Gasoline Components from Synthesis Gas: Design & Economics Analysis

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

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

Recap H2

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

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

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

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)

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

Analysis of NPV% vs. a range of LPG%

Analysis of NPV% vs. a Range of Syngas %

Analysis of NPV% vs. Plant Cost %

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

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.

Site Plant

Process Building

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

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

Questions?

Gasoline Components from Synthesis Gas: Design & Economics Analysis

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