Process Economics Program

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1 IHS Chemical Process Economics Program Report 291 Aromatics from Light Hydrocarbons By Syed Naqvi November 2014 ihs.com/chemical

2 IHS Chemical agrees to assign professionally qualified personnel to the preparation of the Process Economics Program s reports and will perform the work in conformance with generally accepted professional standards. No other warranties expressed or implied are made. Because the reports are of an advisory nature, neither IHS Chemical nor its employees will assume any liability for the special or consequential damages arising from the Client s use of the results contained in the reports. The Client agrees to indemnify, defend, and hold IHS Chemical, its officers, and employees harmless from any liability to any third party resulting directly or indirectly from the Client s use of the reports or other deliverables produced by IHS Chemical pursuant to this agreement. For detailed marketing data and information, the reader is referred to one of the IHS Chemical programs specializing in marketing research. THE IHS CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced throughout the world. In addition the IHS DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States, Europe, East Asia, China, India, South & Central America, the Middle East & Africa, Canada, and Mexico. November 2014 ii 2014 IHS

3 PEP Report 291 Aromatics from Light Hydrocarbons By Syed Naqvi November 2014 Abstract This report presents a technical and economic evaluation of three technologies used in the production of benzene, toluene, and xylenes (BTX). The feedstocks for the BTX processes are C 3 -C 4 range aliphatic/olefinic hydrocarbons. PEP Reports 129A, 129B, and 182B (published in 1996, 2006, and 2008, respectively), covered BTX technologies based on the catalytic reforming of light naphtha or pyrolysis gasoline. The current report, however, focuses on BTX produced from liquefied petroleum gas (LPG) as individual, refined products that serve as feedstocks for several other commercially important derivative chemicals. Hence, the starting materials covered in this report differ from those in previous reports covering aromatics. From the perspective of feedstocks, LPG has a cost advantage over light naphtha-range hydrocarbons. However, many LPG production regions are remote, resulting in high transportation costs, leading LPG producers to look for ways to convert LPG (or C 3 -C 4 -rich streams) into more valuable products that are in higher demand, such as BTX.The three technologies analyzed in this report are UOP-BP Cyclar technology, SINOPEC Luoyang GTA technology, and Mitsubishi-Chiyoda Z-Forming technology. UOP-BP s Cyclar technology is based on a bifunctional catalyst consisting of a metal (gallium) modified zeolite (ZSM-5) base material. The highlight of this process is the proprietary continuous catalyst regeneration system (CCR system), a feature used by UOP for the last 40 years. Another important feature of the process is the type of reforming system, which consists of a series of vertically stacked reactors in which catalyst flows down under gravity in the form of a dense medium and reactants flow through the catalyst bed in a radial direction. Operating conditions are 896-1,022 F ( C) at <100 psia. BTX yield can be up to wt%. Feed to process is LPG or light naphtha. For BTX separation, only simple distillation (SD) is used. SINOPEC Luoyang s GTA technology is also based on a bifunctional catalyst consisting of a metal (undisclosed, but likely zinc or gallium) modified zeolite (ZSM-5) base material. The reforming reactors are of an adiabatic, fixed-bed type. Operating conditions are F ( C) at <70 psia. BTX yield can be up to wt%. Feed to process is C 4 -rich olefinic streams. For BTX separation, only SD is used. Mitsubishi-Chiyoda s Z-Forming technology is also based on a bifunctional catalyst consisting of a metal (undisclosed, but likely zinc) modified zeolite (ZSM-5) base material. The reforming reactors are of an adiabatic, fixed-bed type. Operating conditions are 932-1,112 F ( C) at <100 psia. BTX yield can be up to wt%. Feed to process is LPG or light naphtha. For BTX separation, only SD is used. November 2014 iii 2014 IHS

4 Contents 1. Introduction Summary... 2 Feedstocks... 3 Reaction conditions... 4 Catalysts... 4 Design conditions... 5 Light-naphtha-based processes... 7 Process economics... 8 Overall economic conclusion for the Cyclar process... 9 Overall economic conclusion for the GTA process... 9 Overall economic conclusion for the Z-Forming process Industry status Capacity, production and consumption Benzene Toluene Xylenes (mixed) Technical review Catalysts Monofunctional catalysts Dual-function catalysts Feedstocks Reaction conditions/parameters Selectivity and conversion Staged aromatization Reactors UOP process for BTX production by catalytic reforming of LPG Process description Process discussion Process design choices Feedstock Conversion parameters Reformer heaters sizing Fired-heaters fuel consumption efficiency Product recovery Refrigeration Materials of construction Cost estimates November 2014 iv 2014 IHS

5 Fixed capital costs Production costs Overall economic conclusion SINOPEC Luoyang GTA process for BTX production by catalytic reforming of C 4 raffinate-ii Process description Process discussion Process design choices Catalyst Reactor Feedstock Product recovery Product spectrum Refrigeration Materials of construction Cost estimates Fixed capital costs Production costs Overall economic conclusion Mitsubishi-Chiyoda Z-Forming process for BTX production by catalytic reforming of C 4 (butanes) Process description Process discussion Process design choices Catalyst Reactor Feedstock Product recovery Product spectrum Refrigeration Materials of construction Cost estimates Fixed capital costs Production costs Overall economic conclusion Appendix A: Patent summary tables Appendix B: Design cost bases Design conditions Cost bases Capital investment Production costs November 2014 v 2014 IHS

6 Appendix C: Cited references Appendix D: Patent references by company Appendix E: Process flow diagrams Tables Table 2.1: BTX Technologies Salient Operating Features... 3 Table 2.2: Cyclar Process... 5 Table 2.3: GTA Process... 6 Table 2.4: Z-Forming Process... 7 Table 2.5: Comparative Economics of C 3 -C 4 Hydrocarbons-based BTX Technologies Total Capital Investment Table 2.6: Comparative Economics of C 3 -C 4 Hydrocarbons-based BTX Technologies Production Costs Table 2.7: Carbon Footprint for Different BTX Production Technologies Table 3.1: Global Annual Capacities for Benzene Table 3.2: Global Benzene Production and Consumption Table 3.3: Global Annual Capacities for Toluene Table 3.4: Global Toluene Production and Consumption Table 3.5: Regional Mixed Xylenes Capacities, Production and Consumption Table 4.1: Ethane Conversion on Different Types of Pt-Sn Catalysts Table 4.2: Ethane Conversion on Different Types of Pt-Ga Catalysts Table 4.3: Performance Test Results of Aromatization Catalysts for Two-staged Reformers Table 4.4: Performance Comparison of One-Stage and Two-Stage Aromatization Reactors Table 5.1: UOP Process for BTX Production by Catalytic Reforming of LPG Design Bases Table 5.2: UOP Process for Production of BTX by Catalytic Reforming of LPG Stream Flows Table 5.3: UOP Process for Production of BTX by Catalytic Reforming of LPG Equipment List Table 5.4: UOP Process for Production of BTX by Catalytic Reforming of LPG Utilities Summary Table 5.5: UOP Process for Production of BTX by Catalytic Reforming of LPG Total Capital Investment Table 5.6: UOP Process for Production of BTX by Catalytic Reforming of LPG Production Costs Table 6.1: SINOPEC Luoyang GTA Process for BTX Production by Catalytic Reforming of C 4 Raffinate Design Bases Table 6.2: SINOPEC Luoyang GTA Process for Production of BTX by Catalytic Reforming of C 4 Raffinate Stream Flows Table 6.3: SINOPEC Luoyang GTA Process for Production of BTX by Catalytic Reforming of C 4 Raffinate Equipment List Table 6.4: SINOPEC Luoyang GTA Process for Production of BTX by Catalytic Reforming of C 4 Raffinate Utilities Summary Table 6.5: SINOPEC Luoyang GTA Process for Production of BTX by Catalytic Reforming of C 4 Raffinate Total Capital Investment November 2014 vi 2014 IHS

7 Table 6.6: SINOPEC Luoyang GTA Process for Production of BTX by Catalytic Reforming of C 4 Raffinate Production Costs Table 7.1: Mitsubishi-Chiyoda Z-Forming Process for BTX Production by Catalytic Reforming of C 4 (butanes) Design Bases Table 7.2: Mitsubishi-Chiyoda Z-Forming Process for BTX Production by Catalytic Reforming of C 4 (butanes) Stream Flows Table 7.3: Mitsubishi-Chiyoda Z-Forming Process for BTX Production by Catalytic Reforming of C 4 (butanes) Equipment List Table 7.4: Mitsubishi-Chiyoda Z-Forming Process for BTX Production by Catalytic Reforming of C 4 (butanes) Utilities Summary Table 7.5: Mitsubishi-Chiyoda Z-Forming Process for BTX Production by Catalytic Reforming of C 4 (butanes) Utilities Summary Table 7.6: Mitsubishi-Chiyoda Z-Forming Process for BTX Production by Catalytic Reforming of C 4 (butanes) Production Costs Table A.1: Production of BTX from C 3 -C 4 Hydrocarbons Patent Summary Figures Figure 3.1: Global Benzene Capacity by Process (2013) Figure 3.2: Global Benzene Production by Feedstock Type (2013) Figure 3.3: Global Benzene Demand by Derivative Products (2013) Figure 3.4: Global Toluene Demand by Derivative Products (2013) Figure 3.5: Global Toluene Production by Feedstock Type (2013) Figure 3.6: Global Toluene Supply and Demand (2013) Figure 3.7: Global Mixed Xylenes Demand by Derivative Products (2013) Figure 3.8: Global Mixed Xylenes Production by Feedstock Type (2013) Figure 3.9: Global Mixed Xylenes Supply and Demand (2013) Figure 4.1: Single-Stage Aromatization Process Flow Schematic Figure 4.2: Two-Stage Aromatization Process Flow Schematic Figure 5.1: UOP Process for BTX Production by Catalytic Reforming of LPG Figure 5.2: UOP Process for Production of BTX by Catalytic Reforming of LPG Figure 6.1: SINOPEC Luoyang GTA Process for BTX Production by Catalytic Reforming of C 4 Raffinate Figure 6.2: SINOPEC Luoyang GTA Process for Production of BTX by Catalytic Reforming of C 4 Raffinate Figure 7.1: Mitsubishi-Chiyoda Process for BTX Production by Catalytic Reforming of C 4 (butanes) Figure 7.2: Mitsubishi-Chiyoda Z-Forming Process for BTX Production by Catalytic Reforming of C 4 (butanes) November 2014 vii 2014 IHS