Syngas production from petroleum coke gasification
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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 5, 2011. Syngas Production from Petroleum Coke Gasification. Project Purpose. What we are doing?

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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


Bill Keesom – Jacobs Consultancy

Jeffery Perl, PhD – UIC Dept. Of Chemical Engineering

April 5, 2011

Syngas Production from Petroleum Coke Gasification

Project purpose

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

Overall block flow

Overall Block Flow

Questions from last time

Questions from Last Time

  • None



  • Discussed Our Aspen Simulation

    • Gasifier

    • Sulfur Removal

    • Water Gas Shift

    • CO2 Removal

    • Claus Process

  • Heat Loads

    • Optimization

  • Equipment Costs and Sizes

  • Independent Economics

    • Sensitivity Analysis

  • Location

Today s agenda

Today’s Agenda

  • PFD’s

  • Initial Control Schemes

  • Plant Layout (General Arrangement)

  • Calculations

  • Refined Individual Economics

  • Joint Economics with Team Golf

Pfd overall process

PFD: Overall Process

Pfd hydrogen sulfide removal

PFD: Hydrogen Sulfide Removal

Simulation problems

Simulation Problems

  • Gasification

    • Heat Exchanger Delta T

    • Ideal Cyclone Separation

  • H2S Removal

    • Selexol Recycle Connection

  • Claus Process

    • Sulfur Water Outlet Mixed

    • Tail Gas Treatment

    • Superclaus Operation

  • CO2 Removal

    • Solvent Optimization

    • Compressor Sizes

Control scheme h2s removal

Control Scheme: H2S Removal

Overall plant layout 4923 port rd pasadena tx

Overall Plant Layout: 4923 Port Rd., Pasadena, TX

Plant layout gasification island

Plant Layout: Gasification Island

Plant layout h2s removal

Plant Layout: H2S Removal



Calculations continued

Calculations (Continued)

Calculations continued1

Calculations (Continued)

Refined independent economics raw material cost

Refined Independent Economics:Raw Material Cost

Catalyst and solvent costs

Catalyst and Solvent Costs

Capital cost analysis

Capital Cost Analysis

Economics summary

Economics Summary

Pay back period

Pay-Back Period

Sensitivity analysis

Sensitivity Analysis

Sensitivity analysis1

Sensitivity Analysis

Sensitivity analysis2

Sensitivity Analysis

Sensitivity analysis3

Sensitivity Analysis



  • PFD

  • Control Schemes

  • Plant Layout

  • Calculations

  • Refined Economics

Next steps

Next Steps

  • Revise Report

  • Finish Poster

  • Eliminate Overlap in Economics

  • Address Simulation Issues





  • Richard Parkinson.  “Where Does It Go? An Introduction to the Placement of Process Equipment.”  UOP  PowerPoint.  2009.  2 April 2011.

Report outline

Report Outline

  • Final Report:

    • Executive SummaryIP

    • DiscussionIP

    • Recommendations IP

  • Appendices

    • Design Basis: Done

    • Block Flow Diagram: Done

    • Process Flow Showing Major Equip.: Done

Report outline1

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

Report outline2

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

Pfd gasification

PFD: Gasification

Pfd claus process

PFD: Claus Process

Pfd water gas shift

PFD: Water Gas Shift

Pfd co2 absorption

PFD: CO2 Absorption

Pfd co2 sequestration

PFD: CO2 Sequestration

Control scheme water gas shift

Control Scheme: Water Gas Shift

Control scheme co2 absorption

Control Scheme: CO2 Absorption

Control scheme co2 sequestration

Control Scheme: CO2 Sequestration

Control scheme gasifier

Control Scheme: Gasifier

Control scheme claus process

Control Scheme: Claus Process

Energy balance around wgs reactor

Energy Balance Around WGS Reactor

Energy balance around wgs reactor1

Energy BalanceAround WGS Reactor

Heat loads

Heat Loads

Co2 sequestration

CO2 Sequestration

  • CO2 in our syngas is absorbed on Selexol to be selectively removed

  • Delete only one CO2 slide.

Syngas production from petroleum coke gasification

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