Production of Gasoline Components from Synthesis GasChE 397 Senior DesignGroup Alpha

Ayesha RizviBernard HsuJeff TyskaMohammad ShehadehYacoub Awwad

2011.04.05

Presentation Overview Recap PFD Initial Control Scheme Refined Economics Plant Layout Calculations

RecapH2

Block Flow DiagramMethanolReactor

CO

H2

MeOHH2, CO

Cooling and Separation

MeOH

H2, CO

Methanol to Gasoline (MTG) Reactors

Water Separation

Hydrocarbons

Water

Water

Hydrocarbons

Deethanizer(Dist. Col.)

C1/C2

DistillationColumns

HeavyHydrocarbons

Liquefied Petroleum Gas

Gasoline

Purge

Questions from Last Presentation• Why are we using the fluidized bed MTG reactor?

– Catalyst Regeneration– Economics– Data

• Why is our methanol reactor at this pressure?– Normal operation

• How do we startup our facility– Syngas– Methane

• We are using an inefficient distillation scheme– Varied stages/RR ratio to no avail

Design Basis 6000 Short tons syngas/day 518 °F (270 °C) 725 psi (5 Mpa) Product

Gasoline – 15,974 barrels/day LPG – 4,263 barrels/day

Economics Overview Plant Revenue: $575 Million/year Profit: $87.2 Million per year Simple Payback: 4.16 years Plant Upfront cost: $363 Million IRR of 25% Cost of utilities, maintenance, and catalyst:

$22.7 Million/yr (reduced by 1/2)

Analysis of NPV% vs. a Range of Gasoline Prices.

0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.25 4.50 4.75 5.00

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NPV%

NPV%

$ Gasoline per gallon

NPV

%

Analysis of NPV% vs. a range of LPG%

25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 4750

50

100

150

200

250

300

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450

500

NPV%

NPV

LPG %

NPV

%

Analysis of NPV% vs. a Range of Syngas %

13 35 57 78 100 122 143 165 187 209

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1000

NPV%

NPV

Syngas%

NPV

%

Analysis of NPV% vs. Plant Cost %

25 50 75 100 125 150 175 200 225 250 275 300-20

0

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NPV Percentage Vs Plant Cost %

npv

Percent of Plant Cost

NPV

%

Detailed MTG Reactor Pricing Sizing from NREL standards Original price from NREL 6/10 factor for reactors CEPCI to update prices Total reactor cost = 13.8 Million

Plant LayoutConsiderations:

1. Location:- 1. It must be far from public areas (schools, living

communities, etc)2. Must have access to any transportation (Railroads,

roads, sea, etc)2. Safety & design

1. Employees safety plays an important role in plant design.

2. Also taking into account, for any future expansion & Space for maintenance.

3. Cost:1. Includes: capital and operating.

Site Plant

Process Building

Methanol Reactor Detailed Sizing Calculation Heat transfer and kinetics U = 150 BTU/hr Q = UAΔ T GHSV 8000 1/hr Volume inside tubes D = 8.3 ft, H = 33.2 ft

MTG Reactor Sizing Diameter: 2.68 ft Flow rate: 95,400 Velocity: 3.04

Height: 77.89 ft

Volume of the reactors is now the volume of the catalyst.

Mass: 40,761 lb Density: 9310

Ft/Sec

Questions?