Arno de Klerk. Fischer Tropsch Refining

Transcription

1 Arno de Klerk Fischer Tropsch Refining

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3 Arno de Klerk Fischer Tropsch Refining

4 Further Reading Arpe, Hans-Jürgen Industrial Organic Chemistry 5th, completely revised edition 2010 ISBN: Wijngaarden, Ruud I./Westerterp, K. Roel/Kronberg, Alexander/Bos, A.N.R. (Eds.) Industrial Catalysis Optimizing Catalysts and Processes 2011 ISBN: Olah, G. A., Goeppert, A., Prakash, G. K. S. Beyond Oil and Gas: The Methanol Economy 2010 Softcover ISBN: Barbaro, P., Bianchini, C. (Eds.) Catalysis for Sustainable Energy Production 2009 ISBN: Stolten, D. (Ed.) Hydrogen and Fuel Cells Fundamentals, Technologies and Applications 2010 ISBN: Kolb, G. Fuel Processing for Fuel Cells 2008 ISBN: Deublein, D., Steinhauser, A. Biogas from Waste and Renewable Resources An Introduction 2011 ISBN: Häring, H.-W. (Ed.) Industrial Gases Processing 2008 ISBN: Al-Qahtani, Khalid Y./Elkamel, Ali Planning and Integration of Refinery and Petrochemical Operations 2010 ISBN: Elvers, B. (Ed.) Handbook of Fuels 2008 ISBN:

5 Arno de Klerk Fischer Tropsch Refining

6 The Author Arno de Klerk University of Alberta Chemical and Materials Engineering Edmonton, Alberta, T6G 2V4 Canada All books published by Wiley-VCH are carefully produced. Nevertheless, authors, editors, and publisher do not warrant the information contained in these books, including this book, to be free of errors. Readers are advised to keep in mind that statements, data, illustrations, procedural details or other items may inadvertently be inaccurate. Library of Congress Card No.: applied for British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. Bibliographic information published by the Deutsche Nationalbibliothek The Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data are available on the Internet at < Wiley-VCH Verlag & Co. KGaA, Boschstr. 12, Weinheim, Germany All rights reserved (including those of translation into other languages). No part of this book may be reproduced in any form by photoprinting, microfilm, or any other means nor transmitted or translated into a machine language without written permission from the publishers. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law. Cover Design Formgeber, Eppelheim Typesetting Laserwords Private Limited, Chennai, India Printing and Binding Printed in Singapore Printed on acid-free paper Print ISBN: epdf ISBN: obook ISBN: epub ISBN:

7 To my wife, Chèrie,wholovesandsupportsmesomuch. V

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9 VII Contents Preface XIX Part I Introduction 1 1 Fischer Tropsch Facilities at a Glance Introduction Feed-to-Syngas Conversion Feed Logistics and Feed Preparation Syngas Production Syngas Cleaning and Conditioning Syngas-to-Syncrude Conversion Syncrude-to-Product Conversion Upgrading versus Refining Fuels versus Chemicals Crude Oil Compared to Syncrude Indirect Liquefaction Economics Feed Cost Product Pricing Capital Cost 17 References 19 2 Refining and Refineries at a Glance Introduction Conventional Crude Oil Hydrocarbons in Crude Oil Sulfur Compounds in Crude Oil Nitrogen Compounds in Crude Oil Oxygenates in Crude Oil Metals in Crude Oil Physical Properties Products from Crude Oil Boiling Range and Product Quality Evolution of Crude Oil Refineries 31

10 VIII Contents First-Generation Crude Oil Refineries Second-Generation Crude Oil Refineries Third-Generation Crude Oil Refineries Fourth-Generation Crude Oil Refineries Petrochemical Refineries Lubricant Base Oil Refineries 44 References 46 Part II Production of Fischer Tropsch Syncrude 49 3 Synthesis Gas Production, Cleaning, and Conditioning Introduction Raw Materials Natural Gas Solid Carbon Sources Syngas from Natural Gas Natural Gas Cleaning Adiabatic Prereforming Steam Reforming Adiabatic Oxidative Reforming Gas Reforming Comparison Syngas from Solid Carbon Sources Gasification of Heteroatoms Low-Temperature Moving Bed Gasification Medium-Temperature Fluidized Bed Gasification High-Temperature Entrained Flow Gasification Gasification Comparison Syngas Cleaning Acid Gas Removal Syngas Conditioning Water Gas Shift Conversion Air Separation Unit 70 References 71 4 Fischer Tropsch Synthesis Introduction Fischer Tropsch Mechanism Fischer Tropsch Product Selectivity Probability of Chain Growth Hydrogenation versus Desorption Readsorption Chemistry Selectivity Manipulation in Fischer Tropsch Synthesis Fischer Tropsch Catalyst Formulation Fischer Tropsch Operating Conditions Fischer Tropsch Reaction Engineering 84

11 Contents IX 4.5 Fischer Tropsch Catalyst Deactivation Poisoning by Syngas Contaminants Volatile Metal Carbonyl Formation Metal Carboxylate Formation Mechanical Catalyst Degradation Deactivation of Fe-HTFT Catalysts Deactivation of Fe-LTFT Catalysts Deactivation of Co-LTFT Catalysts 95 References 99 5 Fischer Tropsch Gas Loop Introduction Gas Loop Configurations Open Gas Loop Design Closed Gas Loop Design Syncrude Cooling and Separation Pressure Separation Cryogenic Separation Oxygenate Partitioning HTFT Syncrude Recovery LTFT Syncrude Recovery 114 References 116 Part III Industrial Fischer Tropsch Facilities German Fischer Tropsch Facilities Introduction Synthesis Gas Production Fischer Tropsch Synthesis Normal-Pressure Synthesis Medium-Pressure Synthesis Gas Loop Design Carbon Efficiency Fischer Tropsch Refining Refining C 3 C 4 Crude LPG Refining Carbon Gasoline Refining of Condensate Oil Refining of Waxes Aqueous Product Refining Discussion of the Refinery Design 137 References American Hydrocol Facility Introduction Synthesis Gas Production 142

12 X Contents 7.3 Fischer Tropsch Synthesis Fischer Tropsch Refining Oil Product Refining Refining Aqueous Product Discussion of the Refinery Design 150 References Sasol 1 Facility Introduction Synthesis Gas Production Lurgi Dry Ash Coal Gasification Rectisol Synthesis Gas Cleaning Fischer Tropsch synthesis Kellogg HTFT synthesis Arge LTFT Synthesis Gas Loop Design Fischer Tropsch Refining Kellogg HTFT Oil Refining Arge LTFT Oil Refining Aqueous Product Refining Coal Pyrolysis Product Refining Synthetic Fuel Properties Evolution of the Sasol 1 Facility Changes in Synthesis Gas Production Changes in Fischer Tropsch Synthesis Changes in Fischer Tropsch Refining Changes in Coal Pyrolysis Product Refining Discussion of the Refinery Design 177 References Sasol 2 and 3 Facilities Introduction Synthesis Gas Production Lurgi Dry Ash Coal Gasification Synthesis Gas Cleaning Fischer Tropsch Synthesis Gas Loop Design Fischer Tropsch Refining Synthol HTFT Condensate Refining Synthol HTFT Oil Refining Aqueous Product Refining Coal Pyrolysis Product Refining Synthetic Fuel Properties Evolution of Sasol Synfuels Changes in Synthesis Gas Production 201

13 Contents XI Changes in Fischer Tropsch Synthesis Changes in Fischer Tropsch Condensate Refining Extraction of Linear 1-Alkenes Changes in Fischer Tropsch Oil Refining Changes in Fischer Tropsch Aqueous Product Refining Changes in Coal Pyrolysis Product Refining Synthetic Jet Fuel Discussion of the Refinery Design 212 References Mossgas Facility Introduction Synthesis Gas Production Natural Gas Liquid Recovery Gas Reforming Fischer Tropsch Synthesis Gas Loop Design Fischer Tropsch Refining Oil Refining Aqueous Product Refining Synthetic Fuel Properties Evolution of the PetroSA Facility Addition of Low-Temperature Fischer Tropsch Synthesis Changes in the Fischer Tropsch Refinery Discussion of the Refinery Design 228 References Shell Middle Distillate Synthesis (SMDS) Facilities Introduction Synthesis Gas Production in Bintulu GTL Fischer Tropsch Synthesis in Bintulu GTL Fischer Tropsch Refining in Bintulu GTL Oil Refining Aqueous Product Treatment Pearl GTL Facility Discussion of the Refinery Design 239 References Oryx and Escravos Gas-to-Liquids Facilities Introduction Synthesis Gas Production in Oryx GTL Fischer Tropsch Synthesis in Oryx GTL Fischer Tropsch Refining in Oryx GTL Oil Refining Aqueous Product Treatment 247

14 XII Contents 12.5 Discussion of the Refinery Design 247 References 248 Part IV Synthetic Transportation Fuels Motor-Gasoline Introduction Motor-Gasoline Specifications Motor-Gasoline Properties Octane Number Density Volatility Fuel Stability Alkene Content Aromatic Content Sulfur Content Oxygenate Content Metal Content Aviation-Gasoline Future Motor-Gasoline Specification Changes 265 References Jet Fuel Introduction Jet Fuel Specifications Synthetic Jet Fuel Fuel for Military Use Jet Fuel Properties Net Heat of Combustion Density and Viscosity Freezing Point Temperature Aromatic Content and Smoke Point Sulfur and Acid Content Volatility Stability Elastomer Compatibility and Lubricity Future Jet Fuel Specification Changes 280 References Diesel Fuel Introduction DieselFuelSpecifications DieselFuelProperties Cetane Number Density and Viscosity 290

15 Contents XIII Flash Point Lubricity Aromatic Content Sulfur Content Cold-Flow Properties Stability Elastomer Compatibility Diesel Fuel Additives That Affect Refinery Design Future Diesel Fuel Specification Changes 296 References 297 Part V Refining Technology Refining Technology Selection Introduction Hydrotreating Hydrogenation of Alkenes Hydrodeoxygenation Addition and Removal of Oxygen Dehydration Etherification Hydration Esterification Carbonyl Aromatization Hydroformylation Autoxidation Alkene Conversion Double Bond Isomerization Metathesis Skeletal Isomerization Oligomerization Aliphatic Alkylation Aromatic Alkylation Alkane Conversion Hydroisomerization Hydrocracking Naphtha Reforming and Aromatization Dehydrogenation Residue Conversion Catalytic Cracking Visbreaking Thermal Cracking Coking Fischer Tropsch Refining Technology Selection 326 References 328