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Production of Gasoline Components from Synthesis Gas. ChE 397 Senior Design Group Alpha Ayesha Rizvi Bernard Hsu Jeff Tyska Mohammad Shehadeh Yacoub Awwad 2011.04.26. Overview. Process Basics Block Flow Diagram Plant and Equipment Layout General Economics

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Production of gasoline components from synthesis gas

Production of Gasoline Components from Synthesis Gas

ChE 397 Senior Design

Group Alpha

Ayesha Rizvi

Bernard Hsu

Jeff Tyska

Mohammad Shehadeh

YacoubAwwad

2011.04.26


Overview
Overview

  • Process Basics

  • Block Flow Diagram

  • Plant and Equipment Layout

  • General Economics

  • Conclusions and Further Improvements



Process equation
Process Equation

2H2 + CO

ZSM-5

C5+ + H2O + LPG (C3/C4)


Why gasoline and mobil process
Why Gasoline and Mobil Process?

  • Existing infrastructure

  • Established and high demand

    product

  • Great amount of C5+ gasoline in the final product

  • Lower Gasoline Price

  • Reduced Sox/GHG emissions

  • Easy to scale

  • Renewable feedstock

  • Energy Independence

SO2


Competing processes
Competing Processes

(2n+1) H2 + n CO → CnH(2n+2) + n H2O

  • Fischer-Tropsch

  • Oil

  • Tar Sands

43%

http://portland.indymedia.org/media/images/2010/12/404850.jpg

http://tonto.eia.doe.gov/country/index.cfm?view=production


Process summary
Process Summary

  • Syngas  Methanol

  • Methanol  Water/Hydrocarbons

  • Water/Hydrocarbons  Water + Hydrocarbons

  • Hydrocarbons  Gasoline and Liquefied Petroleum Gas (LPG)


Block flow diagram
Block Flow Diagram

CO

Cooling and

Separation

Methanol to

Gasoline (MTG)

Reactors

MeOH

Methanol

Reactor

MeOH

H2, CO

H2

Purge

H2, CO

Hydrocarbons

Water

C1/C2

Liquefied Petroleum Gas

Water

Separation

Distillation

Columns

Heavy

Hydrocarbons

Deethanizer

(Dist. Col.)

Hydrocarbons

Water

Gasoline


T (518F)

P (725psi)

T (518F)

P (725psi)

Methanol

Reactor

Syngas & MeOH

Syngas

CO 23,059 lbmol/hr

H2 58,373 lbmol/hr

MeOH 15,948 lbmol/hr

CO 15,967 lbmol/hr

H2 31,935 lbmol/hr

CO 22,464 lbmol/hr

H2 57,182 lbmol/hr

MeOH 576 lbmol/hr

T (345F)

P (725psi)

Rec Syngas

T (518F)

P (725psi)

T (364F)

P (435psi)

Cooling and

Separation

MeOH

CO 23,059 lbmol/hr

H2 58,373 lbmol/hr

MeOH 15,948 lbmol/hr

MeOH 5 lbmol/hr

T (364F)

P (435psi)

CO 136 lbmol/hr

H2 23 lbmol/hr

Syngas & MeOH

Syngas


T (364F)

P (435psi)

Methanol to

Gasoline (MTG)

Reactors

MeOH

MeOH 5 lbmol/hr

H2O 15,111 lbmol/hr

L.G(C1,C2) 211.8 lbmol/hr

LPG(C3,C4) 792.5 lbmol/hr

C5+(gasoline)2290.8 lbmol/hr

T (716F)

P (362psi)

Hydrocarbons/Water

Water

Separation

T (305F)

P (72psi)

T (68F)

P (391psi)

Water

Hydrocarbons

H2O 15,109 lbmol/hr

H2O 2 lbmol/hr

L.G(C1,C2) 211.8 lbmol/hr

LPG(C3,C4) 792.5 lbmol/hr

C5+(gasoline)2290.8 lbmol/hr


T (71F)

P (391psi)

T (68F)

P (391psi)

Deethanizer

(Dist. Col.)

Hydrocarbons

C1/C2

L.G(C1,C2) 209.2 lbmol/hr

LPG(C3,C4) 121.5 lbmol/hr

C5+(gasoline) 0.02 lbmol/hr

H2O 2 lbmol/hr

L.G(C1,C2) 211.8 lbmol/hr

LPG(C3,C4) 792.5 lbmol/hr

C5+(gasoline)2290.8 lbmol/hr

H2O 2 lbmol/hr

LPG(C3,C4) 670 lbmol/hr

C5+(gasoline)2290.1 lbmol/hr

T (365F)

P (363psi)

Heavy

Hydrocarbons

T (77F)

P (73psi)

T (101F)

P (96psi)

LPG

Gasoline

Distillation

Columns

H2O 0.30 lbmol/hr

LPG(C3,C4) 7.6 lbmol/hr

C5+(gasoline)1,805 lbmol/hr

H2O 1.3 lbmol/hr

LPG(C3,C4) 663 lbmol/hr

C5+(gasoline)485 lbmol/hr


Design basis
Design Basis

  • 6000 Short tons syngas/day

  • 518 °F (270 °C)

  • 725 psi (5 Mpa)

  • Product

    • Gasoline – 15,974 barrels/day

    • LPG – 4,263 barrels/day





Economics
Economics

  • Capital Cost = $374 Million

  • Syngas cost = $250/ton

  • Gasoline Sold at $2.75 / gallon

  • LPG sold at $1.00 / gallon

  • Plant is profitable

    • 30% IRR

    • $1.473 billion NPV

    • $104 Million in profit / year



Future of the mobil process
Future of the Mobil Process

  • Coal to gasoline

  • Plants are starting to be built

  • Primus Green – Pennsylvania

    • Biomass to Gasoline

  • South Dakota – New plant in 2012


Process overview
Process Overview

  • 6000 Short Tons / Day Syngas Feed

    • Gasoline- 15,974 barrels/day @ $2.75/gal

    • LPG – 4,263 barrels/day @ $1.00/gal

  • Newton County, Indiana

    • Adjacent to Gasification Plant

  • Plant is profitable

    • Capital Cost = $374 Million

    • Syngas cost = $250/ton

    • 30% IRR

    • $1.473 billion NPV

    • $104 Million in profit / year


Conclusions further improvements
Conclusions & Further Improvements

Further Improvements

Reacting out Durene to increase gasoline quality.

Alkylation of C4 olefins.

Air coolers to reduce cooling water loads.

New methods of catalyst regeneration for ZSM-5.

Different distillation column set-ups.

Pinch analysis for the process.

The construction and implementation of this process is recommended.

Durene


Questions from last presentation
Questions From Last Presentation

  • Our catalyst regeneration for the MTG results in higher alcohols. Is this okay?

    • Yes, they will also be converted to gasoline components

  • You should decouple the reboiler heat duty from the flow of the feed to the distillation columns

    • We will be using bias control


  • Important references

    Questions?

    Important References

    • Phillips, S. D., Tarud, J. K., Biddy, M. J., & Dutta, A. (2010, January). Gasoline from Wood via integrated gasification, synthesis and methanol to gasoline technology. Retrieved from nrel.gov: http://www.nrel.gov/docs/fy11osti/47594.pdf

    • (1994). Kirk-Othmer Encyclopedia of Chemical Technology. In Volume 22 (pp. p 166-168).

    • Exxon Mobil Research and Engineering. (2009). Methanol to Gasoline: Production of clean gasoline from coal.

    • Kooy, P., & Kirk, D. C. (n.d.). The production of methanol and gasoline. Retrieved from http://nzic.org.nz/ChemProcesses/energy/7D.pdf


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