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Convert Refinery Residue Waste to Energy With This Complete Syngas Gasification Plant Available For Sale From IPP. Can Support Petcoke and Coal Gasification or Small Scale GTL Process.



Estimated Refinery Savings From Gasification*
Process Area Savings (US $ per day)
Waste Disposal
2,000 - 3,000
High-Purity Hydrogen
3,000 - 22,000
FCCU O2 for Air Enrichment
4,000 - 25,000
SRU O2 for Air Enrichment
1,500 - 2,400
Refinery Nitrogen
2,500

source: US DOE's NETL

Table 1

"The greatest impact on improving the economics of gas-to liquids plants is through 1) decreasing capital costs associated with syngas production and 2) improving the thermal efficiency with better heat integration and utilization."

Preliminary Screening — Technical and Economic Assessment of Synthesis Gas to Fuels and Chemicals with Emphasis on the Potential for Biomass-Derived Syngas national renewable energy laboratory logo

Highlights

  • Gasify heavy refinery residues, petcoke or coal into clean syngas (synthetic natural gas).
  • Convert up to 1,400 tons per day of residue waste into up to 3,000 tons of clean syngas.

Increase Refinery Economic Value

  • Create more economic value by converting residue into energy and valuable commodities like steam and hydrogen instead of low margin asphalt and bitumen. See Table 1.
  • Great alternative source of natural gas in regions with high prices. See Figure 1.
  • 3,000 tons per day of syngas was more than enough to power previous owner's 300 MW turbine generator (generator not included with gasification plant), and has enough energy value to run a 1200 Ton/Day Methanol Plant.

Support Small Scale GTL & Improve GTL Economics

  • Provide source of syngas for gas-to-liquid (GTL) processes. Produces enough syngas to support small scale GTL operation of over 2,000 bpd.
  • Buying an existing gasification plant improves the economics of your GTL plant by drastically cutting the capital costs of the syngas production unit, one of the 2 most significant ways to improve those economics according to the National Renewable Energy Laboratory. New syngas production plants of this size can cost over $100MM. This plant, once it is bought, dismantled, relocated and rebuilt will cost a fraction of that.
  • Get your GTL operations up & running in less time. Typically, existing plants like this one can be dismantled, shipped and rebuilt in about half the time it takes to design and build a new one.

Key Plant Features

  • Young plant: started in 2003, recently upgraded to high alloy piping, shutdown in December, 2012.
  • Gasification technology: licensed from Texaco (GE Gasification), ABB, UOP, Parson (Claus units), and Praxair.
  • Over-designed to use grades other than Arab Heavy like Basrah medium high sulfur or Iranian Heavy.
  • Includes 70 ton / hour Air Separation Unit, available for purchase separately, that produces >95% pure oxygen, a level used in steel production. Can produce higher purity levels with modifications. View more details on the air separation unit.
  • Plant can be modified to gasify coal or petcoke. Contact IPP for more info on converting the plant to coal gasification.
  • Plenty of spare parts, excellent documentation in hard and soft copy, and gasification process control by ABB Advant DCS are included.
  • Dismantling & shipping plant is made easier since site has its own harbor on an ocean as well has good rail and truck access. 

Figure 1

chart of syngas price based on input costs

This chart is a demonstration calculation of the syngas' effective price (in US $) based on the ratio of the feedstock input to the syngas output's thermal energy value. It does not include operating or capital expenses.  For example, if refinery residue cost $117/ton to purchase as feedstock, that equates to an effective price of ~$4/MMBTU, which is similar to current future prices for US natural gas. Similarly, if a refinery pays $175/ton to dispose of its residue waste and pays more than $6/MMBTU for natural gas, it may make economic sense to gasify that waste as an alternative source for your natural gas needs. 

Refinery Residue Waste to Gas Gasification Plant Details
(use form at right to request full equipment lists, documentation)

Gasification Unit
Operates at 62 bar and outlet temperature of 1,375 °C using GE gasification technology

  • Feed preparation with high-end Uraca feed pumps.  Density of highly viscous refinery residue consumed currently is 1,075 kg/m3
  • 2 quench gasifiers - good for preventing clogs in heat recovery steam generator when feed product has a high concentration of metals.
  • Syngas is produced by chemical reactions that result from partially oxidizing the heavy hydrocarbons in the input feed.
  • Delicate balance of oxygen concentration required for the gasification process is controlled by specially made globe valves made of Monel.
  • Syngas produced by the gasifiers typically has an energy value of 13,900 kJ/kg and is composed of almost equal parts CO and H2 with single digit % of CO2 
  • 2 scrubber systems with nozzle scrubber and vane-type mist eliminator designed to remove soot and particulates. 

Carbon Extraction Unit
Recycles soot from the gasification waste back into the refinery waste feed of the gasification process.

Gas Cooling Unit
recovers heat energy from syngas gasification process output through generation of steam at 3 different pressures. Gas expander stage produces 3 MW of electricity.  Carbonyl sulfide hydrolysis reactors included. Technology by ABB Lummus Global.

Acid Gas Removal Unit:
Hydrogen sulfide is removed using UOP Selexol technology. Energy is recovered in this unit with a 150 kW liquid turbine-generator and a 1.6 MW gas expansion turbine-generator.

Sulfur Recovery Unit:
Two independent Claus units with catalytic converters using Parsons technology. Energy is recovered in this unit by the generation of 20 bar, 6 bar and 1 bar steam. Tailgas treatment unit is included using Ucarsol MDEA absorption technology.

Air Separation Unit (available for purchase separately):
The air separation unit (ASU) produces the oxygen necessary for gasification and for the Claus units (70 metric tons/hr total oxygen). This operation is based on the traditional principle of fractionated distillation of liquid air.

  • This Praxair licensed facility produces oxygen of greater than >95% purity at 76 bar and 132°C. The final oxygen product is delivered from the coldbox at 4.7 bar, which is high enough for the Sulfur Recovery Unit operations.
  • Nitrogen is produced at 36 bar and 50°C and is expanded to recover energy that runs a generator which produces the electricity to run the refrigeration in the unit's cryogenic distillation section. The nitrogen is then used for dilution in the gas turbine feedstream.
  • Requires simple modifications to achieve 98% oxygen purity required for coal to gas operation as a coal gasification plant. 
  • 99+% purity required for chemical use is possible and requires an additional distillation column to remove the argon.  The argon can be sold to defray cost of adding the column.
ASU main air compressor photo
Main air compressor is a four-stage Sulzer centrifugal unit with a 23 MW ABB motor.
ASU booster air compressor photo
Booster air compressor is a Borsig unit with a 3.1 MW ABB electric motor, boosting the air pressure from 8.2 to 22.5 bar.
ASU oxygen  compressor photo
Oxygen compressor is a Sulzer three-stage unit with a 5.5 MW ABB motor taking O2 from 4.7 to 76 bar (max. 90 bar).

Grey Water Treatment Unit:
This unit prepares 33 M³/Hour of grey water (soot in water) for biological treatment. Solid filter cake contains metals and can be sold to metals recovery companies to offset operating costs.

Sour Water Stripper Unit:
This unit cleans up the sour water to < 20 mg/l ammonia equivalent, then recycles water back to the Carbon Extraction Unit.

Access: This site is located directly on the ocean and has its own harbor for crude oil unloading and finished product loading. It also has good rail and truck access.

Excellent Documentation Available (including Process Description)

 
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