels, Lurgis route through methanol to transportation fuels.
Lurgi also is active again in the FT-field as JV partner in the company GTL.F1 which is developing/commercialising a modern FT-technology.
22
Comparison Lurgi MtSynfuels - FT Synthesis Product Slate and Properties

Product Slate Naphtha : Kero+Diesel (max.) Gasoline : Kero+Diesel Product Properties Spec (Europe from 2005) Gasoline -Aromatics vol.% max. -Benzene vol.% max. -Sulphur wppm max. -Olefins vol.% max. 2) -RON -MON 2) Diesel -Polyaromatics vol.% max. -Sulphur wppm max. -Cetane No. min.
1) 2)
Lurgi Route 1:8 Lurgi Route
FT Synthesis 1 : 2.3 1 : 6 FT Synthesis3)
35 1 50/10 1) 18 91/95/98 82.5/85/88 11 50/10 1) 51
11 << 1 << 1 6 92 80 << 1 << 1 > 52
<1 << 1 <1 > 30 < 40 < 40 <1 <5 > 70
Diesel with 10 wppm sulphur has to be available on the market RON / MON for Regular Gasoline / Euro-Super / Super-Plus 3) Properties of FT-naphtha
23
Comparative Economics1) - Cost of Production Estimate
GTL Technology Total Capital Investment Total Plant Capital NG to Process (LHV) Cat. & Chemicals Utilities
MtSynfuels 1,181 MM $() 19,680 $()/bpd 3.82 $()/bbl 7.64 MMBtu/bbl 2.19 $()/bbl 0.28 $()/bbl
existing FT1) 1,671 MM $ 27,856 $/bpd 4.22 $/bbl 8.44 MMBtu/bbl 1.53 $/bbl 0.8 $/bbl 28.68 $/bbl US Nymex 51.5 53.6
Cost of Production + ROI Market Prices 2) - Gasoline - Diesel

1) 2)
22.47 $()/bbl W.Europe 56.9 48.3
[$/bbl] [$/bbl]
ChemSystems 2001 Corresponding Crude Oil Price: about 42 $/bbl

24
Gas-based Petrochemistry
Feedstock
OIL conventional route
Intermediates
Aromatics
Cracker Benzene Toluene Xylenes
Petrochemical Products
Polyolefins PE, PP Acrylates Polycondensates PC, PET, PBT Solvents
Natural Gas Associated Gas Stranded Gas emerging route
MTO Lurgis MegaSyn Lurgis MTP
Olefins
Ethylene Propylene
Syngas COAL/Biomass future route ?
Methanol Oxigenates
Alcohols, Ethers, Esters, Acids, Aldehydes
Lurgi MegaMethanol Lurgis MTC
Fuels Fuel additives
25
Valuable Products (Petrochemicals) from Natural Gas
Natural Gas Methane
Syngas CO + H2
MeOHPlant
Methanol
MTP Plant
Propylene
PPPlant
Polypropylene
Propylene
Propylene
OxoalcoholPlant
Acrylic Acid 2-EHOH BuOH
Acrylic Acid Plant

Acrylic Acid
Acrylic Acid
2-EHOH Acryl. Plant
Bu-Acryl. Plant
2EHAC
2-Ethylhexylacrylate
BuAc
Butylacrylate
26
Conclusions
Lurgis MegaSyn and MegaMethanol open new routes of gas monetisation:

Dimethyl ether (DME) can be produced at attractive costs to become an economical fuel Propylene is a high-demand, high value product. It can be produced cheaper than by conventional processes The economics of MtSynfuels are comparable to FT routes A gas-based petrochemistry is developed by Lurgi
27
Thank You!
Contact: Dr. Waldemar Liebner

Director GTC Technology Lurgi AG Dept. A-TM Lurgiallee 5 D-60295 Frankfurt am Main Germany
!
Phone Fax Mobile e-mail
Questions?
x49 69 5808 3799 x49 69 5808 3115 0174 7469 313 dr_waldemar_liebner@lurgi.de
28

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Gas To Chemicals (GTC)

Lurgis Gas To Chemicals (GTC):

Advanced technologies for natural gas monetisation GASTECH 2005

Gas To Chemicals (GTC)

Gas To Chemicals (GTC)

Flared Natural Gas

E.Europe &FSU 6,3% West. Europe C&S 2,2% America 11,6%

Middle East 13,7%

total amount flared world-wide: 81 *109 m per year

North America 15,7%

Far East & Oceania 7,2%

Source: Cedigaz, 2003

Gas To Chemicals (GTC)

Gas to Chemicals Processing Routes

Fuel Gas LPG

Acrylic Acid/Acrylates Ethylene/Propylene Power/Fuel/DME(Diesel) Hydrogen

Lurgi proprietary process

Gas To Chemicals (GTC)

The Lurgi MegaMethanol Concept

Gas To Chemicals (GTC)

Simplified Diagram of Lurgis MegaMethanol Technology

Gas-Cooled Water-Cooled Reactor Reactor

Boiler Feed Water

methanol production cost: 65 $/t

Gas To Chemicals (GTC)

Latest LurgiMethanol Project References

DrLb / GTC_Gastech05_pres / 25.02.05

Gas To Chemicals (GTC)

Dimethyl Ether (DME) Alternative to Conventional Diesel Fuel

Gas To Chemicals (GTC)

Lurgi MegaDME Dimethyl Ether Production by Methanol Dehydration

Gas To Chemicals (GTC)

Lurgi DME - Economics

MegaMethanol & Dehydration Plant = MegaDME

Gas To Chemicals (GTC)

DME projects in a sense

Lurgi will build several large DME plants, however

Status contract signed LOI, financing

contract (pre-)BE 2009 LOI, financing 2009

Gas To Chemicals (GTC)

MTP: Simplified Process Flow Diagram with production figures

Methanol, Grade AA 1.667 x 106 t/a = 5000 t/d

Fuel Gas 15,000 t/a internal use

Propylene 519,000 t/a

Gasoline 143,000 t/a

Olefin Recycle Water Recycle

Product Fractionation Process Water 936,000 t/a

DrLb / GTC_Gastech05_pres / 25.02.05

Gas To Chemicals (GTC)

Block Flow Diagram - PP Complex

3.8 Mio Nm/d

12.3 Mio Nm/d Syngas

1,700,000 t/a Methanol

520,000 t/a Propylene

520,000 t/a Polypropylene

Gas To Chemicals (GTC)

Block Flow Diagram - PP Complex

3.8 Mio Nm/d Natural Gas

0.52 Mt/a Propylene

0.52 Mt/a Polypropylene

Gas To Chemicals (GTC)

WORLD POLYPROPYLENE PRICE COMPARISON

USGC-Contract West Europe-Contract SEA Spot