Team:
FOXTROT
Mentor: Dan Rusinak
Crew: Ali, Mudassir
Drake, Stephen
Meaux, Kevin
Sieve, Brandon
Foxtrot, University of Illinois at Chicago
1
Foxtrot, University of Illinois at Chicago
2

Is Cobalt a better choice for a catalyst as
compared to Iron?
◦ Catalyst comparison: $8/lb Fe vs. $40/lb Co
Co prices tend to be volatile
compared to iron. Also need
to contend with hazardous
waste disposal.
◦ Fe gives a better alpha value for wax (0.95) when
compared to Co (0.92)
◦ The diesel output of Fe plants (58%) are similar to
Co plants (60%)
Foxtrot, University of Illinois at Chicago
3

How to model the SCBR?
◦ On a preliminary level we will avoid modeling the
SCBR by using the syncrude composition predicted
by De Klerk
◦ If time is available for further modeling we plan to
use an equilibrium reactor simulation in Aspen
Foxtrot, University of Illinois at Chicago
4

What role does the rwgs reaction play?
◦ The functional form of Keq for the wgs is
◦ Keq(603 K) is 142
◦ The rwgs reaction is not thermodynamically
favored
◦ We will need to look at kinetics to see if wgs
significantly effects our feed requirements
Foxtrot, University of Illinois at Chicago
5
Energy
Density
(Btu/gal)
Natural
Gas
Crude
Oil
$/MM Btu
Energy
Efficiency
$/ MM
Btu of
Product
140
$3.24
44%
$7.43
138,000
$16.79
80%
$21.00
Foxtrot, University of Illinois at Chicago
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6
Area 1
SBCR
Area 3
Hydrocracker/
Separation Units
Area 2
Alkylation/
Separation Units
Area 4
Transportation
fuels
Foxtrot, University of Illinois at Chicago
7
FT
Alkylation
Reaction
Hydrocracking
Foxtrot, University of Illinois at Chicago
8
FT Reaction Area PFD
Foxtrot, University of Illinois at Chicago
9
Arno De Clerk
Foxtrot, University of Illinois at
Chicago
10
Material Balance for FT Reaction Area
Stream No.
1
Description
Unit
2
3
4
5
Syngas
Feed
lb-mol/hr
6
7
8
9
10
H2 Permeate
Syngas to
Reactor
lb-mol/hr
lb-mol/hr
11
12
Wax
FischerTropsch
Products
Recycle
Hot
Condensat
e
FischerTropsch
Products
Cold
Condens
ate
Aqueous
Products
Tail Gas
Hot and
Cold
Condensate
lb-mol/hr
lb-mol/hr
lb-mol/hr
lb-mol/hr
lb-mol/hr
lbmol/hr
lb-mol/hr
lb-mol/hr
lb-mol/hr
CO
3809.58
0.00
3809.58
0.00
1523.83
0.00
0.00
1523.83
0.00
0.00
1523.83
0.00
H2
9524.17
1714.53
7809.64
0.00
3123.86
0.00
0.00
3123.86
0.00
0.00
3123.86
0.00
N2
77.92
0.00
77.92
0.00
77.92
0.00
0.00
77.92
0.00
0.00
77.92
0.00
H2O
0.00
0.00
0.00
0.00
2285.75
0.00
0.00
2285.75
0.00
2285.75
0.00
0.00
CO2
394.17
0.00
394.17
0.00
394.17
0.00
0.00
394.17
0.00
0.00
394.17
0.00
C1
0.00
0.00
0.00
0.00
98.29
0.00
0.00
98.29
0.00
0.00
98.29
0.00
C2 alkene
0.00
0.00
0.00
0.00
22.86
0.00
0.00
22.86
0.00
0.00
22.86
0.00
C2 alkane
0.00
0.00
0.00
0.00
22.86
0.00
0.00
22.86
0.00
0.00
22.86
0.00
C3-C4 alkene
0.00
0.00
0.00
0.00
137.14
0.00
0.00
137.14
137.14
0.00
0.00
137.14
C3-C4 alkane
0.00
0.00
0.00
0.00
41.14
0.00
0.00
41.14
41.14
0.00
0.00
41.14
C5-C10 alkene
0.00
0.00
0.00
0.00
176.00
0.00
0.00
176.00
176.00
0.00
0.00
176.00
C5-C10 alkane
0.00
0.00
0.00
0.00
75.43
0.00
0.00
75.43
75.43
0.00
0.00
75.43
C5-C10 oxygenate
0.00
0.00
0.00
0.00
29.71
0.00
0.00
29.71
29.71
0.00
0.00
29.71
C11-C22 alkene
0.00
0.00
0.00
0.00
130.29
0.00
130.29
0.00
0.00
0.00
0.00
130.29
C11-C22 alkane
0.00
0.00
0.00
0.00
308.58
0.00
308.58
0.00
0.00
0.00
0.00
308.58
C11-C22 oxygenate
0.00
0.00
0.00
0.00
6.86
0.00
6.86
0.00
0.00
0.00
0.00
6.86
C22+ alkene
0.00
0.00
0.00
16.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
C22+ alkane
0.00
0.00
0.00
1124.59
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
aqueous alcohol
0.00
0.00
0.00
0.00
89.14
0.00
0.00
89.14
0.00
89.14
0.00
0.00
aqueous carboxylic
acid
0.00
0.00
0.00
0.00
6.86
0.00
0.00
6.86
0.00
6.86
0.00
0.00
13805.84
1714.53
12091.31
1140.59
8550.69
0.00
445.72
8104.96
459.44
2381.75
5263.78
905.16
Total
Foxtrot, University of Illinois at Chicago
11
Energy Balance for FT Reaction Area
h 603k
KJ/Kgmole
h 603 K
Btu/lbmole
3
(lbmol/hr)
4
(lbmol/hr)
5
(lbmol/hr)
h in
Btu/hr
h out
Btu/hr
CO
-101625
-43791
3810
0
1524
-166825016
-66730007
H2
8784
3785
7810
0
3124
29560307
11824123
N2
8845
3811
78
0
78
296984
296984
H2O
-275552
-118738
0
0
2286
0
-271404830
CO2
-382185
-164687
394
0
394
-64914586
-64914586
-64012
-27583
0
0
98
0
-2711068
C2 alkene
65555
28248
0
0
23
0
645679
C2 alkane
-67688
-29167
0
0
23
0
-666688
C3-C4 alkene
36524
15739
0
0
137
0
2158458
C3-C4 alkane
-82339
-35481
0
0
41
0
-1459791
C5-C10 alkene
7851
3383
0
0
176
0
595454
C5-C10 alkane
-132063
-56907
0
0
75
0
-4292494
C5-C10 oxygenate
-187950
-80989
0
0
30
0
-2406577
C11-C22 alkene
-79576
-34290
0
0
130
0
-4467566
C11-C22 alkane
-365094
-157322
0
0
309
0
-48545824
1510
651
0
0
7
0
4462
C22+ alkene
-197500
-85105
0
16
0
0
-1361693
C22+ alkane
-511033
-220209
0
1125
0
0
-247644300
aqueous alcohol
-309600
-133409
0
0
89
0
-11892675
aqueous carboxylic
acid
-527235
-227190
0
0
7
0
-1557900
12091
1141
8551
-201882312
-714530839
C1
C11-C22 oxygenate
total
Q reactor=
Q reactor=
-512648527
Btu/hour
-150.2 MW
Foxtrot, University of Illinois at Chicago
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Akylation Area PFD
Foxtrot, University of Illinois at Chicago
13
Hydrocracking Area PFD
Foxtrot, University of Illinois at Chicago
14
Alkylation vs. Oligomerization
o Foxtrot needed a process to convert LPG, Naptha, and Distillate olefins to
heavier hydrocarbons
o Oligomerization tends to be more expensive; it requires more H2, more
expensive catalyst, and produces straight chain alkanes
o Alkylation reacts olefins with paraffins which produces twice as much
high quality naptha product
o Alkylation also has the advantage of producing branched naptha (a very
high quality naptha), which can be blended with lower-quality naptha
produced by hydrocracker
o Diesel with lower Cetane rating can be blended with high-quality diesel to
improve cold weather properties
Foxtrot, University of Illinois at
Foxtrot, University of Illinois
Chicago
at Chicago
15
15

<5000 BPD plant has TIC of $120,000 to
$150,000 per BPD
>20,000 BPD plant has TIC of $75,000 to
$100,000 per BPD
These values include an SMR/ATR unit, but
no alkylation unit
FT synthesis/refining accounts for 35% of TIC

Therefore, TIC = 210 – 262 MM$

We will produce 80k lb/day of steam



*Estimates obtained from private communication with Rentech
Foxtrot, University of Illinois at Chicago
16
Per
Gallon
[2]
Per
Barrel
Barrel/Year
(Million)
Diesel
Fuel
Naptha
$3.97
$167
1.06
Annual
Revenue
(Million)
$177
$3.63
$152
0.26
$40
Jet Fuel
$3.30
$139
0.26
$36
LPG
$0.99
$42
0.14
$6
1.72
$259
Total
Foxtrot, University of Illinois at Chicago
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







US Geological Survey, Minerals Commodities
Summaries.
Dividing Wall Columns, Michael A. Schultz, Douglas
G. Stewart, James M. Harris, Steven P. Rosenblum,
Mohammed S. Shakur and Dennis E. O’Brien UOP.
Dividing Wall Columns,2010 AiChE, Jacobs
consultancy .
STRATCO, Alkylation unit.
Bechtel Article, 2001
M E DRY, 2008
Fischer Tropsch refining, arno de klerk.
US Energy Information Administration, www.eia.gov

Foxtrot, University of Illinois at Chicago
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 Questions please.
Foxtrot, University of Illinois at Chicago
19


Sequence Distillation
A (lightest) B ( Middle) C (Heaviest)
Foxtrot, University of Illinois at Chicago
20


Energy lost
Thermal inefficiency
Foxtrot, University of Illinois at Chicago
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Foxtrot, University of Illinois at
Chicago
22
.
Foxtrot, University of Illinois at Chicago
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
Because the Petlyuk arrangement has fewer
pieces of major equipment than does the
conventional two-column sequence, total
capital costs may be reduced.
Foxtrot, University of Illinois at
Chicago
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.
Foxtrot, University of Illinois at Chicago
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


Reduces the energy cost by 30%
Reduces equipment cost by 50%
Reduction is the capital cost by 40%
Foxtrot, University of Illinois at
Chicago
26


Alkylation is a major way of upgrading
petroleum
Formation of heavier highly branched alkanes
from the reaction between isobutanes and
alkenes.
Foxtrot, University of Illinois at Chicago
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Foxtrot, University of Illinois at
Chicago
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Foxtrot, University of Illinois at
Chicago
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Foxtrot, University of Illinois at
Chicago
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


Utilizes a liquid-full reactor system where the
heat of reaction is removed with an internal heat
exchanger.
Vaporization is prevented by maintaining the
reactor system at sufficient pressure.
The obvious advantage of the liquid-full system
(STRATCO ) is that the isobutane remains in the
liquid state continuously available for reaction in
higher concentrations.
Foxtrot, University of Illinois at
Chicago
31

Easy operation

No worries about the acid or hydrocarbon
levels in the reactor system

High internal circulation rates for even heat
dissipation

Highly dispersed hydrocarbon in acid
emulsion
Foxtrot, University of Illinois at
Chicago
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



Increased interfacial catalyst area provided by
mixing
Reduced acid consumption
Superior quality alkylate 1.5 octane
number advantage
Ease of reactor operation
Foxtrot, University of Illinois at
Chicago
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



Upgrading waxes to alkanes
It is a hydrogen addition technology that
removes heteroatoms, increases the H:C ratio
of the product
It is nearly isothermal giving a conversion of
70-80% conversion of wax to products
Will use a divided wall column and a low
pressure column to separate products
Foxtrot, University of Illinois at Chicago
34
Foxtrot, University of Illinois at
Chicago
35