Refinery Gasification - Predicted Performance of Heavy Oil Based IGCC
Subtitle: Overview of Refinery Gasification
Publisher: Xlibris
Published: 2007
Table of contents: title: Overview of Refinery Gasification; title: Gasification has a long history of research, development and commercialization stretching back more than 50 years. Over 129 plants have been constructed and operated worldwide, and as many as 34 new plants are in various stages of planning and construction [1]. The majority of the existing plants were constructed for the production of synthesis gas or syngas, a mixture containing carbon monoxide (CO) and hydrogen (H2), used in the manufacture of a wide variety of chemicals. The wide range of uses for syngas is depicted in Figure 1. The second largest application has been the production of liquid fuels via the Fischer-Tropsch synthesis. Almost all of these units are located in South Africa, although future plants may be built in a variety of locations around the world for the conversion of stranded natural gas to liquid fuels. Near-term development of gasification technology is focused on the clean production of electric power. This application has been the subject of a number of commercial ventures and demonstrations in recent years. Within the U.S., major demonstration projects supported by the DOE have been sited at Tampa Electric’s power station in Polk County, FL (1996) and Global Energy’s Wabash River station in Indiana (1995). These projects have been based on coal and employ Integrated Gasification Combined Cycle (IGCC) plant configurations. Petcoke has also been tested in these facilities. Commercial applications worldwide have focused on petroleum refining, many involving the trigeneration of hydrogen, power and steam. Recent projects include U.S. refineries in El Dorado,KS (Frontier Oil, formerly Texaco), Coffeyville, KS (Farmland Industries), Delaware City, DE (Motiva), and Baytown, TX (ExxonMobil); and European refineries in Falconara, It. (API), Sicily, It. (ISAB), Sardinia, It. (Sarlux), and Pernis, Neth. (Shell). These refinery applications are the main focus of this report.; title: Possible Products from Synthesis Gas; title: Combined Heat & Power Generation; title: Hydrogen; title: FT Syncrude; title: Methanol; title: &; title: Higher Alcohols; title: SynGas; title: To Hydrogenations (pet refining & other); title: To Hydrocracking; title: To Ammonia Synthesis; title: Possible Fuel-Cell Fuel; title: To Oxo Chemicals &; title: Derivatives; title: Possible Fuel-Cell Fuel; title: MTBE; title: Formaldehyde; title: DME; title: Acetic Acid; title: Acetaldehyde; title: Acetic Anhydride; title: Chloromethanes; title: DMT; title: MMA; title: Methyl Amine; title: Urea (fertilizers); title: To Refinery Upgrading; title: To Naphtha Steam Cracker; title: Alpha Olefins; title: Lube Oil Base Stock; title: Specialty Waxes; title: Gasoline &; title: Diesel Fuel; title: Ethylene &; title: Propylene; title: National Energy Technology Laboratory 06/30/03; title: 4; title: A wide variety of feedstocks can be considered for gasification, ranging from solids to liquids to; title: gaseous streams. Although when the feed is a gas or liquid, the operation is frequently referred to as; title: partial oxidation (POX). From a process perspective, partial oxidation of gases and liquids is very; title: similar to the gasification of solids. The term “gasification” will be used to refer to all these applications; title: within this report. The major requirement for a suitable feedstock is that it contains a significant content; title: of carbon and hydrogen. Solid feedstocks include coal, petcoke, biomass, and other solid waste; title: streams. There are many hydrocarbon containing gas and liquid streams that may be used as a; title: feedstock for gasification. However, the streams most commonly employed are generally low-value byproducts; title: or waste streams generated by other processes. Refinery feedstocks often considered are; title: process off-gas streams and residual oils such as vacuum resid, visbreaker tar, and deasphalter pitch.; title: These residuals are often referred to generically as “heavy oils.” This report develops profile data for; title: both petcoke and heavy oils. Table 1 lists typical compositions and properties of these feedstocks.; title: Refinery off-gases are not considered here.; title: Table 1. Typical Feedstocks for Refinery Gasification; title: Major developers/licensors of gasification technologies include ChevronTexaco, Shell, Global Energy; title: and others. Each of these technologies has its own unique features, which are discussed briefly later in; title: this report. The profiles developed here are primarily based on the Texaco quench gasification process.; title: Supporting technologies include air separation, acid gas removal, hydrogen separation and combinedcycle; title: power generation. All major commercial applications of gasification technology have relied on; title: Units; title: Vacuum; title: Resdiude; title: Visbreaker; title: Tar; title: Asphalt Petcoke; title: Ultimate Analysis; title: C wt/wt 84.9% 86.1% 85.1% 88.6%; title: H " 10.4% 10.4% 9.1% 2.8%; title: Na " 0.5% 0.6% 0.7% 1.1%; title: Sa " 4.2% 2.4% 5.1% 7.3%; title: O " 0.5% 0.0%; title: Ash " 0.0% 0.1% 0.2%; title: Total wt/wt 100.0% 100.0% 100.0% 100.0%; title: H2/C Ratio mol/mol 0.727 0.720 0.640 0.188; title: Density; title: Specific Gravity 60o/60o 1.028 1.008 1.070 0.863; title: API Gravity oAPI 6.2 8.88 0.8 -; title: Heating Values; title: HHV (dry) M Btu/lb 17.72 18.6 17.28 14.85; title: LHV (dry) " 16.77 17.6 16.45 14.48; title: a Nitrogen & sulfur contents vary widely.; title: National Energy Technology Laboratory 06/30/03; title: 5; title: cryogenic air fractionation processes; however, novel membrane separation-based technologies are; title: currently under development for this application. Major suppliers of cryogenic air separation unit; title: (ASU) include Air Liquide, Air Products & Chemicals, Linde and Praxair. A wide variety of acid gas; title: removal technologies have been employed. Major providers of these technologies include Lurgi and; title: UOP. UOP is also a major supplier of hydrogen purification technologies. Gas turbine technologies; title: used in combined-cycle power generation systems are available from General Electric and; title: Siemens/Westinghouse.