fischer-tropsch liquids refining plant
DESCRIPTION
Fischer-Tropsch Liquids refining Plant . Team Foxtrot Presentation #4 – April 9, 2013 Mentor: Dan Rusinak, PE Team: Mudassir Ali Stephen Drake Kevin Meaux Brandon Sieve. CHE 397 University of Illinois at Chicago Chemical Engineering Department. Today, Team Foxtrot will Address: - PowerPoint PPT PresentationTRANSCRIPT
FISCHER-TROPSCHLIQUIDS REFINING PLANT
Team FoxtrotPresentation #4 – April 9, 2013
Mentor: Dan Rusinak, PE
Team:Mudassir Ali
Stephen DrakeKevin MeauxBrandon SieveCHE 397
University of Illinois at ChicagoChemical Engineering Department
1University of Illinois at Chicago
Today, Team Foxtrot will Address:
• Questions/Topics from Presentation #3 • Complete PFD • Process Control Scheme• Plant Layout• Refined Economics
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Design Project Outline• Executive Summary• Discussion• Recommendations
Appendices1. Design Basis 2. Block Flow Diagram 3. Process Flow Diagram showing major equipment 4. Material and Energy Balance (w/ Integration Review)5. Calculations 6. Annotated Equipment List 7. Economic Evaluation factored from Equipment Costs 8. Utilities 9. Conceptual Control Scheme 10. General Arrangement – Major Equipment Layout 11. Distribution and End-use Issues Review12. Constraints Review13. Applicable Standards14. Project Communications File15. Information Sources and References
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Topics from Last Presentation
4
Distillate Bottoms Condenser Pressure
Reboiler Temp
Trays Height Diameter
T-101 LPG C5+ 253 psia 793 F 25 6.5’ 42’
T-102 Naphtha C11+ 0.2 psia 312 F 15 5.5’ 62’
T-100 Jet Diesel 0.2 psia 304 F 15 12.5’ 42’
T-103 LPG C5+ 253 psia 879 F 15 4’ 42’
T-104 Naphtha C11+ 1.2 psia 350 F 43 4’ 98’
T-105 Jet/Diesel
Wax/Res 0.2 psia 484 F 29 15.5’ 70’
T-106 Jet Diesel 0.1 290 F 29 7.5’ 70’
- Oligomerization - Hydrocracker
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Detailed PFD with Level Controls• The next slides will consist of:
• PFD Level controls around• Air Membrane Separators• Exchangers• Compressors• 2 Phase Separators• 3 Phase Separators• Vessels• Fired Heater• Reactors
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Foxtrot, University of Illinois at Chicago 6
Overall FT LoopUniversity of Illinois at Chicago 6
Area 1- FT Loop PFDFT Loop Area 1 PFD
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1
3
4
5
2
6Unit Descrip.R-100 SBCRR-101 Cat-RejK-100 compressr
P-100 Pump
Equipment List
FT loop Area 2 PFD
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7
13
12
11
10
9
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Unit Descrip.K-100 Compressor
E-100 Exchangers
S-100 2 phase Sep
T-101 Tanks
P-100 Pump
Equipment List
Oligimerization Loop overall PFD
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Oligomerization PFD Area 1
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1
5
3
4
2
Unit Descrip.K-100 Compressor
E-100 Exchangers
S-100 2 phase Sep
T-101 Tanks
P-100 Pump
Oligomerization PFD Area 2
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Oligomerization PFD Area 3
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13
Hydrocracker Overall PFD
TIC
TIC
FIC
FIC
TIC
LIC
IC
IC IC
Close up Hydrocracker Reactor PFDUniversity of Illinois at Chicago 14
Hydrocracker Overall PFD
TIC
TIC
FIC
FIC
TIC
LIC
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Reactor SpecificationsFT Reactor Hydrocracker Oligomerization
Temperature, F 428 680 356
Pressure, psia 537 1015 551
Height, ft 50 24 48
Diameter, ft 16 7 5.5
Heat Load, BTU/hr - 5.87e8 - 3.13e6 - 1.52e7
Boiler Water Feed, GPM 775 5 20
H2 Feed, lb/hr - 5,150 300
Volumetric Feed, bbl/day
- 3,000 3,000
TIC, $ 153 MM [1] 43 MM [2] 11 MM [2]
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Flare
UtilityLoading
FiredHeater
Process
Offices
Parking Lot
Labs
Hig
hway Tank Farm
Road
Roa
d
Road
Road
Road
Conceptual Plant Layout
Perimeter Fence
Wind
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R-100 Side Pipe Rack
Main Pipe Rack
Cold dike D=59ftV= 11070ft^3
VGO dike D=43ftV= 5310ft^3
Resid dike D=43ftV= 5310ft^3Hot dike D=47ft
V= 7062ft^3
M-100 R-100 R-101 R-102
AC-101
V-100
V-101
V-102
T-104
T-105
T-106
T-107
T-108
T-101
T-102
T-103
30’
15’
30’
10’ 10’
30’
15’
150’
50’
C-100
C-101
C-102
C-103
C-104
C-105
C-106
C-107
K-100
K-101
K-102
K-103
K-104
K-105
K-106
K-107
Detailed Process Area Layout
Process Area Dimensions
400’x500’
Reactor Spacing
150’
Pipe Rack Spacing
15’
Distillation Tower Spacing
30’
Storage Tank Spacing
50’
Component Spacing
10’
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Storage
• Require 10 floating roof storage tanks (for naphtha, jet, diesel, VGO, and residuum) and 2 pressurized storage tanks (for LPG and cold condensate)
• 4 storage tanks in process area, 8 in tank farm • Pipeline access every 2 days, will transfer 75% of tank contents• Dike areas must contain the maximum amount of liquid in a tank• $2,600/m3 of storage
Liquid NFPA-30 Designation
LPG Class 1A
Naphtha Class IB Jet Fuel Class IC, Class IIA
Diesel Class IC, Class IIA Gas Oil Class IIIB
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Tank Farm
S-107
LPG tank, pressurized D=26.2’,H=9.8’
Gasoline tank, floating roof D=26.2’,H=30’
Jet Fuel tank, floating roofD=26.2’,H=30’
Diesel tank, floating roof D=32.8’,H=32.8’
Pip
e R
ack
Bund (Concrete): 6’ High
Bund
Bun
d
Bund
50’
25’ 25’
S-105
S-102
S-100
S-103
S-104
S-106
S-101
50’
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Economics• 20 year plant life• 30 workers,5 managers
• Total Cost: $7.3 MM/year • Utility, catalyst, and maintenance costs: $28.5 MM/year
• Cooling water, Steam: $8.1 MM/year• Electricity: $3.79 MM/year• Catalyst: $4.4 MM/year• Maintenance: $12.2 MM/year
Year 1 10 20Revenue $165,407,634 $197,677,434 $240,967,689
Expenses $67,666,358 $62,349,835 $56,383,885Income After
Taxes$58,644,766 $81,644,766 $110,750,282
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FTL Plant Production• Feed from Syngas Plant:
• Total: 243,558 lb/hr To CHP plant: 103,504 lb/hr• 68 mol% H2 -36 mol% CH4• 28 mol% CO -34 mole % H2• 2 mol% N2 -16 mol% CO• 2 mol% CH4 -9 mol % N2
-4 mol % Ethane
• Total Product Volume: 5,100 bbl/day To Water treatment plant: • 500 bbl/day LPG (10%) -121,159 lb/hr• 1,100 bbl/day Gasoline (21%) -96 mol % Water• 1,000 bbl/day Jet Fuel (20%) -3.8 mol % Alcohol • 2,500 bbl/day Diesel (49%) -0.2 mol % Carboxylic
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Investment Economics
• Capital Cost: $406 MM• NPV: $455 MM• IRR: 21.96%• Interest: 8.00%• Simple Payback: 4.68 years
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Calculations
• *2
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Bibliography
[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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Thanks For Your Time!
Questions?
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