Syngas Production from Petroleum Coke Gasification

Team Hotel:Russel 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 13/8/2011

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

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http://coalgasificationnews.com/tag/petcoke-gasification/

3/8/2011

Review from Presentation 2

Discussed the Shell™ membrane gasifier

Discussed our syngas cleaning processes Sulfur Removal Claus Process Water Gas Shift

Flow Sheets Early Material and Energy Balances

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Questions Brought Up Last Time

What was the heat rate brought up in the gasifier comparisons?

Why use N2 as a transport gas and not CO2?

How are we absorbing CO2? What is a better definition of the

quench?

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Agenda

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

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Flow Sheeting

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Flow Sheeting

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Flow Sheeting

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Flow Sheeting

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Flow Sheeting

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Flow Sheeting

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Heat Load Identification

Sulfur Cleanup Table showing stripper, flash , cooler &

heat load Claus Process

Table showing furnace, flash, cat. reactor, cooler & heat load

Gasifier Section Table showing gasifier and syngas

cooling

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Heat Sink Optimization

Stream Pre-heating Lower Heater / Cooler Duties Higher Duty vs. Heat Ex. Cost

Furnace Cooler

HX

Acid Gas Cold

Acid Gas Hot

To Claus Catalyst

s Hot Furnace

Gas

Cold Furnace

Gas

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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.o

Sulfur Stripper Cooler -200.0

Selexol Cooler -40.7

Rich / Lean Heat Exchanger 274.9 3/8/2011

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Heat Loads (Heat Duties)

Claus Process Equipment Heat Load (MMBtu/hr)

Claus Furnace -3.26

Condenser (Modeled Cooler and Flash) 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 3/8/2011

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Energy Balance

Energy Balance

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Gasification Process

Solid Removal

Claus Process

CO2 Absorption

Water-gas Shift

Final syngasproduct

Gasification

SIZE INDIRECT COST

DIRECT COST

Air SeparationUnit

N/A N/A $100,000,000

Petroleum Coke Crusher $ 5,401,890.00

$ 7,022,455.00

Gasifier N/AN/A

$66,000,000

Heat Exchanger $305,741.91

$ 642,058.00

Total

Gasification Process

Solid Removal

Claus Process

CO2 Absorption

Water-gas Shift

Final syngasproduct

Solids Removal

SIZE EQUIP COST TOTAL COST

Candle Filter $ 364,770.77 $ 510,679.07

Gasification Process

Solid Removal

Claus Process

Water-Gas Shift

CO2 Absorption

Final syngasproduct

Claus Process (Sulfur Removal)

SIZE EQUIP COST TOTAL COST

Reactor $ 103,115.04

$ 164,984.06

Absorber 1 10737 cub. ft $ 1,500,000.00

Absorber 2 10737 cub. ft $ 1,500,000.00

Stripper 6636 cub. ft $ 102,585.15

$ 178,400.00

Heat Exchanger

1200 sq ft (trs area)

$ 121,978.84

$ 256,155.55

Cooler 1

6739 sq ft

$ 168,800.00

$ 320,600.00

Cooler 2

440 sq ft

$ 16,700.00

$ 79,200.00

Cooler 3

258 sq ft

$ 13,600.00

$ 73,600.00

Cooler 4

163 sq ft

$ 11,800.00

$ 69,800.00

Gasification Process

Solid Removal

Claus Process

Water-Gas Shift

CO2 Absorption

Final syngasproduct

Water-Gas Shift (WGS)

Equipment Cost Direct Cost Size

WGS reactor $224,140.08 $358,624.13 144 ft3

Gasification Process

Solid Removal

Claus Process

Water-Gas Shift

CO2 Absorption

Final syngasproduct

CO2 Absorption

Equipment Cost Direct Cost Size

CO2 absorber

CO2 Stripper 2020 ft3

CO2 capture n/a $ 55,477,294.50

n/a

Compressor $272,889.23 $ 409,333.84

Total

Gasification Process

Solid Removal

Claus Process

Water-Gas Shift

CO2 Absorption

Final syngasproduct

Summary of Equipment Cost

Other Fixed Cost

Other Fixed Cost

License Fees and Royalties

2% of Capital Cost

$ 4.7 million

Maintenance

5% of Capital

Cost

$ 12 million

Laboratory Cost

30% Labor Cost

$ 5.4 million

Insurance 1% Capital Cost

$ 2.4 million

Capital Cost as of now= $ 237,000,000

Labor Cost as of now = $ 18,000,000

Expected Revenue

Product and Side Products

Unit Price (per ton)

Unit Price (per year)

Syngas $150.00 $ 86.60 million

CO2 $40.00 $ 7.00 million

Sulfur $10.00 $ 0.30 million

Slag TBD TBD

Total $200.00 ~ $ 94 million

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Location

Victoria, Texas Between Houston

and Corpus Christi 200 acres Kansas City

Southern, Union Pacific, and Burlington Northern Santa Fe railways

Gulf Intracoastal Waterway

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Report Outline

Final Report: Executive Summary IP Discussion IP Recommendations IP

Appendices Design Basis: Done Block Flow Diagram: Done Process Flow Showing Major Equip.: IP

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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

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Report Outline

Appendices (Continued) Distribution and End-use Issues:

N/A Constraints Review: IP Applicable Standards: N/A Project Communications File: IP Information Sources and References:

IP

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References

http://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpg

http://coalgasificationnews.com/tag/petcoke-gasification/

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CO2 Sequestration

CO2 in our syngas is absorbed on Selexol to be selectively removed

Delete only one CO2 slide.

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http://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpg3/8/2011