A multi-perspectives analysis of methane oxidative coupling process based on miniplant-scale experimental data

Godini, Hamid Reza; Azadi, Mohammadreza; Penteado, Alberto; Khadivi, Mohammadali; Wozny, Günter; Repke, J.‐U.

doi:10.1016/j.cherd.2019.08.002

Cited by 13 publications

(10 citation statements)

References 22 publications

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“…Based on the evaluated scientific papers, seven different main subject streams have been identified: (1) modelling of the OCM process, embracing phenomenological and empirical mathematical descriptions of reactors and respective chemical kinetics [7][8][9][10][11][12][13][14][15][16][17][18][19][20][21][22], but also involving theoretical analyses of mechanistic models [23][24][25][26][27][28][29]; (2) economic evaluation of actual OCM commercial implementations, involving the analysis of capital and operational costs [30][31][32][33][34][35]; (3) assessment of environmental impacts, mainly involving the analysis of CO 2 emissions [31]; (4) development of new and/or improved catalysts for the production of ethylene from OCM reactions [27,; (5) development of alternative processes for CH 4 conversion into ethylene and/or other products, including, for instance, the non-oxidative coupling of methane [74][75][76]; (6) investigation of downstream purification strategies [77][78][79], concerning mainly the separation of products from the OCM reactor output stream; and finally, (7) the design, optimisation and development of OCM reactors for ethylene production, including the analysis of distinct reactor concepts (such as chemical looping…”

Section: What Are Ocm Scientific Publications and Patents About?mentioning

confidence: 99%

Oxidative Coupling of Methane for Ethylene Production: Reviewing Kinetic Modelling Approaches, Thermodynamics and Catalysts

et al. 2021

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Ethylene production via oxidative coupling of methane (OCM) represents an interesting route for natural gas upscaling, being the focus of intensive research worldwide. Here, OCM developments are analysed in terms of kinetic mechanisms and respective applications in chemical reactor models, discussing current challenges and directions for further developments. Furthermore, some thermodynamic aspects of the OCM reactions are also revised, providing achievable olefins yields in a wide range of operational reaction conditions. Finally, OCM catalysts are reviewed in terms of respective catalytic performances and thermal stability, providing an executive summary for future studies on OCM economic feasibility.

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Section: What Are Ocm Scientific Publications and Patents About?mentioning

confidence: 99%

Oxidative Coupling of Methane for Ethylene Production: Reviewing Kinetic Modelling Approaches, Thermodynamics and Catalysts

et al. 2021

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“…Two different designs are compared on an economic basis for this section. The first one is herein called traditional configuration because it has been previously adopted by several authors [39][40][41]. The traditional configuration uses only external refrigeration cycles to generate the cold utility required to condense the columns' top products.…”

Section: Distillation Modelmentioning

confidence: 99%

Economic Potential of Bio-Ethylene Production via Oxidative Coupling of Methane in Biogas from Anaerobic Digestion of Industrial Effluents

et al. 2021

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Brazil’s large biofuels industry generates significant amounts of effluents, e.g., vinasse from bioethanol, that can effectively be used as substrate for production of biogas via Anaerobic Digestion (AD). The Oxidative Coupling of Methane (OCM) is the heterogeneous catalytic oxidation of methane into ethylene, which is a main building block for the chemical industry. This work investigates the potential and competitiveness of bio-ethylene production via OCM using biogas produced by biological anaerobiosis of vinasse as a feedstock. The proposed process can add incentive to treat of vinasse via AD and replace fossil ethylene, thus potentially reducing emissions of Greenhouse Gases (GHG). A process model is developed in Aspen Plus v10 software and used to design an economic Biogas-based Oxidative Coupling of Methane (Bio-OCM) process that consumes biogas and oxygen as educts and produces ethylene, ethane, and light off-gases as products. Operating conditions in the reaction section are optimized and a reaction product yield of 16.12% is reached by applying two adiabatic Packed Bed Reactors (PBRs) in series. For the downstream CO2 removal section, a standalone amine-absorption process is simulated and compared to a hybrid membrane-absorption process on an economic basis. For the distillation section, two different configurations with and without Recycle Split Vapor (RSV) are simulated and compared. The bio-ethylene production cost for a Bio-OCM plant to be installed in Brazil is estimated considering a wide range of prices for educts, utility, side products, and equipment within a Monte Carlo simulation. The resulting average production cost of bio-ethylene is 0.53 ±0.73 USD.kgC2H4-1. The production cost is highly sensitive to the sales price assigned to a light off-gas side-product stream containing mostly the un-reacted methane. A sales price close to that of Brazilian pipeline natural gas has been assumed based on the characteristics of this stream. The Monte Carlo simulation shows that a bio-ethylene production cost below or equal to 0.70 USD.kgC2H4-1 is achieved with a 55.2% confidence, whereas market values for fossil ethylene typically lie between 0.70USD.kgC2H4-1–1.50USD.kgC2H4-1. Technical and economic challenges for the industrial implementation of the proposed Bio-OCM process are identified and relevant opportunities for further research and improvement are discussed.

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“…The operation and the design characteristics of different unit operations, as well as the whole integrated process, will be discussed in this paper. As the first step, the specifications and the selected performances of the OCM reactor and CO 2 -separation units in the lights of mini plant-scale experimental observations [5] are analyzed.…”

Section: Feed Specificationsmentioning

confidence: 99%

“…CO 2 is a side product of the OCM reactions and can be relatively easily separated in the downstream units and recycled back to the OCM reactor. Moreover, Biogas, which contains methane and carbon dioxide, can be also considered as an alternative OCM feed in this manner if a sizable quantity of biogas is available [5]. Having considered the above-mentioned potentials for utilizing and treating large-scale CO 2 streams, further process integration and minimization of the overall CO 2 emission are addressed in an integrated OCM process structure shown in Figure 1.…”

Section: Feed Specificationsmentioning

confidence: 99%

Multi-Scale Analysis of Integrated C1 (CH4 and CO2) Utilization Catalytic Processes: Impacts of Catalysts Characteristics up to Industrial-Scale Process Flowsheeting, Part II: Techno-Economic Analysis of Integrated C1 Utilization Process Scenarios

et al. 2020

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In the second part of this paper (Part II), the potentials and characteristics of an industrial-scale Oxidative Coupling of Methane (OCM) process integrated with CO2-hydrogenation, ethane dehydrogenation, and methane reforming processes are highlighted. This novel process concept comprises a direct conversion of methane to ethane and ethylene and further conversion of the resulted carbon dioxide and remaining unreacted methane, respectively, to methanol and syngas. In this context, the selected experimental results of the catalytic CO2-hydrogenation to methanol reported in the first part of this paper (Part I), were utilized to represent its industrial-scale performance. The experimental results of the mini plant-scale operation of an OCM reactor and CO2 removal units along with the experimental and industrial data available for representing the operation and performance of all process-units in the integrated process structures were utilized to perform a comparative techno-economic environmental analysis using Aspen-Plus simulation and an Aspen Economic Process Analyzer. The experimental procedure and the results of testing the sequence of OCM and CO2-hydrogenation reactors are particularly discussed in this context. It was observed that in the sequential operation of these reactors, ethylene will be also hydrogenated to ethane over the investigated catalysts. Therefore, the parallel-operation of these reactors was found to be a promising alternative in such an integrated process. The main assumptions and the conceptual conclusions made in this analysis are reviewed and discussed in this paper in the light of the practical limitations encountered in the experimentations. In the context of a multi-scale analysis, the contributions of the design and operating parameters in the scale of catalyst and reactor as well as in the process-scale represented by analyzing the type and operating conditions of the downstream-units and the process-flowsheets on the economic and environmental performance of the integrated process structures were studied. Moreover, the economic impacts of extra ethylene and methanol produced respectively via the integrated ethane dehydrogenation and CO2-hydrogenation sections were analyzed in detail. The required capital investment was found to be even smaller than the yearly operating cost of the plant. The environmental impacts and sustainability of the integrated OCM process were found to be enhanced by securing a minimum direct CO2-emission and energy-efficient conversion of CO2 and the unreacted CH4, respectively, to methanol and syngas. Besides producing such value-added by-products, efficient operation of downstream process-units was secured by minimizing the energy usage and ethylene losses. Under the considered conditions in this analysis, the specifications of the finally selected integrated OCM process structure, providing the fastest return of investments (less than 8 years), are highlighted.

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A multi-perspectives analysis of methane oxidative coupling process based on miniplant-scale experimental data

Cited by 13 publications

References 22 publications

Oxidative Coupling of Methane for Ethylene Production: Reviewing Kinetic Modelling Approaches, Thermodynamics and Catalysts

Oxidative Coupling of Methane for Ethylene Production: Reviewing Kinetic Modelling Approaches, Thermodynamics and Catalysts

Economic Potential of Bio-Ethylene Production via Oxidative Coupling of Methane in Biogas from Anaerobic Digestion of Industrial Effluents

Multi-Scale Analysis of Integrated C1 (CH4 and CO2) Utilization Catalytic Processes: Impacts of Catalysts Characteristics up to Industrial-Scale Process Flowsheeting, Part II: Techno-Economic Analysis of Integrated C1 Utilization Process Scenarios

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