Methanol for Gasoline Blending from Petroleum Coke David Netzer & Chris Wallsgrove (Speaker) Me. OH
The Premise • • • Upgrading Heavy Oil Normally Produces Petroleum Coke (Petcoke) Petcoke is Often Sold as Low-Cost Fuel Petcoke Can be Gasified to Syngas (Proven Technology) Methanol (Me. OH) is Produced from Syngas Me. OH Can be Blended with Gasoline 7% to 10% Blend of Me. OH in Gasoline Can Fuel Existing Cars (Proven Technology)
• • • Other Methanol Uses Methanol to Gasoline (MTG) – but WHY? If We Can Use Methanol AS Gasoline Methanol to DME – Diesel and/or LPG Subtitute Methanol to Propylene (MTP) or Ethylene (MTO) – Compete with Steam Crackers? Methanol to Acetic Acid & Derivatives – Limited Market Methanol to Formaldehyde & Derivatives – Same
Process Units • • Gasification – To Produce Raw Syngas • • • Shift – With Control of CO/H 2 Ratio Air Separation (ASU) – To Produce Oxygen the Gasification Rectisol – Remove H 2 S/COS and Recover CO 2 Methanol Synthesis – Makes 50, 000 BPSD Methanol Purification (Distillation) Units to Recover H 2 and Sulfur fo
Process Units Selection • • • Quench Gasifiers – Operate at High Pressure to Avoid Syngas Compression Unconverted Carbon to Boilers Gas Cooling Produces Steam Rectisol (Two Trains) Uses Methanol Solvent Two Methanol Synthesis Reactors (Large, Heavy Vessels) in Parallel Conventional PSA for H 2 Recovery, and Claus. Type Sulfur Units
Petcoke 7, 400 tpd Air Separation Nitrogen CO 2 130 bar 11, 700 tpd CO 2 Compression Oxygen 6, 600 tpd Coke Preparation And Slurrying Water, Fluxing Agent Steam & Power Systems CO 2 Gasification 87 bar Unconverted Carbon Shift & Gas Cooling Tail Gas Syn. Gas Acid Gases Steam EHP, MP, LP Steam HP, LP Rectisol Units Sulfur Plants Methanol Synthsis 78 bar Purge Gas Hydrogen Product 16 MMscfd Methanol 6, 400 tpd Sulfur Product PSA Hydrogen Recovery Reactor Purge Gas Methanol Purification 50, 000 bpsd Block Flow Diagram – Petcoke to Methanol
Energy Systems • • Totally Self-Sufficient in Steam and Power • • Steam Driven ASU Compressors – 63 MW • Fluidized Boilers, for Petcoke and Coal Plus Unconverted Carbon from Gasification MP Steam Superheating in a Fired Heater, Using PSA Purge Gas as Fuel Balance of Steam to a Generator – Excess Power Exported (About 80 MW Export) All Other Drivers Electric
130 Bar Steam From Shift De. NOx Econo Air Pre. Heat Lime Scrub SRU Tail Gas PSA Purge Gas 125 bar Steam To ASU Drivers Me. OH Bottoms Unconverted Carbon Petcoke Limestone Coal (& Biomass) Spent Gypsum PSA Purge Gas ~80% 3 x 55% Fluidized Boilers Turbine 25 bar Generator 3. 5 bar Steam From Process D/A 27 bar Steam From Process Steam & Energy Block Diagram – Petcoke to Methanol ~
Capital Cost Savings • • • Quench Gasification vrs High Efficiency with 130 Bar Steam – Saves ~$200 Million 320 MW Fluidized Boilers vrs IGCC – Saves ~$450 Million 67% CO 2 Capture vrs 95% (Shift + H 2 Power Cycle + Parasitic Mw) - Saves ~$250 Million Avoid 25 MW Methanol Synthesis Compressor – Saves ~$50 Million Other Miscellaneous Rational Savings ~$135 Million
Carbon Dioxide Disposal • • If Underground Sequestration, Costs $$$ • In Either Case, CO 2 Must Be Compressed to At Least ~125 Bar • • If Sold for Enhanced Oil Recovery (EOR), is Revenue $ Modest (67%) CO 2 Recovery Mine-To-Wheel CO 2 Release is ~Equal to Ethanol Blend
Methanol in Gasoline • • • 7% to 10% Blends – Equivalent to Current Ethanol Blends – RVP Increase Manageable Methanol is Biodegradable - Half-Life in the Environment is ~24 Hours M-10 (10% Methanol) and Higher in Current Use in China Toxicity – Gasoline is Toxic. Adding 10% Methanol Does Not Change That! Current E-10 Blend Infrastructure is Already In-Place
Methanol in Spark-Ignition Engines • • • Modern Engines Designed for E-10 Fuel ECU/Fuel Injection Makes CLEAN Engines Higher Octane but Lower Energy Content Then Now • NO CHANGES REQUIRED
Costs? • • Estimated Total Capital Cost US $2. 8 Billion • Methanol Production Cost is ~$0. 50 per US Gal IF CO 2 is Sold for EOR Makes 50, 000 BPSD (Replacing Imported Oil) From Carbon Resource ALREADY Existing • Methanol Production Cost is ~$0. 88 per US Gal • • if CO 2 is NOT Sold for EOR Lower Cost Than Ethanol OR Gasoline No Additional Vehicle OR Infrastructure Costs
Conclusions • • • No Obvious Renewability or “Greenhouse” Advantage of Et. OH over Me. OH No Obvious Safety or Toxicity or Hazard Advantage of Et. OH over Me. OH Obvious Economic Advantage of Methanol Over Ethanol No Additional Vehicle OR Infrastructure Costs No Vehicle Performance Issues
We Had Valuable Help From: • • • Air Liquide/Lurgi – Frankfurt, Germany • Don Koza, Marshal (Bud) Bell, John Lehman, Dennis Dembicki, Michael Murphy & Others Who Wish to Remain Anonymous… Linde – Munich, Germany Haldor Topsoe – Houston, TX HDR Inc. , Ann Arbor, MI Methanol Institute – Washington DC and Singapore
Contact Information Chris Wallsgrove David Netzer Brinderson Engineers & Constructors Consultant Costa Mesa, CA Houston, TX chris@wallsgrove. com netzerd@sbcglobal. net (713) 240 8633 (832) 251 1271
Thanks to Pennwell Publishing, for publishing a synopsis of this paper in two parts, June and July 2011 Oil & Gas Journal THE END Mercifully…
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