PROCESS FOR CONVERSION OF

METHANOL TO OLEFINS (MTO)

CH3OH

>C=C<
Dr. R. P. Badoni
Distinguished professor

Process Licensors
UOP
Norsk Hydro ,Oslo Norway (100%
Conversion in Half ton Methanol
per day plant).

MANUFACTURE
Changing Natural gas To Olefins Is a Two Step
Process :
Natural gas
Methanol

Methanol
Olefins (UOP/HYDRO)

UOP/HYDRO MTO Process primarily converts the

methanol into ethylene and propylene.
Other technologies for indirect conversion of
methane to higher value products do exist. These
process have lower yields, less economical
compared to UOP/HYDRO MTO Process.
The UOP/HYDRO MTO Process provides an

 Exceptional
UOP HYDRO
value for direct conversion

PROCESS
of methane
to polymer grade ethylene
and propylene.
Direct use of ethylene and propylene in
chemical grade products with greater
than 98% purity using a flow scheme
that

does

not

ethylene/ethane

require
or

expensive

propylene/propane

splitters.
Limited

production

of

by-products

compared to a steam cracker, which

results in a simplified product recovery

UOP/HYDRO MTO PROCESS

OFFERS

Easy integration in to existing naphtha

cracker facilities due to low paraffin
yields.
Flexibility to change the ethylene to
propylene product weight ratio from
1.5 to 0.75.
It

also

has

significantly

lower

environmental emissions, such as NOX and

Chemical reaction
Dehydration with shape selective
transformation to low molecular
weight alkanes.
Methanol
SAPO-34[AlPO4]
Molecular
Propylene
EthyleneCatalyst
Seive
Butylenes

MTO FLUIDIZED-BED REACTOR

AND REGENERATOR SECTION
Heat
Recovery

Flue GAS

To Compression
& Product
Recovery
Section

Air

Crude
Methanol

REACTO
R

REGENERATO
R

Heat
Recover
y
Wat
er

Vaporization &
Preheating

MTO PROCESS RECOVERY SECTION

Feed from Reaction

C3
Splitter

Debutanizer

Compressi
on

ORU unit

Drying
Depropaniz
er

Co2
Removal

Acetylene
Saturation

C2

C2 Splitter

Deethanis
er

Compressio
n

Demethani
zer

C1

C3
C4

& Regeneration
Section

C5+

FEEDSTOCK
S
Feedstock

for

the

UOP/HYDRO

MTO

process is crude, non-distilled methanol

usually produced from synthesis gas,
which is produced from the reforming
of abundant natural gas.
Synthesis gas can also be produced by
steam reforming of petroleum products
such as naphtha, partial oxidation of
natural gas and petroleum products,
and coal gasification.

CATALYST
The reaction is catalyzed by the MTO100 silicoaluminophosphate synthetic
molecular sieve based catalyst.
The catalyst has demonstrated the
degree of attrition resistance and
stability required to handle multiple
regenerations
and
fluidized
bed
conditions over the long term.
The catalyst is extremely selective
towards the production of ethylene
and propylene.

Catalyst
Zeolite consists of framework
built of Tetrahedra
Each tetrahedra comprises a Tatom bound to Four oxygen
atom.
Oxygen bridges connect the
tetrahedra.
T- atoms are Si or Al.

Silica Alumina
Framework
O
O

T
O

Crystalline micro porous (Pore Dia- 3-14

Anstron.
Framework density greater than 20 T atoms /
1000
Anstron.

Range of pore Sizes of

Molecular Dimension

Small 8 Ring - ~ 4 A
Medium 10 Rings - ~ 5-6 A
Large - 12 rings - ~ 6-8 A
Very Large - > 12 Rings - ~ 8 A

TYPICAL MTO OPERATING CONDITIONS

REACTOR

REGENERATOR

TEMPERATURE (0C)

350-530

600-720

PRESSURE (atm)

1-2

1-2

Operating Mode

Vapor Phase,

Vapor phase

Fluidized bed

Fluidized bed

Byproducts of the
Process

Water and Hydrogen

Carbon Monoxide and Carbon Dioxide.
Methane to C5 Paraffins
C5+
Coke

Component

Ethylene

Maximum
Ethylene
Mode
48%

Maximum
Propylene
Mode
34%

Propylene

31%

45%

Butenes

9%

12%

C2=/C3=

1.5

0.75

APPLICATIONS
1. This process can be utilized in locations with cheap,
abundant natural gas reserves.
2. By integrating UOP/HYDR MTO process in to gas to
olefins (GTO) complex, feedstock prices can be held
down and natural gas can be converted in to a form
that is more easily transported and of higher value.
3. Existing naphtha or ethane-propane cracker facilities
can increase olefin production and feedstock flexibility
by installing an MTO reactor section and feeding in to a
revamped cracker fractionation section to minimize
the capital investment
4. Downstream of an existing methanol plant with excess
capacity , to meet local demands for olefins and

Areas for Research Modelling of

MTO process in a circulating
Fluidized bed reactor
The simulation combined with
kinetic model with SAPO-34 as
catalyst and the core annulus
type hydrodynamic model.
Modelling studies may indicate
ethylene selectivity vs increase in
coke deposition on the catalyst
Cage Effect, Methanol
conversion vs coke deposit.
Optimum % of coke deposit vs

Simulation
The influence of the exit
geometry such as smooth exit,
abrupts exist & exits with a
projected end on solid hold up
and thereby on methanol
conversion.
Simulator prediction of the flow
characteristics within CFB.