On-Purpose Chemicals and Fuels Reaction 35, LLC

Transcription

1 On-Purpose Chemicals and Fuels Reaction 35, LLC 861 Ward Drive Santa Barbara, CA 93111

2 Reaction 35, LLC Overview Developer of Bromine-Mediated Technology Laboratory Development Conceptual Engineering Cost Analysis The Reaction 35 Platform Technology Bromine as an Alkane Activating Agent Feedstock and Product Flexible High Product Selectivity Developed over 10 years Extensive International Patent Protection Business Model Technology Developer Equity Partner in Commercial Facilities Licensor 2

3 The Reaction 35 Technology: A Three-Step Alkane Conversion Process Regeneration: HBr Br 2 Br 2 HBr Alkane Feedstocks Activation: Alkane + Br 2 R-Br Conversion: Alkyl Bromide Products Reaction Conditions Bromination: Determined by feedstock composition Conversion: Determined by desired product Regeneration: Consistent across all feedstocks and products 3

4 Reaction 35 Products from Alkyl Bromide Intermediates R-Br 4

5 Ethane, Propane and Higher Alkanes: Excellent Feedstocks for R35 Technology Brominate under mild conditions Require less bromine circulation High single pass yield Contain secondary (2 ) and/or tertiary (3 ) carbon atoms React differently with bromine Enables selective bromination Methane Ethane Propane n-butane 1 i-butane Reactivity Towards Bromine: < << << Methyl Primary (1 ) Secondary (2 ) Tertiary (3 ) 5

6 Propane Reaction 35 Technology: Propane to Propylene Chemistry Example Propylene Propyl Bromide Activation: Conversion: HBr Bromine Thermal Bromination HBr Catalytic Dehydrobromination Regeneration: Catalytic Oxidation H 2 O Oxygen Overall: C 3 H 8 + ½ O 2 C 3 H 6 + H 2 O 6

7 R35 Propane to Propylene (P2P) Process: Block Diagram 7

8 Process Comparison: P2P Process vs. Propane Dehydrogenation Oleflex* Catofin* R35 P2P Propane / Propylene (kg) Reaction/Separation Pressures (bar) 1.1 / / / 35 Refrigeration & Cold Box Both Both Neither Operating Cost High High Low (~ $150 less/mt) Capital Cost High High Low (~ 30% lower) Olefin Catalyst Pt on Alumina Cr on Alumina Low cost (proprietary) Olefin Reactor Type Moving Beds 5-8 Parallel Fixed Beds 2 Parallel fixed beds Operating Mode Continuous Catalysis Regeneration with H Minute Cyclic Regeneration Continuous with infrequent regeneration Temperature Range ( o C) CO 2 Footprint High High ~50% lower *Source: Propane Dehydrogenation Technology Report, Intratec & CMAI (2011) 8

9 Class IV Capital Cost Estimate (Fluor Enterprises, Inc.) 9

10 P2P Process: Capital Cost Estimate* (450 kta) R35 Propane to Propylene (P2P) Process Item Cost ($ million) ISBL 162 OSBL 117 Project Cost 58 Contingency 89 Total 426 Hydrogen plant 17 EPC** Cost Estimate (includes H 2 plant) 443 Conventional Propane Dehydrogenation (Oleflex) EPC** Cost Estimate 629 The R35 P2P Process: ~ 30% capital cost advantage over PDH *Class IV; 1 st Quarter 2012, U.S. Gulf Coast Cost Basis **EPC = Fluor Enterprises, Inc. 10

11 Feed & Energy Comparison (per 1000 kg Propylene) P2P OLEFLEX Propane (kg) Net Heat (MMBTU) Electricity (kwh) Refrigeration (kwh) Operating cost advantage for the P2P process > $150** per 1000 kg propylene > $175 after accounting for catalyst replacement costs > 50% reduction in CO 2 emissions **Basis: Propane - $0.66/kg, Fuel - $5/MMBTU (including methane for hydrogen plant, Electricity - $0.10/kwhr 11

12 R35 Propane to Propylene Process: Status Most developed application - Pilot Plant ready Design of Integrated Pilot in progress Reactions studied in detail at the laboratory scale Materials of Construction selected, validated Pilot Scale Demonstration of oxidation, bromination reactions PFD and simulation models completed Commercial facility cost estimate developed Class IV by Fluor Enterprises, Inc. Intellectual Property Over 30 U.S. Patents on the Reaction 35 Technology Broad (>40 Countries) international protection Rights held exclusively by Reaction 35 Freedom to Operate review completed Additional patents pending 12

13 R35 Olefins Technology: Summary Competitive advantages Feedstock efficiency > 99% Far simpler separations No alkane/olefin splitter No cold box or refrigeration Low compression Tolerant to feedstock impurities Direct production of high purity olefins Polymer-grade propylene High purity butylenes, amylenes (iso and/or normal) Mixed (iso & normal) or single component feedstock No MTBE or TBA required 13

14 Other R35 Products from NGL Feedstocks Aromatics (BTX) Feedstock: Ethane or C3+ alkanes Controllable BTX Ratio Reactions studied extensively at the laboratory scale PFD and simulation models completed Preliminary capital cost estimates developed Distillate Fuels from Light Alkanes (C3+) Feedstock: C3+ alkanes Analogous to MOGD Process Many process elements in common with R35 olefins technology Lower capital and operating costs Status: Proof of concept experiments completed R35 Priority Applications Propane to Propylene Isobutane to Isobutylene Ethane to Aromatics 14

15 R35 Technology: Full Y-Grade Integration 15

16 THANK YOU! Reaction 35, LLC 861 Ward Drive Santa Barbara, CA 93111