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SARAWAK COAL

GASIFICATION PROCESS
FOR THE PRODUCTION OF
ETHYLENE
BY ENELYT CORP SDN. BHD.
7 TH JANUARY 2017
PROBLEM STATEMENT
Sub-bituminous
62% of total Sarawak coal (Sia and Abdullah, 2012)
High moisture content (27.1 wt% as received) (Sia and Abdullah, 2012)
Less efficient for power generation (Sia and Abdullah, 2012)
Ethylene
Production depends mainly on petroleum
Global petroleum resources decreases
Demand of ethylene increase
MARKET DEMAND
World consumption of ethylene grew at 4.5% per year (IHS, 2014)

Ethylene Capacity and Demand in Year 2015


900
800
700
600
500
400
300
200
100
0
Indonesia Philipines
Ethylene Capacity 550 320
Ethylene Demand 777.5 472.5
TARGETED ETHYLENE PRODUCTION RATE
To fulfil 5% of deficit in Indonesia and Philippines
Targeted annual revenue from ethylene production: 19.16 MM USD
Expected annual coal required: 293 KTpa (4.8 MM USD)

Subject Value
Total deficit in Indonesia and Philippines 379.9 Ktpa

Designed Plant Capacity 18.1 Ktpa


Design ethylene daily Production Rate 54 tonnes / day
PRODUCTION PROCESS OVERVIEW

Water Gas Methanol to


Coal Methanol
Shift Reaction Olefins (MTO)
Gasification Synthesis
(WGSR) Conversion
Process Control
Pressure Level

Temperature Flow
Controlled
Parameter
Plant layout and location
Total area: 7.69 hectare or equivalent to 0.0679 km2
Half of the area is reserved from expansion and only about 0.0206 km2 is used to
build the ethylene plant
Consists of 3 areas which are processing area, non processing and administrative
area
Plant is designed according to the process sequence to reduce the construction
due to shortest run of connecting pipe between equipment
Plant is located at Mukah due to the accessibility and availability of the raw
material since it takes only 21.2 km away from the coal mine to the plant location.
Mukah area is chosen to decrease the transportation cost of the raw material to
the plant
Process Safety
First Protection Layer: Process Design: Inherently Safer Chemical Reaction
Second Protection Layer: Basic process control and alarm
Third Protection Layer: Critical alarm
Forth Protection layer: Automatic Emergency Shutdown & Safety Interlock System
Fifth Protection Layer: Relief system
Sixth Protection Layer: Dikes, Material selection for unit operation
Seven Protection Layer: Emergency shutdown procedure
Environmental Management
Pollutant(s) Source Impact(s) Control Technology/ Method
Hydrogen Acid Gas Treating i. Acid rain Sulphur recovery using Wet Sulphuric Acid (WSA)
sulphide (H2S) Unit (AGRU) ii. Odour problem (EPA, 2016)
iii. Degradation of ambient
air quality

Ammonia Coal gasification, Air pollution Wet scrubber specifically packed tower where it
(NH3) Wet Sulphuric control efficiencies up to 99%.
Acid

Methane (CH4) Coal gasification Global warming Flaring method reduce methane emissions by 95-
99% depending on the flare efficiency.
Coal Dust Coal gasification Air pollution i. Use of enclosed loading and storage structures
ii. covering exposed stockpiles where possible.
ECONOMIC ANALYSIS
Value Unit
Total Investment Required 135.75 MM USD
Total Revenue 39.47 MM USD
Total Production Cost 8.51 MM USD
Gross Margin 34.68 MM USD
Gross Profit 30.96 MM USD
Simple Payback Period 4.38 Years
Discounted Payback Period 6.8 Years
Pre-tax ROI 22.8 %
Conclusion and Recommendation
Plant Location: Mukah
Ethylene Production Efficiency : 6.2 %
Gross Profit at full capacity: 30.96 MM USD
Recommendation : Production of ethylene should be extended in terms of extra
unit operation for
up scaling the capacity production of ethylene
avoid of disruption of process during maintenance
Question & Answer
THE END

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