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
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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 What was the heat rate
brought up in the gasifier comparisons?
Why use N2 as a transport gas and not CO2?
How are we absorbing CO2?
What is a better definition of the quench?
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Agenda
Recent changes Using Selexol instead of MDEA Using the Superclaus
Aspen Simulation Heat Load Identification Economics
Aspen Price Evaluator (ICARUS) Equipment Sizing Energy Balance Location Update
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Flow Sheeting: Overall Process
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Gasification Sulfur Removal Claus Process
Water Gas ShiftCO2 Removal
Flow Sheeting: Gasification
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Flow Sheeting: Sulfur Removal
93/8/2011To WGS
Flow Sheeting: WGS & CO2
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Flow Sheeting: Claus Process
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Flow Sheeting: Claus Cont.
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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 -11.2Condenser 3 -5.97Condenser 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 1.72Catalytic Reactor 3 -5.73
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Heat Sink Optimization
Stream Pre-heating Lower Heater / Cooler Duties Heat Duty and Heat Ex. Cost Tradeoff
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Furnace CoolerHX
Acid Gas Cold
Acid Gas Hot
To Claus Catalyst
s Hot Furnace
Gas
Cold Furnace
Gas
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Gasification Process
$240,000,000
Solid Removal
Claus Process
CO2 Absorption
Water-gas Shift
Final syngasproduct
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Gasification
SIZE INDIRECT COST
DIRECT COST
Air SeparationUnit
N/A N/A $100,000,000
Petroleum Coke Crusher $ 5,401,890 $ 7,022,455
Gasifier (x2) N/A N/A $ 132,000,000
Heat Exchanger (x2)
$611,480 $ 1,284,120 163/8/2011
Solid Removal$670,000
CO2 Absorption
Water-gas Shift
Final syngasproduct
Sulfur Removal
Gasification Process
$240,000,000
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Solid RemovalSIZE INDIRECT
COSTDIRECT COST
Filter 16 sq ft $ 364,770 $ 510,680
Cyclone (x3) (Removes Fly
Ash)5 ft dia. $ 307,800 $ 477,000
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Sulfur Removal
$9,300,000
Water-Gas Shift
CO2 Absorption
Final syngasproduct
Solid Removal$670,000
Gasification Process
$240,000,000
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Sulfur RemovalSIZE 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
Heat Exchanger 1200 sq ft $ 121,980 $ 256,155
Reactor (x3) TBD $ (103,115)* $ (164,985)*
Cooler 1 6739 sq ft $ 168,800 $ 320,600
Cooler 2 440 sq ft $ 16,700 $ 79,200
Cooler 3 258 sq ft $ 13,600 $ 73,600
Cooler 4 163 sq ft $ 11,800 $ 69,800
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WGS ReactorCO2 AbsorptionFinal syngas
product
Sulfur Removal
$9,300,000
$56,000,000144 ft3
$360,000
Gasification Process
$240,000,000
Solid Removal$670,000
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CO2 AbsorptionEquipment 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$ 272,889 $ 409,333
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CO2 Absorption$56,000,00
0
Final syngasproduct
Solid Removal$670,000
Gasification Process
$240,000,000
Sulfur Removal
$9,300,000
WGS Reactor$360,000
$306,430,000
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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= $ 306,430,000
Labor Cost as of now = $ 18,000,000
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Overall Expenses
Type Cost of year 1 ($ Million/year)
Cost at the end of 25th year
Assumptions
Loan $20.5 $ 1.5 Based on 6% interest
Cooling water $1.9 $ 6.0 Based on 5% inflation rate
Electrical $1.8 $ 5.8 Estimated from a plant’s electrical cost
Salaries and Fringes
$ 24 $ 77 Average of 35 people/shift
Maintenance $17 $ 55 5 % of the capital cost
Royalties $ 5 $15.8 5% of production revenue
Insurance $3.4 $ 11 1% of the capital cost
Raw materials $ 34 $107.6
Depreciation $14 $14 Capital cost/25 years
Total $121.6 $293. 1
Capital Cost as of now = $ 306,430,000Estimated Revenue as of now = $ 94,000,000
Expected RevenueProduct and Side Products
Unit Price (per ton)
Revenue (per year)
Syngas $150.00 $ 86.60 million
CO2 $40.00 $ 7.00 million
Sulfur $10.00 $ 0.30 million
~ $ 94 million
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Location Victoria, Texas Between Houston
and Corpus Christi 200 acres Kansas City
Southern, Union Pacific, and Burlington Northern Santa Fe railways
Gulf Intracoastal Waterway
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Conclusion
Overall ASPEN procedure Gasification
Rough Economics Cost estimate: Profit estimate:
Location: Victoria, Texas
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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
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
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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
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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
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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
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Questions?
3/8/2011
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 LoadsGasifier 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 57.0Sulfur Stripper Cooler -200.0
Selexol Cooler -40.7 Rich / Lean Heat Exchanger 274.9
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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
39http://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpg3/8/2011
