Methanol Production from Natural Gas (Steam Reforming)
Methanol Production Costs Report | Issue A | Q4 2024
| Report Details |
| 1,000 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 1,000 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study presents the economics of large-scale Methanol production from natural gas in the United States. In the process examined, natural gas is first converted into synthesis gas (syngas) by means of conventional steam reforming and then the syngas is converted into Methanol.
The report provides a comprehensive study of Methanol production and related Methanol production cost, covering three key aspects: a complete description of the Methanol production process examined; an in-depth analysis of the related Methanol plant capital cost (Capex); and an evaluation of the respective Methanol plant operating costs (Opex).
The Methanol production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Methanol plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Methanol plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) syngas generation; (2) methanol synthesis; and (3) purification.
Syngas generation. Natural gas feedstock is treated in a fixed-bed-type reactor that converts higher hydrocarbons contained in the feed gas into a gas rich in methane and hydrogen, in order to protect the catalyst. Then, the treated gas is converted to syngas in a steam reformer. There, methane reacts catalytically with steam, generating CO and H2. The reformer outlet stream is then cooled and the condensed water is separated from the syngas.
Methanol synthesis. The syngas is compressed and mixed with recycle gas and fed to the methanol-synthesis reaction system, where CO and CO2 react with hydrogen to generate methanol. The reactor outlet gas is mainly comprised of methanol, water vapor, unconverted hydrogen, CO and CO2. This stream is cooled, and methanol and water are separated from the gases by condensation. The separated gas is used as fuel with a small purge. The water-methanol condensate stream is sent to the purification steps.
Purification. The purification area is composed of two distillation columns. The topping column removes the dissolved gases from the crude methanol stream. In the refining column, part of the methanol produced is obtained from the top of the column while water obtained as column bottoms is recycled as process water.
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Production Process Information
Process Consumptions
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Operating Cost Summary
Production Costs Datasheet
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Methanol production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Methanol process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Methanol production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Methanol plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
Other Methanol Production Cost Reports
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This report presents an economic analysis of Methanol production from naphtha in the United States. In this process, naphtha undergoes partial oxidation producing syngas, which is then converted to Methanol.
Details: 1,700 kta United States-based plant | Q4 2024 | 107 pages | Issue D From $1,199 USD
The cost analyses presented in this report target a 1,700 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Methanol Production from Coal
This feasibility study approaches the economics of Methanol production in China via coal gasification. In this process, coal is initially gasified to produce syngas. This syngas is then converted to Methanol in a dual reactor system comprising an isothermal reactor in series with a gas-cooled reactor.
Details: 1,500 kta China-based plant | Q4 2024 | 107 pages | Issue G From $1,199 USD
The cost analyses presented in this report target a 1,500 kta (kilo metric ton per annum per annum) China-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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