FISCHER-TROPSCHLIQUIDS REFINING PLANT

Team Foxtrot

Presentation #5 – April 23, 2013

Mentor:

Dan Rusinak, PE

Team:

Mudassir Ali

Stephen Drake

Kevin Meaux

Brandon Sieve

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Summary• Introduction• Motivation• BFD/Design basis• PFD• Economic analysis• Environmental Consideration• Recommendations

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Introduction

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eia.gov

Motivation

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• Advantage of the arbitrage in energy markets

• Improved process efficiency of 80% by combining concurrent modern technologies as

compared to 16%.

• A feedstock of natural gas results in a sulfur and aromatic-free fuel, which is more

environmentally and consumer friendly than fuels derived from crude oil.

• Derived transportation fuels have excellent cold flow properties, high cetane rating and high

octane rating.

• Clean and powerful fuels for the future

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Product Striking Characteristic

Use

LPG No CO emissions

Fork lift trucks, indoor vehicles.

Naphtha High octane rating

Alternative and Premium blend stock for conventional gasoline

Jet fuel Excellent cold flow properties

Alternative and premium blend stock for jet fuel

Diesel Cetane rating of 72

Alternative and premium blend stock for conventional diesel

Design Basis/Block Flow Diagram

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FT Reactor

CondensationTrain

OligUnit

Hydro-Cracker

Fractionation

Total 5100 bbl/dDiesel 2500 bbl/d

Gasoline 1100 bbl/dJet 1000 bbl/dLPG 500 bbl/d

Syngas250Klb/hr

(Aq) stream 120Klb/hr Tail Gas 100Klb/hr

Design Basis• 250,000 lb/hr of fresh Syngas is used as the feed stock

with a ratio of 2.05:1 of H2 to CO.• 120,000 lb/hr of Aqueous Product is sent to the Water

Treatment Plant. • 100,000 lb/hr of Tail Gas is sent to the CHP plant. • 5,100 bbl/day of Final Products

• 2,500 bbl/day of Diesel (49%)• 1,100 bbl/day of Gasoline (21%)• 1,000 bbl/day of Jet Fuel (20%)• 500 bbl/day of LPG (10%)

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Process Flow Diagram8

H2 Membrane

Syngas P-2

Fischer-Tropsch ReactorFlash Drum

H2

3-Way Separator

Water

Oligomerization

Purge

DistillationColumn

LPG

DistillationColumn

Jet Fuel

DieselDistillation

Column

Gasoline

Hydrocracker

Wax

DistillationColumn

LPG

H2

H2

Distillate

DistillationColumn

Gasoline

DistillationColumn

Jet Fuel

DistillationColumn

Diesel

DistillationColumn

VGO/Residuum Recycle

H2

P-55

H2 Membrane

Syngas P-2

Fischer-Tropsch ReactorFlash Drum

H2

3-Way Separator

Water

Oligomerization

Purge

DistillationColumn

LPG

DistillationColumn

Jet Fuel

DieselDistillation

Column

Gasoline

Hydrocracker

Wax

DistillationColumn

LPG

H2

H2

Distillate

DistillationColumn

Gasoline

DistillationColumn

Jet Fuel

DistillationColumn

Diesel

DistillationColumn

VGO/Residuum Recycle

H2

P-55

H2 Membrane

Syngas P-2

Fischer-Tropsch ReactorFlash Drum

H2

3-Way Separator

Water

Oligomerization

Purge

DistillationColumn

LPG

DistillationColumn

Jet Fuel

DieselDistillation

Column

Gasoline

Hydrocracker

Wax

DistillationColumn

LPG

H2

H2

Distillate

DistillationColumn

Gasoline

DistillationColumn

Jet Fuel

DistillationColumn

Diesel

DistillationColumn

VGO/Residuum Recycle

H2

P-55

H2 Membrane

SyngasP-2

Fischer-Tropsch Reactor

Flash Drum

H2

3-Way Separator

Water

Oligomerization

Purge

DistillationColumn

LPG

DistillationColumn

J et Fuel

DieselDistillation

Column

Gasoline

Hydrocracker

Wax

DistillationColumn

LPG

H2

H2

Distillate

DistillationColumn

Gasoline

DistillationColumn

J et Fuel

DistillationColumn

Diesel

DistillationColumn

VGO/Residuum Recycle

H2

P-55

Integrated Shale Gas Complex

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• The Fischer-Tropsch Refinery is one of nine plants of an integrated shell gas complex.

• The Fischer-Tropsch Refinery is receiving the Syngas from the Syngas plant, Electricity, Steam and Boiler Feed Water from the CHP plant at no cost.

• The purge is being sent out to the CHP plant to produce electricity and steam.

• The aqueous stream is being sent to the Water Treatment plant.

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Integrated Shale Gas Complex

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• Expected simple payback period is 4.24 years.

• Prices of natural gas are expected to decrease further, which will cause the payback period to decrease significantly.

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Revenue from Products ($ Million)Products Year 1 Year 5 Year 10 Year 20

LPG 6.2 6.7 7.4 9Naphtha 50 54 60 73Jet Fuel 44 48 53 65Diesel 110 120 132 161

Total Revenue 211 230 253 308Total Expenses 56 59 63 73Total Profit 93 486 1.03B 2.3B* NO TRANSFER PRICES/ NO LOANS

Expenses

.

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$ MillionYear 1 Year 5 Year 10 Year 20

Catalyst 4 5 5 6Depreciation 26 26 26 26Salaries and Fringes 10 11 13 18Maintenance 16 17 19 23

Costs

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COST (USD) TIC (USD)FT Reactor 153,000,000 667,080,000Oligomerization 33,000,000 143,880,000Hydrocracker 132,000,000 575,520,000Medal Membrane 125,000 545,000

Profit

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Million $Total Revenue 211 230 253 308Total Expenses 56 59 63 73Income before taxes 155 170 189 23540 % taxes 62 68 72 94Income after taxes 93 102 117 141Total Income 93 487 1,031 2,312

Summary

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NPV $744,490,895IRR 23.57%Breakeven 4.24Interest 8.00%

Environmental Analysis

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• High Cetane rating causes the thermodynamic efficiency of the diesel engine to improve, which reduces CO2 and CO emissions in the atmosphere.

• Due to the absence of aromatics in the process, the resultant LPG, Diesel, Jet, and Naphtha are very clean. Absolutely no soot formation occurs in the engines, which further reduces the CO2 and CO emissions in the environment.

• Due to the absence of sulfur, there are no SOx emissions and no sulphuric acid droplets in the Tropopause. Therefore, no acid-gas mist formation occurs. Droplet and SOx accumulation in the Tropopause causes global cooling, thus interfering with the global climate.

Recommendations• Installing a DWC will reduce the equipment cost

significantly and improve process efficiency.

• It is recommended to go ahead with this project to stage gate 2 as it is a money maker and is environmental friendly.

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Summary• The process starts with 250,000 lb/hr of fresh Syngas is

used as the feed stock with a ratio of 2.05:1 of H2 to CO

• It takes 4.24 years for pay back

• NPV 745 Million Dollars – 20 years

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Bibliography

www.eia.gov

[1] Bartholomew, Calvin, and Robert Fauratto. Fundamentals of Industrial Catalytic Processes. 2nd ed. N.p.: John Wiley & Sons, 2006. Print.

[2] Private communication with UOP LLC.

[3] De Klerk, Arno. Fischer-Tropsch Refining. Germany: Weinheim, 2011. Print.

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