lurgi mega methanol by combined reforming

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Lurgi’s MegaMethanol® Process

Atlas and Beyond

Jim Aiello

Houston - January 19, 2005

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AgendaAgenda

MegaMethanol® Concept

Atlas Execution

MegaMethanol® Status

Technology Improvements

Downstream Technologies

Conclusions

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MegaMethanol® ConceptMegaMethanol® Concept

MegaMethanol®– > 1 million t/a methanol single train capacity

Technical Features– Oxygen-blown synthesis gas production– Two-step methanol synthesis– Hydrogen recovery

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Atlas Methanol:World’s largest operating MeOH Plant at 5000 mtpd

Low investment and very competitive production cost

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Atlas ExecutionAtlas Execution

First of its kind MegaMethanol® Plant

Single train process

Largest Methanol Plant at 5,000 mt/d

Energy consumption of less than 30 million BTU per mt methanol

Lurgi executed lump sum turn-key project

Consideration of Client´s input / optimization throughout the entire project execution period

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Proven process concept (Lurgi MegaMethanol® by Combined Reforming)

Desulphur-ization

Pre-Reforming

AutothermalReforming

Two-StepSynthesis

MethanolDistillation

Air-Separation

PurePureMethanolMethanol

Oxygen

Natural GasNatural Gas

PSAAir

SteamReforming

IntermediateTank Farm

WaterTreatment Desalination Sweet Water

CoolingSea WaterCooling

EmergencyPower Gen.

Instument-& Plant Air

FlareSystem

MethanolTank Farm

Fire FightingSystem

AuxiliaryBoiler

Rain WaterSystem

FiredHeater

SteamSystem

Fuel

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Competitive Engineering - Lurgi home office and Lurgi subsidiaries

A. Design

2 water cooled methanol reactors and 1 gas cooled methanol reactor (new development)

largest Autothermal Reformer worldwide with a new burner design (new development)

Process optimization and combination / selection of individual process steps in order to realize the scale-up of the plant

large equipment due to scale-upe.g.fired heater / atmospheric column / waste heat boiler system

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Atlas Execution

Autothermal Reformer

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Atlas Execution

Methanol Synthesis

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B. Procurement

World-wide procurement of equipment

Bankruptcy of some equipment suppliers

Quality: comprehensive expediting & inspection to ensure high quality standards

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Atlas Execution

C. Construction

4 million man-hours without lost time accident

8.5 million construction man-hours in total

peak 150 Lurgi construction personnel

peak 2,200 people from construction subcontractors

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D. Quantities

Largest equipment: atmospheric column, 80m long, 500 tonsauxiliary boiler, 480 tonsgas cooled methanol reactor, 460 tons

4,500 piles

20,000 m³ concrete

4,100 t steel structure

4,100 t piping incl. PU

5,500 m FRP piping

230,000 m cable

3,000 instruments

50,000 m² painting

60,000 m² insulation

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Time schedule

Pre-Engineering Dec. 2000 - May 2001

Contract effective date Sept. 1st, 2001

Construction Sept. 2001 - May 2004

Pre-Commissioning Sept. 2003 - March 2004

Commissioning Nov. 2003 - May 2004

1st Methanol Production June 2nd, 2004

Commercial Production (85%) July 24th, 2004

Performance Test passed Oct. 5th, 2004

Atlas Execution

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Lurgi MegaMethanol® StatusLurgi MegaMethanol® Status

Contract status:

On stream:

Atlas Methanol, Trinidad 5,000 t/d

Under construction:

Zagros I, Iran 5,000 t/d

Zagros II, Iran 5,000 t/d

Chile IV, Chile 2,400 t/d

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Lurgi MegaMethanol® StatusLurgi MegaMethanol® Status

Lurgi Contract status

Under design:

Hainan, China 2,000 t/d

Acetex / Tasnee, Saudi Arabia 5,400 t/d

Qafac, Qatar 6,750 t/d

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… are the driving force to lower production costs of methanol

* gas prices in the range between US$ 0.5 and 1.00 per MMBTU

Period Plant Capacity Net Production Costper t of methanol *

1995 - 1999 approx. 2.000 tpd US$ 100,00 - 120,00

1999 - 2000 approx. 2.500 tpd US$ 80,00 - 90,00

2000 - 2003 approx. 5.000 tpd US$ 50,00 - 60,00

Future synthesis gasproduction using high-pressure process(HP Pox Freiberg)

approx. 10.000 tpd US$ <40,00

Technology improvements…Technology improvements…

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approx. 30 bar operating pressure in conventional plantsapprox. 70 - 100 bar operating pressure in new development (HP-POX)

Synthesis GasProduction

Synthesis GasProduction

Methanol SynthesisMethanol Synthesis

Air SeparationUnit

Air SeparationUnit

AssociatedGas

NaturalGas

Methanol

60% of theplant cost *)

40% of theplant cost*)

Oxygen

Technology Improvements:

Synthesis gas production has strong impact on plant cost

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Technology Improvements:

Combined Reforming at PetroSA (Mossgas) Fischer-Tropsch Plant

Capacity: 3 x 268 MMSCFD syngasStart-up: 1992

The largest synthesis gas plant in the world

ATR is the key for large-scale syngas plants and the only way to benefit from economy of scale

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Technology improvements

Vision for future / new developments

Further increase of one train capacity - Lurgi pilot plant HP POX Freiberg- Pure Autothermal Reforming at higher pressure without syngas compressor

Further development of downstream applications (MTO, MTP®, MTC, MtPower®)

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Downsteam Technologies

Ammonia/Urea/Fertilizer

DieselGasolineLPGFuel GasWaxes/Lube OilPowerFuel CellsChemicals (MTBE, Acetic Acid, Formaldehyde)Diesel/GasolinePropylene/PolypropyleneAcrylic Acid/AcrylatesEthylene/PropyleneFuel (DME)Hydrogen

MegaSyn®

Fischer Tropsch

Synthesis

Mega-Methanol®

Upgrading

MTO

MTD

MTH

MtSynfuels

Acrylic Acid

MTP®

Natural Gas / Associated Gas

Megammonia®

MtPower

MegaSyn® & MegaMethanol® “open the door” for Gas-to-Chemicals

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Downstream Technologies:

MTP® - Current Status

More than 7000 operating hours of pilot plant in Frankfurt

~ 11000 operating hours in Demo Unit at Statoil TBO plant - results confirm expectations for selectivities, conversion, lifetime- results exceed expectations for cycle lengths

Catalyst is commercially manufactured and available

Process Design of Commercial Plant is completed

First Commercial Plant (100,000 tpa) is signed

Several LOI signed for world-scale capacities

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Downstream Technologies:

Beyond Mega-Plants: The “Hub” Concept

Gas GenerationASU MeOH Synloop& distillation

Natural Gas

MeOH5000 MTPD

GOX

Gas Generation NH3 Synloop

Natural Gas

NH34000 MTPD

Air

Air

SN=2.05

H2/N2

Stan

d A

lone

C

once

pt

Gas GenerationASU MeOH Synloop& distillation

Natural Gas

NH3 SynloopGAN

GOX

Air

SN=2.05

H2/N2

MeOH5000 MTPD

NH34000 MTPD

The

“Hub

” C

once

pt

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Dimethylether

DME Plant

Fuels

Fuel Additives

Propylene

COD Plant Diesel

Kerosene

Gasoline

Ammonia

Plant

H2N2

AdhesivesSolvents

FilmsAcetatesAcetic Acid

PlantCO

MeOH

SAPDiapersAcrylic AcidO2

PipesFilms

Packaging

O2

H2

CO

Methanol

ASU

MTP Plant

MeOHPlant

PolypropyleneSyngas

Plant

NaturalGas

AssociatedGas

Air FibresABS/SAN

Ammonia

AcrylonitrileO2

DispersionsPaints

Oxo-Alcohol Plant

AcrylatesCO/H2

Downstream Technologies:“Hub Concept” / “Gas Based Refinery”

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Conclusions

Lurgi´s gas conversion technologies (MegaSyn® and MegaMethanol®) “open the door” for downstream methane based petrochemical applications

MTP® converts methane to Propylene and is being commercially implemented

Methanol is a commercially viable fuel for power generation and acceptable to turbine manufacturers

The “Hub” concept / “gas-based refinery” is ready for implementation

The economics of MtSynfuels are comparable to those of Fischer Tropsch

Lurgi MegaMethanol® is a very competitive plant concept

Lurgi R&D is actively developing further plant capacity increases

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ThankThankYou!You!

!!!!

!!Questions?Questions?

Contact:

James G. AielloDirectorBusiness Development

Lurgi Phone 281-582-8892333 N. Sam Houston Pkwy E., Suite 400 Fax 281-582-8894Houston, Texas e-mail [email protected]

lurgi mega methanol by combined reforming

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