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Methanol for Gasoline Blending from Petroleum Coke

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Presentation on theme: "Methanol for Gasoline Blending from Petroleum Coke"— 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 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/H2 Ratio Rectisol – Remove H2S/COS and Recover CO2 Methanol Synthesis – Makes 50,000 BPSD Methanol Purification (Distillation) Units to Recover H2 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 H2 Recovery, and Claus- Type Sulfur Units

6 Block Flow Diagram – Petcoke to Methanol
7,400 tpd Air CO2 130 bar 11,700 tpd Air Separation CO2 Compression Nitrogen Oxygen 6,600 tpd CO2 Coke Preparation And Slurrying Gasification 87 bar Shift & Gas Cooling Rectisol Units Unconverted Carbon Water, Fluxing Agent Syn- Gas Steam EHP, HP, MP, LP Acid Gases Steam & Power Systems Methanol Synthsis 78 bar Steam HP, LP Sulfur Plants Tail Gas Purge Gas Methanol 6,400 tpd Sulfur Product Hydrogen Product 16 MMscfd PSA Hydrogen Recovery Methanol Purification Reactor Purge Gas 50,000 bpsd Block Flow Diagram – Petcoke to Methanol

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

9 Capital Cost Savings Quench Gasification vrs High Efficiency with Bar Steam – Saves ~$200 Million 320 MW Fluidized Bed Boilers vrs IGCC – Saves ~$450 Million 67% CO2 Capture vrs 95% (Shift + H2 Power Cycle + Parasitic Mw) - Saves ~$250 Million Avoid 25 MW Methanol Synthesis Compressor – Saves ~$50 Million Other Miscellaneous Rational Savings ~$ 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 CO2 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, CO2 Must Be Compressed to At Least ~125 Bar Modest (67%) CO2 Recovery Mine-To-Wheel CO2 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
Modern Engines Designed for E-10 Fuel ECU/Fuel Injection Makes CLEAN Engines Higher Octane but Lower Energy Content NO CHANGES REQUIRED Now Then

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 CO2 is Sold for EOR Methanol Production Cost is ~$0.88 per US Gal if CO2 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 Wallsgrove David Netzer Brinderson Engineers & Constructors Consultant Costa Mesa, CA Houston, 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 THE END Mercifully…

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