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/flowsheet  Heat Duties  Sizing  Economics  Summary

Recap H2H2

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

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

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

Methanol Reactor Syngas (1) Hot MeOH Product (3) MeOH REACTOR Cooled MeOH Product (6) MeOH-Water HX Steam (5) Recycle Syngas from Comp (2B) Warm Water(4) Stream Name Syngas (1) Recycled Syngas from Comp(2B) Recycled Syngas to Comp(2A) Hot MeOH Product (3) Warm Water (4) Steam (5) Cooled MeOH Product (6) H2 (kmol/hr) CO (kmol/hr) Methanol (kmol/hr) Water (kmol/hr) Temperature (F ) Presssure (psi) Enthalpy (Btu/lb) Recycle Syngas To Comp (2A)

MeOH Recycle and HX Cooled MeOH Product (6) MeOH- Syngas HX Hot Rec. Syngas (9) Recycle Syngas To Comp (2A) Purge Syngas (10) Cooler MeOH product(7) Cool Rec. Syngas(8) Stream name Cooler Meoh Product (7) Cool Rec.Syngas (8)Hot Rec.Syngas (9)Purge Syngas (10) H2 (Kmol/hr CO (Kmol/hr) MeOH (Kmol/hr) Temperature (F) Pressure (psi) Enthalpy (BTU/#)

To MTG Reactor Cooler MeOH Product (7) Light Gas— MeOH HX Cold Light Gas (11) Cooled MeOH (13A) Flash Cool Rec. Syngas (8) Product- MeOH HX Hot HCs(15) Cool HCs (17 A) Warm MeOH (16) Light Gas Out (12) (14) MeOH to MTG Stream name Cold Light Gas (11) Light Gas Out (12) Cooled MeOH (13A) Cold MeOH (13B)MeOH to MTG (14) H2 (Kmol/hr CO (Kmol/hr) Water (Kmol/hr)00000 MeOH (Kmol/hr) Light Gases (C1-C2) (Kmol/hr) LPGS (C3-C4) (Kmol/hr) Temperature (F) Pressure (psi) Enthalpy (BTU/#) Cooler Cold MeOH (13B)

MTG Reactors Hot HCS(15) Warm MeOH (16) Heater Hot MeOH (17 B ) MTG Reactors Stream nameHot HCs (15) Warm MeOH (16) Cool HCs (17 A )Hot MeOH ( 17 B) H2 (Kmol/hr0100 CO (Kmol/hr)0620 Water (Kmol/hr) MeOH (Kmol/hr) Light Gases (C1-C2) (Kmol/hr)980 0 LPGS (C3-C4) (Kmol/hr) C5+ Compounds (gasoline) (Kmol/hr) Aromatics (Kmol/hr) Temperature (F) Pressure (psi) Enthalpy (BTU/#)

Stream nameCWS (18) Cooled Hydrocarbons (19) Cold Hydrocarbons (20) ‘Dirty’ Water (21)HCs (22)Pump HCs (23) C3 + HCs (24) Water (Kmol/hr) Light Gases (C1-C2) (Kmol/hr) LPGS (C3-C4) (Kmol/hr) C5+ Compounds (gasoline) (Kmol/hr) Temperature (F) Pressure (psi) Enthalpy (BTU/#) Product Refining 2 nd Gas HX Cool HCs (17A) Cooled HCs (19) Cooler Cold HCs (20) Decanter HCs(22) ‘Dirty’ Water (21) CWS (18) Warm Water (4) Cold Light Gas (11) C3+ HCS (24) Deethanizer Pump Pump HCs(23)

Water ‘Dirty’ Water (21) Water Flash ‘Clean’ Water (25 A) CWS (18) Extra Cooling H2O (25 B) Offgas (26) Stream name‘Clean’ Water (25 A)Extra Cooling H2O (25 B)Offgas (26) Water (Kmol/hr) Light Gases (C1-C2) (Kmol/hr) LPGS (C3-C4) (Kmol/hr) C5+ Compounds (gasoline) (Kmol/hr) Aromatics (Kmol/hr) Temp (F) Pressure (psi)15 Enthalpy (BTU/#)

Product Refining II C3+ HCs(24) Gasoline (29) LPG + Pentanes (28) Pentanes (31) LPG (30) Gasoline Product (32) Hydrocarbon Separator Debutanizer Stream name LPG+ Pentanes Gasoline (29)LPG (30)Pentanes (31)Final Product Water (Kmol/hr) LPGS (C3-C4) (Kmol/hr) C5+ Compounds (gasoline) (Kmol/hr) Aromatics (Kmol/hr) Temp (F) Pressure (psi) Enthalpy (BTU/#)

Overall Process

Heat Duties Heat Exchanger Duties, total662MMbtu/hr Reactor heat duties, total-589MMbtu/hr Heater/Reboiler heat duties, total-193MMbtu/hr Cooler/Condenser heat duties, total125MMbtu/hr  Heaters/coolers, HX, reactors, dist. col.  The rest are adiabatic  Light gas burning not included

Detailed Heat Duties Unit Heat Duty (MMbtu/hr) MeOH reactor-475 MeOH and water HX201 MeOH and recycle gas HX67 MeOH and Light Gas HX1 Methanol Flash Block0 Methanol and Gasoline HX231 Last Methanol Heater118 MTG Reactors-29 Gasoline and Water HX162 Gasoline Cooler-84 Decanter0 Deethanizer Condenser-4 Deethanizer Reboiler44 Distillation Column 2 (Gasoline) Condenser-20 Distillation Column 2 (Gasoline) Reboiler17 Pentane Distillation Column Condenser-16 Pentane Distillation Column Reboiler14

Sizing  Reactor sizing done by hand  Used LHSV/GHSV data  Other sizing done in ASPEN  Distillation Columns  trays  6.5 – 8.5 ft Diameter  64 – 92 ft High  Heat Exchangers  1,000 – 10,000 ft 2

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

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

Field Cost Distribution DOLLARSDOLLARS

Non-Field Cost Distribution DOLLARSDOLLARS

Indirect Field Cost Distribution DOLLARSDOLLARS

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  Klb/hr  14.8 Million Dollars/year  Steam generation  Steam costs not included in upkeep

Catalyst Pricing  

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)

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

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

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

Questions?

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

Methanol to Gasoline Reactors Sizing Calculations  Size of Reactors

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 2 nd Distillation Column Heavy Hydrocarbons Liquefied Petroleum Gas Gasoline Purge

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

Equipment Costs I Miscellaneous Flowsheet Area2NDGASHXDHE FLOAT HEAD Miscellaneous Flowsheet AreaCOOLERDHE FLOAT HEAD Miscellaneous Flowsheet AreaFLASH-flash vesselDVT CYLINDER Miscellaneous Flowsheet AreaGASMEHXDHE FLOAT HEAD Miscellaneous Flowsheet AreaGASSPLITC00 Miscellaneous Flowsheet AreaH2OMIXERC00 Miscellaneous Flowsheet AreaHEATERDHE FLOAT HEAD1.54E E+06 Miscellaneous Flowsheet AreaHEATEXDHE FLOAT HEAD Miscellaneous Flowsheet AreaLGMEOHHXDHE FLOAT HEAD Miscellaneous Flowsheet AreaMEOHH2OXDHE FLOAT HEAD Miscellaneous Flowsheet AreaMEOHRXNDTW PACKED Miscellaneous Flowsheet AreaSPLITC00

Equipment Costs II S-12NDFLASH-flash vesselDVT CYLINDER S-1DEETHAN-bottoms splitC00 S-1DEETHAN-condDHE FIXED T S S-1DEETHAN-cond accDHT HORIZ DRUM S-1DEETHAN-overhead splitC00 S-1DEETHAN-rebDRB U TUBE S-1DEETHAN-reflux pumpDCP CENTRIF S-1DEETHAN-towerDTW TRAYED S-1FINALDIS-bottoms splitC00 S-1FINALDIS-condDHE FIXED T S S-1FINALDIS-cond accDHT HORIZ DRUM S-1FINALDIS-overhead splitC00 S-1FINALDIS-rebDRB U TUBE S-1FINALDIS-reflux pumpDCP CENTRIF S-1FINALDIS-towerDTW TRAYED S-1GASLMIXC00 S-1GASLMIXEC00 S-1GASPROD1DTW PACKED S-1GASPROD2DTW PACKED S-1GASPROD3DTW PACKED S-1MEOHCOLRDHE FLOAT HEAD S-1PENTCOLM-bottoms splitC00 S-1PENTCOLM-condDHE FIXED T S1.42E S-1PENTCOLM-cond accDHT HORIZ DRUM S-1PENTCOLM-overhead splitC00 S-1PENTCOLM-rebDRB U TUBE S-1PENTCOLM-reflux pumpDCP CENTRIF S-1PENTCOLM-towerDTW TRAYED S-1 S-2DECANTERDVT CYLINDER S-2HCSPUMPDCP CENTRIF