Abstract Process Economics Program Report 274 FUEL ALCOHOLS AND ELECTRICITY COGENERATION FROM PETROLEUM COKE GASIFICATION (December 2010)

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1 Abstract Process Economics Program Report 274 FUEL ALCOHOLS AND ELECTRICITY COGENERATION FROM PETROLEUM COKE GASIFICATION (December 2010) Increasing use of heavy crude oil in refineries in recent years gives a corresponding increase in low value refinery residues, such as residual fuel oil and petroleum coke. Meanwhile, increasingly stringent environmental regulation appears to be reducing the markets for such residues, particularly pet coke. Integrated gasification combined cycle (IGCC) technology offers a solution that consumes such residues and returns electrical power. Previous studies have looked at power generation in light of deregulation. This report alters that focus to cogeneration of power and chemicals, specifically fuel alcohols. Such a process would offer both power production and large scale fuel production for transportation fuels. The focus of this report is the economics of cogeneration of electric power and mixed fuel alcohols via the gasification of fuel-grade petroleum coke. The scope includes a gasification process based on pet coke to give raw syngas, a mixed alcohol process to produce fuel alcohols, and a power generation process using the alcohol synthesis purge gas and the methanol fraction of the mixed alcohols. The combined process resembles the IGCC process, but with a portion of the generated syngas used for alcohol synthesis and the resulting off gas from alcohol synthesis and the methanol fraction replacing direct syngas use in the combustion chamber of the gas turbine. SRI Consulting PEP Report 274

2 A private report by the Process Economics Program Report No. 274 FUEL ALCOHOLS AND ELECTRICITY COGENERATION FROM PETROLEUM COKE GASIFICATION by Pete Pavlechko December 2010 Menlo Park, California 94025

3 SRIC agrees to assign professionally qualified personnel to the preparation of the Process Economics Program s reports and will perform the work in conformance with generally accepted professional standards. No other warranties expressed or implied are made. Because the reports are of an advisory nature, neither SRIC nor its employees will assume any liability for the special or consequential damages arising from the Client s use of the results contained in the reports. The Client agrees to indemnify, defend, and hold SRIC, its officers, and employees harmless from any liability to any third party resulting directly or indirectly from the Client s use of the reports or other deliverables produced by SRIC pursuant to this agreement. For detailed marketing data and information, the reader is referred to one of the SRI Consulting programs specializing in marketing research. THE CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS PROGRAM covers major hydrocarbons and their derivatives on a worldwide basis. In addition the SRIC DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States, Western Europe, Canada, and East Asia, South America and Mexico.

4 CONTENTS 1 INTRODUCTION SUMMARY GASIFICATION OF PETROLEUM COKE ALCOHOL SYNTHESIS POWER GENERATION AND SULFUR RECOVERY INTEGRATION INDUSTRY STATUS PETROLEUM COKE Supply and Demand FUEL ALCOHOLS TECHNOLOGY SUMMARY LITERATURE REFERENCES Biomass Carbon Source Coal Carbon Source Multi-Source Carbon Cogeneration Emission Treatment Process Efficiency Industry News Government Sponsored Studies PATENT LITERATURE European Patents US Patents PEP RESOURCES MOST RELEVANT RESOURCES SRI Consulting iii PEP Report 274

5 CONTENTS (Continued) BACKGROUND Support Processes Air Separation Unit (ASU) Acid Gas Removal (AGR) Claus Unit PETROLEUM COKE GASIFICATION GASIFICATION CHEMISTRY PROCESS CONFIGURATION ISSUES PROCESS DESCRIPTION Petroleum Coke Slurry Preparation Solids Handling and Milling Slurry Preparation Air Separation Unit (ASU) Gasification Syngas Processing Slag Handling PROCESS DISCUSSION COST ESTIMATION CONCLUSIONS FUEL ALCOHOLS FROM SYNGAS PROCESS DESCRIPTION Gas Processing Syngas Recycle Shift Conversion Condensing and Heat Integration Sour Stripping Carbon Bed Acid Gas Removal (AGR) SRI Consulting iv PEP Report 274

6 CONTENTS (Concluded) Fuel Alcohol Production Fuel Alcohol Synthesis Fuel Alcohol Purification PROCESS DISCUSSION COST ESTIMATION CONCLUSIONS HRSG AND POWER GENERATION WITH CLAUS UNIT PROCESS DESCRIPTION PROCESS DISCUSSION COST ESTIMATION CONCLUSIONS FUEL ALCOHOLS AND POWER COGENERATION FROM PETROLEUM COKE PROCESS DESCRIPTION COST ESTIMATION CONCLUSIONS APPENDIX A PATENT SUMMARIES... A-1 APPENDIX B DESIGN AND COST BASES... B-1 APPENDIX C CITED REFERENCES... C-1 APPENDIX D PATENT REFERENCES BY COMPANY...D-1 APPENDIX E PROCESS FLOW DIAGRAMS... E-1 SRI Consulting v PEP Report 274

7 FIGURES 4.1 Mixed Alcohols from Syngas Process Flow Diagram... E Methanol from Coal Process Process Flow Diagram... E Typical ASU Block Flow Diagram Conventional AGR Process Flow Diagram Physical Solvent AGR Process Flow Diagram Selective AGR Process Flow Diagram Typical Three Stage Claus Plant Fuel Alcohols and Power Cogeneration from Petroleum Coke Process Flow Diagram... E Fuel Alcohols and Power Cogeneration from Petroluem Coke Process Flow Diagram... E Fuel Alcohols and Power Cogeneration from Petroluem Coke Process Flow Diagram... E Fuel Alcohols and Power Cogeneration from Petroleum Coke Integrated Process Block Flow Diagram SRI Consulting vi PEP Report 274

8 TABLES 5.1 Fuel Alcohols and Power Cogeneration from Petoleum Coke Gasification Design Assumptions Fuel Alcohols and Power Cogeneration from Petoleum Coke Stream Flows, 55% Unreacted Syngas Recycle Fuel Alcohols and Power Cogeneration from Petoleum Coke Stream Flows, 0% Unreacted Syngas Recycle Fuel Alcohols and Power Cogeneration from Petoleum Coke Stream Flows, 97% Unreacted Syngas Recycle Raw Syngas from Pet Coke, 55% Unreacted Syngas Recycle Major Equipment Raw Syngas from Pet Coke, 55% Unreacted Syngas Recycle Utilities Summary Raw Syngas from Pet Coke, 55% Unreacted Syngas Recycle Total Capital Investment Raw Syngas from Pet Coke, 55% Unreacted Syngas Recycle Production Costs Raw Syngas from Pet Coke, 0% Unreacted Syngas Recycle Utilities Summary Raw Syngas from Pet Coke, 0% Unreacted Syngas Recycle Total Capital Investment Raw Syngas from Pet Coke, 0% Unreacted Syngas Recycle Production Costs Raw Syngas from Pet Coke, 97% Unreacted Syngas Recycle Utilities Summary Raw Syngas from Pet Coke, 97% Unreacted Syngas Recycle Total Capital Investment Raw Syngas from Pet Coke, 97% Unreacted Syngas Recycle Production Costs Fuel Alcohols and Power Cogeneration from Petoleum Coke Gas Processing and Fuel Alcohols Design Assumptions Fuel Alcohols and Power Cogeneration from Petoleum Coke Stream Flows, 55% Unreacted Syngas Recycle Fuel Alcohols and Power Cogeneration from Petoleum Coke Stream Flows, 0% Unreacted Syngas Recycle SRI Consulting vii PEP Report 274

9 TABLES (Continued) 6.4 Fuel Alcohols and Power Cogeneration from Petoleum Coke Stream Flows, 97% Unreacted Syngas Recycle Fuel Alcohols from Raw Syngas, 55% Unreacted Syngas Recycle Major Equipment Fuel Alcohols from Raw Syngas, 55% Unreacted Syngas Recycle Utilities Summary Fuel Alcohols from Raw Syngas, 55% Unreacted Syngas Recycle Total Capital Investment Fuel Alcohols from Raw Syngas, 55% Unreacted Syngas Recycle Production Costs Fuel Alcohols from Raw Syngas, 0% Syngas Recycle Utilities Summary Fuel Alcohols from Raw Syngas, 0% Syngas Recycle Total Capital Investment Fuel Alcohols from Raw Syngas, 0% Syngas Recycle Production Costs Fuel Alcohols from Raw Syngas, 97% Syngas Recycle Utilities Summary Fuel Alcohols from Raw Syngas, 97% Syngas Recycle Total Capital Investment Fuel Alcohols from Raw Syngas, 97% Syngas Recycle Production Costs Fuel Alcohols and Power Cogeneration from Petroleum Coke HRSG & Power Generation with Claus Unit Design Assumptions Fuel Alcohols and Power Cogeneration from Petroleum Coke Stream Flows, 55% Unreacted Syngas Recycle Fuel Alcohols and Power Cogeneration from Petroleum Coke Stream Flows, 0% Unreacted Syngas Recycle Fuel Alcohols and Power Cogeneration from Petroleum Coke Stream Flows, 97% Unreacted Syngas Recycle Sulfur Recovery from Acid Gas, 55% Syngas Recycle Major Equipment Sulfur Recovery from Acid Gas, 55% Syngas Recycle Utilities Summary SRI Consulting viii PEP Report 274

10 TABLES (Continued) 7.7 Sulfur Recovery from Acid Gas, 55% Syngas Recycle Total Capital Investment Sulfur Recovery from Acid Gas, 55% Syngas Recycle Production Costs Sulfur Recovery from Acid Gas, 0% Syngas Recycle Utilities Summary Sulfur Recovery from Acid Gas, 0% Syngas Recycle Total Capital Investment Sulfur Recovery from Acid Gas, 0% Syngas Recycle Production Costs Sulfur Recovery from Acid Gas, 97% Syngas Recycle Utilities Summary Sulfur Recovery from Acid Gas, 97% Syngas Recycle Total Capital Investment Sulfur Recovery from Acid Gas, 97% Syngas Recycle Production Costs Fuel Alcohols and Power Cogeneration from Petroleum Coke Design Assumptions Fuel Alcohol & Power from Pet Coke, 55% Recycle Major Equipment Fuel Alcohol & Power from Pet Coke, 55% Recycle Utilities Summary Fuel Alcohol & Power from Pet Coke, 55% Recycle Total Capital Investment Fuel Alcohol & Power from Pet Coke, 55% Recycle Production Costs Fuel Alcohol & Power from Pet Coke, 0% Recycle Utilities Summary Fuel Alcohol & Power from Pet Coke, 0% Recycle Total Capital Investment Fuel Alcohol & Power from Pet Coke, 0% Recycle Production Costs Fuel Alcohol & Power from Pet Coke, 97% Recycle Utilities Summary SRI Consulting ix PEP Report 274

11 TABLES (Concluded) 8.10 Fuel Alcohol & Power from Pet Coke, 97% Recycle Total Capital Investment Fuel Alcohol & Power from Pet Coke, 97% Recycle Production Costs Fuel Alcohol & Power from Pet Coke, 97% Recycle Production Costs Fuel Alcohol & Power from Pet Coke, 97% Recycle Production Costs SRI Consulting x PEP Report 274