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XtL – the Topsøe Approach

XtL – the Topsøe Approach. Presentation outline. General introduction Haldor Topsøe What is XtL? Focus of this presentation Building blocks Gasification Sour gas shift Gas purification including Acid Gas Removal (AGR) Downstream synthesis TIGAS Conclusions. Haldor Topsøe A/S.

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XtL – the Topsøe Approach

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  1. XtL – the Topsøe Approach

  2. Presentation outline • General introduction • Haldor Topsøe • What is XtL? • Focus of this presentation • Building blocks • Gasification • Sour gas shift • Gas purification including Acid Gas Removal (AGR) • Downstream synthesis • TIGAS • Conclusions

  3. Haldor Topsøe A/S Year of establishment: 1940; Incorporated: 1972 Ownership: Haldor Topsøe Holding A/S (100%) Subsidiaries: • Haldor Topsoe, Inc. • Haldor Topsøe International A/S, Denmark • Haldor Topsoe India Pvt. Ltd. India • ZAO Haldor Topsøe, Russia • Topsoe Fuel Cell A/S, Denmark Annual turnover (2009): • > 4.25 billion DKK (~572 MM EUR) • Number of employees (2009): ~2100

  4. Copenhagen Moscow Beijing Tokyo Edmonton Los Angeles Houston New Delhi Bahrain Buenos Aires Offices worldwide Headquarters City of Topsøe office Research Production Engineering Sale & Marketing

  5. Topsøe is dedicated to… • Research and development in heterogeneous catalysis • Production and sale of catalysts • Licensing of technology • Equipment supply • Engineering and construction of plants based on catalytic processes

  6. Business areas • Fertiliser industry • The heavy chemical and petrochemical industries • The refining industry • The environmental and power sector

  7. What is XtL? • Any feedstock (bio, coal, natural gas) for production of liquid products • Relatively well-known building blocks • Challenges within • Gasifier characteristics • Gas conditioning • Selection of Acid Gas Removal (AGR) • Integration with downstream synthesis

  8. Topsøe XtL technologies • Ammonia • Methanol • DME • Gasoline - TIGAS • Higher alcohols 34,000 bbl/d GTL plant 2100 TPD ammonia plant

  9. A simple block diagram

  10. Focus of this presentation • Describing the route from coal gas to gasoline via Topsøe’s TIGAS process • Many other end products exist, but time limits description of alternatives

  11. Building blocks • Gasification • Sour gas shift • Gas purification including Acid Gas Removal (AGR) • Downstream synthesis

  12. Coal gas conditioning Air Air Separation unit Sulfur Recovery (WSA) Sulphuric acid O2 CO2/ H2S Coal Gasification Sour WaterGas Shift Acid Gas Removal Final Gas Purification Synthesis gas H2O H2/CO = 1 (TIGAS/DME) H2/CO = 2 (MeOH/FT) H2/CO = 3 (SNG) H2/CO = ∞ (H2, NH3) CO2

  13. Gasification 900-1500°C 20-70 bar Hydrogen Ammonia Methanol DME Gasoline Diesel SNG CO H2 CO2 Coal Biomass Synthesis Gas

  14. Sour shift • Module (H2/CO) adjustment • CO + H2O ↔ CO2 + H2 • Extent of shift depending on gasifier and synthesis • H2S in raw feed gas • Low steam to dry gas ratio preferred • Low CO2 emission • Higher efficiency

  15. Gas purification Syngas from CO2-removal • Catalyst poison removal • Arsenic • Chlorine • H2S • COS • Organic sulphur • Etc. • ppb & ppm reactions Pure syngas << 10 ppb sulphur!

  16. TIGAS– from natural gas, coal, biomass or waste to clean transportation fuels

  17. TIGAS - History • Houston demonstration in mid 80-ies • Mobil’s MTG in New Zealand (1984-1995) • Crude oil price development caused a ‘cooled-down’ interest in synthetic gasoline • Renewed interest in MTG and TIGAS (~ 2005) • One plant in China started up (2009) based on ExxonMobil’s MTG • TIGAS granted DOE funding (25 million USD) in 2009 – bio feedstock

  18. Coal gas to gasoline CO2 Off-gas LOW RECYCLERATE ( R/M < 1) CO2 removal C3-C4 MeOH/DME synthesis Gasoline synthesis Synthesis gas Separation Gasoline Water REDUCED STEAM CONSUMPTION (LESS MODULE ADJUSTMENT) ”DRY” FEED (lowPH2O ) LESS PROCESS CONDENSATE IMPROVED CONVERSION

  19. Methanol to gasoline Mobil (MTG): SynGas  MeOH ; MeOH  DME  Gasoline MTG (Methanol To Gasoline) 15,000 bbl/d Industrial Plant, Motonui, NZ Topsøe (TIGAS): SynGas  MeOH/DME  Gasoline TIGAS (Topsøe Integrated GAsoline Synthesis) > 20,000 hrs. Pilot Plant Operation

  20. MTG Methanol To Gasoline TIGAS Topsøe Integrated Gasoline Synthesis Methanol synthesis Day tank (raw methanol) Synthesis gas Off-gas MeOH/DME synthesis C3-C4 Gasoline synthesis Separation MeOH↔DME Gasoline Water • Simple process layout • No methanol condensation / re-evaporation • Low recycle • Moderate pressure

  21. MeOH/DME synthesis (at low H2/CO) 2H2 + CO= MeOH 2MeOH = DME + H2O CO + H2O = CO2 + H2 3H2 + 3CO = CH3OCH3 + CO2

  22. H2/CO= 1 is the optimum for DME ▼ DME MeOH H2O (equilibrium) mol-% CO2 Adjust module by SHIFT inside loop -eliminates the need for upstream module adjustment High conversion makes CO2 removal inside synthesis loop feasible CO Recycle H2/CO ≈ 1 H2 ▼ H2/CO  H2/CO < 1

  23. TIGAS - Latest development -Wood to gasoline project, Chicago ~25 million USD funding by DOE O2

  24. Conclusions • TIGAS is a viable option for XtL • Feedstock flexibility • TIGAS is an interesting option for the utilisation of associated gas • Mix of legislative, economic and political factors as main drivers • Demonstration in Chicago • TIGAS is CCS ready

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