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 March 8, 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 ▪ CO to H2 molar ratio of 0.409 ▪ CO2 and N2 mixed in 2 http://coalgasificationnews.com/tag/petcoke- gasification/ 3/8/2011

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4.  Discussed the Shell ™ membrane gasifier  Discussed our syngas processes  Sulfur Removal  Claus Process  Water Gas Shift  Flow Sheets  Early Material and Energy Balances 4 3/8/2011

5.  What was the heat rate brought up in the gasifier comparisons?  Why use N 2 as a transport gas and not CO 2 ?  How are we absorbing CO 2 ?  What is a better definition of the quench? 5 3/8/2011

6.  Recent changes  Using Selexol instead of MDEA  Using the Superclaus  Aspen Simulation  Heat Load Identification  Economics  Aspen Price Evaluator (ICARUS)  Equipment Sizing  Energy Balance  Location Update 6 3/8/2011

7. 7 Gasification Sulfur Removal Claus Process Water Gas Shift CO2 Removal

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9. 9 To WGS

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13. 13 Claus Process EquipmentHeat 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 19.72 Re-heater 25.29 Re-heater 33.46 Catalytic Reactor 13.03 Catalytic Reactor 21.72 Catalytic Reactor 3-5.73 3/8/2011

14.  Stream Pre-heating  Lower Heater / Cooler Duties  Heat Duty and Heat Ex. Cost Tradeoff 14 Furnace Cooler HX Acid Gas Cold Acid Gas Hot To Claus Catalysts Hot Furnace Gas Cold Furnace Gas 3/8/2011

15. Gasification Process $240,000,000 Solid Removal Claus Process CO2 Absorption Water-gas Shift Final syngas product 15 3/8/2011

16. SIZEINDIRECT COST DIRECT COST Air Separation Unit N/A $100,000,000 Petroleum Coke Crusher $ 5,401,890 $ 7,022,455 Gasifier (x2) N/A $ 132,000,000 Heat Exchanger (x2) $611,480 $ 1,284,120 16 3/8/2011

17. Solid Removal $670,000 CO2 Absorption Water-gas Shift Final syngas product Sulfur Removal Gasification Process $240,000,000 17 3/8/2011

18. SIZEINDIRECT COST DIRECT COST Filter 16 sq ft $ 364,770 $ 510,680 Cyclone (x3) (Removes Fly Ash) 5 ft dia.$ 307,800$ 477,000 18 3/8/2011

19. Sulfur Removal $9,300,000 Water-Gas Shift CO2 Absorption Final syngas product Solid Removal $670,000 Gasification Process $240,000,000 19 3/8/2011

20. SIZE EQUIP COSTTOTAL 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 Heat Exchanger1200 sq ft $ 121,980 $ 256,155 Reactor (x3) TBD $ (103,115)* $ (164,985)* Cooler 1 6739 sq ft$ 168,800 $ 320,600 Cooler 2 440 sq ft$ 16,700 $ 79,200 Cooler 3 258 sq ft$ 13,600 $ 73,600 Cooler 4 163 sq ft$ 11,800 $ 69,800 20 3/8/2011

21. WGS Reactor CO2 Absorption Final syngas product Sulfur Removal $9,300,000 $56,000,000 144 ft3 $360,000 Gasification Process $240,000,000 Solid Removal $670,000 21 3/8/2011

22. EquipmentSizeEquip CostDirect Cost CO2 Absorber (x2) 12.7 x 60 ftN/A $ 3,000,000 CO2 Stripper (x2) 17 x 30 ft $ 203,170 $ 256,800 Compressor $ 272,889$ 409,333 22 3/8/2011

23. CO2 Absorption $56,000,000 Final syngas product Solid Removal $670,000 Gasification Process $240,000,000 Sulfur Removal $9,300,000 WGS Reactor $360,000 $306,430,000 23 3/8/2011

24. 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 Capital Cost as of now= $ 306,430,000 Labor Cost as of now = $ 18,000,000 243/8/2011

25. Type Cost of year 1 ($ Million/year) Cost at the end of 25 th year Assumptions Loan $20.5$ 1.5Based on 6% interest Cooling water $1.9$ 6.0Based on 5% inflation rate Electrical $1.8$ 5.8Estimated from a plant’s electrical cost Salaries and Fringes $ 24$ 77 Average of 35 people/shift Maintenance $17$ 555 % of the capital cost Royalties $ 5$15.85% of production revenue Insurance $3.4$ 111% of the capital cost Raw materials $ 34$107.6 Depreciation $14 Capital cost/25 years Total $121.6$293. 1 25 Capital Cost as of now = $ 306,430,000 Estimated Revenue as of now = $ 94,000,000

26. Product and Side Products Unit Price (per ton) Revenue (per year) Syngas $150.00$ 86.60 million CO2 $40.00$ 7.00 million Sulfur $10.00$ 0.30 million ~ $ 94 million 26 3/8/2011

27.  Victoria, Texas  Between Houston and Corpus Christi  200 acres  Kansas City Southern, Union Pacific, and Burlington Northern Santa Fe railways  Gulf Intracoastal Waterway 27 3/8/2011

28.  Overall ASPEN procedure  Gasification  Rough Economics  Cost estimate:  Profit estimate:  Location: Victoria, Texas 3/8/201128

29.  Final process flow diagram  Control scheme  Optimize economy scale  Revise capital costs  Major equipments list and plant layout  Revise report 3/8/201129

30.  http://fossil.energy.gov/images/programs/seq uestration/what_sequestration_lg.jpg http://fossil.energy.gov/images/programs/seq uestration/what_sequestration_lg.jpg  http://coalgasificationnews.com/tag/petcoke- gasification/ http://coalgasificationnews.com/tag/petcoke- gasification/  http://www.huffingtonpost.com/dr-orin- levine/questions-as-mileposts- of_b_448870.html http://www.huffingtonpost.com/dr-orin- levine/questions-as-mileposts- of_b_448870.html 30 3/8/2011

31.  Final Report:  Executive SummaryIP  DiscussionIP  Recommendations IP  Appendices  Design Basis: Done  Block Flow Diagram: Done  Process Flow Showing Major Equip.: IP 31 3/8/2011

32.  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 32 3/8/2011

33.  Appendices (Continued)  Distribution and End-use Issues:IP  Constraints Review: IP  Applicable Standards: IP  Project Communications File: IP  Information Sources and References:IP 33 3/8/2011

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36. 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 36 3/8/2011

37. 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 3/8/2011 37

38.  CO2 in our syngas is absorbed on Selexol to be selectively removed  Delete only one CO2 slide. 383/8/2011

39. 39 http://fossil.energy.gov/images/programs/sequestration/what_sequestration _lg.jpg 3/8/2011