Abstract

1.1

Introduction

1-1

1.2

Objective

1-1

1.3

Background

1-1

1.4

Common Study Basis

1-2

1.4.1

LPMAS Yield

1-2

1.4.2

Alcohol Selectivity

1-2

1.4.3

LPMAS Syngas Conversion

1-2

1.4.4

LPMAS Reactor Design Basis

1-3

1.4.5

Alcohol Separation

1-3

1.4.6

Alcohol Dehydration

1-3

1.4.7

Ether Production

1-4

1.5

References

1-4

1.6

Tables and Figures

1-5

Table 1-1 Demonstrated Alcohol Product Distribution

1-5

Table 1-2 Study Basis Alcohol Product Distribution

1-5

Figure 1-1 MTBE/methanol price survey

1-6

2.1

Background

2-1

2.2

Study Basis

2-1

2.2.1

Power Demand Level

2-1

2.2.2

Gasification/Combined Cycle

2-1

2.2.3

Syngas Conversion/Recycling

2-2

2.3

Economic Analysis

2-2

2.4

Results

2-3

2.4.1

Required Ether Price

2-3

2.4.2

Required Catalyst Productivity

2-3

2.5

Sensitivity Study - LPMAS Space Velocity

2-3

2.6

Case 1 Conclusions

2-3

2.7

Tables and Figures

2-4

Table 2-1 Coal Analysis

2-4

Table 2-2 Clean Syngas Composition (dry)

2-4

Table 2-3 Material Balance Sample

2-5

Table 2-3 Material Balance Sample (cont'd)

2-6

Table 2-4 Case 1 - IGCC/LPMAS Operating Summary

2-7

Table 2-5 Case 1 - IGCC/LPMAS Economic Summary

2-8

Figure 2-1 Case 1 - IGCC/LPMAS Block Flow Diagram

2-9

Figure 2-2 Gasification Feed Rates

2-10

Figure 2-3 LPMAS Capacity/Alcohol Production

2-11

Figure 2-4 Ether Production

2-12

Figure 2-5 LPMAS Plant Block Flow Diagram

2-13

Figure 2-6 LPMAS Reactor Feed Rates

2-14

Figure 2-7 Required Ether Price

2-15

Figure 2-8 Required Catalyst Productivity

2-16

Figure 2-9 Effect of LPMAS Reactor Space Velocity

2-17

3.1

Background

3-1

3.2

Study Basis

3-1

3.2.1

Gasification

3-1

3.2.2

Syngas Conversion

3-1

3.2.3

LPMAS Recycling

3-1

3.3

Linear Programming Analysis

3-2

3.3.1

Objective Function

3-2

3.3.2

Base Case - Petroleum Refinery

3-2

3.3.3

Modification for Coke Gasification/LPMAS

3-3

3.4

Case Studies

3-3

3.5

Economic Analysis

3-4

3.6

Results

3-4

3.7

Conclusions

3-5

3.8

References

3-5

3.9

Tables and Figures

3-6

Table 3-1 Petroleum Coke Analysis

3-6

Table 3-2 Coke Gasification Raw Syngas Composition

3-6

Table 3-3 Feedstock Purchases for Base Case

3-7

Table 3-4 Utilities for Base Case

3-7

Table 3-5 Case 2 - Cash Flows/Objective Function

3-8

Table 3-6 Case 2 - Refinery/LPMAS Operating Summary

3-9

Table 3-7 Case 2 - Refinery/LPMAS Economic Summary

3-10

Figure 3-1 Case 2 Petroleum Refinery/LPMAS Block Flow Diagram

3-11

Figure 3-2 Case 2 LPMAS Block Flow Diagram

3-12

Figure 3-3 Per Pass Syngas Conversion vs. Recycle Ratio

3-13

Figure 3-4 Linear Programming Refinery Model

3-14

Figure 3-5 Case 2 Rate of Return

3-15

Figure 3-6 Catalyst Productivity

3-16

4.1

Background

4-1

4.2

Study Basis

4-1

4.2.1

Partial Oxidation

4-1

4.2.2

Syngas Conversion

4-1

4.2.3

LPMAS Recycling

4-1

4.3

Economic Analysis

4-1

4.4

Results

4-2

4.5

Sensitivity Study - Natural Gas Feedstock Price

4-2

4.6

Sensitivity Study - Location Factor

4-2

4.7

Sensitivity Study - Elimination of CO₂ Recovery System

4-2

4.8

Conclusions

4-3

4.9

Tables and Figures

4-4

Table 4-1 Syngas Production from Partial Oxidation

4-4

Table 4-2 Case 3 - Standalone LPMAS Operating Summary

4-5

Table 4-3 Case 3 - Standalone LPMAS Economic Summary

4-6

Table 4-4 Modified Syngas Production - No CO₂ Recovery

4-7

Figure 4-1 Case 3 Standalone LPMAS Block Flow Diagram

4-8

Figure 4-2 Case 3 LPMAS Block Flow Diagram

4-9

Figure 4-3 LPMAS Recycle Ratio

4-10

Figure 4-4 Required Ether Price

4-11

Figure 4-5 Required Catalyst Productivity

4-12

Figure 4-6 Effect of Natural Gas Price

4-13

Figure 4-7 Effect of Location Factor

4-14

Figure 4-8 Modified Syngas Production Block Flow Diagram

4-15

Figure 4-9 Effect of Alcohol Selectivity

4-16

5.0

Summary

5-1

5.1

Conclusions

5-1

5.2

Tables and Figures

5-2

Table 5-1 Summary of Conditions

5-2