ﭘ ﻊﯾﺎﻨﺻ ﯽﻠﻣ ﺖﮐ NPC-RT · PDF file · 2017-01-16Lab and pilot scale catalyst production setups 4×100 gr catatest setup (parallel beds) 1500 gr catalyst pilot

Petrochemical Research & Technologyپژوهش و فناوري پتروشیمی

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NPCNPC--RTRT

Propylene via Methanol TechnologyPropylene via Methanol Technology

Methanol ZeoliteCatalyst

Propylene

December December 20162016

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Natural Gas Value ChainNatural Gas Value Chain

Methanol Demand & SupplyMethanol Demand & Supply

Methanol and Propylene Price Methanol and Propylene Price

Overview of NPCOverview of NPC--RT PVM TechnologyRT PVM Technology

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Natural Natural GasGas

MethanolMethanol PropylenePropylene

PVMPVM

PlantPlant

Methanol Methanol

PlantPlant

Propylene Propylene

ProcessingProcessing

PropylenePropyleneDerivativesDerivatives

PPPP

$$$$$ $$$$$$$$ $$$$$$$$$$

Acrylic AcidAcrylic Acid


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400 oC, 1 atm

Fluidized bed Reactor

SAPO-34 Catalyst

460 oC, 1.5 atm

Fixed bed Reactor

ZSM-5 Catalyst

UOP/Hydro MTOUOP/Hydro MTO LurgiLurgi/NPC/NPC--RT, PVM RT, PVM

Easier Operation (more Convenient)

Lower Fix.Cap. Inv.

More Propylene Production

Iran Olefin Cracking Plants for

Ethylene Production

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C3=

Gas SeparationReaction Compression Purification LPG

Gasoline

MeOH, DME

HC

Cold Water SystemSteam System Refr. System

Regeneration

Nitrogen, Plant Air, Instrument Air, Electrical Power, Fuel, LPG for startup, etc.

FlareDM WaterHP Steam HP Condensate

Water

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MeOH


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Process Water(for internal use)

Product Fractionation

Gasoline 49 kt/a

LPG 18 kt/a

Propylene 120 kt/a

optional Ethylene

Fuel Gas(for internal

use)

PVM Reactors(2 operating + 1 reg.)

DMEReactor

Olefin Recycle

Water Recycle

Methanol 457 kt/a

PropylenePropylene GasolineGasoline LPGLPG CC22

Products selectivityProducts selectivity(dry basis)(dry basis)

6161..7373%% 2424..55%% 99..2727%% 44..55%%

Reaction section

Quench and Compression section

Separation section

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Catalyst and Chemical Summary List

Filling or Consumption

Life-time

Catalysts and support Material

DME Catalyst (for 01-R-0111) 32700 kg 2 years

Inert balls for DME Reactor ( ½” / ¼”) 2000/2000 kg 2 years

PVM Catalyst (for 01-R-0151 AB/C) 124820 kg12000hrs

( 3 reactor)

Inert balls for DME Reactor (½” /¼” /½”) 32700 / 33000 / 65300 kg 2 years

Adsorbents and Support Material

Molecular sieve for drying of olefinicproduct streams (01-D-0491 A/B / 01-D-0492 A/B)

48000 kg 2 – 3 years

Molecular sieve for CO2-Adsorption( for 01-D-0532 A/B)

98560 kg ) 2 – 3 years

Adsorbent for DME (Guard bed)(for 01-D-0533 A/B)

20480 kg 2 – 3 years

Inert Balls for Adsorbers (1” / ¼ “ / ½”) 8000/4200/3920 kg 2-3 years

Ion Exchanger

Methanol polisher (for 01-D-0611) 9900kg Approx. 5 years

Chemicals

Caustic Soda (28%) Approx. 50 kg/h -

Gasoline Stabilizer (44% solution) 15 kg/h -

Corrosion Inhibitor (cooling water) 1.5 kg/h In 10000 m3/h

water circulation (norm. op)

Biocide in coolig water NaOCI solution(12 wt%cl)

17 kg/h


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Utility Utility UnitUnit DemandDemand

Electrical Power Consumption

KWh Electricity / t propylene 372

High Pressure Steam Consumption (39.5 barg)

tHP steam / t Propylene 4.81

Boiler Feed Water Consumption (HP)

t Boiler Feed Water / t Propylene 2.47

Cooling Water Consumption

M3 Circulating Water,T=10°C / t Propylene 887

Instrument Air Consumption

Nm3Instrument air/ tPropylene 50


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Pure Methanol SpecificationPure Methanol Specification

GradeGrade AAAA

Acetone and Aldehydes 0.003 percent by weight, maximum

Acetone 0.002 percent by weight, maximum

Acidity (as acetic acid) 0.003 percent by weight, maximum

Alkalinity (as ammonia) 0.003 percent by weight, maximum

AppearanceFree of opalescence, suspended matter and sediment (clear-colorless)

Carbonizable impurities, ColorNot darker than color standard No. 30 of ASTM D 1209, platinum cobalt scale

ColorNot darker than color standard No. 5 of ASTM D 1209, platinum cobalt scale

Distillation range at 760 mm Hg, maximum 1.0°C (and shall incl. 64.6°C ± 0.1°C)

Ethanol, percent by weight, maximum 0.001

Non-volatile content, g per 100 ml, maximum

0.0010

Odour Characteristics: non-residual

Permanganate fading time No discharge of color in 50 min.

Specific gravity at 20°, maximum 0.7928

Water, percent by weight, maximum 0.10

Methanol, percent by weight, minimum 99.85


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Propylene Propylene (Polymer Grade(Polymer Grade))

Propylene 99.60 percent by weight, minimum

Methane, ethane, ethylene, propane 0.40 percent by weight, maximum

Other paraffines, olefins, naphthenes, aromatics 200 ppm by weight, maximum

Other components (see below) 40 ppm by weight, maximum

Hydrogen 5 ppm by weight, maximum

Carbon Monoxide 0.03 ppm by weight, maximum

Carbon Dioxide 3 ppm by weight, maximum

Oxygen 5 ppm by weight, maximum

Water 5 ppm by weight, maximum

Acetylene 2 ppm by weight, maximum

Methyl acetylene 2 ppm by weight, maximum

Propadiene 1 ppm by weight, maximum

Butadienes 3 ppm by weight, maximum

Dimethylether (DME) 5 ppm by weight, maximum

Acetone 3 ppm by weight, maximum

Methanol 5 ppm by weight, maximum

Cyclopentadiene 0.05 ppm by weight, maximum


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LPG (Liquefied Petroleum Gas)

C2- Hydrocarbons 0.2 percent by weight, maximum

C3 Hydrocarbons 10 – 25 percent by weight

C4 Hydrocarbons 75 – 90 percent by weight

C5+ Hydrocarbons 2.0 percent by weight, maximum

Total Sulfur Components 5 ppm by weight, maximum

Gasoline

Density @ 15 °C 740 – 790 kg/m³

Equivalent Dry Vapour Pressure (DVPE, EN 13016-1) 0.45 – 0.70 bar

Research Octane Number (RON) 90 – 95

Composition

Paraffins and Naphthenes 45 – 65 percent by weight

Olefins 20 – 25 percent by weight

Aromatics 15 – 30 percent by weight

Benzene 1.0 percent by volume, maximum

Total Sulfur Components 5 ppm by weight, maximum


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High propylene yield (~High propylene yield (~6262%%, on C basis), on C basis)

Simple process (lowSimple process (low--cost propylene production)cost propylene production)

Simple fixedSimple fixed--bed adiabatic reactor systembed adiabatic reactor system

Simple wellSimple well--known purification sectionknown purification section

Moderate operating conditionModerate operating condition

Valuable byValuable by--products (LPG, Gasoline)products (LPG, Gasoline)

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Several microrecator setups with online analyzers

Lab and pilot scale catalyst production setups

4×100 gr catatest setup (parallel beds)

1500 gr catalyst pilot plant with main separation units

PVM Demo plant with complete comercial features (world‘s first demonstration PVM plant)

Complete analytical facilities

Expert research and engineering team

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PVM PVM MicrorecatorMicrorecator setup setup

(up to (up to 50 50 gr catalyst)gr catalyst)

Fixed bed reactor

Reaction in adiabatic conditions

Steam generation

Catalyst testing

Modification of reaction conditions

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PVM Pilot Plant (PVM Pilot Plant (11..5 5 kg)kg)

Six adiabatic PVM reactors with DME

pre-reactors

compressor (23 bar)

continuous C4/C5 recycle

DME removal column

In-depth & long-term investigation of

recycle effects

Data acquisition for process design

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Six stage adiabatic PVM reactor

DME adiabatic reactor

Capacity:

Propylene 1 ton/day

LPG 165 kg/day

Gasoline 295 kg/day

Complete separation to achieve

pure propylene (Polymer grade)

Complete recycle system to

increase the propylene production

Compatibility with commercial unit

DEMO Unit

DEMO Plant unitDEMO Plant unit

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Lab. Scales

4×100 gr 1.5 kg 180 kgCommercial

Scales

1.5 kg/hr MeOH 150 kg/hr MeOHUp to (3×) 29000 kg/hr MeOH

0.3 kg/hr MeOH ×5 ×100 ×470×120

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More than 24000 hour-on-stream pilot plant run

More than 7000 hour-on-stream DEMO plant run

Development of a new catalyst with great performance

Preparing PVM basic design package (120 kta)

Kimya garan sabzevar co. and Fanavaran petrochemical co.

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Modification in reactor control loops in demo plant and

modify of basic engineering industrial documents

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Modification in reactor control loops in demo plant and

modify of basic engineering industrial documents

Replace the main reactor preheater, steam super heater and

recycle streams preheater by gas furnace,(Redesign

industrial furnace and the recycle streams preheater is

removed.

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Modification in reactor control loops in demo plant and modify of basic engineering industrial documents

Replace the main reactor preheater, steam super heater and recycle streams preheater by gas furnace,(Redesign industrial furnace and the recycle streams preheater is removed.

Modification the catalyst regeneration recipe and decreasing the nitrogen consumption over than 60%.

Modification in lines, isometrics and also type of insulation to decrease heat lost .

The operating manual is modified for good operation practice. i.e. separation unit.

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NPCNPC--RT PVM catalystRT PVM catalyst

Reaction: T= 480˚C, WHSV=0.9h-1

P= 1 atm , MeOH/ H2O = 1/1 wt%

NPCNPC--RT PVM RT PVM

Catalyst Pilot TestCatalyst Pilot Test

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TitleFilling

dateAssignee

Preparation of solid catalyst for DME synthesis in fixed bed reactor 2007 NPC

Methanol Conversion to Propylene by Catalyst base on Aluminosilicate 2008 NPC

Conversion of methanol to propylene on modified mordenite catalyst 2008 NPC

Preparation of nanocatalyst H-ZSM-5 for methanol to propylene process 2009 NPC

MFI Catalyst Preparation in atmospheric Pressure for Methanol Conversion to Light Olefines 2009 NPC

Preparation of Aluminosilicate catalyst for DME synthesis 2010 NPC

Propylene Production via Methanol and DME Process 2011 NPC

Aluminosilicate Catalyst for Preparation Propylene via Methanol 2013 NPC

Increasing Propylene Production via Methanol by Recycle Stream 2015 NPC

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www.npc-rt.ir PVM Demo UnitPVM Demo Unit

Thank you for Thank you for

your kind attentionyour kind attention

Q / A ?Q / A ?

Documents

ﭘ ﻊﯾﺎﻨﺻ ﯽﻠﻣ ﺖﮐ NPC-RT · PDF file · 2017-01-16Lab and pilot scale catalyst production setups 4×100 gr catatest setup (parallel beds) 1500 gr catalyst pilot