Exelus has invented a new catalytic technology that allows
for the first time selectivity of 80% at full methanol conversion.
Through careful catalyst and process design, techniques to
maximize the rate of styrene formation have been discovered
and exploited to produce exceptionally high reaction yields.
This breakthrough catalyst permits the development of a simple,
fixed-bed process. Some of the benefits of this process are:
Lower Temperature Operation – The reaction
occurs around 400ºC, compared to >600ºC required
for conventional SM technologies. This means that the heat
of reaction is added at a lower, and therefore more efficient,
temperature.
Lower Capital Cost – the milder reaction conditions
reduce the capital cost requirements significantly. The conventional
SM process requires large amounts of steam generated at near
900ºC to provide the heat of reaction. Eliminating
this requirement further reduces cost. Also eliminated
is the entire EB synthesis plant.
Reduced Feedstock Cost – the economics of
styrene production are completely altered using this new
synthesis route. Benzene ($940/MT) and ethylene ($1100/MT)
are replaced by toluene ($650/MT) and methanol ($350/MT).
This results in a feedstock savings of approximately $340/MT.
Low Utility Consumption – The hydrogen co-product
is easily recovered and burned to provide most of the energy
required to run the process, greatly reducing carbon emissions.
