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Production of Gasoline Components from Synthesis Gas

Production of Gasoline Components from Synthesis Gas. ChE 397 Senior Design Group Alpha Ayesha Rizvi Bernard Hsu Jeff Tyska Mohammad Shehadeh Yacoub Awwad 2011.03.08. Presentation Overview. Recap PFD/ flowsheet Heat Duties Sizing Economics Summary. Recap. H 2.

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Production of Gasoline Components from Synthesis Gas

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  1. Production of Gasoline Components from Synthesis Gas ChE 397 Senior Design Group Alpha Ayesha Rizvi Bernard Hsu Jeff Tyska Mohammad Shehadeh YacoubAwwad 2011.03.08

  2. Presentation Overview • Recap • PFD/flowsheet • Heat Duties • Sizing • Economics • Summary

  3. Recap H2

  4. Questions from last presentation • Will the Carbon steel be weakening at our high temperatures? • Should be fine, below max recommended T • Should we separate our Aromatics? • Numbers last time were unduly high, normal now • Don’t quote retail prices • Gasoline price quotes are spot prices from the EIA

  5. Process Changes • Fluidized bed Methanol to Gasoline reactor • Continuous regeneration • No DME reactor • Different product separation scheme • Different product distribution (closer to normal gasoline)

  6. Design Basis • 6000 Short tons syngas/day • 518 °F (270 °C) • 725 psi (5 Mpa) • Product • Gasoline – 16,300 bpd • LPG – 4350 bpd

  7. Methanol Reactor Hot MeOH Product (3) Syngas (1) Warm Water(4) MeOH-Water HX Recycle Syngas from Comp (2B) MeOH REACTOR Recycle Syngas To Comp (2A) Cooled MeOH Product (6) Steam (5)

  8. MeOH Recycle and HX Cool Rec. Syngas(8) Cooled MeOH Product (6) Recycle Syngas To Comp (2A) MeOH-Syngas HX Purge Syngas (10) Hot Rec. Syngas (9) Cooler MeOH product(7)

  9. To MTG Reactor Cool Rec. Syngas (8) Cold Light Gas (11) Cooler MeOH Product (7) Light Gas—MeOH HX Hot HCs(15) Product-MeOH HX Cold MeOH (13B) Flash Light Gas Out (12) Cooler Cooled MeOH(13A) Cool HCs (17 A) Warm MeOH (16) (14) MeOH to MTG

  10. Hot HCS(15) MTG Reactors Warm MeOH (16) MTG Reactors Heater Hot MeOH (17 B )

  11. Product Refining Cool HCs (17A) CWS (18) Cold Light Gas (11) 2nd Gas HX Warm Water (4) Deethanizer Pump HCs(22) Cooled HCs (19) Pump HCs(23) C3+ HCS (24) Cooler Decanter Cold HCs (20) ‘Dirty’ Water (21)

  12. Offgas (26) Water ‘Clean’ Water (25 A) ‘Dirty’ Water (21) CWS (18) Water Flash Extra Cooling H2O (25 B)

  13. Product Refining II LPG (30) LPG + Pentanes (28) Debutanizer Pentanes (31) C3+ HCs(24) Hydrocarbon Separator Gasoline Product (32) Gasoline (29)

  14. Overall Process

  15. Heat Duties • Heaters/coolers, HX, reactors, dist. col. • The rest are adiabatic • Light gas burning not included

  16. Detailed Heat Duties

  17. Sizing • Reactor sizing done by hand • Used LHSV/GHSV data • Other sizing done in ASPEN • Distillation Columns • 25-40 trays • 6.5 – 8.5 ft Diameter • 64 – 92 ft High • Heat Exchangers • 1,000 – 10,000 ft2

  18. Methanol Reactor Sizing Calculations • Boiling water reactor • Catalyst on tube side • 400 psia steam • Tube area fraction = .45 • GHSV = 8,000 hr-1 • 1:4 D:H ratio • D = 8.3 ft, H = 33.2 feet

  19. Process Economics • Detailed summary in IPE • TIC (ISBL) = $22,050,000 • Indirect field costs = $1,900,000 • Non field costs =$3,400,000 • Total startup cost = $27,350,000 • Upkeep = $16,700,000/year • Includes catalyst prices and utilities

  20. Field Cost Distribution D O L L A R S

  21. Non-Field Cost Distribution D O L L A R S

  22. Indirect Field Cost Distribution D O L L A R S

  23. Utilities • Cooling water • 70,000 gpm • 4 Million Dollars/year • 100 psia Pressure Steam • 30.4 Klb/hr • 2 Million Dollars/year • 400 psia Pressure steam • 157.5 Klb/hr • 14.8 Million Dollars/year • Steam generation • Steam costs not included in upkeep

  24. Catalyst Pricing • http://www.nrel.gov/docs/fy11osti/47594.pdf

  25. Syngas and Product Cost • Syngas cost = $250/ton • Total syngas cost / year = $500 Million • Gasoline price = $2.25/gallon ($94.5/bbl) • EIA spot price • LPG price = $1/gallon ($42/bbl)

  26. Outside Battery Limit Process Economics • Total Installed Cost (TIC) didn’t include buildings, etc. • Factor of 8 • New TIC = $218 Million • About 45% of syngas cost/year • Gasoline and syngas prices

  27. Final Economics • Total revenue per year = $575 Million • Profit = $56 Million/year • IRR = 26% (20 year plant life) • Simple payback = 3.8 years

  28. Summary • 16,300 bbl/day gasoline • 4,350 bbl/day LPG • Lots of potential for heat recovery • 26% IRR • Gasoline and syngas price

  29. Questions?

  30. Steam Gen. from MeOH reactor • -475 MMBTU • 10% lost • 440 KLb per hour • Enough to satisfy our requirements • Working with gasifier group • Use in process • Electricity generation

  31. Methanol to Gasoline Reactors Sizing Calculations Size of Reactors

  32. Block Flow Diagram CO Cooling and Separation Methanol to Gasoline (MTG) Reactors MeOH Methanol Reactor MeOH H2, CO H2 Purge H2, CO Hydrocarbons Water C1/C2 Liquefied Petroleum Gas Water Separation 2nd Distillation Column Heavy Hydrocarbons Deethanizer (Dist. Col.) Hydrocarbons Water Gasoline

  33. Carbon Steel Limits • Max temp based on creep = 450 C • Max temp based on rupture = 540 C • Our max temp = 380 C Heat Resistant Materials by Joseph R. Davis

  34. Equipment Costs I

  35. Equipment Costs II

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