Methanol, production from natural gas

A. Stratton, D. F. Hemming, and M. Teper, Methanol Production from Natural Gas or Coal, report no. E4/82, International Energy Agency Coal Research, London, 1982. 

However, there are several issues with widespread methanol usage. Methanol production from natural gas is relatively inefficient ( 67%), and this largely offsets the vehicular improvement in efficiency and carbon dioxide reduction (since gasoline can be made with "85% efficiency from oil). Additionally, the PEM fuel cell demands very pure methanol, which is difficult to deliver using existing oil pipelines and may require a new fuel distribution infrastructure. 

These, and other developments may ultimately lead to considerable savings in methanol production from natural gas. 

Edwards, J.H., and Foster, N.R. (1986) The Potential for Methanol Production from Natural Gas by Direct Catalytic Partial Oxidation , Fuel Sci. Tech. Int l. 4, 365-90. 

Mackie JC. Partial oxidation of methane the role of gas phase reaction. Catal Rev Sci Eng 1991 33 169. Edwards JH, Foster NR. The potential for methanol production from natural gas by direct catalytic partial oxidation. Fuel Sci Technol Int 1986 4 365—90. 

Produced from a.tura.1 Ga.s, Cost assessments of methanol produced from natural gas have been performed (13—18). Projections depend on such factors as the estimated costs of the methanol production faciUty, the value of the feedstock, and operating, maintenance, and shipping costs. Estimates vary for each of these factors. Costs also depend on the value of oil. Oil price not only affects the value of natural gas, it also affects the costs of plant components, labor, and shipping. 

Produced from Co l. Estimates of the cost of producing methanol from coal have been made by the U.S. Department of Energy (DOE) (12,17) and they are more uncertain than those using natural gas. Experience in coal-to-methanol faciUties of the type and size that would offer the most competitive product is limited. The projected costs of coal-derived methanol are considerably higher than those of methanol produced from natural gas. The cost of the production faciUty accounts for most of the increase (11). Coal-derived methanol is not expected to compete with gasoline unless oil prices exceed 0.31/L ( 50/bbl). Successful development of lower cost entrained gasification technologies could reduce the cost so as to make coal-derived methanol competitive at oil prices as low as 0.25/L ( 40/bbl) (17) (see Coal conversion processes). 

When methanol is made from natural gas, the gas reacts with steam to produce synthesis gas, a mixture of hydrogen and carbon monoxide. This then reacts with a catalytic substance at high temperatures and pressures to produce methanol. The process is similar when methanol is produced by the gasification of biomass. The production of methanol from biomass or coal can cost almost twice as much as production from natural gas. 

In Canada, hydrogen production from natural gas via a fluidised bed reactor with hydrogen purification via a selective membrane is under investigation. Also, a methanol micro-reformer which includes an integrated metal membrane purification unit is being developed. 

It is certain that world use of natural gas will increase dramatically in the near future as industrialized countries replace coal-fired facilities with cleaner-burning natural gas. In addition, a number of countries remote from major markets are in the process of installing world-scale plants for utilization of natural gas and gas liquids for production of fertilizers, methanol, premium gasoline blending stocks, and other basic petrochemical derivatives that will result in higher-value products from natural gas and gas liquids for which there are no local markets. 

Produced from Coal. Estimates of the cost of producing methanol from coal have been made by the U.S. Department of Energy (DOE) (12,17) and they are more uncertain than those using natural gas. Experience in coal-to-metlianol facilities of the type and size that would offer the most competitive product is limited. The projected costs of coal-derived methanol are considerably higher than those of methanol produced from natural gas. 

Methanol to Gasoline Process (MTG) Process. Methanol, produced from natural gas or coal, can be converted to high-quality, aromatics-rich gasoline in a two-stage fixed- or trickle-bed process with pentasil catalysts. Namral gas based production and cleavage of methanol has been operated since 1985 in New Zealand, where it covers one-third of gasoline demand. 

If a fermentation process is used for PHA synthesis this problem can partially be overcome by using cheap surplus and waste materials as renewable carbon sources (e.g. molasses, whey, cellulose hydrolysate) or other cheap carbon sources from fossil resources like methanol derived from natural gas, because roughly 50% of the total production costs derive from the carbon source costs. Unfortunately many of the well known production strains can not be used for PHA production from such substrates, because these microbial strains show either low yields or low production rates, when they grow on these substrates, or they simply cannot utilize these carbon sources at all. These drawbacks can be overcome either by isolating new microbial strains or by applying genetically modified strains for the production process. 

Methanol. If methanol is to compete with conventional gasoline and diesel fuel it must be readily available and inexpensively produced. Thus methanol production from a low-cost feed stock such as natural gas [8006-14-2] or coal is essential (see Feedstocks). There is an abundance of natural gas (see Gas, natural) woddwide and reserves of coal are even greater than those of natural gas. 

The Texaco process was first utilized for the production of ammonia synthesis gas from natural gas and oxygen. It was later (1957) appHed to the partial oxidation of heavy fuel oils. This appHcation has had the widest use because it has made possible the production of ammonia and methanol synthesis gases, as well as pure hydrogen, at locations where the lighter hydrocarbons have been unavailable or expensive such as in Maine, Puerto Rico, Brazil, Norway, and Japan. 

Other energy sector concerns are methane emissions from unburned fuel, and from natural gas leaks at various stages of natural gas production, transmission and distribution. The curtailment of venting and flaring stranded gas (remotely located natural gas sources that are not economical to produce liquefied natural gas or methanol), and more efficient use of natural gas have significantly reduced atmospheric release. But growth in natural gas production and consumption may reverse this trend. Methane has... 

Natural gas and crude oils are the main sources for hydrocarbon intermediates or secondary raw materials for the production of petrochemicals. From natural gas, ethane and LPG are recovered for use as intermediates in the production of olefins and diolefms. Important chemicals such as methanol and ammonia are also based on methane via synthesis gas. On the other hand, refinery gases from different crude oil processing schemes are important sources for olefins and LPG. Crude oil distillates and residues are precursors for olefins and aromatics via cracking and reforming processes. This chapter reviews the properties of the different hydrocarbon intermediates—paraffins, olefins, diolefms, and aromatics. Petroleum fractions and residues as mixtures of different hydrocarbon classes and hydrocarbon derivatives are discussed separately at the end of the chapter. 

The production of synthesis gas from natural gas and coal is the basis of the 33 000000 tpa methanol production and is also used in the production of ammonia. After removal of sulfur impurities, methane and water are reacted over a nickel oxide on calcium aluminate catalyst at 730 °C and 30 bar pressure. The reaction is highly endothermic (210 kJmol ) (Equation 6.6). 

Steinberg, M., Production of hydrogen and methanol from natural gas with reduced C02 emission, Int. J. Hydrogen Energ., 23, 419, 1998. 

Dong, Y. Steinberg, M., Hynol—an economical process for methanol production from biomass and natural gas with reduced C02 emission. In 10th World Hydrogen Energy Conference, Block, D. L., Veziroglu, T. N. Eds., Beach, Florida, June 20-24,1994, pp. 495-504. 

Methanol and ethanol are alcohol fuels that can be produced from various renewable sources. Alcohol fuels are converted from biomass or other feedstocks using one or several conversion techniques. Both government and private research programs are finding more effective, less costly methods of converting biomass to alcohol fuels. Methanol was originally a by-product of charcoal production, but today it is primarily produced from natural gas and can also be made from biomass and coal. 

Petrochemicals and fossil fuels entail chemicals produced from hydrocarbon feedstocks, such as crude oil products and natural gas. They include such chemicals as hydrocarbons and industrial chemicals (e.g., alcohols, acrylates, acetates), aromatics (e.g., benzene, toluene, xylenes), and olefins (e.g., ethylene, propylene, butadiene, methanol). 

Before 1920s, methanol was obtained from wood as a co-product of charcoal production, hence the name wood alcohol. Methanol is currently manufactured worldwide from syngas, which is derived from natural gas, refinery off-gas, coal or petroleum, as ... 

The above reaction can be carried out in the presence of a variety of catalysts including Ni, Cu/Zn, Cu/SiO, Pd/SiO, and Pd/ZnO. In the case of coal, it is first pulverized and cleaned, then fed to a gasifier bed where it is reacted with oxygen and steam to produce the syngas. A 2 1 mole ratio of hydrogen to carbon monoxide is fed to a fixed-catalyst bed reactor for methanol production. Also, the technology for making methanol from natural gas is already in place and in wide use. Ciurent natural gas feedstocks are so inexpensive that even with tax incentives renewable methanol has not been able to compete economically. 

Formaldehyde. The two commercial processes for the production of formaldehyde are the oxidation of light hydrocarbons and the oxidation of methanol, which in turn may be derived from natural gas. The current production rate of formaldehyde is approximately 200,000,000 pounds per year (water-free basis), of which 80% is used in the plastics industry (12). 

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