1. 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

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

3. Recap H2H2

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 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)1448557181 2647700 CO (kmol/hr)724322464 1045900 Methanol (kmol/hr)0576 723400 Water (kmol/hr)00008163 0 Temperature (F )518331203518212237264 Presssure (psi)725 43572515 725 Enthalpy (Btu/lb)-1194-1275-1372-1672-6316-5695-1830 Recycle Syngas To Comp (2A)

8. 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/hr2647726467 529 CO (Kmol/hr)1045910397 208 MeOH (Kmol/hr)7234267 5 Temperature (F)24886203 Pressure (psi)725435 Enthalpy (BTU/#)-1883-1457-1371

9. 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/hr0026477 10 CO (Kmol/hr)0010459 62 Water (Kmol/hr)00000 MeOH (Kmol/hr)007234 6967 Light Gases (C1-C2) (Kmol/hr) 80 000 LPGS (C3-C4) (Kmol/hr)53 000 Temperature (F)7521224810286 Pressure (psi)368 725 435 Enthalpy (BTU/#)-906-821-1883-2130-3180 Cooler Cold MeOH (13B)

10. 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)69940 0 MeOH (Kmol/hr)069670 Light Gases (C1-C2) (Kmol/hr)980 0 LPGS (C3-C4) (Kmol/hr)3670 0 C5+ Compounds (gasoline) (Kmol/hr) 8320 0 Aromatics (Kmol/hr)2190 0 Temperature (F)716363408590 Pressure (psi)362435362435 Enthalpy (BTU/#)-3169-2714-3635-2477

11. Stream nameCWS (18) Cooled Hydrocarbons (19) Cold Hydrocarbons (20) ‘Dirty’ Water (21)HCs (22)Pump HCs (23) C3 + HCs (24) Water (Kmol/hr)81636994 0.73 Light Gases (C1-C2) (Kmol/hr) 0.01081 1.280 0.001 LPGS (C3-C4) (Kmol/hr) 0200 0199 147 C5+ Compounds (gasoline) (Kmol/hr) 0.010832 0.210832 Temperature (F)772397368 372 Pressure (psi)15362375362 364368 Enthalpy (BTU/#)-6814-3960-5691-6811-715 -512 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)

12. 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)699311700.19 Light Gases (C1-C2) (Kmol/hr)0.0101.19 LPGS (C3-C4) (Kmol/hr)000.25 C5+ Compounds (gasoline) (Kmol/hr) 0.0100.2 Aromatics (Kmol/hr)0.0100.09 Temp (F)12077120 Pressure (psi)15 Enthalpy (BTU/#)-6814-6813-815

13. 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)0.70.10.60.10.2 LPGS (C3-C4) (Kmol/hr)294.32.7293.50.83.5 C5+ Compounds (gasoline) (Kmol/hr) 106.4725.70.1106.3832.0 Aromatics (Kmol/hr)0.4218.30.00.4218.6 Temp (F)19241077390309 Pressure (psi)221 74 Enthalpy (BTU/#)-973-385-154-845-431

14. Overall Process

15. 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

16. 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

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 ft 2

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 DOLLARSDOLLARS

21. Non-Field Cost Distribution DOLLARSDOLLARS

22. Indirect Field Cost Distribution DOLLARSDOLLARS

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 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

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 Miscellaneous Flowsheet Area2NDGASHXDHE FLOAT HEAD331800177300 Miscellaneous Flowsheet AreaCOOLERDHE FLOAT HEAD266200123500 Miscellaneous Flowsheet AreaFLASH-flash vesselDVT CYLINDER401800238100 Miscellaneous Flowsheet AreaGASMEHXDHE FLOAT HEAD514200231800 Miscellaneous Flowsheet AreaGASSPLITC00 Miscellaneous Flowsheet AreaH2OMIXERC00 Miscellaneous Flowsheet AreaHEATERDHE FLOAT HEAD1.54E+061.01E+06 Miscellaneous Flowsheet AreaHEATEXDHE FLOAT HEAD248100113200 Miscellaneous Flowsheet AreaLGMEOHHXDHE FLOAT HEAD6740011300 Miscellaneous Flowsheet AreaMEOHH2OXDHE FLOAT HEAD425900259300 Miscellaneous Flowsheet AreaMEOHRXNDTW PACKED21540075700 Miscellaneous Flowsheet AreaSPLITC00

35. Equipment Costs II S-12NDFLASH-flash vesselDVT CYLINDER16900062500 S-1DEETHAN-bottoms splitC00 S-1DEETHAN-condDHE FIXED T S7940016800 S-1DEETHAN-cond accDHT HORIZ DRUM7890019800 S-1DEETHAN-overhead splitC00 S-1DEETHAN-rebDRB U TUBE225600124500 S-1DEETHAN-reflux pumpDCP CENTRIF331005300 S-1DEETHAN-towerDTW TRAYED838400514000 S-1FINALDIS-bottoms splitC00 S-1FINALDIS-condDHE FIXED T S11110029800 S-1FINALDIS-cond accDHT HORIZ DRUM15090045300 S-1FINALDIS-overhead splitC00 S-1FINALDIS-rebDRB U TUBE17080084800 S-1FINALDIS-reflux pumpDCP CENTRIF5720010500 S-1FINALDIS-towerDTW TRAYED621600341300 S-1GASLMIXC00 S-1GASLMIXEC00 S-1GASPROD1DTW PACKED636200231000 S-1GASPROD2DTW PACKED318100115500 S-1GASPROD3DTW PACKED318100115500 S-1MEOHCOLRDHE FLOAT HEAD863200589000 S-1PENTCOLM-bottoms splitC00 S-1PENTCOLM-condDHE FIXED T S1.42E+06930800 S-1PENTCOLM-cond accDHT HORIZ DRUM10800025500 S-1PENTCOLM-overhead splitC00 S-1PENTCOLM-rebDRB U TUBE10870028200 S-1PENTCOLM-reflux pumpDCP CENTRIF458008100 S-1PENTCOLM-towerDTW TRAYED400200184800 S-1 S-2DECANTERDVT CYLINDER17990071700 S-2HCSPUMPDCP CENTRIF522008800