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Efficient and energy-saving complete technology for catalytic and separation of polymerization-grade olefins from methanol
S-MTO: Methanol efficiently produces olefins, with high yields and low consumption, ensuring energy security.
Type
Process technology
Tags
Industrial energy conservation
Energy-saving
Chemical
Separation
Catalytic
Organic chemistry
Olefin
Methanol
Applicable industry
Manufacturing
Applications
Organic chemical
Key innovations
This project creates a high-performance nano-platelet molecular sieve catalyst, pioneered a reduced-diameter fast fluidized bed reaction technology, invented precise carbon deposition control and efficient olefin separation technology, and realized the coupling of MTO and petroleum ethylene processes for the first time.
Potential economic benefits
The new output value was 6.4 billion yuan, and the new profits and taxes were 1.3 billion yuan. High diene yield, reduced energy consumption, catalyst and methanol consumption, and greatly reduced operating costs.
Potential climate benefits
This project reduces energy consumption by optimizing the heat network, reduces methanol consumption by 12.5%, improves raw material utilization and overall efficiency, directly reduces energy consumption in the production process and carbon emissions from upstream methanol production, and significantly reduces the carbon footprint of olefin production.
Solution supplier
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Sinopec Shanghai Petrochemical Research Institute
Sinopec Shanghai Petrochemical Research Institute
Sinopec Shanghai Petrochemical Research Institute is deeply engaged in petrochemical technology research and development and innovation to promote the upgrading of the energy and chemical industry.
Shanghai,China
Solution details

This project belongs to the field of organic chemical industry. In the increasingly severe global oil shortage situation, methanol-to-olefins technology, as an important bridge connecting modern coal chemical industry and petrochemical industry, is of great significance to promoting the sustainable development of the national economy and ensuring national energy security. Therefore, this technology has been one of the most important research topics in the field of chemical industry at home and abroad in the past ten years. In recent years, multiple research teams, including this project, have simultaneously achieved remarkable industrialization breakthroughs, promoting the revolution in methanol-to-olefins technology. As a new process route, the industrialization of methanol-to-olefins technology needs to solve a series of technical problems such as creation of high-performance catalysts, development of continuous methanol conversion reaction-catalyst recycling regeneration processes, energy-saving and efficient olefin product separation, environmental protection and long-term operation. After more than 10 years of continuous innovation, starting from reaction mechanism research, this project has established the structure-activity relationship of catalytic material structure-carbon deposition-diffusion-performance. It has pioneered and integrated nano-platelet molecular sieve catalysts, reduced-diameter rapid fluidized bed reaction-key technologies such as key technologies such as regeneration process and full-process olefin separation process have successfully developed S-MTO technology, achieving industrialization and technological leadership. The main innovations are as follows: (1) Created a high-performance methanol-to-olefins catalyst. Using composite template technology, we have pioneered nano-platelets and near-zero silicon island distributed silicoaluminophosphate molecular sieve materials with rapid diffusion properties. When used in MTO reactions, it has high activity and selectivity; we have created a highly wear-resistant, well-shaped fluidized bed catalyst with good strength and low loss, with an abrasion index of less than 1.0%. (2) Invented the variable diameter fast fluidized bed reaction technology. For the first time, a variable diameter fast fluidized bed was applied to the MTO process, which reasonably controlled the catalyst density and reaction degree in different reaction zones, ensured the complete conversion of methanol and suppressed the back-mixing side reactions of materials. Operation results of the industrial unit: methanol conversion rate is greater than 99.9%, and ethylene + propylene (referred to as diene) selectivity is more than 81%. (3) Invented the technology for controlling carbon deposition in the reaction-regeneration system. In order to achieve optimal olefin selectivity, it is necessary to accurately control the distribution of carbon deposits on the catalyst. An MTO two-stage process regeneration technology and a multi-strand catalyst efficient mixing process have been developed. The amount of carbon deposits on the catalyst in the reaction zone is stably controlled within the optimal amount of carbon deposits ±0.2%. (4)A new olefin recovery technology with efficient quenching and oxide removal has been invented. The recovery rates of ethylene and propylene have reached more than 99.9%. The product purity of ethylene and propylene is 99.95% and more than 99.60% respectively, reaching or exceeding the polymerization level. (5) Developed a complete set of energy-saving and environmentally friendly technologies coupled with the petroleum-based ethylene process. For the first time, the integration of the MTO process and the petroleum-based ethylene process was realized, converting the light hydrocarbons by-product of S-MTO into dienes, and reducing the consumption of methanol by 12.5%. A single-tube third-stage cyclone separator was developed to reduce catalyst loss (0.18 kg catalyst/t methanol). The full-process heat network has been optimized, and the energy consumption of the 600,000-ton/year S-MTO unit has been reduced to 340 kgEO/t diene. In 2011, this technology was built and applied in Zhongyuan Petrochemical in an industrial unit of 600,000 tons/year. Compared with similar technologies, the diene yield of this technology is 2-3% higher, the catalyst loss is 28% lower, and the industrial unit operates continuously, safely and stably at full load for 22 months, far exceeding similar units, greatly reducing operating costs. Experts believe that the S-MTO catalyst has excellent performance, reasonable process flow, and complete sets of catalysis and separation technologies have reached the international leading level. It has successfully transferred Zhongtian Hechuang, Zhongan Coal Chemical and other companies, and has obtained technical recognition from many domestic and foreign companies. It has broad application prospects. It has applied for 415 domestic and foreign patents, including 194 authorized China invention patents and 23 international invention patents, and published 6 SCI papers. A complete set of technologies with independent intellectual property rights has been formed for the entire catalytic reaction and separation process. In the past three years, the new output value has been 6.4 billion yuan, and the new profits and taxes have been 1.3 billion yuan. This project is of great significance to ensuring my country's energy security and achieving sustainable development.

Last updated
01:01:04, Nov 08, 2025
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