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© 2013 UOP LLC. All rights reserved. UOP 6054A-1
Rick Kempf UOP LLC, A Honeywell Company
Advanced MTO: Breakthrough Technology for the Profitable Production of Light Olefins
2013 Middle East Downstream Week May 12-15, 2013 Abu Dhabi, United Arab Emirates
World Light Olefin Supply & Demand
0
50
100
150
200
250
300
350
400
2000 2005 2010 2015 2020 2025
Millio
n M
TA
Light Olefin Demand*
Propylene
EthyleneWorld demand for ethylene and
propylene growing (about 4%/yr)
More than 100M MTA of additional capacity will be needed by 2025
Consumption being driven by growing middle class in developing regions
Growing demand – supply gap developing for propylene
Propylene is mainly supplied as a by-product from stream cracking and FCC
Propylene gap developing
– Increased use of lighter feedstocks for steam crackers
– Slow gasoline growth
Several options for on-purpose propylene production
* Source: IHS Chemical
UOP 6054A-2
UOP Light Olefin Solutions
Oleflex™
Unit
Propane Dehydrogenation
Propane Propylene
Hydrogen
Methanol to Olefins
Advanced
MTO
Methanol (From coal or gas)
Propylene
Ethylene
Multiple solutions to meet the increased demand for light olefins
MaxEne™
MaxEne™ Naphtha
Naphtha
Cracker
Catalytic
Reformer
Normal Paraffins
Non-Normals VGO
Heavy Products
UOP PetroFCC™ Process
Ethylene
Propylene
PetroFCC
Unit
Gasoline
UOP 6054A-3
Ethylene
Propylene
n-Butenes (optional)
Regen Gas
Air
Methanol
Water
DME Recovery
C4+
By-products
MTO Process Integrated with Olefin Cracking Process (OCP)
Sep Section
OCP
MTO Light Olefin
Recovery
Advanced MTO Technology
UOP 6054A-4
3.8 Ă 5.5 Ă
Discovery of a New Material
Scientists at Union
Carbide (UCC) discovered
a new molecular sieve
family, silicoalumino-
phosphates (SAPO)
during early 1980’s
SAPO-34 has a more
narrow product
distribution but faster
coke formation compared
to ZSM-5
MTO development
transferred from UCC to
UOP in 1988
UOP 6054A-5
Yield Benefits from OCP Integration
2.6 tons of Methanol consumed per ton of light olefin produced
A little more ethylene, a lot more propylene,
and a lot less C4+ by-product
OCP integration increases light olefin yields by >15% UOP 6054A-6
Benefits of Higher Light Olefin Yields
Greater value created from raw materials
Lower operating costs
– Less methanol/coal consumption
– Less energy consumed upstream of MTO
Smaller upstream process units for syngas/methanol production
– Most of the capital required for coal-to-olefins is attributable to units upstream of MTO
Less impact on the environment
– Most of the CO2 emissions for coal-to-olefins are attributable to units upstream of MTO
– Water consumption is minimized
UOP 6054A-7
8
Olefin Cost of Production Comparisons
0
1,000
2,000
$/M
T L
t. O
lefi
ns
Capital Charges (Depreciation + Return)
Cash Cost of Production
Technology:
Feedstock:
Location:
Propylene:
Ethylene:
Feed Price:
Cracker
Ethane
Middle East
---
1000 KMTA
$62/MT
MTO
Methanol
Middle East
600 KMTA
400 KMTA
$350/MT
GTO
Natural Gas
Middle East
600 KMTA
400 KMTA
$1.25/MMBtu
Cracker
Naphtha
China
345 KMTA
655 KMTA
$956/MT
PDH
Propane
USGC
750 KMTA
---
$600/MT
PDH
Propane
China
750 KMTA
---
$800/MT
PDH
Propane
Middle East
750 KMTA
---
$600/MT
On-Purpose Light Olefin Technologies Are Competitive
MTO costs include the production of synthesis gas, methanol, and conversion to polymer-grade ethylene & propylene Cracker yields, utilities, and CAPEX from various sources
Cracker Feeds
Ethane ↑↑
E/P Mix ↑
LPG ↑
Light Naphtha
FBR Naphtha ↓↓
Gas Oil
Cracker Products
Ethylene ↑↑
Propylene ↓
C4 By-products ↓↓
Pygas ↓↓
Shift to low cost ethane puts pressure on
CCOP position of naphtha crackers
Steam Cracker
Cracker Feed Slate Changes
UOP 6054A-9
Total Petrochemicals Process
Demonstration Unit
~10,000 kg/day (10t/d) of MeOH feed
Fully integrated Advanced MTO Process Configuration
2009
INEOS Demo Unit (at the time Hydro)
1995
~1,000 kg/day (maximum) of MeOH feed
Multiple grades/sources of feed
Reactor and regenerator configuration
Development History of UOP Advanced MTO Process
~1 kg/day of MeOH feed
Multiple grades/sources of feed
Reactor and regenerator configuration
UOP Pilot Plant – Operation
1988
UOP 6054A-10
Commercialization Status
Owner Location Scope
LO Capacity
MTA
Expected
On-Stream
Wison (Nanjing) Clean
Energy Company, Ltd.
Nanjing, Jiangsu
MTO / OCP 295,000 2013
Jiutai Energy (Zhungeer)
Company, Ltd.
Ordos, Inner Mongolia
MTO 600,000 2014
Shandong Yangmei
Hengtong Chemicals
Company, Ltd.
Linyi, Shandong
MTO / OCP 295,000 2014
Jiangsu-Sailboat Lianyungang,
Jiangsu MTO / OCP 833,000 2015
The following projects in China have disclosed the selection of the UOP / HYDRO MTOTM Process:
Strong global interest – additional licenses expected in 2013
UOP 6054A-11
Top Ten Reserves, Coal and Gas
Location Gas Reserves
Russian Federation 21.4%
Iran 15.9%
Qatar 12.0%
Turkmenistan 11.7%
US 4.1%
Saudi Arabia 3.9%
United Arab Emirates 2.9%
Venezuela 2.7%
Nigeria 2.5%
Algeria 2.2%
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
Gas Reserves
Location Coal Reserves
US 27.6%
Russian Federation 18.2%
China 13.3%
Australia 8.9%
India 7.0%
Germany 4.7%
Ukraine 3.9%
Kazakhstan 3.9%
South Africa 3.5%
Other Europe & Eurasia 2.6%
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
Coal Reserves
UOP 6054A-13
MTO Summary
Strong demand growth for ethylene and propylene
MTO opens a new path to ethylene and propylene starting from cost advantaged gas and coal
– Lower cost of production compared to oil derived feed
– High yield of ethylene and propylene (> 89%)
– Flexible product ratio (P/E range 1.25 to 1.8)
– Byproduct C4 olefins available for B1, B2, and BD production
Single train capacity up to 1.8 million MTA of light olefin
Fully commercialized in 2013 by Wison Clean Energy – Nanjing, China
Three additional units operating by the end of 2015
UOP 6054A-14