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Methanol for Gasoline Blending from Petroleum Coke David Netzer & Chris Wallsgrove (Speaker) MeOH.

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Presentation on theme: "Methanol for Gasoline Blending from Petroleum Coke David Netzer & Chris Wallsgrove (Speaker) MeOH."— Presentation transcript:

1 Methanol for Gasoline Blending from Petroleum Coke David Netzer & Chris Wallsgrove (Speaker) MeOH

2 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 (MeOH) is Produced from Syngas MeOH Can be Blended with Gasoline 7% to 10% Blend of MeOH in Gasoline Can Fuel Existing Cars (Proven Technology)

3 Other Methanol Uses AS 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

4 Process Units Gasification – To Produce Raw Syngas Air Separation (ASU) – To Produce Oxygen for the Gasification Shift – With Control of CO/H 2 Ratio 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

5 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

6 Petcoke 7,400 tpd Rectisol Units CO 2 Compression Shift & Gas Cooling Gasification 87 bar Steam & Power Systems Coke Preparation And Slurrying Air Separation Methanol Purification Sulfur Plants Methanol Synthsis 78 bar PSA Hydrogen Recovery CO bar 11,700 tpd Hydrogen Product 16 MMscfd Purge Gas Unconverted Carbon Sulfur Product Reactor Purge Gas Methanol 6,400 tpd Nitrogen Air Steam HP, LP Steam EHP, HP, MP, LP Oxygen Tail Gas CO 2 Acid Gases 50,000 bpsd Water, Fluxing Agent 6,600 tpd Block Flow Diagram – Petcoke to Methanol Syn- Gas

7 Energy Systems Totally Self-Sufficient in Steam and Power Fluidized Bed Boilers, for Petcoke and Coal Plus Unconverted Carbon from Gasification MP Steam Superheating in a Fired Heater, Using PSA Purge Gas as Fuel Steam Driven ASU Compressors – 63 MW Balance of Steam to a Generator – Excess Power Exported (About 80 MW Export) All Other Drivers Electric

8 Steam & Energy Block Diagram – Petcoke to Methanol ~ SRU Tail Gas Limestone Coal (& Biomass) Spent Gypsum 27 bar Steam From Process 130 Bar Steam From Shift Unconverted Carbon PSA Purge Gas ~80% Petcoke DeNOx Econo D / A 3.5 bar Steam From Process 3 x 55% Fluidized Bed Boilers TurbineGenerator 25 bar 125 bar Steam To ASU Drivers PSA Purge Gas MeOH Bottoms Air Pre- Heat Lime Scrub

9 Capital Cost Savings Quench Gasification vrs High Efficiency with 130 Bar Steam – Saves ~$200 Million 320 MW Fluidized Bed 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

10 Capital Cost Savings, Continued Avoid Sulfur Plant Tail Gas Treating – Saves ~$45 Million High Pressure Rectisol Avoids Third Train – Saves ~$50 Million Higher CO 2 Flash Pressure Reduces Compressor Cost by ~$20 Million A Single, Common, Rectisol Refrigeration System – Saves ~$20 Million

11 Carbon Dioxide Disposal If Underground Sequestration, Costs $$$ If Sold for Enhanced Oil Recovery (EOR), is Revenue $ In Either Case, CO 2 Must Be Compressed to At Least ~125 Bar Modest (67%) CO 2 Recovery Mine-To-Wheel CO 2 Release is ~Equal to Ethanol Blend

12 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

13 Methanol in Spark-Ignition Engines Now Then Modern Engines Designed for E-10 Fuel ECU/Fuel Injection Makes CLEAN Engines Higher Octane but Lower Energy Content NO CHANGES REQUIRED NO CHANGES REQUIRED

14 Costs? Estimated Total Capital Cost US $2.8 Billion Makes 50,000 BPSD (Replacing Imported Oil) From Carbon Resource ALREADY Existing Methanol Production Cost is ~$0.50 per US Gal IF CO 2 is Sold for EOR 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

15 Conclusions No Obvious Renewability or Greenhouse Advantage of EtOH over MeOH No Obvious Safety or Toxicity or Hazard Advantage of EtOH over MeOH Obvious Economic Advantage of Methanol Over Ethanol No Additional Vehicle OR Infrastructure Costs No Vehicle Performance Issues

16 We Had Valuable Help From: Air Liquide/Lurgi – Frankfurt, Germany Linde – Munich, Germany Haldor Topsoe – Houston, TX HDR Inc., Ann Arbor, MI Methanol Institute – Washington DC and Singapore Don Koza, Marshal (Bud) Bell, John Lehman, Dennis Dembicki, Michael Murphy & Others Who Wish to Remain Anonymous…

17 Contact Information Chris WallsgroveDavid Netzer Brinderson Engineers & ConstructorsConsultant Costa Mesa, CAHouston, TX (713) (832)

18 THE END Mercifully… Thanks to Pennwell Publishing, for publishing a synopsis of this paper in two parts, June and July 2011 Oil & Gas Journal


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