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 26, 2011 1
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▪ H2 to CO molar ratio of 2.5▪ CO2 and N2 mixed in
2
http://coalgasificationnews.com/tag/petcoke-gasification/
4/26/2011
Questions from Last Time How was the PFD generated? What is our feedstock prices?
4/26/2011 3
Recap
PFD’s Control Schemes Plant Layout Calculations Refined Individual Economics Joint Econ Presentation
44/26/2011
Today’s Agenda
4/26/2011 5
Overview of the project from day 1 till the end Brief backgrounds Brief process description▪ Aspen Simulation overview
Economics Overview Recommendations
6
In the Beginning…
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
4/26/2011
7
Major Decisions
Feedstock Choice Petcoke
Gasifier Choice Shell Entrained Flow (Membrane Wall)
Extent of Simulation Solvent
Selexol Syngas Price Location
4/26/2011
8
Petcoke Background
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.4/26/2011
9
Gasification Background
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.
4/26/2011
Shell Entrained Flow Gasifier
10
Process Highlights
Pressure Driven Process Reduction of Pumps
High Conversion of Feedstock Highly Efficient Sulfur Removal
Sulfur removal to 2 ppm
4/26/2011
Overall Block Flow
114/26/2011
12
Overall Aspen Simulation
4/26/2011
Gasifier
H2S Removal
Water Gas Shift
Claus Process
CO2 Capture and Sequestration
13
PFD Example
4/26/2011
14
Control Scheme Example
4/26/2011
15
Economics Overview Total Equipment + Installation
CostProcess Cost in $MMGasification Process 135H2S Removal 14Claus Process 3CO2 Capture 26WGS Reaction 4Total Direct Cost 182
Economic AnalysisCapital Cost $ 321 MMInterest Rate on the Loan 8.00 %
Inflation 3.00 %*Syngas Price ($/ton) $ 457.80 **Sulfur Price ($/ton) $ 70
NPV $1,534 MM IRR 29.79 %Payback Period ~ 5.2 years
4/26/2011
16
Economics Overview
4/26/2011
17
Syngas Pricing
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
4/26/2011
Resources 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
Communication
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 CO2 Capture – Dow Oil & Gas (~4 MMlb/day Selexol)
20
Location and Layout 4923 Port Rd.,
Pasadena, TX
2.5 Miles West of Trinity Bay
Existing Roads and Railroads
140 Acres with Acetic Acid Production (Team Golf)
4/26/2011
21
Advantages
High yield of syngas CO2 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
4/26/2011
22
Disadvantages
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 CO2
4/26/2011
23
Recommendations 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
4/26/2011
Questions?
4/26/2011 24
References
(http://www.netl.doe.gov/technologies/coalpower/gasification/gasifipedia/4-gasifiers/4-1-2-3_shell.html)
4/26/2011 25
Report Outline
Final Report: Executive Summary Done Discussion Done Recommendations Done
Appendices Design Basis: Done Block Flow Diagram: Done Process Flow Showing Major Equip.: Done
264/26/2011
Report Outline
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
274/26/2011
Report Outline
Appendices (Continued) Distribution and End-use Issues:
Done Constraints Review: Done Applicable Standards: Done Project Communications File: Done Information Sources and References:
Done
284/26/2011
Composition of Petcoke(3)
Ultimate Analysis Component Weight
PercentCarbon 83.3Hydrogen 4.00Nitrogen 1.49Sulfur 6.14Oxygen 4.44
Proximate AnalysisComponent Weight
PercentFixed Carbon 84.8Moisture 6.00Volatile Matter 8.60Ash 0.6
Element V Ni F Cu Mg Se Be Pb As Cd Hg
PPM 325-2300
165-580
11 3.5 2.4 <2 1.5 .6 .3 .1 <.01
Average Petcoke Metal Makeup(5)
29
PFD: Gasification
304/26/2011
PFD: Claus Process
4/26/2011 31
PFD: Water Gas Shift
324/26/2011
PFD: CO2 Absorption
334/26/2011
PFD: CO2 Sequestration
344/26/2011
Control Scheme: Water Gas Shift
354/26/2011
36
Control Scheme: CO2 Absorption
4/26/2011
37
Control Scheme: CO2 Sequestration
4/26/2011
38
Control Scheme: Gasifier
4/26/2011
39
Control Scheme: Claus Process
4/26/2011
40
Energy Balance Around WGS Reactor
4/26/2011
Energy BalanceAround WGS ReactorInlet Fraction Clean Syngas Component
Flow for WGS Reactor (lbmoles/hr) for WGS Cp (btu/lbmole* F)
Outlet Syngas Comp (lbmole/hr) from
(WGS)
CO 4946.233 7.118 123.395
H2O 6424.688 15.367 1601.850
N2 199.954 7.158 199.954
H2* 2960.168 6.948 7783.006
CO2 469.211 10.559 5292.049
CH4* 0.255
12.432 0.255
H2S 0.000 0.000 0.000
COS 0.000 0.000 0.000
Total 15000.509 15000.509
414/26/2011
Heat LoadsGasifier 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 57.0Sulfur Stripper Cooler -200.0
Selexol Cooler -40.7 Rich / Lean Heat Exchanger 274.9
4/26/2011 42
43
CO2 Sequestration
CO2 in our syngas is absorbed on Selexol to be selectively removed
Delete only one CO2 slide.
4/26/2011
44http://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpg4/26/2011