Optimum Catalytic Process for Alcohol Fuels from Syngas: Second Quarterly Technical Progress Report

摘要

A base case process for economic studies of making fuel alcohols from syngas has been developed. It uses existing technologies which have been demonstrated to be feasible or have already been commercialized. The process consists of the following steps: coal or natural gas (reforming or partial oxidation) to syngas; syngas to methanol by ICI technology; methanol to light olefins by proprietary UCC technology using molecular sieves; olefins to alcohols by hydroformylation (with a homogeneous rhodium catalyst) followed by hydrogenation. Process economics for the two natural gas-based routes have been developed. With insights gained from this, an optimized and integrated multi-step process has been conceptualized which allows estimation of the lowest cost at which fuel alcohols can be produced. A 60% methanol and 40% higher alcohol mix was assumed to be a suitable fuel alcohol blend for gasoline. At a natural gas price of $2/MMBTU, the cost of producing this, by either partial oxidation or reforming, is $1.12/gal. An integrated process with autothermal reforming at 750 psia and methanol synthesis at 700 psia allows incorporation of the best features of reforming and partial oxidation as well as elimination of syngas compression. The production cost of fuel alcohols by this process is estimated to be $0.90/gal. This is, therefore, the lowest cost at which fuel alcohols can be produced by an integrated, multi-step process. An ''ideal'' process has also been conceptualized which establishes a target production cost that new technology should strive for to be competitive. This process incorporates autothermal reforming for producing syngas followed by conversion to fuel alcohols using emerging technologies. The target production cost is estimated to be $0.65/gal. 16 figs., 10 tabs. (ERA citation 13:000452)