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 26, 2011 Syngas Production from Petroleum Coke Gasification
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 • H2 to CO molar ratio of 2.5 • CO2 and N2 mixed in http://coalgasificationnews.com/tag/petcoke-gasification/
Questions from Last Time • How was the PFD generated? • What is our feedstock prices?
Recap • PFD’s • Control Schemes • Plant Layout • Calculations • Refined Individual Economics • Joint Econ Presentation
Today’s Agenda • Overview of the project from day 1 till the end • Brief backgrounds • Brief process description • Aspen Simulation overview • Economics Overview • Recommendations
In the Beginning… • Mission Statement: • Design a process to produce syngas • Determine if this is a practical process • Meet the requirements of Team Golf • Decide profitability • Decide practicality
Major Decisions • Feedstock Choice • Petcoke • Gasifier Choice • Shell Entrained Flow (Membrane Wall) • Extent of Simulation • Solvent • Selexol • Syngas Price • Location
Petcoke Background • Petcoke is a byproduct of oil-refining • Heating value of 28 MMBtu/ton • More than 55 million tons in 2005 were produced in U.S. oil refineries • The sulfur content is relatively high and must be removed during processing in order to create a usable synthesis gas for the chemical production team as well as to meet the requirements of the EPA.
Gasification Background • Gasification covers the conversion of any carbonaceous fuel to a gaseous product. • This is not a complete combustion process since there is no residual heating value. Shell Entrained Flow Gasifier
Process Highlights • Pressure Driven Process • Reduction of Pumps • High Conversion of Feedstock • Highly Efficient Sulfur Removal • Sulfur removal to 2 ppm
Overall Aspen Simulation Gasifier H2S Removal Claus Process Water Gas Shift CO2 Capture and Sequestration
Syngas Pricing • First prices were generated by comparing heating values with natural gas • This proved to be too low of a price • Negotiations with Team Golf • Joint Presentation afterwards • Price determined by creating an equal IRR
Resources • Equipment Sizing and Cost – Aspen • Amount of Required Catalyst and Solvent -Aspen & Hand Calculations • Economics - Used sheet provided by Mr. Jerry Palmer as a basic template & Microsoft Excel to calculate NPV and IRR • PFD, BFD, and Control Scheme – Aspen, Visio, Microsoft Excel
Communication • Price for Selexol – UOP ($3.20/lb) • Price for Zinc-Oxide – UOP ($55/lb) • Price for Petcoke – Dover ($75/ton) • Amount of Selexol & Equipment Required for CO2 Capture – Dow Oil & Gas (~4 MMlb/day Selexol)
Location and Layout • 4923 Port Rd., Pasadena, TX • 2.5 Miles West of Trinity Bay • Existing Roads and Railroads • 140 Acres with Acetic Acid Production (Team Golf)
Advantages • High yield of syngas • CO2 capture makes the process environmental friendly • Advantage of location: • Supply and ease of transportation of feedstock and product • Feedstock Advantage: • Byproduct of oil refining • It has high calorific content
Disadvantages • Petroleum coke is high in Sulfur content • Expensive Gasifier • Cost of Petroleum coke fluctuates with crude oil prices • Water-Gas shift reaction yields higher amount of CO2
Recomendations • Combining the facilities early on • There is no such thing as a stand alone gasifier plant • Finishing up some of the loose ends of the project • Chemical Disposal • Sulfur • Zinc Oxide • Tail Gas • Slag • Heavy Metals • Complete Heat Integration
References • (http://www.netl.doe.gov/technologies/coalpower/gasification/gasifipedia/4-gasifiers/4-1-2-3_shell.html)
Report Outline • Final Report: • Executive Summary Done • Discussion Done • Recommendations Done • Appendices • Design Basis: Done • Block Flow Diagram: Done • Process Flow Showing Major Equip.: Done
Report Outline • Appendices (Continued) • Material and Energy Balances: Done • Calculations: Done • Annotated Equip. List: Done • Econ. Eval. Factored from Equip. Costs: Done • Utilities: Done • Conceptual Control Scheme: Done • Major Equipment Layout: Done
Report Outline • Appendices (Continued) • Distribution and End-use Issues: Done • Constraints Review: Done • Applicable Standards: Done • Project Communications File: Done • Information Sources and References: Done
Composition of Petcoke(3) • Ultimate Analysis • Proximate Analysis Average Petcoke Metal Makeup(5)
CO2 Sequestration • CO2 in our syngas is absorbed on Selexol to be selectively removed • Delete only one CO2 slide.