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Scale Gas-‐To-‐Methanol Conversion by Engine Reformers

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Scale Gas-‐To-‐Methanol Conversion by Engine Reformers System Model of Small-Scale Gas-to-Methanol Conversion by Engine Reformers By Angela J. Acocella B.S., Mechanical Engineering Rensselaer Polytechnic Institute, 2012 Submitted to the Engineering Systems Division in partial fulfillment of the requirements for the degree of Master of Science in Technology & Policy at the Massachusetts Institute of Technology June 2015 © 2015 Massachusetts Institute of Technology, All rights reserved Signature of Author............................................................................................................. Technology & Policy Program; Engineering Systems Division May 8, 2015 Certified by.............................................................................................................................. Daniel R. Cohn Research Scientist, MIT Energy Initiative Thesis Supervisor Accepted by............................................................................................................................. Dava J. Newman Professor of Aeronautics and Astronautics and Engineering Systems Director, Technology and Policy Program 2 System Model of Small-Scale Gas-to-Methanol Conversion by Engine Reformers by Angela J. Acocella Submitted to the Engineering Systems Division On May 8, 2015 in partial fulfillment of the requirements for the degree of Master of Science in Technology & Policy ABSTRACT As global energy demands grow and environmental concerns over resource extraction methods intensify, high impact solutions are becoming increasingly essential. Venting and flaring of associated natural gas represents significant environmental and financial losses yet it continues in the North Dakota Bakken oil play. The valuable gas resource is wasted due to unfavorable economics and limited pipeline capacity. Similarly in India, underdeveloped gas transport infrastructure and restrictive regulatory frameworks prevent distribution and marketing of natural gas from the northeast regions, leaving it stranded in marginal fields. This thesis establishes a techno-economic model, utilizing Aspen Plus chemical processing software, and a discounted cash flow model to estimate economic feasibility of implementing MIT engine reformer-based gas-to-liquids (GTL) systems in the US or India. The system reforms natural gas via partial oxidation into synthesis gas (syngas) in the cylinders of an internal combustion engine, and can significantly reduce capital costs over conventional GTL reforming processes. The engine is operated in fuel rich conditions to generate the syngas, which is synthesized into methanol and dimethyl ether (DME). Once produced on-site, these liquids are more easily transported than gases. This study assesses the regulatory structures surrounding the upstream methane resource and downstream end product marketability for three scenarios: use of DME to replace existing local (1) diesel and (2) liquefied petroleum gas (LPG), or (3) sale of methanol as a commodity chemical on domestic or global markets. The analysis shows the system is economical in both locations. In the US, the minimum economically efficient production capacity with a 1-2 year payback period is 400,000- 860,000 standard cubic feet per day (scfpd) of natural gas for the range of end use scenarios considered. Differences in costs and product market characteristics in India result in a minimum efficient capacity of 330,000-810,000 scfpd of natural gas for the three scenarios. Thesis Supervisor: Daniel R. Cohn Title: Research Scientist 3 4 Table of Contents ABSTRACT .................................................................................................................................. 3 Table of Contents ..................................................................................................................... 5 List of Figures ............................................................................................................................ 7 List of Tables ............................................................................................................................. 8 Acknowledgments ................................................................................................................... 9 NOMENCLATURE ................................................................................................................... 10 1. INTRODUCTION ................................................................................................................ 11 1.1 Natural Gas Availability & Infrastructure ....................................................................... 11 1.1.1 United States ....................................................................................................................................... 11 1.1.2 India ........................................................................................................................................................ 12 1.2 Solutions ..................................................................................................................................... 16 1.2.1 Traditional & Existing Technologies ......................................................................................... 16 1.2.2 The Engine Reformer ....................................................................................................................... 18 1.2.3 Small Modular Plant Design .......................................................................................................... 19 1.2.4 Implementation .................................................................................................................................. 20 1.3 Fuels Background .................................................................................................................... 21 1.3.1 Fuel Comparison ................................................................................................................................ 21 1.3.2 Natural Gas Vehicles (NGVs): CNG & LNG .............................................................................. 23 1.3.3 LPG ........................................................................................................................................................... 25 1.3.4 DME ......................................................................................................................................................... 26 1.3.5 Methanol ............................................................................................................................................... 28 2. POLICY OVERVIEW .......................................................................................................... 31 2.1 United States and North Dakota ......................................................................................... 31 2.1.1 Gas Flaring Regulations .................................................................................................................. 31 2.1.2 Fuel Specifications ............................................................................................................................ 32 2.1.3 Clean Air Act & Energy Policy Act .............................................................................................. 33 2.1.4 Alternative Fuel Tax Credit ........................................................................................................... 34 2.1.5 Vehicle Fuel Economy And GHG Emissions Standards ..................................................... 34 2.1.6 Vehicle Conversion Standards ..................................................................................................... 34 2.2 India ............................................................................................................................................. 35 2.2.1 Natural Gas Strategies ..................................................................................................................... 35 2.2.2 Fuel and Vehicle Standards & Regulations ............................................................................. 37 2.2.3 LPG Subsidies ...................................................................................................................................... 38 2.2.4 Direct Benefit Transfer (DBT) ..................................................................................................... 38 2.2.5 Emissions .............................................................................................................................................. 39 2.26 Bharat Stage IV Vehicle Emission Standards, 2010 ............................................................. 39 2.2.7 Air (Prevention and Control of Pollution) Act, 1981 ......................................................... 39 2.2.8 Environmental (Protection) Act, 1986 .................................................................................... 40 3. LITERATURE REVIEW ..................................................................................................... 41 3.1 Feedstock: Location, Type, and Availability ................................................................... 41 3.1.1 US .............................................................................................................................................................. 41 3.1.2 India ........................................................................................................................................................ 41 5 3.2 Engines .......................................................................................................................................
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