Gas and petrochemistry
Creation of business projects in the gas chemical industry
in the territories of the countries of Central Asia, the European and African continents
1. Relevance of this proposal
The relevance of this proposal for these regions is due to the fact that they are very rich in natural gas.
Oil refineries are sources of a large number of precursors (precursors of formation) of substances valuable for organic chemistry. These are mainly gases C3-C4, light liquid fractions C5-C6, aromatic hydrocarbons (benzene, toluene, xylenes). A large number of aromatic hydrocarbons are also produced in the coke chemical industry. These substances can be used as raw materials for the synthesis of valuable organic substances by copolymerization with substances obtained as a result of gas synthesis (the starting material is natural gas).
During consultations with local entrepreneurs, it became clear that enterprises in these regions do not have technologies for purifying natural gas from CO2, H2S, H2O and C3-C5 hydrocarbons. The necessary equipment is not manufactured in the region. All measures related to the purification of natural gas, the release of undesirable impurities (fatty gases) from it, must be carried out by us independently, followed by the use of the resulting waste in the purification process in other industries.
In some cases, the issue of exporting such crude natural gas may be considered. Production is limited by demand, and the region’s natural gas reserves amount to hundreds of trillions of cubic meters. But at the same time, it is being used inefficiently.
This determines the economic prospects of our proposed business project, and its great competitive advantages over similar industries in Europe, America, and other advanced economies, since their production is based on the consumption of natural gas purchased at a higher price.
In the regions of Central Asia, the European and African continents there is practically no chemical industry and metallurgy based on the use of natural gas. Therefore, the products of the enterprises we create in the country will be in demand within the said regions, and due to the competitive price, it will not be difficult for them to enter the world market.
The production of nitrogen fertilizers in the world is falling. The main production facilities turned out to be in the EU, Ukraine and many other countries, which sharply began to experience an acute shortage of natural gas, which leads either to an increase in the price of the products received, or production, stops due to its lack of profitability. Significant production volumes still exist in Russia and the countries of the former Soviet Union.
Production facilities are being intensively created only in China. They don’t use natural gas, but coal. In principle, the type of raw material is not important for the quality of the products obtained, but it affects their cost (the processes of converting coal into synthesis gas are more complicated, and its quality (CO+H2 concentrations) is lower). China has not yet had a major impact on the global nitrogen fertilizer market. They are mainly sold on the domestic market. China mainly captures the global market of polymers and other more expensive products.
The global market for base polymers and rubbers is growing by about 3% per year. Special – about 10% per year. Their prices are also rising. Approximately the same situation applies to other valuable organic synthesis products (with prices ranging from $2,000 per ton to $10,000 per ton). Therefore, there is no oversaturation of the global market and is not expected in the near future.
In addition, the presence of our own production of polymer raw materials, synthetic resins, allows us to create our own industry for the production of facing stone and other valuable products using composite technology. China has been very successful at this. Its enterprises occupy the entire domestic and more than 50% of the global market for such products. There is more than enough mineral raw materials needed for such production in the territories of the Central Asia, European and African continents.
Organic synthesis products are necessary to create the production of paint and varnish materials. It is possible to create production of both synthetic resins, solvents, and pigments (colored, black). These products are also in high demand on the market and are sold in large quantities.
2. The subject of this proposal.
By applying gas chemistry processes using individual substances obtained as a result of petrochemical and coke production, it is possible to create the production of almost any organic substances that are in demand as raw materials in other industries. These are fertilizers, polymers, rubbers, plasticizers necessary for their compounding, synthetic oils and lubricants, and much more.
2.1. Synthesis of valuable raw materials from natural gas and its mixtures with fatty gases.
2.1.1. Synthesis of ammonia and products based on it.
Ammonia is used as a raw material in various industries. It will be in demand on the regional market, mainly as an aqueous solution (ammonia alcohol, it is safer to transport and store). Also in the form of its salt, ammonium bicarbonate, which is easily synthesized from ammonia and carbon dioxide and isolated in dry form (this is the safest form of ammonia storage).
Ammonia is the basic raw material for production:
- nitric acid and potassium, sodium, and ammonium nitrates from it (fertilizer);
- carbamide;
- ammonium phosphates; in the territory of the countries of Central Asia, the European and African continents, there are large reserves of phosphates, there is production of phosphoric acid necessary for this production; theoretically, it is possible to create production of phosphoric acid independently;
- melamine (this is the raw material for the production of melamine-formaldehyde resins), is made from carbamide;
- polyamides (polymers, there are a lot of polyamide grades) and many other products of organic synthesis.
The processes of synthesis of ammonia and many substances from it have been developed in industry and implemented in many countries of the world. Blocks designed for the synthesis of these substances can be ordered in many countries of the world, including China (it will be cheaper than in other countries of the world).
2.1.2. Synthesis of dimethyl ether with methanol, their processing into more valuable marketable products.
One of the most interesting destinations. The synthesis of DME and methanol occurs together, then all the synthesis products are easily divided. The synthesis pressure is not high – up to 50 atm., the catalysts are not expensive. The technology has been massively introduced in China. In terms of physical properties, DME is similar to propane. Therefore, it can be used as a household gas.
Dimethyl ether can be processed into ethyl acetate (by the hydroformylation reaction; this is the most valuable component of solvents for paint and varnish materials), ethyl acetate into vinyl acetate and further into polyvinyl acetate. The latter is consumed in very large quantities for the production of wall paints. The share of such paints in their total global and regional markets is more than 50%. Other components are especially pure, highly dispersed calcium carbonate, and we will also be able to produce plasticizers necessary for their production.
Polyvinyl acetate can be processed into polyvinyl alcohol and acetic acid salts. PVA is used as a plasticizer for polymers, resins, for the synthesis of multicomponent polyester resins (as a long-chain monomer), and for some other purposes.
There are other possible ways of processing DME. There are several of them. We will not sort everything out.
Methanol is not a valuable product. It can be processed into formaldehyde. It is in demand in large quantities for the production of melamine-formaldehyde, toluene-formaldehyde resin. They are used for the production of cheap composite materials (of high quality), as plasticizers in concrete.
2.1.3. Synthesis of mixtures of alcohols C1-C4 or C1-C20.
This is a very interesting area. Alcohols C2-C4 are valuable raw materials for gasoline compounding. Their degree of chemical purity from methanol when separated by rectification (the simplest solution) will be high enough for their use for these purposes. Such mixtures significantly improve the quality of gasoline and reduce the amount of soot in its combustion products.
When they are separated to obtain substances with a chemical purity of over 99%, alcohols C2, C3, C4 are the basic raw materials for producing almost all types of rubbers and many other valuable substances. At the same time, the complexity and cost of routes for the synthesis of these substances is much lower than routes based on the use of petroleum raw materials (which are traditionally used all over the world).
Alcohols C8-C20 are used as plasticizers of plastics, components of lubricants.
All alcohols, without exception, can be processed into their corresponding aldehydes and organic acids. They are also used in the manufacture of various products.
The technology of synthesis of alcohol mixtures was developed in France and Ukraine (during the Soviet era). Ukrainian developments were lost due to the current war). Therefore, it is necessary to search for synthesis blocks in France. It is possible that other countries own it.
2.1.4. Synthesis of olefins (alkenes) and their products.
The lowest olefins are most interesting: ethylene, propylene, butylene. They can be used to produce appropriate polymers, copolymers with other monomers, and rubbers.
C5-C8 olefins can be used for the synthesis of light petroleum polymer resins. They are introduced into the composition of paint and varnish materials, and can be used to produce products made of composite materials. Olefins C9-C16 are used for the production of dark petroleum polymer resins, which can also be used for the production of non-ferrous and ferrous coatings.
Higher alcohols, aldehydes, and organic acids can be synthesized on the basis of olefins. They are also in demand as raw materials for other industries, but not in large quantities (each position requires its own marketing analysis of the market).
2.1.5. Synthesis of paraffins (alkanes).
Synthetic paraffins are mainly used as synthetic components of oils and lubricants. In some cases, there are other applications. For example, synthetic gasoline (with their conversion to isoalkanes by isomerization). How interesting this production is in a country where there is a lot of oil is a question. But in any case, these are the most valuable and chemically pure components of gasoline. They can also be used for compounding petroleum fractions of gasoline in order to reduce concentrations of undesirable components in gasoline (producing gasoline according to the Euro 5 standard and higher).
The production of synthetic alkenes and alkanes has been well mastered by Sosol in South Africa. They built the most powerful synthesis units there, due to which they completely replaced oil with coal (which they use to produce synthesis gas). It is worth trying to request technologies and equipment from them.
2.1.6. Synthesis of polyvinyl chloride.
It can be synthesized from ethylene isolated from mixtures of alkenes or from ethanol isolated from mixtures of alcohols C1-C4. The requirements for the indicator of the degree of chemical purity of the precursor are at least 99%.
Polyvinyl chloride is not used in its pure form, but as part of mixtures with plasticizers, inorganic substances capable of absorbing molecular chlorine and hydrogen peroxide (they are released when PVC is heated during molding of products from it). We can also produce all these components in sufficient quantities.
The largest amount of PVC is consumed for the production of plastic windows (profile), as well as for the production of water pipes. We can also produce these products. For their production, glass fiber reinforcement technologies can be mastered. This will increase the durability of such products.
2.1.7. Synthesis of valuable products based on propane-butane mixtures, pentanes, which can be purchased at low prices at refineries.
It is most promising to divide these gases to obtain gases with a CFC of at least 99% (by low-temperature rectification), then convert them into propylene and butylenes, then process them into polypropylene and copolymers of butylenes with ethylene, propylene (polybutylenes without copolymers are practically not used, since they are brittle).
The volume of consumption of such products is huge. It is possible to immediately process them into polymer pipes; they are in high demand on the building materials market.
2.1.8. Synthesis of valuable substances based on benzene, toluene, xylenes, which can be purchased at refineries and coke plants.
Based on these substances, it is possible to synthesize styrene (from benzene) or methyl styrene (from toluene), styrene butadiene rubber (a soft plastic in high demand on the regional and global markets), terephthalic acid (from xylene), which is used to produce polyethylene terephthalate (a base polymer used in other industries in very high volumes). in large quantities).
It is also possible to synthesize many substances that can be used as solvents or copolymers in multicomponent resins. Such resins can be used to produce cheap composite materials.
2.1.9. By-products.
As a result of air separation processes (in order to obtain O2), pure N2 is formed from impurities. It is used as a technical gas to create protective atmospheres, as well as to fill vegetable storages (extending the possible shelf life of vegetables and fruits in such an environment). The volume of its formation will be very large, export to other nearby regions of the countries of Central Asia, the European and African continents is possible.
As a result of cryogenic air separation processes, it is possible to obtain Ar (argon) and some other inert gases. They are in great demand for various technical purposes.
It is also possible to emit a very large amount of CO2 (carbon dioxide); the chemical purity of this gas will be high, so it can be used for carbonating water and beverages. It is also used in industry to create protective atmospheres, carry out carbonation reactions of various raw materials (production of carbonate bricks, artificial marble, for example).
A lot of different by-products (gaseous, liquid, solid) can be formed (each process of organic synthesis has its own). Most of them have some kind of marketable value or can be converted into such products. It is necessary to consider such tasks in an applied manner.
2.1.10. Final provisions of the section.
There are a lot of names of various products in demand by the market. This is several hundred positions. Only the main (basic) directions of development of this business project are listed above. As it is formed and implemented, the tasks of synthesizing substances not mentioned above may arise. This can be done by attaching the appropriate purification units of precursors synthesized according to the processes described above, and then synthesizing the corresponding substances from them.
3. Briefly about the technologies and equipment used for synthesis gas production, organic synthesis and separation of organic synthesis products into separate components.
3.1. Synthesis gas production by thermal steam-air, steam-oxygen conversion of hydrocarbon gases or conversion of these gases in mixtures with CO2 (or mixtures of CO2 + H2O).
These are the methods commonly used in gas chemistry for producing synthesis gas from natural gas and mixtures of hydrocarbon gases. In them, hydrocarbon gases are burned at a temperature of about 1000 °C with a lack of oxygen. As a result, a mixture of gases is formed in the combustion products, which include components valuable for organic synthesis reactions: CO + H2 (+CO2).
To reduce the concentration of N2 in the conversion products, oxygen-enriched air can be used instead (by the method of membrane gas separation; the concentration of O2 will be 35-45% instead of 21%). Either pure O2 from impurities, it is obtained by cryogenic or adsorption gas separation methods at appropriate installations (it is better for us to use cryogenic, since it is more economical in terms of energy consumption).
In order to reduce the combustion temperature and increase the yield of H2, H2O vapors can be added to the gases supplied for conversion. In order to increase the concentration of CO, it is necessary to supply CO2 (instead of H2O). It is possible to obtain pure CO2 from impurities by extracting synthesis gas from the composition (before using it as a raw material for organic synthesis), from retour or flue gases. Technologies for its extraction exist, they are not complicated.
Hydrocarbon gas conversion reactors are technically not complicated. We can make them ourselves (if we have the appropriate production). In any case, it is necessary to create such production, since this equipment is not eternal, and it is not advisable to buy it permanently.
It is possible to simultaneously convert natural gas into synthesis gas: coal of any brand, fuel oil (including watered), and other hydrocarbon liquids with a high calorific value. To do this, it is necessary to create fundamentally different, more expensive equipment. The necessary technologies are available.
It is also possible to use hydrocarbons with a low TC index (for the purpose of their environmentally friendly disposal), but this will lead to a decrease in the concentrations of CO and H2 in the synthesis gas, that is, to a decrease in its quality. There is a possibility to correct this shortcoming in the future, this is briefly described below. But these solutions have their price, so the disposal of such waste should be carried out on a reimbursable basis.
In the EU, the cost of environmentally friendly disposal of transformer oils, other chlorine-containing and toxic liquids is up to 3,000 Euros per ton. This payment with a large margin (more than 10 times) compensates for the economic costs of their disposal. Therefore, it is possible to take such liquids from the EU, as well as in the regions of Central Asia and the African continent with recycling and for less money.
The use of coal and fuel oil makes sense only if there is a shortage or high cost of natural gas. Even if natural gas costs $70 per 1,000 m3 (this is the maximum gas price in this region) these processes are not economically feasible. But it makes sense to work out such a process. It can be implemented in other regions of the world using the resulting gas not only as a raw material for organic synthesis, but also as an energy carrier (for various furnaces, boilers, and other purposes).
3.2. Synthesis gas production by conversion of mixtures of hydrocarbon gases in chemical compression reactors.
There is a better process for converting natural gas, mixtures of hydrocarbon gases into synthesis gas. This is its conversion in chemical compression reactors (hereinafter referred to as CCR). The CCR is a conventional internal combustion engine (with spark ignition), with a reconfigured power supply system (hydrocarbon gases and air are supplied with a different stoichiometric ratio, oxygen is in short supply).
Typically, mixtures of hydrocarbon gases with air are used to power CCR, in which hydrocarbon gases are in large excess relative to the stoichiometric ratio of their total combustion. But in this case, the resulting synthesis gas will contain a large amount (up to 50%) of nitrogen.
It is possible to isolate pure O2 and CO2 from impurities and use them as an oxidizer. In this case, the synthesis gas will contain a lot of CO and will not contain nitrogen.
Due to the large lack of O2, detonation in the CCR is unlikely. Therefore, it can be assumed that the supplied air or O2+CO2 mixtures can be heated. In theory, it is also possible to heat hydrocarbon gases; but to a temperature no higher than 350 °C, since at a higher temperature they will decompose to form coke on heat exchangers. The heat for heating can be taken from the synthesis gas coming out of the CCR; this will lead to an increase in the thermochemical efficiency of the CCR, as well as the concentration of CO +H2 in the resulting synthesis gas.
The engine needs to be slightly loaded. An electric generator synchronized with the company’s network is optimal for this. The power of the EG is about 30% of the possible, which can be developed with the complete combustion of all gas components. There are power plants based on shipboard diesel engines and other powerful internal combustion engines, which can be used to calculate the optimal power (based on the internal combustion engine volume and speed).
There are a lot of decommissioned high-power ship diesel engines in the world. They are sold for the price of scrap metal. They can be bought, repaired, redone, and used as CCR.
The main advantage of the process of converting mixtures of gases into CCR, in contrast to the thermal conversion process, is that the CCR additionally produces electricity, while the thermal process produces only thermal energy (which the plant as a whole produce in very large quantities; decisions are needed on its useful use; more on this below). In other words, this is a more economically beneficial process.
In addition, CCR makes it possible to obtain synthesis gas with a higher concentration of CO +H2 (valuable components) due to the fact that part of the thermal energy consumed to heat it too the
conversion temperature is generated by compressing mixtures in cylinders.
3.3. Purification of synthesis gas from H2S, COS, and other sulfur-containing gases.
The requirements for the chemical purity of the gas used for organic synthesis from all sulfur-containing gases are very high. The standard ones are not higher than 1 millionth, the modern ones are not higher than 0.5 millionth. This is due to the fact that these gases poison the catalysts, and therefore careful purification from them allows you to extend the service life of the catalysts.
The basic principle of all gas purification processes is the selection of several technologies (purification stages), each of which works quite efficiently at a certain range of concentrations of pollutants. It is optimal to immediately purify natural gas before its conversion to concentrations of these gases of less than 0.1%. This is not a difficult task, it is solved by using Lo-Cat technology (cheap equipment, cheap absorbents). This method can be used to purify the source natural gas, as well as for coarse purification of the resulting generator (synthesis) gas.
COS and other sulfur-containing gases are extracted by freezing the gas, adsorption with zeolites, activated carbon at the stages preceding its purification from H2S. This extends the service life of the H2S absorbent. This method can be used to purify both the initial natural gas and for coarse or fine purification of the resulting synthesis gas.
Fine purification of synthesis gas to a concentration of sulfur–containing gases acceptable for its use in organic synthesis is carried out by washing it in solutions of strong oxidizing agents – NaOCl, KMnO4, and others. The effectiveness of these methods depends on the effectiveness of the scrubbers used. The residual concentration of H2S and other S-containing gases below 0.5 millionths can be achieved by this method. Therefore, if unacceptable indicators are obtained, it is simply necessary to add scrubbers to the syngas flow path.
NaOCl can be synthesized directly at this facility from aqueous NaCl solutions. It is also possible to dispose of spent NaOCl solutions.
3.4. Synthesis gas preparation by changing the composition of its components (enrichment of H2 or CO, removal of CO2 and H2O).
It is quite simple to enrich the flow of H2 synthesis gas in the absence of any other source. It is necessary to divide it into two streams. Extract H2 from one stream and direct it to another stream. The residue that does not contain H2 will have a low calorific value; it is advisable to dispose of it by incineration, if necessary, by lighting with natural gas. Other methods (methanation, oxidation WITH ozone) will be much more expensive.
Synthesis gas obtained from conversion reactors usually contains significant concentrations of CO2. If necessary, CO2 can be extracted from other sources and added to this stream. It is also necessary to add H2 to it, obtained by the method described above. Then this gas stream must be heated to a temperature of 300-350 °C; the reaction of CO2 + H2 = CO + H2O will take place (the reaction of the shift conversion of CO, the equilibrium reaction, in this case its direction is reversed, towards the formation of CO). Then cool the resulting stream and extract the H2O from it (it condenses into a liquid).
Theoretically, it is possible to carry out a CO shift conversion reaction in gas produced by gasification of low-value fuels (for example, water-coal suspensions, organic waste) (by adding water vapor to it at a temperature of 300-350 °C. As a result, a gas with high concentrations of H2+CO2 will be formed. Further, it is possible to extract from it:
- hydrogen (by the method of membrane gas separation),
- pure CO2 from impurities (by absorption with an aqueous NaHCO3 solution).
Next, they are mixed in certain ratios and, according to the reversible reaction of the shift conversion of CO, obtain mixtures of H2 + CO+CO2. They will be completely free of nitrogen and all other gases, including sulfur-containing gases. Such gases are very valuable raw materials for many (not all!) organic synthesis processes, since:
- there is no need to compress the ballast components;
- after separation of all organic synthesis products, as well as CO2 and H2O vapors, the retour gases will contain only CO+H2; they can be reused as raw materials for organic synthesis.
Such a synthesis gas production technology requires more technological operations than technologies that do not involve reheating gas mixtures with their subsequent purification from CO2 + H2O. It will also lead to the formation of a large number of retour gases containing low concentrations (3-5%) of CO. These gases must be disposed of by incineration, which requires the consumption of natural gas.
CO2 is an undesirable component in the synthesis gas composition for most organic synthesis processes. In some processes, it is needed, but its concentrations are limited to 1%. The resulting synthesis gas contains much more of it. It can be removed by using one of two technologies (optional): absorption with ethanolamines or an aqueous solution of NaHCO3 (soda). The second process is simpler, and therefore more promising. Both processes make it possible to purify synthesis gas from H2S, the second without regenerating the absorbent (it will have to be replaced, but the resulting CO2 will be pure from H2S).
H2O vapors are also undesirable in the synthesis gas composition. But their concentrations are not particularly limited. It is possible to purify synthesis gas from them by freezing the gas or rinsing it with cooled methanol. There are also selective H2O vapor sorbents (concentrated sulfuric acid, calcined CaCl2), but the regeneration of such sorbents is more expensive than methanol.
3.5. Synthesis Reactors. Synthesis units.
Reactors are pressurized tanks. It houses a water-cooled catalyst. For all its fundamental simplicity of design, in fact, everything is not simple. It is very difficult to maintain the required temperature on all surfaces of the catalyst. As a result of the organic synthesis reaction, a large amount of heat is always released. Its removal occurs with the appearance of a large temperature difference on the surface and in the body of the catalyst. Therefore, setting up such reactors is always a difficult (in some cases, unsolved) technical task.
The synthesis process proceeds under a pressure of 50 to 250 atm. (for different reactions), at a certain temperature (the temperature of the gas supplied to the reactor should approximately correspond to it). Therefore, the reactor must be “tied up” with compressors, expanders, heat exchangers, heating and cooling devices for intermediate coolants supplied to the reactor, and some other equipment. It must be clearly coordinated in terms of material and thermal loads. In general, this entire set should be mounted in a single unit (synthesis), one reactor alone, without this set, has no value.
Such synthesis blocks must be purchased assembled. Mastering the technologies of their independent production requires a lot of time (from 2 to up to 10 years per unit), qualified specialists in these matters, and the necessary production base. But we will have to master this activity, because otherwise this production will critically depend on suppliers of such synthesis units (we won’t even be able to repair them).
Further, after the reactor, the obtained products with part of the components of the initial synthesis gas are supplied to the separation process. The division processes are not complicated. It is possible to develop the necessary technologies and equipment (based on data on the composition and concentrations of the resulting reaction products). At the initial stage of the plant’s construction, it is better to purchase them. Then we will solve the tasks of their production and maintenance (repair) on our own.
3.6. Separation of organic synthesis products.
Organic synthesis always proceeds with the formation of either mixture of target synthesis products (alcohols, olefins, paraffins) or undesirable synthesis by-products. They must be divided. It is important to initially understand what requirements for the degree of chemical purity are imposed on all or individual organic synthesis products. The standard requirements for this task are at least 99%.
Usually, the processes of separation of synthesis products are carried out by the method of rectification. It is quite difficult to obtain substances with a CFS of at least 99% in separation products using this method. Therefore, in some cases, additional methods of azeotropic or extractive rectification, selective sorption, and others are used. To design a production line designed to separate specific mixtures, it is necessary to know the composition and concentrations of synthesis products.
It is particularly difficult to separate synthesis products with a low boiling point (below 0 °C), the lower the temperature, the more difficult the task. For the division of such products, the method of low-temperature rectification is used. Cooling elements are required for the appropriate rectification temperatures of the installation. Well-insulated distillation columns are also needed. This equipment is expensive, and its operation is energy-intensive.
The material and thermal loads between the organic synthesis units and the processing lines intended for the separation of synthesis products should be well coordinated. Intermediate accumulation of synthesis products is possible, but it will require additional economic costs. And, in principle, it does not solve the problem, since synthesis units must be operated continuously. And the distillation columns cannot be operated in any other mode.
It is advisable to purchase such (load-coordinated) production lines in conjunction with synthesis units. But in principle, it is possible to solve the problems of their independent design and manufacture. There may be several possible solutions to the load matching problem, and they need to be considered in an applied manner (for example, to create backup lines with intermediate high–volume storage devices; in this case, they will be started periodically, but for a long period of time, which is acceptable for them).
3.7. Promising sources of the necessary technological equipment for us.
It is most promising to look for such equipment and conclude relevant contracts with enterprises in China, South Korea, and Japan. You can purchase equipment from them with sufficiently high technical and economic indicators of its operation at reasonable prices for equipment and its service support.
It is a very difficult issue to find specialists for such enterprises, which requires additional analysis and study. At the moment, it is still possible to buy inexpensive complete production lines in Europe that were in low use, after which you will have to maintain and repair them yourself.
4. Related industries aimed at the production of other valuable products that can be created in conjunction with the production of organic synthesis products.
4.1. Highly dispersed carbon black.
Highly dispersed carbon black is a valuable commodity product. It is consumed in large quantities as a black pigment in paint and varnish materials, a filler in rubbers in the production of particularly durable rubber products. There are other applications. The cost on the world market is about $ 4 per 1 kg.
It is produced by pyrolysis of methane in an arc plasma. It is not necessary to purify methane from fatty gases. Based on the cost of methane and electricity, the cost of its production will not exceed 0.5 dollars per 1 kg.
The pyrolysis products will contain hydrogen. It can be used to introduce multilayer carbon nanotubes into the synthesis gas used for the production of other organic substances (more on this later).
4.2. Multilayer carbon nanotubes.
The developed technology allows synthesizing nanotubes in industrial volumes. The productivity of one reactor can be up to 1000 kg per hour. Synthesis is carried out at normal pressure, which creates low operating costs for the synthesis reactors.
Their cost is very low, since a cheap catalyst is used (we can produce it in unlimited quantities from cheap and available raw materials). Their production volumes for us can be limited only by the volumes of synthesis gas available for them. Chemical purity from amorphous carbon is high (over 90%). Theoretically, it is possible to supply the entire world market with them. The price is not less than 5 dollars per 1 kg with a cost price of less than 0.5 dollars per 1 kg. They can effectively replace highly dispersed technical carbon used for the production of rubber products, paints and varnishes (their properties will only improve from this replacement).
Such nanotubes are used as reinforcing components in polymers, concrete, and bitumen. They significantly increase the strength of products, which increases their durability or reduces the consumption of materials for these products.
They can also be used as cheap sorbents for the adsorption of certain gases from gas mixtures (processes of adsorption gas separation), separation of liquids (water or aqueous solutions with hydrocarbon liquids), purification of water and chemical solutions from certain substances (some water-soluble salts).
For their synthesis, retur (waste) gases from reactors for the synthesis of other organic substances (which must be disposed of somehow) can be used. Therefore, it is not necessary to produce synthesis gas specifically for this synthesis.
We have a comprehensive description of this technology. It is only necessary to create and put into operation the corresponding reactors.
4.3. Single-layer carbon nanotubes.
Technologies for the synthesis of such nanotubes were developed by the Institute of Catalysis. Boreskova (Novosibirsk).
Positive results have been reported. The synthesis process is carried out by decomposition of impurity-free metal on a cobalt catalyst. The retur gases will contain hydrogen, which is a valuable raw material for the organic synthesis of other substances.
Single-layer nanotubes have a much higher production cost and a market-liquid price. At the same time, they have much greater strength as a reinforcing material. Therefore, they can only be used for the production of particularly valuable products made of composite materials.
They are used in microelectronics. This is due to their special electrophysical properties (low electrical resistance). But their suitability for this is determined not only by the number of layers in the tube, but also by their purity from amorphous carbon, chirality, defects, and length-to-thickness ratio. That is, consultations with certain consumers of such products are necessary.
They can also be used as sorbents for gas separation processes, separation of liquid chemical media, and purification of chemical solutions. It is necessary to determine their suitability for solving a specific technical problem, as with multilayer nanotubes, experimentally.
We will be able to produce the necessary catalyst. Reactor designs and process parameters must be obtained from the technology developer (based on the relevant agreement).
The creation of the production of multilayer and single-layer nanotubes can be considered economically efficient, but connected to the synthesis units of other organic substances by industries. That is, in addition to the other business projects proposed below.
4.4. Disposal of mercury gases (gases escaping from organic synthesis reactors or other chemical reactors using synthesis gas).
Despite the fact that they will be very pure from sulfur-containing gases, they will not be a valuable raw material for organic synthesis. This is due to the fact that the concentrations of CO and H2 in them will be significantly reduced. There are schemes in which gases leaving one reactor are sent to another, which does not have high requirements for the concentrations of these components. For example, the process of synthesis of multilayer carbon nanotubes proposed above.
If such solutions are not applied, then it is possible to extract hydrogen from them (by the method of membrane gas separation) and return it to the stage of preparing synthesis gas for use. It is better to dispose of the remaining gas after this process by co-incineration with natural gas; the generated heat is somehow useful to use. When burning this residue, it is necessary to ensure its combustion temperature of the order of 600 °C, with sufficient (at least 3%) excess O2 and sufficiently intensive mixing of flue gas components at this temperature (in cyclone furnaces). To meet these conditions, a large amount of natural gas will not be required. Theoretically, instead of natural gas or together with it, it is possible to burn water-coal suspensions.
4.5. Purification of return gases formed during the production of nitric acid from NOx. As well as flue gases from any other sources of emissions into the atmosphere.
Nitric acid must be produced to produce nitrates. It is produced by burning ammonia (in order to form NO), oxidizing part of NO to NO2 (pure O2 or air), then jointly dissolving these gases to form mixtures of HNO2+HNO3. Next, HNO2 is separated from HNO3 by evaporation with decomposition and formation of mixtures of nitrogen oxides, NO2 is introduced into their composition and the mixture is re-dissolved in cold water.
The principal task is the oxidation of NO to NO2. Oxidation is usually carried out by air; after dissolving NO+NO2 mixtures in water, significant amounts of NO remain in the residue. They are discharged into the atmosphere with its pollution by this toxic oxide.
It is possible to oxidize and dissolve NO to form nitric acid. To do this, it must be dissolved in an aqueous solution of hydrogen peroxide. Instead, it is possible to use specially synthesized ozone. This will significantly reduce the amount of NO emissions into the atmosphere. In turn, this will allow developing the production of inorganic chemicals related to the consumption of nitric acid and the formation of nitrogen oxides. For example, the production of lead free from impurities, the extraction of gold and other precious metals from rocks, and various wastes.
This method can be used to obtain HNO3 from other flue gas sources containing significant amounts of NO. These are any furnaces with a high (above 1300 °C) combustion temperature of gases. These can be metallurgical furnaces, glass furnaces, furnaces used for melting silicate mass into cast stone, and many others. It is possible to supply ammonia or ammonium bicarbonate synthesized at this production facility and use them to produce ammonium nitrate (a valuable fertilizer).
4.6. The use of waste thermal potentials from all their sources (hydrocarbon conversion reactors, synthesis units, flue gas purification systems, etc.).
Gas chemical production leads to the formation of a large number of waste heat potentials. This is mainly thermal energy with temperatures below 100 °C (from the cooling of synthesis gas, organic synthesis products, compressors, etc.). Heat with a temperature of 200-350 °C can be removed from fusion reactors (approximately corresponds to the operating temperature of the reactor); for this, an intermediate coolant with an appropriate boiling point must be used (the boiling process stabilizes the cooling temperature of the reactor). This thermal energy must be used in some useful way.
To use low-temperature thermal energy, it is possible to propose a related business project for the production of feed protein (feed yeast). It is a basic component of compound feed. They are in demand all over the world in large quantities. The cost depends on their quality. High-quality protein costs 2-3 Euros per kg (we can produce it). Thermal energy for this production is necessary for their drying by convection (heated to 60 °C air). This is the only correct method of solving this problem, since heating them to a higher temperature leads to the destruction of vitamins and other valuable substances in feed.
Synthesizing them is possible:
- made from methane (this is the best solution, it is very cheap for us and is available in conditionally unlimited quantities);
- from alcoholic braga obtained by fermentation of wheat, other starch – containing or sugar – containing food raw materials;
- from synthetic methanol (a very profitable process common in Europe), its mixtures with ethanol (if they are synthesized together).
There are technologies based on the use of non-food raw materials, but they lead to the formation of feed yeast contaminated with toxic substances. Such products are prohibited for production and use in all developed countries of the world. It should not be produced.
The technology of their synthesis is biochemical. It is available for copying. Biochemical media (bacteria) are also available on the market (in the countries of the Customs Union). The synthesis additionally requires ammonia, which we can produce at the same facility.
Thermal energy with a temperature of 200-350 °C can be used to produce saturated water vapor. Steam can be consumed for many industries. It is possible to accumulate it in order to coordinate the thermal loads between the production and consumption of heat in heat at each current moment in time.
Another possible use of waste heat energy is the production of ceramic or glass–ceramic materials. They also need to be dried at temperatures below 100 °C (before firing). You can spend both heat with a temperature below 100 °C and water vapor on this.
Natural gas is required for firing dried glass-ceramic materials. We will have enough of it.
4.7. Creation of related business projects for the extraction of gold and other precious metals from ore rocks.
There are other substances that can dissolve these metals. But they are expensive and often very toxic (sodium cyanide, for example). Concentrations of gold and other precious metals are usually low (for gold, they are always below 4 grams per ton, usually about 1.5 grams or lower). Therefore, the cost of the substances used for extraction determines the economic prospects of such business projects.
It is not necessary to combine the production of nitric acid with such productions on the same site. It is possible to synthesize only ammonia or ammonium bicarbonate (a safe substance in storage and transportation) at this enterprise. It can then be burned in a natural gas environment and then nitric acid can be produced by extracting nitrogen oxides from the resulting flue gases.
4.8. Environmentally friendly disposal of solid organic and inorganic waste.
It is possible to equip this enterprise with equipment that allows for the environmentally friendly disposal of any organic and inorganic waste and their mixtures. Thus, the ecological purity of this production will be ensured.
Theoretically, it is possible to take for disposal the waste generated in the region of construction of such an enterprise. But the economics of such activities are in doubt (they will replace very cheap natural gas). It is possible that positive results will be achieved, but only in relation to certain types of waste. Polymer waste, oil sludge, watered-down fuel oil, and other wastes with high calorific value are the most promising. This issue will be considered after the installation of the relevant pilot pilot production lines.
4.9. Energy supply.
4.9.1. The relevance of the task.
There is a problem of providing energy supply to large consumers, while ensuring the reliability of energy supply. This is due to the low level of development of electrical networks.
The enterprises being created are based on the use of complex multi-stage technological processes, the violation of which may have a man-made danger. Also, the sudden shutdown of such equipment may cause not man-made, but great economic damage to the owners.
In addition, own generation can allow you to receive electricity at a lower cost than that purchased on the energy market. Facilities that have their own generation can be forcibly disconnected from the network only if this is the result of an accident in the networks. At the initiative of the regulator, there is no point.
Therefore, the issue of ensuring uninterrupted power supply to these enterprises (or a group of our enterprises) is very relevant
4.9.2. Solution.
From an energy point of view, it is most promising to use high-capacity combined-cycle gas plants for power generation. They have an efficiency rating of 45 to 56%. This is slightly higher than the efficiency of steam turbines of similar capacity alone.
In a region where there is cheap natural gas, their use is questionable due to the low resource of gas turbines (the standard designated service life before its repair does not exceed 20,000 hours, provided natural gas is used in accordance with GOST). It should be borne in mind that this period strongly depends on the content of sulfur-containing gases in hydrocarbon gases. When using gas with a concentration not exceeding one millionth of a millionth, this period can be extended to 50,000 hours or more.
We will have such gas purification systems. It won’t be a big problem to collect additional ones. Therefore, this decision should be considered as a priority.
There is another problem. CCGT is assembled only in a few countries of the world (Ukraine, Germany, Japan, USA). The Ukrainian company does not work, it is not known whether it will work after the war. And enterprises in other countries ask a lot, both for equipment and for its service support. This circumstance may play a big role in the choice between a CCGT and a steam turbine installation.
4.9.3. Ensuring uninterrupted power supply to equipment whose sudden (unplanned) power outage is unacceptable.
There are standard solutions to ensure uninterrupted power supply to any consumers in case of their sudden disconnection from centralized power supply networks. Their work is based on the use of batteries, as well as additional energy sources such as diesel, gasoline or gas generators. If only the correct output of the equipment from operating mode to idle mode is important, then it is possible to use only the energy stored in the batteries.
It will not be possible to power the entire plant from such sources (CCGT and GT are not suitable for this), since they are not designed to connect megawatt consumers. But it is quite possible to power only those consumers whose energy supply is critically important. This task must be solved at the design stage of the projects corresponding to this problem.