1、Lurgi MegaMethanol Technology Development and Operation鲁奇百万吨级甲醇合成技术发展和运营优势BLE l Presentation for 5thMethanol & Emerging Derivatives Conference 2014第 1 頁(共 28 頁)Agenda议程Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanolLurgi Methanol Technology 鲁奇甲醇技术
2、Advantages of LurgisMethanol Plant Design鲁奇甲醇装置设计优势第 2 頁(共 28 頁)Agenda议程Lurgis Methanol Technology鲁奇甲醇技术 Lurgis Methanol Technology Milestones鲁奇甲醇技术的发展历程 Lurgis MegaMethanol Loop Design鲁奇甲醇技术工艺介绍Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol Wate
3、r Cooled Methanol Reactor甲醇水冷反应器 Gas Cooled Methanol Reactor甲醇气冷反应器 Combined Methanol Converter (CMC) Synthesis两步法甲醇联合转化技术第 3 頁(共 28 頁)Lurgis Methanol Technology Milestones鲁奇甲醇技术的发展历程Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol第 4 頁(共 28 頁)LURG
4、Is Methanol Technology Milestones鲁奇甲醇技术的发展历程 1969 First LP-Methanol Catalyst Test 1969年鲁奇首次进行低压甲醇技术催化剂工业试验 1970 Cooperation with Sd-Chemie for Catalyst Manufacturer 1970年与催化剂 生 产商 Sd-Chemie南方化学 合 作Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol产商
5、作 1970 Operation of a 100 Tubes-Reactor Demonstration Unit 1970年 100根列管的示范性甲醇合成装置投入使用 1972 First 3 LP-Methanol Plants in Operation 1972年三套低压甲醇合成装置首次投入使用第 5 頁(共 28 頁)LURGIs Methanol Technology Milestones鲁奇甲醇技术的发展历程 1997 MegaMethanolTMConcept Published 1997年鲁奇率先提出 MegaMethanolTM百万吨大甲醇概念 2014 eleven co
6、ntracts awarded for MegaMethanolTMplants 2014年 赢得十 套百万吨大甲醇的合同Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol年 一 套百万吨大甲醇的合同 2012 6 MegaMethanolTMplants in operation 2012年 6套百万吨大甲醇装置已投入生产第 6 頁(共 28 頁)LURGIs Methanol Technology Milestones鲁奇甲醇技术的发展历程N
7、atural Gas 17 Plants using Conventional Steam Reforming蒸汽转化 13 Plants using Combined Reforming 两段炉联合转化Natural Gas/Naphtha 4 Plants with a total capacity:0.60MMTPY 4套装置，总生产能力60万吨/年Coal Gas 11 Plants with a total capacity:12.3MMTPY 11套装置，总生产能力1230万吨/年Heavy Residue 7 Plants with a total capacity:2.00MM
8、TPY 7套装置，总生产能力200万吨/年Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol 1 Plant using AutothermalReforming 自热转化 Total capacity of 31 Plants:21.40MMTPY 总生产能力2140万吨/年Total : 53 Plants with a total capacity of 36.30 MMTPY 共 53套装置，总生产能力为 3630万吨 /年第 7 頁(共
9、 28 頁)LURGIs Methanol Technology Milestones鲁奇甲醇技术的发展历程 TITAN, Trinidad 2500 mtpd 1997 YPF, Argentina 1200 mtpd 1999 ATLAS, Trinidad 5000 mtpd 2000 NPC, 4th Methanol, Iran 5000 mtpd 2000 METHANEX, Chile 4 2400 mtpd 2002 QAFAC, Qatar 6750 mtpd 2004 CNOOC, Hainan, China中海油 海南 2000 mtpd 2004 NPC, 5th Me
10、thanol, Iran 5000 mtpd 2004 Methanol Holdco Ltd KSA 5400 mtpd 2004Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol., KSA Shchekinoazot, Russia 1200 mtpd 2005 Yangzhou Yulin, China 兖州 中国 2300 mtpd 2005 PETRONAS, Malaysia 5000 mtpd 2005 DTPOWER, Chin
11、a 大唐 5000 mtpd 2005 SNCG, China (MTP) 神华宁煤 MTP 5000 mtpd 2006 SNCG, China (DME) 神华宁煤 DME 2000 mtpd 2006 Itera, Russia 1800 mtpd 2006 Qinghai 青海盐湖工业集团有限公司 3000 mtpd 2011 Sinopec Zhongtianhechuang 中天合创 2 x 5400 mtpd 2011 SNCG CTL 神华宁煤 煤制油 3000 mtpd 2012 Zhong An 中安联合煤化 5400 mtpd 2014第 8 頁(共 28 頁)Lurgi
12、s MegaMethanol Loop Design鲁奇大甲醇合成工艺技术Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol第 9 頁(共 28 頁)Two step Combined Methanol Converter(CMC) Synthesis Loop两步法甲醇联合转化合成技术Synthesis GasCompressor合成气压缩机RecycleCompressor循环气压缩机MP-Steam中压蒸汽Steam Drum汽包Gas C
13、ooledReactor气冷反应器MP-Steam中压蒸汽Air Liquide, world leader in gases for industry, health and the environment10PurgeGasCrudeMethanolSynthesis Boiler FeedWater合成气 驰放气 粗甲醇GasWater CooledReactor水冷反应器Condensate冷凝液锅炉给水2014 - Lurgi MegaMethanol第 10 頁(共 28 頁)Water Cooled Methanol Reactor甲醇水冷反应器Air Liquide, worl
14、d leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol第 11 頁(共 28 頁)Quasi isothermal operation,Overheating of Catalyst impossible近等温操作 , 不会发生催化剂过热现象High cooling area per cubicmeter of catalyst !Extremely quick transfer of Reaction Heat单位体积催化剂具备较高的换热面积 ,传热效率高Lurgis Water
15、Cooled Methanol Reactor鲁奇甲醇水冷反应器饱和蒸汽气体入口锅炉给水Air Liquide, world leader in gases for industry, health and the environment1280% of Reaction Heat converted to MP steam80%的反应热可转化为中压蒸汽Thermosyphon Circulation - no Pumps (CAPEX plus reliability advantage!)冷媒热虹吸循环 -不需要泵 (节省设备费用且可靠性高 !)Reactor can be totally
16、 fabricated in China反应器完全可以在中国制造催化剂支撑气体出口开车蒸汽催化剂出料口2014 - Lurgi MegaMethanol第 12 頁(共 28 頁)Gas Cooled Methanol Reactor甲醇水冷反应器Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol第 13 頁(共 28 頁)Equal length of all headers 总管等长设计Uniform gas distributionUnif
17、orm cross-section temperature profile气流均匀分布，横截面温度均匀分布Tube/header design for diff. pressure low reactor cost气冷反应器管束根据循环回路压差作为设计压力，降低 了反应器成本Gas Cooled Methanol Reactor甲醇气冷反应器预热后的合成气水冷反应器出口气体进入气冷反应器Air Liquide, world leader in gases for industry, health and the environment14低Free expansion of tube bund
18、le管束自由膨胀Operation close to optimum (temperatures)最佳的操作温度Reactor can be totally fabricated in China反应器完全可以在中国制造反应后积气出口合成气入口人孔催化剂出料口2014 - Lurgi MegaMethanol第 14 頁(共 28 頁)ATLAS METHANOL TRINIDADAir Liquide, world leader in gases for industry, health and the environment15 2014 - Lurgi MegaMethanol第 15
19、頁(共 28 頁)CMC synthesis in reality两步法甲醇联合转化合成装置Air Liquide, world leader in gases for industry, health and the environment16 2014 - Lurgi MegaMethanol第 16 頁(共 28 頁)Part 2 Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanolLurgi Methanol Technology 鲁奇甲醇
20、技术Advantages of LurgisMethanol Plant Design鲁奇甲醇装置设计优势第 17 頁(共 28 頁)Requirements for highly reactive synthesis gas高反应活性合成气的必要条件Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol第 18 頁(共 28 頁) Chemistry化学CO + 2H2= CH3OH H = - 90,8 kJ/kmolCO2+ 3H2= CH3O
21、H + H2O H = - 49,6 kJ/kmol Thermodynamics热力学CO + H O =CO+H H=- 41 2 kJ/kmolRequirements for highly reactive syngas Methanol Formation Reactions高反应活性合成气的必要条件Air Liquide, world leader in gases for industry, health and the environment192= CO2+ H2H = , Optimum Operating Conditions最优操作条件温度 Temperature: 2
22、25 - 270 C压力 Pressure: 5.0 9.0 Mpa化学计量比 SN: 2.05 Reactions produce heat which has to be removed,otherwise the catalyst will be overheated !This is crucial especially for synthesis gases with high CO content (e.g. coal based syngas)反应所放的热应立即移除，否则催化剂会超温、失活，这对于 CO含量高的合成气尤为关键（例如煤基合成气）2014 - Lurgi MegaMe
23、thanol第 19 頁(共 28 頁)Requirements for reactive syngasMethanol Reactor design高活性合成气的必须条件 Very reactive syngas (high CO content) requires fast removal of reaction heat from the catalyst CO含量较高的合成气合成甲醇，需要及时移除反应热 A Methanol Reactor Design with a high cooling area per m3of catalyst is mandatory 此类反应器中的催化剂
24、必须具备较高的换热面积 The outstanding methanol reactor with superior heat removal ability is Lurgis Water Cooled Methanol ReactorAir Liquide, world leader in gases for industry, health and the environment20Cooled thanol 鲁奇的水冷反应器可快速移除反应热 Cooling Area inside Reactor is approx. 90 m2/ m3catalyst ! 换热面积高达 90 m2/
25、m3catalyst High Cooling area allows to go to high per pass conversions and low recycle ratios 高换热面积确保了高转化率、低循环比2014 - Lurgi MegaMethanol第 20 頁(共 28 頁)CAPEX Advantage of Lurgis Design鲁奇工程设计的固定投资成本优势Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol第 2
26、1 頁(共 28 頁)CAPEX advantage of Lurgis design鲁奇工程设计的投资成本优势The low recycle ratio will lead to savings in CAPEX because of smaller catalyst volume, equipment and bulk (piping, valves etc.)低循环比节省固定投资成本，因为可采用体积较小设备，管道和阀Reference Capacity: 1 Train, 5400 t/d装置规模LurgiRR=1.6CaseRR=4.5CAPEX 固定投资成本HtEh A 换热面积 2
27、2% 100%Air Liquide, world leader in gases for industry, health and the environment22Heat Exchanger reaPiping Weight (Synthesis Loop) 管材重量 47% 100%Methanol Synthesis Catalyst 催化剂需求量 90% 100%2014 - Lurgi MegaMethanol第 22 頁(共 28 頁)Recycle Ratio = 1.6Recycle Ratio = 4.538“45.6循环比循环比Influence of Recycle
28、Ratio to CAPEX 循环比导致的固定成本比较Air Liquide, world leader in gases for industry, health and the environment23Example: Reactor Outlet Line, 5400 MTPD Methanol Plant, 900lbs pipe rating例如：反应器出口管线， 5400吨 /天的甲醇装置， 900lbs的管道压力等级Weight: 1320.9 kg/m1056.4PIPE WEIGHT +687 kg/m= Material Cost 208%管道单位重量增加 687 kg/
29、m 导致材料费用增至 208%2014 - Lurgi MegaMethanol第 23 頁(共 28 頁)OPEX Advantage of Lurgis Design鲁奇工程设计的操作成本优势Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol第 24 頁(共 28 頁)OPEX advantage of Lurgis design鲁奇工程设计的操作成本优势The low recycle ratio will lead to savings i
30、n OPEX because of smaller utilities requirement低循环比节省操作成本，因为较低的公用工程消耗Reference Capacity: 1 Train, 5400 t/d装置规模LurgiRR=1.6CaseRR=4.5OPEX 操作成本Electricity 电耗 60% 100%Air Liquide, world leader in gases for industry, health and the environment25Cooling Water 冷却水消耗 40% 100%Compressor Power SOR 压缩机功耗 70% 1
31、00%2014 - Lurgi MegaMethanol第 25 頁(共 28 頁)Conclusions结论Air Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol第 26 頁(共 28 頁)Conclusions 结论Advantages of Lurgis design 鲁奇的技术优势High cooling area inside methanol reactor is mandatory for highly reactive synthes
32、is gas 高活性原料气需要较大的换热面积Lurgis Water Cooled Reactor is the outstanding reactor with high available cooling area鲁奇水冷反应器是具备所需的大换热面积的杰出反应器Air Liquide, world leader in gases for industry, health and the environment27Lurgis Methanol Reactors can be produce high pressure steam without overheating the cataly
33、st鲁奇甲醇反应器可副产高压蒸汽，且不会使催化剂过热Lurgis Methanol Synthesis enables to reduce CAPEX and OPEX because of the possible low recycle ratio due to high available cooling area of Lurgis Water Cooled Methanol Reactor鲁奇水冷反应器具备足够大的换热面积，可在低循环比条件下运行，大大降低了固定投资成本和操作成本2014 - Lurgi MegaMethanol第 27 頁(共 28 頁)The Next Plant to be built by LURGI is with you !Thanks for Your AttentionAir Liquide, world leader in gases for industry, health and the environment2014 - Lurgi MegaMethanol第 28 頁(共 28 頁)
