Syngas Production from Petroleum Coke Gasification
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Syngas Production from Petroleum Coke Gasification Team Hotel: Russell Cabral, Tomi Damo, Ryan Kosak, Vijeta Patel, Lipi Vahanwala Advisors: Bill Keesom – Jacobs Consultancy Jeffery Perl, PhD – UIC Dept. Of Chemical Engineering March 8, 2011 1
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Team Hotel: Russell Cabral, Tomi Damo, Ryan Kosak, Vijeta Patel, Lipi Vahanwala Advisors: Bill Keesom – Jacobs Consultancy Jeffery Perl, PhD – UIC Dept. Of Chemical Engineering March 8, 2011. Syngas Production from Petroleum Coke Gasification. Project Purpose. What we are doing? - PowerPoint PPT Presentation
Transcript of Syngas Production from Petroleum Coke Gasification
Syngas Production from Petroleum Coke Gasification
Team Hotel:Russell Cabral, Tomi Damo, Ryan Kosak, Vijeta Patel, Lipi Vahanwala
Advisors:Bill Keesom – Jacobs Consultancy Jeffery Perl, PhD – UIC Dept. Of Chemical Engineering
March 8, 2011 1
Project Purpose
What we are doing? Producing syngas from petcoke Using entrained flow gasifier Implementing a rigorous syngas
cleaning
Why we are doing this? Making syngas for acetic acid
production Chemical production team specs▪ CO to H2 molar ratio of 0.409▪ CO2 and N2 mixed in
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http://coalgasificationnews.com/tag/petcoke-gasification/
3/8/2011
Overall Block Flow
3
Recap
Discussed the Shell™ membrane gasifier
Discussed our syngas processes Sulfur Removal Claus Process Water Gas Shift
Flow Sheets Early Material and Energy Balances
43/8/2011
Questions Brought Up Last Time
Why use N2 as a transport gas and not CO2?
How are we absorbing CO2?
53/8/2011
Agenda
Recent changes Using Selexol instead of MDEA Using the Superclaus
Aspen Simulation Heat Load Identification Economics
Aspen Price Evaluator (ICARUS) Equipment Sizing Location Update
63/8/2011
Flow Sheeting: Overall Process
73/8/2011
Gasification Sulfur Removal Claus Process
Water Gas ShiftCO2 Removal
Flow Sheeting: Gasification
83/8/2011
To Sulfur Remov
al
Flow Sheeting: Sulfur Removal
93/8/2011To WGS
To Claus
Flow Sheeting: WGS & CO2
103/8/2011
Capture
Ready CO2
To Chem Producti
on
Flow Sheeting: Claus Process
113/8/2011
To Supercl
aus
Flow Sheeting: Claus Cont.
123/8/2011
Heat Loads for Claus Plant
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Claus Process Equipment Heat Load (MMBtu/hr)
Claus Furnace -3.26
Condenser 1 -31.3
Condenser 2 -11.2
Condenser 3 -5.97
Condenser 4 -3.92
Re-heater 1 9.72
Re-heater 2 5.29
Re-heater 3 3.46
Catalytic Reactor 1 3.03
Catalytic Reactor 2 1.72
Catalytic Reactor 3 -5.73
3/8/2011
Heat Sink Optimization
Stream Pre-heating Lower Heater / Cooler Duties Heat Duty and Heat Ex. Cost Tradeoff
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Furnace Cooler
HX
Acid Gas Cold
Acid Gas Hot
To Claus Catalyst
s Hot Furnace
Gas
Cold Furnace
Gas
3/8/2011
WGS ReactorCO2 Absorption
Final syngasproduct
Claus Process
Gasification Price
$240,306,575
Solid Removal
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Sulfur Removal
Economics and Size
Gasification
SIZE INDIRECT COST
DIRECT COST
Air SeparationUnit
Facility N/A $100,000,000
Petroleum Coke Crusher TBD $ 5,401,890 $ 7,022,455
Gasifier (x2) 2000 TPD N/A $ 132,000,000
Heat Exchanger (x2)
3350 sq ft $611,480 $ 1,284,120 163/8/2011
WGS ReactorCO2 AbsorptionFinal syngas
product
Claus Process
Gasification Price
$240,306,575
Solid Removal$670,000
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Sulfur Removal
Equipment Cost and SizeCont.
Solid Removal
SizeINDIRECT
COSTDIRECT
COST
Filter 16 sq ft $ 364,770 $ 510,680
Cyclone (x3) 5 ft (diameter) $ 307,800 $ 477,000
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WGS ReactorCO2 AbsorptionFinal syngas
product
Claus Process
Gasification Price
$240,306,575
Solid Removal$670,000
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Sulfur Removal
$9,600,000
Equipment Cost and SizeCont.
Sulfur Removal
203/8/2011
SIZE EQUIP COST TOTAL COST
Absorber (x2) 12.7 x 60 ft $ 2,400,000 $ 4,800,000
Stripper (x2) 17 x 30 ft $ 1,560,000 $ 3,300,000
Flash Vessels (x2)383 cu. ft
$ 707,215 $ 808,1106980 cu ft
Heat Exchanger 1200 sq ft $ 121,980 $ 256,155
Reactor (x3)TBD $ (103,115)* $ (164,985)*
Cooler 6739 sq ft$ 185,500 $ 400,000
440 sq ft
WGS ReactorCO2
AbsorptionFinal syngasproduct
Claus Process$12,500,000
Gasification Price
$240,306,575
Solid Removal$670,000
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Sulfur Removal$9,600,000
Equipment Cost and SizeCont.
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Equipment Used in Claus Process
Equipment Size Equip Cost Total Cost
Heat Exchanger 298 sq ft TBD TBD
Claus Furnace N/A TBD TBD
Cooler (x3) 439 sq ft
$ 148,300.00 $ 222,600.00257 sq ft
162 sq ft
Flash (x3) 680 cu ft$ 263,033.00 $ 358,000.00461 cu ft
461 cu ft
Heater (x2) 1574 sq ft TBD TBD
996 sq ft
3/8/2011
WGS ReactorCO2 Absorption$35,700,000
Final syngasproduct
Claus Process$12,500,000
Gasification Price
$240,306,575
Solid Removal$670,000
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Sulfur Removal$9,600,000
144 ft3$360,000
Equipment Cost and SizeCont.
CO2 Absorption
Equipment Size Equip Cost Direct Cost
CO2 Absorber (x2) 12.7 x 60 ft N/A $ 3,000,000
CO2 Stripper (x2) 17 x 30 ft $ 203,170 $ 256,800
Compressor N/A$ 272,889 $ 409,333
243/8/2011
Overall Summary of
Capital CostWGS Reactor
144 ft3$360,000
CO2 Absorption$35,700,000
Final syngasProduct$300,000,000
Claus Process$12,500,000
Gasification Price
$240,306,575
Solid Removal$670,000
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Sulfur Removal
$9,600,000
Other Fixed Cost
Other Fixed Cost
License Fees and Royalties
2% of Capital Cost
Maintenance
5% of Capital
Cost
Laboratory Cost
30% Labor Cost
Insurance1%
Capital Cost
Capital Cost as of now= $ 300,000,000Labor Cost as of now = $ 24,000,000
263/8/2011
Overall Expenses
Type Cost of year 1 ($ Million/year)
Cost at the end of 25th year
Loan $18 $ 1
Cooling water $2 $ 6
Electrical $2 $ 6
Salaries and Fringes $ 24 $ 77
Maintenance $15 $ 48
Royalties $ 6 $19
Insurance $3 $ 10
Raw materials $ 54 $175
Depreciation $12 $12
Total $136 $355 27
Capital Cost as of now = $ 300,000,000
Expected Revenue
Product and Side Products
Unit Price (per ton)
Revenue (In MM $ / year)
Syngas $200.00 $ 115.50
CO2 $40.00 $ 7.00
Sulfur $100.00 $ 3.50
Total $ 126.00
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293/8/2011
Economic Analysis($ million/year)
Total Capital Cost $300
Total Expense $136
Total Revenue $126
Income Before the Taxes -$10
40 % Tax on the Income -$4
Income After the Taxes -$6
Add Back Depreciation $12
Cash Flow $6
Net Present Value $-52
Internal Rate of Return 3.58% < 5%
Payback Period 19 years
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Sensitivity Analysis
3/8/2011
$150.00 $170.00 $190.00 $210.00 $230.00 $250.00
-300
-250
-200
-150
-100
-50
0
50
100
150
200 NPV vs. Syngas Prices
NPV
Syngas($/ton)
Net
Pre
sen
t valu
e (
$m
illion
)
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Sensitivity Analysis
3/8/2011
$150.00 $170.00 $190.00 $210.00 $230.00 $250.00
-8.00%
-6.00%
-4.00%
-2.00%
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%IRR vs. Syngas Price
NPV
Syngas ($/ton)
Inte
rnal R
ate
of
retu
rn
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Sensitivity Analysis
3/8/2011
$20 $30 $40 $50 $60 $70 $80 $90
-$150.00
-$100.00
-$50.00
$0.00
$50.00
$100.00
$150.00
$200.00
$250.00
$300.00
NPV vs. Petcoke Cost
NPV
Petcoke Price ($/ton)
Net
Pre
sent
valu
e(
$ m
illions)
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Sensitivity Analysis
3/8/2011
$20 $30 $40 $50 $60 $70 $80 $900.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
IRR vs. Cost of Petcoke
IRR
Petcoke Price ($/ton)
Inte
rnal ra
te o
f re
turn
Location
Victoria, Texas Between Houston
and Corpus Christi 200 acres Kansas City
Southern, Union Pacific, and Burlington Northern Santa Fe railways
Gulf Intracoastal Waterway
343/8/2011
Possible Alternatives
Alberta, Canada Sits on excess
petroleum coke from refineries
Is it Economically viable? Demand Transportation costs
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Conclusion
Overall ASPEN procedure Gasification Syngas Clean Up CO2 Removal
Rough Economics
Location: Victoria, Texas Possible Change
3/8/2011
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Next Steps
Final process flow diagram Control scheme Optimize economy scale
Revise capital costs Major equipments list and plant layout Revise report
3/8/2011
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Questions?
3/8/2011
References
http://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpg
http://coalgasificationnews.com/tag/petcoke-gasification/
http://www.huffingtonpost.com/dr-orin-levine/questions-as-mileposts-of_b_448870.html
http://www.chinaep-tech.com/upload/accessary/8173/DZY08092502.pdf
http://www.chemicals-technology.com/projects/gulfpetrochemicalsco/ 393/8/2011
Report Outline
Final Report: Executive Summary IP Discussion IP Recommendations IP
Appendices Design Basis: Done Block Flow Diagram: Done Process Flow Showing Major Equip.: IP
403/8/2011
Report Outline
Appendices (Continued) Material and Energy Balances: IP Calculations: IP Annotated Equip. List: IP Econ. Eval. Factored from Equip. Costs:
IP Utilities: IP Conceptual Control Scheme: N/A Major Equipment Layout: IP
413/8/2011
Report Outline
Appendices (Continued) Distribution and End-use Issues:
IP Constraints Review: IP Applicable Standards: IP Project Communications File: IP Information Sources and References:
IP
423/8/2011
Energy Balance Around WGS Reactor
Energy BalanceAround WGS ReactorInlet Fraction Clean Syngas Component
Flow for WGS Reactor (lbmoles/hr) for WGS Cp (btu/lbmole* F)
Outlet Syngas Comp (lbmole/hr) from
(WGS)
CO 4946.233 7.118 123.395
H2O 6424.688 15.367 1601.850
N2 199.954 7.158 199.954
H2* 2960.168 6.948 7783.006
CO2 469.211 10.559 5292.049
CH4* 0.255
12.432 0.255
H2S 0.000 0.000 0.000
COS 0.000 0.000 0.000
Total 15000.509 15000.509
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Heat Loads
Gasifier Equipment Heat Load (MMBtu/hr)
Gasifier -34.7
HP Steam Heat Exchanger 139.0
MP Steam Heat Exchanger 281
Cooler -106.8
Flash 2.99
Sulfur Clean Up Equipment Heat Load (MMBtu/hr)
Sulfur Stripper Reboiler 57.0
Sulfur Stripper Cooler -200.0
Selexol Cooler -40.7
Rich / Lean Heat Exchanger 274.93/8/2011 45
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CO2 Sequestration
CO2 in our syngas is absorbed on Selexol to be selectively removed
Delete only one CO2 slide.
3/8/2011
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http://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpg3/8/2011
