CHE 397CHE 397Group CharlieGroup Charlie

Priya Chetty, Scott Morgan, Brian Mottel, Priya Chetty, Scott Morgan, Brian Mottel, Daniyal Qamar, Sukhjinder SinghDaniyal Qamar, Sukhjinder Singh

Mentor: Dennis O’ BrienMentor: Dennis O’ Brien Dr. Jeffery PerlDr. Jeffery Perl

Agenda

Design Basis Chemistry PFD Flow Sheeting Energy Sinks/Loads Costing/Sizing

Design Basis

Utilize the syngas provided by group Delta to synthesize Methanol

Plant located in Chicago because of MSW 2300TPD syngas to produce 1600 TPD

Methanol at a purity of 99.2 wt%

Chemistry CO2 + H2 → CO + H2O ∆Hrxn = 17694 Btu/lbmol

conversion: 0.1 of CO2

CO + 2H2 → CH3OH ∆Hrxn = 39037 Btu/lbmol

Conversion: 0.4 of CO

2CO +4H2 → CH3CH2OH +H2O ∆Hrxn = 147033 Btu/lbmol

Conversion: 0.01 of CO

4CO +8H2 → CH3CH2CH2CH2OH + 3H2O ∆Hrxn = 319862 Btu/lbmol

conversion : 0.005

Process Flow Diagram

FLSHVAP

FEEDREAC

HOTPROD

FLSHIN

FLSHLIQ

INDIST1

DIST1

BOTT1

MEOH

WATER

LOWPPROD

SYNGAS

SYNINRCT

CLDH20IN CLDIN2CLDIN1 CLDOUT1

AAMETH

REACTOR

FLASHVAP

DIST

DIST2

TRBCHRG

RTCOMP

HX01

HX1

TRBOEXP2

VALVE

Heat exchanger: 45000 lb/hr inlet at 70F outlet 1090F

Reactor: Pressure 1200 psi Temperature 518 F

Turbo expander: Pressure drop of 452 psi

Methanol Production

Methanol purification

Flash: 648psi, 118ºF, separates 97% of CO, 100% H2, 75% CO2

Valve: Reduces pressure from 648psi to 31psi

Column 1: Separates ~100% CO, CO2

Column 2: Separates water, methanol, and higher alcohols to obtain 99.2% pure methanol

Turbo Expander 2: Pressure drop of 16.3psi

Flow Sheet

Flow Sheet (cont.)

Energy Sinks & Loads

Equipment Sizing

Reactor size: GHSV = volume feed/volume of reactorVolume of reactor with 3000 GHSV = 43 ft3

Mean Residence time = 1.19 s

Flash Drum Size:Vmax = k[(ρl- ρv)/ ρl]^0.5 = 1.4 ft/sK for 600 psi = 0.3Vol flow = 2.86 ft3/sTotal Volume calculated = 3500 ft3

Heat Exchanger:A=Q/U∆Tlm

With U value of 250 BTU/F Ft2 h, an average for evaporators and heaters A = 6681 ft2

Fixed Capital CostTable 1.1: Cost of specific units in the plant design

Unit Type Description Base Cost / unit No. of Units Total Cost

Separators

FLASHVAP Flash unit 8,100 1 $8,100

DIST Distillation tower 514,600 1 $514,600

DIST2 Distillation tower 1,954,600 1 $1,954,600

SPLIT Splitter 208,540 1 $208,540

Pumps

PMP Explosion proof chemical pump 10,300 1 $10,300

PMP2 Explosion proof chemical pump 8,900 1 $8,900

Heat exchanger

HX01 Heat exchanger 1,440,000 1 $1,440,000

Compressor

RTCOMP Compressor 5,110,000 1 $5,110,000

Continued

Turbo expander

TRBCHRG Turbo expander 178,860 1 $178,860

Reactor

R-300 Reactor 34,200,000 1 $34,200,000

Storage Tanks

Storage tanks Floating roof 76,700 3 $211,404

Safety

PIPE Double wall chemical containment pipes 89,400 1 $89,400

valves and eyewash station

Stainless steel valves and eyewash

station17,800 1 $17,800

Fire and alarm Fire and leakage alarm system 11,000 1 $11,000

Storage facility Lighting protection storage facility 6,000 1 $6,000

Total Equipment Cost $43,969,504

Total Installed Cost $197,862,768

Total Capital Cost $287,862,768

Operating and Utilities Economic AnalysisTable 1.2: Cost of plant operation and utilities

Cost Factor Annual Cost

Feedstocks (raw materials)

Syngas $12,500,000

Make-up feed water $364,000

Catalyst $1,155,108

Total $13,019,108

Utilities

Electricity $12,500,000

Cooling water, 95°F,50psia $7,769,894

Steam generation,327.8°F,100psi $19,211,641

Total $39,481,535

Operations (labor-related)

Direct labor wages $760,000

Direct salaries $280,000

Continued

Property insurance is 0.5% of annual plant costProperty tax is 2% of annual plant cost

Outside legal assistance $150,000

Accountant $45,000

Control laboratory $78,000

Total $1,313,000

Maintenance

Insurance & benefits including vacation $90,600

Taxes (fed/state, workman’s comp etc) $88,000

Plant maintenance cost $390,000

Total $480,600

Property Taxes and Insurance $1,253,335

Cost of manufacture $57,885,661

Depreciation (annual plant life) $20,834,027

Total Methanol Product Sales $228,245,329

Categorized annual cost

Table 1.3: factor units

Cost FactorTypical factor in American engineering units

UtilitiesSteam, 100psi $8.14/1000lbsCooling water $0.12/1000galElectricity $0.076/KWh

Waste treatment $3.00/1000lb

KATALCO 51-8 catalyst price $46.00/lbOperations (labor-related)Operating labor $20/hrSupervision 20% of operating labor

Laboratory 5% of operating labor

Maintenance 3% of cap cost

Depreciation Straight-line depreciation

Taxes

Effective US federal tax rate 40%

Credits

Light gas by-product credit $1.50/million BTU HHV

Higher alcohols by-product $0.12/lb

RISK PROFILE FOR INVESTORSNPV = 446,936,128

IIR = 36.8%

Protections:

-Long term methanol selling contract with large creditworthy U.S Corporation.

-Alliance with Delta group. Long term syngas supply contract with fixed price to meet contractual undertaking between Windy City Methanol and Delta.

-Independent evaluation by more than one geological consulting firm to ensure plant construction area is safe for production of flammable products.

-Hire specialized management personnel with extraordinary methanol marketing experience.

-Have business interruption insurance to pay losses incurred due to plant failure or natural disaster.

-Ensure all critical permits issued prior to plant construction.

-Independent analysis for the technology being used in plant design.

-Obtain high-quality legal advice. Have devised workable dispute settlement mechanism in place.

Solutions to questions from previous presentation

1.Cost of syngas

2.Assumptions-Mostly removed-Reactor has more reactions-Conversion/selectivity set for the reactions

3.Distillation pressure and drop-Pressure adjusted -Two columns-by products

4.Costs for equipment

5.Depriciation cost

Improvements

Add more reactors to simulate quenching Utilize membrane separators to purge off

excess gasses Use water tubes to cool reactor Do sensitivity analysis to find out whether

turbo expanders/heat exchangers are cost effective

Increase Methanol purity

Questions??