Developments in Methanol Production Technology

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TABLE OF CONTENTS
Page I SUMMARY A. B. CHEMISTRY PROCESS TECHNOLOGY 1. Conventional Processes 2. New Technology (a) The Kvaerner/BP Process (b) ICIs Advanced Gas Heated Reformer COMPARATIVE ECONOMICS MARKET ANALYSIS 1. Global Demand 2. Global Supply 3. Global Trade 1 1 4 4 4 5 7 8 12 12 14 14 17 17 18 21 21 21 21 24 24 25 26 29 30 30 31 32

C. D.

II

CURRENT COMMERCIAL TECHNOLOGY A. B. C. INTRODUCTION CHEMISTRY PROCESS DESCRIPTIONS 1. Introduction 2. ICI-Type Steam Reformer and Quench Converter (a) Overflow (b) Desulfurization of Feedstock (c) Steam Reforming (d) Carbon Dioxide Addition and Synthesis Gas Compression (e) Methanol Synthesis (f) Methanol Purification 3. Other Technology Considerations (a) Synthesis Gas Stoichiometry and its Effect on Plant Design (b) Selection of Synthesis Loop Operating Pressure 4. Lurgi-Type Autothermal Reformer

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Page D. PROCESS ECONOMICS 1. Introduction 2. ICI-Type Steam Reformer and Quench Converter 3. Lurgi-Type Autothermal Reformer 4. Summary 33 33 33 38 43 44 44 46 46 47 49 54 54 54 56 61 65 65 65 65 67 69 71 71 71 71 74 74 75

III

REVIEW OF NEW TECHNOLOGY A. INTRODUCTION B. THE KVAERNER/BP PROCESS 1. Background 2. Process Description 3. Economics C. ICIS ADVANCED GAS HEATED REFORMER 1. Overview 2. Process Description 3. Economics D. COMPARATIVE ECONOMICS E. OTHER DEVELOPMENTS 1. Once-Though Methanol Processes (a) Air Products Liquid Phase Methanol Process (b) Twente University Process 2. Starchem/ABB Lummus Methanol Process 3. Direct Routes COMMERCIAL ASSESSMENT A. GLOBAL METHANOL DEMAND 1. Introduction 2. Chemical Uses 3. Demand for Methanol in MTBE (a) Background (b) Global Overview

IV

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Page B. GLOBAL METHANOL SUPPLY 1. Current Capacity Situation 2. New Projects GLOBAL METHANOL TRADE GLOBAL METHANOL SUPPLY/DEMAND BALANCE 76 76 82 84 86 93 94

C. D.

REFERENCES PERP TITLE INDEX

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TABLES
Page Table I.C.1 Table I.C.2 Table I.D.1 Table I.D.2 Table II.C.1 Table II.D.1 Table II.D.2 Table II.D.3 Table II.D.4 Table II.D.5 Table III.B.1 Table III.B.2 Table III.C.1 Table III.C.2 Table III.D.1 Table III.D.2 Table IV.A.1 Table IV.B.1 Table IV.B.2 Table IV.D.1 Table IV.D.2 Economic Comparison of Methanol Processes, USGC 8 Economic Comparison of Methanol Processes, Middle East 9 12 Global Methanol Demand by Region Global Methanol Capacity Development by Region 14 Typical Reformer Outlet Composition for Natural Gas-Based Methanol Plant 30 Cost Estimate of Methanol Production via Conventional ICI-Type Process 36 Cost Estimate of Methanol via Convention ICI-Type Process, Remote Location 37 Cost Estimate of Methanol Production via Lurgi Combined Reforming Process 41 Cost Estimate of Methanol Production via Lurgi Combined Reforming Process, Remote Location 42 Economic Comparison of Conventional Methanol Process 43 Cost Estimate of Methanol Production via Kvaerner/BP Compact Reformer 50 Cost Estimate of Methanol via Kvaerner/BP Compact Reformer, Remote Location 51 Cost Estimate of Methanol Production via ICI Katalco Advanced Gas Heated Reformer 57 Cost Estimate of Methanol via ICI Katalco Advanced Gas Heated Reformer, Remote Location 58 Economic Comparison of Methanol Processes, USGC 61 Economic Comparison of Methanol Processes, Middle East 62 Global MTBE and TAME Demand, 1990-2010 76 Methanol Capacity List, 1997 78-80 Methanol Capacity Changes, 1998-2010 83 Global Methanol Supply and Operating Rate, 1990-2010 87 Methanol Supply/Demand Balance, 1990-2010 89-92

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FIGURES
Page Figure I.B.1 Figure I.C.1 Figure I.C.2 Figure I.D.1 Figure I.D.2 Figure II.C.1 Figure II.C.2 Figure II.C.3 Figure II.C.4 Figure II.D.1 Figure II.D.2 Figure III.A.1 Figure III.B.1 Figure III.B.2 Figure III.B.3 Figure III.C.1 Figure III.C.2 Figure III.C.3 Figure III.D.1 Figure III.D.2 Methanol Plant ISBL Cost Breakdown Economic Comparison of Methanol Process (USGC) Economic Comparison of Methanol Process (Middle East) Historical Methanol Demand by Region Global Methanol Trade Development Process Flow Diagram of Conventional Methanol Process: Reformer Section Process Flow Diagram of Conventional Methanol Process: Synthesis Section Process Flow Diagram of Methanol Process with Autothermal Reformer: Reformer Section Process Flow Diagram of Methanol Process with Autothermal Reformer: Synthesis Section Cost Sensitivity of Methanol to Plant Scale Cost Sensitivity of Methanol to Natural Gas Price Methanol Plant ISBL Cost Breakdown Process Flow Diagram of Kvaerner Compact Reformer via Methanol Process Cost Sensitvity of Kvaerner/BP Methanol Process to Natural Gas Price (for Plant in USGC) Cost Sensitivity of Kvaerner/BP Methanol Process to Total Capital Investment Process Flow Diagram of ICI Katalco AGHR Methanol Process Cost Sensitivity of ICI Katalco AGHR Methanol Process to Natural Gas Price Cost Sensitivity of ICI Katalco AGHR Methanol Process to Total Capital Investment Economic Comparison of Methanol Process (USGC) Economic Comparison of Methanol Process (Middle East) 6 10 11 13 16

22 23 34 35 39 40 45 48 52 53 55 59 60 63 64

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FIGURES (Continued)
Page Figure III.E.1 Figure III.E.2 Figure IV.A.1 Figure IV.A.2 Figure IV.A.3 Figure IV.B.1 Figure IV.C.1 Figure IV.D.1 Twente University Once-Through Methanol Process Starchem/ABB Lummus Autothermal Reforming (ATR) Historical Methanol Demand by Region, 1980-1996 Global Methanol Demand, 1997 Global MTBE/TAME Demand, 1990-2010 Regional Division of Global Methanol Capacity, 1997 Global Methanol Trade Pattern Global Methanol Supply/Demand Outlook, 1990-2010 66 68 72 73 77 81 85 88

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