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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 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

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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 2011.04.26

  2. Overview • Process Basics • Block Flow Diagram • Plant and Equipment Layout • General Economics • Conclusions and Further Improvements

  3. Our Process H2

  4. Process Equation 2H2 + CO ZSM-5 C5+ + H2O + LPG (C3/C4)

  5. 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

  6. 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

  7. Process Summary • Syngas  Methanol • Methanol  Water/Hydrocarbons • Water/Hydrocarbons  Water + Hydrocarbons • Hydrocarbons  Gasoline and Liquefied Petroleum Gas (LPG)

  8. 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

  9. 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

  10. 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

  11. 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

  12. 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

  13. General Plant Layout

  14. Site Plan

  15. Process Building

  16. 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

  17. Gasoline Price Dependence

  18. 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

  19. 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

  20. 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

  21. 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

  22. 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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