Production of Gasoline Components from Synthesis Gas
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Transcript of Production of Gasoline Components from Synthesis Gas
Production of Gasoline Components from Synthesis GasChE 397 Senior DesignGroup Alpha
Ayesha RizviBernard HsuJeff TyskaMohammed ShehadehYacoub Awwad
2011.02.15
Recap
H2
Block Flow Diagram
Methanol
Reactor
Wastewater
treatment
H2O, trace contaminants
CO
H2
MeOH DME
Reactor
Methanol to Gasoline Reactors
DME
H2O
MeOH
Distillation Columns
Heavy Gasoline
Light Gasoline
Storage
Crude Gasoline
Light Gas
Overall Flowsheet
Mass Balance Basis: 3307 Tons per Day Syn Gas
Syngas to Methanol
CO: 8611.72 lbmol/hrH2: 17223.45 lbmol/hr
CO: 141.09 lbmol/hrH2: 18.48 lbmol/hr
CO: 243.98 lbmol/hrH2: 594.88 lbmol/hr
Mass Balance Basis: 3307 Tons per Day Syn Gas
MeOH: 8226.65 lbmol/hr
DME reaction
MeOH: 8226.65 lbmol/hrMeOH: 2468.00 lbmol/hrDME and H2O: 2879.33 lbmol/hr
Mass Balance Basis: 3307 Tons per Day Syn Gas
Methanol to Gasoline
Effluent: 8226.65 lbmol/hr
After the MTG Reaction
Cooling Separator
End Refining
LPGPRG
Final Recycle
Material BalanceMethanol Reactor
Syn Gas: CO: 8612 lbmol/hr purge: CO: 244 lbmolH2: 17223 lbmol/hr H2: 594.9 lbmol
Recycle: CO: 12199 lbmol/hr product: CO: 141.1 lbmolH2: 29744 lbmol/hr H2: 18.48 lbmol
MeOH: 8227 lbmol2.207505519
In Out
Material BalanceDME Reactor
MeOH: 8227 lbmol/hr MeOH: 2468 lbmol/hrH2O: 0 lbmol/hr H2O: 2879 lbmol/hr
DME: 2879 lbmol/hr
2.207505519
In: Out:
Material BalanceComponent Profile
Component lbmol/hrH2 0C1 27.55832CO 0CO2 0C2 = 7.873805C2 8.818661C3 = 10.49841C3 162.3435iC4 142.1629C4 = 10.23595nC4 42.57285
Component lbmol/hrC5's 58.87856C6's 7.870113C7's 3.148045C8's 1.83636C9's 0.655843C10's 0.131169Benzene 9.610079Toluene 50.32388C8 AROM 74.84642C9 AROM 4.842082C10 AROM 1.832139C11 AROM 0.261734Methanol 0DME 0H20 2818.389
Total 3444.69lbmol/hr
Assumptions1. All H2 is taken away in the
light gas2. All CH4 is taken away in the
light gas3. All ethane is taken away in
the light gas4. 30% of the propane is taken
away in the light gas5. None of the butane is taken
away in the light6. All CO/CO2 is lost in the light
gas7. All water is immiscible with
the other components, leaves completely
8. Remaining components are in the second liquid phase
Continued above
Liquid Hydrocarbon Components C3 = 7.34888
C3 113.64iC4 142.163C4 = 10.2359nC4 42.5728C5's 58.8786C6's 7.87011C7's 3.14805C8's 1.83636C9's 0.65584C10's 0.13117Benzene 9.61008Toluene 50.3239C8 AROM 74.8464C9 AROM 4.84208C10 AROM 1.83214C11 AROM 0.26173Total 530.2
lbmol/hr
Material BalanceLPG Flowrates
lbmol/hr %
C1 0 0C2 = 0 0C2 0 0C3 = 7.348884 2.283334C3 113.6405 35.30864iC4 142.1629 44.1707C4 = 10.23595 3.180358nC4 42.57285 13.22759C5's 5.887856 1.829385Total 321.8489
lbmol/hr
Assumptions1. All of the remaining
propane goes out the vapor stream
2. All of the remaining butane goes out the vapor stream
3. 10% of the pentane goes out the vapor stream
4. The liquid component out the stripper is our final product
Material BalanceProduct Composition
C5's 52.9907C6's 7.870113C7's 3.148045C8's 1.83636C9's 0.655843C10's 0.131169Benzene 9.610079Toluene 50.32388C8 AROM 74.84642C9 AROM 4.842082C10 AROM 1.832139C11 AROM 0.261734
Total 208.3486lbmol/hr
Energy Balance
rxnMeOHMeOH
DMEH2O
Heat of formation: ΔHF= m DME,outΔHF(DME)+m MeOH,outΔHF(MeOH)+
mH2O,outΔHF(H2O)- mMeOH,inΔHF(MeOH) =
ΔHF=Σm*cp*(Tout-Tin)+Q Q:heat loss to surroundings Tin=590°F
-29.2 MM Btu/hr
Energy Balance
At heat loss of 3400 Btu Tout= 860°F Heat loss to surroundings negligible Reactor Sizing: PV=nRT V=315.6 Ft3
diameter d=8 Ft , height h=25 Ft considering the reactor as a cylinder Area=2*pi*(d/2)*h+2*pi*(r2 /4) =729 Ft2
Residence Time: 5 seconds for MeOH and Durene Reactor. 10 seconds for MTG Reactors.
Equipment Costs
Component Name Component Type Equipment Cost Total Direct Cost(USD) (USD)
DMEREACT DAT REACTOR 162000 450000FLASH-flash vessel DVT CYLINDER 143000 295100GASMEHX DHE FLOAT HEAD 25900 102000HCCOOLER DHE FLOAT HEAD 20200 98200HEATER DHE FLOAT HEAD 791300 1.21E+06HEATEX DHE FLOAT HEAD 47200 157800MEOHRXN DAT REACTOR 170000 4500003PHASESP-flash vessel DVT CYLINDER 47000 178200ACCMLTR-flash vessel DVT CYLINDER 42700 155700GASPROD1 DAT REACTOR 2.00E+06 6.00E+06GASPROD2 DAT REACTOR 2.00E+06 6.00E+06GASPROD3 DAT REACTOR 2.00E+06 6.00E+06HCSHEAT DHE FLOAT HEAD 16000 77100HEATER2 DHE FLOAT HEAD 14800 77700HEATER3 DHE FLOAT HEAD 14800 77700HEATER4 DHE FLOAT HEAD 14800 77700STRIPPER-cond DHE FIXED T S 15800 77300STRIPPER-cond acc DHT HORIZ DRUM 13100 69200STRIPPER-reb DRB U TUBE 13900 69900STRIPPER-reflux pump DCP CENTRIF 4200 30000STRIPPER-tower DTW TRAYED 89900 243700Catalyst Catalyst 10000000 10000000
Totals: 1.76E+07 3.19E+07USD USD
What affects the Gasoline Prices
Seasonal Switch in Gasoline blends
Crude Oil Cost
Taxes and Fees
Supply and Demand
Transportation and Distribution Cost
Pricing Gasoline
http://www.api.org/aboutoilgas/gasoline/upload/PumpPriceUpdate.pdf
Economics of Products Average gasoline price in the city of Chicago is
$3.29 per gallon
Nationwide the average is $3.13 per gallon
Our gasoline price with low olefin and low Durene is roughly about $ 2.63 per gallon
Product: $84.6 Million / year
LPG : $5.4 Million / year
Major Components of Gasoline
ComponentsTotal Percentage
Composition
n-Alkanes C5, C6, C7, C9, C10-C13 17.3%
Branched Alkanes C4, C5, C6, C7, C8, C9, C10-C13 32.0%
Cycloalkanes C6, C7, C85.0%
Olefins C6
1.8%
Aromatics Benzene, Toluene, Xylenes, Ethylbenzene, C3
– Benzenes, C4-Benzenes
30.5%
Properties of Gasoline Blends
Octane Number (MON/RON) ranges (83/96 – 90/102)
Reid Vapor Pressure (psi) ranges (5 - 12)
Final Boiling Point (°C) ranges (180 - 210)
Sulfur (ppm) ranges (10 - 50)
Mixtures of C5-C10 Hydrocarbons
Major Components of Gasoline
Newton County
MTG Process, IN
RefineryJoliet, IL
Refinery Whiting,
IN
Transporting to Refineries
Key supplier of refined petroleum products to the Midwest.
250,000 barrels of crude per day
Produces ~9 million gallons of gasoline, diesel fuel/day.
Joliet, IL
http://www.exxonmobil.com/Corporate/Files/joliet_brochure.pdf
Whiting, IN
405,000 barrels of raw crude oil/day
Produce 15 million gallons refining products.
Whiting Refinery Modernization Project
http://www.bp.com/sectiongenericarticle.do?categoryId=9030203&contentId=7055766#7205736
Transport of Gasoline Pipeline transport
Railroad transport
Gasoline truck transportation
Gasoline Blending Conversion process in petroleum refining
Fluid Catalytic Cracker (FCC)
Alkylate Catalytic Reforming
• Cracking hydrocarbons by vaporization
• breaking long chained high-boiling hydrocarbon molecules
• presence of a fluidized powdered catalyst
• Isobutane is alkylated with low molecular weight alkenes
• presence of a strong acid catalyst• sulfuric acid or
hydrofluoric acid
• Petroleum refinery naphtha • low octane
• high octane liquid products
Questions from Presentation 1
Catalysts: How long do they last? ZSM-5: Pressure and temp (305 psi,
350ºC) is 52 days Is gasoline >10% olefins?
No, our product is 3.73 wt% olefins. May change with other conditions
Durene High melting point 3-6% from literature 2% Limit
1% in our gasoline Blending Other Methods
End!
Questions From Last Presentation Removal of the water is desirable
because the catalyst may tend to become deactivated by the presence of the water vapor at the reaction temperatures employed, but this step is by no means essential
Sulfuric Acid Alkylation The Alkylation reaction combines
Isobutane with light Olefins primarily a mix of
Butylene and Propylene
in the presence of a strong acid catalyst, Sulfuric Acid
This process results in upgrading the gasoline blend to a high octane blending component.
Low Olefin Content (3.73 wt%)