1. 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

2. 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
4/5/2011

3. Overall Block Flow
4/5/2011

4. 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

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

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

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

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

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

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

11. Flow Sheeting: Claus Cont.
4/5/2011

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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
$ ,560,000
$ 3,300,000
Flash Vessels (x2)
383 cu. ft
$ ,215
$ ,110
6980 cu ft
Heat Exchanger
1200 sq ft
$ ,980
$ ,155
Reactor (x3)
TBD
$ (103,115)*
$ (164,985)*
Cooler
6739 sq ft
$ ,500
$ 400,000
440 sq ft
Split to claus and sulfur removal
4/5/2011

20. 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

21. 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
$ ,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

22. 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

23. 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
$ ,170
$ ,800
Compressor
$ ,889
$ ,333
4/5/2011

24. 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

25. 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

26. 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

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

28. 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

29. Sensitivity Analysis
4/5/2011

30. Sensitivity Analysis
4/5/2011

31. Sensitivity Analysis
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32. Sensitivity Analysis
4/5/2011

33. 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

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

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

36. 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

37. Questions?
4/5/2011

38. References
4/5/2011

39. 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

40. 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

41. 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

42. Energy Balance Around WGS Reactor
4/5/2011

43. 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
7.118
H2O
15.367 N2
7.158
H2*
6.948
CO2
10.559
CH4*
0.255
12.432
H2S
0.000
COS
Total
4/5/2011

44. 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

45. 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

46.
4/5/2011