Abstract

Process Economics Program Report 148A

SYNTHESIS GAS
(November 1995)

This report evaluates three routes for the production of synthesis gas (syngas) with a
H2:CO ratio of 2:1. The three routes are steam reforming of natural gas, partial oxidation of
natural gas, and partial oxidation of a vacuum residue feedstock. Our evaluations indicate that
the natural gas partial oxidation route offers the lowest capital investment and production costs
at the assumed relative prices of feedstocks and by-product credits. However, natural gas
steam reforming becomes the most attractive option if the surplus coproduct hydrogen (that is
an inherent feature of the route) can be disposed of at a chemical (instead of an assumed fuel)
value. Syngas production by partial oxidation of vacuum residue is an option that is frequently
practiced in locations where natural gas is not readily available.
We also present a comprehensive technical review that focuses on the steam reforming
and partial oxidation technologies. The review includes the main new developments in steam
reforming catalysts, recent advances to improve steam reforming thermal efficiencies, and
refinements in the design of partial oxidation reactors.
This report will be useful to companies that produce or consume syngas and to both
chemical and energy-based companies (or equivalent government organizations in various
countries) that have a long-term interest in the potential conversion of syngas to various
chemicals and liquid fuels.

PEP’92 SCN
 CONTENTS

1 INTRODUCTION 1-1

2 SUMMARY 2-1
TECHNICAL REVIEW 2-1
Steam Reforming 2-1
Partial Oxidation 2-2
SRI’S PROCESS CONCEPTS 2-3
Synthesis Gas (H2:CO=2:1) from Natural Gas by Steam Reforming 2-3
Synthesis Gas (H2:CO=2:1) from Natural Gas by Partial Oxidation 2-4
Synthesis Gas (H2:CO=2:1) from Vacuum Residuum by Partial Oxidation 2-4
COST ESTIMATES 2-5

3 TECHNICAL REVIEW 3-1

STEAM REFORMING 3-1
Catalysts 3-2
Prereforming 3-3
Improved Thermal Efficiency 3-4
Reformer Tube Metallurgy 3-5
PARTIAL OXIDATION 3-6
Reactor Design 3-8
Slag Treatment 3-8
Catalytic Partial Oxidation 3-9

4 SYNTHESIS GAS (H2:CO=2:1) FROM NATURAL GAS

BY STEAM REFORMING 4-1
PROCESS DESCRIPTION 4-2
Steam Reforming and Heat Recovery (Section 100) 4-4
Carbon Dioxide Separation (Section 200) 4-5
Hydrogen Skimming (Section 300) 4-5
PROCESS DISCUSSION 4-12
COST ESTIMATES 4-13

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 CONTENTS (Concluded)

5 SYNTHESIS GAS (H2:CO = 2:1) FROM NATURAL GAS

BY PARTIAL OXIDATION 5-1
PROCESS DESCRIPTION 5-2
Partial Oxidation and Heat Recovery (Section 100) 5-2
Air Separation (Section 200) 5-4
Carbon Dioxide Separation (Section 300) 5-4
Steam System 5-5
PROCESS DISCUSSION 5-10
COST ESTIMATES 5-11

6 SYNTHESIS GAS (H2:CO = 2:1) FROM VACUUM RESIDUUM

BY PARTIAL OXIDATION 6-1
PROCESS DESCRIPTION 6-1
Partial Oxidation and Heat Recovery (Section 100) 6-4
Air Separation (Section 200) 6-4
Soot Recovery and Recycle (Section 300) 6-5
Acid Gas Removal and CO Shift (Section 400) 6-5
Steam System 6-6
PROCESS DISCUSSION 6-11
COST ESTIMATES 6-12

APPENDIX A: PATENT SUMMARY TABLE A-1

APPENDIX B: DESIGN AND COST BASES B-1

APPENDIX C: CITED REFERENCES C-1

APPENDIX D: PATENT REFERENCES BY COMPANY D-1

APPENDIX E: PROCESS FLOW DIAGRAMS E-1

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 ILLUSTRATIONS

4.1 Syngas (H2:CO=2:1) from Natural Gas by Steam Reforming

Process Flow Diagram E-3
4.2 Schematic Diagram of Prism® System 4-1
4.3 Syngas from Natural Gas by Steam Reforming
Product Value as a Function of Capacity and the Natural Gas Price 4-19
4.4 Syngas from Natural Gas by Steam Reforming
Base Capacity Product Value as a Function of
By-Product Hydrogen Credit 4-21
5.1 Syngas (H2:CO = 2:1) from Natural Gas by Partial Oxidation
Process Flow Diagram E-5
5.2 Syngas from Natural Gas by Partial Oxidation
Steam Distribution Diagram 5-9
5.3 Syngas from Natural Gas by Partial Oxidation
Product Value as a Function of Capacity and the Natural Gas Price 5-17
6.1 Syngas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation
Process Flow Diagram E-7
6.2 Syngas from Vacuum Residuum by Partial Oxidation
Steam Distribution Diagram 6-3
6.3 Syngas from Vacuum Residuum by Partial Oxidation
Product Value as a Function of Capacity and Feedstock Price 6-18

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 TABLES

2.1 Comparative Syngas Production Costs 2-7

3.1 Synthesis Gas
Patent Summary A-3
4.1 Syngas (H2:CO=2:1) from Natural Gas by Steam Reforming
Design Bases 4-3
4.2 Syngas (H2:CO=2:1) from Natural Gas by Steam Reforming
Stream Flows 4-7
4.3 Syngas (H2:CO=2:1) from Natural Gas by Steam Reforming
Major Equipment 4-8
4.4 Syngas (H2:CO=2:1) from Natural Gas by Steam Reforming
Utilities Summary 4-10
4.5 Syngas (H2:CO=2:1) from Natural Gas by Steam Reforming
Total Capital Investment 4-15
4.6 Syngas (H2:CO=2:1) from Natural Gas by Steam Reforming
Capital Investment by Section 4-16
4.7 Syngas (H2:CO=2:1) from Natural Gas by Steam Reforming
Production Costs 4-17
4.8 Syngas (H2:CO=2:1) from Natural Gas by Steam Reforming
Direct Cost by Section ($1,000/yr) 4-20
5.1 Syngas (H2:CO = 2:1) from Natural Gas by Partial Oxidation
Design Bases 5-3
5.2 Syngas (H2:CO = 2:1) from Natural Gas by Partial Oxidation
Stream Flows 5-6
5.3 Syngas (H2:CO = 2:1) from Natural Gas by Partial Oxidation
Major Equipment 5-7
5.4 Syngas (H2:CO = 2:1) from Natural Gas by Partial Oxidation
Utilities Summary 5-8
5.5 Syngas (H2:CO = 2:1) from Natural Gas by Partial Oxidation
Total Capital Investment 5-13
5.6 Syngas (H2:CO = 2:1) from Natural Gas by Partial Oxidation
Capital Investment by Section 5-14

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 TABLES (Concluded)

5.7 Syngas (H2:CO = 2:1) from Natural Gas by Partial Oxidation

Production Costs 5-15
5.8 Syngas (H2:CO = 2:1) from Natural Gas by Partial Oxidation
Direct Costs by Section ($1,000/yr) 5-18
6.1 Syngas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation
Design Bases 6-2
6.2 Syngas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation
Stream Flows 6-7
6.3 Syngas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation
Major Equipment 6-9
6.4 Syngas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation
Utilities Summary 6-10
6.5 Syngas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation
Total Capital Investment 6-13
6.6 Syngas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation
Capital Investment by Section 6-14
6.7 Syngas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation
Production Costs 6-16
6.8 Syngas (H2:CO = 2:1) from Vacuum Residuum by Partial Oxidation
Direct Costs by Section ($1,000/yr) 6-19

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