Transcript Methanol Production from Municipal Solid Waste Meet 3

CHE 397
Group Charlie
Priya Chetty, Scott Morgan, Brian Mottel, Daniyal
Qamar, Sukhjinder Singh
Mentor: Dennis O’ Brien
Dr. 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
conversion : 0.005
∆Hrxn = 319862 Btu/lbmol
Process Flow Diagram
TRBOEXP2
DIST1
RTCOMP
MEOH
SYNGAS
FLSHVAP
VALVE
INDIST1
SYNINRCT
REACTOR
HOTPROD
TRBCHRG
DIST
BOTT1
FLSHLIQ
HX1
LOWPPROD
DIST2
HX01
FLSHIN
FLASHVAP
WATER
CLDIN1
CLDOUT1
CLDH20IN
CLDIN2
Methanol Production
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 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 reactor
Volume 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/s
K for 600 psi = 0.3
Vol flow = 2.86 ft3/s
Total 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 Cost
Table 1.1: Cost of specific units in the plant design
Description
Base Cost /
unit
No. of Units
Total Cost
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
PMP
Explosion proof chemical
pump
10,300
1
$10,300
PMP2
Explosion proof chemical
pump
8,900
1
$8,900
Heat exchanger
1,440,000
1
$1,440,000
Compressor
5,110,000
1
$5,110,000
Unit Type
Separators
Pumps
Heat exchanger
HX01
Compressor
RTCOMP
Continued
Turbo expander
TRBCHRG
Turbo expander
178,860
1
$178,860
Reactor
34,200,000
1
$34,200,000
Floating roof
76,700
3
$211,404
PIPE
Double wall chemical
containment pipes
89,400
1
$89,400
valves and
eyewash
station
Stainless steel valves
and eyewash
station
17,800
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
Reactor
R-300
Storage Tanks
Storage tanks
Safety
Operating and Utilities Economic Analysis
Table 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)
Continued
Direct labor wages
$760,000
Direct salaries
$280,000
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
Property insurance is 0.5% of annual plant cost
Property tax is 2% of annual plant cost
Categorized annual cost
Table 1.3: factor units
Cost Factor
Typical factor in American engineering
units
Utilities
Steam, 100psi
Cooling water
Electricity
$8.14/1000lbs
$0.12/1000gal
$0.076/KWh
Waste treatment
$3.00/1000lb
KATALCO 51-8 catalyst price
Operations (labor-related)
Operating labor
Supervision
$46.00/lb
Laboratory
5% of operating labor
Maintenance
3% of cap cost
Depreciation
Straight-line depreciation
$20/hr
20% of operating labor
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 INVESTORS
NPV = 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??