UNIVERSITY OF INDONESIA

METHANOL
UNIVERSITY OF INDONESIA

Methanol
„ Introduction
„ Production
„ Uses
„ The Market
„ Capital Investment and Production Cost
„ Technology
„ Advantages
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Introduction
„ The first member of the homologous
series of aliphatic alcohols, with the
formula CH3OH.
„ It is produced commercially from a
mixture of carbon monoxide (CO) and
hydrogen (H2).
UNIVERSITY OF INDONESIA

Introduction
„ Methanol is a
„ highly flammable liquid,
„ boiling point 64.7°C (149°F),
„ is miscible with water and most organic
liquids,
„ highly poisonous substance, and
„ sublethal amounts can cause permanent
blindness.
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Introduction
„ BASF pada tahun 1923 mengenalkan
proses sintesis methanol dari CO dan H2
yang merupakan aplikasi kedua
terbesar mengenai katalis dan teknologi
tekanan tinggi dalam industri kimia.
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Introduction
„ Proses tersebut merupakan penelitian lanjut
dari hidrogenasi CO,
„ CO dan H dapat bereaksi pada tekanan 100 – 300
bar untuk menghasilkan produk yang beragam
dari methanol sampai alkohol yang lebih tinggi,
tergantung pada katalis yang digunakan dan
kondisi operasi
„ juga komponen-komponen yang terhidrogenasi
dan hidrokarbon.
„ Penelitian ini dilakukan oleh Fischer-Tropsch
pada sekitar awal 1930 an.
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Introduction
„ Seperti proses amonia, sintesis
methanol juga tergantung pada
pengembangan katalis yang digunakan.
„ Katalis methanol harus selektif dan aktif.
„ Salah satunya, yang mengandung zinc
oxide dan chromia, tahan sampai sekitar
40 tahun.
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Introduction
„Tahun 1996 ICI memperkenalkan katalis
cooper/zinc oxide/alumina dengan
aktivitas yang lebih besar.
„Dengan katalis ini methanol dapat
bereaksi pada temperatur yang lebih
rendah (kurang dari 300oC) dan tekanan
yang lebih rendah (50-100 bar).
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Introduction
„Hasilnya, jika dibandingkan dengan
proses sebelumnya yang memerlukan
tekanan tinggi.
„ proses menjadi lebih efisien,
„ lebih murah dan
„ lebih rendah biaya modal yang akan
diinvestasikan.
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Introduction
„ Methanol is one of the major industrial
organic chemicals.
„ Its major derivatives are
„ methyl tertiary butyl ether (MTBE),
„ formaldehyde, and
„ acetic acid.
UNIVERSITY OF INDONESIA

Introduction
„ Other derivatives and uses include
„ chloromethanes,
„ methyl methacrylate,
„ methylamines,
„ dimethyl terephthalate,
„ solvents (such as glycol methyl ethers),
„ antifreeze, and
„ fuels.
UNIVERSITY OF INDONESIA

Introduction
„ Methanol is produced naturally in the
anaerobic metabolism of many varieties
of bacteria.
„ As a result, there is a small fraction of
methanol vapor in the atmosphere.
„ Over the course of several days,
atmospheric methanol is oxidized by
oxygen with the help of sunlight to carbon
dioxide and water.
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Introduction
„ Methanol burns in air forming carbon
dioxide and water:
„ 2 CH3OH + 3 O2 → 2 CO2 + 4 H2O
„ A methanol flame is almost colorless.
„ Care should be exercised around burning
methanol to avoid burning oneself on the
almost invisible fire.
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Introduction
„ Methanol is often called wood alcohol
because it was once produced chiefly as
a byproduct of the destructive
distillation of wood.
„ It is now produced synthetically by a
multi-step process.
UNIVERSITY OF INDONESIA

Introduction
„ In short,
„ natural gas and steam are reformed in a
furnace to produce hydrogen and carbon
monoxide; then,
„ hydrogen and carbon monoxide gases
react under pressure in the presence of a
catalyst.
„ The reforming step is endothermic and the
synthesis step is exothermic.
UNIVERSITY OF INDONESIA

Production
„ Today, synthesis gas is most commonly
produced from the methane component
in natural gas rather than from coal.
„ Three processes are commercially
practiced.
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Production
„ At moderate pressures of 1 to 2 MPa
(10–20 atm) and high temperatures
(around 850 °C), methane reacts with
steam on a nickel catalyst to produce
syngas according to the chemical
equation:

CH4 + H2O → CO + 3 H2
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Production
„ This reaction, commonly called steam-
methane reforming or SMR, is
endothermic and the heat transfer
limitations place limits on the size of the
catalytic reactors used.
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Production
„ Methane can also undergo partial oxidation
with molecular oxygen to produce syngas, as
the following equation shows:
2 CH4 + O2 → 2 CO + 4 H2
„ this reaction is exothermic and the heat given off
can be used in-situ to drive the steam-methane
reforming reaction.
„ When the two processes are combined, it is
referred to as autothermal reforming.
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Production
„ The ratio of CO and H2 can be adjusted
by using the water-gas shift reaction,
CO + H2O → CO2 + H2,
„ to provide the appropriate stoichiometry
for methanol synthesis.
„ The carbon monoxide and hydrogen
then react on a second catalyst to
produce methanol.
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Production
„ Today, the most widely used catalyst is
a mixture of copper, zinc oxide, and
alumina first used by ICI in 1966.
„ At 5–10 MPa (50–100 atm) and 250 °C,
it can catalyze the production of
methanol from carbon monoxide and
hydrogen with high selectivity
CO + 2 H2 → CH3OH
UNIVERSITY OF INDONESIA

Production
„ It is worth noting that
„ the production of synthesis gas from
methane produces 3 moles of hydrogen for
every mole of carbon monoxide,
„ while the methanol synthesis consumes
only 2 moles of hydrogen for every mole of
carbon monoxide.
UNIVERSITY OF INDONESIA

Production
„ One way of dealing with the excess
hydrogen is to inject carbon dioxide into
the methanol synthesis reactor, where
it, too, reacts to form methanol
according to the chemical equation
CO2 + 3 H2 → CH3OH + H2O
UNIVERSITY OF INDONESIA

Production
„ Although natural gas is the most economical
and widely used feedstock for methanol
production, other feedstocks can be used.
„ Where natural gas is unavailable, light
petroleum products can be used in its place.
„ The South African firm Sasol produces
methanol using synthesis gas from coal.
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Production
„ Methanol dapat dihasilkan dalam skala
industri secara besar besaran, melalui
konversi katalitik dari gas sintesis.
„ proses tersebut digolongkan menurut
tekanan yang digunakan :
„ 1. Proses tekanan tinggi : 25-30 Mpa (250 –
300 atm)
„ 2. Proses tekanan sedang : 10-25 Mpa (100 –
250 atm)
„ 3. Proses tekanan rendah : 5-10 Mpa (50 –
100 atm)
UNIVERSITY OF INDONESIA

Production
„ Pada sat ini proses pembuatan
methanol pada tekanan sedang dan
tekanan rendah saja yang digunakan.
„ Tetapi sejalan dengan adanya
konservasi energi maka proses pada
tekanan rendah memberikan alternatif
yang paling baik dibandingkan dengan
tekanan sedang.
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Production
„ Keuntungan paling utama dari proses
tekanan rendah adalah :
„ Biaya produksi dan investasi rendah
„ Peningkatan operasional dapat diandalkan
„ Fleksibilitas lebih besar dalam pemilihan
ukuran pabrik
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Production
„ Proses pruduksi methanol dalam
industri terdiri atas :
„ Produksi gas sintesis
„ Sintesis Methanol
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Production
„ Produksi methanol dimulai dengan
produksi gas sintesis yang terdiri dari
hidrogen dan karbonmonoksida.
„ Teknologi yang sering digunakan dalam
proses gas sintesi antara lain :
„ Steam Reforming
„ Oksidasi Parsial
„ Gasifikasi Batubara
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Production
„ Selanjutnya hasil dari syn-gas menjadi
feedstock pada methanol plant, dimana
reaksi sintesis methanol dalah
„ CO + 2H2 Æ CH3OH ∆H298 = -21.684
kkal/mol
UNIVERSITY OF INDONESIA

Production
„ Reaksi pembentukan methanol ini
memiliki konversi yang rendah.
„ Hal ini diakibatkan karena reaksi mudah
untuk mencapai kesetimbangan.
UNIVERSITY OF INDONESIA

Production
„ Untuk mendapatkan konversi yang lebih
tinggi biasanya reaksi dilakukan pada tekanan
yang cukup tinggi dan temperatur yang
rendah.
„ Perkembangan teknologi reaksi sintesis
methanol pada tekanan tinggi mulai
ditinggalkan dengan ditemukannya katalis
yang lebih reaktif dan jenis reaktor yang
sesuai.
UNIVERSITY OF INDONESIA

Production

Recycle P-5

Flash colom

Heat Exchanger Crude Methanol

Gas Sintesis

Reactor Sintesi Methanol

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Production
„ Jenis katalis yang digunakan:
„ Katalis pada tekanan tinggi
„ Katalis pada tekanan rendah
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Production
„ Katalis pada tekanan tinggi
„ Digunakan alkali/ZnO-CuO/Cr2O3 dapat
beroperasi pada tekanan 120-300 bar dan
temperatur 300-425oC.
„ Katalis ini tahan terhadap sulfur dan klorin
yang terdapat dalam syn-gas.
UNIVERSITY OF INDONESIA

Production
„ Katalis pada tekanan tinggi
„ Produksi metanol dengan zinc-oksida-krom
oksida pada proses bertekanan tinggi tidak
lagi bersifat ekonomis.
„ Generasi baru katalis mengandung copper
dengan keaktifan dan selektifitas yang
lebih tinggi.
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Production
„ Katalis pada tekanan rendah
„ Digunakan alkali/CuO-ZnO/Al2O3 dapat
beroperasi pada tekanan 50-100 bar dan
temperatur 275-310oC (120-300 bar dan
suhu 300-425oC, utk tek.tinggi).
„ Penggunaan katalis ini membutuhkan
kondisi syn-gas yang murni dari sulfur dan
klorin (H2S < 0.1 ppm).
UNIVERSITY OF INDONESIA

Production
„ Katalis pada tekanan rendah
„ Karena keaktifan katalis, sintesis metanol
dapat berlangsung pada suhu 220-230oC
dan 5 Mpa.
„ Selektifitas yang tinggi memberikan
kemurnian metanol lebih besar dari 99.5%.
„ Pembentukan produk sampingan seperti
DME, alkohol tinggi, senyawa karbonil dan
metana dapat dihilangkan.
UNIVERSITY OF INDONESIA

Production
„ Produksi methanol secara komersial
dapat dilakukan melalui berbagai
macam proses.
„ Proses yang paling banyak digunakan di
industri methanol adalah ICI.
UNIVERSITY OF INDONESIA

Production
„ Proses proses yang lain diantaranya
adalah :
„ Proses Lurgi,
„ Proses Kellog,
„ Proses Nissui Topsoe dan
„ proses Mitsubishi Gas Company (MGC).
UNIVERSITY OF INDONESIA

Production
„ Jalur sintesis methanol dari proses
proses tersebut sama, yang
membedakan hanya
„ jenis katalis,
„ reaktor yang dipergunakan dan
„ kondisi operasi reaksi.
UNIVERSITY OF INDONESIA

Production

Perbandingan penggunaan proses sintesis methanol didunia

Kellogs
3% MGC
8%
ICI
61%

Lurgi
27%
Other
1%
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Production
„ Dari diagram
„ sebagian besar (61%) proses
menggunakan teknologi ICI pada tekanan
rendah,
„ diikuti dengan proses tekanan rendah
„ yaitu teknologi Lurgi (27%) dan
„ Kellog (3%).
UNIVERSITY OF INDONESIA

Production
„ Proses tekanan sedang sudah jarang
digunakan hanya sebagian kecil sebesar
8% menggunakan teknologi MGC.
 UNIVERSITY OF INDONESIA

Proses Tekanan Rendah ICI

„Campuran gas sintesis umpan segar ditekan dari 50-

100 atm melalui sebuah kompresssor dan diumpan
kedalam reaktor berpendingin (quench type converter)
yang beroperasi pada 270oC.
 UNIVERSITY OF INDONESIA

Proses Tekanan Rendah ICI

Quench converter berupa single bed yang

„
mengandung katalis pendukung yang bersifat
inert.
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Proses Tekanan Rendah ICI

„Aliran produk kemudian didinginkan dan methanol akan

terkondensasi.
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Proses Tekanan Rendah ICI

„Aliran gas purge direcycle ke reformer untuk mengubah

methanol yang terakumulasi dalam gas sintesis.
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Proses Tekanan Rendah ICI

„ Crude methanol akan dipurifikasi dengan cara distilasi.

 UNIVERSITY OF INDONESIA

Proses Tekanan Rendah ICI

„Karena dianggap kurang menguntungkan ICI

mengganti jenis reaktor yang digunakan dari quench
reactor menjadi tube berpendingin yang pada prinsipnya
sama dengan yang digunakan oleh Lurgi.
UNIVERSITY OF INDONESIA

Proses Tekanan Rendah ICI

„ Proses ICI bertekanan rendah ada yang
menggunakan reaktor packed bed
adiabatic tersusun seri.
„ Suhu masukan ke bed ditentukan oleh
suhu dingin dari syn-gas yang
diinjeksikan.
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Proses Tekanan Rendah ICI

„ Tidak ada penukar panas diantara bed
dan hal ini membuat reaktor menjadi
lebih sederhana daripada desain proses
lainnya.
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Proses Tekanan Rendah ICI

UNIVERSITY OF INDONESIA

Proses Tekanan Rendah Lurgi

„ Dalam proses yang ditawarkan oleh
Lurgi untuk sintesis methanol,
„ reaktor sintesis dioperasikan pada rentang
suhu dari 230 – 270oC dan dengan tekanan
operasi 50-100 bar.
„ Perancangan reactor berbeda dengan
ICI.
UNIVERSITY OF INDONESIA

Proses Tekanan Rendah Lurgi

„ Dalam teknologi pertama ICI, katalis
ditumpuk menjadi sebuah unggun serta
dimasukan pada berbagai lokasi sepanjang
unggun dengan tujuan agar diperoleh
distribusi suhu yang merata.
„ Sedangkan Lurgi menggunakan reaktor shell
and tube , tube diisi dengan katalis dan
panas reaksi diserap oleh air yang bersirkulasi
secara alami pada bagian shell.
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Proses Tekanan Rendah Lurgi

„ Pada dasarnya reaktor juga memainkan
peranan kedua yaitu sebagai
pembangkit uap (steam regenarator)
bertekanan 40-50 bar.
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Proses Tekanan Rendah Lurgi

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Proses Tekanan Rendah Lurgi

Lurgi menggunakan reaktor quasi-isothermal dengan

katalis di dalam tube yang didinginkan dengan sirkulasi
boiling water.
 UNIVERSITY OF INDONESIA

Proses Tekanan Rendah Lurgi

Proses Lurgi akan menghasilkan methanol yang murni dengan

proses sintesis methanol dan proses pemurniannya
UNIVERSITY OF INDONESIA

Proses Tekanan Rendah Kellog

„ M.W. Kellog Co. memperkenalkan reaksi
sintesis yang sangat berbeda, tetapi pada
dasarnya merupakan reaktor tipe adiabatik.
„ Reaktor berbentuk bulat dan didalamnya
berisi unggun katalis tunggal.
„ Sintesis gas mengalir melalui beberapa bed
reaktor yang tersusun aksial berseri.
„ Kebalikan dari proses ICI, panas reaksi yang
dihasilkan dikontrol dengan pendingin
intermediat (intermediate coolers).
UNIVERSITY OF INDONESIA

Proses Tekanan Rendah Kellog

„ Proses ini menggunakan katalis tembaga dan
beroperasi pada rentang suhu 200-280oC
serta tekanan 100-150 atm.
„ Suhu didalam unggun katalis dikendalikan
melalui penggunaan sebuah reaktor
berpendingin (quench type converter) dengan
menyerap panas reaksi dalam intermediate
stage boiler.
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Proses Tekanan Sedang Nissui-Topsoe

„ Skema reaktor dari proses Halder Topsoe dari

Denmark didesain oleh Nihin Suiso Kogyo of
Japan.
„ Reaktor bertipe adiabatis dengan aliran radial
berjumlah tiga masing-masing memiliki satu
unggun radial dan penukar panas internal.
„ Tiap reaktor mengandung satu satu unggun
katalis.
„ Tekanan operasi dari proses ini diatas 150
bar dan suhu 200-310oC.
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Proses Tekanan Sedang Nissui-Topsoe

„ Produk pertama perlu didinginkan sebelum

reaktor kedua, hasil pendinginan berupa uap
(steam) bertekanan rendah.
„ Katalis yang digunakan berupa Cu-Zn-Cr yang
aktif pada 230-280oC dan 100-200 atm.
„ Sintesis gas mengalir secara radial melalui
katalis bed.
UNIVERSITY OF INDONESIA

Proses Tekanan Sedang Mitsubishi

Gas Company

„ Perusahaan Jepang MGC pada awalnya

menggunakan proses dengan tekanan sedang
yang beroperasi pada 150 atm kemudian
dikembangkan untuk tekanan kurang dari
100 atm.
„ Saat ini MGC menggunakan rentang tekanan
50-200 atm dan suhu 235-270oC.
„ Hingga saat ini telah dioperasikan tiga buah,
dua diantaranya berlokasi di Jepang dan
sisanya di Arab.
UNIVERSITY OF INDONESIA

Pemlihan Teknologi
„ Dalam proses sintesis metanol, pemilihan
teknologi pertama dilakukan pada proses
produksi gas sintesis menghasilkam hidrogen
dan karbon-monoksida.
„ Untuk menghasilkan gas sintesis, bahan baku
berasal dari gas alam.
„ Steam reforming akan menghasilkan hidrogen
lebih banyak daripada oksidasi parsial yang
menghasilkan lebih banyak karbonmonoksida.
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Pemlihan Teknologi
„ Hidrogen dalam jumlah banyak
dibutuhkan dalam sintesis metanol
sebab diperlukan rasio H2 : CO2 sebesar
3:1 dan rasio H2 : CO sebesar 2:1.
„ Oleh karena itu, proses steam
reforming dipergunakan untuk
memproduksi gas sintesis.
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Pemlihan Teknologi
„ Dalam pemilihan teknologi sintesis
metanol, parameter yang digunakan
adalah:
„ keaktifan katalis,
„ jenis reaktor, dan
„ tekanan operasi yang dipergunakan.
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Pemlihan Teknologi
„ Untuk sintesis metanol,
„ keaktifan dan selektifitas katalis
memegang peranan penting dalam
efisiensi proses,
„ sehingga proses tidak berlangsung pada
tekanan tinggi atau sedang.
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Pemlihan Teknologi
„ Katalis yang digunakan pada tekanan
rendah
„ CuO-ZnO/Al2O3 memiliki keaktifan dan
selektivitas yang lebih tinggi
„ dibandingkan dengan katalis pada tekanan
tinggi ZnO-CuO/Cr2O3.
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Pemlihan Teknologi
„ Selektifitas yang tinggi akan
menghasilkan metanol dengan
kemurnian yang tinggi dan produk
samping yang terjadi dapat dikurangi.
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Pemlihan Teknologi
„ Katalis CuO-ZnO yang digunakan pada
tekanan rendah mempunyai kelebihan
dibadingkan katalis lain, yaitu:
„ Mempunyai struktur yang sangat baik
(well-definedstructural) yaitu susunan
elektron yang menunjang keaktifan katalis
dan selektifitas yang tinggi pada metanol.
„ Mempunyai bentuk (morfologis) yang baik.
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Pemlihan Teknologi
„ Dari parameter katalis, pemilihan
teknologi sintesis metanol dilakukan
pada tekanan rendah, yaitu antara
„ teknologi ICI,
„ Lurgi dan
„ Kellog.
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Pemlihan Teknologi
„ Pemilihan jenis reaktor akan mempengaruhi
biaya investasi untuk mendesain reaktor
tersebut.
„ Pertimbangan jenis reaktor:
„ Desain reaktor yang sederhana sehingga tidak
membutuhkan kontrol suhu yang rumit.
„ Jenis pendingin yang digunakan akan menentukan
sistem pengontrolan suhu dalam sistem ketika
terjadi kenaikan suhu yang besar.
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Pemlihan Teknologi
• Pada reaktor quench converter (reaktor
berpendingin) pada ICI,
• umpan yang masuk langsung bertemu
dengan unggun katalis
• sehingga menyebabkan kerusakan pada
katalis dan
• menyebabkan reaksi terhenti.
UNIVERSITY OF INDONESIA

Pemlihan Teknologi
• Pada reaktor shell and tube pada Lurgi,
• pendingin menggunakan boiling water
yang mengalir di dalam shell
• dapat menyerap panas yang dihasilkan
reaksi di dalam tube yang berisi katalis
• sehingga reakor dapat mempertahankan
suhunya.
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Pemlihan Teknologi
• Pada teknologi Kellog digunakan
pendingin intermediate coolers yang
akan memperbesar investasi desain
reaktor.
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Pemlihan Teknologi
• Dari pertimbangan diatas, dapat ditarik
kesimpulan bahwa
• teknologi Lurgi tidak membutuhkan desain
reaktor yang rumit
• dimana kontrol suhu dapat dilakukan
dengan mengalirkan boiling water pada
shell.
UNIVERSITY OF INDONESIA

Pemlihan Teknologi
• Keunggulan teknologi Lurgi lainnya yaitu
• dihasilkannya steam bertekanan sedang yang
memberikan solusi bagi penghematan energi.
• Steam yang dihasilkan digunakan untuk
pemanasan umpan reaktor dan sebagai reboiler
dalam proses distilasi metanol.
• Perolehan steam ini memperkecil beban pendidih
(boiler) untuk memproduksi steam.
UNIVERSITY OF INDONESIA

Uses
„ Methanol is used on a limited basis to fuel
internal combustion engines, mainly by virtue
of the fact that it is not nearly as flammable
as gasoline.
„ Methanol blends are the fuel of choice in
open wheel racing circuits like Champcars, as
well as in radio controlled model airplanes
(required in the "glow-plug" engines that
primarily power them), cars and trucks.
UNIVERSITY OF INDONESIA

Uses
„ Dirt circle track racecars such as Sprint cars, Late
Models, and Modifieds use methanol to fuel their
engines.
„ Drag racers and mud racers also use methanol as
their primary fuel source.
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Uses
„ Methanol is required with a supercharged engine in a
Top Alcohol Dragster and, until the end of the 2005
season, all vehicles in the Indianapolis 500 had to
run methanol.
„ Mud racers have mixed methanol with gasoline and
nitrous oxide to produce more power than gasoline
and nitrous oxide alone.
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Uses
„ Methanol is a traditional ingredient in
methylated spirit or denatured alcohol.
„ During World War II, methanol was
used as a fuel in several Nazi Germany
military rocket designs, under name M-
Stoff, and in a mixture as C-Stoff.
UNIVERSITY OF INDONESIA

Uses
„ One of the drawbacks of methanol as a
fuel is its corrosivity to some metals,
including aluminium.
„ Methanol, although a weak acid, attacks
the oxide coating that normally protects
the aluminium from corrosion:
6 CH3OH + Al2O3 → 2 Al(OCH3)3 + 3 H2O
UNIVERSITY OF INDONESIA

Uses
„ The resulting methoxide salts are soluble in
methanol, resulting in clean aluminium
surface, which is readily oxidised by some
dissolved oxygen.
„ Also the methanol can act as a oxidiser:
6 CH3OH + 4 Al → 2 Al2(OCH3)3 + 3 H2
„ So the corrosion continues until the metal is
eaten away.
UNIVERSITY OF INDONESIA

Uses
„ When produced from wood or other organic
materials, the resulting organic methanol
(bioalcohol) has been suggested as
renewable alternative to petroleum-based
hydrocarbons.
„ However, one cannot use BA100 (100%
bioalcohol) in modern petroleum cars without
modification.
UNIVERSITY OF INDONESIA

Uses
„ Methanol is also used as a solvent and as an
antifreeze in pipelines.
„ The largest use of methanol by far, however,
is in making other chemicals.
„ About 40% of methanol is converted to
formaldehyde, and from there into products
as diverse as plastics, plywood, paints,
explosives, and permanent press textiles.
UNIVERSITY OF INDONESIA

Uses
„ In some wastewater treatment plants,
„ a small amount of methanol is added to
wastewater
„ to provide a food source of carbon for the
denitrification bacteria,
„ which convert nitrates to nitrogen.
UNIVERSITY OF INDONESIA

Uses
„ In the 1990s, large amounts of
methanol were used in the United
States to produce the gasoline additive
methyl tert-butyl ether (MTBE).
„ The 1990 Clean Air Act required certain
major cities to use MTBE in their
gasoline to reduce photochemical smog.
UNIVERSITY OF INDONESIA

Uses
„ However, by the late 1990s, it was found that
MTBE had leaked out of gasoline storage
tanks and into the groundwater in sufficient
amounts to affect the taste of municipal
drinking water in many areas.
UNIVERSITY OF INDONESIA

Uses
„ Moreover, MTBE was found to be a
carcinogen in animal studies.
„ In the resulting backlash, several states
banned the use of MTBE, and its future
production remains uncertain.
UNIVERSITY OF INDONESIA

Uses
„ Direct-methanol fuel cells are unique in their
low temperature, atmospheric pressure
operation, allowing them to be miniaturized
to an unprecedented degree.
„ This, combined with the relatively easy and
safe storage and handling of methanol may
open the possibility of fuel cell-powered
consumer electronics.
UNIVERSITY OF INDONESIA

Uses
„ Other chemical derivatives of methanol
include dimethyl ether, which has replaced
chlorofluorocarbons as an aerosol spray
propellant, and acetic acid.
„ There are now plans to use the chemical in
eco-friendly fuel cells for laptop computers,
the cells will break down methanol via an
electrochemical process.
UNIVERSITY OF INDONESIA

The Market
„ Methanol is
„ an important multipurpose base chemical,
„ a simple molecule which can be recovered
from many resources, predominantly
natural gas.
UNIVERSITY OF INDONESIA

The Market
„ By tradition, methanol is principally
used to produce
„ formaldehyde,
„ methyl tertiary butyl ether (MTBE) and
„ acetic acid
UNIVERSITY OF INDONESIA
UNIVERSITY OF INDONESIA

The Market
„ To a lesser extend, methanol is used as a
general solvent and as fuel and for producing
other chemicals.
„ Global demand for methanol amounts to
about 32 million tons per year, with growth
rates at or near GDP.
„ The demand corresponds to the capacity of
about 35 million tons which is available
worldwide.
UNIVERSITY OF INDONESIA

The Market
„ Asia is becoming the main growth driver
for the demand for methanol and its
derivatives.
„ Average growth rates are expected to
be for:
„ Methanol: 3.8 %/a based on about 10
million tons in 2003,
„ Acetic acid: 4.8 %/a,
„ Formaldehyde: 4.4 %/a.
UNIVERSITY OF INDONESIA

The Market
„ Reducing the cost of production by installing
“Mega” production facilities fed with low-
cost natural gas is opening up new
promising methanol outlets. such as for the
production of:
„ Ethylene and/or propylene, methanol to
propylene, e. g. by applying Lurgi MTP®
technology.
„ Dimethyl ether as a substitute for diesel fuel
„ Liquid fuels
UNIVERSITY OF INDONESIA

The Market
„ Reducing the cost of production by installing
“Mega” production facilities fed with low-
cost natural gas is opening up new
promising methanol outlets. such as for the
production of:
„ Hydrogen or
„ Feed material for power generating systems or
„ Use in integrated schemes combined with an
ammonia/urea complex, for example.
UNIVERSITY OF INDONESIA

The Market
„ Methanol consumption for fuel cells to be
used in automobiles, for power generation
and portable equipment is bound to increase
in the near future.
„ Proved reserves of natural gas in the Middle
East exceed 71 trillion cubic meters
equivalent to a 41 % share of the total
world gas reserves with Iran and Qatar
having the largest potential reserves i. e.
about 30 %.
UNIVERSITY OF INDONESIA

The Market
„ Middle East and some regions of South
America and Africa will raise their methanol
production significantly because of:
„ low feedstock cost and
„ low capital cost thanks to the economies of scale
provided by “Mega” plants.
„ According to CMAI some 15 million tons of
capacity, nearly 50 % of world demand, will
be added within a period of five years.
UNIVERSITY OF INDONESIA

The Market
„ Considering the plentiful natural gas
reserves and the evermore stringent
environmental regulations to curb the
wide-spread flaring-off, for example,
„ methanol production is a real alternative
for converting natural gas or associated
gas to a commodity with high value
added.
UNIVERSITY OF INDONESIA

The Market
„ Monetizing the abundant natural gas in stranded
gas regions, where the main end-user markets are
geographically remote from the source, is highly
attractive.
„ Methanol is a versatile natural gas product with value
added.
„ Methanol has excellent characteristics being easily
transportable in comparison with gas, for example.
„ Methanol production cost in the range of US$ 50 per ton
opens up a completely new field for further down-stream
derivatives like propylene or other new applications.
UNIVERSITY OF INDONESIA Capital Investment
and Production
Cost

„ Starting from the same feedstock price for

natural gas,
„ the production cost of methanol based on Lurgi
MegaMethanol® technology is by far lower,
„ typically in the range of 25 %,
„ compared to the cost based on combined
reforming and conventional steam reforming,
respectively,
„ at half the capacity of the MegaMethanol® plant.
„ The differences clearly show the economy of
scale effect for the single train plant.
UNIVERSITY OF INDONESIA
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost
„ The double capacity of the
MegaMethanol® plant only requires
additional capital expenditure of about
50 % of the plant investment cost
based on the reforming technologies
mentioned above.
„ These figures demonstrate the
superiority of Lurgi MegaMethanol®
technology.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost

„ Since 1995
„ the capacities of methanol plants have
been increased from 2,000 t/d to 5,000 t/d
in 2003
„ and will rise further to 10,000 t/d in the
near future.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost

„ The companies operating “Mega” plants

are experiencing a tremendous
reduction in production cost ex gate
from about US$ 110/t to 50/t and
ultimately less than 40/t, as shown in
the diagram.
UNIVERSITY OF INDONESIA
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost
„ The conversion of natural gas to methanol
and downstream petrochemicals is highly
economic on a natural gas price level below
US$ 1/million BTU.
„ Some regions such as the Middle East,
locations in South America or Africa allow for
natural gas prices of between US$ 0.2 and
0.7/million BTU, compared to an oil price of
between US$ 12 and 14/barrel.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost

„ This price scenario of gas-based

methanol production cost and
equivalent oil cost will certainly have an
impact on the downstream products
and process routes based on oil.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost

„ Lurgi offers all technologies for

methanol production including synthesis
gas production based on:
„ conventional steam reforming,
„ combined reforming,
„ autothermal reforming.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost
„ Accordingly, Lurgi accepts single line
responsibility for small plants or for
MegaMethanol® facilities on a LSTK basis if
specified.
„ In view of this know how and the experience
gained with the design, supply and
commissioning of numerous plants, Lurgi is
able to offer the optimum concept combined
with project development and financing for
any feedstock, capacity and other conditions
specified by the client.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost
„ Aiming at reducing the synthesis gas
and methanol production cost further,
even below an oil equivalent of US$
10/barrel, a high pressure
demonstration plant is being operated.
„ The test results supplement the design
basis for extremely large synthesis gas
capacities.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost

„ The development of a two-stage reactor

system for methanol synthesis is
another example and proof that Lurgi
research and development activities
continuously focus on lowering capital
and operating cost for large scale
production facilities.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost

„ Lurgi is in the unique position to license

the MegaSyn® and MegaMethanol®
technologies in order to increase the
benefit for the client.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost

„ Lurgi also offers complete routes or

integrated schemes of proprietary
technologies such as
„ the conversion of natural gas to propylene
via methanol or
„ integrated schemes combining various
products like ammonia and methanol, for
example.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost
„ The advantages are quite obvious:
„ All process streams and compounds are
useful, i. e. no generation of by-products
and therefore no environmental impact.
„ Feed and utility consumption can be
optimized due to plant and heat
integration.
„ “Mega” systems will reduce the production
cost additionally.
UNIVERSITY OF INDONESIA Capital
Investment and
Production Cost
„ Contracts for 16 methanol plants including 3
Mega-Methanol® facilities have been awarded
to Lurgi since 1994.
„ Lurgi is the only company which boasts 3
MegaMethanol® reference plants.
„ Lurgi has a 60 to 70 % market share of the
methanol capacities globally installed and
leads the market as number 1.
 UNIVERSITY OF INDONESIA

The compressed, desulfurized - optionally

prereformed -feedstock, predominantly natural
gas, is reformed to synthesis gas using oxygen
as the reforming agent.
 UNIVERSITY OF INDONESIA

The optimum synthesis gas composition is

achieved by recycling hydrogen that can be
separated from the purge gas stream of the
methanol synthesis loop.
 UNIVERSITY OF INDONESIA

The synthesis gas is compressed and

enters the methanol synthesis loop.
 UNIVERSITY OF INDONESIA

The innovative Lurgi MegaMethanol® technology

is mainly based on the two-stage reactor system
consisting of a gas-cooled and a water-cooled
reactor.
 UNIVERSITY OF INDONESIA

This system results in outstanding technical and

economic features due to the extremely favorable
temperature profiles over the catalyst beds.
 UNIVERSITY OF INDONESIA

Methanol distillation provides the specified

product quality which may range from fuel grade
methanol to highly pure methanol.
UNIVERSITY OF INDONESIA

Advantages
UNIVERSITY OF INDONESIA

Tugas
„ Jelaskan mengapa pada reaksi
pembuatan metanol yang eksotermis
lebih disukai pada tekanan tinggi dan
suhu rendah
„ CO + 2H2 Æ CH3OH ∆H298 = -21.684
kkal/mol
„ Berapa harga pasar metanol/ton