GAS-TO-LIQUIDS PROCESSES FOR CHEMICALS AND ENERGY PRODUCTION

Transcription

1 GAS-TO-LIQUIDS PROCESSES FOR CHEMICALS AND ENERGY PRODUCTION EGY021B January 2009 Kevin Gainer Project Analyst ISBN: BCC Research 49 Walnut Park, Building 2 Wellesley, MA USA (toll-free within the USA), or (+1) info@bccresearch.com

2 TABLE OF CONTENTS CHAPTER 1 INTRODUCTION 2 STUDY GOALS AND OBJECTIVES 2 REASONS FOR DOING THE STUDY 2 INTENDED AUDIENCE 4 SCOPE OF REPORT 4 METHODOLOGY AND INFORMATION SOURCES 5 ANALYST CREDENTIALS 5 RELATED BCC PUBLICATIONS 5 BCC ONLINE SERVICES 5 DISCLAIMER 6 CHAPTER 2 SUMMARY 8 MAJOR FINDINGS 8 KEY FINDINGS OF THIS STUDY 9 SUMMARY TABLE GLOBAL MARKET FORECAST OF PRODUCTS PRODUCED VIA GTL WITH COMPARISONS TO CTL AND BTL, THROUGH 2014 ($ BILLIONS) SUMMARY FIGURE GLOBAL MARKET FORECAST OF PRODUCTS PRODUCED VIA GTL WITH COMPARISONS TO CTL AND BTL, ($ BILLIONS) CHAPTER 3 OVERVIEW 13 TABLE 1 DISTRIBUTION OF WORLD STRANDED NATURAL GAS RESOURCES BY REGION, 2008 (PERCENT DISTRIBUTION) CARBON REGULATIONS AND GTL MARKET PROSPECTS 14 FACTORS DRIVING ADOPTION OF GTL PROCESSES 14 OVERVIEW OF RECENT ACTIVITY 15 TABLE 2 KEY EXAMPLES OF GTL DEMONSTRATION PLANTS 16 SASOL 16 RENTECH 17 SYNTROLEUM 17 MODEC 17 WORLD GTL 17 BHP BILLITON 18 EXXON 18 SHELL 18 QATAR AND EGYPT: MAJOR FOCUS FOR GTL PROJECTS 18 PROJECT LIST 19 TABLE 3 LIST OF PRINCIPAL GTL PLANTS AROUND THE WORLD 19 TEST 21 HISTORY OF THE GTL INDUSTRY 21 FIGURE 1 GTL PRODUCTION OPTIONS, TRANSPORTATION FUELS, AND CHEMICALS 21 TABLE 4 CURRENT WORLD COMMERICAL SYNFUELS CAPACITY (BBL/D) 22 TABLE 5 COMPARATIVE MERITS AND DRAWBACKS OF FT 23 PRINCIPAL GTL PRODUCTION PROCESSES 23 SHELL SMDS 23 SASOL GTL PROCESSES 24 SASOL CTL PLANTS 26 13

3 STATOIL AND PETROSA 27 RENTECH 28 EXXONMOBIL S ADVANCED GAS CONVERSION 30 SYNTROLEUM 31 BP PILOT PLANT IN ALASKA 32 CHOREN INDUSTRIES 33 SYNFUELS INTERNATIONAL 33 CANMET ENERGY TECHNOLOGY CENTER CETC SUPERCETANE TECHNOLOGY COMPACT GTL 36 LNG MARKETS AND CTL 38 COAL TO LIQUIDS 40 National Energy Technology Laboratory Study 40 Baard Energy CTL Plant 40 TABLE 6 OPERATING AND PLANNED LARGE COAL GASIFICATION/CTL PLANTS STATUS AS OF 2008 GTL TECHNOLOGIES 44 INTRODUCTION 44 GTL OUTPUTS 47 REFORMING 49 Adiabatic Prereforming 50 Tubular (or Primary) Reforming 50 Advanced Reforming 50 Sulfur-Passivated Reforming 50 Autothermal Reforming (Catalytic Partial Oxidation) 51 Two-Step Reforming or Combined Tubular/Secondary Reforming 51 Heat Exchange Reforming 51 HYDROGEN SHIFT CONVERSION AND METHANATION 52 SHIFT CONVERSION 52 METHANATION CHAPTER 4 INDUSTRY STRUCTURE AND COMPETITIVE DEVELOPMENTS 55 TIER 1 LARGE DEVELOPERS/PATENT HOLDERS 55 BHP BILLITON 55 BP 56 CHEVRON CORP. 56 CONOCOPHILLIPS CO. 57 EXXONMOBIL 58 IVANHOE ENERGY 59 MARATHON OIL CO. 60 METHANEX CORP. 61 PETROSA 61 RENTECH, INC. 62 REPSOL 63 ROYAL DUTCH SHELL 64 SASOL CHEVRON 65 SASOL SYNFUELS INTERNATIONAL (SSI) 65 STATOIL 66

4 SYNTROLEUM CORP. 67 TOTAL 69 TIER 2 COMPONENT AND ENGINEERING SERVICES SUPPLIERS 70 ABB LUMMUS GLOBAL GMBH 70 AIR LIQUIDE GROUP 70 AIR PRODUCTS AND CHEMICALS, INC. 71 AMEC PROCESS AND ENERGY, LTD. 72 AXENS 73 BASF CORP. 73 BLACK &VEATCH HOLDING CO. 74 CHICAGO BRIDGE AND IRON CO. 75 CRYOMECH, INC. 77 DELTA HUDSON ENGINEERING, LTD. 77 DESCON ENGINEERING CO., INC. 78 DOW CHEMICAL CO. 78 ELTRON RESEARCH & DEVELOPMENT, INC. 79 FLUOR CORP. 80 FMC TECHNOLOGIES 81 FOSTER WHEELER CORP. 82 HALDOR TOPSØE A/S 83 INTEGRATED CONCEPTS AND RESEARCH CORP. (ICRC) 84 JAPAN OIL, GAS, AND METALS NATIONAL CORP. (JOGMEC) 85 JOHNSON MATTHEY CATALYSTS 86 KINETICS TECHNOLOGY INTERNATIONAL CORP. (KTI), INC. 87 THE LINDE GROUP 87 LURGI AG 88 MODEC, INC. (MITSUI OCEAN DEVELOPMENT & ENGINEERING CO., LTD) 89 NIPPON STEEL 89 OXFORD CATALYSTS 90 PALL CORP. 93 PRAXAIR, INC. 93 SIEMENS 94 STORK BV 95 SYNFUELS INTERNATIONAL 95 TECHNIP 96 UOP-HONEYWELL 97 TIER 3 DEVELOPMENT STAGE COMPANIES 98 ARKENOL 98 BAARD ENERGY, LLC 98 CARBON SCIENCES, INC. 99 COMPACTGTL, PLC 100 HYDROGENICS CORP. 102 POWER ECALENE FUELS, INC. (PEFI) 102 SYNTHESIS ENERGY SYSTEMS 103 WORLD GTL 104 SCIENTIFIC, GOVERNMENT AND EDUCATION ORGANIZATIONS 105 ALASKA NATURAL RESOURCES TO LIQUIDS, LLC 105

5 ALLIANCE FOR SYNTHETIC FUELS IN EUROPE 105 ARGONNE NATIONAL LABORATORY (ANL) 106 CANMET ENERGY TECHNOLOGY CENTER (CETC) 106 DOE OFFICE OF FOSSIL ENERGY 107 NATIONAL ENERGY TECHNOLOGY CENTER 107 IDAHO NATIONAL LABORATORY (INL) 107 INSTITUTE FRANÇAIS DU PETROLE (IFP) 108 LEHIGH UNIVERSITY 108 NATIONAL RENEWABLE ENERGY LABORATORY (NREL) 109 OAK RIDGE NATIONAL LABORATORY (ORNL) 109 OFFICE OF INDUSTRIAL TECHNOLOGIES DOE 110 UNIVERSITY OF HOUSTON 110 UNIVERSITY OF KENTUCKY 111 CHAPTER 5 GTL PRODUCT DEMAND FORECASTS 113 PRODUCT OVERVIEW 113 TABLE 7 GLOBAL MARKET FORECAST FOR PRODUCTS PRODUCED VIA GTL WITH COMPARISONS TO CTL AND BTL, THROUGH 2014 ($ BILLIONS) TOTAL UNCONVENTIONAL FUELS MARKET 114 TABLE 8 PROJECTED GLOBAL UNCONVENTIONAL LIQUID FUELS MARKET, (MBBL/D) GTL-FT FUEL DEMAND BY PRODUCT TYPE 115 DIESEL 115 GASOLINE 115 OTHER GTL PRODUCTS 116 TABLE 9 PROJECTED GLOBAL MARKET FOR FT-GTL TRANSPORTATION FUELS BY PRODUCT TYPE, ($ BILLIONS) FT-GTL CHEMICALS DEMAND BY PRODUCT TYPE 116 TABLE 10 PROJECTED GLOBAL MARKET FOR FT-GTL CHEMICALS BY PRODUCT, $ BILLIONS GTL CHEMICALS PROCESSING 117 THE METHANOL MARKET 118 METHANOL TO GASOLINE PROCESSING 119 GTL PRODUCTS - WAXES 120 FUELS THAT WILL COMPETE WITH GTL 123 GTL COMPETITORS 123 Alaska North Slope Possible for GTL by GROWING GLOBAL LNG DEMAND 124 CHANGING LNG PROJECT ECONOMICS 125 WORLDWIDE DEMAND FOR NATURAL GAS 125 RESOURCE DEVELOPMENT POLICIES EFFECT ON SUPPLY FOR GTL PLANTS 126 COAL-TO-LIQUIDS 127 FIGURE 2 FLOW CHART: TWO APPROACHES TO PRODUCING LIQUID FUELS FROM COALS CTL PROJECT ECONOMICS 129 BIOMASS-TO-LIQUIDS DEVELOPMENTS 130 TABLE 11 COMMERCIAL BIOMASS-BASED GASIFICATION PLANTS, BIOFUELS AND RENEWABLE BIOFUELS

6 ETHANOL 132 BIODIESEL 133 OTHER SYNTHETIC CRUDE OILS 134 OIL SANDS 134 EXTRA-HEAVY OIL 135 SHALE OIL 136 CHAPTER 6 REGULATORY DRIVERS THE MACRO ENVIRONMENT 139 EARLY SYNTHETIC FUELS LEGISLATION DEVELOPMENTS 140 GHGS WILL BECOME A PRIORITY IN LAW AND REGULATION 142 STATE INITIAVES RELATIVE TO FUELS CO2 EMISSIONS 143 FUEL STANDARDS ARE DRIVING THE ADOPTION OF GTL 145 EARLIER INITIATIVES 146 GOVERNMENT FUNDING FOR GTL RESEARCH AND DEVELOPMENT 147 SNYGAS RESEARCH FUNDING VIA THE HYDROGEN FUEL INITIATIVE 149 CHAPTER 7 RECENT SIGNIFICANT PATENT ACTIVITY 153 TABLE 12 COMPANIES ASSIGNED MULTIPLE U.S. PATENTS RELATING TO GTL PRODUCTION DURING THE LAST YEAR (NUMBER) SELECTED PATENTS 154 CONVERSION PROCESS 154 HIGH SURFACE AREA, SMALL CRYSTALLITE SIZE CATALYST FOR FISCHER-TROPSCH SYNTHESIS PRODUCTION OF ALCOHOLS FROM SYNTHESIS GAS 155 AMMONIA PLANT CONFIGURATION AND METHODS 155 METHOD AND APPARATUS FOR PRODUCING PRODUCTS FROM NATURAL GAS INCLUDING HELIUM AND LIQUEFIED NATURAL GAS METHOD OF GENERATING HYDROCARBON REAGENTS FROM DIESEL, NATURAL GAS, AND OTHER LOGISTICAL FUELS PROCESS FOR SYNTHESIZING HYDROCARBONS 156 HIGH PURITY OLEFINIC NAPHTHAS FOR THE PRODUCTION OF ETHYLENE AND PROPYLENE PROCESS FOR IMPROVING PREREFORMING AND REFORMING OF NATURAL GAS CONTAINING HIGHER HYDROCARBONS ALONG WITH METHANE SYNTHESIS GAS AND CARBON DIOXIDE GENERATION METHOD 158 PROCESS FOR THE PREPARATION OF A SUPPORTED CATALYST 158 PROCESS AND SYSTEM FOR PRODUCING SYNTHETIC LIQUID HYDROCARBON FUELS PREPARATION OF TITANIA AND COBALT ALUMINATE CATALYST SUPPORTS AND THEIR USE IN FISCHER-TROPSCH SYNTHESIS PROCESS FOR REMOVING ALUMINUM CONTAMINANTS FROM FISCHER-TROPSCH FEED STREAMS USING DICARBOXYLIC ACID HYDROGEN RECOVERY FROM HYDROCARBON SYNTHESIS PROCESSES 160 PROCESS FOR THE PRODUCTION OF MIDDLE DISTILLATES BY HYDROISOMERISATION AND HYDROCRACKING FEEDS FROM THE FISCHER-TROPSCH PROCESS STABILIZED TRANSITION ALUMINA CATALYST SUPPORT FROM BOEHMITE AND CATALYSTS MADE THEREFROM

7 RECOVERY OF ALCOHOLS FROM FISCHER-TROPSCH NAPHTHA AND DISTILLATE FUELS CONTAINING THE SAME PRODUCTION OF SYNTHETIC TRANSPORTATION FUELS FROM CARBONACEOUS MATERIAL USING SELF-SUSTAINED HYDRO-GASIFICATION PROCESS FOR PRODUCING SYNTHESIS GAS FOR THE FISCHER-TROPSCH SYNTHESIS AND PRODUCING APPARATUS THEREOF LOW SULPHUR DIESEL FUEL AND AVIATION TURBINE FUEL 163 PROCESSES FOR MAKING LUBRICANT BLENDS WITH LOW BROOKFIELD VISCOSITIES PROCESS AND APPARATUS FOR THE PRODUCTION OF USEFUL PRODUCTS FROM CARBONACEOUS FEEDSTOCK PRODUCTION OF LOW SULFUR, MODERATELY AROMATIC DISTILLATE FUELS BY HYDROCRACKING OF COMBINED FISCHER-TROPSCH AND PETROLEUM STREAMS CATALYSTS 165 FISCHER-TROPSCH COMPOSITION AND PROCESS 166 SUPPORTED CATALYST 166 FISCHER-TROPSCH CATALYST PRODUCTION 166 PROCESS TO PREPARE A HEAVY AND A LIGHT LUBRICATING BASE OIL 167 HYDROPROCESSING METHODS AND APPARATUS FOR USE IN THE PREPARATION OF LIQUID HYDROCARBONS SYSTEMS AND METHODS OF IMPROVING DIESEL FUEL PERFORMANCE IN COLD CLIMATES METHOD FOR PRODUCING LONG-CHAIN HYDROCARBONS FROM NATURAL GAS FISCHER-TROPSCH CATALYST, PREPARATION, AND USE THEREOF 169 HOMOGENEOUS MODIFIED-ALUMINA FISCHER-TROPSCH CATALYST SUPPORTS BLENDING FOR DENSITY SPECIFICATIONS USING FISCHER-TROPSCH DIESEL FUEL OXYGENATE TREATMENT OF DEWAXING CATALYST FOR GREATER YIELD OF DEWAXED PRODUCT PROCESS FOR REMOVING CONTAMINANTS FROM FISCHER-TROPSCH FEED STREAMS PROCESS TO PREPARE A WAXY RAFFINATE 171 PROCESS FOR THE PRODUCTION OF MIDDLE DISTILLATES BY HYDROISOMERISATION AND HYDROCRACKING FEEDS FROM THE FISCHER-TROPSCH PROCESS RECEPTION, PROCESSING, HANDLING, AND DISTRIBUTION OF HYDROCARBONS AND OTHER FLUIDS PRODUCTION OF HYDROCARBONS 173 METHOD AND APPARATUS FOR REGENERATING AN IRON-BASED FISCHER-TROPSCH CATALYST PROCESS FOR CONVERTING GASEOUS ALKANES TO LIQUID HYDROCARBONS INTEGRATED PROCESSING OF NATURAL GAS INTO LIQUID PRODUCTS 174 GAS-TO-LIQUIDS FACILITY FOR FIXED OFFSHORE HYDROCARBON PRODUCTION PLATFORMS MODIFICATION OF A METHANOL PLANT FOR CONVERTING NATURAL GAS TO LIQUID HYDROCARBONS PROCESS FOR THE RECOVERY OF OIL FROM A NATURAL OIL RESERVOIR

8 APPARATUS FOR PRODUCING HIGH MOLECULAR WEIGHT LIQUID HYDROCARBONS FROM METHANE AND/OR NATURAL GAS MANAGING HYDROGEN IN A GAS TO LIQUID PLANT 177 METHOD FOR CONVERTING NATURAL GAS TO LIQUID HYDROCARBONS

9 LIST OF TABLES TABLE HEADING SUMMARY TABLE GLOBAL MARKET FORECAST OF PRODUCTS PRODUCED VIA GTL WITH COMPARISONS TO CTL AND BTL, THROUGH 2014 ($ BILLIONS) TABLE 1 DISTRIBUTION OF WORLD STRANDED NATURAL GAS RESOURCES BY REGION, 2008 (PERCENT DISTRIBUTION) TABLE 2 KEY EXAMPLES OF GTL DEMONSTRATION PLANTS 16 TABLE 3 LIST OF PRINCIPAL GTL PLANTS AROUND THE WORLD 19 TABLE 4 CURRENT WORLD COMMERICAL SYNFUELS CAPACITY (BBL/D) 22 TABLE 5 COMPARATIVE MERITS AND DRAWBACKS OF FT 23 TABLE 6 OPERATING AND PLANNED LARGE COAL GASIFICATION/CTL PLANTS STATUS AS OF 2008 TABLE 7 GLOBAL MARKET FORECAST FOR PRODUCTS PRODUCED VIA GTL WITH COMPARISONS TO CTL AND BTL, THROUGH 2014 ($ BILLIONS) TABLE 8 PROJECTED GLOBAL UNCONVENTIONAL LIQUID FUELS MARKET, (MBBL/D) TABLE 9 PROJECTED GLOBAL MARKET FOR FT-GTL TRANSPORTATION FUELS BY PRODUCT TYPE, ($ BILLIONS) TABLE 10 PROJECTED GLOBAL MARKET FOR FT-GTL CHEMICALS BY PRODUCT, $ BILLIONS TABLE 11 COMMERCIAL BIOMASS-BASED GASIFICATION PLANTS, TABLE 12 COMPANIES ASSIGNED MULTIPLE U.S. PATENTS RELATING TO GTL PRODUCTION DURING THE LAST YEAR (NUMBER)

10 LIST OF FIGURES FIGURE TITLE SUMMARY FIGURE GLOBAL MARKET FORECAST OF PRODUCTS PRODUCED VIA GTL WITH COMPARISONS TO CTL AND BTL, ($ BILLIONS) FIGURE 1 GTL PRODUCTION OPTIONS, TRANSPORTATION FUELS, AND CHEMICALS 21 FIGURE 2 FLOW CHART: TWO APPROACHES TO PRODUCING LIQUID FUELS FROM COALS