methaforming production of gasoline from naphtha and ... · total npv, $million 1 300 1 080 + 220....

Methaforming®

Production of gasoline from naphtha and methanol at 1/3 the cost

NGTS customer presentation for ERTC 8Oct17 metric 1

Methaforming: One Step Conversion of Naphtha with Methanol into Gasoline


• Simple one step process

• No precious metals in the catalyst

• High yield of high-octane gasoline blendstock

• Capital and operating costs like a hydrotreater

Methaforming

unit

10 atm

380 C Stab

ilize

r

Methanol or FCC

dry gas (25%)

Naphtha (35-180°C)

H2, H2S

С1-С4

Gasoline blendstock 92 RON

10-30 ppm sulfur

<1.3% benzene

Water

Methaformer: Process Flow and Yields

• Process flow like a hydrotreater except: • Methanol instead of hydrogen

• No recycle compressor

• Yields like a CCR reformer except: • Most benzene converted to toluene

• Half of methanol becomes water


Methaforming vs Reforming: Simpler and Cheaper

Catalytic reforming and isomerization Methaforming

• Most common technology Reduce costs to 1/3

• Feed hydrotreater required

• Several process units


*for sulfur <1000ppm in naphtha

Catalytic Reforming & Isomerization

Hydrotreater*

Reforming

Isomerization

85 – 180 C

35 – 85 C

Naphtha

High octane

gasoline

Benzene reduction

Methaformer vs Traditional Reforming Suite (HDS+CCR+isom)

Methaforming is better than combined process with CCR reformer $ 18 million/yr profit margin advantage $106 million lower capex

Net present value @12% is $220 million better What % of the worldwide reformers are semi-regen?


New 860 K tpa unit (20 K BPD)

Methaforming Alternative ∆ Methaforming -

Alternative

Yields, $million/yr 206 202 + 4

OpEx, $million/yr 7 21 - 14

CapEx, $million 50 156 - 106

Total NPV, $million 1 300 1 080 + 220

Slido Poll

What % of the worldwide reformers are semi-regen?


Upgrade Semi-regen Reformer to Methaformer

Methaforming is better than a semi-regen reformer:

$ 64 million /yr profit margin advantage

$ 20 million capex for conversion

Net present value @12% is $410 million better


Existing 860 K tpa unit (20 K BPD)

Methaforming Alternative ∆ Methaforming -

Alternative



CapEx, $million 20 - - 20

Total NPV, $million 1 330 920 + 410

Methaforming: Flexibility for Many Applications


1. FCC dry gas olefins can replace MeOH

Increases margin by $100/t of naphtha

2. Process light virgin naphtha

Upgrade by $170/t with MeOH and $330/t with C2=

380 k tpa unit is $12 million/yr better than isomerization

3. Upgrade raffinate from aromatics extraction and C6-rich

stream bypassed to gasoline by $200/t

4. Process natural gasoline, FCC & coker naphthas

Remove 90% of sulfur and increase octane

Methaforming Light Virgin Naphtha with C2= vs Isomerization with Recycle

Methaforming is better than isomerization: $ 12 million/yr profit margin advantage $ 20 million lower capex

Net present value @12% is $110 million better


New 380 K tpa unit (10 K bpd )

Methaforming Alternative

(isom) ∆ Methaforming-

Alternative



CapEx, $million 30 50 - 20

Total NPV, $million 860 750 + 110

Grassroots Methaformer to Process Raffinate and FCC dry gas

Methaforming gives a $27 million/yr profit margin advantage

upgrading 88 K tpa raffinate

Net present value of the project @12% is $160 million


New 88 K tpa unit (2 K BPD)

Methaforming

Alternative (direct

blending)

∆ Methaforming- Alternative

Yields, $million/yr 89 60 +29

OpEx, $million/yr 2 0 +2

CapEx, $million/yr 17 0 +17

Total NPV, $million 160 n/a +160


Core Team: Chemical Science, Engineering and Business Building

Denis Pchelintsev, PhD – CEO Co-founder of several technology startups. Author of oil spill clean-up technology

Joseph Lischiner, PhD (25 patents) – Technologist Co-inventor, author of gas-to-methanol-to-gasoline and oligomerization plants.

Stephen Sims – President of NGTS-North America Energy Advisor at Houston Technology Center and World Bank.

Pres of General Methanol. Career with major oil: Exxon, Citgo, ConocoPhillips.

Alexei Beltyukov – Chairman of the Board Entrepreneur, several profitable exits. Started Brunswick Rail (now >$2bn);

managed a portfolio of industrial assets, IRR>42% over 9 years. Previously at

McKinsey.

Co-inventor of the catalyst. Successful tech projects with Bayer, Eni.

Olga Malova, PhD (30 patents) – Head of Catalysis

Pilot Plant

Micro plant

Reactor volume – 10 ml, 0.19 l/d

Total test time - 5+ years

Laboratory plant

Reactor volume – 0.1 L, 1.9 l/d

Total test hours > 2000

Typical hours per test – 6

Pilot plant

Reactor volume – 2 L, 38 l/d

Start up – Feb 2015

Confirm yields, catalyst run & life


Laboratory plant

Pilot plant

• Completed 2 Preliminary Technology Packages

• Completed Freedom to Operate analysis

• Guided by US patent attorney

• 4 patents in PCT process national phase

• 2 recent PCT patents

• Catalyst protected by trade secrets


Current Status: Intellectual Property

Current Status

6 k tpa (150 bpd) commercial plant start-up in Oct

• Initial feed: mix of low-octane naphtha

• Located east of Moscow


Ongoing Refiner Discussions

• Owner of the site for the 6 k tpa commercial plant: 120 k tpa Methaformer at their other site

• Major Russian refiner: 470 k tpa (11 k bpd) Methaformer in long-range plan for 2020

• Conducted 50 feed-specific pilot plant tests totaling 500 hrs

• Feed: raffinate, benzene precursor naphtha, light FCC naphtha & FCC dry gas

• Major Russian refiner: 21 k tpa (500 bpd) Methaformer

• Conducted 3 sets of pilot plant tests

• Feed: light naphtha, full range naphtha

• Idle process unit in China: Convert to 150 k tpa (3.5 k bpd) Methaformer for full range naphtha


Convert Idle Unit: Low Capex Way to Benefit from Methaforming

Convert an idle existing hydrotreater or reformer to Methaformer for < $ 5 million

Do you have an idle unit ?


Methaforming: Summary

• Upgrade low octane naphtha by $130-330/t

• Produce gasoline from naphtha and methanol at 1/3 the cost with comparable yields

• We can predict results for your naphtha


Denis Pchelintsev E. Europe, Middle Asia [email protected] +7 (903) 527-2200

Stephen Sims Americas, W. Europe

[email protected]

+1 (832) 640-5921

methaforming production of gasoline from naphtha and ... · total npv, $million 1 300 1 080 + 220....

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