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

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

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Questions from Last Time

How was the PFD generated? What is our feedstock prices?

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Recap

PFD’s Control Schemes Plant Layout Calculations Refined Individual Economics Joint Econ Presentation

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Today’s Agenda

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Overview of the project from day 1 till the end Brief backgrounds Brief process description▪ Aspen simulation overview

Economics overview Recommendations

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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

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Major Decisions

Feedstock Choice Petcoke

Gasifier Choice Shell Entrained Flow (Membrane Wall)

Extent of Simulation Solvent

Selexol Syngas Price Location

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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

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Gasification Background

Gasification coverts a carbon rich fuel into a gaseous product

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Shell Entrained Flow Gasifier

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Process Highlights

Pressure Driven Process Reduced compression requirements

High Conversion of Feedstock Highly Efficient Sulfur Removal

Sulfur removal to 2 ppm

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Overall Block Flow

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Overall Aspen Simulation

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Gasifier

H2S Removal

Water Gas Shift

Claus Process

CO2 Capture and Sequestration

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PFD Example

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Control Scheme Example

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Economics Overview

Total Equipment + Installation Cost

Process Cost in $MMGasification Process 135

H2S 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

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Economics Overview

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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

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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)

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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)

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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

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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

Sensitivity to feedstock and product price changes

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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 Integration4/26/2011

Questions?

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References

(http://www.netl.doe.gov/technologies/coalpower/gasification/gasifipedia/4-gasifiers/4-1-2-3_shell.html)

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Report Outline

Final Report: Executive Summary Done Discussion Done Recommendations Done

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

Done264/26/2011

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

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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

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Composition of Petcoke(3)

Ultimate Analysis Component Weight

Percent

Carbon 83.3

Hydrogen 4.00

Nitrogen 1.49

Sulfur 6.14

Oxygen 4.44

Proximate AnalysisComponent Weight

Percent

Fixed Carbon 84.8

Moisture 6.00

Volatile Matter 8.60

Ash 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)

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PFD: Gasification

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PFD: Claus Process

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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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Control Scheme: Water Gas Shift

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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 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 57.0

Sulfur Stripper Cooler -200.0

Selexol Cooler -40.7

Rich / Lean Heat Exchanger 274.94/26/2011 42

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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.jpg4/26/2011