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Gasoline Component Production from Synthesis Gas: Design Overview & Economics Analysis

This presentation covers the design of a plant for producing gasoline components from synthesis gas, including process flow diagrams, control schemes, economics, and plant layout considerations. It also explores reactor sizing calculations, cost analysis, and safety considerations for the plant design. The economic analysis includes revenue, profit, payback period, and pricing details for the MTG reactors.

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Gasoline Component Production from Synthesis Gas: Design Overview & Economics Analysis

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  1. Production of Gasoline Components from Synthesis Gas ChE 397 Senior Design Group Alpha Ayesha Rizvi Bernard Hsu Jeff Tyska Mohammad Shehadeh YacoubAwwad 2011.04.05

  2. Presentation Overview • Recap • PFD • Initial Control Scheme • Refined Economics • Plant Layout • Calculations

  3. Recap H2

  4. 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

  5. Questions from Last Presentation • Why are we using the fluidized bed MTG reactor? • Catalyst Regeneration • Economics • Data • Why is our methanol reactor at this pressure? • Normal operation • How do we startup our facility • Syngas • Methane • We are using an inefficient distillation scheme • Varied stages/RR ratio to no avail

  6. 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

  7. Economics Overview • Plant Revenue: $575 Million/year • Profit: $87.2 Million per year • Simple Payback: 4.16 years • Plant Upfront cost: $363 Million • IRR of 25% • Cost of utilities, maintenance, and catalyst: $22.7 Million/yr (reduced by 1/2)

  8. Analysis of NPV% vs. a Range of Gasoline Prices.

  9. Analysis of NPV% vs. a range of LPG%

  10. Analysis of NPV% vs. a Range of Syngas %

  11. Analysis of NPV% vs. Plant Cost %

  12. Detailed MTG Reactor Pricing • Sizing from NREL standards • Original price from NREL • 6/10 factor for reactors • CEPCI to update prices • Total reactor cost = 13.8 Million

  13. Plant Layout Considerations: • Location:- • It must be far from public areas (schools, living communities, etc) • Must have access to any transportation (Railroads, roads, sea, etc) • Safety & design • Employees safety plays an important role in plant design. • Also taking into account, for any future expansion & Space for maintenance. • Cost: • Includes: capital and operating.

  14. Site Plant

  15. Process Building

  16. Methanol Reactor Detailed Sizing Calculation • Heat transfer and kinetics • U = 150 BTU/hr • Q = UAΔ T • GHSV 8000 1/hr • Volume inside tubes • D = 8.3 ft, H = 33.2 ft

  17. MTG Reactor Sizing • Diameter: 2.68 ft • Flow rate: 95,400 • Velocity: 3.04 • Height: 77.89 ft • Volume of the reactors is now the volume of the catalyst. • Mass: 40,761 lb Density: 93 10 Ft/Sec

  18. Questions?

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