Production of Gasoline Components from Synthesis GasChE 397 Senior DesignGroup Alpha

Ayesha RizviBernard HsuJeff TyskaMohammad ShehadehYacoub Awwad

2011.04.26

Overview

Process Basics Block Flow Diagram Plant and Equipment Layout General Economics Conclusions and Further Improvements

Our ProcessH2

Process Equation

2H2 + CO

ZSM-5

C5+ + H2O + LPG (C3/C4)

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

Competing Processes Fischer-Tropsch

Oil

Tar Sands

(2n+1) H2 + n CO → CnH(2n+2) + n H2O

http://portland.indymedia.org/media/images/2010/12/404850.jpg

http://tonto.eia.doe.gov/country/index.cfm?view=production

43%

Process Summary

Syngas Methanol Methanol Water/Hydrocarbons Water/Hydrocarbons Water +

Hydrocarbons Hydrocarbons Gasoline and

Liquefied Petroleum Gas (LPG)

Block Flow Diagram

Methanol

Reactor

CO

H2

MeOHH2, CO

Cooling and Separation

MeOH

H2, CO

Methanol to Gasoline (MTG) Reactors

Water Separation

Hydrocarbons

Water

Water

Hydrocarbons

Deethanizer(Dist. Col.)

C1/C2

DistillationColumns

Heavy

Hydrocarbons

Liquefied Petroleum Gas

Gasoline

Purge

Methanol

Reactor

Cooling and Separation

T (518F)

P (725psi)

CO 15,967 lbmol/hr

H2 31,935 lbmol/hr

T (518F)

P (725psi)

CO 23,059 lbmol/hr

H2 58,373 lbmol/hr

MeOH 15,948 lbmol/hr

T (345F)

P (725psi)

CO 22,464 lbmol/hr

H2 57,182 lbmol/hr

MeOH 576 lbmol/hr

T (518F)

P (725psi)

CO 23,059 lbmol/hr

H2 58,373 lbmol/hr

MeOH 15,948 lbmol/hr

T (364F)

P (435psi)

T (364F)

P (435psi)

MeOH 5 lbmol/hr

CO 136 lbmol/hr

H2 23 lbmol/hr

Rec Syngas

Syngas Syngas & MeOH

Syngas & MeOH

Syngas

MeOH

Methanol to Gasoline (MTG) Reactors

Water Separation

T (716F)

P (362psi)

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

MeOH 5 lbmol/hr

T (364F)

P (435psi)

H2O 15,109 lbmol/hr

T (305F)

P (72psi)

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

T (68F)

P (391psi)

MeOH

Hydrocarbons/Water

WaterHydrocarbons

Deethanizer(Dist. Col.)

DistillationColumns

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

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

LPG(C3,C4) 670 lbmol/hr

C5+(gasoline)2290.1 lbmol/hr

T (68F)

P (391psi)

T (71F)

P (391psi)

T (365F)

P (363psi)

H2O 1.3 lbmol/hr

LPG(C3,C4) 663 lbmol/hr

C5+(gasoline)485 lbmol/hr

H2O 0.30 lbmol/hr

LPG(C3,C4) 7.6 lbmol/hr

C5+(gasoline)1,805 lbmol/hr

T (101F)

P (96psi)

T (77F)

P (73psi)

GasolineLPG

C1/C2

Heavy

Hydrocarbons

Hydrocarbons

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

General Plant Layout

Site Plan

Process Building

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

Gasoline Price Dependence

0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.25 4.50 4.75 5.00

-8000

-6000

-4000

-2000

0

2000

4000

6000

8000

10000NPV Versus Gasoline Price

NPV

Dollars Per Gallon of Gasoline (Spot Price - .25)

NP

V (

Millions)

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

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

Conclusions & Further Improvements

The construction and implementation of this process is recommended.

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.

Durene

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

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

Questions?