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    Cmai

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    harvin95
    This document proposes converting petroleum coke, a byproduct of upgrading heavy oil, into methanol for gasoline blending. Petcoke can be gasified into syngas and then converted to methanol using proven technology. Blending 7-10% methanol into gasoline can fuel existing vehicles. The proposed process involves gasifying petcoke, producing syngas, converting it to methanol, and blending the methanol into gasoline. This could utilize an existing waste product for fuel production at a potentially lower cost than ethanol or imported oil.

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    Cmai

    Uploaded by

    harvin95
    77 views17 pages
    This document proposes converting petroleum coke, a byproduct of upgrading heavy oil, into methanol for gasoline blending. Petcoke can be gasified into syngas and then converted to methanol using proven technology. Blending 7-10% methanol into gasoline can fuel existing vehicles. The proposed process involves gasifying petcoke, producing syngas, converting it to methanol, and blending the methanol into gasoline. This could utilize an existing waste product for fuel production at a potentially lower cost than ethanol or imported oil.

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    This document proposes converting petroleum coke, a byproduct of upgrading heavy oil, into methanol for gasoline blending. Petcoke can be gasified into syngas and then converted to methanol using proven technology. Blending 7-10% methanol into gasoline can fuel existing vehicles. The proposed process involves gasifying petcoke, producing syngas, converting it to methanol, and blending the methanol into gasoline. This could utilize an existing waste product for fuel production at a potentially lower cost than ethanol or imported oil.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    77 views17 pages

    Cmai

    Uploaded by

    harvin95
    This document proposes converting petroleum coke, a byproduct of upgrading heavy oil, into methanol for gasoline blending. Petcoke can be gasified into syngas and then converted to methanol using proven technology. Blending 7-10% methanol into gasoline can fuel existing vehicles. The proposed process involves gasifying petcoke, producing syngas, converting it to methanol, and blending the methanol into gasoline. This could utilize an existing waste product for fuel production at a potentially lower cost than ethanol or imported oil.

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    Methanol for

    Gasoline Blending
    from
    Petroleum Coke
    David Netzer
    &
    Chris Wallsgrove
    (Speaker)

    MeOH
    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)
    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
    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
    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
    Petcoke
    7,400 tpd
    Air
    CO2
    Air CO2
    130 bar
    Separation Compression
    11,700 tpd
    Nitrogen

    Oxygen 6,600 tpd CO2

    Coke Preparation Gasification Shift & Gas Rectisol


    And Slurrying 87 bar Cooling Units

    Water, Unconverted
    Fluxing Agent Syn-
    Carbon
    Steam EHP, HP, Acid Gases Gas
    MP, LP

    Steam & Sulfur Methanol


    Steam HP, LP Synthsis
    Power Plants
    Systems Tail Gas 78 bar

    Purge Gas

    Sulfur Methanol
    Product 6,400 tpd
    Hydrogen
    PSA Hydrogen Methanol
    Product
    Recovery Reactor Purge Gas Purification
    16 MMscfd
    50,000
    bpsd

    Block Flow Diagram – Petcoke to Methanol


    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
    130 Bar Steam
    From Shift

    Econo DeNOx Air Pre- Lime


    Heat Scrub

    SRU Tail Gas


    PSA Purge Gas 125 bar Steam 125 bar Steam
    MeOH Bottoms To ASU Drivers
    Unconverted
    Carbon
    Petcoke

    Limestone 3 x 55% Turbine Generator ~


    Fluidized
    Coal
    Bed
    (& Biomass)
    Boilers 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


    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% 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 ~$135
    Million
    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
    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
    Methanol in Spark-Ignition Engines
    • Modern Engines Designed for E-10 Fuel
    • ECU/Fuel Injection Makes CLEAN Engines
    • Higher Octane but Lower Energy Content

    Now Then

    • NO CHANGES REQUIRED
    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
    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
    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…
    Contact Information

    Chris Wallsgrove David Netzer


    Brinderson Engineers & Constructors Consultant
    Costa Mesa, CA Houston, TX

    chris@wallsgrove.com netzerd@sbcglobal.net
    (713) 240 8633 (832) 251 1271
    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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