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Catalytic Conversion (via Soft Oxidation) of Methane to Ethylene

Catalytic Conversion (via Soft Oxidation) of Methane to Ethylene. Group 5. Agenda. Background Introduction Project Objectives and Production Targets Constraints and Tentative Flow Diagram Safety and Environmental Concerns Market Analysis. Introduction.

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Catalytic Conversion (via Soft Oxidation) of Methane to Ethylene

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  1. Catalytic Conversion (via Soft Oxidation) of Methane to Ethylene Group 5

  2. Agenda • Background Introduction • Project Objectives and Production Targets • Constraints and Tentative Flow Diagram • Safety and Environmental Concerns • Market Analysis

  3. Introduction Why we are interested in ethylene and its derivatives? Ethylene is the world’s largest commodity chemical and the chemical industry’s fundamental building block. Ethylene and its derivatives applications

  4. Introduction • Natural gas: is abundant hydrocarbon feedstock. • Methane: is the principal component of natural gas, has high hydrogen: carbon ratio.

  5. Introduction Current approaches for the direct, large-scale chemical transformation of methane to useful chemicals: aromatization, oxyclorination, and oxidative coupling. Disadvantages: modest selectivity and yield, requirement for corrosive reagents, heat management and temperature control.  New approach???

  6. Sulfur: a soft oxidant for conversion of methane to ethylene => Using gaseous sulfur (S2) as a soft oxidant can hinder the over-oxidation of methane when compared with using O2 as oxidant.

  7. Project Objectives • With feedstock as natural gas that has the same composition in project 1, we study and maximize ethylene production from methane through oxidation conversion. • CHEMCAD would be used as design simulator to assert the process and economic feasibility of the project.

  8. Production Targets 100 molar basis of feed gas: • The highest possible recovery ethylene C2H4. • Minimal H2S release to meet environmental regulation. • Minimize the formation of undesirable byproducts during the conversion of CH4 to C2H4. • High ROI.

  9. Constraints • Modest selectivities and yields • Heat management and temperature control • Requirement for corrosive reagents • Dependence on highly toxic halogenated intermediates • Highly capital-intensive

  10. GENERAL STEPS • Reaction Site • Soft oxidation of methane with sulfur • Purification Site • H2S absorption with DEA • Regeneration of DEA • Separation Site • CS2 removal • CH4 removal (Recycle back to feed) • C2H6 removal

  11. UNIT OPERATIONS • Kinetic Reactor • Pumps • Heat Exchangers • Mixers • Absorber • Distillation Column

  12. TENTATIVE FLOW DIAGRAM

  13. Environmental concerns Three main issues considered when dealing with the production of ethylene : • Global warming • Greenhouse gas effects contributed by CS2 and CH4 • Extensive use of land • Drilling pads • Landscape damage • Ethylene environmental hazard: • C2H4 can cause damage to plants and materials as a VOC

  14. Health Concerns

  15. Exposure Limits Regulations OSHA: Occupational safety and Health Administration ACGIH: American Conference of Industrial Hygienists PEL: Permissible Exposure Limit ; STEL: Short-term exposure limit TWA: Time-weighted average

  16. Safety Precautions HIGH CONTROL SYSTEMS • Vibration alarms, toxic gas detectors, combustible gas or fire detectors to potential emergency situations detections • Enclose operations and provide local exhaust ventilation at the site of chemical release. • Provision of fire protection and emergency facilities by additional facilities for emergency shutdown and isolation. • Secondary enclosures (building a vessel around the equipment) for catching leaks for storage or handling of highly toxic materials discharges, or others. • Use of respiratory and protective equipment

  17. Ethylene, Methanol and PropyleneExpanding At A Rapid Pace • Ethylene is the largest of the basic chemical building blocks • Ethylene, propylene and methanol are expanding at a rapid pace…driven by shale in North America • Benzene and chlorine showing more modest growth

  18. Ethylene, Methanol and PropyleneExpanding At A Rapid Pace 2020 Global Capacity: • Ethylene:200 Million Tons • Methanol:160 Million Tons • Propylene:140 Million Tons

  19. Price trend of Ethylene

  20. Demand for Basic Chemicals Driven ByDurable/Non-durable Goods • Strong economic growth • supports basic chemical • demand growth • Modest growth in 2012/13 • suggesting lower • consumer spending • Emerging markets are • driving tomorrows demand • growth • China dynamics are • changing, but remains • critical to most markets

  21. Ethylene Investments

  22. North America Ethylene CapacityForecast To Reach 45 Million Metric Tons

  23. Thank you! QUESTIONS????

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