Syngas Production from Petroleum Coke Gasification 3/8/2011 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 April 5, 2011 4/5/2011

Project Purpose What we are doing? Why we are doing this? 3/8/2011 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 What we are doing, and why we are doing it 2730 tons/day of syngas Desired CO to H2 ratio – 1:2.4 molar ratio Desired C to H ratio – 1:4.4 molar ratio Desired Temperature and Pressure 400°F 290 psia http://coalgasificationnews.com/tag/petcoke-gasification/ 4/5/2011

Overall Block Flow 4/5/2011

Recap Discussed our Aspen PDF Heat Loads Equipment Costs and Sizes Gasifier Sulfur Removal Water Gas Shift CO2 Removal Claus Process Heat Loads Optimization Equipment Costs and Sizes Individual Economics Sensitivity Analysis Location 4/5/2011

Agenda PFD Initial Control Scheme Plant Layout (General Arrangement) Calculations Refined Economics Report Poster Preview???? 4/5/2011

Flow Sheeting: Overall Process 3/8/2011 Flow Sheeting: Overall Process Gasification Sulfur Removal Claus Process Water Gas Shift CO2 Removal 4/5/2011

Flow Sheeting: Gasification To Sulfur Removal 4/5/2011

Flow Sheeting: Sulfur Removal To Claus To WGS 4/5/2011

Flow Sheeting: WGS & CO2 To Chem Production Capture Ready CO2 4/5/2011

Flow Sheeting: Claus Process To Superclaus 4/5/2011

Flow Sheeting: Claus Cont. 4/5/2011

Heat Loads for Claus Plant 3/8/2011 Heat Loads for Claus Plant Claus Process Equipment Heat Load (MMBtu/hr) Claus Furnace -3.26 Condenser 1 -31.3 Condenser 2 -11.2 Condenser 3 -5.97 Condenser 4 -3.92 Re-heater 1 9.72 Re-heater 2 5.29 Re-heater 3 3.46 Catalytic Reactor 1 3.03 Catalytic Reactor 2 1.72 Catalytic Reactor 3 -5.73 4/5/2011

Heat Sink Optimization 3/8/2011 Heat Sink Optimization Cold Furnace Gas Acid Gas Cold Acid Gas Hot Cooler HX Furnace To Claus Catalysts Hot Furnace Gas Stream Pre-heating Lower Heater / Cooler Duties Heat Duty and Heat Ex. Cost Tradeoff 4/5/2011

Economics and Size Solid Removal Gasification Price $240,306,575 Sulfur Removal Economics and Size Claus Process Final syngas product CO2 Absorption WGS Reactor 4/5/2011

Gasification SIZE INDIRECT COST DIRECT COST Air Separation Unit Facility N/A $100,000,000 Petroleum Coke Crusher TBD $ 5,401,890 $ 7,022,455 Gasifier (x2) 2000 TPD $ 132,000,000 Heat Exchanger (x2) 3350 sq ft $611,480 $ 1,284,120 4/5/2011

Equipment Cost and Size Cont. Gasification Price $240,306,575 Solid Removal $670,000 Sulfur Removal Equipment Cost and Size Cont. Claus Process CO2 Absorption WGS Reactor Final syngas product 4/5/2011

Solid Removal Size INDIRECT COST DIRECT COST Filter 16 sq ft $ 364,770 $ 364,770 $ 510,680 Cyclone (x3) 5 ft (diameter) $ 307,800 $ 477,000 4/5/2011

Equipment Cost and Size Cont. Gasification Price $240,306,575 Solid Removal $670,000 Sulfur Removal $9,600,000 Equipment Cost and Size Cont. Claus Process CO2 Absorption WGS Reactor Final syngas product 4/5/2011

Sulfur Removal SIZE Absorber (x2) 12.7 x 60 ft $ 2,400,000 $ 4,800,000 3/8/2011 Sulfur Removal SIZE EQUIP COST TOTAL COST Absorber (x2) 12.7 x 60 ft $ 2,400,000 $ 4,800,000 Stripper (x2) 17 x 30 ft $ 1,560,000 $ 3,300,000 Flash Vessels (x2) 383 cu. ft $ 707,215 $ 808,110 6980 cu ft Heat Exchanger 1200 sq ft $ 121,980 $ 256,155 Reactor (x3) TBD $ (103,115)* $ (164,985)* Cooler 6739 sq ft $ 185,500 $ 400,000 440 sq ft Split to claus and sulfur removal 4/5/2011

Equipment Cost and Size Cont. Gasification Price $240,306,575 Solid Removal $670,000 Sulfur Removal $9,600,000 Equipment Cost and Size Cont. Claus Process $12,500,000 CO2 Absorption WGS Reactor Final syngas product 4/5/2011

Equipment Used in Claus Process Size Equip Cost Total Cost Heat Exchanger 298 sq ft TBD Claus Furnace N/A Cooler (x3) 439 sq ft $ 148,300.00 $ 222,600.00 257 sq ft 162 sq ft Flash (x3) 680 cu ft $ 263,033.00 $ 358,000.00 461 cu ft Heater (x2) 1574 sq ft 996 sq ft 4/5/2011

Equipment Cost and Size Cont. Gasification Price $240,306,575 Solid Removal $670,000 Sulfur Removal $9,600,000 Equipment Cost and Size Cont. Claus Process $12,500,000 CO2 Absorption $35,700,000 WGS Reactor Final syngas product 144 ft3 $360,000 4/5/2011

CO2 Absorption CO2 Absorber (x2) CO2 Stripper (x2) Compressor Equipment Size Equip Cost Direct Cost CO2 Absorber (x2) 12.7 x 60 ft N/A $ 3,000,000 CO2 Stripper (x2) 17 x 30 ft $ 203,170 $ 256,800 Compressor $ 272,889 $ 409,333 4/5/2011

Overall Summary of Capital Cost Solid Removal Gasification Price $240,306,575 Solid Removal $670,000 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 4/5/2011

Capital Cost as of now= $ 300,000,000 Other Fixed Cost Capital Cost as of now= $ 300,000,000 Labor Cost as of now = $ 24,000,000 Other Fixed Cost License Fees and Royalties 2% of Capital Cost Maintenance 5% of Capital Cost Laboratory Cost 30% Labor Cost Insurance 1% Capital Cost 4/5/2011

Cost at the end of 25th year Overall Expenses Capital Cost as of now = $ 300,000,000 Type Cost of year 1 ($ Million/year) Cost at the end of 25th year Loan $18 $ 1 Cooling water $2 $ 6 Electrical Salaries and Fringes $ 24 $ 77 Maintenance $15 $ 48 Royalties $19 Insurance $3 $ 10 Raw materials $ 54 $175 Depreciation $12 Total $136 $355 4/5/2011

Product and Side Products Expected Revenue Product and Side Products Unit Price (per ton) Revenue (In MM $ / year) Syngas $200.00 $ 115.50 CO2 $40.00 $ 7.00 Sulfur $100.00 $ 3.50 Total $ 126.00 4/5/2011

Economic Analysis ($ million/year) Total Capital Cost $300 Total Expense $136 Total Revenue $126 Income Before the Taxes -$10 40 % Tax on the Income -$4 Income After the Taxes -$6 Add Back Depreciation $12 Cash Flow $6 Net Present Value $-52 Internal Rate of Return 3.58% < 5% Payback Period 19 years 4/5/2011

Sensitivity Analysis 4/5/2011

Sensitivity Analysis 4/5/2011

Sensitivity Analysis 4/5/2011

Sensitivity Analysis 4/5/2011

Location Victoria, Texas Between Houston and Corpus Christi 200 acres Kansas City Southern, Union Pacific, and Burlington Northern Santa Fe railways Gulf Intracoastal Waterway 4/5/2011

Possible Alternatives Alberta, Canada Sits on excess petroleum coke from refineries Is it Economically viable? Demand Transportation costs 4/5/2011

Conclusion Overall ASPEN procedure Rough Economics Gasification Syngas Clean Up CO2 Removal Rough Economics Location: Victoria, Texas Possible Change 4/5/2011

Next Steps Final process flow diagram Control scheme Optimize economy scale Revise capital costs Major equipments list and plant layout Revise report 4/5/2011

Questions? 4/5/2011

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/ 4/5/2011

Report Outline Final Report: Appendices Executive Summary IP Discussion IP Recommendations IP Appendices Design Basis: Done Block Flow Diagram: Done Process Flow Showing Major Equip.: IP 4/5/2011

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 4/5/2011

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 4/5/2011

Energy Balance Around WGS Reactor 4/5/2011

Energy Balance Around WGS Reactor Inlet Fraction Clean Syngas Component Flow for WGS Reactor (lbmoles/hr) for WGS Cp (btu/lbmole* F) Outlet Syngas Comp (lbmole/hr) from (WGS) CO 4946.233 7.118 123.395 H2O 6424.688 15.367 1601.850 N2 199.954 7.158 H2* 2960.168 6.948 7783.006 CO2 469.211 10.559 5292.049 CH4* 0.255 12.432 H2S 0.000 COS Total 15000.509 4/5/2011

Sulfur Clean Up Equipment Heat Loads Gasifier Equipment Heat Load (MMBtu/hr) Gasifier -34.7 HP Steam Heat Exchanger 139.0 MP Steam Heat Exchanger 281 Cooler -106.8 Flash 2.99 Sulfur Clean Up Equipment Heat Load (MMBtu/hr) Sulfur Stripper Reboiler 57.0 Sulfur Stripper Cooler -200.0 Selexol Cooler -40.7 Rich / Lean Heat Exchanger 274.9 4/5/2011

3/8/2011 CO2 Sequestration CO2 in our syngas is absorbed on Selexol to be selectively removed Delete only one CO2 slide. One slide; Have what we are doing with CO2, What we are not doing (Shooting it into to the atm), We are planning to transport the CO2 to the crude oil company, but we are still working on finding a better company. (Lipi) 4/5/2011

http://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpg 4/5/2011