ൡditional amine scrubbing and claus sulfur plant

Desulfurization

Выступающий

Заметки для презентации

The Start Catalyst process desulfurizes natural gas by directly converting H2S into elemental sulfur at 1/4 the cost of the traditional amine scrubbing and Claus sulfur plant.

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General information

1. Date of creation: 2005 2. Founders: Russian citizens - scientists of Moscow State University, Institute of

Petrochemical Synthesis RAS, with Ph.D. and D.Sc. degrees. 3. Director: Lyudmila Tyurina, Doctor of Chemical Sciences, Senior Research

Fellow Department of Chemistry, Moscow State University 4. Employees: citizens of the Russian Federation - highly qualified specialists,

experts in the field of technological processes for the preparation, processing and purification of hydrocarbons.

5. Location: Russia, 119992, Moscow, Leninskie Gori, str. 1, b. 75 6. Current stage • Technologies and catalysts are patented • Pilot projects successfully completed • Industrial exploitation and production of the catalyst 7. Information: http://community.sk.ru/net/1120385/ 8. Contacts: tel.: +7-495-505-08-92 fax: +7-495-635-13-40 e-mail: [email protected]

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Applicability of the proposed technologies

Oil refineries

Gas chemical facilities

Electricity generation O

IL

Gas processing

plants

GA

S APG

Technologies applicable to any objects

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Technological innovativeness +record quality of purification

The Best Available Technology Start – Catalyst

Key stage

Number of stages 8-11 1-2

Residual H2S 200 ppb 1 ppb

Direct oxidation process

Super Claus

Claus

Amine MEROX Gas +

H2S +RSH

PURE GAS Super Claus

Claus

Amine MEROX

Gas + H2S +RSH

Solution:

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standard techniques & equipment + patented catalysts

Oil

gas + H2S + RSH

Sulfur, disulfides

Oil + H2S + RSH APG, SH < 8%

Desulfurization unit

Stripping column

gas

Desulfurization/demercaptanization of Oil and APG

Pure gas SH = 10-0,001 ppm

20 000 nm3/h, SH 2%

Heating Pure gas

SH = 10-0,001 ppm Bubbler Т = 25оС V = 20 m3

Direct oxidation reactor

Т = 220оС V = 6 m3

Condenser

Gas + H2S + RSH Cooling

90% of sulfur, disulfides

10% of sulfur, disulfides

Essence of technology:

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Start Catalyst – 1-2 Stages Direct Catalytic Desulfurization

Process flow

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The Start Catalyst process is a two-step, direct catalytic oxidation of H2S and mercaptans into elemental sulfur and disulfides. The 1st stage is over a heterogeneous catalyst at modest temperature that achieves 0.1% H2S and can operate up to 60 atm The 2nd stage is a homogeneous liquid phase polisher that reduces H2S to <1 ppm When the gas sulfur content is below 1%, it may be treated with just the homogeneous liquid phase polisher to achieve the <1 ppm

Start Catalyst: fewer stages than Amine + Claus with Tail Gas Treater (TGT)

Reactor

Sour Gas

< 1% H2S gas sulfur condenser

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Amine + Claus + TGT

Absorber

Regeneration

Reactor 1 (thermal)

Reactor 2 (catalytic)

Sour Gas

pumps, riboyler, filtration

saturated solution of amine Treated gas

regenerated solution Cooling

acid gas

sulfur

sulfur condenser

treated tail gas to stack

Reactor 3 (catalytic)

Tail Gas Treater (catalytic)

sulfur condenser

sulfur condenser

sulfur condenser

sulfur

Bubbler

< 1ppm H2S

Start-Catalyst

Air

Air sulfur

Treated gas

Heating

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The Start Catalyst process requires only 1 or 2 steps. Traditional amine scrubbing and Claus sulfur plant requires as many as 6 steps. Amine scrubbing and regeneration 3 Claus catalytic converters Tail gas treating for air emission purification. Because of the fewer steps our process may be economically scaled down for cleanup of small scale stranded associated gas which is our target US market.

Capex 20% and opex 18% of Amine + Claus +TGT

Start Catalyst is better than Amine + Claus + TGT • $18.9 MM lower capex • $5.9 MM/yr lower opex • $59 MM total present value

MM $

30 K nm3/h (25MM Scf/D) gas cleanup, 10 ton S /day

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As result of minimizing of total numbers of technological steps the Start-Catalyst process has lower capex and opex. Capex is $4.2 MM vs $24MM for Claus More importantly, 2/3 of the total present value of the cost savings come from the lower opex At 12% DCF annuity factor on 15 years is 6.8 The Bakken is a good example where 30% of the gas is currently (and temporarily) allowed to be flared.

What have we done to date?

Process and catalyst developed and patented

Industrial production of the catalyst by experienced manufacturer

(9 days for 30 t)

Tested in 2 pilot plants

Industrial demonstration

Catalyst

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We were searching for a better Claus catalyst but failed. Instead we found a much better process than Claus itself. We have arranged toll manufacturing of the catalyst by an experienced producer

Details of pilot plants

• Pilot plant #1 associated gas 339 Scf/D for 24 days

heterogeneous catalyst, at 220-270°C, 1.2 atm 3.3% of H2S + RSH down to 0.1%

• Pilot plant #2 associated gas 68 Scf/D for total 80 days over 500 test runs homogeneous catalyst at 25° C, 1 atm 1.8% H2S + 0.2% RSH down to <1 ppm

• Claus tail gas industrial demonstration 38 MM Scf/D for total 43 months heterogeneous catalyst at 220-270° C, 1.2 atm 1% H2S down to 0.1%

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Two pilot plants and one commercial-sized plant have successfully demonstrated performance and operability.

Nikolay Kopytin Chief Engineer Engineered largest Sulfur Units of GAZPROM and desulfurization plants in CIS

Team: Science + Engineering + Business

General Director, Dchem, created catalysts and catalytic technologies for the oil companies in Russia, CIS

Liudmila Tyurina

Andrey Pimenov Chief Marketing Officer Implements technological projects for the largest oil companies in Russia

Chief Scientist, DChem, professor Further research and development of new catalysts

Mark Tsodikov

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Our team is the union of science, engineering and business: - General Director has years of research experience creating new catalysts and processes - Chief Engineer Engineered the largest Sulfur Units of GAZPROM and desulfurization plants in CIS - Chief Marketing Officer Implements technological projects for the largest oil companies in Russia We have 6 to 8 scientists working on the process and guiding the process engineering. We have nearby engineering group that they use as subcontractors and similarly an equipment production company group. Have made arrangement with an existing catalyst manufacturer to produce the catalyst.

IP status and plans

IP status: 3 Russian patents Catalyst manufacturing protected as trade secrets

IP plans: 3 international patents – 2015 / 2016 for at least:

United States EU Kazakhstan China

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We have 3 Russian patents and plan to apply for 3 more as well as for international protection. However, most of our R&D is protected as know-how in particular the catalyst manufacture.

Next plants in Russia

№ Feedstock Capacity, MM Scf/D

Sulfur content Plant Cost, MM$

Status In, % Out, ppm

1 Associated gas 1 0.1 0,1 1

Engineering, Construction

in 2015

2 Associated gas 10 0.3 8 2

Expect agreement

in 2015 3 Tail gas 13 1.0 10 6

4 Condensate 10 K BPD 50 ppm 5 3

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Our nearest sales plan to build 4 plants in Russia. These will further demonstrate the process performance and reliability �

Financial Forecast

-200

-100

0

100

200

300

400

500

600

700

800

-10

-5

0

5

10

15

20

25

30

35

40

2015 2016 2017 2018 2019 2020

Revenue, $MM # of std units Accum. CF, $MM MM Scf/D

Break even in 2 years

Cash required - $6,6M

Accum. CF- $32M

$MM MM Scf/D

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After the first year of a first commercial plant, Start will be in a position to significantly grow sales. To achieve that growth Start will likely exit by sale of the company to a licensing company (e.g. UOP, Axens) or an EPC (e.g. KBR, Jacobs). Jacobs currently has about 30% of the sulfur plant market. Recognize that a worldscale size sulfur plant is 70 times larger than these standard associated gas units. Once the process has been further proven, the amount of licensing can increase dramatically.

What do we need now?

• Industrial demonstration plants in Russia – $1 MM in 2015 – $11 MM in 2016 • Associated gas desulfurization plant in US

– $5 MM in 2015

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Investment – $1 MM for Industrial Demonstration Plant (with capacity about 1 MM Scf/D) Investment - $11 MM for commercially viable plants

Other opportunities

Start Catalyst is better than chemisorbents for low sulfur gas • $4 MM lower capex • $2.2 MM/yr lower opex • $19 MM total present value (25MM Scf/D)

Start Catalyst is better than Merox for light oils • $2.7 MM lower capex • $1.7 MM/yr lower opex • $14 MM total present value (10 k BPD LPG)

Start Catalyst is better than Amine+Claus+SCOT for big plant • comparable capex at $80MM • $ 446 MM/yr lower opex • $ 3 billion total present value (2 billion Scf/D, 700 tpd)

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Start Catalyst has other potential applications which have been tested One is single stage treatment of low sulfur gas. Another is the removal of sulfur compounds from light oils. Long potential to replace Claus for even large plants added potential benefits from Start. Start stage I & 2 can operate from 1-60 atm. This can enable optimizing equipment design depending on the specific application. The Start 2nd stage bubbler can operate from 25-60° C. As a result the process can accommodate this wide range of gas plus air combined temperature without external heating or cooling. Start 2nd stage bubbler can also operate as a dehydrator when the typical hydrocarbon solvent is replaced with glycol. In this variant the process needs also a glycol regenerator. Typical existing natural gas cleanup systems have a dehydrator after the amine absorber and before refrigeration to recover C3/C4. Start two-stage process can handle C-1 through C4. As a result the high sulfur, high BTU raw gas can be desulfurized and dehydrated in the Start unit and then go directly to refrigeration for C3 /C4 recovery.

Business model

• Sale of licenses

• Sale of equipment and catalyst by contract

manufacturer

• Sale through partner engineering company

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Primary business model is licensing the process and catalyst production.

Market

>30% of the world oil & gas deposits require gas desulfurization

Oil refineries, gas processing plants

Gas chemical facilities

Initial focus: cleanup of remote stranded associated gas

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Start Catalyst also better for low-sulfur gas than chemisorbents

MM $

Start Catalyst is better than metal oxide chemisorbents

• $4 MM lower capex • $2.2 MM/yr lower opex • $19 MM total present value

30 K nm3/h (25MM Scf/D) gas cleanup, 0,1 ton S /day

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Other opportunities: Start Catalyst can treat light oils with fewer steps

Start-Catalyst

MEROX Washing from alkali

NaO

H

Mer

ox r

eact

or

Wat

er

Waste water purification

Clarifying tank

Rea

ctor

Start Catalyst is better than Merox • $2.7 MM lower capex • $1.7 MM/yr lower opex • $14 MM total present value

10K BPD LPG with 100 ppm mercaptan

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Capex 20% of amine + Claus with Tail Gas Treater (TGT)

Start-Catalyst Amine+Claus SCOT Equipment Price, k USD Equipment Price, k USD Equipment Price, k USD

Separators 2 m3 29 Compressor to get 30 atm. 980 500 Pumps 58 Pumps 200 131 Gas heater 570 Absorber 24 m3 283 180 Filters 57 Desorber 48 m3 572 290 Other tank equipment with pipelines

20 m3 86 Other tank equipment with pipelines

70 m3 1 140 460

Reactor 1 10 m3 57 Thermal reactor 43 t 855 heater 120 Reactor 2 30 m3 60 Catalytic reactors 16 t 210 reactor 98 Sulfur condenser 39 t 850 Sulfur condenser 39 t 850 water purification 100

Heaters 8 t 285 compressor H2S

from water 100

Incinerator 8 t 285 cooler 200 Burners 143 Fittings 143 Fittings 837 360 Instrumentation sensors 140 Instrumentation sensors 860 400 Air compressor 27 Air compressor 140 Automatic process control system

200 Automatic process control system

1 000 300

Compressor to get 30 atm. 500 TOTAL 2 776 TOTAL 8 640 3 239 Project 20% 550 30% 2 592

3 239 Construction 70% 1 943 70% 6 048 4 726 17 280 6 479

25MM Scf/D gas cleanup, 10 ton S /day

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Opex 18% of amine + Claus with Tail Gas Treater (TGT)

25MM Scf/D gas cleanup, 10 ton S /day Start-Catalyst Amine+Claus+SCOT

k USD/year k USD/year Staff 660 Amine 660 4 shifts of 6 people Claus 660

kWh kWh Pumps 15 Pumps 75 Air compressor 2 Air compressor 10 Automatic process control system 5 Automatic process control system 50

(8,56 ¢ /kWh) 22 16,5 (8,56 ¢ /kWh) 135 101,2

Scf/D Steam t/h Gas for heating (0,5 ¢ /Scf) 339 000 618,7 Desorbers 15 Liquid sulfur 10 25 3 612,5 Steam circulation kWh Desorbes 750 Liquid sulfur 30 (8,56 ¢ /kWh) 780 584,9

Catalyst 200 Catalysts, reagents, etc. 300 H2 1 500 1 495,2 7 418,6

overall cost 164$ / MM Scf overall cost 813$ / MM Scf

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ൡditional amine scrubbing and claus sulfur plant

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