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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. Syngas Production from Petroleum Coke Gasification. Project Purpose. What we are doing?

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Syngas Production from Petroleum Coke Gasification

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  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 March 8, 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 • CO to H2 molar ratio of 0.409 • CO2 and N2 mixed in http://coalgasificationnews.com/tag/petcoke-gasification/

  3. Overall Block Flow

  4. Recap • Discussed the Shell™ membrane gasifier • Discussed our syngas processes • Sulfur Removal • Claus Process • Water Gas Shift • Flow Sheets • Early Material and Energy Balances

  5. Questions Brought Up Last Time • Why use N2 as a transport gas and not CO2? • How are we absorbing CO2?

  6. 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

  7. Flow Sheeting: Overall Process Gasification Sulfur Removal Claus Process Water Gas Shift CO2 Removal

  8. Flow Sheeting: Gasification To Sulfur Removal

  9. Flow Sheeting: Sulfur Removal To Claus To WGS

  10. Flow Sheeting: WGS & CO2 To Chem Production Capture Ready CO2

  11. Flow Sheeting: Claus Process To Superclaus

  12. Flow Sheeting: Claus Cont.

  13. Heat Loads for Claus Plant

  14. Heat Sink Optimization • Stream Pre-heating • Lower Heater / Cooler Duties • Heat Duty and Heat Ex. Cost Tradeoff Cold Furnace Gas Acid Gas Cold Acid Gas Hot Cooler HX Furnace To Claus Catalysts Hot Furnace Gas

  15. Solid Removal Gasification Price $240,306,575 Sulfur Removal Economics and Size Claus Process Final syngas product CO2 Absorption WGS Reactor

  16. Gasification

  17. Solid Removal $670,000 Gasification Price $240,306,575 Sulfur Removal EquipmentCostandSize Cont. Claus Process CO2 Absorption WGS Reactor Final syngas product

  18. Solid Removal

  19. Solid Removal $670,000 Gasification Price $240,306,575 SulfurRemoval $9,600,000 EquipmentCostandSize Cont. Claus Process CO2 Absorption WGS Reactor Final syngas product

  20. Sulfur Removal

  21. Solid Removal $670,000 Gasification Price $240,306,575 Sulfur Removal $9,600,000 Claus Process $12,500,000 EquipmentCostandSize Cont. CO2 Absorption WGS Reactor Final syngas product

  22. Equipment Used in Claus Process

  23. Solid Removal $670,000 Gasification Price $240,306,575 Sulfur Removal $9,600,000 EquipmentCostandSize Cont. Claus Process $12,500,000 CO2 Absorption $35,700,000 WGS Reactor Final syngas product 144 ft3 $360,000

  24. CO2 Absorption

  25. Solid Removal $670,000 Gasification Price $240,306,575 Sulfur Removal $9,600,000 Overall Summary of Capital Cost Claus Process $12,500,000 CO2 Absorption $35,700,000 WGS Reactor 144 ft3 $360,000 Final syngas Product $300,000,000

  26. Other Fixed Cost Capital Cost as of now= $ 300,000,000 Labor Cost as of now = $ 24,000,000

  27. Overall Expenses Capital Cost as of now = $ 300,000,000

  28. Expected Revenue

  29. Sensitivity Analysis

  30. Sensitivity Analysis

  31. Sensitivity Analysis

  32. Sensitivity Analysis

  33. Location • Victoria, Texas • Between Houston and Corpus Christi • 200 acres • Kansas City Southern, Union Pacific, and Burlington Northern Santa Fe railways • Gulf Intracoastal Waterway

  34. Possible Alternatives • Alberta, Canada • Sits on excess petroleum coke from refineries • Is it Economically viable? • Demand • Transportation costs

  35. Conclusion • Overall ASPEN procedure • Gasification • Syngas Clean Up • CO2 Removal • Rough Economics • Location: Victoria, Texas • Possible Change

  36. Next Steps • Final process flow diagram • Control scheme • Optimize economy scale • Revise capital costs • Major equipments list and plant layout • Revise report

  37. Questions?

  38. 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/

  39. 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

  40. 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

  41. 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

  42. Energy Balance Around WGS Reactor

  43. Energy BalanceAround WGS Reactor

  44. Heat Loads

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

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

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