Coal To Olefins &

Methanol To Olefins
Chemical Process Technology.
Professor:- Dr. Pravin Kodgire
 The Presentors
This is our team for todays presentation:-

Dev Thakar (22BCH005) Pratham Patel (22BCH40)

Kintu David (22BCH007) Pratik Makwana (22BCH041)

Sandip Tiwari (22BCH022)

Vinay Sukhiyajiwala (22BCH031)

Milap Jogidas (22BCH035)

Harshwardhan Pawale (22BCH037)

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 Table of contents
01 02
Introduction Coal to olefins
What are olefins? Coal as a feedstock.

03 04
Methanol to olefins Conclusion
Directly using methanol as Our thoughts and your questions
feedstock
 01
Intoduction
What are olefins? What are they used for? What is the economic value for
it?
 Olefins!
Olefins are unsaturated compounds with a formula of
CnH2n. The name of these compounds ends with –ene,
such as ethene (ethylene) and propene (propylene)
 Introduction to Olefins
Olefins are a class of chemicals made up of
hydrogen and carbon with one or more
pairs of carbon atoms linked by a double
bond. They are used as building block
materials for products such as plastics,
detergents, and adhesives. Ethylene,
propylene and 1,3-butadiene are examples
of olefins.
One of the earliest processes where
olefins were produced came in the
early 1900s through thermal cracking.
This technique uses high
temperatures and high pressure to
break up large hydrocarbons into
smaller compounds. They can also be
produced by other forms of cracking,
such as hydrocracking and fluid
catalytic cracking.
 Importance of Olefins
Olefins, also known as alkenes, are vital
compounds used in various industries due to their
versatile properties. They are key in processes like
steam cracking, where saturated hydrocarbons are
broken down into smaller molecules. Commonly
derived from petroleum, olefins serve as
precursors for a wide range of products, including
plastics and chemicals. Understanding their
behavior through techniques like NMR
spectroscopy is crucial for studying their structure
and reactivity.
 Two basic Olefins:-
Ethylene
Ethylene, a crucial organic compound, is
extensively manufactured worldwide from
petroleum and natural gas through thermal
cracking. This process involves applying heat
and pressure to break down molecules.
Additionally, ethylene is naturally present in
the environment and is emitted by various
sources like plants, forest fires, cigarette
smoke, and incomplete combustion of fossil
fuels.
1,3 Butadiene
1,3-Butadiene is a colourless gas with a
mild gasoline odor. Many consumer goods
and materials, including tires, synthetic turf,
carpet backings, gloves and wetsuits, are
made from the synthetic elastomers,
latexes and plastics produced using
styrene-butadiene rubber, polybutadiene
rubber and neoprene.
Chemicals from coal:-
 Two major process of olefins mfg:-

CTO AND MTO

Coal to olefins method Methanol to olefins
uses coal as a feedstock. method uses methanol as
a feedstock.
 Coal to Olefins:-
Coal
Coal serves as a valuable resource for
olefins feedstock, offering an alternative to
traditional sources like petroleum and
natural gas. Processes such as coal-to-
olefins enable the conversion of coal into
olefins, providing a pathway for chemical
production . This utilization of coal
diversifies feedstock options.
Syngas
Syngas, also known as synthesis gas, is a versatile
mixture of hydrogen and carbon monoxide, typically
with varying ratios and containing traces of carbon
dioxide and methane . It is primarily produced through
gasification technology, often from waste biomasses,
resulting in a mixture of H2, CO, and CO2. This
combustible gas plays a vital role in various
applications, including power generation, fuel
synthesis, and chemical production, offering a flexible
and sustainable energy source

Fischer Tropsch
The Fischer-Tropsch (FT) process is a renowned chemical
Conversion
reaction mechanism converting a blend of carbon
After syngas production it is
monoxide and hydrogen, known as syngas, into a variety of converted into methanol and the
hydrocarbons, including liquid fuels. Originally discovered
by German chemists, it's utilized for synthesizing liquid is again converted into olefins
fuels from diverse hydrocarbon sources, showcasing its
versatility. This synthesis holds significance in various from the methanol produced from
applications, such as gasification and liquid fuel production,
offering a pathway for utilizing diverse feedstocks like coal,
the syngas through a series of
natural gas, and biomass to produce valuable various operations and
hydrocarbons.
processes.
 Process Explanation:-
Process name Biology Physics
A little brief about the process. Venus has extremely high Neptune is far away from us
temperatures

Astronomy Medicine Technology

Mercury is the closest planet to Saturn is a gas giant with several Jupiter is the biggest planet of
the Sun rings them all
 Different Processes and Technological trends:-
Conceptual Design and Analysis of a Alternative
Natural Gas Assisted Coal-to Olefins
Process for CO2 Reuse Steam Cracking feedstock
Shale gas , Biomass, etc.

Alternative Catalytic Coal Direct Coal

Technologies Pyrolysis
Advances in catalytic coal pyrolysis technology
Valorizing methane into higher
enable the conversion of coal into olefins through
hydrocarbons. controlled heating in the presence of catalysts,
offering a more efficient and environmentally friendly
route
Liquefaction
Direct coal liquefaction technologies involve the
conversion of coal into liquid hydrocarbons, including
olefins, through hydrogenation processes. Continuous
advancements aim to enhance the selectivity and
yield of olefins in this process
Advantages and disadvantages:-
Advantages:-
1.) Abundant feedstock.
2.) Reduced product cost.
3.) CO2 reduction potential.
4.) Energy efficient.
5.) Diversification of feedstock.
6.) Strategic utilization of resources.
Disadvantages:-
1.) High Cost.
2.) Environmental concerns.
3.) Resource intensive.
Olefin production distribution:-
“The best way to predict the
future is to create it."

—Peter Drucker
Methanol to olefins:-
In this process the feedstock used is directly the
methanol skipping the syngas production and cracking
process and starting the conversion from the methanol.
 Approx. 400
million tons.
The annual global production of olefins from methanol
varies depending on market demand and production
capacity. However, it's estimated that approximately
400 million tons of olefins are produced annually,
utilizing about one billion tons of hydrocarbon
feedstock, including methanol
 Methanol
Methanol plays a crucial role in the methanol-to-olefins (MTO) production process.
In MTO, methanol undergoes a catalytic conversion into light olefins such as
ethylene and propylene. The process involves the dehydration of methanol to form
dimethyl ether (DME), which then undergoes further conversion to produce olefins.
Methanol serves as a versatile feedstock for olefin production, offering advantages
such as cost-effectiveness and flexibility in sourcing

Catalyst
The catalysts commonly involved in the Methanol to Olefins (MTO)
process are zeolites, particularly ZSM-5 and SAPO-34 [1]. These
catalysts facilitate the conversion of methanol into valuable olefins
like ethylene and propylene

Process
The process through which methanol is converted to olefins is commonly known as
the "Methanol-to-Olefins" (MTO) process . In the MTO process, methanol undergoes
a series of reactions over catalysts such as acidic zeolites like ZSM-5, resulting in
the production of light olefins, predominantly ethylene and propylene. This reaction
is an autocatalytic process, where the initial formation of products enhances the
conversion of methanol.

25%
Feedstock Preparation
Methanol, a simple alcohol derived
from various sources like natural gas
or biomass, serves as the primary
feedstock
Process Brief:-
50% 75%
Catalytic Reaction Product Separation
Methanol undergoes conversion over The produced olefins are separated from
solid acid catalysts, typically zeolites the reaction mixture using various
separation techniques, ensuring high purity
like H-ZSM-5
and yield of the desired products.

Step 01
Methanol, typically derived
from natural gas, coal, or
biomass, serves as the
primary feedstock for the
MTO process
Step 03
The conversion of methanol to
olefins occurs via several
complex reaction pathways,
including methanol dehydration,
carbocation formation, and
subsequent oligomerization and
cracking reactions
Step by step
Step 02
01 02 Methanol undergoes catalytic
conversion in the presence of zeolite-
Methanol based catalysts, such as SAPO-34 or
H-ZSM-5, at elevated temperatures
TO
(~350-550°C) to form lower olefins,
primarily ethylene and propylene
Olefins
Step 04
03 04 The reactor effluent containing
olefins, heavier hydrocarbons,
water, and other byproducts is
cooled, and water is separated
from the product gas stream.
 Step by step

Step 05 Step 06
Separation technologies, such as 05 06 The separated olefinic fraction
distillation or adsorption, are undergoes further purification
employed to separate olefins Methanol TO and refining processes to
from other components in the remove impurities and optimize
product stream Olefins product quality

Step 07 Step 08
The purified ethylene and 07 08 The Produced olefins
propylene obtained from the
MTO process serve as crucial are then used in
feedstocks for various manufacturing of
downstream industries,
various other
including plastics, chemicals,
and polymers products.
 Catalysts in MTO process:-
The catalyst commonly used in the methanol-to-olefins (MTO)
process is zeolite-based, with the most prevalent types being
H-ZSM-5 and SAPO-34. These catalysts facilitate the
conversion of methanol into light olefins, primarily ethylene
and propylene, through a series of complex reactions. H-ZSM-
5, a highly siliceous zeolite, offers high selectivity to
propylene, making it advantageous for industrial applications.
SAPO-34, on the other hand, provides superior selectivity to
ethylene. Both catalysts possess unique pore structures and
acidic properties, enabling them to catalyze the dehydration,
carbocation formation, and subsequent oligomerization and
cracking reactions involved in the MTO process efficiently. The
choice between these catalysts depends on factors such as
desired product distribution, process conditions, and economic
considerations
 Different Processes and Technological trends:-
MAPO-18 have been studied for
their potential in the MTO
process
Hybrid
Technologies
Hybrid technologies integrating MTO with other
processes, such as methanol-to-gasoline (MTG),
are being explored to diversify product
portfolios and maximize resource utilization
Integration of Renewable
Energy
Integration of
Digitalization and
Automation
Industry 4.0 principles are increasingly applied
in MTO plants, leveraging digitalization and
automation to optimize operations, enhance
safety, and reduce operational costs
Process Optimization
and Intensification:
Scale-up of
Commercial Plants
With successful pilot projects, there's a trend
towards scaling up MTO plants for commercial
production, driven by advancements in
technology and favorable market conditions
Advantages and disadvantages:-
Advantages:-
1.) Diverse feedstock.
2.) Reduced green house gas emissions.
3.) Low energy comsumption.
4.) High product selectivity..
Disadvantages:-
1.) Catalyst Deactivation.
2.) Complex Reaction Mechanism.
3.) Capital Intensive
4.) Energy intensive seperation.
REFERENCES:-

https://www.chemicalsafetyfacts.org/chemicals/olefins/
https://www.petro-online.com/news/fuel-for-thought/13/breaking-news/an-introduction-to-olefins/48730
https://www.sciencedirect.com/science/article/pii/S2095809917302965
https://www.researchgate.net/figure/Simplified-layout-of-a-methanol-to-olefins-plant_fig7_286732627

Modeling of methanol to olefins (MTO) process in a ... - ScienceDirect

Methanol-to-olefins process technology: current status and ... - ResearchGate
Kinetic Modeling of Catalytic Olefin Cracking and Methanol ... - MDPI
Advances in Catalysis for Methanol-to-Olefins Conversion – ScienceDirect
The view of technological innovation in coal industry under - Springer
Analysis of China's olefin industry using a system ... - ScienceDirect
New olefin production routes—A review of defossilised ... - Frontiers
New Trends in Olefin Production – Engineering
REFERENCES:-

https://www.researchgate.net/publication/330659912_Methanol-to-
olefins_process_technology_current_status_and_future_prospects
https://pubs.acs.org/doi/10.1021/acscatal.5b00007
https://www.linkedin.com/pulse/upcoming-trends-methanol-market-2023-2031-mahesh-j-my2pf?trk=article-ssr-
frontend-pulse_more-articles_related-content-card
https://www.spglobal.com/commodityinsights/en/ci/products/chemical-technology-pep-methanol-to-olefins-
2007.html
https://www.tandfonline.com/doi/full/10.1080/10916466.2018.1555589
https://d-nb.info/1082978582/34