NOVEL ROUTES IN CO2 UTILIZATION: A SUSTAINABLE APPROACH · • Broaden the utilization of CO 2 as a feedstock for chemicals and polymers production, which includes methanol, acrylic

NOVEL ROUTES IN CO2 UTILIZATION: A SUSTAINABLE APPROACH

Dr. Khalid Albahily

SABIC CRD at KAUST

2

Classification: General Business Use

SABIC AT-A-GLANCE

*Forbes 2018 **Billion

1976

Company established

34,000

Employeesaround the world

50

Countries of operations

3rd

Largest globalchemical company*

120th

Largest publiccompany in the world*

4

Corebusinesses

64

World-classplants worldwide

11,534

Global patentfilings

≈ 150

New productseach year

US$ B**

Total assets

86US$ B**

Net income

4.9US$ B**

Annual revenue

39.9

SABIC COPYRIGHT 2018

3


OUR BUSINESSES

* Supplied under SABIC brand through Hadeed, a fully-owned SABIC Affiliate

Polyolefins, Polycarbonates and Blends, PVC , Polyester and Polystyrene

Synthetic Rubbers

Specialty Polymers & Polymer Additives

Glycols, Olefins, Oxygenates and Aromatics

Chemical Intermediates & Industrial Gases

Long SteelRebarWire RodRebar in Coil

Flat SteelHot Rolled CoilsCold Rolled CoilsGalvanized Rolled CoilsPre-painted Rolled Coils

• NitrogenPrilled UreaGranular UreaAmmonia

• PhosphateDAP and Dark DAPMAP

• Specialty NPKTGU

• Engineered Thermoplastics

• Specialty Compounds• Sheet & Film• Composites• Additive Manufacturing• Fluids• Thermosets and

Additives

BUSINESS PORTFOLIO

METALS*AGRI-NUTRIENTSPETROCHEMICALS SPECIALTIES


4


OUR SUSTAINABILITY STRATEGY:MAIN FOCUS AREAS AND ACHIEVEMENTS IN 2017

* Assured by KPMG

- We are currently refreshing our materiality priorities and have linked SDG’s to the current sustainability priorities

Sustainability Report 2017

Learn more about SABIC’s sustainability facts and figures.

► Access Report here

Innovation and Sustainability Solutions

82Total Sustainability Solutions

Human Capital Development

+24,900Training program participants

Supply Chain

93%solids 100%liquids

Safety and Quality Assessment System (SQAS)

EHSS and Product Safety

14%Decrease in Total Recordable Incident Rate

Resource and Energy Efficiency*

9.3%GHG Emissions Intensity

35.2%Material-loss Intensity

8.8%Water Intensity

7.6%Energy Intensity

43%Reduction in Flaring Emissions

3.5 million MT

Total Current CO2

Utilization


https://www.sabic.com/assets/en/Images/SABIC-Sustainability-Report-ENGLISH-2017_tcm1010-12631.pdf

5


SABIC T&I Global NetworkSABIC GLOBAL T&I NETWORK


Geleen

Bangalore

Houston

Riyadh

Jubail

Shanghai

Cartagena

BoZ

Moka

Thuwal

Research CentersApplication CentersSABIC Plastic Application Center at KSU, RiyadhSABIC Corporate Research & Development Center at KAUST

Five key geographies with innovation hubs in Middle East, USA, Europe, South East Asia, North East Asia

6


SABIC GOALS FOR CO2 EMISSION REDUCTION

In KSA, SABIC plants vent a total volume of 5.2 Million Tons/year of “High Concentration” CO2 as waste streams from all MEGs, ammonia and steel plants. From this total vented CO2, around 3.4 Million tons/year will be utilized by 2025.

TECHNICAL OPTIONS FOR CONTROLLING CO2 EMISSIONS:

• Energy efficiency

• CO2 purification

• CO2 utilization

CURRENT FOCUS

• Broaden the utilization of CO2 as a feedstock for chemicals and polymers production, which includes methanol, acrylic acid, MEG, aromatics and special grades of polymers


7


CO2 TO CHEMICALS: OVERVIEW OF PATENTS ALONG VARIOUS DIMENSIONS

• The top three assignees are, Sabic, BASF and Covestro .

• Other assignees active in this field include, Sinopec, Shell, Casale, LG etc.

• Sabic, Casale, Bayer, Ekokap found active and make entry to the top assignee list in this

quarter; whereas Chinese Academy of science found as less active player in this quarter.

Key Contributing Assignees Products obtained

22

13 12

86 6 6 5 5 4 4

0

5

10

15

20

25

No

. of

Pat

ents

Assignee

48

42 42

31 30 28

22 2118 17

106 6 5

2 2 2 10

10

20

30

40

50

60

No

of

Pat

ents

Products


8

HP METHANOL CATALYST DEVELOPMENT

9


TECHNOLOGY DEVELOPMENTCO2 UTILIZATION IN METHANOL PRODUCTION

SABIC is developing a catalytic technologyto reduce the poisoning effect of CO2 on the methanol catalyst, thereby increasing the potential use of CO2 as feedstock in the process

17% less CH4 intake

3 times higher CO2

captivated per ton of Methanol


10


DRIVE AND VALUE PROPOSITION

TECHNOLOGY GAP/ BUSINESS DRIVE

• Development of high performance catalyst for methanol production

• Enhancement of catalyst stability under CO2-rich syngas feed (up to 14%)

Cu

Zn Zr

M Al

LaMActivity Stability Selectivit

y

Assembling

Preparation method

High dispersion of active metals (Cu) to increase activity

Enhance the interaction of metals and support to increase selectivity of methanol

APPROACH


11


CO2 INJECTION INTO H2/CO

Feed gas: 55% H2/11% CO/x% CO2/ Ar Reaction conditions: 240 oC, 40 bar, and 5000 h-1


• Feed gas: 55% H2/11% CO/x% CO2/ Ar• Reaction conditions: 220 oC, 40 bar, and 5000 h-1

700600500400300

0.7

0.6

0.5

0.4

0.3

0.2

0.1

TOS [h]

ST

Y (

Kg

-Me

OH

/L-c

at.

h)

SABIC

Reference

300280260240220200180

0.9

0.8

0.7

0.6

0.5

0.4

TOS [h]

STY

(Kg

-MeO

H/L

-cat

.h)

8% 9% 10 to 18%

12

PRODUCTION OF HYDROGEN FROM

S, CO2 / H2O

13


CO2 REDUCTION BY ELEMENTAL SULPHUR

SABIC developed a process for hydrogen and CO production from Sulphur, water and CO2. Catalyst development for ‘S2+CO2’ chemistry was demonstrated in a labscale reactor. The performance and stability of the catalyst were demonstrated up to 250 hours. Several catalyst found to be able to split CO2 to produce CO in presence of elemental sulfur


• Both Sulphur and CO2 are inexpensive raw materials and easily available

• Energy intensity = 25 MMBTU/ton H2

BENEFITS

14


PROJECT HIGHLIGHTS

• Syngas is an important feedstock for Petrochemicals

• Fossil sources are depleting around the world• Explore alternative feedstock's for future need• Non-hydrocarbon based technology

Reduce CO2 using ‘S’ to produce CO and SO2.

Produce H2 / syngas by water gas shift reaction.

Utilize SO2 in H2SO4 production.

S

CO2

CO/H2

H2O


OBJECTIVES

TECHNOLOGY GAP/DRIVE

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PROCESS SCHEME

S + CO2

(>1000 °C)SO2 + CO

H2 + CO2

xH2 + yCO +zCO2

CO

SO3

SO2

0.5 O2 H2O H2SO4

(Sulfuric Acid)

H2

- CO2

H2O

H2O

xH2 + yCO(Synthesis Gas)

- CO2

APPLICATIONS

• Fertilizers

• Chemicals

• Performance Chemicals

• Metals


16


PROCESS FLOWCHART

Sulfur Melter Reactor QuenchCO2

Scrubber

SO3

Reactor

Water-Gas Shift Reactor

CO2

Sulfur

CO2 recycle

SO2 removal(Absorption Column)

Compressor

Sulfuric Acid Process

CO-rich gasCO2+H2 CO/COS Separation

Oxidation

PSAH2

Feed heater

purge

CO

350 oC

400 oC

500 oC

1100 oC

30 oC

COS

CO2 SO2


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Two main criteria have been selected to drive

formulation of potential catalyst:

• Thermal stability of material (either oxide and

sulfide)

MOx + S2(g) → MSy + SO2

MSy+ CO2 → MOx + CO + SO2

• An material that exhibit ability to switch easily

from oxide to sulfide and vice-versa

Catalyst formulation

TECHNICAL APPROACH

Reaction Pathways

ReactionsΔH

kcal/mol

4CO2 + 1.325 S2 => 3.35CO + 0.65COS + 2SO2 82.2

3.35CO + 3.35H2O => 3.35CO2 +3.35H2 -29.9

0.65COS + 0.975 O2 => 0.65CO2 + 0.65SO2 -85.4

2.65SO2 + 1.325O2 => 2.65SO3 -62.2

Net -95.3

Overall1.34S2 + 2.28O2 + 3.356H2O => 3.35H2 + 2.64SO3

or

OverallS2 + 1.7O2 + 2.5H2O => 2.5H2 + 2SO3


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CONVERSION VS. SELECTIVITY

0 10 20 3060

65

70

75

80

85

90

95

100

CO

sel

ectiv

ity (%

)

CO2 conversion (%)

Total control over CO and COS selectivity by controlling the CO2 conversion

Catalyst maintained CO2 conversion however, selectivity varied over 10 days due to transformation in catalyst composition, which could be overcome to better catalyst design with higher temperature and mechanical stability


19


WE HAVE A CLEAR AMBITION

To be successful in CO2 emission reduction and achieve our targets

We believe that innovation is our roadmap to success and leadership

Bring state of the art material solutions


THANK YOU

Documents

NOVEL ROUTES IN CO2 UTILIZATION: A SUSTAINABLE APPROACH · • Broaden the utilization of CO 2 as a feedstock for chemicals and polymers production, which includes methanol, acrylic