1. Team Hotel: Russel Cabral, Tomi Damo, Ryan Kosak, Vijeta Patel, Lipi Vahanwala Advisors: Bill Keesom – Jacobs Consultancy Jeffery Perl, PhD – UIC Dept. Of Chemical Engineering March 8, 2011 1

2.  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 ▪ CO to H2 molar ratio of 0.409 ▪ CO2 and N2 mixed in 2 http://coalgasificationnews.com/tag/petcoke- gasification/ 3/8/2011

3.  Discussed the Shell ™ membrane gasifier  Discussed our syngas cleaning processes  Sulfur Removal  Claus Process  Water Gas Shift  Flow Sheets  Early Material and Energy Balances 3 3/8/2011

4.  What was the heat rate brought up in the gasifier comparisons?  Why use N 2 as a transport gas and not CO 2 ?  How are we absorbing CO 2 ?  What is a better definition of the quench? 4 3/8/2011

5.  Recent changes  Using Selexol instead of MDEA  Using the Superclaus  Aspen Simulation  Heat Load Identification  Economics  Aspen Price Evaluator (ICARUS)  Equipment Sizing  Energy Balance  Location Update 5 3/8/2011

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12.  Stream Pre-heating  Lower Heater / Cooler Duties  Higher Duty vs. Heat Ex. Cost 12 Furnace Cooler HX Acid Gas Cold Acid Gas Hot To Claus Catalysts Hot Furnace Gas Cold Furnace Gas 3/8/2011

13. Gasifier EquipmentHeat Load (Btu/hr) Gasifier-34.7 x 10 6 HP Steam Heat Exchanger139.0 x 10 6 MP Steam Heat Exchanger281 x 10 6 COS Reactor-4284 Cooler-106.8 x 10 6 Flash2.99 x 10 6 13 Sulfur Clean Up EquipmentHeat Load (Btu/hr) Sulfur Stripper Reboiler57.o x 10 6 Sulfur Stripper Cooler-200.0 x 10 6 Selexol Cooler-40.7 x 10 6 Rich / Lean Heat Exchanger274.9 x 10 6 3/8/2011

14. 14 Claus Process EquipmentHeat Load (Btu/hr) Claus Furnace-3.26 x 10 6 Condenser (Modeled Cooler and Flash) 1-31.3 x 10 6 Condenser 2-11.2 x10 6 Condenser 3-5.97 x 10 6 Condenser 4-3.92 x 10 6 Re-heater 19.72 x 10 6 Re-heater 25.29 x 10 6 Re-heater 33.46 x 10 6 Catalytic Reactor 13.03 x 10 6 Catalytic Reactor 21.72 x 10 6 Catalytic Reactor 3-5.73 x 10 6 3/8/2011

15. Inlet Fraction Clean Syngas Component Flow for WGS Reactor(lbmoles/hr) for WGSCP (btu/lbmole* F) outlet syngas Comp (lbmole/hr) form (WGS) CO4946.2337.118123.395 H2O6424.68815.3671601.850 N2199.9547.158199.954 H2*2960.1686.9487783.006 CO2469.21110.5595292.049 CH4*0.255 12.4320.255 H2S0.000 COS0.000 Total15000.509 15 3/8/2011

16. Gasification Process $240,000,000 Solid Removal Claus Process CO2 Absorption Water-gas Shift Final syngas product

17. SIZEINDIRECT COST DIRECT COST Air Separation Unit N/A $100,000,00 0 Petroleum Coke Crusher $ 5,401,890 $ 7,022,455 Gasifier (x2)N/A $ 132,000,000 Heat Exchanger (x2) $305,740 $ 642,060

18. Solid Removal $670,000 CO2 Absorption Water-gas Shift Final syngas product Sulfur Removal Gasification Process $240,000,000

19. SIZEINDIRECT COST DIRECT COST Candle Filter $ 364,770 $ 510,680 Cyclone (remove fly ash) $ 102,600$ 159,000

20. Sulfur Removal $9,300,000 Water-Gas Shift CO2 Absorption Final syngas product Solid Removal $670,000 Gasification Process $240,000,000

21. SIZE EQUIP COSTTOTAL COST Reactor (COS) Reactor (CP) $ 103,115.04$ 164,984.06 Absorber (CP) 10737 cub. ftN/A $ 1,500,000.00 Absorber (CP) 10737 cub. ftN/A $ 1,500,000.00 Stripper (CP) 6636 cub. ft $ 102,585.15 $ 178,400.00 Stripper (CP) Heat Exchanger (CP)1200 sq ft $ 121,978.84 $ 256,155.55 Cooler 6739 sq ft$ 168,800.00 $ 320,600.00 Cooler 440 sq ft$ 16,700.00 $ 79,200.00 Cooler 258 sq ft$ 13,600.00 $ 73,600.00 Cooler 163 sq ft$ 11,800.00 $ 69,800.00

22. WGS Reactor CO2 Absorption Final syngas product Sulfur Removal $9,300,000 $56,000,000 144 ft3 $360,000 Gasification Process $240,000,000 Solid Removal $670,000

23. EquipmentSizeCostDirect Cost CO2 absorber CO2 Stripper2020 ft 3 Compressor$272,889$ 409,333

24. CO2 Absorption $56,000,000 Final syngas product Solid Removal $670,000 Gasification Process $240,000,000 Sulfur Removal $9,300,000 WGS Reactor $360,000 $306,430,000

25. TypeCost of year 1 ($/year) Cost at the end of 25 th year Assumptions Loan$20.5 million$ 1.5 millionBased on 6% interest Cooling water$1.9 million$ 6.0 millionBased on 5% inflation rate electrical$1.8 million$ 5.8 millionEstimated from a plant’s electrical cost Salaries and fringes$ 24 million$ 77 million average of 20 people/shift Maintenance$17 million$ 55 million5 % of the capital cost Royalties$ 5 million$15.8 million5% of production revenue Insurance$3.4 million$ 11 million1% of the capital cost Raw materials$ 34 million$107.6 million Depreciation$14 million Capital cost/25 years Total$121.6 million$293. 1 million 25 Capital Cost as of now = $ 306,430,000 Estimated Revenue as of now = $ 94,000,000

26. Other Fixed Cost License Fees and Royalties 2% of Capital Cost $ 4.7 million Maintenance 5% of Capital Cost $ 12 million Laboratory Cost 30% Labor Cost $ 5.4 million Insurance 1% Capital Cost $ 2.4 million Capital Cost as of now= $ 306,430,000 Labor Cost as of now = $ 18,000,000

27. Product and Side Products Unit Price (per ton) Unit Price (per year) Syngas$150.00$ 86.60 million CO2$40.00$ 7.00 million Sulfur$10.00$ 0.30 million SlagTBD Total$200.00~ $ 94 million

28.  Victoria, Texas  Between Houston and Corpus Christi  200 acres  Kansas City Southern, Union Pacific, and Burlington Northern Santa Fe railways  Gulf Intracoastal Waterway 3/8/201128

29.  Final Report:  Executive SummaryIP  DiscussionIP  Recommendations IP  Appendices  Design Basis: Done  Block Flow Diagram: Done  Process Flow Showing Major Equip.: IP 29 3/8/2011

30.  Appendices (Continued)  Material and Energy Balances:IP  Calculations: IP  Annotated Equip. List: IP  Econ. Eval. Factored from Equip. Costs: IP  Utilities: IP  Conceptual Control Scheme: N/A  Major Equipment Layout: IP 30 3/8/2011

31.  Appendices (Continued)  Distribution and End-use Issues:N/A  Constraints Review: IP  Applicable Standards: N/A  Project Communications File: IP  Information Sources and References:IP 31 3/8/2011

32.  http://fossil.energy.gov/images/programs/seq uestration/what_sequestration_lg.jpg http://fossil.energy.gov/images/programs/seq uestration/what_sequestration_lg.jpg  http://coalgasificationnews.com/tag/petcoke- gasification/ http://coalgasificationnews.com/tag/petcoke- gasification/  http://www.huffingtonpost.com/dr-orin- levine/questions-as-mileposts- of_b_448870.html http://www.huffingtonpost.com/dr-orin- levine/questions-as-mileposts- of_b_448870.html 32 3/8/2011

33.  CO2 in our syngas is absorbed on Selexol to be selectively removed  Delete only one CO2 slide. 333/8/2011

34. 34 http://fossil.energy.gov/images/programs/sequestration/what_sequestration _lg.jpg 3/8/2011