Methanol for gasoline blending from petroleum coke
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Methanol for Gasoline Blending from Petroleum Coke. David Netzer & Chris Wallsgrove (Speaker). MeOH. The Premise. Upgrading Heavy Oil Normally Produces Petroleum Coke ( Petcoke ) Petcoke is Often Sold as Low-Cost Fuel Petcoke Can be Gasified to Syngas (Proven Technology)

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Methanol for Gasoline Blending from Petroleum Coke

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Methanol for gasoline blending from petroleum coke

Methanol forGasoline BlendingfromPetroleum Coke

David Netzer

&

Chris Wallsgrove

(Speaker)

MeOH


The premise

The Premise

Upgrading Heavy Oil Normally Produces Petroleum Coke (Petcoke)

Petcoke is Often Sold as Low-Cost Fuel

Petcoke Can be Gasified to Syngas (Proven Technology)

Methanol (MeOH) is Produced from Syngas

MeOH Can be Blended with Gasoline

7% to 10% Blend of MeOH in Gasoline Can Fuel Existing Cars (Proven Technology)


Other methanol uses

Other Methanol Uses

Methanol to Gasoline (MTG) – but WHY? If We Can Use Methanol AS Gasoline

Methanol to DME – Diesel and/or LPG Subtitute

Methanol to Propylene (MTP) or Ethylene (MTO) – Compete with Steam Crackers?

Methanol to Acetic Acid & Derivatives – Limited Market

Methanol to Formaldehyde & Derivatives – Same


Process units

Process Units

Gasification – To Produce Raw Syngas

Air Separation (ASU) – To Produce Oxygen for the Gasification

Shift – With Control of CO/H2 Ratio

Rectisol – Remove H2S/COS and Recover CO2

Methanol Synthesis – Makes 50,000 BPSD

Methanol Purification (Distillation)

Units to Recover H2 and Sulfur


Process units selection

Process Units Selection

Quench Gasifiers – Operate at High Pressure to Avoid Syngas Compression

Unconverted Carbon to Boilers

Gas Cooling Produces Steam

Rectisol (Two Trains) Uses Methanol Solvent

Two Methanol Synthesis Reactors (Large, Heavy Vessels) in Parallel

Conventional PSA for H2 Recovery, and Claus-Type Sulfur Units


Methanol for gasoline blending from petroleum coke

Petcoke

7,400 tpd

Air

CO2

130 bar

11,700 tpd

CO2

Compression

Air

Separation

Nitrogen

Oxygen

CO2

6,600 tpd

Gasification

87 bar

Coke Preparation

And Slurrying

Shift & Gas

Cooling

Rectisol

Units

Unconverted

Carbon

Syn-

Gas

Water,

Fluxing Agent

Acid Gases

Steam EHP, HP,

MP, LP

Methanol

Synthsis

78 bar

Steam &

Power

Systems

Sulfur

Plants

Steam HP, LP

Tail Gas

Purge Gas

Methanol

6,400 tpd

Sulfur

Product

Hydrogen

Product

16 MMscfd

PSA Hydrogen

Recovery

Methanol

Purification

Reactor Purge Gas

50,000

bpsd

Block Flow Diagram – Petcoke to Methanol


Energy systems

Energy Systems

Totally Self-Sufficient in Steam and Power

Fluidized Bed Boilers, for Petcoke and Coal

Plus Unconverted Carbon from Gasification

MP Steam Superheating in a Fired Heater, Using PSA Purge Gas as Fuel

Steam Driven ASU Compressors – 63 MW

Balance of Steam to a Generator – Excess Power Exported (About 80 MW Export)

All Other Drivers Electric


Methanol for gasoline blending from petroleum coke

130 Bar Steam

From Shift

Air Pre-

Heat

Lime

Scrub

DeNOx

Econo

SRU Tail Gas

PSA Purge Gas

125 bar Steam

125 bar Steam

To ASU Drivers

MeOH Bottoms

Unconverted

Carbon

Petcoke

~

Turbine

Generator

3 x 55%

Fluidized

Bed

Boilers

Limestone

Coal

(& Biomass)

25 bar

Spent Gypsum

3.5 bar Steam

From Process

D / A

PSA Purge Gas

~80%

27 bar Steam

From Process

Steam & Energy Block Diagram – Petcoke to Methanol


Capital cost savings

Capital Cost Savings

  • Quench Gasification vrs High Efficiency with 130 Bar Steam – Saves ~$200 Million

  • 320 MW Fluidized Bed Boilers vrs IGCC – Saves ~$450 Million

  • 67% CO2 Capture vrs 95% (Shift + H2 Power Cycle + Parasitic Mw) - Saves ~$250 Million

  • Avoid 25 MW Methanol Synthesis Compressor – Saves ~$50 Million

  • Other Miscellaneous Rational Savings ~$135 Million


Carbon dioxide disposal

Carbon Dioxide Disposal

  • If Underground Sequestration, Costs $$$

  • If Sold for Enhanced Oil Recovery (EOR), is Revenue $

  • In Either Case, CO2 Must Be Compressed to At Least ~125 Bar

  • Modest (67%) CO2 Recovery

  • Mine-To-Wheel CO2 Release is ~Equal to Ethanol Blend


Methanol in gasoline

Methanol in Gasoline

  • 7% to 10% Blends – Equivalent to Current Ethanol Blends – RVP Increase Manageable

  • Methanol is Biodegradable - Half-Life in the Environment is ~24 Hours

  • M-10 (10% Methanol) and Higher in Current Use in China

  • Toxicity – Gasoline is Toxic. Adding 10% Methanol Does Not Change That!

  • Current E-10 Blend Infrastructure is Already In-Place


Methanol in spark ignition engines

Methanol in Spark-Ignition Engines

  • Modern Engines Designed for E-10 Fuel

  • ECU/Fuel Injection Makes CLEAN Engines

  • Higher Octane but Lower Energy Content

  • NO CHANGES REQUIRED

Then

Now


Costs

Costs?

  • Estimated Total Capital Cost US $2.8 Billion

  • Makes 50,000 BPSD (Replacing Imported Oil) From Carbon Resource ALREADY Existing

  • Methanol Production Cost is ~$0.50 per US Gal IF CO2 is Sold for EOR

  • Methanol Production Cost is ~$0.88 per US Gal if CO2 is NOT Sold for EOR

  • Lower Cost Than Ethanol OR Gasoline

  • No Additional Vehicle OR Infrastructure Costs


Conclusions

Conclusions

  • No Obvious Renewability or “Greenhouse” Advantage of EtOH over MeOH

  • No Obvious Safety or Toxicity or Hazard Advantage of EtOHover MeOH

  • Obvious Economic Advantage of Methanol Over Ethanol

  • No Additional Vehicle OR Infrastructure Costs

  • No Vehicle Performance Issues


We had valuable help from

We Had Valuable Help From:

  • Air Liquide/Lurgi – Frankfurt, Germany

  • Linde – Munich, Germany

  • Haldor Topsoe – Houston, TX

  • HDR Inc., Ann Arbor, MI

  • Methanol Institute – Washington DC and Singapore

  • Don Koza, Marshal (Bud) Bell, John Lehman, Dennis Dembicki, Michael Murphy & Others Who Wish to Remain Anonymous…


Contact information

Contact Information

Chris WallsgroveDavid Netzer

Brinderson Engineers & ConstructorsConsultant

Costa Mesa, CAHouston, TX

[email protected]@sbcglobal.net

(713) 240 8633(832) 251 1271


The end

THE END

Mercifully…

Thanks to Pennwell Publishing, for publishing

a synopsis of this paper in two parts,

June and July 2011 Oil & Gas Journal


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