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 5, 2011
1

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
http://coalgasificationnews.com/tag/petcokegasification/
▪ CO to H2 molar ratio of 0.409
▪ CO2 and N2 mixed in
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
Discussed Our Aspen Simulation






Gasifier
Sulfur Removal
Water Gas Shift
CO2 Removal
Claus Process
Heat Loads
 Optimization


Equipment Costs and Sizes
Individual Economics
 Sensitivity Analysis

Location
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
PFD

Initial Control Scheme

Plant Layout (General Arrangement)

Calculations

Refined Economics
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Raw Materials
Petcoke (T/D)
Zinc Oxide
(lbm/day)
Selexol
Ferro-chrome
Aluminium Oxide
Oxygen
Total
Quantity
(lbm/day)
Price ($/lbm)
Total Cost (day)
Cost ($)/(year)
4,409,200
0.034
$ 150,000
$ 52,500,000
392.73
55.00
$21,600
$ 7,560,053
6,200,000
3.20
$19,840,000
$ 19,840,000
53,001
1.33
$ 70,492
$ 24,672,215
450
23.17
$ 10,416
$ 3,645,468
4,232,832
0.028
$ 117,120
$ 40,992,000
$ 149,209,735
Annual Operating Cost
CW+NG+Elec,
21.5, 12%
Maintenance,
7, 4%
Labor, 0.9, 0%
Raw Material cost
Raw Material
Cost
149
84%
4/5/2011
Labor
CW+NG+Elec
Maintenance
22
CO2
Sequatration,
17%
$31 mm
Sulfur Removal, 9%
$17 mm
Gasifier, 74%
$135 mm
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1st year
2nd Year
Revenue
$
Cap. Cost
$ 25,546,569
Op. Cost
Total Expense
$
-
-
$ 25,546,569
$
3Rd year
-
$ 104,011,033
$
-
$ 104,011,033
$
4th year
-
$ 129,570,000
$ 72,990,199
$ 20,072,305
$
$ 72,990,199
$ 151,307,886
$ 281,203,980
$ 13,144,845
$ 83,909,549
$
-
$
-
Income After
Tax
$
-
$
-
$
-
NPV
-
$ 242,943,820
-
$129,557,602
$
$ 111,070,226
$
$ 25,546,569
$ 240,352,994
-
Income tax
40%
Cumulative
Cash Flow
19th Year
$202,547,801
$89,282,710
IRR
N/A
Interest
8%
$
19,717,268
$125,864,323
$ 168,810,442
$1,540,424,893
Cumulative Cash Flow ($MM/year)
$1,550
$1,350
$1,150
($MM/YR)
$950
$750
$550
$350
$150
-$50
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
-$250
Years
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NPV Vs. Syngas Prices
$600.00
Net Present value ($million)
$500.00
$400.00
$300.00
NPV
$200.00
$100.00
$0.00
$150.00
-$100.00
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$170.00
$190.00
$210.00
$230.00
$250.00
$270.00
$290.00
$310.00
$330.00
Syngas($/ton)
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IRR vs. Syngas Price
35.00%
30.00%
25.00%
Internal Rate of return
20.00%
15.00%
10.00%
IRR
5.00%
0.00%
$150.00
$170.00
$190.00
$210.00
$230.00
$250.00
$270.00
$290.00
$310.00
$330.00
-5.00%
-10.00%
-15.00%
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Syngas ($/ton)
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NPV Vs. Petcoke Prices
600
Net Present value ($million)
500
400
300
NPV
200
100
0
0
20
40
60
80
100
120
140
160
Petcoke($/ton)
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IRR vs. Petcoke Price
35.00%
30.00%
Internal Rate of return
25.00%
20.00%
IRR
15.00%
10.00%
5.00%
0.00%
50
70
90
110
130
150
170
Petcoke ($/ton)
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
PFD

Control Schemes

Plant Layout

Calculations

Refined Economics
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
Revise report
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
Richard Parkinson. “Where Does It Go? An
Introduction to the Placement of Process
Equipment.” UOP PowerPoint. 2009. 2 April
2011.
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
Final Report:
 Executive Summary
 Discussion
 Recommendations

IP
IP
IP
Appendices
 Design Basis:
 Block Flow Diagram:
 Process Flow Showing Major Equip.:
4/5/2011
Done
Done
Done
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
Appendices (Continued)
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Material and Energy Balances:
Done
Calculations:
IP
Annotated Equip. List:
Done
Econ. Eval. Factored from Equip. Costs:
Done
 Utilities:
IP
 Conceptual Control Scheme:
Done
 Major Equipment Layout:
Done
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
Appendices (Continued)
 Distribution and End-use Issues:

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IP
Constraints Review:
IP
Applicable Standards:
IP
Project Communications File:
IP
Information Sources and References: IP
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Inlet Fraction Clean
Syngas Component
Flow for WGS Reactor (lbmoles/hr) for WGS
4/5/2011
Cp (btu/lbmole* F)
Outlet Syngas Comp
(lbmole/hr) from
(WGS)
CO
4946.233
7.118
123.395
H2O
6424.688
15.367
1601.850
N2
199.954
7.158
199.954
H2*
2960.168
6.948
7783.006
CO2
469.211
10.559
5292.049
CH4*
0.255
12.432
0.255
H2S
0.000
0.000
0.000
COS
0.000
0.000
0.000
Total
15000.509
15000.509
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Gasifier Equipment
Heat Load (MMBtu/hr)
Gasifier
-34.7
HP Steam Heat Exchanger
139.0
MP Steam Heat Exchanger
281
Cooler
-106.8
Flash
2.99
Sulfur Clean Up Equipment
Heat Load (MMBtu/hr)
Sulfur Stripper Reboiler
57.0
Sulfur Stripper Cooler
-200.0
Selexol Cooler
-40.7
Rich / Lean Heat Exchanger
274.9
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

CO2 in our
syngas is
absorbed on
Selexol to be
selectively
removed
Delete only one
CO2 slide.
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http://fossil.energy.gov/images/programs/sequestration/what_sequestration
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_lg.jpg
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