Beruflich Dokumente
Kultur Dokumente
Jim Aiello
Agenda
MegaMethanol Concept Atlas Execution MegaMethanol Status Technology Improvements Downstream Technologies Conclusions
MegaMethanol Concept
MegaMethanol
> 1 million t/a methanol single train capacity
Technical Features Oxygen-blown synthesis gas production Two-step methanol synthesis Hydrogen recovery
Atlas 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 Clients input / optimization throughout the entire project execution period
Atlas Execution
Proven process concept (Lurgi MegaMethanol by Combined Reforming)
Natural Gas PreReforming Steam Reforming Fired Heater Steam System
Desulphurization
Autothermal Reforming
Two-Step Synthesis
Methanol Distillation
Oxygen AirSeparation Water Treatment Flare System Desalination Methanol Tank Farm
Atlas Execution
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-up e.g.fired heater / atmospheric column / waste heat boiler system
Atlas Execution
Autothermal Reformer
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Atlas Execution
Methanol Synthesis
Atlas Execution
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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Atlas Execution
D. Quantities Largest equipment: atmospheric column, 80m long, 500 tons auxiliary boiler, 480 tons gas cooled methanol reactor, 460 tons
4,500 piles 20,000 m 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 m painting
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60,000 m insulation
Atlas Execution
Time schedule Pre-Engineering Contract effective date Construction Pre-Commissioning Commissioning 1st Methanol Production Commercial Production (85%) Performance Test passed
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Dec. 2000 - May 2001 Sept. 1st, 2001 Sept. 2001 - May 2004 Sept. 2003 - March 2004 Nov. 2003 - May 2004 June 2nd, 2004 July 24th, 2004 Oct. 5th, 2004
Under construction: Zagros I, Iran Zagros II, Iran Chile IV, Chile 5,000 t/d 5,000 t/d 2,400 t/d
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Technology improvements
Period Plant Capacity Net Production Cost per t of methanol *
US$ 100,00 - 120,00 US$ 80,00 - 90,00 US$ 50,00 - 60,00 US$ <40,00
1995 - 1999 1999 - 2000 2000 - 2003 Future synthesis gas production using highpressure process
(HP Pox Freiberg)
approx. 2.000 tpd approx. 2.500 tpd approx. 5.000 tpd approx. 10.000 tpd
Technology Improvements: Synthesis gas production has strong impact on plant cost
Methanol
approx. 30 bar operating pressure in conventional plants approx. 70 - 100 bar operating pressure in new development (HP-POX)
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Technology Improvements: Combined Reforming at PetroSA (Mossgas) Fischer-Tropsch Plant 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
Diesel Gasoline
Fischer Tropsch Synthesis Upgrading
MtPower
Power Fuel Cells Chemicals (MTBE, Acetic Acid, Formaldehyde) Diesel/Gasoline Propylene/Polypropylene
Acrylic Acid
MegaSyn
MtSynfuels
MegaMethanol
Megammonia
Downstream Technologies:
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:
Natural Gas H2/N2 Air Gas Generation NH3 Synloop NH3 4000 MTPD
Air
Natural Gas GOX ASU Gas Generation SN=2.05 MeOH Synloop & distillation MeOH 5000 MTPD
GAN
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Downstream Technologies:
COD Plant
Propylene
Diesel Gasoline
Fuel Additives
Syngas Plant
MeOH Plant
CO
Methanol
MTP Plant
Polypropylene
Pipes Films Packaging SAP Diapers Dispersions Paints Fibres ABS/SAN Adhesives Solvents Films
ASU
O2 N2 H2
O2
CO/H2 O2
Air
Ammonia Plant
Acrylonitrile
Ammonia
Acetates
CO
Conclusions
Lurgi MegaMethanol is a very competitive plant concept Lurgi R&D is actively developing further plant capacity increases Lurgis 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 economics of MtSynfuels are comparable to those of Fischer Tropsch The Hub concept / gas-based refinery is ready for implementation
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Thank You!
Questions?
281-582-8892 281-582-8894 Jaiello@lurgipsi.com
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