CO2 UTILISATION
IN MeOH
AND NH3/UREA
PLANTS
Casale is a Swiss global supplier of
technologies & engineering solutions
CASALE TECHNOLOGIES
NG
Syngas
generation
Methanol
Nitric Acid
Ammonia
Ammonium
Nitrate
Solution
Solid AN
PRIL/GRAN/C
AN
Nitrogen
Fertilizer
UAN
Melamine
Urea
Super
Phosphate
SSP/TSP/USP
DAP / NP /
NPK
Phosphate
Fertilizer
Complex
Fertilizer
Most of Methanol and
NH3/Urea is produced
from natural gas
These plants utilise the
‘Steam Reforming’
(SMR) for the syngas
generation.
CO2
0.5 t/t MeOH
0.25 t/t Urea
This process is based on the reaction between methane and
steam.
CH4+H2O=CO+3H2 (very endothermic)
CO+H2O=CO2+H2 (slightly exothermic)
T=800/850 C
P=25/35 bar
The reaction heat is supplied by burning fuel (NG)
A standard MeOH plant has a capacity of 3’000 MTD and the CO2
emissions from the SMR are ab. 1’500 MTD
A standard NH3/Urea plant has a capacity of 2’000/3’200 MTD and
the CO2 emissions from the SMR are ab.1’100 MTD
Urea
Urea is the key to nitrogen fertilization
World production is ab. 200 Million TY
Without nitrogen fertilization, the earth could sustain a
maximum of 4 billion people… but we are 7 billion!
NO UREA
NO PARTY
NH3/Urea
The syngas produced, is converted into NH3, and then Urea,
3H2+ N2=2NH3
2NH3+CO2=(NH2)2CO+H2O
The CO2 comes from the SMR reaction and from the shift reaction
Natural gas
Steam
Fuel
CO2
Flue gas
Primary
Reformer
CO2
Air
Secondary
Reformer
CO shift
CO2 removal
H2, N2
Ammonia
synthesis
NH3
Urea
synthesis
Urea
NH3/Urea
The amount of CO2 available in the syngas is 10 % short
of the necessary to convert all ammonia into urea
The CO2 necessary is available in the stack gas of the
steam reformer
Natural gas
Steam
Fuel
CO2
Flue gas
Primary
Reformer
CO2
recovery
CO2
Air
Secondary
Reformer
CO shift
CO2 removal
H2, N2
Ammonia
synthesis
NH3
Urea
synthesis
Urea
MeOH
Demand By Use and Region (2012)
MeOH
MeOH
The syngas produced, is converted into methanol, at about 80 bar, on a catalyst,
CO+2H2=CH3OH
CO2+3H2=CH3OH+H2O
The synthesis gas produced in the SMR is short of H2
Natural gas
Steam
Fuel
Flue gas
CO2
Primary
Reformer
H2, CO
H2
Compression
MeOH
Synthesis
Distillation
MeOH
MeOH
If CO2 can be provided in addition, then the plant capacity
can be increased by 20 % with minimal modifications.
The CO2 necessary is available in the stack gas of the
steam reformer
Natural gas
Steam
Fuel
CO2
Flue gas
Primary
Reformer
CO2
recovery
CO2
H2, CO
Compression
MeOH
Synthesis
Distillation
MeOH
CDR Economics
CAPEX
Additional
$/T MEOH
$/T MEOH
OPEX
NG COST $/MBTU
DEPRECIATION. YEARS
CONCLUSIONS
• The use of a CDR allows to upgrade easily Methanol and
NH3/Urea plants, utilizing CO2 presently vented
• The key to its success is the capital cost and the operability
• The research project Casale/ETH is focused on developing a
new CDR concept to
• reduce the investement cost and the energy
consumption
•
Improve the operability
…THANK YOU….