Syngas Production from Petroleum Coke Gasification

1. 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 April 26, 2011 Syngas Production from Petroleum Coke Gasification

2. 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 • H2 to CO molar ratio of 2.5 • CO2 and N2 mixed in http://coalgasificationnews.com/tag/petcoke-gasification/

3. Questions from Last Time • How was the PFD generated? • What is our feedstock prices?

4. Recap • PFD’s • Control Schemes • Plant Layout • Calculations • Refined Individual Economics • Joint Econ Presentation

5. Today’s Agenda • Overview of the project from day 1 till the end • Brief backgrounds • Brief process description • Aspen Simulation overview • Economics Overview • Recommendations

6. In the Beginning… • Mission Statement: • Design a process to produce syngas • Determine if this is a practical process • Meet the requirements of Team Golf • Decide profitability • Decide practicality

7. Major Decisions • Feedstock Choice • Petcoke • Gasifier Choice • Shell Entrained Flow (Membrane Wall) • Extent of Simulation • Solvent • Selexol • Syngas Price • Location

8. Petcoke Background • Petcoke is a byproduct of oil-refining • Heating value of 28 MMBtu/ton • More than 55 million tons in 2005 were produced in U.S. oil refineries • The sulfur content is relatively high and must be removed during processing in order to create a usable synthesis gas for the chemical production team as well as to meet the requirements of the EPA.

9. Gasification Background • Gasification covers the conversion of any carbonaceous fuel to a gaseous product. • This is not a complete combustion process since there is no residual heating value. Shell Entrained Flow Gasifier

10. Process Highlights • Pressure Driven Process • Reduction of Pumps • High Conversion of Feedstock • Highly Efficient Sulfur Removal • Sulfur removal to 2 ppm

11. Overall Block Flow

12. Overall Aspen Simulation Gasifier H2S Removal Claus Process Water Gas Shift CO2 Capture and Sequestration

13. PFD Example

14. Control Scheme Example

15. Economics Overview

16. Economics Overview

17. Syngas Pricing • First prices were generated by comparing heating values with natural gas • This proved to be too low of a price • Negotiations with Team Golf • Joint Presentation afterwards • Price determined by creating an equal IRR

18. Resources • Equipment Sizing and Cost – Aspen • Amount of Required Catalyst and Solvent -Aspen & Hand Calculations • Economics - Used sheet provided by Mr. Jerry Palmer as a basic template & Microsoft Excel to calculate NPV and IRR • PFD, BFD, and Control Scheme – Aspen, Visio, Microsoft Excel

19. Communication • Price for Selexol – UOP ($3.20/lb) • Price for Zinc-Oxide – UOP ($55/lb) • Price for Petcoke – Dover ($75/ton) • Amount of Selexol & Equipment Required for CO2 Capture – Dow Oil & Gas (~4 MMlb/day Selexol)

20. Location and Layout • 4923 Port Rd., Pasadena, TX • 2.5 Miles West of Trinity Bay • Existing Roads and Railroads • 140 Acres with Acetic Acid Production (Team Golf)

21. Advantages • High yield of syngas • CO2 capture makes the process environmental friendly • Advantage of location: • Supply and ease of transportation of feedstock and product • Feedstock Advantage: • Byproduct of oil refining • It has high calorific content

22. Disadvantages • Petroleum coke is high in Sulfur content • Expensive Gasifier • Cost of Petroleum coke fluctuates with crude oil prices • Water-Gas shift reaction yields higher amount of CO2

23. Recomendations • Combining the facilities early on • There is no such thing as a stand alone gasifier plant • Finishing up some of the loose ends of the project • Chemical Disposal • Sulfur • Zinc Oxide • Tail Gas • Slag • Heavy Metals • Complete Heat Integration

24. Questions?

25. References • (http://www.netl.doe.gov/technologies/coalpower/gasification/gasifipedia/4-gasifiers/4-1-2-3_shell.html)

26. Report Outline • Final Report: • Executive Summary Done • Discussion Done • Recommendations Done • Appendices • Design Basis: Done • Block Flow Diagram: Done • Process Flow Showing Major Equip.: Done

27. Report Outline • Appendices (Continued) • Material and Energy Balances: Done • Calculations: Done • Annotated Equip. List: Done • Econ. Eval. Factored from Equip. Costs: Done • Utilities: Done • Conceptual Control Scheme: Done • Major Equipment Layout: Done

28. Report Outline • Appendices (Continued) • Distribution and End-use Issues: Done • Constraints Review: Done • Applicable Standards: Done • Project Communications File: Done • Information Sources and References: Done

29. Composition of Petcoke(3) • Ultimate Analysis • Proximate Analysis Average Petcoke Metal Makeup(5)

30. PFD: Gasification

31. PFD: Claus Process

32. PFD: Water Gas Shift

33. PFD: CO2 Absorption

34. PFD: CO2 Sequestration

35. Control Scheme: Water Gas Shift

36. Control Scheme: CO2 Absorption

37. Control Scheme: CO2 Sequestration

38. Control Scheme: Gasifier

39. Control Scheme: Claus Process

40. Energy Balance Around WGS Reactor

41. Energy BalanceAround WGS Reactor

42. Heat Loads

43. CO2 Sequestration • CO2 in our syngas is absorbed on Selexol to be selectively removed • Delete only one CO2 slide.

44. http://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpghttp://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpg