ABSTRACT Process Economics Program Report 25D ADVANCES IN P-XYLENE TECHNOLOGIES (November 2006)

Transcription

1 ABSTRACT Process Economics Program Report 25D ADVANCES IN P-XYLENE TECHNOLOGIES (November 2006) Global demand for xylene isomers has been steadily increasing, with p-xylene leading the way. p-xylene is a key raw material for the large polyester fiber industry, which is experiencing global growth rates near 6% per year. Future polyester growth will continue to be driven by the Asia region and, more specifically, by the Chinese market. After a period of severe overcapacity during , global operating rates for p-xylene were above 90% in 2005, and a number of new capacity additions are underway. The high demand for p-xylene has created incentives for technological advances. Catalyst innovations have significantly improved the processes for on-purpose xylene production, such as toluene disproportionation, transalkylation, and xylene isomerization. A relatively new development is the toluene alkylation process, in which p-xylene is obtained by reacting toluene and methanol with little benzene by-product. In the p-xylene recovery field, adsorptive separation has been the dominant process worldwide, although crystallization technology has attracted renewed interest. In addition to updated configuration and processing schemes, which result in higher unit efficiency, modern crystallization plants use more reliable and larger-scale equipment. New p-xylene crystallization capacity additions have been made in combination with the paraselective toluene disproportionation technology. The focus of this report is on recent improvements in technologies for p-xylene production and recovery. We also developed conceptual designs and preliminary economics for three configurations of an aromatics complex producing p-xylene and benzene. The main feed streams of the complex are a C 8 aromatics fraction and a BT extract fraction, both derived from catalytic reformate. Each design includes a toluene conversion section, a C 9+ and o-xylene separation section, a p-xylene recovery section, and an isomerization section. The following process configurations were evaluated: Toluene conversion by selective disproportionation and p-xylene recovery by adsorption. Toluene conversion by alkylation with methanol and p-xylene recovery by adsorption. Toluene conversion by selective disproportionation and p-xylene recovery by crystallization. For the two plants using selective toluene disproportionation, the crystallization process has slightly better economics than the adsorption process. At current market prices for benzene, the plant using toluene alkylation has the lowest capital cost but the highest production cost among the three design cases. However, since toluene alkylation produces very little benzene byproduct, the technology becomes very competitive at low benzene prices. SRI Consulting PEP Report 25D

2 R eport No. 25D A DV A NC E S IN P -XY L E NE T E C HNOL OG IE S by Marc os C es ar November 2006 A private report by the P R OC E S S E C ONOMIC S P R OG R A M SR I Menlo P ark, C alifornia 94025

3 SRIC 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 SRIC 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 SRIC, 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 SRIC pursuant to this agreement For detailed marketing data and information, the reader is referred to one of the SRI Consulting programs specializing in marketing research. THE CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS PROGRAM covers major hydrocarbons and their derivatives on a worldwide basis. In addition the SRIC DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States, Western Europe, Canada, and East Asia, South America and Mexico.

4 CONTENTS 1 INTRODUCTION SUMMARY COMMERCIAL ASPECTS TECHNICAL ASPECTS Toluene Disproportionation Transalkylation Toluene Alkylation p-xylene Recovery Adsorption Processes Crystallization Processes Xylene Isomerization PROCESS ECONOMICS INDUSTY STATUS XYLENE DERIVATIVES AND END USES P-XYLENE SUPPLY AND DEMAND Asian p-xylene Outlook US p-xylene Outlook Western Europe p-xylene Outlook Middle Eastern p-xylene Outlook XYLENES SOURCES AND RECOVERY METHODS Toluene Disproportionation Transalkylation Isomerization Xylene Recovery Toluene Alkylation PROCESS TECHNOLOGIES AND LICENSORS SRI Consulting iii PEP Report 25D

5 CONTENTS (Continued) PRODUCERS AND PLANT CAPACITIES CHEMISTRY TOLUENE DISPROPORTIONATION (TDP) Selective Toluene Disproportionation (STDP) TRANSALKYLATION OF C 9+ AROMATICS WITH TOLUENE OR BENZENE ALKYLATION OF TOLUENE WITH METHANOL XYLENES ISOMERIZATION Xylene Isomerization EB Isomerization EB Dealkylation REVIEW OF TECHNICAL DEVELOPMENTS AROMATICS COMPLEX OVERVIEW CONVENTIONAL TOLUENE DISPROPORTIONATION (TDP) Commercial TDP Process ExxonMobil MTDP PARA-SELECTIVE TOLUENE DISPROPORTIONATION PROCESS Mobil Selective Toluene Disproportionation (MSTDP) In Situ Catalyst Pretreatment Process Performance Commercial Aspects ExxonMobil PxMax Process Ex Situ Catalyst Pretreatment Process Performance Commercial Aspects UOP PX-Plus Process TOLUENE METHYLATION SRI Consulting iv PEP Report 25D

6 CONTENTS (Continued) TRANSAKYLATION OF C 9 AROMATICS UOP Tatoray Process UOP TAC9 Process ExxonMobil TransPlus Process XYLENE SEPARATION P-XYLENE RECOVERY BY ADSORPTION Adsorptive Separation Principles Selectivity Capacity Reversibility UOP Sorbex Technology p-xylene Recovery Via Parex Process Parex Operation Parex Performance Improvements Parex Mechanical Improvements Parex Feedstock Considerations Axens-IFP Eluxyl Process Toray Aromax Process P-XYLENE RECOVERY BY CRYSTALLIZATION Crystallization Technology Conventional Crystallization Operation Recent Advance in Crystallization Crystallization Process Licensors GTC s CrystPX Process Sulzer Chemtech Process Befs Prokem Process UOP/Badger/Niro Process Technology Combination Hybird Crystallization Process Axens-Chevron Phillips Hybird Eluxyl Process SRI Consulting v PEP Report 25D

7 CONTENTS (Continued) ALTERNATIVE P-XYLENE RECOVERY METHODS Vapor-Phase PSA Process Membrane Separation XYLENE ISOMERIZATION Commercial Process ExxonMobil s XyMax Process UOP Isomar Process EB Isomerization Catalysts EB Dealkylation Catalysts Axens-Engelhard Octafining Process P-XYLENE BY ADSORPTION PROCESS CASE A-STDP XYLENE FEED PROCESS DISCRIPTION Selective Toluene Disproportionation (STDP)-Section C 9+ and o-xylene Separation-Section Parex Adsorption-Section Isomerization-Section PROCESS DISCUSSION Selective Toluene Disproportionation Section C 9+ and o-xylene Separation Section Parex Section Isomerization Section Materials of Construction COST ESTIMATES Capital Investment Production Cost P-XYLENE BY ADSORPTION PROCESS CASE B-TOLUENE ALKYLATE FEED 7-1 PROCESS DESCRIPTION SRI Consulting vi PEP Report 25D

8 CONTENTS (Continued) Toluene Alkylation-Section C 9+ and o-xylene Separation-Section Parex Adsorption-Section Isomerization PROCESS DISCUSSION COST ESTIMATES Capital Investment Production Cost P-XYLENE BY CRYSTALLIZATION PROCESS PROCESS DISCRIPTION Selective Toluene Disproportionation (STDP)-Section C 9+ and o-xylene Separation-Section Crystallization-Section Isomerization-Section PROCESS DISCUSSION Selective Toluene Disproportionation Section C 9+ and o-xylene Separation Section Crystallization Section Isomerization Section Materials of Construction COST ESTIMATES Capital Investment Production Cost APPENDIX A: PATENT SUMMARY TABLES... A-1 APPENDIX B: DESIGN AND COST BASES... B-1 APPENDIX C: CITED REFERENCES... C-1 SRI Consulting vii PEP Report 25D

9 CONTENTS (Concluded) APPENDIX D: PATENT REFERENCES BY COMPANY... D-1 APPENDIX E: PROCESS FLOW DIAGRAM... E-1 SRI Consulting viii PEP Report 25D

10 ILLUSTRATIONS 2.1 p-xylene From Heavy Reformate Effect of Benzene Price on Product Value Schematic Diagram of an Olefins/Aromatics Complex Model for p-xylene Selectivity Zeolite Aromatics Complex Based on Reformate Feedstock Parex Simulated Moving Bed Process Cascade Ethylene/Propylene Refrigeration System Ammonia Absorption Refrigeration (AAR) Cycle CrystPX Process for p-xylene Recovery Sulzer Heat Pump Crystallization Process Badger/Niro Crystallization Process ExxonMobil s Dual-Bed Xylene Isomerization Process Selective Toluene Disproportionation Process... E p-xylene by Parex Adsorption Process... E p-xylene by Adsorption Process Case A-STDP Xylene Feed Effect of Plant Capacity on Investment Costs p-xylene by Adsorption Process Case A-STDP Xylene Feed Effect of Benzene Price on p-xylene Production Cost and Product Value p-xylene by Adsorption Process Case A-STDP Xylene Feed Effect of Gasoline Value on p-xylene Production Cost and Product Value p-xylene by Adsorption Process Case A-STDP Xylene Feed Effect of Operating Level and Plant Capacity on Product Value Toluene Alkylation Process... E p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Effect of Plant Capacity on Investment Costs p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Effect of Benzene Price on p-xylene Production Cost and Product Value p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Effect of Gasoline Value on p-xylene Production Cost and Product Value p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Effect of Operating Level and Plant Capacity on Product Value SRI Consulting ix PEP Report 25D

11 ILLUSTRATIONS (Concluded) 8.1 p-xylene by Crystallization Process... E p-xylene by Crystallization Process Effect of Plant Capacity on Investment Costs p-xylene by Crystallization Process Effect of Benzene Price on p-xylene Production Cost and Product Value p-xylene by Crystallization Process Effect of Gasoline Value on p-xylene Production Cost and Product Value p-xylene by Crystallization Process Effect of Operating Level and Plant Capacity on Product Value SRI Consulting x PEP Report 25D

12 TABLES 2.1 p-xylene From Heavy Reformate Comparison of Total Capital Investment p-xylene From Heavy Reformate Comparison of Battery Limits Investments by Section p-xylene From Heavy Reformate Comparison of Production Costs Historical and Projected World p-xylene Capacity Production and Consumption by Region Xylene Production and Recovery Technologies World p-xylene Capacity Properties of Xylene Isomers and Ethylbeneze p-xylene by Adsorption Process Case A-STDP Xylene Feed Design Bases and Assumptions p-xylene by Adsorption Process Case A-STDP Xylene Feed Stream Flows p-xylene by Adsorption Process Case A-STDP Xylene Feed Major Equipment p-xylene by Adsorption Process Case A-STDP Xylene Feed Utilities Summary p-xylene by Adsorption Process Case A-STDP Xylene Feed Total Capital Investment p-xylene by Adsorption Process Case A-STDP Xylene Feed Capital Investment by Section p-xylene by Adsorption Process Case A-STDP Xylene Feed Production Costs p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Design Bases and Assumptions p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Stream Flows p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Major Equipment p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Utilities Summary SRI Consulting xi PEP Report 25D

13 TABLES (Concluded) 7.5 p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Total Capital Investment p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Capital Investment by Section p-xylene by Adsorption Process Case B-Toluene Alkylate Feed Production Costs p-xylene by Crystallization Process Design Bases and Assumptions p-xylene by Crystallization Process Stream Flows p-xylene by Crystallization Process Major Equipment p-xylene by Crystallization Process Utilities Summary p-xylene by Crystallization Process Total Capital Investment p-xylene by Crystallization Process Capital Investment by Section p-xylene by Crystallization Process Production Costs SRI Consulting xii PEP Report 25D