JE Final Presentation

Clean Fuels Project Diesel Hydrotreating Unit

Scoping Study

Lauren Brickner Chi Lo

Pamela Morse

Jacobs Engineering Liaisons: Daniel LaRiviere

Gary Gough

Project Description and Scope

l  New regulations require highway diesel to have below 15 ppm of sulfur (reduced from 500 ppm)

l  Benefit of producing ultra low sulfur diesel (ULSD) is about $0.10/gal

l  Evaluate ability of existing equipment to adapt to modified process to produce ULSD

l  Economic feasibility of producing ULSD

Design: Material & Energy Balances

Reactor

QuenchTreat

87 mol% H23,500 scf/bbl

H2 consumed = 6,022,500 SCFD

ΔHrxn = 29,408 Btu/bbl

Recycle86.12 mol% H2

Hydrogen Plant99.9 mol% H2

Reformer81.53 mol% H2FRH

90 mol% H2

Oil Feed

Qquench

Qin

Qout Mole BalanceFRH = Freformer + FHplantnRH*FRH = nreformer*Freformer + nHplant*FHplant

FRH + Frecycle = FTreatnRH*FRH + nrecycle*Frecycle = nTreat*FTreat

Energy BalanceQin + Qquench + ΔHrxn = Qout

Qquench 1579 lbmol/hr

Design: Heaters

Heater

HPHSReactor

Oil Feed Hydrogen

Feed

Feed/Effluent Exchangers

Heater

HPHS

Reactor

Oil Feed

Hydrogen Feed

Feed/Effluent Exchangers

Current Configuration

Proposed Configuration

Design: Water Injections System

ProcessStream

Fan Cooler

Water Injection

Design Considerations: 1.  25% of injected water remain in the liquid phase

downstream of the injection point. 2.  Concentration of ammonia bisulfide in the HPHS

sour water be maintained at or below 4 wt%

Design: Compressors/Pumps

Recycle Hydrogen

Plant and Reformer

Given From HYSYS TM

Capacity (ACFM) Efficiency Capacity (ACFM) Horsepower

Stage 1 GC1 1111:= E1 .903:= C1 877.2:= H1 610.5hp⋅:=

Stage 2 GC2 488.5:= E2 .928:= C2 469.4:= H2 820.1hp⋅:=

Stage 3 GC3 231.7:= E3 .914:= C3 204:= H3 565.6hp⋅:=

Stage 4 GC4 562.8:= E4 .76:= C4 452.3:= H4 395.5hp⋅:=

P-101 Pump Curves

2000

2500

3000

3500

4000

4500

5000

5500

0 100 200 300 400 500 600

Flow (GPM)

TDH

(ft)

9.35" 9.88"

Design: Separators and Fractionator

Specifications Naphtha Kerosene Diesel (ULSD)Distillation Sim Dist. D-86 D-8610%, °F - 401 max -90%, °F - 550 max 640 maxEnd Point, °F 400 max 572 max -

Product Specifications

Design Goals: 1.  Ensure products are

separated to desired specifications

2. Ensure adequate vapor/liquid disengagement

3. Ensure adequate surge capacity

Design Conclusions / Recommendations

1.  New Feed Tank §  To ensure constant feed flow §  Be a holding tank for catalyst change out and shutdowns

2.  New Feed Pump §  Flow = 590 GPM §  Total dynamic head (TDH) = 4142 ft §  Max impeller diameter TDH = 3200 ft

3.  Heat Exchangers §  Replace reactor feed/effluent exchangers §  Add heat exchanger to feed

4.  Compressor §  Required hp = 2378 (motors rated at 4000 hp) §  Adequate capacity §  No changes to be made

Design Conclusions / Recommendations

5.  Water Injection System §  8330 lb/hr water required to remove ammonia bisulfide

6.  High Pressure Hot Separator §  Adequate vapor/liquid disengagement §  Surge capacity too small §  Will not replace – install safety devices to prevent overflow

7.  Fractionating Tower §  Produces adequate product specifications §  Replace trays to prevent weeping

8.  Piping §  Sized to fit constraints of: maximum velocity, slug flow, ΔP/100 ft

Economics – Equipment Bare Module Costs

Total bare module cost ~ $5 million

Equipment Costs

Instruments7%

Piping7%

Reactor & Fractionator

Internals50%

Equipment36%

Total Variable Costs

Catalyst4%

Heating Fuel Oil 71%

Electricity11%

Steam2%

Hydrogen10%

Water2%

Economics – Annual Costs & Product Selling Prices

Annual Cost Breakdown Variable Costs: $14.7 Million Crude Oil Cost: $365 Million

Operating Costs: $541 Million

Product Selling Prices ULSD: $1.93 / GAL

Naphtha: $1.53 / GAL Kerosene: $1.94 / GAL

Economics: Cash Flow Analysis

Ultra Low Sulfur Diesel Process Cash FlowSelling Price = 1.93

-$20,000

$0

$20,000

$40,000

$60,000

$80,000

$100,000

$120,000

$140,000

$160,000

2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Years

Cas

h Fl

ow ($

k)

l  IRR = 141.7% l  NPV = $913M (at the beginning

of each period) l  ROI = 56.5% l  PBP = 1.8 years

Comments and Future Recommendations

l  Liaison/Student Communication l Project description and equipment

documentation l Time constraints l Project scope

To our liaisons (Dan and Gary)

and Jacobs Engineering