Team: FOXTROTMentor: Dan Rusinak

Crew: Ali, MudassirDrake, Stephen

Meaux, KevinSieve, Brandon

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Is Cobalt a better choice for a catalyst as compared to Iron?◦ Catalyst comparison: $8/lb Fe vs. $40/lb Co

◦ Fe gives a better alpha value for wax (0.95) when compared to Co (0.92)

◦ The diesel output of Fe plants (58%) are similar to Co plants (60%)

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Co prices tend to be volatile compared to iron. Also need to contend with hazardous waste disposal.

How to model the SCBR?◦ On a preliminary level we will avoid modeling the

SCBR by using the syncrude composition predicted by De Klerk

◦ If time is available for further modeling we plan to use an equilibrium reactor simulation in Aspen

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What role does the rwgs reaction play?◦ The functional form of Keq for the wgs is

◦ Keq(603 K) is 142◦ The rwgs reaction is not thermodynamically

favored◦ We will need to look at kinetics to see if wgs

significantly effects our feed requirements

Energy Density(Btu/gal)

$/MM BtuEnergy

Efficiency

$/ MM Btu of

Product

Natural Gas

140 $3.24 44% $7.43

Crude Oil

138,000 $16.79 80% $21.00

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Area 1

SBCR

Area 2

Alkylation/ Separation

Units

Area 3

Hydrocracker/Separation

Units

Area 4

Transportation fuels

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FT

Reaction

Hydrocracking

Alkylation

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FT Reaction Area PFD

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Arno De Clerk

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Material Balance for FT Reaction AreaStream No. 1 2 3 4 5 6 7 8 9 10 11 12

Description Syngas Feed H2 Permeate Syngas to

Reactor Wax Fischer-Tropsch Products

RecycleHot

Condensate

Fischer-Tropsch Products

Cold Condens

ate

Aqueous Products Tail Gas

Hot and Cold

Condensate

Unit lb-mol/hr lb-mol/hr lb-mol/hr lb-mol/hr lb-mol/hr lb-mol/hr lb-mol/hr lb-mol/hrlb-mol/

hr lb-mol/hr lb-mol/hr lb-mol/hr

CO 3809.58 0.00 3809.58 0.00 1523.83 0.00 0.00 1523.83 0.00 0.00 1523.83 0.00

H2 9524.17 1714.53 7809.64 0.00 3123.86 0.00 0.00 3123.86 0.00 0.00 3123.86 0.00

N2 77.92 0.00 77.92 0.00 77.92 0.00 0.00 77.92 0.00 0.00 77.92 0.00

H2O 0.00 0.00 0.00 0.00 2285.75 0.00 0.00 2285.75 0.00 2285.75 0.00 0.00

CO2 394.17 0.00 394.17 0.00 394.17 0.00 0.00 394.17 0.00 0.00 394.17 0.00

C1 0.00 0.00 0.00 0.00 98.29 0.00 0.00 98.29 0.00 0.00 98.29 0.00

C2 alkene 0.00 0.00 0.00 0.00 22.86 0.00 0.00 22.86 0.00 0.00 22.86 0.00

C2 alkane 0.00 0.00 0.00 0.00 22.86 0.00 0.00 22.86 0.00 0.00 22.86 0.00

C3-C4 alkene 0.00 0.00 0.00 0.00 137.14 0.00 0.00 137.14 137.14 0.00 0.00 137.14

C3-C4 alkane 0.00 0.00 0.00 0.00 41.14 0.00 0.00 41.14 41.14 0.00 0.00 41.14

C5-C10 alkene 0.00 0.00 0.00 0.00 176.00 0.00 0.00 176.00 176.00 0.00 0.00 176.00

C5-C10 alkane 0.00 0.00 0.00 0.00 75.43 0.00 0.00 75.43 75.43 0.00 0.00 75.43

C5-C10 oxygenate 0.00 0.00 0.00 0.00 29.71 0.00 0.00 29.71 29.71 0.00 0.00 29.71

C11-C22 alkene 0.00 0.00 0.00 0.00 130.29 0.00 130.29 0.00 0.00 0.00 0.00 130.29

C11-C22 alkane 0.00 0.00 0.00 0.00 308.58 0.00 308.58 0.00 0.00 0.00 0.00 308.58

C11-C22 oxygenate 0.00 0.00 0.00 0.00 6.86 0.00 6.86 0.00 0.00 0.00 0.00 6.86

C22+ alkene 0.00 0.00 0.00 16.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

C22+ alkane 0.00 0.00 0.00 1124.59 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

aqueous alcohol 0.00 0.00 0.00 0.00 89.14 0.00 0.00 89.14 0.00 89.14 0.00 0.00

aqueous carboxylic acid 0.00 0.00 0.00 0.00 6.86 0.00 0.00 6.86 0.00 6.86 0.00 0.00

Total 13805.84 1714.53 12091.31 1140.59 8550.69 0.00 445.72 8104.96 459.44 2381.75 5263.78 905.16

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 h 603k

KJ/Kgmoleh 603 K

Btu/lbmole3

(lbmol/hr)4

(lbmol/hr)5

(lbmol/hr)h in

Btu/hrh out Btu/hr

CO -101625 -43791 3810 0 1524 -166825016 -66730007

H2 8784 3785 7810 0 3124 29560307 11824123

N2 8845 3811 78 0 78 296984 296984

H2O -275552 -118738 0 0 2286 0 -271404830

CO2 -382185 -164687 394 0 394 -64914586 -64914586

C1 -64012 -27583 0 0 98 0 -2711068

C2 alkene 65555 28248 0 0 23 0 645679

C2 alkane -67688 -29167 0 0 23 0 -666688

C3-C4 alkene 36524 15739 0 0 137 0 2158458

C3-C4 alkane -82339 -35481 0 0 41 0 -1459791

C5-C10 alkene 7851 3383 0 0 176 0 595454

C5-C10 alkane -132063 -56907 0 0 75 0 -4292494

C5-C10 oxygenate -187950 -80989 0 0 30 0 -2406577

C11-C22 alkene -79576 -34290 0 0 130 0 -4467566

C11-C22 alkane -365094 -157322 0 0 309 0 -48545824

C11-C22 oxygenate 1510 651 0 0 7 0 4462

C22+ alkene -197500 -85105 0 16 0 0 -1361693

C22+ alkane -511033 -220209 0 1125 0 0 -247644300

aqueous alcohol -309600 -133409 0 0 89 0 -11892675

aqueous carboxylic acid -527235 -227190 0 0 7 0 -1557900

total     12091 1141 8551 -201882312 -714530839

      Q reactor= -512648527 Btu/hour    

   

 Q reactor= -150.2 MW

Energy Balance for FT Reaction Area

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Akylation Area PFD

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Hydrocracking Area PFD

Alkylation vs. Oligomerization

o Foxtrot needed a process to convert LPG, Naptha, and Distillate olefins to heavier hydrocarbons

o Oligomerization tends to be more expensive; it requires more H2, more expensive catalyst, and produces straight chain alkanes

o Alkylation reacts olefins with paraffins which produces twice as much high quality naptha product

o Alkylation also has the advantage of producing branched naptha (a very high quality naptha), which can be blended with lower-quality naptha produced by hydrocracker

o Diesel with lower Cetane rating can be blended with high-quality diesel to improve cold weather properties

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<5000 BPD plant has TIC of $120,000 to $150,000 per BPD

>20,000 BPD plant has TIC of $75,000 to $100,000 per BPD

These values include an SMR/ATR unit, but no alkylation unit

FT synthesis/refining accounts for 35% of TIC

Therefore, TIC = 210 – 262 MM$ We will produce 80k lb/day of steam

*Estimates obtained from private communication with Rentech

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Per Gallon

[2]

Per Barrel

Barrel/Year

(Million)

Annual Revenue(Million)

Diesel Fuel

$3.97 $167 1.06 $177

Naptha $3.63 $152 0.26 $40

Jet Fuel $3.30 $139 0.26 $36

LPG $0.99 $42 0.14 $6

Total 1.72 $259

US Geological Survey, Minerals Commodities Summaries.

Dividing Wall Columns, Michael A. Schultz, Douglas G. Stewart, James M. Harris, Steven P. Rosenblum, Mohammed S. Shakur and Dennis E. O’Brien UOP.

Dividing Wall Columns,2010 AiChE, Jacobs consultancy .

STRATCO, Alkylation unit. Bechtel Article, 2001 M E DRY, 2008 Fischer Tropsch refining, arno de klerk. US Energy Information Administration, www.eia.gov

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Questions please.

Sequence Distillation A (lightest) B ( Middle) C (Heaviest)

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Energy lost Thermal inefficiency

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.

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Because the Petlyuk arrangement has fewer pieces of major equipment than does the conventional two-column sequence, total capital costs may be reduced.

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.

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Reduces the energy cost by 30% Reduces equipment cost by 50% Reduction is the capital cost by 40%

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Alkylation is a major way of upgrading petroleum

Formation of heavier highly branched alkanes from the reaction between isobutanes and alkenes.

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Utilizes a liquid-full reactor system where the heat of reaction is removed with an internal heat exchanger.

Vaporization is prevented by maintaining the reactor system at sufficient pressure.

The obvious advantage of the liquid-full system (STRATCO ) is that the isobutane remains in the liquid state continuously available for reaction in higher concentrations.

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Easy operation

No worries about the acid or hydrocarbon levels in the reactor system

High internal circulation rates for even heat dissipation

Highly dispersed hydrocarbon in acid emulsion

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Increased interfacial catalyst area provided by mixing

Reduced acid consumption

Superior quality alkylate 1.5 octane number advantage

Ease of reactor operation

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Upgrading waxes to alkanes It is a hydrogen addition technology that

removes heteroatoms, increases the H:C ratio of the product

It is nearly isothermal giving a conversion of 70-80% conversion of wax to products

Will use a divided wall column and a low pressure column to separate products

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