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Prof . Gennaro J. Maffia “ Jerry ” Often called a fracking engineer; or words to that effect

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Prof . Gennaro J. Maffia “ Jerry ” Often called a fracking engineer; or words to that effect

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  1. Shale gas conversion: Processing and economicsGennaro J Maffia, gennaro.maffia@manhattan.edu, Alex Bertuccio. Chemical Engineering, Manhattan College, Riverdale, NY, NY 10471, United StatesWith the discovery of vast quantities of natural gas available in various shale formations in Pennsylvania, New York and several adjoining states comes the opportunity to convert this gas, traditionally used for fuel, into more value added products. The methane fraction can be converted into intermediates such as ethylene via oxidative coupling, whereas the ethane/propane fraction can be converted into ethylene via conventional steam pyrolysis. In this paper the processing requirements of a variety of technologies starting with methane and E/P mixes will be presented along with the expected material and energy balances and production economics.

  2. Prof. Gennaro J. Maffia “Jerry” Often called a fracking engineer; or words to that effect

  3. Jerry Maffia – background • Professor of Chemical Engineering – Manhattan College 2. Manager of Technology Development – ARCO a. Petrochemical & Refining b. Start-up & Technical Services gennaro.maffia@manhattan.edu http://home.manhattan.edu/~gennaro.maffia/ACS2013.pptx

  4. Jerry Maffia – some projects Energy Related Projects a. Alaskan Pipeline and Remote Gas b. Fuel Oxygenates c. Biofuels/Bioseparations d. Energy Integration e. Novel Separations f. Manufacture of Proppants

  5. Shale Gas – an opportunity • One point of view

  6. “The outlook for advantaged U.S. natural gas was a significant factor in Dow’s decision to invest $4 billion to grow our overall ethylene and propylene production capabilities in the U.S. Gulf Coast region,” said Jim Fitterling, Dow Executive Vice President and President of Feedstocks & Energy and Corporate Development. “Today, 70 percent of the Company’s global ethylene assets are in regions with cost advantaged feedstocks – and we’ve seen the benefits this advantage provides given oil-based naphtha margin pressure in Europe and Asia. This plan represents a game-changing move to strengthen the competitiveness of our high-margin, high-growth derivatives businesses as we continue to capture growth in the Americas.”

  7. Economic ImpactA World Scale Petrochemical Plant In Pittsburgh.....are you crazy professor?Maybe, but ...............

  8. Shale Gas – a curse • Another point of view

  9. Shale Gas – a textbook • Call a professor

  10. Mining Natural Gas – Wiley Text (work in progress) Table of Contents Chapter 1 Worldwide energy picture Chapter 2 Current domestic energy situation and opportunities Chapter 3 Worldwide carbon dioxide balance – current and anticipated Chapter 4 Review of basic fluid flow Chapter 5 Overview of hydraulic fracturing – all issues Chapter 6 Two phase flow and flow through porous media Chapter 7 Fluidization, sedimentation and suspension of proppants Chapter 8 Details of the hydraulic fracturing process Chapter 9 Composition of fracturing fluids – current and alternatives Chapter 10 Alternative fracturing methods and fluids Chapter 11 Environmental issues and safety concerns Chapter 12 Economic evaluation Chapter 13 Societal impact and safety concerns Chapter 14 Sustainability issues Chapter 15 Future expectations

  11. What is all the fuss about .........

  12. Mining

  13. Methodology….... hydraulic fracturing ……….how? drill a vertical well extend the drilling horizontally case the well perforate the casing pump in high pressure water and sand to fracture the shale at the perforations recover/dispose of the water cap the well bore send gas to treatment treated gas to interstate pipeline system

  14. Hey Jerry what’s the story?

  15. Hey Professor, would it help if we didn’t use water? Dry Frac Atmospheric CO2 – approaching 400 ppm Flue Gas CO2 – much higher, depends on EA Light HCs

  16. The FracKINGS Design Group Morgan, Jimmy, Amanda, Amanda

  17. Drexel University Senior Project Team – Using CO2 as a Fracking Fluid Amanda, Amanda

  18. Prof. M. and the FracKINGS

  19. SOME HEADLINES.........Regulations and Current Policy

  20. May 2012 News Safe Drinking Water Act Several statutes may be leveraged to protect water quality, but EPA's central authority to protect drinking water is drawn from the Safe Drinking Water Act (SDWA). The protection of USDWs is focused in the Underground Injection Control (UIC) program, which regulates the subsurface emplacement of fluid. Congress provided for exclusions to UIC authority (SDWA § 1421(d)), however, with the most recent language added via the Energy Policy Act of 2005:

  21. May 2012 News "The term 'underground injection' – (A) means the subsurface emplacement of fluids by well injection; and (B) excludes – (i) the underground injection of natural gas for purposes of storage; and (ii) the underground injection of fluids or propping agents (other than diesel fuels) pursuant to hydraulic fracturing operations related to oil, gas, or geothermal production activities."   While the SDWA specifically excludes hydraulic fracturing from UIC regulation under SDWA § 1421 (d)(1), the use of diesel fuel during hydraulic fracturing is still regulated by the UIC program.

  22. May 2012 News State oil and gas agencies may have additional regulations for hydraulic fracturing. In addition, states or EPA have authority under the Clean Water Act to regulate discharge of produced waters from hydraulic fracturing operations. Clean Water Act Disposal offlowbackinto surface waters of the United States is regulated by the National Pollutant Discharge Elimination System (NPDES) permit program. The Clean Water Act authorizes the NPDES program.

  23. Topics • Current Ethylene Business Environment • ODH and Competing Cases – Processing • Economics • Preliminary Reactor Design • CO2 Sequestration and Management • ODH Upside Potential – Energy Upgrade

  24. Ethylene Business Background • Current Cracking Strategy • Feedstocks and Leveraging Issues

  25. Ethylene Producers • Domestic • North America • World-wide

  26. US Producers

  27. Petral Information • Raw data – play it straight

  28. Implications: In the US, with its advantaged natural gas–based feedstock, cash margins in the next cycle should be 2.4x the average of the past 20 years. Dow and LyondellBasell should be the main beneficiaries. Asian utilization rates are set to tighten the most from current low levels. In Asia/Middle East, we prefer companies with exposure to gas-based feedstocks such as PTT Chemicals and SABIC. Europe should remain structurally weak due to low demand, high feedstock costs, and proximity to potential Middle East imports.

  29. Definitions VC = RMC + Utilities FC = LC + MC + OVHD + Other CC = FC + VC RNB = FC + VC + CR

  30. The US and Europe Have Driven Ethylene Demand From 1990 to 2000, global ethylene demand growth averaged 5.0%, or 1.9x global GDP growth. However, from 2000 to 2009, it averaged just 2.5%, or 0.9x global GDP growth.

  31. The US and Europe Have Driven Ethylene Demand From 1990 to 2000, global ethylene demand growth averaged 5.0%, or 1.9x global GDP growth. However, from 2000 to 2009, it averaged just 2.5%, or 0.9x global GDP growth.

  32. The ethane to ethylene program is an offshoot from another related TDC program which involves alternatives routes to styrene starting from ethane as one of the components in the feed. The new reaction concept of ethane to ethylene is a controlled catalytic oxydehydrogenation (ODH) process at low temperature. This process undergoes no reaction in the absence of the catalyst till a temperature of 400 C . This new process provides an alternative to ethylene production compared to naphtha or ethane cracker. The main driver for this program is that the process has several potential applications including an alternative to present day ethane cracker, replacement of recycle cracker and the possibility of feed for EB/SM and EO plants.

  33. C2H6 + ½ O2 C2H4 + H2O + Heat The process operates at low temperature (< 400 oC) and dry run experiments have proven that there are no reactions without the catalyst.

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