Production of Gasoline Components from Synthesis Gas

Production of Gasoline Components from Synthesis GasChE 397 Senior DesignGroup Alpha

Ayesha RizviBernard HsuJeff TyskaMohammad ShehadehYacoub Awwad

2011.03.08

Presentation Overview Recap PFD/flowsheet Heat Duties Sizing Economics Summary

RecapH2

Questions from last presentation Will the Carbon steel be weakening at

our high temperatures?Should be fine, below max recommended T

Should we separate our Aromatics? Numbers last time were unduly high,

normal now Don’t quote retail prices

Gasoline price quotes are spot prices from the EIA

Process Changes Fluidized bed Methanol to Gasoline

reactor Continuous regeneration No DME reactor Different product separation scheme Different product distribution (closer to

normal gasoline)

Design Basis 6000 Short tons syngas/day 518 °F (270 °C) 725 psi (5 Mpa) Product

Gasoline – 16,300 bpd LPG – 4350 bpd

Methanol ReactorSyngas (1)

Hot MeOH Product(3)

MeOH REACTOR

Cooled MeOH Product (6)

MeOH-Water HX

Steam (5)

Recycle Syngas from Comp (2B)

Warm Water(4)

Stream NameSyngas (1)

Recycled Syngas from Comp(2B)

Recycled Syngas to Comp(2A)

Hot MeOH Product (3)

Warm Water (4)

Steam (5)

Cooled MeOH Product (6)

H2 (kmol/hr) 14485 57181 57181 26477 0 0 26477

CO (kmol/hr) 7243 22464 22464 10459 0 0 10459Methanol (kmol/hr) 0 576 576 7234 0 0 7234

Water (kmol/hr) 0 0 0 0 8163 8163 0

Temperature (F ) 518 331 203 518 212 237 264Presssure (psi) 725 725 435 725 15 15 725Enthalpy (Btu/lb) -1194 -1275 -1372 -1672 -6316 -5695 -1830

SYNCOMP

Recycle Syngas To Comp (2A)

MeOH Recycle and HXCooled MeOH Product (6)

MeOH-Syngas HX

Hot Rec. Syngas (9)

Recycle Syngas To Comp (2A)

Purge Syngas (10) Cooler MeOH

product(7)

Cool Rec. Syngas(8)

Stream name Cooler Meoh Product (7) Cool Rec.Syngas (8) Hot Rec.Syngas (9) Purge Syngas (10)

H2 (Kmol/hr 26477 26467 26467 529

CO (Kmol/hr) 10459 10397 10397 208

MeOH (Kmol/hr) 7234 267 267 5

Temperature (F) 248 86 203 203

Pressure (psi) 725 435 435 435

Enthalpy (BTU/#) -1883 -1457 -1371 -1371

To MTG Reactor

Cooler MeOH Product (7)Light Gas—

MeOH HX

Cold Light Gas(11)

CooledMeOH (13A)

Flash

Cool Rec. Syngas (8)

Product-MeOH HX

Hot HCs(15)

Cool HCs (17 A) Warm MeOH (16)

Light Gas Out (12)

(14) MeOH to MTG

Stream name Cold Light Gas (11) Light Gas Out (12) Cooled MeOH

(13A) Cold MeOH (13B) MeOH to MTG (14)

H2 (Kmol/hr 0 0 26477 26477 10CO (Kmol/hr) 0 0 10459 10459 62

Water (Kmol/hr) 0 0 0 0 0

MeOH (Kmol/hr) 0 0 7234 7234 6967Light Gases (C1-C2) (Kmol/hr) 80 80 0 0 0

LPGS (C3-C4) (Kmol/hr) 53 53 0 0 0

Temperature (F) 75 212 248 102 86

Pressure (psi) 368 368 725 725 435

Enthalpy (BTU/#) -906 -821 -1883 -2130 -3180

Cooler

Cold MeOH (13B)

MTG Reactors Hot HCS(15)Warm MeOH (16)

Heater

Hot MeOH (17 B )

MTG Reactors

Stream name Hot HCs (15) Warm MeOH (16) Cool HCs (17 A ) Hot MeOH ( 17 B)

H2 (Kmol/hr 0 10 0 10CO (Kmol/hr) 0 62 0 62Water (Kmol/hr) 6994 0 6994 0MeOH (Kmol/hr) 0 6967 0 6967Light Gases (C1-C2) (Kmol/hr) 98 0 98 0

LPGS (C3-C4) (Kmol/hr) 367 0 367 0C5+ Compounds (gasoline) (Kmol/hr) 832 0 832 0

Aromatics (Kmol/hr) 219 0 219 0

Temperature (F) 716 363 408 590

Pressure (psi) 362 435 362 435

Enthalpy (BTU/#) -3169 -2714 -3635 -2477

Stream name CWS (18) Cooled Hydrocarbons (19)

Cold Hydrocarbons (20)

‘Dirty’ Water (21) HCs (22) Pump HCs (23) C3 + HCs (24)

Water (Kmol/hr) 8163 6994 6994 6994 0.73 0.73 0.73Light Gases (C1-C2) (Kmol/hr) 0.010 81 81 1.2 80 80 0.001

LPGS (C3-C4) (Kmol/hr) 0 200 200 0 199 199 147

C5+ Compounds (gasoline) (Kmol/hr) 0.010 832 832 0.210 832 832 832

Temperature (F) 77 239 73 68 68 68 372

Pressure (psi) 15 362 375 362 362 364 368

Enthalpy (BTU/#) -6814 -3960 -5691 -6811 -715 -715 -512

Product Refining2nd Gas HX

Cool HCs (17A)

Cooled HCs (19)

Cooler

Cold HCs (20)

Decanter

HCs(22)

‘Dirty’ Water (21)

CWS (18)

Warm Water (4)

Cold Light Gas (11)

C3+ HCS (24)

Deethanizer Pump

Pump HCs(23)

Water ‘Dirty’ Water (21)

Water Flash

‘Clean’ Water (25 A)

CWS (18)

Extra Cooling H2O (25 B)

Offgas (26)

Stream name ‘Clean’ Water (25 A) Extra Cooling H2O (25 B) Offgas (26)

Water (Kmol/hr) 6993 1170 0.19

Light Gases (C1-C2) (Kmol/hr) 0.01 0 1.19

LPGS (C3-C4) (Kmol/hr) 0 0 0.25

C5+ Compounds (gasoline) (Kmol/hr) 0.01 0 0.2

Aromatics (Kmol/hr) 0.01 0 0.09

Temp (F) 120 77 120

Pressure (psi) 15 15 15

Enthalpy (BTU/#) -6814 -6813 -815

Product Refining II

C3+ HCs(24)

Gasoline (29)

LPG + Pentanes (28)

Pentanes (31)

LPG (30)

Gasoline Product (32)

Hydrocarbon Separator

Debutanizer

Stream name LPG+ Pentanes Gasoline (29) LPG (30) Pentanes (31) Final Product

Water (Kmol/hr) 0.7 0.1 0.6 0.1 0.2

LPGS (C3-C4) (Kmol/hr) 294.3 2.7 293.5 0.8 3.5

C5+ Compounds (gasoline) (Kmol/hr) 106.4 725.7 0.1 106.3 832.0

Aromatics (Kmol/hr) 0.4 218.3 0.0 0.4 218.6

Temp (F) 192 410 77 390 309

Pressure (psi) 221 221 74 74 74

Enthalpy (BTU/#) -973 -385 -154 -845 -431

Overall Process

Heat Duties

Heat Exchanger Duties, total 662 MMbtu/hr

Reactor heat duties, total -589 MMbtu/hr

Heater/Reboiler heat duties, total -193 MMbtu/hr

Cooler/Condenser heat duties, total 125 MMbtu/hr

Heaters/coolers, HX, reactors, dist. col. The rest are adiabatic

Light gas burning not included

Detailed Heat DutiesUnit

Heat Duty (MMbtu/hr)

MeOH reactor -475MeOH and water HX 201MeOH and recycle gas HX 67MeOH and Light Gas HX 1Methanol Flash Block 0Methanol and Gasoline HX 231Last Methanol Heater 118MTG Reactors -29Gasoline and Water HX 162Gasoline Cooler -84Decanter 0Deethanizer Condenser -4Deethanizer Reboiler 44Distillation Column 2 (Gasoline) Condenser -20Distillation Column 2 (Gasoline) Reboiler 17Pentane Distillation Column Condenser -16Pentane Distillation Column Reboiler 14

Sizing Reactor sizing done by hand

Used LHSV/GHSV data Other sizing done in ASPEN

Distillation Columns 25-40 trays 6.5 – 8.5 ft Diameter 64 – 92 ft High

Heat Exchangers 1,000 – 10,000 ft2

Methanol Reactor Sizing Calculations

Boiling water reactor Catalyst on tube side 400 psia steam Tube area fraction = .45

GHSV = 8,000 hr-1

1:4 D:H ratio D = 8.3 ft, H = 33.2 feet

Process Economics Detailed summary in IPE TIC (ISBL) = $22,050,000 Indirect field costs = $1,900,000 Non field costs =$3,400,000 Total startup cost = $27,350,000 Upkeep = $16,700,000/year

Includes catalyst prices and utilities

Field Cost Distribution

DOLLARS

Non-Field Cost Distribution

DOLLARS

Indirect Field Cost Distribution

DOLLARS

Utilities Cooling water

70,000 gpm 4 Million Dollars/year

100 psia Pressure Steam 30.4 Klb/hr 2 Million Dollars/year

400 psia Pressure steam 157.5 Klb/hr 14.8 Million Dollars/year

Steam generation Steam costs not included in upkeep

Catalyst Pricing    

http://www.nrel.gov/docs/fy11osti/47594.pdf

Syngas and Product Cost

Syngas cost = $250/ton Total syngas cost / year = $500 Million Gasoline price = $2.25/gallon

($94.5/bbl) EIA spot price

LPG price = $1/gallon ($42/bbl)

Outside Battery Limit Process Economics

Total Installed Cost (TIC) didn’t include buildings, etc.

Factor of 8 New TIC = $218 Million

About 45% of syngas cost/year Gasoline and syngas prices

Final Economics

Total revenue per year = $575 Million Profit = $56 Million/year IRR = 26% (20 year plant life) Simple payback = 3.8 years

Summary

16,300 bbl/day gasoline4,350 bbl/day LPG

Lots of potential for heat recovery 26% IRR Gasoline and syngas price

Questions?

Steam Gen. from MeOH reactor -475 MMBTU 10% lost 440 KLb per hour Enough to satisfy our requirements Working with gasifier group

Use in process Electricity generation

Methanol to Gasoline Reactors Sizing Calculations

Size of Reactors

Block Flow DiagramMethanolReactor

CO

H2

MeOHH2, CO

Cooling and Separation

MeOH

H2, CO

Methanol to Gasoline (MTG) Reactors

Water Separation

Hydrocarbons

Water

Water

Hydrocarbons

Deethanizer(Dist. Col.)

C1/C2

2nd DistillationColumn

HeavyHydrocarbons

Liquefied Petroleum Gas

Gasoline

Purge

Carbon Steel Limits Max temp based on creep = 450 C Max temp based on rupture = 540 C Our max temp = 380 C

Heat Resistant Materials by Joseph R. Davis

Equipment Costs IMiscellaneous Flowsheet Area 2NDGASHX

DHE FLOAT HEAD 331800 177300

Miscellaneous Flowsheet Area COOLER

DHE FLOAT HEAD 266200 123500

Miscellaneous Flowsheet Area FLASH-flash vessel

DVT CYLINDER 401800 238100

Miscellaneous Flowsheet Area GASMEHX

DHE FLOAT HEAD 514200 231800

Miscellaneous Flowsheet Area GASSPLIT C 0 0Miscellaneous Flowsheet Area H2OMIXER C 0 0Miscellaneous Flowsheet Area HEATER

DHE FLOAT HEAD 1.54E+06 1.01E+06

Miscellaneous Flowsheet Area HEATEX

DHE FLOAT HEAD 248100 113200

Miscellaneous Flowsheet Area LGMEOHHX

DHE FLOAT HEAD 67400 11300

Miscellaneous Flowsheet Area MEOHH2OX

DHE FLOAT HEAD 425900 259300

Miscellaneous Flowsheet Area MEOHRXN

DTW PACKED 215400 75700

Miscellaneous Flowsheet Area SPLIT C 0 0

Equipment Costs IIS-1 2NDFLASH-flash vessel DVT CYLINDER 169000 62500S-1 DEETHAN-bottoms split C 0 0S-1 DEETHAN-cond DHE FIXED T S 79400 16800S-1 DEETHAN-cond acc DHT HORIZ DRUM 78900 19800S-1 DEETHAN-overhead split C 0 0S-1 DEETHAN-reb DRB U TUBE 225600 124500S-1 DEETHAN-reflux pump DCP CENTRIF 33100 5300S-1 DEETHAN-tower DTW TRAYED 838400 514000S-1 FINALDIS-bottoms split C 0 0S-1 FINALDIS-cond DHE FIXED T S 111100 29800S-1 FINALDIS-cond acc DHT HORIZ DRUM 150900 45300S-1 FINALDIS-overhead split C 0 0S-1 FINALDIS-reb DRB U TUBE 170800 84800S-1 FINALDIS-reflux pump DCP CENTRIF 57200 10500S-1 FINALDIS-tower DTW TRAYED 621600 341300S-1 GASLMIX C 0 0S-1 GASLMIXE C 0 0S-1 GASPROD1 DTW PACKED 636200 231000S-1 GASPROD2 DTW PACKED 318100 115500S-1 GASPROD3 DTW PACKED 318100 115500S-1 MEOHCOLR DHE FLOAT HEAD 863200 589000S-1 PENTCOLM-bottoms split C 0 0S-1 PENTCOLM-cond DHE FIXED T S 1.42E+06 930800S-1 PENTCOLM-cond acc DHT HORIZ DRUM 108000 25500S-1 PENTCOLM-overhead split C 0 0S-1 PENTCOLM-reb DRB U TUBE 108700 28200S-1 PENTCOLM-reflux pump DCP CENTRIF 45800 8100S-1 PENTCOLM-tower DTW TRAYED 400200 184800S-1

S-2 DECANTER DVT CYLINDER 179900 71700S-2 HCSPUMP DCP CENTRIF 52200 8800