Techno-economic evaluation of a process for direct conversion of methane to aromatics

Natural gas is widely abundant and relatively inexpensive. As such, large quantities are flared every year. This presents an opportunity to use natural gas as a chemical feedstock. Non-oxidative dehydroaromatization of methane, the major component of natural gas is proposed as an option to monetize natural gas. This study evaluates the economics of the methane to benzene process. A catalytic membrane reactor model written in MATLAB has been directly implemented in an Aspen Plus V9 process model using CAPE-OPEN interoperability. Minimum utility requirements and heat exchanger designs were identified in Aspen Energy Analyzer, and process economics for a variety of feed and product prices were assessed using Aspen Process Economic Analyzer. The results indicate that the venture is profitable (profitability index of 1.17, IRR of 35.5%, NRR of 18.2%). The capital cost was found to be $35,500 per daily standard barrel of benzene. Additionally, the process remains economically attractive so long as either the price of benzene remains above $470/ton, or the price of hydrogen remains above $0.8/kg. •Non-oxidative conversion of methane to benzene is reaction equilibrium-limited.•Techno-economic analysis of a process with catalytic membrane reactor was evaluated.•Thermal pinch analysis was used for energy targets and heat exchange network design.•The venture is profitable (profitability index of 1.17, IRR of 35.5%, NRR of 18.2%).•Price of benzene and hydrogen must be greater than $470/mt and $0.8/kg, respectively.