Early Entrance Coproduction Plant. Phase I. Preliminary Concept Report. May 17, 2001. Book 1. Tasks 1-3.

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Early Entrance Coproduction Plant. Phase I. Preliminary Concept Report. May 17, 2001. Book 1. Tasks 1-3. - 2001

Abughazaleh, John S. (KBR)
Mushtaq, Ahmed (Praxair)
Ashok, Anand (GE)
Anderson, John (TESI)
Benham, Charles (Rentech)
Brent, Fred D. (Texaco)
Chance, Thomas E. (GE)
Davis, William K. (Texaco)
Drnevich, Raymond F. (Praxair)
Hall, Larry, (KBR)
He, Ming (Texaco)
Lang, Stephen A. (KBR)
Mintner, David (KBR)
Moore, Wendy (KBR)
Ong, Jimmy O. (Texaco)
Potoczniak, George (KBR)
Sanchez, Adela G. (Texaco)
Schrader, Charles H. (TESI)
Shah, Lalit S. (Texaco)
Sheth, Kalapi D. (Texaco)
Shires, Phil J. (KBR)
Song, Rai (Texaco)

Texaco Energy Systems Inc.

In the pdf format this document has 63 pages and is 720kb

Table of Contents

Book Cover
Transmittal Letter
Title Page
Disclaimer						i
Abstract						ii
Table of Contents						iii
List of Tables, Figures and Drawings						TFD-1
Executive Summary						ES-1
Experimental						E-1
Results and Discussion						RD-1
Conclusion						C-1
References						R-1
List of Acronyms						A-1
TASK 1
1.0	Project Plan					1-1
	1.1	Project Management Plan				1-1
		1.1.1	Work Breakdown Structure			1-1
		1.1.2	Schedule and Milestones			1-1
		1.1.3	Manning and Project Cash Flow Projections			1-1
		1.1.4	DOE Review			1-1
		1.1.5	Final Issue			1-2
TASK 2
2.0	Concept Definition, Development, and Technical Assessment					2-1
Overview						2-1
	2.1	Overall Concept Definition and Development				2-2
		2.1.1	Market			2-2
		2.1.2	Technical			2-4
			2.1.2.1	F-T Product Upgrading Options		2-4
			2.1.2.2	F-T Catalyst Wax Separation		2-6
			2.1.2.3	F-T Wastewater Treating/Utilization		2-6
		2.1.3	Economics/Optimizations			2-7
			2.1.3.1	F-T Feed Gas H₂:CO Optimum Ratio		2-8
			2.1.3.2	Heat and Process Integration		2-9
			2.1.3.3	Percent of CO₂ in the F-T Feed Gas		2-10
			2.1.3.4	Acid Gas Removal Scheme		2-11
			2.1.3.5	F-T Tail Gas Utilization Study		2-11
				2.1.3.5.1	Reactors in Series	2-12
				2.1.3.5.2	Recycle to the F-T Reactor	2-12
				2.1.3.5.3	Recycle to the Syngas Generation Unit	2-12
				2.1.3.5.4	Fuel for Power Generation	2-13
				2.1.3.5.5	Other Utilization Options	2-13
				2.1.3.5.6	EECP Concept - Selected Tail Gas Utilization Concept	2-13
	2.2	Alternative Site Design Options - Assessment and Selection				2-13
		2.2.1	Introduction			2-13
		2.2.2	Results and Discussion			2-15
			2.2.2.1	Design Basis		2-15
				2.2.2.1.1	Design Basis - Product Upgrading Summary	2-23
			2.2.2.2	Block Flow Diagrams		2-28
			2.2.2.3	Process Descriptions		2-33
				2.2.2.3.1	Overall Block Flow Diagram	2-33
				2.2.2.3.2	Port Arthur Cases - PARHCU and PARFW	2-33
				2.2.2.3.3	Tampa Electric Polk Station Cases - THCU and TSC	2-35
			2.2.2.4	Stream Summaries		2-37
			2.2.2.5	Equipment List		2-62
			2.2.2.6	Overall Utility Summaryies		2-74
			2.2.2.7	Heat and Process Integration		2-79
			2.2.2.8	Acid Gas Removal Options		2-80
			2.2.2.9	Capital Cost Estimate		2-81
				2.2.2.9.1	Purpose and Scope	2-81
				2.2.2.9.2	Approach	2-82
				2.2.2.9.3	Estimate Structure	2-82
				2.2.2.9.4	Methodology	2-83
			2.2.2.10	Environmental Considerations		2-87
			2.2.2.11	Marketing Considerations		2-88
				2.2.2.11.1	Plant Site Selection Criteria	2-88
				2.2.2.11.2	Objectives	2-88
				2.2.2.11.3	Background Information	2-88
				2.2.2.11.4	Product Slate and Pricing	2-89
				2.2.2.11.5	Product Valuation Methodologies	2-90
		2.2.3	Conclusions			2-94
	2.3	Design Considerations for Advanced Subsystems				2-98
		2.3.1	Fischer-Tropsch Synthesis			2-99
		2.3.2	Gas Turbine			2-102
		2.3.3	Fischer-Tropsch Product Upgrading			2-105
TASK 2 - Attachments
2-A	Attachment 2-A: F-T Product Upgrade Options Study					2A-1
2-B	Attachment 2-B: F-T Wastewater Treating/Utilization Study					2B-1
2-C	Attachment 2-C: F-T Feed Gas H₂:CO Optimum Ratio Study					2C-1
2-D	Attachment 2-D: F-T Feed Gas Optimum Percent CO₂ Study					2E-1
2-E	Attachment 2-E: Acid Gas Removal Selection Study					2E-1
2-F	Attachment 2-F: Evaluation of a Combined Primary and Tail Gas Treating Amine System					2F-1
TASK 3
3.0	Technical Assessment of Subsystems					3-1
Overview						3-1
	3.1	Basic Engineering Design Data				3-2
	3.2	Air Separation Unit				3-3
		3.2.1	Process Arrangement			3-3
		3.2.2	Design Basis			3-3
	3.3	Gasification				3-9
	3.4	Acid Gas Removal				3-11
		3.4.1	Stripping Nitrogen			3-11
	3.5	Sulfur Recovery Unit/Tail Gas Treating Unit				3-13
	3.6	Fischer-Tropsch Synthesis				3-15
		3.6.1	Battery Limit Conditions			3-15
		3.6.2	Syngas			3-16
		3.6.3	Zinc Oxide Bed Design Basis			3-17
		3.6.4	Fischer-Tropsch Synthesis Reactor Yields			3-17
		3.6.5	Fischer-Tropsch Catalyst Properities			3-17
		3.6.6	Catalyst Activation			3-17
	3.7	Gas Turbine/Generator				3-18
	3.8	Steam System				3-22
		3.8.1	Steam System Header Pressure			3-22
		3.8.2	Steam Condensate Systems			3-22
		3.8.3	Water Systems			3-22
	3.9	Fischer-Tropsch Product Upgrading				3-23
		3.9.1	Scope of Work			3-23
		3.9.2	Feedstock and Product Properties			3-24
		3.9.3	Feed Rates and Process Yields			3-29
		3.9.4	Hydrogen Make-Up Gas			3-29
		3.9.5	Unit Design Basis			3-30
			3.9.5.1	Service Factor		3-30
			3.9.5.2	Design Considerations		3-30
		3.9.6	Battery Limit Conditions			3-31
		3.9.7	Unit Turn-Down			3-31
	3.10	Off Site				3-31
		3.10.1	Purge Nitrogen			3-31
		3.10.2	Flare System			3-32
		3.10.3	Secondary Fuel Specifications			3-32
		3.10.4	Plant and Instrument Air			3-33
		3.10.5	Electric Power			3-33
		3.10.6	Cooling Water			3-34
	3.11	Unit/Equipment Numbering				3-35
TASK 4
4.0	Subsystem Design Specifications					4-1
Overview						4-1
	4.1	EECP Concept				4-2
		4.1.1	Concept Process Description			4-2
		4.1.2	Overall Block Flow Diagrams			4-4
		4.1.3	Refinery Integration			4-9
		4.1.4	Pinch Analysis			4-10
	4.2	Process Description				4-10
		4.2.1	Air Separation Unit			4-10
			4.2.1.1	Gas Turbine Extraction Air Supply		4-11
			4.2.1.2	Main Air Feed Filtration and Compressions		4-11
			4.2.1.3	Air Cooling and Purification		4-11
			4.2.1.4	Cryogenic Distillation		4-11
			4.2.1.5	Product Compression		4-12
		4.2.2	Gasification			4-12
			4.2.2.1	Coke Handling Unit (U-2000)		4-12
			4.2.2.2	Slurry Preparation Unit (U-3000)		4-12
			4.2.2.3	Gasification Unit (U-4000)		4-13
			4.2.2.4	Coarse Slag Handling Unit (U-5000)		4-13
			4.2.2.5	Black Water Flash Unit (U-6000)		4-13
			4.2.2.6	Fines Handling Unit (U-7000)		4-14
			4.2.2.7	Low Temperature Gas Cooling (U-8000)		4-14
		4.2.3	Acid Gas Removal Unit			4-14
		4.2.4	Fischer-Tropsch Synthesis			4-15
			4.2.4.1	Fischer-Tropsch REactor		4-15
			4.2.4.2	F-T Product Separation		4-15
			4.2.4.3	F-T Reaction Heat Removal System		4-16
			4.2.4.4	Catalyst Handling System		4-16
		4.2.5	F-T Upgrading			4-17
			4.2.5.1	General		4-17
			4.2.5.2	Description of Flow		4-18
		4.2.6	Power Block			4-20
			4.2.6.1	Gas Turbine		4-21
			4.2.6.2	Steam Turbine		4-22
			4.2.6.3	Generators		4-22
			4.2.6.4	Heat Recovery Steam Generator		4-22
			4.2.6.5	Unit Controls		4-23
			4.2.6.6	Feedwater System		4-23
		4.2.7	SRU/TGTU Process Description			4-23
		4.2.8	Steam System Process Description			4-24
		4.2.9	Off Site			4-26
	4.3	Process Flow Sketches				4-26
		4.3.1	Air Separation Unit			4-26
		4.3.2	Gasification Unit			4-26
		4.3.3	Acid Gas Removal Unit			4-26
		4.3.4	F-T Synthesis Unit			4-26
		4.3.5	F-T Upgrading Unit			4-26
		4.3.6	Power Block Unit			4-26
		4.3.7	Sulfur Recovery Unit/Tail Gas Treating Unit			4-26
		4.3.8	Steam System			4-27
		4.3.9	Off Site			4-27
		4.3.10	Power Distribution Network			4-27
	4.4	Stream Summaries				4-50
		4.4.1	ASU Stream Summaries			4-50
		4.4.2	Gasification			4-51
		4.4.3	Acid Gas Removal			4-54
		4.4.4	F-T Synthesis			4-54
		4.4.5	F-T Upgrading			4-65
		4.4.6	Power Block			4-66
		4.4.7	SRU/TGTU			4-68
	4.5	Equipment List				4-70
		4.5.1	ASU			4-70
		4.5.2	Gasification			4-73
		4.5.3	AGR			4-73
		4.5.4	F-T Synthesis			4-74
		4.5.5	F-T Product Upgrading Equipment List			4-75
4.5.6		Power Block			4-77
4.5.7		SRU/TGTU			4-77
4.5.8		Steam System Equipment List			4-78
4.5.9		Off Site Equipment List			4-79
4.6	Utility/Catalyst/Chemical Summary				4-80
	4.6.1	ASU			4-83
	4.6.2	Gasification			4-83
	4.6.3	AGR			4-86
	4.6.4	F-T Synthesis			4-87
	4.6.5	F-T Upgrading			4-91
	4.6.6	Power Block			4-92
	4.6.7	SRU/TGTU			4-92
	4.6.8	Steam System			4-95
	4.6.9	Off Site			4-95
	4.6.10	Overall Utility Plan			4-96
4.7	Subsystem Plot Plans				4-96
	4.7.1	Overall Plot Plan			4-96
	4.7.2	Air Separation Unit			4-96
	4.7.3	Gasification			4-96
	4.7.4	AGR			4-96
	4.7.5	F-T Synthesis			4-96
	4.7.6	F-T Upgrading			4-96
	4.7.7	Power Block			4-96
	4.7.8	SRU/TGTU/AGR			4-96
4.8	Technical Barriers				4-105
	4.8.1	F-T Synthesis			4-105
		4.8.1.1	Reactor Design Concerns		4-106
			4.8.1.1.1	Confirmation of Catalyst Performance	4-106
			4.8.1.1.2	Catalyst Replacement Rate	4-107
			4.8.1.1.3	Water Gas Shift Activity	4-107
			4.8.1.1.4	Hydrodynamics	4-107
			4.8.1.1.5	Scale-Up	4-108
			4.8.1.1.6	Design of Reactor Internals	4-109
		4.8.1.2	Catalyst/Wax Separation		4-109
			4.8.1.2.1	Rentech Primary Separation	4-110
			4.8.1.2.2	Rentech Second Stage Separation	4-110
		4.8.1.3	Equipment Design		4-110
			4.8.1.3.1	Activation Vessel	4-110
			4.8.1.3.2	Catalyst Slurry Pump	4-110
			4.8.1.3.3	Catalyst Addition/Withdrawal	4-110
		4.8.1.4	Environmental		4-111
			4.8.1.4.1	F-T Tail Gas Utilization	4-111
			4.8.1.4.2	Disposal of Catalyst	4-111
			4.8.1.4.3	F-T Water Usage	4-112
	4.8.2	Power Block			4-112
	4.8.3	F-T Product Upgrading			4-112
		4.8.3.1	Hy-Finishing Technology		4-114
			4.8.3.1.1	Olefins and Oxygenates	4-115
			4.8.3.1.2	Yields and Properties	4-115
			4.8.3.1.3	Thermal Degradation	4-115
			4.8.3.1.4	Iron Contamination	4-116
			4.8.3.1.5	Zero Sulfur	4-116
		4.8.3.2	Conclusion		4-117
	4.8.4	Technical Barriers - Acid Gas Removal (AGR)			4-118
	4.8.5	Risk Assessment			4-119
		4.8.5.1	Case A: Total EECP Facility		4-120
		4.8.5.2	Case B: EECP System Excluding Units 10000 and 11000		4-120
		4.8.5.3	Case C: Power Island Only		4-121
		4.8.5.4	Case A-1: Spared Compressors in Unit 1100		4-122
		4.8.5.5	Conclusions and Recommendations		4-122
TASK 4 - Attachments
4-A	Attachment A: Pinch Analysis					4A-1
4-B	Attachment B: Facilities Reliability Study					4B-1
TASK 5
5.0	Market Assessment					5-1
Overview						5-1
	5.1	Market Analysis of Products				5-1
		5.1.1	Diesel			5-1
			5.1.1.1	Current Market Size		5-1
			5.1.1.2	Supply and Demand		5-2
			5.1.1.3	Projected 10-Year Growth Rates		5-2
			5.1.1.4	Current Prices		5-2
			5.1.1.5	Projected 10-Year Prices		5-3
			5.1.1.6	Projected New Markets		5-3
		5.1.2	Finished Waxes			5-3
			5.1.2.1	Current Market Size		5-4
			5.1.2.2	Supply and Demand		5-4
			5.1.2.3	Projected 10-Year Growth Rates		5-4
			5.1.2.4	Current Prices		5-4
			5.1.2.5	Project 10-Year Prices		5-5
			5.1.2.6	Projected New Markets		5-5
		5.1.3	F-T Naphtha			5-6
			5.1.3.1	Current Market Size		5-6
			5.1.3.2	Supply and Demand		5-6
			5.1.3.3	Projected 10-Year Growth Rates		5-6
			5.1.3.4	Current Prices		5-7
			5.1.3.5	Projected 10-Year Prices		5-7
			5.1.3.6	Projected New Markets		5-11
	5.2	Market Assessment of Technology				5-11
		5.2.1	Feedstock Availability			5-11
		5.2.2	Environmental Factors			5-12
		5.2.3	Technology Factors			5-12
	5.3	Fischer-Tropsch Product Slate and Analysis				5-15
		5.3.1	Diesel			5-15
		5.3.2	Naphtha			5-16
		5.3.3	Specialty Low and Medium Melt Waxes			5-18
		5.3.4	Specialty High Melt Waxes			5-19
	5.4	Full-Scale Commercial Plant				5-20
		5.4.1	Price and Feedstock Availability			5-20
		5.4.2	Proximity to Markets			5-21
		5.4.3	Environmental Considerations			5-21
		5.4.4	Infrastructure and Process Integration			5-22
TASK 6
6.0	Preliminary Site Analysis					6-1
Overview						6-1
	6.1	Site Selection Process				6-1
		6.1.1	Synergy with Existing Infrastructure			6-1
		6.1.2	Construction Requirements			6-1
		6.1.3	Site Access			6-4
		6.1.4	Environmental Requirements			6-4
		6.1.5	Community			6-4
		6.1.6	Geotechnic and Topographic Investigation			6-4
		6.1.7	Economic Factors			6-4
		6.1.8	Site Commitment to Project			6-4
	6.2	Identify Specific Sites				6-4
	6.3	Identify Additional Commitments/Parties for EECP Participation				6-7
TASK 7
7.0	Environmental Assessment					7-1
Overview						7-1
	7.1	Summary				7-1
		7.1.1	NEPA Requirements			7-1
		7.1.2	Air Permit Requirements			7-1
		7.1.3	Wastewater Permit Requirements			7-2
		7.1.4	Solid Waste Permit Requirements			7-2
	7.2	Emission Levels				7-2
	7.3	Adaptability for CO₂ Sequestration				7-6
		7.3.1	Introduction			7-6
			7.3.1.1	CO₂ Emissions for EECP Phase I Project		7-6
			7.3.1.2	EECP Adaptability for CO₂ Sequestration		7-6
		7.3.2	Sequestration Options			7-7
			7.3.2.1	Membrane Contactor		7-7
			7.3.2.2	Kerr-McGee/ABB Lummus CO₂ Recovery Technology		7-7
			7.3.2.3	Mitsubishi Heavy Industries, Ltd. Technology		7-8
			7.3.2.4	Membranes		7-8
			7.3.2.5	Carbon Fiber Composite Molecular Sieve		7-8
			7.3.2.6	Others		7-8
		7.3.3	CO₂ Sequestration			7-9
			7.3.3.1	Chemical Utilization of CO₂		7-9
			7.3.3.2	Enhanced Oil Recovery		7-9
			7.3.3.3	CO₂ Storage		7-9
			7.3.3.4	Advanced Concepts		7-10
			7.3.3.5	Forestation		7-10
	7.4	Water Use and Remediation				7-11
	7.5	Solid Waste Byproducts				7-11
	7.6	NEPA Requirements				7-12
	7.7	Permitting Requirements				7-13
		7.7.1	Air			7-13
		7.7.2	Wastewater			7-16
		7.7.3	Solid Waste			7-17
			7.7.3.1	Non-Hazardous Wastes		7-17
			7.7.3.2	Hazardous Wastes		7-17
	7.8	Integration of Existing Facilities with New Treatment Facilities				7-17
		7.8.1	Wastewater Treatment			7-17
		7.8.2	Solid Waste Disposal			7-18
TASK 8
8.0	Economic Assessment					8-1
Overview						8-1
	8.1	Feedstock Cost and Product Price Evaluation				8-2
		8.1.1	Economic Parameters			8-4
		8.1.2	Economic Sensitivity Analysis			8-4
		8.1.3	Taxes, Royalties, and Inflation			8-4
	8.2	Cost Estimates				8-5
		8.2.1	Capital Estimates Methodology			8-5
		8.2.2	Operating Costs			8-11
		8.2.3	Refinery Site Methodology			8-5
	8.3	Role of Government Incentives for Commercial Viability of EECP				8-13
		8.3.1	Tax Relief			8-13
		8.3.2	Energy Plicy Act (EPACT) Alternate Fuels			8-14
		8.3.3	Long-Term F-T Liquids Purchase Agreement			8-14
		8.3.4	Cost Sharing			8-14