Syngas Production from Petroleum Coke Gasification
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Transcript of Syngas Production from Petroleum Coke Gasification
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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
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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/
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Overall Block Flow
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Recap Discussed Our Aspen Simulation
Gasifier Sulfur Removal Water Gas Shift CO2 Removal Claus Process
Heat Loads Optimization
Equipment Costs and Sizes Individual Economics
Sensitivity Analysis Location
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Agenda
PFD
Initial Control Scheme
Plant Layout (General Arrangement)
Calculations
Refined Economics54/5/2011
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PFD: Overall Process
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PFD: Gasification
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PFD: Hydrogen Sulfide Removal
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PFD: Water Gas Shift
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PFD: CO2 Absorption
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PFD: CO2 Sequestration
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PFD: Claus Process
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Control Scheme: H2S Removal
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Control Scheme: Water Gas Shift
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Plant Layout: Overall
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Plant Layout: Gasification Island
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Plant Layout: H2S Removal
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Calculations
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Refined Economics:Raw Material Cost
Raw Materials
Quantity (lbm/day) Price ($/lbm)
Total Cost (day)
Cost ($)/(year)
Petcoke (T/D) 4,409,200 0.034 $ 150,000 $ 52,500,000 Zinc Oxide (lbm/day) 392.73 55.00 $21,600 $ 7,560,053
Selexol 6,200,000 3.20 $19,840,000 $ 19,840,000
Ferro-chrome 53,001 1.33 $ 70,492 $ 24,672,215 Aluminium Oxide 450 23.17 $ 10,416 $ 3,645,468
Oxygen 4,232,832 0.028 $ 117,120 $ 40,992,000
Total $
149,209,735
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Annual Operating Cost
Raw Ma-
terial Cost14984%
Labor0.91%
CW+NG+E
lec21.512%
Maintenance7
4%
Annual Operating Cost
Raw Material costLaborCW+NG+ElecMaintenance
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Capital Cost Analysis
Gasifier, 74%$135 mm
Sulfur Removal, 9%
$17 mm
CO2 Sequa-tration, 17%
$31 mm
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Economics Summary 1st year 2nd Year 3Rd year 4th year 19th Year
Revenue $ - $ - $ - $ 129,570,000 $ 240,352,994
Cap. Cost $ 25,546,569 $ 104,011,033 $ 72,990,199 $ 20,072,305 $ -
Op. Cost $ - $ - $ - $ 111,070,226 $ 242,943,820
Total Expense $ 25,546,569 $ 104,011,033 $ 72,990,199 $ 151,307,886 $ 281,203,980
Income tax 40%
$ - $ - $ - $ 13,144,845 $ 83,909,549
Income After Tax
$ - $ - $ - $ 19,717,268 $125,864,323
Cumulative Cash Flow
$ 25,546,569 $129,557,602 $202,547,801 $ 168,810,442 $1,540,424,893
NPV $89,282,710IRR N/AInterest 8%
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0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
-$250
-$50
$150
$350
$550
$750
$950
$1,150
$1,350
$1,550Cumulative Cash Flow ($MM/year)
Years
($M
M/Y
R)
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Sensitivity Analysis
$150.00 $170.00 $190.00 $210.00 $230.00 $250.00 $270.00 $290.00 $310.00 $330.00
-$100.00
$0.00
$100.00
$200.00
$300.00
$400.00
$500.00
$600.00
NPV Vs. Syngas Prices
NPV
Syngas($/ton)
Net
Pre
sent
val
ue (
$mill
ion)
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Sensitivity Analysis
$150.00 $170.00 $190.00 $210.00 $230.00 $250.00 $270.00 $290.00 $310.00 $330.00
-15.00%
-10.00%
-5.00%
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
IRR vs. Syngas Price
IRR
Syngas ($/ton)
Inte
rnal
Rat
e of
ret
urn
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Sensitivity Analysis
60 70 80 90 100 110 120 130 140 150 1600
100
200
300
400
500
600
NPV Vs. Petcoke Prices
NPV
Petcoke($/ton)
Net
Pre
sent
val
ue (
$mill
ion)
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Sensitivity Analysis
50 70 90 110 130 150 1700.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
IRR vs. Petcoke Price
IRR
Petcoke ($/ton)
Inte
rnal
Rat
e of
ret
urn
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Conclusion
PFD
Control Schemes
Plant Layout
Calculations
Refined Economics
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Next Steps
Revise report
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Questions?
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References
Richard Parkinson. “Where Does It Go? An Introduction to the Placement of Process Equipment.” UOP PowerPoint. 2009. 2 April 2011.
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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.: Done
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Report Outline
Appendices (Continued) Material and Energy Balances: Done Calculations: IP Annotated Equip. List: Done Econ. Eval. Factored from Equip. Costs:
Done Utilities: IP Conceptual Control Scheme: Done Major Equipment Layout: Done
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Report Outline
Appendices (Continued) Distribution and End-use Issues:
IP Constraints Review: IP Applicable Standards: IP Project Communications File: IP Information Sources and References:
IP
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Control Scheme: CO2 Absorption
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Control Scheme: CO2 Sequestration
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Control Scheme: Gasifier
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Control Scheme: Claus Process
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Energy Balance Around WGS Reactor
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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
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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
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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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45http://fossil.energy.gov/images/programs/sequestration/what_sequestration_lg.jpg4/5/2011