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INDEX
1 PROJECT DETAILS
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4 DME-CHALLENGES TO MARKET GROWTH 37-37
INTRODUCTION:
The following project is an attempt towards designing a plant to produce 30,000 MTPA
Dimethyl Ether (DME) through Natural gas using one step DME Synthesis route.
The widespread use of Dimethyl Ether (DME) as a non-petroleum based alternative fuel
is propelling the market. Since it is considered as a clean and high-performance
compression ignition fuel, it can be extensively used in diesel engines; its use eliminates
particulate exhaust emissions of automobiles and can significantly save the high cost of
diesel particulate filters. Besides this, it is applicable as an aerosol propellant, power
generation and LPG by blending are the chief uses of the DME. This has spurred the
demand for DME across transportation sector and domestic sector.
a. Clean fuel for transportation: DME is one of the most promising alternative
automotive fuel solutions among the various ultra-clean, renewable, and low-carbon
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fuels under consideration worldwide. DME can be used as fuel in diesel engines,
gasoline engines (30% DME/70% LPG), and gas turbines. Only modest modifications
are required to convert a diesel engine to run on DME, and engine and vehicle
manufacturers, including Nissan and Volvo, have developed heavy vehicles running on
diesel engines fueled with DME.
As an automotive fuel, when compared with petroleum-derived diesel, DME’s
performance demonstrates a number of significant benefits:
Ultra-low exhaust emissions
No particulate matter (PM); very low NOx; no SOx)
Low CO2 emissions
Low engine noise
High fuel economy
High well-to-wheel efficiency
Thermal efficiency equivalent to diesel engine performance
Ignition characteristics equivalent to diesel engine performance
b. Clean fuel for cooking and heating: Often described as “synthetic LPG”, DME can
be blended with LPG (in a proportion of up to 20%) and used for domestic cooking and
heating, without modifications to equipment or distribution networks. Growth in DME’s
use for domestic applications is expected to increase sharply as DME use and blending
becomes more widespread within the large and growing LPG market – especially in
developing countries where portable (bottled) fuel is providing a safer, cleaner and more
environmentally benign fuel for cooking and heating.
c. Clean fuel for power generation: DME has a performance comparable to natural gas
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when used for the production of electric power, and it has been approved by
manufacturers such as General Electric, Hitachi and Mitsubishi as a fuel for use in their
gas turbines. DME is an efficient alternative to other energy sources for medium-sized
power plants, especially in isolated or remote locations where it can be difficult to
transport natural gas and where the construction of liquefied natural gas (LNG)
regasification terminals would not be viable.
d. Spray propellant: Dimethyl ether (DME) has been increasingly used as a propellant
in aerosol formulations to replace chlorofluorocarbons, which are found to destroy the
ozone layer of the atmosphere. DME is nontoxic and easily degrades in the troposphere.
Although about 90% of the major current U.S. aerosol industry uses hydrocarbon-based
propellants (mostly iso-butane and propane), DME could become a more widely used
propellant in the next five years. Several aerosol-based household products include
colognes, hair sprays and dyes, personal care mousses, antiperspirants, and room air
fresheners. DME can be used as pesticide, polishing agent, and anti-rust agent.
iii) Solvent: Dimethyl ether is a low-temperature solvent and extraction agent applicable
to specialized laboratory procedures.
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iv) Alkylating agent: Dimethyl ether is the precursor to the useful alkylating agent,
trimethyloxonium tetrafluoroborate.
v) Dimethyl sulfate: DME is a useful intermediate for the preparation of many
important chemicals, including oxygenates, acetaldehyde, acetic acid, ethylene glycol
intermediate like DMET and methyl sulfate. Dimethyl sulfate is an important
commercial commodity as a solvent and also as an electrolyte in high energy density
batteries.
vi) Synthesis of hydrocarbons: Dimethyl ether is also an essential intermediate in the
synthesis of hydrocarbons from coal or natural gas derived syngas. Lower olefins like
ethylene and propylene or higher molecular weight compounds such as gasoline range
boiling hydrocarbons are produced from syngas using dimethyl ether as an intermediate.
g. Treating warts: A mixture of dimethyl ether and propane is used in an over-the-
counter device to treat warts, by freezing them.
h. Coolant: Dimethyl ether is the main constituent of "freeze spray", a spot-coolant used
in field testing of electronic components. In this role it has supplanted halocarbon
compounds (Freon), which have been suspected of contributing to ozone depletion in the
Earth's atmosphere.
i. Blowtorch gas: Dimethyl ether is also a component of certain high temperature
"MAP-plus" blowtorch gas blends, supplanting the use of methyl acetylene and
propadiene mixtures.
Dimethyl ether (DME), also known as methoxymethane, is the simplest ether which has
widespread applications in chemicals industry and is extensively used as aerosol
propellant. DME can be produced using a variety of feedstock such as biomass,
methanol, and fossil fuels. The most prominent feedstock is natural gas, particularly in
North America, or coal, especially in various Asian countries. The compound has
several properties similar to LPG and is therefore extensively used as an excellent
substitute for traditional fuels. In addition, various characteristic fuel properties of DME,
particularly high cetane number and energy efficiency, make it attractive to be used in
several diesel engines. Other popular applications of DME are as transportation fuel,
power generation fuel, and domestic gas, thus it forms a crucial element stimulating the
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growth of transportation, agriculture, and construction industries.
DME is now being tried in USA and Japan to achieve severe emission reduction targets
of as low as 50% of the proposed Euro-IV levels. Recognizing that DME can be a new
economical fuel, India's Ministry of Petroleum & Natural Gas invited British Petroleum
(BP) in 1997 to develop DME supplies in an exclusive partnership with India's leading
energy marketers and research organizations. Intention of this project was to establish
DME as a multi-purpose fuel for India but in the initial stages the project identified some
southern Indian states to supply DME as a feedstock for power plants. In INDIA a 265
KTPY capacity plant is planned. Australia’s CSIRO and its equivalent in India, the
Council of Scientific and Industrial Research (CSIR), have launched a three-year,
US$5.6-million collaboration focused on the production of dimethyl ether (DME). The
project is being jointly funded by the Australian and Indian governments.
Due to no major plant for DME export of DME is very little. DME is produced at a
minor level for basic uses and research purposes. In India there is lack of technology and
awareness about using DME.
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As shown in Fig. 2, DME from syngas can be produced in two distinct ways:
Extensive research has been conducted on finding better catalysts that have higher
selectivity toward DME formation and a lower tendency to generate hydrocarbons and
coke. Catalysts for the process are bi-functional catalysts composed of a metallic
function for methanol synthesis and a solid-acid function for the transformation of
methanol into DME. It should be noted that the heat conduction of the bi-functional
catalysts is poor; hence, the applied working temperature of the bi-functional catalysts is
in a temperature range of 523–673 K and pressures up to 10 bar. The metallic function is
mainly composed of such oxides as CuO, ZnO, Al2O3 and Cr2O3. Moreover, a myriad of
solid-acid catalysts have been explored including γ-Al2O3, modified alumina with silica,
TiO2-ZrO2, clays, ion exchange resins, Boehmite (AlOOH) and zeolites such as H-ZSM-
5, HY, mordenites. In CuO–ZnO–Al2O3 (CZA) catalysts, metallic copper clusters are
the active sites for both methanol synthesis and WGS reactions and conversion of
syngas to methanol depends on the copper metal surface area, ZnO plays a pivotal role
in maintaining the active copper metal in optimal dispersion, thus providing a high
number of active sites exposed to gaseous reactants. However, Hadipour and Sohrabi
observed that excess of ZnO in CZA had a negative effect on the activity. Presence of
CuO and Al2O3 in excess amount enhanced the catalyst activity by increasing the
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dispersion of active sites and hence promoted the surface area of catalyst.
PRODUCTION OF SYNGAS
There are 4 ways to produce Syngas:
• Coal Gasification
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• Auto-thermal reforming of Natural Gas
The outlet temperature of the syngas is between 950-1100 ºC and outlet pressure can be
as high as 100 bar.
There are no other alternative processes are available to convert syn gas to DME.
Indirect method is also used if we have supply of methanol and we wish to convert it to
DME. Otherwise, direct synthesis is more feasible to produce DME from syngas as is
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requires less equipment therefore less capital costs and very less cost is encountered in
handling methanol.
Rather, there are some alternatives processes available to produce syngas from natural
gas
A detailed analysis has been done for Auto-thermal reformation and Steam reformation.
Steam reforming is a method for producing hydrogen, carbon monoxide, or other useful
products from hydrocarbon fuels such as natural gas. This is achieved in a processing
device called a reformer where steam reacts at high temperature with the fossil fuel. The
steam methane reformer is widely used in industry to make hydrogen. There is also
interest in the development of much smaller units based on similar technology to
produce hydrogen as a feedstock for fuel cells. Small-scale steam reforming units to
supply fuel cells are currently the subject of research and development, typically
involving the reforming of methanol, but other fuels are also being considered such as
propane, gasoline, auto gas, diesel fuel, and ethanol.
Phase separation, residual water condensed; gas phase compressed, cooled, and
sent to methanol reactor
Source: https://www.netl.doe.gov/publications/proceedings/03/reciprocating/10-30oberto.pdf
The main difference between SMR and ATR is that SMR only uses oxygen via air for
combustion as a heat source to create steam, while ATR directly combusts oxygen. The
advantage of ATR is that the H2:CO can be varied, this is particularly useful for
producing certain second-generation biofuels, such as DME which requires a 1:1 H2:CO
ratio.
Source: https://en.wikipedia.org/wiki/Steam_reforming
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Advantages of Steam Methanol Reformation (SMR):
• Efficient and proven technology for generating syngas, oxogas and carbon
monoxide
• Well referenced technology for large plant sizes using natural gas
Indirect Method:
Indirect method is used where production of DME is desired form methanol. Aiming to
promote the widespread of DME fuel, nine companies; Mitsubishi Gas Chemical,
ITOCHU, JAPEX, Taiyo Oil, Total Di-Methyl Japan, Toyota Tsusho, JGC, Mitsubishi
Heavy Industries and Mitsubishi Chemical, established a joint venture company “Fuel
DME Production Co. Ltd.” To produce annually 80,000 tons of DME (potential
expansion up to 100,000 tons). The DME production plant was constructed in Niigata
factory of Mitsubishi Gas Chemical, and started the operation in August, 2008. Fuel
grade DME (purity 99.8%) is produced from imported methanol by the methanol
dehydration process of Mitsubishi Gas Chemical, and it is used as boiler fuel of food
companies, fuel for DME truck of transportation companies, etc. in Niigata prefecture.
Direct Method:
In order to develop the DME direct synthesis technology to such extent that its
commercialization is feasible, the technical development was conducted with support
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from the Ministry of Economy, Trade and Industry of the Japanese government for five
years from fiscal year 2002, using a demonstration plant of 100 tons in daily production,
by a research company “DME Development Co. Ltd.” , which had been established by
10 companies; JFE, Taiyo, Nissan, Toyota Tsusho, Hitachi, Marubeni, Idemitsu Kosan,
INPEX, LNG Japan, JAPEX and Total. Five test operations including a long-term
continuous operation for five months were done between fiscal year 2003 and fiscal year
2006, and the technology has been demonstrated, various engineering data is acquired,
and scale-up technology to commercial plant is established. This technology is now
taken over jointly by four companies (Toyota Tsusho, INPEX, JAPEX and Total).
BASIS OF SELECTION:
Reactor productivities, catalyst life and activity were significantly higher in the co-
production case. In terms of catalyst deactivation, the rate of thermal aging of methanol
synthesis catalyst becomes slower when it is used in a co-production mode along with 𝜸-
alumina. Moreover, the process exhibits excellent control because it is possible to co-
produce dimethyl ether and methanol in any desired proportion, from 5% DME to 95%
DME, by varying the mass ratios of the methanol synthesis catalyst to the methanol
dehydration catalyst. Water gas shift reaction simultaneously converts by-product water
to give carbon dioxide as by-product, therefore the water does not accumulate near the
synthesis catalyst. Water leads the catalyst to degradation. To bring longer catalyst life,
it’s important to avoid water accumulation over time.
Separation or distillation of DME from CO2 is much efficient and not energy consuming
compared with separation from water (in the case of indirect method). The methanol
synthesis technology faces a serious impediment because the reaction is severely limited
by chemical equilibrium. Due to the reversible nature of the methanol synthesis reaction,
the maximum per-pass conversion of syngas is restricted. However, the potential of the
reverse reaction and the chemical equilibrium limitation can be alleviated by chemically
converting methanol into another chemical species that is not affected by the equilibrium
constraint.
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DIRECT SYNTHESIS METHOD: DETAILS
Synthesis of dimethyl ether from syngas (the LPDME process) can be carried out in the
liquid phase at moderate temperature and pressure, 250℃ and 1000 psi. This single-
stage process involves dual catalysts slurried in a liquid oil medium (Witco-40). The bi-
functional catalyst consists of a mixture of methanol synthesis catalyst (Cu/ZnO/Al2O3)
and methanol dehydration catalyst (H-ZSM-5).
The DME synthesis reaction (1) from synthesis gas (H2 and CO) is composed of three
reactions:
Methanol synthesis reaction (2), methanol dehydration reaction (3), and water gas shift
reaction (4). The overall reaction is exothermic, and the reaction heat in the methanol
synthesis step is dominant.
In each reaction, the equilibrium conversion reaches its maximum point when the H2/CO
ratio is equal to its stoichiometric number, which are 1.0 for (1) and 2.0 for (2).
Therefore, we may expect a higher per-pass conversion than that by the other two
reactions. This is because the higher equilibrium conversion of DME synthesis creates
much more reaction heat that may create hot spots in the reactor and could damage the
catalyst. The hot spots generally take place in a gas-solid phase and non-adiabatic
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packed bed tubular reactors. On the other hand, a slurry bed reactor can remove reaction
heat by circulating slurry and easily maintains the uniform temperature
Fig. 4. Equilibrium Conversion of Methanol Synthesis and DME Synthesis at 260 °C and 5
MPa
The mechanism of the reactions in the slurry composed of an inert solvent containing
fine catalyst particles and the simplified schematic diagram is shown in Figure 5. The
reactant gas or synthesis gas of CO and H2 is supplied from the bottom of the reactor
shown in Figure 3. Gas bubbles may be generated and diffuse into the solvent, and the
chemical reactions take place on the surface of the catalyst.
Firstly, the methanol synthesis reaction occurs and then methanol is dehydrated to
produce DME. Water generated by the dehydration reaction quickly reacts with CO and
is removed from the system. Therefore, no water remains on the surface of the catalyst.
The heat of reaction is absorbed by the solvent, which has a large heat capacity, and
thanks to the highly effective heat conductivity, the temperature distribution in the slurry
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could be homogeneous. The reaction heat is finally removed through the generation of
steam. In this connection, a catalyst that is appropriate for the slurry phase reactor has
been designed and developed. In order to enable a large-scale test, mass production
technology for the catalyst has also been developed. The inert solvent is selected as a
hydrocarbon fraction with a narrow and high boiling point range around 400 °C, which
may not influence the reaction performance and is not vaporized under reaction
conditions. The catalyst with the size of the order of 10-micrometer is suspended in the
solvent. It is a mixed catalyst that has functions of methanol synthesis, dehydration and
shift gas reactions, and contains CuO, ZnO and Al2O3. Water may damage the catalyst
activity so that the water removal mechanism by the shift reaction to convert CO to CO 2
is very essential. DME synthesis reactor effluent contains DME, CO2 and the unreacted
synthesis gas which are all in gas phase at the reactor outlet and are easily separated
from the slurry phase so that the separation of liquid product and catalyst becomes
unnecessary.
Operational units of chemical engineering are commonly used for the separation and
purification of DME in the synthesis process. Through absorption, flash and distillation,
H2, N2, CH4, and CO2 are removed; methanol is recovered and the final DME product is
obtained. Moreover, since the methanol synthesis is a thermodynamically limited
process, consumption of methanol in the consequent reaction to form DME will shift the
methanol synthesis equilibrium toward higher methanol conversion. The separation of
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DME and CO2 becomes more difficult when methanol is present in the system. Thus, in
a proposed process, the methanol and water resulted from the one-step reaction were
first condensed and then absorbed by water; finally, the liquid stream containing DME
was distilled for final DME product. This separation process is demonstrated to be
feasible to synthesize DME with high purity. The schematic of this process is shown in
the process flowsheet.
The technology is based on the work done by study of research literature, patents, and
the initial findings of work done by Haldor Topsoe, JFE Holdings, Korea Gas
Corporation, Air Products, Toyo, MGC, Lurgi and Udhe Davy Process Technology.
Further research work is expected to come up in this area in 2008 by US Department of
Energy, JFE Holdings and other institutions working in this field especially in China and
Japan.
The project involves production of Syngas from Natural Gas and then DME from
Syngas.
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Natural gas is a naturally occurring hydrocarbon gas mixture consisting primarily of
methane, but commonly including varying amounts of other higher alkanes, and
sometimes a small percentage of carbon dioxide, nitrogen, hydrogen sulfide, or helium.
It is formed when layers of decomposing plant and animal matter are exposed to intense
heat and pressure under the surface of the Earth over millions of years. The energy that
the plants originally obtained from the sun is stored in the form of chemical bonds in the
gas.
Natural gas is a fossil fuel used as a source of energy for heating, cooking, and
electricity generation. It is also used as a fuel for vehicles and as a chemical feedstock in
the manufacture of plastics and other commercially important organic chemicals. Fossil
fuel based natural gas is a non-renewable resource. Natural gas is found in deep
underground rock formations or associated with other hydrocarbon reservoirs in coal
beds and as methane clathrates. Petroleum is another resource and fossil fuel found in
close proximity to and with natural gas.
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Typical Analysis Range
Component
(mole %) (mole %)
* The gross heating value is the total heat obtained by complete combustion at constant pressure of a unit volume of
gas in air, including the heat released by condensing the water vapor in the combustion products (gas, air, and
combustion products taken at standard temperature and pressure).
Source: https://www.uniongas.com/about-us/about-natural-gas/chemical-composition-of-natural-gas
Liquefied Natural Gas (LNG) - Natural Gas which has been liquefied at –
(Minus) 160 degree Centigrade. Natural Gas is liquefied to facilitate
transportation in large volumes in cryogenic tankers across sea.
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on the virtue of being cleaner fuel than liquid fuels.
Piped Natural gas (PNG) - Natural Gas distributed through a pipeline network
that has safety valves to maintain the pressure, assuring safe, uninterrupted
supply to the domestic sector for cooking and heating / cooling applications.
Source: http://www.gailonline.com/BV-NarutalGas.html
30,000 MTPA Dimethyl Ether (DME) Production Plant through Natural gas using one
step DME Synthesis route.
Assumptions:
It is assumed that our raw material ‘Natural gas’ consists of 95% methane and 5%
ethane.
DME of very high purity is formed so final product contain less amount of impurities
which can be neglected.
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Average operating time of the plant is 330 days/year, it turns out to be equivalent to
3787.88 kg/h of Dimethyl Ether produced.
India had 38 trillion cubic feet (Tcf) of proven natural gas reserves as of January
2007.The total gas production in India was about 31,400 mcm in 2002-03 compared
with 2,358 mcm in 1980-81. At this production level, India's reserves are likely to last
for around 29 years; that is significantly longer than the 19 years estimated for oil
reserves. Almost 70% of India’s natural gas reserves are found in the Bombay High
basin and in Gujarat. Offshore gas reserves are also located in Andhra Pradesh coast
(Krishna Godavari Basin) and Tamil Nadu coast (Cauvery Basin). Onshore reserves are
located in Gujarat and the North Eastern states (Assam and Tripura).
Commissioned Capacity
Project State (MW)
RGPPL, Anjanvel Maharashtra 1480
Dadri Uttar Pradesh 817
Paguthan Gujarat 654.73
Auraiya Uttar Pradesh 652
Jhanor-Gandhar Gujarat 648
Kawas Gujarat 645
Faridabad Haryana 430
Anta Rajasthan 413
Vemagiri Power Generation Andhra
Ltd. Pradesh 388.5
Rajiv Gandhi CCPP
Kayamkulam Kerala 350
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Source: http://www.eai.in/ref/fe/nag/nag.html
Table 4: Crude Oil and Natural Gas Production in India
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Fig. 10. Region wise distribution of Natural Gas
As India does not have any pipeline connection, all the gas currently imported is LNG.
Current operational LNG import capacity is 13.5 mtpa (18 bcm). India joined the global
LNG market in March 2004 when the Dahej LNG terminal went into operation. Petronet
LNG Limited (PLL), a joint venture promoted by GAIL, IOCL, Bahrat Petroleum
(BPCL), GDF Suez, the Asian Development Bank (ADB) and ONGC was formed to
import LNG in order to meet the growing gas demand. PLL expanded this terminal from
5 to 10 mtpa (6.8 to 13.6 bcm) in early 2009. The second LNG terminal is the Shell and
Total 3.5 mtpa (4.8 bcm) terminal located in Hazira, which was commissioned in April
2005.12 Both are located on the western coast and could be further expanded to 15 and
10 mtpa respectively. The third terminal, the Dabhol Ratnagiri LNG terminal, is
expected to become operational in 2010, after many delays. It has a total capacity of 5.5
MTPA (7.5 bcm), with about 2.9 MTPA (3.9 bcm) available for merchant sales. The
commissioning date was delayed from mid-April 2009 to an unspecified date in 2010
because of the monsoon season, breakwater facilities and construction costs, and no new
commissioning date has been given since. It would first only operate at a capacity of 1
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mtpa (1.4 bcm) and ramp up to planned capacity gradually.
Natural gas available in India can broadly be classified into two categories, viz. (i)
Domestic Natural Gas and (ii) Imported Re-gasified Liquefied Natural Gas (R-LNG).
Supply and distribution of domestically produced gas is being carried out under the
policy guidelines issued by the Government Policies from time to time. The import of
RLNG falls under the list of Open General License Item and the marketers are free to
import LNG and sell the RLNG to customers. A statement showing sector-wise supplies
between April-Dec.’2016 of natural gas is given in table below.
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Table 6: MMSCMD data for Natural Gas
In accordance with Para 8 of the “New Domestic Natural Gas Pricing Guidelines, 2014”
issued by Ministry of Petroleum and Natural Gas, Govt. of India, the price of domestic
natural gas for the period 1st October,2018 to 31st March,2019 is US $3.36/MMTBTU
on Gross Calorific Value (GCV) basis.
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commissioning and commissioning of pipelines.
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fuel used by a gas turbine, and with regard to the
type of information necessary to quantify the
expected environmental impact.
14. IS 15666(Part 8):2006 This standard states the principles for systems
and
procedures to assure the integrity of a packager’s
product and services. It gives guidance on the
inspection, testing, installation and commissioning
required for the package and packaged equipment. It
outlines the responsibilities between the purchaser
and packager for inspection, coordination, reporting
and recording.
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centrifugal
pumps, including pumps running in reverse as
hydraulic power recovery turbines, for use in
petroleum, petrochemical and gas industry process
services.
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materials, equipments and accessories for hot
tapping and stopple plugging/line plugging
operations of onshore natural gas pipelines. It covers
the minimum safety requirements to be maintained
during welding, cutting and plug setting, etc, while
carrying out the hot tapping and stopple
plugging/line plugging operations on pipelines.
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of natural gas and related safety aspects. These
guidelines cover five types of meters namely orifice,
turbine, ultrasonic, rotary and coriolis.
Assumptions:
Calculation:
Reactions Involved:
2CH4+O2+CO2 → 3CO+3H2+H2O
Syngas to DME:
Overall reaction:
3CO+3H2 → CH3OCH3+CO2 -246.0 kJ/DME-mol (1)
Reactions:
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Capacity= 30000 MTPA = 90.579 kmol/hr (24 hours for 300 days)
We know from literature approximately ⅕ mole methanol is produced per mol DME
produced, Therefore
CH3OH Produced = 18.115 kmol/hr
H2O Produced = 18.115 kmol/hr
CO2 Produced = 18.115 kmol/hr
Unit 1: Compressor
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Assumptions: ISENTROPIC EFFICIENCY = 1.0
MECHANICAL EFFICIENCY = 1.0
CO2 CO2-1
To COMP H3
From COMP
VAPOR VAPOR
Substream:
MIXED
Mole Flow kmol/hr
CO2 70 70
Temperature °C 25 314.2825
Pressure bar 1 30
Vapor Frac 1 1
Liquid Frac 0 0
Solid Frac 0 0
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VAPOR PHASE
Unit 2: Compressor-1
O2 O2-1
To COMP-1 H2
From COMP-1
Substream:
MIXED
Mole Flow kmol/hr
O2 118.759 118.759
Temperature C 25 470.7019
Pressure bar 1 30
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Vapor Frac 1 1
Liquid Frac 0 0
Solid Frac 0 0
VAPOR
PHASE
Viscosity Pa-sec 2.06E-05 4.06E-05
Unit 3: Heater-1
NG NG1
To H1 MIXER
From H1
Substream:
MIXED
Mole Flow kmol/hr
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Temperature C 25 400
Pressure bar 30 30
Vapor Frac 1 1
Liquid Frac 0 0
Solid Frac 0 0
VAPOR
PHASE
Viscosity Pa-sec 1.17E-05 2.14E-05
Unit 4: Heater-2
O2-1 O2-2
To H2 ATR
From COMP-1 H2
Substream:
MIXED
Mole Flow kmol/hr
O2 118.759 118.759
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Total Flow kg/hr 3800.145 3800.145
Pressure bar 30 30
Vapor Frac 1 1
Liquid Frac 0 0
Solid Frac 0 0
VAPOR
PHASE
Viscosity Pa-sec 4.06E-05 3.80E-05
Unit 5: Heater-3
CO2 CO2-1
To COMP H3
From COMP
Substream:
MIXED
Mole Flow kmol/hr
CO2 70 70
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Total Flow kg/hr 3080.686 3080.686
Temperature C 25 314.2825
Pressure bar 1 30
Vapor Frac 1 1
Liquid Frac 0 0
Solid Frac 0 0
VAPOR
PHASE
Viscosity Pa-sec 1.50E-05 2.75E-05
Unit 6: Mixer
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To MIXER MIXER ATR MIXER
From H3 H1 MIXER H8
Substream:
MIXED
Mole Flow kmol/hr
Pressure bar 30 30 30 30
Vapor Frac 1 1 1 1
Liquid Frac 0 0 0 0
Solid Frac 0 0 0 0
VAPOR
PHASE
Viscosity Pa-sec 3.04E-05 2.14E-05 2.66E-05 3.04E-05
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NG1+C02 O2-2 SNG+H2O
To ATR ATR FD
Substream:
MIXED
Mole Flow kmol/hr
CO2 138.7617 0 0
H20 0 0 221.2797
CH4 155 0 0
H2 0 0 88.72034
O2 0 118.759 0
CO 0 0 293.7617
DME 0 0 0
CH3OH 0 0 0
Pressure bar 30 30 90
Vapor Frac 1 1 1
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Liquid Frac 0 0 0
Solid Frac 0 0 0
VAPOR
PHASE
Viscosity Pa-sec 2.66E-05 3.80E-05 5.40E-05
To COMP-2 FD
From FD FD ATR
Substream:
MIXED
Mole Flow kmol/hr
CO2 0 0 0
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H20 220.5656 0.714023 221.2797
CH4 0 0 0
O2 0 0 0
DME 0 0 0
CH3OH 0 0 0
Temperature C 50 50 1100
Pressure bar 90 90 90
Vapor Frac 0 1 1
Liquid Frac 1 0 0
Solid Frac 0 0 0
VAPOR
PHASE
Viscosity Pa-sec 1.97E-05 5.40E-05
Unit 9: Compressor-2
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SNG SNG-1
To COMP-2 MIXER-1
From FD COMP-2
Substream:
MIXED
Mole Flow kmol/hr
H2 88.72031 88.72031
CO 273.2463 273.2463
Temperature C 50 16.07344
Pressure bar 90 60
Solid Frac 0 0
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Average MW 21.63184 21.63184
VAPOR
PHASE
Viscosity Pa-sec 1.97E-05 1.78E-05
LIQUID
PHASE
Viscosity Pa-sec 7.05E-04
CO+H2 S6 SNG-1
To MIXER-1 H5 MIXER-1
Substream:
MIXED
Mole Flow kmol/hr
CO2 0 0 0
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CH4 0 0 0
O2 0 0 0
DME 0 0 0
CH3OH 0 0 0
Pressure bar 60 25 60
Solid Frac 0 0 0
VAPOR
PHASE
Viscosity Pa-sec 2.28E-05 1.83E-05 1.78E-05
LIQUID
PHASE
Viscosity Pa-sec 7.05E-04
To H5 Sep-01 H5 COMP-2
Substream:
MIXED
Mole Flow kmol/hr
CH4 0 0 0 0
O2 0 0 0 0
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Temperature C 260 148.1303 40.72171 50
Pressure bar 60 60 25 90
Vapor Frac 1 1 1 1
Liquid Frac 0 0 0 0
Solid Frac 0 0 0 0
VAPOR
PHASE
Viscosity Pa-sec 2.30E-05 1.95E-05 1.83E-05 1.97E-05
S13 SG
To DME-REAC H6
From H6 H5
Substream:
MIXED
Mole Flow kmol/hr
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CO2 0 0
CH4 0 0
H2 117.3618 117.3704
O2 0 0
CO 353.4989 353.4693
DME 0 0
CH3OH 0 0
Pressure bar 60 25
Vapor Frac 1 1
Liquid Frac 0 0
Solid Frac 0 0
VAPOR
PHASE
Viscosity Pa-sec 2.63E-05 2.35E-05
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DME S13
To H5 DME-REAC
From DME-REAC H6
Substream:
MIXED
Mole Flow kmol/hr
CO2 68.76166 0
CH4 0 0
H2 28.65013 117.3618
O2 0 0
CO 80.22306 353.4989
DME 85.95038 0
CH3OH 17.18872 0
Pressure bar 60 60
Vapor Frac 1 1
Liquid Frac 0 0
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Solid Frac 0 0
VAPOR
PHASE
Viscosity Pa-sec 2.30E-05 2.63E-05
To Sep-01 MS DC1
Substream:
MIXED
Mole Flow kmol/hr
CH4 0 0 0
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H2 28.65013 28.65013 0
O2 0 0 0
CO 80.22306 80.22307 0
Pressure bar 60 60 60
Vapor Frac 1 1 0
Liquid Frac 0 0 1
Solid Frac 0 0 0
VAPOR
PHASE
Viscosity Pa-sec 1.95E-05 2.25E-05
LIQUID
PHASE
Viscosity Pa-sec 9.28E-05
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CO+H2 GASES PURE-CO2
To MIXER-1 MS TUR
From MS Sep-01 MS
Substream:
MIXED
Mole Flow kmol/hr
H20 0 0 0
CH4 0 0 0
H2 28.65013 28.65013 0
O2 0 0 0
CO 80.22307 80.22307 0
DME 0 0 0
CH3OH 0 0 0
Pressure bar 60 60 60
Vapor Frac 1 1 1
Liquid Frac 0 0 0
Solid Frac 0 0 0
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Density gm/cc 0.035612 0.05209 0.083974
VAPOR
PHASE
Viscosity Pa-sec 2.28E-05 2.25E-05 2.21E-05
Substream:
MIXED
Mole Flow kmol/hr
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Temperatu C 148.1303 140.2201 19.23134
re
Pressure bar 60 8 5
Vapor Frac 0 0 0
Liquid 1 1 1
Frac
Solid Frac 0 0 0
To DC2
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Substream:
MIXED
Mole Flow kmol/hr
CO2 0 0 0
CH4 0 0 0
H2 0 0 0
O2 0 0 0
CO 0 0 0
Pressure bar 2 8 9
Vapor Frac 0 0 0
Liquid Frac 1 1 1
Solid Frac 0 0 0
LIQUID
PHASE
Viscosity Pa-sec 2.92E-04 1.92E-04 1.53E-04
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Unit 18- Turbine
PUR-CO2 PURE-CO2
To H8 TUR
From TUR MS
Substream:
MIXED
Mole Flow kmol/hr
Pressure bar 30 60
Vapor Frac 1 1
Liquid Frac 0 0
Solid Frac 0 0
VAPOR
PHASE
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Viscosity Pa-sec 1.88E-05 2.21E-05
PUR-CO2 REC-CO2
To H8 MIXER
From TUR H8
Substream:
MIXED
Mole Flow kmol/hr
H20 0 0
CH4 0 0
H2 0 0
O2 0 0
CO 0 0
DME 0 0
CH3OH 0 0
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Pressure bar 30 30
Vapor Frac 1 1
Liquid Frac 0 0
Solid Frac 0 0
VAPOR
PHASE
Viscosity Pa-sec 1.88E-05 3.04E-05
LIQUID
PHASE
Viscosity Pa-sec
Thermal Watt/m-K
Conductivity
CP J/kg-K
2. MARKET PROSPECTS
The widespread use of dimethyl ether as a non-petroleum based alternative fuel is propelling
the market. Since it is considered as a clean and high-performance compression ignition fuel,
it can be extensively used in diesel engines; its use eliminates particulate exhaust emissions
of automobiles and can significantly save the high cost of diesel particulate filters. This has
spurred the demand for DME across transportation sector, especially in the North America.
Dimethyl Ether Market is forecast to reach USD 11 billion according to a new research report
(“Dimethyl Ether (DME) -Market Demand, Growth, Opportunities and Analysis of Top Key
Player Forecast To 2023”, Wiseguy Reports). Growing demand for liquified petroleum gas
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for domestic as well as commercial applications will be the chief growth driver for the
dimethyl ether (DME) market over the forecast duration. LPG is blended with dimethyl ether
for domestic applications such as heating and cooking. Increasing popularity of cleaner, eco-
friendly and safer fuel for cooking will drive the industry growth by 2024. Moreover, oil
price hikes and increasing butane and propane prices has driven LPG demand over the recent
years. Increasing LPG demand, blended with DME, for domestic applications will propel
product demand for the forecast timeframe.
Currently, more than 65% DME produced globally is blended with LPG. Blending offers
many benefits in terms of its use as ultra-clean fuel for several domestic applications. China
has upped the production of DME blended with LPG by using methanol as feedstock;
commercial production of DME has helped China reduce the reliance on LPG-based fuel.
Dehydrating methanol enhances the combustion efficiency of DME and hence is used as
cost-effective fuel alternatives in heavy-duty trucks and ships. These trends are offering
lucrative avenues for the market players to capitalize on.
Dimethyl Ether Market size was USD 5.16 billion in 2015 and is projected witness 9.9%
CAGR by 2024.
Fig. 11. U.S. Dimethyl Ether Market size, by application, 2013-2024 (USD Million)
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Global Dimethyl Ether (DME) Market: Market Potential
By Raw Material
Fossil fuel based dimethyl ether is produced particularly from natural gas and coal. Abundant
natural gas availability along with increasing diesel prices is forecast to be key factor
propelling dimethyl ether market size. It also offers potentially low cost than diesel vehicle at
high volume. However, stringent government regulations towards clean energy may
negatively impact on dimethyl ether market growth over the forecast period.
Bio based dimethyl ether market size is projected to expand at a greater rate more than 11%
CAGR in terms of revenue. Bio based dimethyl ether, is an energy containing molecule that
is condensation of two bio methanol molecules. It consists of carbon monoxide and hydrogen
molecules consequent from methanol processing. Also, methanol can be produced from
pyrolysis gases generated from waste or garbage and paper mill residue. Due to these raw
materials utilized for bio based DME production, its use does not release mercury, sulfur
oxides, or nitrous oxides, which makes the product environment friendly. Furthermore,
increasing product application as aerosol propellant in domestic personal care industry is
likely to complement industry growth from 2016 to 2024.
By Application
Aerosol propellants applications were valued above USD 1 billion in 2015. They offer low
relative cost, stability & purity, low odor, extensive range of boiling points, wide vapor
pressures range, low toxicity, versatility & efficiency, flammability and environmental
friendly characteristics owing to boost industry growth over the projected timeframe.
Transportation fuel is anticipated to witness highest gains at over 14% CAGR by 2024. Due
to its decent ignition quality, along with high cetane number, it can be used in diesel engines
as an alternative for traditional diesel fuel. Increasing stringent regulations accompanied with
rising awareness to minimize air pollutants by adoption non-petroleum based alternative fuels
will complement dimethyl ether market size by 2024. However, compared to diesel fuel it has
a lower viscosity and poor lubricity which may obstruct industry growth over the forecast
timeframe.
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Concurrent applications of DME as transportation fuel in several regions such as in Europe,
Japan, and North America, portend well for the market. The use of DME, either standalone or
blended with LPG, is proliferating in large number of automobiles in industrialized nations as
they are considered as cleaner energy. This has in turn increasingly reduced the dependency
on LPG to fuel their economies. Various performance evaluation plans are underway,
especially in North America, to assess the viability of DME as alternative fuel in large
commercial vehicles and urban fleets. Producers of DME source the raw materials from
natural organic waste found in urban landfills, which is expected to considerably reduce the
carbon footprint in the coming years. Led by these promising developments, Oberon Fuels, a
producer of the Dimethyl Ether (DME) fuel, has recently announced the start of a customer
demonstration of a Pinnacle-series heavy duty trucks from Mack Trucks. Oberon has
partnered with the American truck manufacturing company and they are working with the
NYC Department of Sanitation (DSNY) to test the vehicle operation at the Fresh Kills
Landfill to evaluate fuel performance and viability. If this drives become successful, DME
will expectedly reduce GHC emissions by as much as 80% by 2050. Initiatives such as these
expand the potential of the market in developed and emerging nations.
Currently, Asia Pacific is a major market for DME where it is primarily used for blending
with LPG and as aerosol propellant. Advancement in infrastructure for providing domestic
fuel supply to several Asian countries coupled with the surge in demand for cost-effective,
clean, and alternative fuels in transportation sector have stimulated the use of DME fuels.
Increasing R&D activities related to DME production in advanced nations of Asia Pacific
along with increasing production capacity in Japan and China are anticipated to boost the
regional market.
U.S. dimethyl ether market size marked revenue close to USD 300 million in 2015. Regional
market is anticipated to be driven by increasing bio based dimethyl ether acceptance on
account of its low emission characteristics. In addition, Europe is forecast to experience gains
at over 10% CAGR from 2016 to 2024. Increasing automakers initiative such as R&D
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towards low emitting vehicles will drive industry growth. For instance, Ford Motors
announced R&D investment of approximately USD 3.5 million towards latest internal
combustion engines with environmental benefits similar to an electric vehicle.
Key automakers and fuel producers are making substantial investments in various programs
meant for evaluating the viability of DME as a cost-effective and environmental-friendly
fuel. Out of large number of companies exploring lucrative avenues in the DME market,
major players include Akzo Nobel NV, Korea Gas Corporation, China Energy Ltd., Royal
Dutch Shell plc, Mitsubishi Corporation, Oberon Fuels, Inc., Shenhua Ningxia Coal Industry
Group Co., Ltd., Fuel DME Production Co., Ltd., and Grillo-Werke AG, and Guangdong
JOVO Group Co., Ltd.
DME (dimethyl ether) is a clean, colourless gas that is easy to liquefy and transport. It has
remarkable potential for increased use as an automotive fuel, for electric power generation,
and in domestic applications such as heating and cooking.
DME has been used for decades in the personal care industry (as a benign aerosol propellant),
and is now increasingly being exploited for use as a clean burning alternative to LPG
(liquefied
petroleum gas), diesel and gasoline.
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Fig. 12. DME Milestones (International DME Association)
The report "Dimethyl Ether Market” published by MarketsandMarkets says DME is projected
to reach USD 9.7 Million in terms of value by 2020, signifying firm annualized growth of
19.65% between 2015 and 2020.
The majority of global DME production is currently in China. Japan has production facilities,
and major new capacity additions are planned or under construction in Trinidad and Tobago,
North America, Indonesia, and Uzbekistan. Asia-Pacific is the largest market of DME,
registering a significant share of 95.66% of the total market.
Fig. 14. DME Current and Planned Production Capacity (International DME Association)
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2.2 DME: Production in INDIA
Production of DME
DME is now being tried in USA and Japan to achieve severe emission reduction targets of as
low as 50% of the proposed Euro-IV levels. Recognizing that DME can be a new economical
fuel, India's Ministry of Petroleum & Natural Gas invited British Petroleum (BP) in 1997 to
develop DME supplies in an exclusive partnership with India's leading energy marketers and
research organizations.
Intention of this project was to establish DME as a multi-purpose fuel for India but in the
initial stages the project identified some southern Indian states to supply DME as a feedstock
for power plants.
In INDIA a 265 KTPY capacity plant is planned. Australia’s CSIRO and its equivalent in
India, the Council of Scientific and Industrial Research (CSIR), have launched a three-year,
US$5.6-million collaboration focused on the production of dimethyl ether (DME). The
project is being jointly funded by the Australian and Indian governments.
More than 75% of DME currently produced is blended with LPG. DME can be blended with
LPG and used for domestic cooking and heating. Growth in DME’s use for such domestic
applications is increasing sharply as DME blending becomes more widespread within the
large, and growing, LPG market – in particular in developing countries where portable
(bottled) fuel is providing a safer, cleaner, and more environmentally benign fuel for cooking
and heating. Only modest modifications are required to convert a diesel engine to run on
DME, and engine and vehicle manufacturers, including Volvo, Mack, Isuzu, Nissan, and
Shanghai Diesel have developed heavy vehicles running on diesel engines fuelled with DME.
It is as a replacement for diesel fuel that DME particularly demonstrates its most distinct
advantages.
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Fig. 15. Consumption of DME in Different areas
Worldwide market for DME is segmented into ENN Group Company, AKzo Nobel N.V,
Grillo-Werk AG, Korea Gas Corp, and Oberon fuels, The Chemours Company, Jiutai Energy
Group, Royal Dutch Shell Plc., Zagros Petrochemical Company, China Energy Limited and
Methanex Corp. Due to unavailability of export infrastructure and trading norms of DME, the
compound is rarely traded among the countries. In the recent times, there have been
numerous DME plant announcements; this is expected to bridge the gap between potential
DME demands.
With slight modification in fuel injection systems, DME could further replace diesel in
conventional engines. In addition, Continuous increase in diesel consumption will impact the
DME market as the transport fuel. Furthermore, due to clean combustion property of DME,
market is likely to undergo high growth over the forecast period. Overall market for DME
application is segmented into power generation, LPG blending, aerosol propellant and others.
Dimethyl ether market also finds its applications in welding and brazing operations, chemical
feedstock and refrigerant. Being the most dominant regional market, Asia Pacific will
account for the maximum growth over the coming years. China consumes more than 85% of
the worldwide demand for DME. Japan, South Korea, India and Indonesia are the regions
projected to undergo considerable growth. This will majorly impact the development of DME
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manufacturing.
Conventional fuel injection & delivery systems are not compatible for DME use, as the
product has no lubrication properties. Hence, diesel engines require a fuel-tolerant system or
must find ways for necessary lubrication. These factors may pose challenges to DME market
growth in the coming years.
5. REFERENCES
1. https://en.wikipedia.org/wiki/Steam_reforming
2. https://en.wikipedia.org/wiki/Natural_gas
3. Dongsen Mao and Xiaoming Guo, “Dimethyl Ether Synthesis from Syngas over the
4. https://www.toyo-eng.com/jp/en/products/energy/dme/
6. https://www.engineering-airliquide.com/autothermal-reforming-atr-syngas-generation
7. https://pubs.acs.org/doi/full/10.1021/cs500967j?src=recsys
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8. https://www.sciencedirect.com/science/article/pii/S0378775305007846
9. https://www.tandfonline.com/doi/full/10.1080/10916466.2018.1428630?src=recsys&
10. http://encyclopedia.che.engin.umich.edu/Pages/Reactors/Slurry/Slurry.html
11. http://ppac.org.in/content/155_1_GasPrices.aspx
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