Production of Gasoline Components from Synthesis Gas ChE 397 Senior Design Group Alpha Ayesha Rizvi Bernard Hsu Jeff Tyska Mohammad Shehadeh Yacoub Awwad

Presentation Overview  Recap  PFD  Initial Control Scheme  Refined Economics  Plant Layout  Calculations

Recap H2H2

Block Flow Diagram Methanol Reactor CO H2H2 MeOH H 2, CO Cooling and Separation MeOH H 2, CO Methanol to Gasoline (MTG) Reactors Water Separation Hydrocarbons Water Hydrocarbons Deethanizer (Dist. Col.) C1/C2 Distillation Columns Heavy Hydrocarbons Liquefied Petroleum Gas Gasoline Purge

Questions from Last Presentation Why are we using the fluidized bed MTG reactor? – Catalyst Regeneration – Economics – Data Why is our methanol reactor at this pressure? – Normal operation How do we startup our facility – Syngas – Methane We are using an inefficient distillation scheme – Varied stages/RR ratio to no avail

Design Basis  6000 Short tons syngas/day  518 °F (270 °C)  725 psi (5 Mpa)  Product  Gasoline – 15,974 barrels/day  LPG – 4,263 barrels/day

Economics Overview  Plant Revenue: $575 Million/year  Profit: $87.2 Million per year  Simple Payback: 4.16 years  Plant Upfront cost: $363 Million  IRR of 25%  Cost of utilities, maintenance, and catalyst: $22.7 Million/yr (reduced by 1/2)

Analysis of NPV% vs. a Range of Gasoline Prices.

Analysis of NPV% vs. a range of LPG%

Analysis of NPV% vs. a Range of Syngas %

Analysis of NPV% vs. Plant Cost %

Detailed MTG Reactor Pricing  Sizing from NREL standards  Original price from NREL  6/10 factor for reactors  CEPCI to update prices  Total reactor cost = 13.8 Million

Plant Layout Considerations: 1. Location:- 1. It must be far from public areas (schools, living communities, etc) 2. Must have access to any transportation (Railroads, roads, sea, etc) 2. Safety & design 1. Employees safety plays an important role in plant design. 2. Also taking into account, for any future expansion & Space for maintenance. 3. Cost: 1. Includes: capital and operating.

Site Plant

Process Building

Methanol Reactor Detailed Sizing Calculation  Heat transfer and kinetics  U = 150 BTU/hr  Q = UA Δ T  GHSV /hr  Volume inside tubes  D = 8.3 ft, H = 33.2 ft

MTG Reactor Sizing 10 Ft/Sec

Questions?