This page is maintained by Ayşenur Demirci and Dündar Alp Erkenci as a part of requirement Econ 318 at Bilkent
University for the 2018-2019 Spring Semester, supervised by Gökberk Bilgin. This
project is finalized by June 11, 2019. The information reported here uses available
information by this date.
Turkey may have several natural gas transportation routes in the future.
This may cause excess supply of natural gas. Turkey may benefit from this
excess supply by producing various petrochemical products such as methanol.
We studied two methods to produce methanol: sg-CTM and d-CTM. Turkey spent 205,227,944 USD to import 614,364,435
kg of
methanol in 2017. Our simulations suggest that to produce 614,364,435 kg of
methanol via sg-CTM, it requires about 0.603 bcm of
natural gas and it costs us 190,016,551
USD per
year. If d-CTM is used to produce methanol, its cost is 374,951,875 USD for the same amount. Thus, adopting a sg-CTM
project produces net present value of 46.65 million USD. Methanol is one of the most essential product that can be produced by natural gas. Thus, producing
items that have high
value addition to contribution of the natural gas imports will contribute more to the
Turkish Economy.
Natural gas prices might be indexed to oil prices with a delay. Thus,
current lower prices in oil (even if that might decrease natural gas in the
future.) may make methanol production not economically viable in the current
period. However, as long as the relative price fluctuation of natural gas to
oil is less than 4.216%, then this natural gas based methanol
production is economically feasible.
Natural gas is a fossil energy source that formed
deep beneath the earth's surface. It contains many different compounds. The
largest component of natural gas is methane (CH4). Natural gas
contains smaller amounts of natural
gas liquids (NGL; which are also hydrocarbon
gas liquids), and non-hydrocarbon gases, such as carbon dioxide and water vapor. It
can also be used gas as a fuel and to make materials and chemicals. Natural gas
is an ingredient used to make products such as fertilizer, antifreeze,
plastics, pharmaceuticals and fabrics. It is also used to manufacture a wide
range of chemicals such as ammonia, methanol, butane, ethane, propane, and
acetic acid. We use for
industry, conversion and service sectors and housing.
LNG is a way of transporting natural gas
long distances when pipelines are not an option—across oceans, for example.
Producing LNG involves compressing and cooling natural gas to around minus 260
degrees Fahrenheit. That process converts the gas to a liquid and cuts its
volume to 1/600th of the original, making it possible to ship the LNG in
special tankers. Once it gets to its destination, the LNG can be unloaded at a
receiving terminal and regasified—turned back into a gas. It can then be
delivered through local pipelines to customers. The infrastructure for LNG—for
cooling and compressing, shipping and regasifying—can be extensive and
expensive. A natural gas processing plant is a facility designed to “clean” raw
natural gas by separating impurities and various non-methane hydrocarbons and
fluids to produce what is known as 'pipeline quality' dry natural gas.
The fastest growing use of natural gas today is for the generation of
electric power. Natural gas power plants usually generate electricity in gas
turbines, directly using the hot exhaust gases of fuel combustion. Residential
and commercial uses include heating buildings for space and water heating and
for cooking.
Natural gas is an important and emerging commodity.
Turkey is an important importer of the commodity. Natural gas has an important
use in Petrochemical Sector. Natural gas sees a broad range of other uses in
industry, as a source of both heat and power and as an input for producing
plastics and chemicals. Most hydrogen gas (H₂) production, for example, comes from
reacting high temperature water vapor (steam) with methane.
Table
1: Turkey's Amount of Imported Natural Gas by Countries between 2005-2017
(in
million cubic meters)
Year\Country |
Russia |
Iran |
Azerbaijan |
Algeria |
Nigeria |
Others* |
Total |
2005 |
17,524 |
4,248 |
0 |
3,786 |
1,013 |
0 |
26,571 |
2006 |
19,316 |
5,594 |
0 |
4,132 |
1,100 |
79 |
30,221 |
2007 |
22,762 |
6,054 |
1,258 |
4,205 |
1,396 |
167 |
35,842 |
2008 |
23,159 |
4,113 |
4,580 |
4,148 |
1,017 |
333 |
37,350 |
2009 |
19,473 |
5,252 |
4,960 |
4,487 |
903 |
781 |
35,856 |
2010 |
17,576 |
7,765 |
4,521 |
3,906 |
1,189 |
3,079 |
38,036 |
2011 |
25,406 |
8,190 |
3,806 |
4,156 |
1,248 |
1,069 |
43,874 |
2012 |
26,491 |
8,215 |
3,354 |
4,076 |
1,322 |
2,464 |
45,922 |
2013 |
26,212 |
8,730 |
4,245 |
3,917 |
1,274 |
892 |
45,269 |
2014 |
26,975 |
8,932 |
6,074 |
4,179 |
1,414 |
1,689 |
49,262 |
2015 |
26,783 |
7,826 |
6,169 |
3,916 |
1,240 |
2,493 |
48,427 |
2016 |
24,540 |
7,705 |
6,480 |
4,284 |
1,220 |
2,124 |
46,352 |
2017 |
28,690 |
9,251 |
6,544 |
4,617 |
1,344 |
4,804 |
55,250 |
*Others
represent the countries of imported spot LNG.
Sources:
Doğal Gaz Piyasası Sektör Raporu 2017 published by T.C. EPDK.
Turkish
Natural Gas Market Report 2015 published by T.C. EPDK.
“Sektöre Dair” 2018 published by
TPAO.
Table
2: Usage of Natural Gas in Turkey (2017)
Area of Usage |
Ratio |
Amount (mcm) |
Industry
sector (18% is used in Petrochemistry.) |
28% |
15,078.16 |
Conversion
sector (94% is used in power stations.) |
39% |
20,484.20 |
Housing
(mostly used in heating.) |
25% |
13,301.49 |
Service
sector |
6% |
3,874.30 |
Other |
2% |
649.10 |
Source:
GAZBİR’s 2017 Doğal Gaz Sektör Raporu (2018).
Table 2.1: Turkey Natural Gas Consumption
by Sector in 2017 (more detailed)
Sector |
Consumption (mcm) |
1. Conversion Sector |
20,484.20 |
1.1 Power Plants |
19,309.90 |
1.2 Heat and Power Plants (CHP) |
58.21 |
1.3 Heat Plants |
0.00 |
2. Energy Sector |
503.60 |
2.1 Oil Refineries |
180.70 |
2.2 Blast Furnaces |
306.12 |
2.3 Consumed as fuel in
Electricity, CHP and Heat Power Plants |
10.53 |
3. Transportation Sector |
141.50 |
3.1 Vehicle fuel |
83.43 |
3.2 Pipeline transportation |
56.70 |
4. Industry Sector |
15,078.16 |
4.1 Wood products processing |
195.21 |
4.2 Chemical (including
petrochemical) |
2,593.89 |
4.3 Mining and quarrying |
140.38 |
4.4 Machinery Industry |
67.29 |
4.5 Textiles, leather &
clothing industry |
802.37 |
4.6 Tobacco and tobacco products |
12.70 |
4.7 Transportation vehicles
industry (automotive, aircraft industry, etc.) |
150.31 |
4.8 Alcohol and alcohol products |
19.87 |
4.9 Nonmetallic minerals (glass,
ceramic, cement, etc.) |
1,786.70 |
4.10 Iron – Steel |
1,518.93 |
4.11 Non-ferrous metal production and
processing (chrome, copper, etc.) |
450.05 |
4.12 Food and beverage |
1,139.74 |
4.13 Fertilizer |
493.40 |
4.14 Construction |
600.56 |
4.15 Paper, cellulose and printing |
255.82 |
5. Service Industry |
3,874.30 |
5.1 Business |
1,835.06 |
6.1 Housing |
13,301.49 |
6.2 Agriculture / Forestry |
20.46 |
6.3 Livestock breeding |
58.62 |
Source: GAZBİR’s 2017
Doğal Gaz Sektör Raporu (2018).
Table
3: Top 10 Major Natural Gas Producer Countries (2018)
Country |
Production
(in billion cubic meters) |
The United States |
687 |
Russia |
627 |
Iran |
163 |
Qatar |
155 |
Canada |
137 |
China |
115 |
Norway |
109 |
Netherlands |
86 |
Saudi Arabia |
84 |
Algeria |
55 |
Source:
“Top 10 Largest Gas Producing Countries In The World” published by The Daily Records,
2019.
Table
4: Top 10 Major Countries by Proven Natural Gas Reserves (start of 2018)
Country |
Proven Reserves (in trillion cubic meters) |
Russia |
35 |
Iran |
33,2 |
Qatar |
24,9 |
Turkmenistan |
19,5 |
The
United States |
8,7 |
Saudi
Arabia |
8 |
Venezuela |
6,4 |
The
United Arab Emirates |
5,9 |
China |
5,5 |
Nigeria |
5,2 |
Source:
BP, Statistical Review of World Energy,
2018.
Table 5: Uses of Natural
Gas in Petrochemical Industry
Production |
Conversion |
Type |
Usage |
methanol
(CH₃OH) |
ethylene,propylene, formaldehyde |
stable* |
-Can
turn into a variety of materials such as polyethylene, PVC plastics, resins,
antifreeze, paints, automotive components, materials packaging, textiles, and
countless other specialty plastics and foams, paint, glue, fuel additive,
acetic acid |
ethane
(C₂H₆) |
|||
propane (C3H8) |
|||
butane (C4H10) |
|||
ammonia (NH3) |
|
|
-
world synthetic fertilizers -nitrogen
compounds ( nitric acid, ammonia nitrate) -refrigerant
as replacement for CFC’s |
methane (CH4) |
|
|
-The
modern method of direct reduction of iron to produce steel directly removes
oxygen by reacting the ore with a hydrogen-rich gas and CO-produced by
catalyzing rich methane. As in the production of fertilizers, natural gas
provides the energy and raw materials for the process |
|
electricity |
|
aluminium
production |
Higher molecular weighted hydrocarbons:
Heptane (C7H16) or Pentane (C5H12) |
|
|
liquefied
petroleum gas |
propane (C3H8)
and butane (C4H10) together |
|
|
household
fuel |
|
liquid motor fuel |
|
With
gas-to-liquid technology |
Production in US |
|
|
Mostly
methanol-based products, with increasing role of ethane. Both of them
includes polyethylene, PVC plastics, resins, antifreeze, paints, automotive
components, materials packaging, textiles, and countless other specialty
plastics and foams, paint, glue, fuel additives, acetic acid. |
*Can
be transported by pipeline or special vessels for petrochemical plants
Source:
Grossman Research Group.
Natural
gas may be used as replacement for coal as the primary early carbon management
technique (source reduction). Deployment of
highly efficient Natural Gas Combined Cycle plants for electricity
production and chemical plant cogeneration may increase.
For
many financial intermediates, there might be a competition between methane and
ethane feedstocks resulting from advances in catalysis, energy efficiency, and
process design optimization. Its permanency will depend on how long shale gas
remains plentiful and whether it is wet or dry. If plentiful and wet, then the
existing US ethane-based chemical industry infrastructure will remain world
competitive. If plentiful but dry, new
methane chemistries will emerge, but based on methane steam reforming
syngas. If oil shale is developed using
directional drilling and hydraulic fracturing gas shale technology, the role
for naphtha cracking infrastructure may be extended.
Table
6: Future of Natural Gas in Chemical Industry
Possible event |
Detail |
Possible
Future Use |
|
Natural
gas may be used as replacement for coal. |
As
early carbon management technique (source reduction). |
Natural gas may be used
in deployment of highly efficient Natural Gas Combined Cycle plants. |
For electricity
production and chemical plant cogeneration. |
Existing ethane-based
chemical industry will remain world competitive. |
If shale gas remains
plentiful and wet. |
New methane chemistries
may emerge but based on methane steam reforming syngas |
If shale gas remains
plentiful but dry. |
The role of naphtha
cracking infrastructure may be extended. By that, we can use it as raw
materials for the creation of petrochemicals including butane and gasoline.
(See table 5 for uses of butane in petrochemical industry) |
If oil shale is developed
using directional drilling and hydraulic fracturing gas shale technology. |
Remote
Future |
|
Electricity power plant fuel switching could dominate
the rate of shale gas development. |
|
Amount of gas producible
from shale formations might be less than predicted. |
|
Additional shale
formations might be more expensive to produce than first experiences suggest. |
|
Some shale formations
might be geologically inappropriate for development (e.g. shallow formations
near groundwater supplies). |
|
Production technologies
(especially hydraulic fracturing) might have unintended environmental
consequences leading to political or regulatory restrictions. |
|
Source:
Petroblogger.
U.S. natural gas plant liquids (NGPL)
production has nearly doubled since 2010, outpacing the rate of natural gas
production growth and setting an annual record of 3.7 million barrels per day
(b/d) in 2017. NGPLs are produced at natural gas processing plants, which
separate liquids from raw natural gas to produce pipeline-quality dry natural
gas. Marketed natural gas includes both NGPLs and dry natural gas.
Growth in U.S. natural gas production
has been driven by shale gas, particularly from the Appalachian region, and to
a lesser extent by associated natural gas, a byproduct of crude oil production.
The high liquids content of many shale plays means that growth in marketed
natural gas production has led to increased production of NGPLs.
NGPLs accounted for a growing share of
marketed natural gas production between 2010 and 2017, making up 15% of total
marketed production in 2017 in energy content terms, up from 11% in 2010. The
increased share of NGPL production can be attributed to expanded capacity to
produce, transport, and consume NGPL products. Increases in NGPL production
pushed two measures of total natural gas production—gross withdrawals and
marketed production—to record highs in 2017.
NGPLs that come out of natural gas
plants are a mix of ethane, propane, isobutane and normal butane, and natural
gasoline that requires further processing to convert into separate marketable
products. The yield of these liquid products, especially ethane, varies
significantly depending on product prices, the ability to process and
distribute them to market, and the makeup of the raw natural gas.
With the exception of ethane, natural
gas plant operators may leave only trace amounts of NGPLs in
dry—pipeline-quality—natural gas. Natural gas specifications set by pipeline
operators allow for significant amounts of ethane to be left in dry gas at the
discretion of natural gas plant operators. If ethane prices are low relative to
the price of natural gas on a heating-value equivalent basis, more ethane is
likely to be left in the dry natural gas stream, provided that the mix can
still meet specifications required by natural gas pipeline operators.
Table
6.1: Change in U.S. Ethane Prices by Years
Year |
U.S. Ethane Prices |
2011-2012 |
Began declining. |
2013-2015 |
Remained consistently lower than the price of natural
gas. As a result, the ethane share of total U.S. NGPLs declined between 2012
and 2015, when natural gas producers had the incentive to leave as much
ethane in pipeline natural gas as possible to capture its value as a heating
fuel instead of recovering and selling it as a separate product. |
2016-2017 |
Began to increase. Ethane prices surpassed natural gas
prices on a heat-content equivalent basis, causing the ethane share of U.S.
NGPL production to increase as well. |
Source:
MacIntyre 2018
Two U.S. ethane export terminals opened
in 2016, and two U.S. ethane-consuming petrochemical plants opened in 2017,
providing additional sources of demand. Annual average U.S. NGPL production
increased nearly 400,000 b/d between 2015 and 2017, and about 175,000 b/d of
this increase resulted from growth in ethane production.
Several more petrochemical plants are
expected to come online in the United States in 2018 and 2019, further driving
increases in ethane demand and prices. First-quarter 2018 U.S. ethane
production was 260,000 b/d higher than the first-quarter 2017 level. Ethane
production will increase by another 440,000 b/d between the first quarter of
2018 and the fourth quarter of 2019, according to EIA’s Short-Term Energy
Outlook, accounting for 52% of the growth in NGPL production. (MacIntyre 2018).
Table
7: Import Product Groups of Chemical (including petrochemical) Industry in
Turkey (Value: US$ 1,000)
Product/Year |
2015 |
2016 |
2017 (January-August) |
Fuels
/ mineral oils |
37,843,294 |
27,169,080 |
23,354,890 |
Inorganic
chemicals |
1,388,743 |
1,219,692 |
891,813 |
Organic
chemicals |
4,715,525 |
4,359,682 |
3,466,661 |
Pharmaceutical
substances |
4,296,440 |
4,217,114 |
2,772,705 |
Fertilizer |
1,250,919 |
1,275,609 |
907,670 |
Dyes,
sealants, varnishes |
1,808,606 |
1,738,937 |
1,302,884 |
Perfumery
and cosmetics |
1,101,905 |
1,113,776 |
797,777 |
Soaps |
779,400 |
772,612 |
565,536 |
Albuminoid
products |
466,029 |
435,625 |
295,683 |
Explosive
materials |
55,052 |
47,137 |
31,851 |
Substances
for cinematography and photography |
156,804 |
145,579 |
88,487 |
Various
chemicals |
2,049,569 |
2,024,132 |
1,460,186 |
Plastics
and derivatives |
12,268,256 |
11,627,985 |
8,716,916 |
Rubber
and derivatives |
2,525,199 |
2,560,926 |
1,877,001 |
Total |
70,705,741 |
58,707,887 |
46,530,062 |
Source:
TÜİK
7.1.Defined by methane content
and formation process
As previously mentioned, natural gas is
primarily methane (CH4)
with smaller quantities of other hydrocarbons. It was formed millions of years
ago when dead marine organisms sunk to the bottom of the ocean and were buried
under deposits of sedimentary rock. Subject to intense heat and pressure, these
organisms underwent a transformation in which they were converted to a gas over
millions of years (EIA, 2015).
There are two general types of natural
gas, defined by their methane content, that reflect differences in the
formation processes:
➢
Biogenic gas (±
95% methane), or “dry” gas, which was formed by bacterial decay at shallow
depth. Biogenic gas is created by methanogenic organisms in marshes, bogs,
landfills, and shallow sediments. Deeper in the earth, at greater temperature
and pressure, thermogenic gas is created from buried organic material (US Geological Survey, 2010 &
EIA). It is more appropriate to produce ethane due to its rich methane content.
➢
Thermogenic gas
(<95% methane), is available as associated gas in crude oil reservoirs and
as non-associated gas in natural gas reservoirs and in the form of condensates
(also known as wet gas) (Senthamaraikkannan, Chakrabarti & Prasad,
2014). Thermogenic gas is a lower quality gas formed at high temperatures. Wet
gas on the other hand contains compounds such as ethane and butane, in addition
to methane. These natural gas liquids (NGLs for short) can be separated and
sold individually for various uses, such as refrigerants and to produce
petrochemical products, like plastics (House of Commons, 2011). Thermogenic
hydrocarbon gases are primarily derived from oil and gas migration from deeper
strata. The bulk of the gases migrate up to the seafloor where suitable P-T
conditions exist for the formation of natural gas hydrate; small amounts of gas
hydrate thermogenic gas can remain sequestrated within the submarine sediments.
These hydrocarbon molecules are rather large. So they form larger gas hydrate
structures — large enough to contain methane and other hydrocarbons (Zou, 2013). In short, it is appropriate to
produce ethane (but not as
biogenic gas) and butane and also it is suitable to form larger gas hydrate structures containing
methane and other hydrocarbons.
7.2.Defined by being
conventional or unconventional
Natural gas that is economical to
extract and easily accessible is considered “conventional.” Conventional gas is
trapped in permeable material beneath impermeable rock. Natural gas found in
other geological settings is not always so easy or practical to extract. This
gas is called “unconventional.” New technologies and processes are always being
developed to make this unconventional gas more accessible and economically
viable. Over time, gas that was considered “unconventional” can become
conventional (National Geographic Society, 2012). In addition, most of the
conventional reserves exist in Eastern Europe and the Middle East, while Asia
Pacific and North America hold the majority of the unconventional reserves (Senthamaraikkannan, Chakrabarti & Prasad,
2014).
7.2.1. Biogas
Biogas is a type of gas that is produced
when organic matter decomposes without oxygen being present. This process is
called anaerobic decomposition, and it takes place in landfills or where
organic material such as animal waste, sewage, or industrial byproducts are
decomposing. Biogas is biological matter
that comes from plants or animals, which can be living or nonliving. This
material, such as forest residues, can be combusted to create a renewable
energy source. Biogas contains less methane than natural gas, but can be
refined and used as an energy source (National Geographic Society, 2012).
7.2.2. Deep Natural Gas
Deep natural gas is an unconventional
gas. While most conventional gas can be found just a few thousand meters deep,
deep natural gas is located in deposits at least 4,500 meters (15,000 feet)
below the surface of the Earth. Drilling for deep natural gas is not always
economically practical, although techniques to extract it have been developed
and improved (National Geographic Society, 2012).
7.2.3. Shale
Shale gas is another type of
unconventional deposit. Shale is a fine-grained, sedimentary rock that does not
disintegrate in water. Some scientists say shale is so impermeable that marble
is considered “spongy” in comparison. Thick sheets of this impermeable rock can
“sandwich” a layer of natural gas between them. Shale gas is considered an
unconventional source because of the difficult processes necessary to access
it: hydraulic fracturing (also known as fracking) and horizontal drilling. Fracking
is a procedure that splits open rock with a high-pressure stream of water, and
then “props” it open with tiny grains of sand, glass, or silica. This allows
gas to flow more freely out of the well. Horizontal drilling is a process of
drilling straight down into the ground, then drilling sideways, or parallel, to
the Earth’s surface (National Geographic Society, 2012).
7.2.4. Tight Gas
Tight gas is an unconventional natural
gas trapped underground in an impermeable rock formation that makes it extremely
difficult to extract. Extracting gas from “tight” rock formations usually
requires expensive and difficult methods, such as fracking and acidizing
(National Geographic Society, 2012).
7.2.5. Coalbed Methane
Coalbed methane is another type of
unconventional natural gas. As its name implies, coalbed methane is commonly
found along seams of coal that run underground. Historically, when coal was
mined, the natural gas was intentionally vented out of the mine and into the
atmosphere as a waste product. Today, coalbed methane is collected and is a
popular energy source (National Geographic Society, 2012).
7.2.6. Gas in Geopressurized Zones
Another source of unconventional natural
gas is geopressurized zones. Geopressurized zones form 3,000-7,600 meters
(10,000-25,000 feet) below the Earth’s surface. These zones form when layers of
clay rapidly accumulate and compact on top of material that is more porous,
such as sand or silt. Because the natural gas is forced out of the compressed
clay, it is deposited under very high pressure into the sand, silt, or other
absorbent material below. Geopressurized zones are very difficult to mine, but
they may contain a very high amount of natural gas. In the United States, most
geopressurized zones have been found in the Gulf Coast region (National
Geographic Society, 2012).
7.2.7. Methane Hydrates
Methane hydrates are another type of
unconventional natural gas. Methane hydrates were discovered only recently in
ocean sediments and permafrost areas of the Arctic. Methane hydrates form at
low temperatures (around 0°C, or 32°F) and under high pressure. When
environmental conditions change, methane hydrates are released into the
atmosphere. The United States Geological Survey (USGS) estimates that methane
hydrates could contain twice the amount of carbon than all of the coal, oil,
and conventional natural gas in the world, combined (National Geographic
Society, 2012).
7.3.Defined by being fuel gas
7.3.1.
Associated petroleum gas (APG)
Associated petroleum gas (APG), or associated gas, is a form of natural
gas which
is found with deposits of petroleum, either dissolved in the oil or as a
free "gas cap" above the oil in the reservoir (Røland; 2010 and The
Society of Petroleum Engineers; 2005). Historically, this type of gas was
released as a waste product from the petroleum extraction industry. It may be a
stranded
gas reserve due to the remote location of the oil field, either at sea or on land,
this gas is simply burnt off in gas
flares(Schlumberger
Limited, 2011). When this occurs the gas is referred to as flare gas. The gas
can be utilized in a number of ways after processing: sold and included in the
natural gas distribution networks, used for on-site electricity generation with
engines (Clarke Energy, 2011) or turbines, reinjected for enhanced
oil recovery, converted from gas
to liquids producing synthetic
fuels or used
as feedstock for the petrochemical
industry
(Knizhnikov, A. & N Poussenkova, 2009).
7.3.2.
Coalbed
methane (CBM)
Coalbed methane (CBM or coal-bed methane), coalbed gas, coal seam gas
(CSG), or coal-mine methane (CMM) is a form of natural gas extracted from coal
beds (Clark Energy, 2014). In recent decades it has become an important source
of energy in United States, Canada, Australia, and other countries. The term
refers to methane adsorbed into the solid matrix of the coal. It is called
'sweet gas' because of its lack of hydrogen sulfide. The presence of this gas
is well known from its occurrence in underground coal mining, where it presents
a serious safety risk. Coalbed methane is distinct from a typical sandstone or
other conventional gas reservoir, as the methane is stored within the coal by a
process called adsorption. The methane is in a near-liquid state, lining the
inside of pores within the coal (called the matrix). The open fractures in the
coal (called the cleats) can also contain free gas or can be saturated with water
(Islam, 2014). Unlike much natural gas from conventional reservoirs, coalbed
methane contains very little heavier hydrocarbons such as propane or butane,
and no natural-gas condensate. It often contains up to a few percent carbon
dioxide.
7.3.3.
Compressed natural gas (CNG)
Compressed natural gas (CNG) (methane stored at high pressure) is a fuel
which can be used in place of gasoline, diesel fuel and propane/LPG (Liquefied
Petroleum Gas). CNG combustion produces fewer undesirable gases than the
aforementioned fuels. In comparison to other fuels, natural gas poses less of a
threat in the event of a spill, because it is lighter than air and disperses
quickly when released. Biomethane – cleaned-up biogas from anaerobic digestion
or landfills – can be used. CNG (Compressed natural gas) is made by compressing
natural gas, (which is mainly composed of methane, CH4), to less
than 1 percent of the volume it occupies at standard atmospheric pressure. It
is stored and distributed in hard containers at a pressure of 20–25 MPa
(2,900–3,600 psi), usually in cylindrical or spherical shapes (Shah, 2017).
7.3.4.
HCNG
Blending of hydrogen with CNG provides a blended gas termed as
hydrogen-enriched natural gas (HCNG). HCNG stands for hydrogen enriched
compressed natural gas and it combines the advantages of both hydrogen and
methane. HCNG allows customers early
hydrogen deployment with nearly commercial technology. It is being
treated as the first step towards future hydrogen economy. Engines can be calibrated
for lower NOx or greenhouse gas emissions. Any natural gas engine is
compatible to run on HCNG and can do so with minimum modifications. It also allows governments and agencies to
promote the use of hydrogen to greater number of people at less cost. HCNG can
help the hydrogen industry to develop volume and transportation solutions
while reducing costs.
HCNG can take
advantage of existing
investment in natural
gas infrastructure and also has much higher volumetric energy storage
density than pure hydrogen (Nanthagopal, Subbarao, Elango, Baskar &
Annamalai, 2011).
7.3.5.
Natural-gas condensate
Natural-gas condensate is a low-density mixture of hydrocarbon liquids
that are present as gaseous components in the raw natural gas produced from many
natural gas fields. Some gas species within the raw natural gas will condense
to a liquid state if the temperature is reduced to below the hydrocarbon
dewpoint temperature at a set pressure (Speight, 2018). The natural gas
condensate is also called condensate, or gas condensate, or sometimes natural
gasoline because it contains hydrocarbons within the gasoline boiling range
(Sujan, Jamal, Hossain, Khanam & Ismail, 2015).
7.3.6.
Substitute natural gas (SNG)
Substitute Natural Gas, which is interchangeable with Natural Gas can be
manufactured from other fossil fuels by combining three main reaction stages;
the gasification of the feedstock with steam, or a mixture of steam and oxygen,
to produce a gas from which Methane can be synthesized from the carbon oxides
and hydrogen, and the removal of carbon dioxide.
A number of large plants were built in the United States and Japan in
the early 1970s to make SNG from Sight distillate oils to meet predicted
shortages in natural gas supplies. The process used was the CRG (Catalytic Rich
Gas) process developed by British Gas. In this process, the distillate oil is
first hydro-desulfurized and it is then gasified catalytically with steam in an
adiabatic reactor to produce a gas containing about 64% methane, 17% hydrogen
and 21% carbon dioxide, by volume, on a dry basis (Lacey, 2011).
7.3.7.
Renewable Natural Gas (RNG of Bio-SNG)
Renewable Natural Gas (RNG), also known as Sustainable Natural Gas (SNG)
or biomethane, is a biogas which has been upgraded to a quality similar to
fossil natural gas and having a methane concentration of 90% or greater (Al
Mamun & Torii, 2017). A biogas is a gaseous form of methane obtained from
biomass. By upgrading the quality to that of natural gas, it becomes possible
to distribute the gas to customers via the existing gas grid within existing
appliances (Chuol, 2010). Renewable natural gas is a subset of synthetic
natural gas or substitute natural gas (SNG). Renewable natural gas can be
produced and distributed via the existing gas grid, making it an attractive
means of supplying existing premises with renewable heat and renewable gas
energy, while requiring no extra capital outlay of the customer. Renewable
natural gas can be converted into liquefied natural gas (LNG) for direct use as
fuel in transport sector. LNG pricing compete with gasoline or diesel as it can
replace these fuels in the transport sector.
There are two primary sources of gas:
associated gas reserves and non-associated gas reserves. The economic drivers
for monetizing gas from these two basic sources are quite different and are
likely to lead to different gas utilization routes. Hence, it is useful to
understand the difference in economic characteristics of these two broad
categories of gas sources.
8.1.Nonassociated gas
Nonassociated
(natural gas reserves in unconventional oil fields) gas reserves are developed
primarily to produce natural gas. There may or may not be condensate production
together with the gas. Under these conditions, it is essential that there be a
profitable market to which to deliver the gas. As a reminder, most of the
unconventional reserves exist in Asia Pacific and North America, while Eastern
Europe and the Middle East hold the majority of the unconventional reserves (Senthamaraikkannan, Chakrabarti & Prasad,
2014).
8.2.Associated gas
Associated gas (natural gas reserves in
conventional oil fields) is gas produced as a byproduct of the production of
crude oil. Associated gas reserves are typically developed for the production
of crude oil, which pays for the field development costs. The reserves
typically produce at peak levels for a few years and then decline. Associated
gas is generally regarded as an undesirable byproduct, which is either
reinjected, flared, or vented.
According to 2010 statistics from the US
Energy Information Administration, worldwide approximately 4.3 Tcf/yr of gas
was flared or vented, and an additional 17.1 Tcf/yr of gas was reinjected (EIA,
2010). The need to produce oil and dispose of natural gas (as is the case with
associated gas) requires unique approaches in the field-development plans.
With increasing focus on sustainable
development, flaring may cease to be an option. Some countries have already
legislated against gas flaring. For example, current Nigerian policy required
all flaring to be eliminated by 2008. This policy is expected to eliminate the
waste of a valuable resource for Nigeria and attendant negative impacts on the
environment. Consequently, several key gas utilization projects have either
been recently completed or are at various stages of implementation in Nigeria.
Examples of such projects include:
Obite
Gas Plant
ChevronTexaco
Escravos GTL project
West
African gas pipeline project
Nigeria
liquefied natural gas (LNG) project (Erinne, 2001).
Methanol is a type of alcohol made primarily from natural gas. It’s a
base material in acetic acid and formaldehyde, and in recent years it is also
increasingly being used in ethylene (C2H4) and propylene
(C3H6). Mixing methanol with substances like these
enables it to be used as an intermediate material to make literally thousands
of methanol and methanol derivative products used in practically every aspect
of our lives. Methanol and its derivative products such as acetic acid and
formaldehyde created via chemical reactions are used as base materials in
acrylic plastic; synthetic fabrics and fibers used to make clothing; adhesives,
paint, and plywood used in construction; and as a chemical agent in
pharmaceuticals and agrichemicals. Its endless myriad applications have made
methanol ubiquitous in our lives and throughout society.
The versatility of methanol is making it a common fuel resource in the
power generation industry. At MGC (Mitsubishi Gas Chemical Company), they use methanol as a fuel
source not only in liquid form, but also in the form of highly efficient fuel
cell batteries. Locations and conditions where it is impractical to utilize
commercial power commonly currently use rechargeable batteries, solar cells,
and gas-powered engine generators. MGC direct methanol fuel cells (DMFCs) offer
another solution that is unmatched for its efficiency and versatility.
10. Methanol Production,
Imports and Consumption in Turkey
In Turkey, industrial production of
methanol in an amount to be used as input is not possible. However, it is known
that methanol is obtained as a by-product in various productions. For example,
methanol is produced as a by-product after the fermentation process during the
production of raw morphine from the capsule. Furthermore, after the use of
methanol in the production of DMT (DiMethyl Terephthalate), the methanol used
may also be recovered and the recovered methanol is also re-evaluated in DMT production
(Altınay, 2008). There is no methanol production in Turkey.
Table
8: Methanol Import Figures by Years in Turkey between 2002 and 2017
Year |
Amount
(kg) |
Trade
Value ($) |
2002 |
165,496,963 |
26,331,559 |
2003 |
180,952,916 |
43,202,493 |
2004 |
239,206,881 |
61,268,279 |
2005 |
285,823,225 |
76,185,791 |
2006 |
349,901,590 |
139,022,018 |
2007 |
335,575,617 |
136,279,516 |
2008 |
330,690,401 |
145,605,358 |
2009 |
331,085,428 |
77,638,762 |
2010 |
415,247,810 |
129,284,529 |
2011 |
432,921,205 |
164,776,697 |
2012 |
431,091,385 |
166,770,737 |
2013 |
463,109,009 |
217,546,856 |
2014 |
503,124,231 |
227,191,343 |
2015 |
525,646,396 |
172,248,939 |
2016 |
548,254,244 |
120,581,317 |
2017 |
Source:
TÜİK
Table
8.1: Capacities of Methanol User Companies Registered between June 2003-June
2006 and Their Breakdown by Sectors in Turkey
Methanol Industry / Production Issue |
Number of Companies |
Total Annual Methanol Consumption Capacity
(tonne / year) |
Biodiesel
Production |
158 |
427,635 |
Wood
Products Industry |
9 |
332,665 |
Chemical
Industry |
44 |
243,944 |
Other
|
71 |
60,415 |
Pharmaceutical
Industry |
10 |
43,742 |
TOTAL |
292 |
1,108,401 |
Source: TAPDK (2008).
11. How much needed natural gas
to produce methanol imported by Turkey?
In order to obtain 1 million tonnes of
methanol, approximately 0.91 bcm natural gas must be used. Additionally, in
order to attain 1 million tonnes of liquefied natural gas, approximately 1.36
bcm natural gas must be used and 1 bcm natural gas is equal to 35.5 million
mmbtu.
Table
9: The Amount of NG & LNG Needed to Produce Methanol Imported by Turkey
between 2002 and 2017
Year |
Amount
of NG (bcm) |
Amount
of NG (mmbtu) |
Amount
of LNG (kg) |
2002 |
0.15060224 |
5,346,379.52 |
110,736,941 |
2003 |
0.16466715 |
5,845,683.825 |
121,078,787 |
2004 |
0.21767826 |
7,727,578.23 |
160,057,544 |
2005 |
0.26009913 |
9,233,519.115 |
191,249,360 |
2006 |
0.31841045 |
11,303,570.98 |
234,125,331 |
2007 |
0.30537381 |
10,840,770.26 |
224,539,566 |
2008 |
0.30092826 |
10,682,953.23 |
221,270,779 |
2009 |
0.30128774 |
10,695,714.77 |
221,535,103 |
2010 |
0.37787551 |
13,414,580.61 |
277,849,640 |
2011 |
0.39395830 |
13,985,519.65 |
289,675,221 |
2012 |
0.39229316 |
13,926,407.18 |
288,450,853 |
2013 |
0.42142920 |
14,960,736.6 |
309,874,412 |
2014 |
0.45784305 |
16,253,428.28 |
336,649,301 |
2015 |
0.47833822 |
16,981,006.81 |
351,719,279 |
2016 |
0.49891136 |
17,711,353.28 |
366,846,588 |
2017 |
0.55907164 |
19,847,043.22 |
411,082,088 |
Source:
The Author’s Calculation
12. Methanol Production in the
World
Table 10: Methanol Production
Capacities of the Countries having Methanol Plants in the World (2014)
County |
KTPA (Kilo Tonnes Per Annum) |
Algeria |
100 |
Argentina |
400 |
Australia |
100 |
Azerbaijan |
560 |
Belarus |
80 |
Brazil |
200 |
Burma |
150 |
Canada |
560 |
Chile |
1,000 |
China |
49,390 |
Egypt |
1,000 |
Equatorial Guinea |
1,500 |
Germany |
1,840 |
Indonesia |
700 |
Iran |
4,300 |
Libya |
600 |
Malaysia |
1,000 |
Mexico |
180 |
Netherlands |
1,000 |
New Zealand |
700 |
Norway |
900 |
Omar |
1,031 |
Poland |
100 |
Qatar |
1,000 |
Russia |
4,137 |
Saudi Arabia |
7,750 |
South Africa |
140 |
The United States |
2,432 |
Trinidad and Tobago |
6,620 |
Ukraine |
190 |
Uzbekistan |
32 |
Venezuela |
1,500 |
Source:
TargetMap
13. Methanol Production
Capacities by World Methanol Companies
Table
11: Methanol Production Capacities of Methanol Companies in the World
Company |
Country |
Capacity
(*1000 tonnes/year) |
Achema |
Lithuania |
130 |
Angarsk Petrochemical |
Russia |
200 |
Ar-Razi Saudi Methanol
Co. |
Saudi Arabia |
850 |
Assam PC |
India |
165 |
Atlantic Methanol
Production Company LLC |
Equitorial Guinea |
1,000 |
Azmeco |
Azerbaijan |
560 |
Azot Severodonetsk |
Ukraine |
200 |
Azot Shchekino |
Russia |
450 |
BASF |
Germany |
480 |
BioMCN |
Netherlands |
1,000 |
BP Refining &
Petrochemicals |
Germany |
300 |
Brunei Methanol Company |
Brunei |
850 |
Caribbean Gas Chemical
Ltd |
Trinidad and Tobago |
1,000 |
Castleton Commodities
International |
USA |
1,800 |
Celanese |
USA |
1,400 |
China National Offshore
Oil Corp. |
China |
800 |
Datang International
Power Generation |
China |
1,680 |
Deepak Fertilizers and
Petrochemicals |
India |
100 |
EMethanex |
Egypt |
1,300 |
ENI |
Italy |
750 |
G2X Energy |
USA |
1,400 |
GPC Quimica |
Brazil |
50 |
Grodno Azot |
Belarus |
80 |
GSFC |
India |
165 |
Gujarat Narmada Valley
Fertilizers |
India |
240 |
Henan Lantian |
China |
760 |
IBN SINA National
Methanol Company |
Saudi Arabia |
1,000 |
Inner Mongolia Boyuan
United Chemical |
China |
1,000 |
JSC Ammonity |
Russia |
230 |
JSC Shchekinoazot |
Russia |
450 |
Kaltim Methanol Industry |
Indonesia |
660 |
Kaveh Methanol Co |
Iran |
2,300 |
Kharg 2 |
Iran |
1,400 |
Lake Charles |
USA |
1,280 |
Legend Holdings |
China |
720 |
LyondellBasell |
USA |
780 |
Metafrax |
Russia |
1,000 |
Methanex |
New Zealand |
650 |
Methanex |
Canada |
470 |
Methanex |
USA |
1,000 |
Metor 2 |
Venezuela |
850 |
Mider-Helm Methanol |
Germany |
660 |
MSK |
Serbia |
200 |
National Fertilizers |
India |
25 |
Nevinnomyssk Azot |
Russia |
140 |
Novomoskovsk Azot |
Russia |
400 |
OAO Acron |
Russia |
70 |
OAO Novatek |
Russia |
52 |
OCI Beaumont |
USA |
850 |
OCI North America
(Natgasoline) |
USA |
1,750 |
Pandora Methanol |
USA |
850 |
Petrobas |
Brazil |
721 |
Petronas Fertilizer |
Malaysia |
70 |
Petronas Methanol Labuan |
Malaysia |
2,360 |
PT Medco Methanol Bunyu |
Indonesia |
330 |
QAFAC |
Qatar |
3000 |
Rashtriya Chemicals and
Fertilizers |
India |
72 |
Salalah Methanol |
Oman |
1,300 |
Schekino Azot |
Russia |
450 |
Shandong Jiutai Energy |
China |
1,000 |
Shanghai Coking &
Chemical |
China |
800 |
Shell & DEA Oil |
Germany |
400 |
Shenhua Baotou Coal
Chemicals |
China |
1,800 |
Shenhua Ningxia Coal |
China |
1,670 |
Sichuan Vinylon Plant |
China |
970 |
Silekol |
Poland |
100 |
SOCAR Methanol LLC |
Azerbaijan |
500 |
South Louisiana Methanol |
USA |
1,860 |
Statoil |
Norway |
900 |
Togliatti Azot |
Russia |
1,000 |
Tomskneftekhim |
Russia |
825 |
Trinidad and Tobago
Methanol Company |
Trinidad and Tobago |
4,100 |
Valero |
USA |
1,600 |
Viromet |
Romania |
225 |
Xinjiang Guanghui
Industry |
China |
1,200 |
Yuhuang Chemical |
USA |
1,700 |
ZAO Ural Methanol Group |
Russia |
600 |
Source:
ICIS
14.
Methanol
Exports in the World
Table
12: The Share of Countries Exporting Methanol between 2008 and 2017
Country |
Export
Value (million $) |
Percent
(%) |
Algeria |
24.5 |
0.28 |
Austria |
2.74 |
0.032 |
Azerbaijan |
43 |
0.50 |
Bahrain |
47.2 |
0.55 |
Belarus |
6.74 |
0.078 |
Belgium-Luxembourg |
124 |
1.4 |
Brunei |
154 |
1.8 |
Bulgaria |
0.638 |
0.0074 |
Cambodia |
0.00105 |
0.000012 |
Canada |
98.2 |
1.1 |
Chile |
139 |
1.6 |
China |
24.3 |
0.28 |
Cyprus |
7.06 |
0.082 |
Denmark |
0.136 |
0.0016 |
Egypt |
0.444 |
0.0052 |
Equatorial Guinea |
176 |
2.0 |
Estonia |
5.25 |
0.061 |
Finland |
65.4 |
0.76 |
France |
7.96 |
0.092 |
Gabon |
0.00139 |
0.000016 |
Georgia |
3.46 |
0.040 |
Germany |
138 |
1.6 |
Guinea |
4.18 |
0.049 |
Hong Kong |
3.52 |
0.041 |
Hungary |
0.366 |
0.0043 |
Iceland |
0.450 |
0.0052 |
India |
4.05 |
0.047 |
Indonesia |
81.6 |
0.95 |
Iran |
1170 |
14 |
Ireland |
0.148 |
0.0017 |
Italy |
17.3 |
0.20 |
Japan |
8.24 |
0.096 |
Kenya |
0.145 |
0.0017 |
Libya |
32.4 |
0.38 |
Lithuania |
2.09 |
0.024 |
Macedonia |
0.00123 |
0.000014 |
Malaysia |
553 |
6.4 |
Malta |
0.501 |
0.0058 |
Mauritius |
0.0597 |
0.00069 |
Moldova |
0.167 |
0.0019 |
Netherlands |
397 |
4.6 |
New Zealand |
570 |
6.6 |
Norway |
199 |
2.3 |
Oman |
681 |
7.9 |
Other Asia |
0.301 |
0.0035 |
Pakistan |
0.036.4 |
0.00042 |
Poland |
32.5 |
0.38 |
Portugal |
5.78 |
0.067 |
Qatar |
203 |
2.4 |
Romania |
4.76 |
0.055 |
Russia |
469 |
5.4 |
Saudi Arabia |
1000 |
12 |
Serbia |
41.5 |
0.48 |
Singapore |
15.9 |
0.18 |
Slovakia |
12.1 |
0.14 |
Slovenia |
12.7 |
0.15 |
South Africa |
2.14 |
0.025 |
South Korea |
2.06 |
0.024 |
Spain |
4.96 |
0.058 |
Sweden |
21.8 |
0.25 |
Switzerland |
0.728 |
0.0085 |
Tanzania |
0.122 |
0.0014 |
Thailand |
1.04 |
0.012 |
The Czech Republic |
2.32 |
0.027 |
The Philippines |
0.076.9 |
0.00089 |
The United Arab Emirates |
35.5 |
0.41 |
The United Kingdom |
17.2 |
0.20 |
The United States |
371 |
4.3 |
Trinidad and Tobago |
1150 |
13 |
Tunisia |
0.025.9 |
0.00030 |
Turkey |
2.3 |
0.027 |
Ukraine |
0.666 |
0.0077 |
Uzbekistan |
0.411 |
0.0048 |
Venezuela |
401 |
4.7 |
Vietnam |
0.722 |
0.0084 |
Total
|
8610 |
100 |
Sources:
The Center for International Data from Robert Feenstra
UN
Comtrade
World’s
leader methanol producers are Atlantic Methanol Production Companies, Azelis,
Billion Miles, Clariant, Coogee Energy, Ecofuel, Enerkem, Fitech, G2X Energy,
Haldor Topsde, IMTT, Johnson Mattey, Lanxess, Metafrax, Methanex, Mhtl,
Mitsubishi Gas Chemical America, Mitsubishi International Cooperation,
Muntajat, NW Innovation Works, OCI N.V., Oman Methanol Company, Petronas,
Qafac, Sabic, Salalah Methanol Company, Southern Chemical Cooperation, Sipchem,
Solvadis, Tricon Energy, United Chemical Company and Vitusa Products (Source:
Methanol Institute).
16. Methanol Production Technologies
High plant availability and energy
efficiency and low capital cost are essential for ensuring the best performance
in methanol production.
One Step
Methanol uses tubular steam reforming as synthesis gas
generator. The optimal capacity range is from 500 up to 2500 MTPD
(7-Methyl-triazabicyclodecene). This can be extended to 3000 MTPD if
approximate 25% of the hydrocarbon feed is CO2.
Two Step
Methanol is the most commonly used methanol
technology. It uses a combination of tubular steam reforming and oxygen
reforming as synthesis gas generator to produce a stoichiometric methanol
synthesis gas.
SynCOR Methanol™ is the most cost
efficient methanol technology available. The optimal single train capacity is
500 MTPD up to 10.000 MTPD. The highly efficient, fully automated SynCOR™
syngas generator based on oxygen reforming at unique low steam carbon is the
core of the process. Together with the most efficient methanol synthesis SynCOR
Methanol™ provides the lowest CAPEX and OPEX, high availability and lowest
environmental impact in a capacity range from low scale and up to very large
scale single train capacity.
Small scale
Methanol for capacities in the range 100 MTPD to 1000
MTPD take advantage of the knowhow achieved from large scale production in
combination with specific small scale solutions.
Kırklareli OZI is a candidate for being
the second biggest city of Thrace after Çerkezköy with an expansion capacity of
850 Hectares. As of 2014, the wastewater treatment capacity of Kırklareli
Organized Industrial Zone has increased to 2800 m³ / day with the existing 600
m³ / day wastewater treatment plant.
Large-scale industrial investments
(allocated in the food, pharmaceutical and yarn sectors) in the OIZ are rapidly
continuing.
OZI Stage I Electrical rehabilitation
works have been completed, OZI Stage II Infrastructure electrical installations
are about to be completed.
Within the scope of OZI Stage II
Infrastructure construction works, Gallery Infrastructure Manufacturing which
is 7 km in length, 3,30 m x 2,65 m in dimensions, two-eyed and accommodates
electricity, telecommunication, water and steam lines has been completed.
Infrastructure services are provided within the gallery.
OZI Stage II Natural Gas Construction
Work has been tendered and approximately 7 km long of natural gas network has
been completed. Eventually, uninterrupted natural gas supply is provided to all
companies.
Kırklareli OZI contains 50 different
factory firms. The distributions of these firms are as follows:
Participants in production phase (25)
Participants in the machine assembly
phase (8)
Participants in the construction phase
(11)
Participants in the project phase (6)
Table
13: Gross Heat Content of Dry Natural Gas of Countries in 1995 (Btu per Cubic Foot)
Country |
Heat Cont. |
939 |
|
Armenia |
911 |
Austria |
1,063 |
Azerbaijan |
911 |
Bosnia and Herzegovina
|
955 |
Bulgaria |
943 |
Croatia |
912 |
Egypt |
1,047 |
Georgia |
911 |
Germany |
985 |
Greece |
1,558 |
Hungary |
926 |
Iran |
1,056 |
Iraq |
1,047 |
Israel |
1,039 |
Italy |
1,001 |
Jordan |
1,047 |
Kazakhstan |
911 |
Kuwait |
1,047 |
Libya |
1,047 |
Macedonia |
955 |
Moldova |
911 |
Romania |
909 |
Russia |
905 |
Saudi
Arabia |
1,047 |
Serbia
and Montenegro |
955 |
Slovakia |
877 |
Slovenia |
955 |
Switzerland |
1,082 |
Syria |
1,047 |
Turkey |
1,028 |
Turkmenistan |
911 |
Ukraine |
911 |
Source:
Kilgore (1995, pp.
138-140).
Table
13.1: Countries’ Dry
Natural Gas Consumption, Production and Heat Content in 2012
Country |
Production (bcf) |
Consumption (bcf) |
Res. tcf |
Heat Cont. |
Egypt |
2,141 |
1,882 |
77 |
1,020 |
Germany |
434 |
3,080 |
6 |
944 |
Iran |
5,649 |
5,511 |
1,168 |
1,056 |
304 |
2,646 |
2 |
1,023 |
|
Russia |
21,685 |
15,437 |
1,680 |
1,026 |
Saudi
Arabia |
3,585 |
3,585 |
284 |
1,020 |
Turkey |
22 |
1,598 |
0 |
1,026 |
Turkmenistan |
2,492 |
868 |
265 |
1,012 |
Ukraine |
694 |
1,856 |
39 |
993 |
Source:
Dahl (2015, pp. 187-188).
Table
14: Comparison of Sg-CTM and d-CTM
|
Sg-CTM |
d-CTM |
Methanol Production |
464 kta |
464 kta |
H2 Consumption |
- |
99.04 kta |
CO2 Consumption |
- |
664.8 kta |
Syngas Consumption |
536 kta |
- |
CO2 Emission |
15.56 ton CO2eq/h |
19.02 ton CO2eq/h |
Vapor (ton/ton) |
0.30 |
1.26 |
Cooling water (m3/ton) |
67.93 |
101.18 |
Electricity (gJ/ton) |
1.34 |
3.36 |
Total Annual Cost Estimate |
$143,595,569 |
$283,351,254 |
Natural Gas Needed |
309.33 kta |
? |
Total Annual Cost Estimate for 614 kta |
kta=kilotons
per annum
Source:
Machado,Alsayegh, LNGIndustry
As Sg-CTM is the conventional method, it
would be easier for Turkey -as a new investor in this area- to use that method.
Furthermore, methanol production from syngas emits less CO2 when compared to direct
conversion from CO2 to
methanol. It costs less electricity, less vapor and less cooling water.
Therefore, Turkey must use this method to produce methanol.
Turkey may establish partnership with QAFAC - Qatar Fuel Additives Company Limited
which produces a little under 1 million metric tons per year. QAFAC is one of
the leaders of the methanol market, which can assist Turkey in establishing
Sg-CTM technology. Bilateral relations of Turkey with Qatar may fasten the
process.
20.
The
Costs of Methanol Production via Synthesis Gas
We adopted Alysayegh et al. (2019) study
to estimate the methanol production costs from natural gas for Turkey. We chose
sg-CTM method to produce methanol rather than d-CTM because of its cost
advantages & environmentally friendly technology. Our estimation suggests
that producing 614 kta of methanol costs $190,016,551.23.
Methanol production from natural gas for Turkey is estimated under following
assumptions:
- Syngas
selling price, $0.10/m3 has been used in order to get the worst case result.
(LNGIndustry.com). The cost of producing syngas from methane is below the
syngas selling price.
- Table a
reports the price data we use. Syngas selling price used is from 2015
($0.10/m3). (LNGIndustry.com). Other data are from 2019 that gathered from
Alsayegh et al. (2019). We also assumed that syngas selling prices remained
constant during time, for the calculations.
- There is
no impurity present in syngas. It is needed for converting m3 to kilograms.
Thus we converted unit of measurement from unit of volume (m3) to unit of mass
(kg).
Steam
Reforming of Methane (SRM) method is used in order to produce syngas from
methane. Steam Reforming Method (SRM) gave the highest cost estimates in
comparison to other methods. We chose this in order to get the worst-case
scenario. Other methods give lower costs.
Table
b reports the estimates of the syngas weight for each m3. Table c
reports the cost items of methanol production.
Table a:
Unit Prices for 2019
|
Prices |
CO2 |
$0.035/kg |
H2 |
$0.65/kg |
Syngas |
$0.10/m3* |
Cooling Water |
$0.033/m3 |
Electricity |
$0.087/kwh |
|
|
*Syngas price is from 2015.
Sources: Alsayegh, LNGIndustry.com
Table b:
Comparison of Different Syngas Production Methods |
||
Methods of
Syngas Production from NG |
1m3 |
|
Steam
Reforming of Methane (SRM) |
0.38 kg |
|
Dry
Reforming of Methane (DRM) |
0.67 kg |
|
Water Gas
Shift (WGS) |
0.47 kg |
Table
c: Costs of Sg-CTM Method
Sg-CTM |
|
Methanol Production |
464 kta |
H2 Consumption |
- |
CO2 Consumption |
- |
Syngas Consumption |
536 kta |
$ 141,052,631.58 |
|
Cooling water (m3/ton) |
67.93 |
$ 1,040,144.16 |
|
Electricity (gJ/ton) |
1,34 |
$ 1,502,793.92 |
|
Total Annual Cost Estimate |
$ 143,595,569.66 |
Sources:
Alsayegh, LNGIndustry.com
Turkey’s methanol import is 614 kta.
According to our results, if Turkey produces all of that methanol, it will cost
Turkey $190,016,551.23 annually.
20.1.
Methanol
via Direct CTM (d-CTM)
D-CTM is the name of the method which
corresponds to the production of methanol by hydrogenation of CO2
(direct CTM, d-CTM).
There are at least two differences in the
paths for methanol synthesis using syngas or a mixture of H2 and CO2 as raw material. The analysis carried out in
this work has revealed that, d-CTM process presents more consumption of
utilities as vapor, cooling water and electricity per ton of methanol
production. Moreover, d-CTM process emits 19.02 ton CO2 equivalent per hour against an emission
of 15.56 ton CO2
equivalent per hour for sg-CTM. Regarding the consumption of raw material,
d-CTM process is more demanding because of the high stroichiometry ratio, which
requires a high H2/CO2 ratio. In the d-CTM
process, the most suitable process conditions for methanol production are
pressure higher than 80 bar and high value N parameter, but these values must
be adjusted for economic viability. Therefore, the d-CTM process still requires
more study about process condition in order minimize electric energy and
thermal energy expenses, and to reduce pressure requirements as low as the
economics of the process allows. This will reduce operating costs improving
process economics.
20.2.
Methanol
via Syn gas (Sg-CTM)
Sg-CTM is the name of the method which
corresponds to the production of methanol from synthesis gas. It is the
conventional industrial process used in large scale worldwide. (Machado)
As mentioned, Sg-CTM is the dominant
method. Therefore, it is used in most of the methanol producer countries
mentioned in the tables.
A major breakthrough came in the early
1970s with the development of low pressure processes replacing the high
pressure route. Today, nearly all production is based on these processes
consuming natural gas, naphtha or refinery light gas with a shift in production
to those countries with low cost natural gas.
Synthesis gas, a mixture of carbon
monoxide, carbon dioxide and hydrogen, is first produced in a reformer. This is
carried out by passing a mixture of the hydrocarbon feedstock and steam through
a heated tubular reformer. The ratio of hydrogen and carbon in the syngas may
need to be adjusted by purging excess hydrogen or adding carbon dioxide.
Developments include the use of
autothermal reforming, either alone or in combination with a primary reformer,
in which oxygen is mixed with the steam.
The syngas is cooled and then compressed
before being fed to the methanol converter. The methanol synthesis takes place
in the presence of copper-based catalysts at 250-260 oC. The crude methanol is
recovered and purified by distillation.
20.2.1. What is syngas?
Syngas is an abbreviation for synthesis
gas, which is a mixture comprising of carbon monoxide, carbon dioxide, and
hydrogen. The syngas is produced by gasification of a carbon containing fuel to
a gaseous product that has some heating value. Some of the examples of syngas
production include gasification of coal emissions, waste emissions to energy
gasification, and steam reforming of coke.
The name of syngas is derived from the
use as an intermediate in generating synthetic natural gas and to create
ammonia or methanol. It is a gas that can be used to synthesize other
chemicals, hence the name synthesis gas, which was shortened to syngas. Syngas
is also an intermediate in creating synthetic petroleum to use as a lubricant
or fuel.
Syngas has 50% of the energy density of
natural gas. It cannot be burnt directly, but is used as a fuel source. The
other use is as an intermediate to produce other chemicals. The production of
syngas for use as a raw material in fuel production is accomplished by the
gasification of coal or municipal waste. In these reactions, carbon combines
with water or oxygen to give rise to carbon dioxide, carbon monoxide, and
hydrogen. Syngas is used as an intermediate in the industrial synthesis of
ammonia and fertilizer. During this process, methane (from natural gas)
combines with water to generate carbon monoxide and hydrogen.
The
gasification process is used to convert any material that has carbon to longer
hydrocarbon chains. As carbon chain size increases, molecule become less and
less water soluble. One of the uses of this syngas is as a fuel to manufacture
steam or electricity. Another use is as a basic chemical building block for
many petrochemical and refining processes.
The general raw materials used for
gasification (creation of syngas) are coal, petroleum based materials, or other
materials that would be rejected as waste. From these materials, a feedstock is
prepared. This is inserted to the gasifier in dry or slurry form. In the
gasifier, this feedstock reacts in an oxygen starved environment with steam at
elevated pressure and temperature. The resultant syngas is composed of 85%
carbon monoxide and hydrogen and small amounts of methane and carbon dioxide.
The syngas may contain some trace
elements of impurities, which are removed through further processing and either
recovered or redirected to the gasifier. For example, sulfur is recovered in
the elemental form or as sulfuric acid and both of these can be marketed.
Syngas is a primary source of sulfuric acid. If syngas contains a considerable
quantity of nitrogen, the nitrogen must be separated to avoid production of
nitric oxides, which are pollutants and contribute to acid rain production.
Both carbon monoxide and nitrogen have similar boiling points so recovering
pure carbon monoxide requires cryogenic processing, which is very difficult.
If the syngas is to be put to use to
generate electricity, then it is generally used as a fuel in an IGCC
(integrated gasification combine cycle) power generation configuration. The
energy is then utilized by the factor that original produce the syngas, thereby
lowering operating costs. There are commercially available technologies to
process syngas to generate industrial gases, fertilizers, chemicals, fuels and
other products.
21.
Is
Methanol a Byproduct?
At the Point Lisas Methanol Complex,
methanol is made using the ICI Low Pressure Methanol Synthesis Process. The two
main raw materials used are natural gas (96% methane), received from the
National Gas Company (NGC) to provide the carbon, and hydrogen components and
water from the Water and Sewerage Authority (WASA) to provide the oxygen
component. These raw materials undergo a series of chemical reactions to
produce crude methanol which is then purified to yield refined methanol, having
a purity exceeding 99.9%. As it has a purity exceeding 99.9%, it is not a
byproduct.
22.
The
Details of Methanol Plants
The methanol plants operate continuously
24 hours a day in a production process that can be divided into four main
stages: Feed Purification, Reforming, Methanol Synthesis and Methanol
Purification.
STEP 1: FEED PURIFICATION
The two main feedstocks, natural gas and
water, both require purification before use. Natural Gas contains low levels of
sulphur compounds and undergo a desulphurization process to reduce the sulphur
to levels of less than one part per million. Impurities in the water are
reduced to undetectable or parts per billion levels before being converted to
steam and added to the process. If not removed, these impurities can result in
reduced heat efficiency and significant damage to major pieces of equipment.
STEP 2: REFORMING
Reforming is the process which transforms
the methane (CH4) and the steam (H2O) to intermediate
reactants of hydrogen (H2), carbon dioxide (CO2), and carbon
monoxide (CO). Carbon dioxide is also added to the feed gas stream at this
stage to produce a mixture of components in the ideal ratio to efficiently
produce methanol. This process is carried out in a Reformer furnace which is
heated by burning natural gas as fuel.
STEP 3: METHANOL SYNTHESIS
After removing excess heat from the
“reformed gas” it is compressed before being sent to the methanol production
stage in the synthesis reactor. Here the reactants are converted to methanol
and separated out as crude product with a composition of methanol (68%) and
water (31%). Traces of byproducts are also formed. Methanol conversion is at a
rate of 5% per pass hence there is a continual recycling of the unreacted gases
in the synthesis loop.
This
continual recycling of the synthesis gas however results in a build-up of inert
gases in the system and this is continuously purged and sent to the reformer
where it is burnt as fuel. The crude methanol formed is condensed and sent to
the methanol purification step which is the final step in the process.
STEP 4: METHANOL PURIFICATION
The 68% methanol solution is purified in
two distinct steps in tall distillation columns called the topping column and
refining column to yield a refined product with a purity of 99% methanol
classified as Grade AA refined methanol.
The methanol process is tested at various
stages and the finished product is stored in a large secured tankage area off
the plant until such time that it is ready to be delivered to customers. Since
99% of our product is sold on the overseas market, it is shipped by ocean going
tankers while local sales are made via pipelines and drums.
23.
Principal
Uses of Methanol
Methanol is used to produce a variety of
chemicals, including formaldehyde and acetic acid.
Formaldehyde is added to adhesives used
in wood industry, such as plywood, particle board and laminates. Formaldehyde
is also a key component of resins used to coat paper and plastic products.
Industrial uses of acetic acid include preparing metal acetates, used in some
printing processes; vinyl acetate, used to produce plastics; and cellulose
acetate, used in photographic films and textiles; and butyl acetates, widely
used as solvents in paints, lacquers and resins.
Globally,
methanol is also used to produce chemicals used to manufacture polyester
fabrics and fibers; acrylic plastics; pesticides; textile solvents;
pharmaceuticals; and windshield wiper fluid.
Methanol is also used as a direct fuel
for automobile engines, as a blended fuel with gasoline (M85), and as an octane
booster/additive in MTBE (methyl tertiary butyl ether) reformulated gasoline.
All these uses (and more) mean methanol
is produced, stored, and shipped in large quantities. World consumption is
expected to reach 46 million metric tons this year. Constantly changing global
economic and environmental issues affect methanol markets, as does worldwide
energy policies and the ups and downs of business cycles in key use industries.
24.
Daily Usage
Traditionally Methanol is used in a
variety of industrial applications. Methanol is primarily used as an industrial
solvent for inks, resins, adhesives to wood items, and dyes. It is used as a
solvent in the manufacture of cholesterol, streptomycin, vitamins, hormones,
and other pharmaceuticals. Methanol is used as an antifreeze for automotive
radiators, Productsan ingredient of gasoline (as an antifreezing agent and
octane booster), and as fuel for picnic stoves. Methanol is also an ingredient
in paint and varnish removers. We find methanol applied in such everyday items
as windshield washer fluid, fertilizers, carpets, clothing and plastics.
25. Questions & Answers
Q1:
Can methanol be a substitution for oil and
coal?
A1:
Over the last 10 years, methanol has become a notable substitute for oil and
coal. Its consumption has increased from approximately 35 metric MMtpy in 2004
to approximately 64 metric MMtpy in 2014. Of the 64 metric MMt of consumption
in that year, approximately 60% was in chemical applications (Abazajian, 2018).
The
chemical applications of methanol are not substituting oil- or coal-based
products. These applications tend to grow with the increased use of polymers in
the general economy. Approximately 40% of the methanol consumption is in
oil-substitute applications. In addition, approximately 5 MMt, 6 of captive
methanol production from coal in China typically is not considered part of the
methanol market, but it also substitutes for oil (Abazajian, 2018).
The
prime alternative of producing ethylene and propylene in the Far East is by
cracking naphtha, a product of oil refining. This methanol is converted into
olefins via methanol-to-olefins (MTO) or into gasoline via methanol-to-gasoline
(MTG) onsite. Another 4.9 MMt of methanol capacity were in the late stages of
construction or in startup in 2015 (Abazajian, 2018).
Assuming
a 70% coal-to-olefins (CTO) capacity utilization rate and correcting for the
oxygen content of methanol, methanol substitution of crude oil is approximately
equal to 0.35 MMbpd, or 0.4% of the total crude oil demand. If one is to make
the broad assumption that the difference between GDP growth and crude oil
demand growth is due to efficiency improvements and substitution, then methanol
substitution is responsible for approximately 30% of the total 1.3%
efficiency/substitution effect (Abazajian, 2018).
Some
of the methanol substitutes are so-called “drop-in” substitutes. These are
chemically similar enough that they involve no changes to the product
distribution infrastructure. Other methanol-based substitutes are chemically
dissimilar functional substitutes that require the adaptation of distribution
and utilization systems (Abazajian, 2018).
A
number of processes to convert methanol into substitute products have been
developed and commercialized. Other processes exist, but they have not yet been
used in oil substitution applications, or they must be modified to fit it.
Still others are under development (Abazajian, 2018).
Q2: Is
there any benefit of using methanol fuel? If any, what are the benefits?
A2:
It’s
a low-emission fuel: Methanol is a
clean-burning fuel that produces fewer smog-causing emissions — such as sulphur
oxides (SOx), nitrogen oxides (NOx) and particulate
matter — and can improve air quality and related human health issues (Methanex,
2016).
It
can be made from a variety of sources, including renewables:
Methanol is most commonly produced on a commercial scale from natural gas. It
can also be produced from renewable sources such as biomass and recycled carbon
dioxide and anything that is, or ever was, a plant! (Methanex, 2016).
It’s
high-octane – improving performance and efficiency:
As a high-octane vehicle fuel, methanol offers excellent acceleration and
power. It also improves vehicle efficiency (Methanex, 2016).
It’s
used in vehicles worldwide: Methanol fuel blends are
used in vehicles around the world, particularly in China. With more than 100
million passenger vehicles, China is the world’s largest user of methanol for
automotive fuel (Methanex, 2016).
It’s
an economical option: Methanol can be produced,
distributed and sold to consumers at prices competitive to those of gasoline
and diesel with no need for government subsidies (Methanex, 2016).
It’s
accessible all around the world: Methanol is one of the
top five chemical commodities shipped around the world each year, and unlike
some alternative fuels, is readily accessible through existing global terminal
infrastructure (Methanex, 2016).
Q3:
What is Methanol Economy and what are the advantages of this?
A3:
The methanol economy is an idea that was promoted by the late
Nobel-prize-winning chemist George Olah since the 1990s. The idea is to replace fossil fuels with
methanol for energy storage, ground transportation fuel, and raw material for
hydrocarbon-based products. Methanol is
the simplest alcohol and can be produced from a wide variety of sources ranging
from fossil fuels to agricultural products to just carbon dioxide. Methanol can be used directly as a fuel or it
can be reformed into hydrogen, which can then itself be used as a fuel
(EarthWise, 2017).
26. Russia and Its Methanol
Importers
Table
15: The Methanol Importers of the Russian Federation (2017)
Partner (Importer) |
Amount (kg) |
Trade Value ($) |
Finland |
867,432,890 |
220,296,587 |
Poland |
230,652,880 |
66,558,247 |
Slovakia |
177,819,620 |
51,311,575 |
Romania |
103,209,490 |
30,777,893 |
Belarus |
68,449,345 |
18,374,540 |
Lithuania |
60,453,420 |
16,470,877 |
Ukraine |
30,742,515 |
9,594,242 |
Kazakhstan |
22,688,490 |
8,606,126 |
Turkey |
21,336,000 |
5,951,113 |
Netherlands |
19,981,550 |
4,971,762 |
Belgium |
18,375,760 |
4,832,609 |
The
United Arab Emirates |
16,256,900 |
4,571,028 |
Switzerland |
15,059,500 |
3,666,698 |
Germany |
6,909,400 |
2,634,875 |
Estonia |
10,420,570 |
2,298,036 |
Latvia |
5,936,690 |
1,608,979 |
The
United Kingdom |
4,694,375 |
977,744 |
Bulgaria |
1,998,000 |
638,178 |
China |
924,330 |
187,151 |
The
Republic of Molova |
435,520 |
130,174 |
Uzbekistan |
255,300 |
90,632 |
World |
1,684,032,546 |
454,549,066 |
Source:
UN Comtrade
27. The Petrochemical
Importation of Turkey
Table 16: Petrochemicals Imported by Turkey
in 2017
Petrochemical |
Amount (kg) |
Trade Value ($) |
Propane
(liquefied) |
134,344,007 |
62,486,164 |
Butane
(liquefied) |
2,350 |
14,314 |
Polymers
of propylene, other olefins (in primary forms) |
2,136,285,527 |
2,722,285,855 |
Polypropylene
(in primary forms) |
1,721,172,493 |
2,117,619,023 |
Polyethylene
terephthalate (in primary forms) |
325,109,492 |
348,210,758 |
Polymers
of ethylene (in primary forms) |
1,814,278,145 |
2,442,065,291 |
Polyethylene |
1,846,000,000 |
2,496,000,0000 |
LLDPE |
455,000,000 |
561,000,000 |
LDPE |
311,000,000 |
516,000,000 |
HDPE |
869,000,000 |
1,084,000,000 |
Others |
212,000,000 |
335,000,0000 |
Polymers
of styrene (in primary forms) |
534,552,245 |
880,628,814 |
Styrene |
287,433,436 |
371,965,151 |
Polystyrene,
expansible (primary forms) |
90,735,254 |
145,873,964 |
Polystyrene,
other than expansible (primary forms) |
250,533,739 |
371,292,375 |
Benzene |
606 |
14,414 |
Toluene |
73,259,396 |
54,593,918 |
Source: TÜİK (UN Comtrade)
28. Global Methanol Prices and Large
Methanol Exporter Countries’ Methanol Prices
Table 17: Global Methanol Prices (January
2019)
US MMSA
Contract Index FOB
USGC (USD/metric
ton) |
$441 |
US MMSA
Spot Barge Wtd Avg FOB
USGC (USD/metric
ton) |
$337 |
Europe MMSA Contract FOB Rotterdam T2 (USD/metric
ton) |
$402 |
Europe MMSA
Spot Avg FOB
Rotterdam T2 (USD/metric
ton) |
$318 |
NEA/SEA MMSA
Contract Net Transaction Reference Wtd
Avg (USD/metric ton) |
$283 |
China MMSA
Spot, Avg. CFR
China Main Ports (USD/metric
ton) |
$281 |
Source: Methanol Institute, MMSA, 2019.
Table 18: Methanol Prices of the Large
Methanol Exporters (2017)
Country |
Price ($/kg) |
Price ($/ton) |
Iran |
0.29131699 |
264.278328 |
Malaysia |
0.29756796 |
269.949112 |
The
Netherlands |
0.35434458 |
321.455996 |
Saudi
Arabia |
184.3891149 |
167,274.991 |
Oman |
0.57325678 |
520.049803 |
Russia |
0.26991703 |
244.864611 |
Trinidad
and Tobago |
0.28467123 |
258.249396 |
The
United States |
0.2362197 |
214.294907 |
Venezuela |
0.37196018 |
337.436599 |
Germany |
0.40472616 |
367.161396 |
The
United Arab Emirates |
0.40020211 |
363.057247 |
The
United Kingdom |
0.85774339 |
778.131714 |
Sources:
The Author’s Calculation
29. Calculations of Costs of
Constructing a Methanol Plant in Turkey
Imported
CH3OH Amount = 614,364,435 kg = 677,220.86573 ton
Trade
Value = $205,227,944 (per year)
Cost
of Producing CH3OH
Total
Cost: $190,016,551 (per year)
Cost
of Constructing a CH3OH Plant
Cost
of the methanol plant: $90,000,000 (In USA, the cost is $60,000,000)
Initial
Investment: $30,000,000
Raised
Capital: $60,000,000
Expected
Lifespan of the Plant: 30 years
Interest
rate = 8%
Time
(years) = 7
Payment
in 7 years=$102,354,490
Annual
payment = $14,622,070 (AFC)
Average
Total Cost
Total
Annual Payment for first 7 years = 190,016,551+14,622,070 = $204,638,621
Annual
Net Receivables for first 7 years = $589,323
Annual
Net Receivables after 7 years = $15,211,393
Net
Present Value (of the project) = $46,652,408
30. Calculation of Natural Gas
Based Methanol Production Compared to Oil
Total
Revenue = $205,227,944
TVC
= $190,016,551
NG
Cost = $186,509,328
Non-NG
Cost = $3,507,223
TFC
= $90,000,000
Annual
TFC = 0.08 * TFC = $7,200,000
Annual
TC = TVC + Annual TCF = $197,216,551
Total
Return = $8,011,393
Breathing
Space = Total Return / TVC = 4.216%
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