Return to DOE Report Table of Contents

Return to Process Development Unit Table of Contents

Economic Analysis LPMEOH™ Process as an Add-On to Integrated Gasification Combined Cycle (IGCC) For Co-Production - 1998

Air Products and Chemicals, Inc.

In the pdf format this document has 65 pages and is 226kb.

Table of Contents

Abstract 3
Acronyms and Definitions 6
Executive Summary 8

1

 Introduction 10
  1.1 Process Flow Diagram 11`
1.2 Typical Synthesis Gas Conversion 11
  1.2.1 Balanced Synthesis Gas 13
1.2.2 Heavy Oil Residue Synthesis Gas 13
1.2.3 Coal-derived Synthesis Gas 13

1.3

 Distillation 17
  1.3.1 Chemical Grade AA Methanol 17
1.3.2 Fuel Grade Methanol 17
1.3.3 MTBE Grade Methanol 17

2

 Cost Estimation Screening Program 18
  2.1 Spreadsheet Inputs 18
2.2 Capital Cost Calculations 18
2.3 Operating Cost Calculations 20

2.3.1

 Distillation Costs 21

2.4

 Sample From Cost Estimation Screening Program - Case 5-HW 22

3

 Results and Discussion 26
 

3.1

 Conversion Cost for Methanol Production from Texaco-Type Synthesis Gas 26
  3.1.1 Opimum Space Velocity as a Function of Operating Pressure 26
3.1.2 Methanol Conversion Cost from CO-rich Syngas - 500psig Feed Gas Pressure 28
3.1.3 Methanol Conversion Cost from CO-rich Syngas - 1,000psig Feed Gas Pressure 34
3.1.4 Effect of Plant Size on Methanol Conversion Cost 40

3.2

 Methanol Product Purification Cost 43
  3.2.1 Balanced Synthesis Gas 43
3.2.2 Texaco-Type Synthesis Gas 52
3.2.3 Shell-Type Synthesis Gas 52

4

 Sensitivity Studies 55
 

4.1

 Syngas Composition Variations - Impact on Liquid Phase and Gas Phase 55
  4.1.1 Sulfur Content 55
4.1.2 Inert Content 55
4.1.3 Effect of Capacity Factor 58

4.2

 Syngas Usage - Impact on IGCC Power Plant 59
  4.2.1 Impact of Process on Syngas Usage 59
4.2.2 Impact of Mass Flow on Power 60

5

 Examples of Cost of Methanol in IGCC Applications 61

6

 Conclusions - Summary of Cost Advantages (LPMEOH™ Vs Gas Phase) 63

7

 Future Improvements and Recommendations 64