Presentation made to China National Development and Reform Commission at their request by Scott Charpentier and Steve Wittrig on the global experience and guidance to China for methanol as a transport fuel.
Design For Accessibility: Getting it right from the start
Bp methanol presentation to China ndrc for methanol as fuels 2006
1. Methanol as a Fuel
Status of International Research
BP Presentation to NDRC
Beijing May 16, 2006
Steve Wittrig/Scott Charpentier
2. 2
Outline
• Methanol production technology and economics
• Methanol engine technology
• Issues associated with the use of methanol as a fuel (problem
definition, risks and mitigation strategies)
− Toxicity
− Methanol/Gasoline blends
− Methanol logistics and infrastructure cost
− Biodegradability in the environment
− Emissions and air pollution
− Corrosiveness/Materials compatibility
− Cold Start/Operability
4. 4
BP’s Trinidad-Based Methanol Projects
Lurgi Technology and Major Contractor
• Titan Methanol Plant
− 2500 tonnes/day (single train), largest in world at the time
− Natural Gas Consumption:80 MMSCFD
− Start up: Dec 1999
• Atlas Methanol Plant
− First implementation of Lurgi megamethanol technology
− 5000 tonnes/day (single train), currently largest in world
− Natural Gas Consumption:160 MMSCFD
− Start up: June 2004
5. 5
Methanol from Natural Gas
• Megamethanol technology recently commercialized in Trinidad
profitably produces methanol at $110 per tonne (using $1 / MMBTU
gas)
• $140 per tonne methanol from $2 / MMBTU gas (add $30 per tonne for
additional $1 / MMBTU gas)
• Technology breakthrough (20% lower cost than next best technology)
13. 13
Next Generation Technology
High Pressure POX (Another 10% lower cost?)
• Lurgi’s Pure ATR – eliminate steam reformer
− Lower capital costs
− Lower CO2 emissions
• Increased pressure to 80 bar
− Eliminate compressors
Demonstration plant for
production of Syngas from
Natural Gas, Liquid
Hydrocarbons/Slurries at
pressures up to 100 bar
sponsored by BMWA, SMWK, mg
technologies
14. 14
Methanol from Coal
• BP is not expert on coal conversion or the costs to produce
methanol from coal gasification.
• Some of our colleagues in China tell us that methanol can be
produced from coal at a cost of 800 – 1200 RMB per tonne.
• We are interested to know more about the costs and processes
used in China for producing methanol
• If methanol can be produced in China for 1200 RMB per tonne,
that is equivalent to gasoline at 1.5 RMB per litre.
• We are interested to know if China will use this opportunity for
transportation fuel made from coal in China.
15. 15
Life Cycle Energy Balance - Fuel Yield
Methanol and Fischer Tropsch Diesel
5 Tonne Coal
2.5 Tonne
Methanol
0.9 Tonne
FT Liquids
Equivalent to
0.3 Tonne
Naphtha (not auto fuel)
1.1 Tonne
Diesel Equivalent
0.6 Tonne
FT Diesel
Fischer Tropsch
Methanol
Divide by 2.3
for conversion
16. 16
Life Cycle Energy Balance - Fuel Yield
Methanol and Fischer Tropsch Diesel
1 MM SCF Gas
29.9 Tonne
Methanol
11.1 Tonne
FT Liquids
Equivalent to
3.6 Tonne
Naphtha (not auto fuel)
13 Tonne
Diesel Equivalent
7.5 Tonne
FT Diesel
Fischer Tropsch
Methanol
Divide by 2.3
for conversion
18. 18
Engines and Autos for methanol fuel
• Thousands of methanol flex fuel vehicles have been manufactured and sold in the
West in the last 20 years
• The technology exists to build consumer or commercial autos and trucks that
efficiently and safely use methanol and methanol/gasoline blends as fuel
• Engines that are designed and built specifically for methanol are probably not
generally more costly than gasoline or diesel engines. The technology is very similar.
There are some different materials that need to be specified for methanol service,
but they are not generally more expensive materials.
• The M85 FFV Ford Taurus sold in the US was $340 cheaper than the gasoline
version.
• Many companies and research entities have continued development of methanol
fueled engines and there are modern prototype methanol engines that take
advantage of methanol’s octane and vapor pressure characteristics to achieve very
high engine efficiencies.
• The potential relative cost of methanol fueled engines is an issue that can be
estimated from work done over the last 20 years by engine designers such as FEV
• The production of methanol fueled cars and buses could be a significant opportunity
for Chinese auto companies.
31. 31
Toxicity of Methanol
• Methanol is poisonous and should not be drunk
• The lethal dose of methanol ranges from 25-90 ml, the lethal
dose of gasoline in humans is approx. 400 ml (70 kg body),
• There have been reported instances of pure methanol being
intentionally mixed with drinks and poisoning people
• One very effective strategy for preventing these problems is
to add some gasoline or bitter additives (this is the strategy
used for ethanol fuel as well).
• Another strategy is for methanol to be used by professional
drivers (such as bus fleets or taxi drivers or delivery vehicles)
and only dispense it from a limited number of sites (e.g., 4-6
bus terminals in a city dispensing methanol for buses
designed for methanol fuel).
33. 33
Phase separation and water problems
• In low concentration blends, methanol/gasoline blends are not very stable
in the presence of water. The gasoline and the methanol can separate if
there is some moisture or water contamination. This is one of the
primary problems caused by mixing a small amount of methanol with
gasoline (M5 – M15).
• It can cause problems in retail or distribution storage
• It can cause problems in driveability of cars using blends.
• The primary strategies for dealing with the problem are compatibilizer
additives and special design and careful operation of storage and
dispensing infrastructure to keep out water.
• These problems with low fraction methanol/gasoline blends can be
managed, but they do cause extra expense and require attention.
• These problems are not particularly evident with M85 or not at all for
M100. One way that China might effectively use methanol would be as
M100 for city buses, taxis and delivery vehicles
35. 35
Methanol Corrosiveness
• Methanol has different chemical characteristics than gasoline.
It is not compatible with some elastomers and other materials
(notably aluminum) that are commonly used in gasoline cars
and distribution infrastructure.
• If a car or a dispensing system is designed with the knowledge
that it will be exposed to methanol, it is only a matter of proper
material selection and design.
• This problem leads to many of the problems that can occur
with the use of methanol blends (such as M15) in automobiles
that are not designed for methanol use. It is the main reason
that auto companies object to unregulated blending of
methanol into gasoline.
37. 37
Moving, storing and distributing methanol
• Methanol is an item of commerce that is sold, shipped and stored around
the world
• BP is the largest buyer of methanol in the world (for our acetic acid
business)
• BP is part owner of the largest methanol plant in the world (Atlas in
Trinidad)
• BP has a lot of information and know-how on methanol shipping and
handling
• However, the major issues in the past for methanol as a fuel have been
associated with methanol blends (M5 – M15) (Phase separation, water take-
up and fuel quality and corrosiveness in systems not designed to handle
methanol).
• These are all issues that require attention and some cost to handle. There
is significant experience in the world in how to design and operate systems
to handle methanol/gasoline blends. BP can offer advice and guidance to
China if desired
38. 38
CONCAWE/EUCAR study
• Conventional fuels, bio-fuels, synthetics fuels (from gas, coal and
biomass) and hydrogen
• Assessment of future vehicle technologies
• Based on European Resources and product infrastructure
• Results - Life cycle costs, Energy efficiency and GHG emissions
• Analysis of light duty market only
• Methanol results based on 100% methanol for Fuel cell use.
• Results are not directly applicable to China. But do show the
type of analysis that needs to be done and demonstrates the
potential of BP and Ford sponsored work at Tsinghua
University with Zhang Aling’s group
39. 39
Economic analysis and Life cycle energy
balance
• EUCAR, CONCAWE and JRC have performed a joint evaluation of
the Well-to-Wheels energy use and greenhouse gas (GHG)
emissions for a wide range of potential future fuels and powertrain
options.
• 2005 Revision http://ies.jrc.cec.eu.int/wtw.html
• Objectives
− Establish, in a transparent and objective manner, a consensual
well-to-wheels energy use and Greenhouse gas (GHG) emissions
assessment of a wide range of automotive fuels and powertrains
relevant to Europe in 2010 and beyond.
− Consider the viability of each fuel pathway and estimate the
associated macro-economic costs
40. 40
Incremental Well-to-Tank costs for coal
derived fuels
$25 / bbl Oil
0
2
4
6
8
10
12
14
16
18
F
T
diesel
M
ethan
ol
D
M
E
Euro/GJ
Production Distribution
Refueling
$50 / bbl Oil
0
2
4
6
8
10
12
14
16
18
F
T
diesel
M
ethan
ol
D
M
E
Euro/GJ
Production Distribution
Refueling
Incremental Vehicle Costs – DME 2995 Euro/unit (6.3
Euro/GJ), methanol 1990 Euro/unit (est)
Methanol at
$250/tonne
Assume an extra
500,000 RMB for
one retail station
41. 41
BP/Ford/Tsinghua University Programme
• Replicate the CONCAWE/EUCAR study showing Economics,
Energy Efficiency and GHG Emissions for a range of Chinese fuel
options including methanol in gasoline vehicles and DME for diesel
vehicles.
• Primary resources – Oil, Naturals gas, coal, and renewables
(biomass, solar, wind etc.)
• 1 year programme
• Completion due in June 2006
43. 43
Methanol and the environment
• Ground Water and Spills
− Methanol biodegrades very quickly in soil and water.
− Methanol and water are the major components of windshield
washer fluid around the world. All of the methanol used in
this application end up in soil or water and quickly are
consumed by natural bacteria.
− Any cases of environmental damage or poisoning or toxic
effects to humans caused by methanol spills or accidents
are extremely rare, if ever (I’m not aware of any).
44. 44
Methanol and the environment
Combustion emissions and air pollution
− Methanol burns very cleanly and is generally a better fuel for air
pollution than either gasoline or diesel
− If methanol is used in poorly designed or tuned engines and
without catalyst aftertreatment, the incomplete combustion of
methanol can lead to somewhat elevated levels of formaldehyde.
− This is reported to be about the same level or less of formaldehyde
from diesel combustion.
− The issue of formaldehyde emissions from methanol engines is
well studied and there are well known solutions that can be applied
to design and operation of methanol fueled cars.
47. 47
Cold Start
• Methanol (and ethanol) have low vapor pressure in cold (e.g., -20
C) temperatures. This can cause problems with starting a
methanol engine in a cold environment.
• If methanol is used as M85 or M100 for city buses or taxi fleets,
the vehicles will typically be started once a day, they can be
parked in heated garages if the weather is very cold and they
can be started and warmed up according to established
procedures to solve this problem.
• There are also straightforward engineering solutions to this
problem for cars and buses that will operate in cold
environments (just as there are for gasoline and diesel engines).
One example is shown on the next slide.