At
IndianOil Institute of Petroleum Management,
Gurgaon, India on March 6, 2008
Outline
Introduction
Technology
Innovations and
Feedstocks
Coal & Natural Gas
Aromatics
Olefins
Summary
Vora International Process (VIP) Corp
Petrochemicals
There are three basic raw materials
that make up major part of
Petrochemical industry
1.
2. Aromatics
Benzene, Toluene and Xylenes (BTX) and
its derivatives
3. Olefins
Ethylene, Propylene and its derivatives
Outline
Introduction
Technology
Innovations and
Feedstocks
Coal & Natural Gas
Aromatics
Olefins
Summary
Petrochemicals:Methane Derivatives
GTL Fuel
FT
Coal
Coal Gasification
Fuel
DME
Steam
Electricity
LNG
Natural
Gas
Synthesis
Gas
Ethylene
Propylene
MTO
Reforming,
Partial Ox.
MTG
Methanol
Fuel
Hydrogen
Ammonia
Urea
Fuel
Liquid
Fuel
Formaldehyde
Acetic acid
MTBE & Other
Chemicals
LNG
Natural
Natural Gas
Gas
Coal
Gasification
Steam
Reforming,
Partial Ox
Synthesis
Gas
Methanol
Fuel
MTO
Ethylene, Propylene
Linear
paraffins
Wax
FisherTropsch
GTL
Synthesis
Gas
Liquid Fuel
DME
Fuel
UOP 4628I-34
1990s
2000-2008
Venezuela
Russia-Siberia
Norway
Chile
Saudi Arabia
Iran
Iran
Malaysia
Qatar,
Qatar
Ukraine
Saudi Arabia
Oman
Libya
Trinidad
China-Coal
New Zealand
Libya
Indonesia
Chile
Indonesia
Malaysia
Methanol-Summary
Outline
Introduction
Technology
Innovations and
Feedstocks
Coal & Natural Gas
Aromatics
Olefins
Summary
Petrochemicals:BTX Derivatives
Benzene
2007: 38 mm MTA
Toluene
2007: 36 mm MTA
Xylene
2007: 33 mm MTA
EB-Styrene
Toluene diisocynate
pX-PTA-Polyester
Cumene-PhenolPhenolic resins
Motor Fuel-Octane
Enhancement
oX-Phathalic anhydride
LAB
Solvent
mX-isophthalic acid
Cyclohexane
Conversion to Bz-pX
Cyclohexnol
Cyclohexanone
Caprolectum-Nylon
Adipicacid-Nylon
oX/mX Conversion to
pX
Aromatics (BTX)
Naphtha reforming
Pyrolysis of Naphtha
1400
p-Xylene, KMTA
1200
Parex
Parex Units
Units On-Stream
On-Stream
Parex
Parex Units
Units Under
Under Construction
Construction
1000
800
600
400
200
0
1970
1975
1980
1985
1990
1995
2000
2005
2010
Source: UOP
Benzene- Paraxylene
Summary
Sulfolane continues to be preferred
solvent for aromatics extraction
Adsorptive separation is preferred
technology for paraxylene
No radical shift foreseen in use of raw
material or technology, Naphtha
remains dominant raw material
n-paraffins
n- paraffins
Adsorptive
separation
linear olefins + H2
LAB
Catalytic
dehydrogenation
HF Acid or
Solid acid Catalysis
Capacity, KMTA
3,500
3,000
2,500
2,000
1,500
1,000
500
0
1965
1970
1975
1980
1985
1990
1995
2000
Year
Source: UOP
2005
Outline
Introduction
Technology
Innovations and
Feedstocks
Coal & Natural Gas
Aromatics
Olefins
Summary
Petrochemicals:Olefins Derivatives
Ethylene
2007: 120 mm MTA
Propylene
2007: 70 mm MTA
Butadiene
2007: 10 mm MTA
Polymers and copolymers
with styrene and ACN
Polyethylene
Polypropylene
EB-Styrene
Acrylonitrile
Cumene-Phenol
nButene-MEK
EDC, VCM
Propylene Oxide
Isobutene-TBA
Vinyl acetate
Epichlorohydrin,
Glycerol
Diisobutene, triisobutene
& polyisobutene
Ethyl alcohol
acetaldehyde
Nonylphenol
Tetramer
Isobutene-MTBE
ABS
Technology
Thermal Pyrolysis
Ethylene
USA
79
65
35
91
75
25
WE
06
70
30
79
4
96
Japan
91
8
92
79
10
90
91
2
98
MTA
7
11
18
2012
35
(Steam Crackers)
Others
Others
2%
2%
Ethane
Ethane
29%
29%
Naphtha
Naphtha
52%
52%
180
160
53%
140
47%
120
2012
2010
2008
2006
100
2014
Gas
Gas Oil
Oil
5%
5%
Non-ethane
Non-ethane
Ethane
Ethane
Current
Current Base
Base
Demand
Demand
million MTA
2006 Supply
Butane
Butane Propane
Propane
4%
8%
4%
8%
Production
Production from
from ethane
ethane crackers
crackers will
will increase
increase
Non
-ethane sources
Non-ethane
sources of
of ethylene
ethylene are
are needed
needed to
to
meet
meet the
the demand
demand
UOP 4585F-04
Incremental Supply
100
43%
90
14%
80
42%
70
2014
2012
60
2010
Steam
Crackers
62%
2008
FCC
31%
Other
2%
2006
PDH
3%
Metath. OC
0.3%
2%
On-purpose propylene
FCC Refineries
Steam Crackers
Current Base
Demand
110
million MTA
Substantially
Substantiallymore
morepropylene
propylenewill
willcome
comefrom
from
on-purpose
on-purpose propylene
technologies
propylene
technologies
PDH = Propane Dehydrogenation, Metath. = Metathesis,
OC = Olefin Cracking, MTO = Methanol-to-Olefins
On-purpose propylene = PDH + Metath. + OC + MTO
UOP 4585F-05
600
Installed Capacity
Size of New Units
4.0
500
400
3.0
300
2.0
200
1.0
100
0.0
0
1990
1994
1998 2002
2006
Capacity, MM MTA
5.0
2010
UOP 4824D-06
-H2O
+H2O
CH3-O-CH3
-H2O
Isoparaffins
Aromatics
C6+ olefins
C2 - C5 olefins
Chang, Silvestri, and Smith,
US 3894103 and 3928483
3.8
H
O
(Al-O)3Si
H
O
Al(O-P)3
Small Pore
Weak Acid Sites
(Si/Al-O)3Si
Al(O-Si)3
Medium Pore
Strong Acid Sites
Source: UOP
% Yield
40
SAPO-34
ZSM-5
30
20
10
0
C2=
C3=
C4=
C5+
C1-C5
Paraffins
Coke +
COx
Source: UOP
1400
Installed Capacity
Size of New Units
4.0
1200
1000
3.0
800
2.0
600
400
1.0
Capacity, MM MTA
5.0
200
0
0.0
1996
2000
2004
2008
2012
UOP 4824D-06
100
90
80
70
60
50
40
30
20
10
0
Syngas to MeOH
Syngas to C2+ alcohol
Syngas to FT Liquid
Year
20
06
20
04
20
02
20
00
19
98
19
96
19
94
19
92
19
90
19
88
19
86
19
84
MTO + MTG
19
82
19
80
# US Patents
Syngas Conversion
Ethylene-Propylene
Summary
Value of Products, $
10
8
6
4
2
0
Natural
Gas
LNG
Gasoline
Methanol
Olefins
Polymers
Worldscale
economic capacity
Gas needed
mm SCMD
30 Years
Consumption
billion SCM
LNG
5 MM MTA
LNG
22.2
222
GTL
100,000 BPD
F-T Liquids
26.8
268
GTP
1,000,000 MTA
PE + PP
7.5
75
LNG and GTL are suitable for only the largest gas fields
GTP can be implemented on many more gas fields
100%
90%
Large Fields
=13%
80%
50 - 500 Tcf
5-50 Tcf
1 - 5 Tcf
0.5 - 1 Tcf
0.25 - 0.5 Tcf
0.1 - 0.25 Tcf
0.01 - 0.1 Tcf
< 0.01 Tcf
70%
60%
50%
40%
30%
20%
10%
0%
Number of Fields
Source: Oil & Gas Journal
Kcal/M3
@ 1 atm.
25C
H2
gas
Methane
gas
DME
gas
Methanol
liquid
Naphtha
liquid
2400
8600
14200
3.97x106
8.2x106
300
C o st, $ /M T m etha no l
269
250
200
150
121
100
Shipping
15% ROC
Depreciation
Fixed costs
Consumables
Nat. gas
136
85
50
0
Industrial
location
$5.00
1500
Stranded
gas location
$0.75
3000
Mega-scale
methanol
Mega-scale
Methanol
$0.50
7500
$2.00
7500
2005-2007 Closure
Japan 100%
Norway 100%
Beaumont, USA
850
500
Korea 100%
Italy 100%
Spain 100%
Edmonton, Canada
France 100%
USA
Pemex, Mexico
Part of it
Methanor, Netherland
Canada Part of it
800
180
1000
700
5150
Methanol Plant
MTO Plant
Polyolefin Plant
Polyolefin Markets
100
90
80
70
60
50
40
30
20
10
0
Syngas to MeOH
Syngas to C2+ alcohol
Syngas to FT Liquid
Year
20
06
20
04
20
02
20
00
19
98
19
96
19
94
19
92
19
90
19
88
19
86
19
84
MTO + MTG
19
82
19
80
# US Patents
Syngas Conversion
Overall Summary
Overall Summary
Acknowledgement
My thanks to UOP and UOP
colleagues for providing me
updates on UOP processes