DOE’s Xlerator program to fund piloting of Exelus’ styrene monomer process
Exelus, Inc. has received a grant totaling $500,000 under the Department of Energy’s (DOE’s) XLerator program to fund piloting of Exelus’ styrene monomer process (ExSyM).
“These projects, funded as part of DOE's SBIR Xlerator program, will help small businesses develop manufacturing processes to scale up production of their new, proven technologies, creating new markets and new jobs” said US Secretary of Energy Steven Chu.
Styrene is an important monomer used in a variety of plastic products. In terms of monomer production rate, styrene ranks fourth in the US behind ethylene, vinyl chloride and propylene. Global styrene demand was estimated at 26 million metric tons in 2009. Styrene is made conventionally by alkylation of benzene with ethylene to produce ethylbenzene which is then catalytically dehydrogenated to styrene monomer. Because the reaction is equilibrium-limited, endothermic, and requires such a high operating temperature, styrene plants use vast amounts of energy. High feedstock, labor, and energy prices in the US and Europe have led to massive closures of styrene plants in recent years, with production moving to lower cost centers like the Middle East and China.
The Exelus styrene monomer process (ExSyM) uses the side-chain alkylation of toluene with methanol to produce styrene. This route has two practical benefits - a steep reduction in feedstock costs and avoids the energy-intensive dehydrogenation reaction. The economic drivers of this technology are a 30% reduction in feedstock costs (about $300/ton) along with a large reduction in energy consumption – which leads to an equivalent reduction in GHG emissions. This new technology also offers much lower capital costs than conventional plants by eliminating the need for large amounts of 900°C steam used to provide the heat of reaction.
The pilot-plant is expected to begin operating in early December.
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