FISCHER-TROPSCHLIQUIDS REFINING PLANT

Team FoxtrotPresentation #4 – April 9, 2013

Mentor: Dan Rusinak, PE

Team:Mudassir Ali

Stephen DrakeKevin MeauxBrandon SieveCHE 397

University of Illinois at ChicagoChemical Engineering Department

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Today, Team Foxtrot will Address:

• Questions/Topics from Presentation #3 • Complete PFD • Process Control Scheme• Plant Layout• Refined Economics

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Design Project Outline• Executive Summary• Discussion• Recommendations

Appendices1. Design Basis 2. Block Flow Diagram 3. Process Flow Diagram showing major equipment 4. Material and Energy Balance (w/ Integration Review)5. Calculations 6. Annotated Equipment List 7. Economic Evaluation factored from Equipment Costs 8. Utilities 9. Conceptual Control Scheme 10. General Arrangement – Major Equipment Layout 11. Distribution and End-use Issues Review12. Constraints Review13. Applicable Standards14. Project Communications File15. Information Sources and References

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Topics from Last Presentation

4

Distillate Bottoms Condenser Pressure

Reboiler Temp

Trays Height Diameter

T-101 LPG C5+ 253 psia 793 F 25 6.5’ 42’

T-102 Naphtha C11+ 0.2 psia 312 F 15 5.5’ 62’

T-100 Jet Diesel 0.2 psia 304 F 15 12.5’ 42’

T-103 LPG C5+ 253 psia 879 F 15 4’ 42’

T-104 Naphtha C11+ 1.2 psia 350 F 43 4’ 98’

T-105 Jet/Diesel

Wax/Res 0.2 psia 484 F 29 15.5’ 70’

T-106 Jet Diesel 0.1 290 F 29 7.5’ 70’

- Oligomerization - Hydrocracker

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Detailed PFD with Level Controls• The next slides will consist of:

• PFD Level controls around• Air Membrane Separators• Exchangers• Compressors• 2 Phase Separators• 3 Phase Separators• Vessels• Fired Heater• Reactors

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Foxtrot, University of Illinois at Chicago 6

Overall FT LoopUniversity of Illinois at Chicago 6

Area 1- FT Loop PFDFT Loop Area 1 PFD

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7 7

1

3

4

5

2

6Unit Descrip.R-100 SBCRR-101 Cat-RejK-100 compressr

P-100 Pump

Equipment List

FT loop Area 2 PFD

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7

13

12

11

10

9

8 14

Unit Descrip.K-100 Compressor

E-100 Exchangers

S-100 2 phase Sep

T-101 Tanks

P-100 Pump

Equipment List

Oligimerization Loop overall PFD

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Oligomerization PFD Area 1

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1

5

3

4

2

Unit Descrip.K-100 Compressor

E-100 Exchangers

S-100 2 phase Sep

T-101 Tanks

P-100 Pump

Oligomerization PFD Area 2

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Oligomerization PFD Area 3

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Hydrocracker Overall PFD

TIC

TIC

FIC

FIC

TIC

LIC

IC

IC IC

Close up Hydrocracker Reactor PFDUniversity of Illinois at Chicago 14

Hydrocracker Overall PFD

TIC

TIC

FIC

FIC

TIC

LIC

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Reactor SpecificationsFT Reactor Hydrocracker Oligomerization

Temperature, F 428 680 356

Pressure, psia 537 1015 551

Height, ft 50 24 48

Diameter, ft 16 7 5.5

Heat Load, BTU/hr - 5.87e8 - 3.13e6 - 1.52e7

Boiler Water Feed, GPM 775 5 20

H2 Feed, lb/hr - 5,150 300

Volumetric Feed, bbl/day

- 3,000 3,000

TIC, $ 153 MM [1] 43 MM [2] 11 MM [2]

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Flare

UtilityLoading

FiredHeater

Process

Offices

Parking Lot

Labs

Hig

hway Tank Farm

Road

Roa

d

Road

Road

Road

Conceptual Plant Layout

Perimeter Fence

Wind

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R-100 Side Pipe Rack

Main Pipe Rack

Cold dike D=59ftV= 11070ft^3

VGO dike D=43ftV= 5310ft^3

Resid dike D=43ftV= 5310ft^3Hot dike D=47ft

V= 7062ft^3

M-100 R-100 R-101 R-102

AC-101

V-100

V-101

V-102

T-104

T-105

T-106

T-107

T-108

T-101

T-102

T-103

30’

15’

30’

10’ 10’

30’

15’

150’

50’

C-100

C-101

C-102

C-103

C-104

C-105

C-106

C-107

K-100

K-101

K-102

K-103

K-104

K-105

K-106

K-107

Detailed Process Area Layout

Process Area Dimensions

400’x500’

Reactor Spacing

150’

Pipe Rack Spacing

15’

Distillation Tower Spacing

30’

Storage Tank Spacing

50’

Component Spacing

10’

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Storage

• Require 10 floating roof storage tanks (for naphtha, jet, diesel, VGO, and residuum) and 2 pressurized storage tanks (for LPG and cold condensate)

• 4 storage tanks in process area, 8 in tank farm • Pipeline access every 2 days, will transfer 75% of tank contents• Dike areas must contain the maximum amount of liquid in a tank• $2,600/m3 of storage

Liquid NFPA-30 Designation

LPG Class 1A

Naphtha Class IB Jet Fuel Class IC, Class IIA

Diesel Class IC, Class IIA Gas Oil Class IIIB

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Tank Farm

S-107

LPG tank, pressurized D=26.2’,H=9.8’

Gasoline tank, floating roof D=26.2’,H=30’

Jet Fuel tank, floating roofD=26.2’,H=30’

Diesel tank, floating roof D=32.8’,H=32.8’

Pip

e R

ack

Bund (Concrete): 6’ High

Bund

Bun

d

Bund

50’

25’ 25’

S-105

S-102

S-100

S-103

S-104

S-106

S-101

50’

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Economics• 20 year plant life• 30 workers,5 managers

• Total Cost: $7.3 MM/year • Utility, catalyst, and maintenance costs: $28.5 MM/year

• Cooling water, Steam: $8.1 MM/year• Electricity: $3.79 MM/year• Catalyst: $4.4 MM/year• Maintenance: $12.2 MM/year

Year 1 10 20Revenue $165,407,634 $197,677,434 $240,967,689

Expenses $67,666,358 $62,349,835 $56,383,885Income After

Taxes$58,644,766 $81,644,766 $110,750,282

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FTL Plant Production• Feed from Syngas Plant:

• Total: 243,558 lb/hr To CHP plant: 103,504 lb/hr• 68 mol% H2 -36 mol% CH4• 28 mol% CO -34 mole % H2• 2 mol% N2 -16 mol% CO• 2 mol% CH4 -9 mol % N2

-4 mol % Ethane

• Total Product Volume: 5,100 bbl/day To Water treatment plant: • 500 bbl/day LPG (10%) -121,159 lb/hr• 1,100 bbl/day Gasoline (21%) -96 mol % Water• 1,000 bbl/day Jet Fuel (20%) -3.8 mol % Alcohol • 2,500 bbl/day Diesel (49%) -0.2 mol % Carboxylic

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Investment Economics

• Capital Cost: $406 MM• NPV: $455 MM• IRR: 21.96%• Interest: 8.00%• Simple Payback: 4.68 years

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Calculations

• *2

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Bibliography

[1] Bartholomew, Calvin, and Robert Fauratto. Fundamentals of Industrial Catalytic Processes. 2nd ed. N.p.: John Wiley & Sons, 2006. Print.

[2] Private communication with UOP LLC.[3] De Klerk, Arno. Fischer-Tropsch Refining. Germany:

Weinheim, 2011. Print.

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Thanks For Your Time!

Questions?

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