Design and economic analysis of industrial-scale methanol-to-olefins plants

Implications in the production of defossilized methanol: A study on carbon sources

The transition of the current fossil based chemical industry to a carbon-neutral industry can be done by the substitution of fossil carbon for defossilized carbon in the production of base chemicals. Methanol is one of the seven base chemicals, which could be used to produce other base chemicals (light olefins and aromatics). In this research, we evaluated the synthesis of methanol based on defossilized carbon sources (maize, waste biomass, direct air capture of CO2 (DAC), and CO2 from the cement industry) by considering carbon source availability, energy, water, and land demand. This evaluation was based on a carbon balance for each of the carbon sources. Our results show that maize, waste biomass, and CO2 cement could supply 0.7, 2, 15 times the carbon demand for methanol respectively. Regarding the energy demand maize, waste biomass, DAC, and CO2 from cement demand 25, 21, 48, and 45GJtonMeOH separately. The demand for water is 5300, 220, 8, and 8m3tonMeOH. And lastly, land demand was estimated to 1031, 36, 83, and 77m2tonMeOH per carbon source. The high-demanding-resource production of defossilized methanol is dependent on the availability of resources per location. Therefore, we analyzed the production of defossilized methanol in the Netherlands, Saudi Arabia, China, and the USA. China is the only country where CO2 from the cement industry could provide all the demand of carbon. But as we envision society becoming carbon neutral, CO2 from the cement industry would diminish in time, as a consequence, it would not be sufficient to supply the demand for carbon. DAC would be the only source able to provide the demand for defossilized carbon.

ZSM-5 Catalysts for MTO: Effect and Optimization of the Tetrapropylammonium Hydroxide Concentration on Synthesis and Performance

Light olefin production from methanol using various zeolite catalysts has industrial and economic importance considering the growth of the petrochemical market. Zeolites are generally synthesized using various organic templates as structure-directing agents (SDAs). In this study, synthesis of a series of ZSM-5 zeolites was performed systematically using the microwave-assisted crystallization method, and these samples were analyzed in detail to understand the effect of the SDA concentration. Powder diffraction, N₂ adsorption, scanning electron microscopy, ammonia adsorption desorption, and ²⁷Al and ²⁹Si NMR spectroscopies were used for the characterization. The organic SDA tetrapropyl ammonium hydroxide (TPAOH/SiO₂ mole ratio = 0.0500) is found to have an optimum concentration against the silica precursor for achieving the highest crystallinity, suitable morphology, ideal pore size, effective pore volume, and tuned microporous/mesoporous area. For samples with a template concentration ratio of 0.050 or higher, ²⁹Si and ²⁷Al NMR data revealed the presence of an intact ZSM-5 structure. Using a fixed bed reactor at 500 °C and atmospheric pressure, the catalytic performance of the selected catalysts from the series is investigated for the methanol-to-olefin conversion reaction. The sample with the highest crystallinity showed the best conversion, selectivity toward light olefins, and time on stream stability. It is also worth noting that the highest crystallinity, micropore area, and micropore volume are reached for the optimum value rather than the highest template concentration. This allows for a reduction in the template concentration and a move closer to a synthesis pathway benign to environment and economics.