1. 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 26, 2011 1

2.  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 ▪ H2 to CO molar ratio of 2.5 ▪ CO2 and N2 mixed in 2 http://coalgasificationnews.com/tag/petcoke- gasification/ 4/26/2011

3.  How was the PFD generated?  What is our feedstock prices? 4/26/2011 3

4.  PFD’s  Control Schemes  Plant Layout  Calculations  Refined Individual Economics  Joint Econ Presentation 4 4/26/2011

5. 5  Overview of the project from day 1 till the end  Brief backgrounds  Brief process description ▪ Aspen Simulation overview  Economics Overview  Recommendations

6.  Mission Statement:  Design a process to produce syngas ▪ Determine if this is a practical process  Meet the requirements of Team Golf  Decide profitability  Decide practicality 4/26/20116

7.  Feedstock Choice  Petcoke  Gasifier Choice  Shell Entrained Flow (Membrane Wall)  Extent of Simulation  Solvent  Selexol  Syngas Price  Location 4/26/20117

8.  Petcoke is a byproduct of oil-refining  Heating value of 28 MMBtu/ton  More than 55 million tons in 2005 were produced in U.S. oil refineries  The sulfur content is relatively high and must be removed during processing in order to create a usable synthesis gas for the chemical production team as well as to meet the requirements of the EPA. 4/26/20118

9.  Gasification covers the conversion of any carbonaceous fuel to a gaseous product.  This is not a complete combustion process since there is no residual heating value. 4/26/20119 Shell Entrained Flow Gasifier

10.  Pressure Driven Process  Reduction of Pumps  High Conversion of Feedstock  Highly Efficient Sulfur Removal  Sulfur removal to 2 ppm 4/26/201110

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12. 12 Gasifier H2S Removal Water Gas Shift Claus Process CO2 Capture and Sequestration

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15. Total Equipment + Installation Cost ProcessCost in $MM Gasification Process 135 H 2 S Removal14 Claus Process3 CO 2 Capture26 WGS Reaction4 Total Direct Cost 182 Economic Analysis Capital Cost$ 321 MM Interest Rate on the Loan 8.00 % Inflation3.00 % *Syngas Price ($/ton) $ 457.80 **Sulfur Price ($/ton) $ 70 NPV$1,534 MM IRR29.79 % Payback Period~ 5.2 years 4/26/201115

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17.  First prices were generated by comparing heating values with natural gas  This proved to be too low of a price  Negotiations with Team Golf  Joint Presentation afterwards ▪ Price determined by creating an equal IRR 4/26/201117

18.  Equipment Sizing and Cost – Aspen  Amount of Required Catalyst and Solvent - Aspen & Hand Calculations  Economics - Used sheet provided by Mr. Jerry Palmer as a basic template & Microsoft Excel to calculate NPV and IRR  PFD, BFD, and Control Scheme – Aspen, Visio, Microsoft Excel

19.  Price for Selexol – UOP ($3.20/lb)  Price for Zinc-Oxide – UOP ($55/lb)  Price for Petcoke – Dover ($75/ton)  Amount of Selexol & Equipment Required for CO 2 Capture – Dow Oil & Gas (~4 MMlb/day Selexol)

20.  4923 Port Rd., Pasadena, TX  2.5 Miles West of Trinity Bay  Existing Roads and Railroads  140 Acres with Acetic Acid Production (Team Golf) 4/26/201120

21.  High yield of syngas  CO 2 capture makes the process environmental friendly  Advantage of location:  Supply and ease of transportation of feedstock and product  Feedstock Advantage:  Byproduct of oil refining  It has high calorific content 4/26/201121

22.  Petroleum coke is high in Sulfur content  Expensive Gasifier  Cost of Petroleum coke fluctuates with crude oil prices  Water-Gas shift reaction yields higher amount of CO 2 4/26/201122

23.  Combining the facilities early on  There is no such thing as a stand alone gasifier plant  Finishing up some of the loose ends of the project  Chemical Disposal ▪ Sulfur ▪ Zinc Oxide  Tail Gas  Slag ▪ Heavy Metals  Complete Heat Integration 4/26/201123

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25.  (http://www.netl.doe.gov/technologies/coalp ower/gasification/gasifipedia/4-gasifiers/4-1- 2-3_shell.html)http://www.netl.doe.gov/technologies/coalp ower/gasification/gasifipedia/4-gasifiers/4-1- 2-3_shell.html 4/26/2011 25

26.  Final Report:  Executive SummaryDone  DiscussionDone  Recommendations Done  Appendices  Design Basis: Done  Block Flow Diagram: Done  Process Flow Showing Major Equip.: Done 26 4/26/2011

27.  Appendices (Continued)  Material and Energy Balances:Done  Calculations: Done  Annotated Equip. List: Done  Econ. Eval. Factored from Equip. Costs: Done  Utilities: Done  Conceptual Control Scheme: Done  Major Equipment Layout: Done 27 4/26/2011

28.  Appendices (Continued)  Distribution and End-use Issues:Done  Constraints Review: Done  Applicable Standards: Done  Project Communications File: Done  Information Sources and References:Done 28 4/26/2011

29. Ultimate Analysis ComponentWeight Percent Carbon83.3 Hydrogen4.00 Nitrogen1.49 Sulfur6.14 Oxygen4.44 Proximate Analysis ComponentWeight Percent Fixed Carbon84.8 Moisture6.00 Volatile Matter8.60 Ash0.6 Element VNiFCuMgSeBePbAsCdHg PPM325- 2300 165- 580 113.52.4<21.5.6.3.1<.01 Average Petcoke Metal Makeup (5) 29

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41. Inlet Fraction Clean Syngas Component Flow for WGS Reactor(lbmoles/hr) for WGSCp (btu/lbmole* F) Outlet Syngas Comp (lbmole/hr) from (WGS) CO4946.2337.118123.395 H2O6424.68815.3671601.850 N2199.9547.158199.954 H2*2960.1686.9487783.006 CO2469.21110.5595292.049 CH4*0.255 12.4320.255 H2S0.000 COS0.000 Total15000.509 41 4/26/2011

42. Gasifier EquipmentHeat Load (MMBtu/hr) Gasifier-34.7 HP Steam Heat Exchanger139.0 MP Steam Heat Exchanger281 Cooler-106.8 Flash2.99 Sulfur Clean Up EquipmentHeat Load (MMBtu/hr) Sulfur Stripper Reboiler57.0 Sulfur Stripper Cooler-200.0 Selexol Cooler-40.7 Rich / Lean Heat Exchanger274.9 4/26/2011 42

43.  CO2 in our syngas is absorbed on Selexol to be selectively removed  Delete only one CO2 slide. 434/26/2011

44. 44 http://fossil.energy.gov/images/programs/sequestration/what_sequestration _lg.jpg 4/26/2011