A national laboratory of the U.S. Department of Energy Office of Energy Efficiency & Renewable Energy National Renewable Energy Laboratory Innovation for Our Energy Future Equipment Design and Cost Subcontract Report NREL/SR-510-39943 Estimation for Small Modular May 2006 Biomass Systems, Synthesis Gas Cleanup, and Oxygen Separation Equipment Task 1: Cost Estimates of Small Modular Systems Nexant Inc. San Francisco, California NREL is operated by Midwest Research Institute ● Battelle Contract No. DE-AC36-99-GO10337 Equipment Design and Cost Subcontract Report NREL/SR-510-39943 Estimation for Small Modular May 2006 Biomass Systems, Synthesis Gas Cleanup, and Oxygen Separation Equipment Task 1: Cost Estimates of Small Modular Systems Nexant Inc. San Francisco, California NREL Technical Monitor: Kelly Ibsen Prepared under Subcontract No. ACO-5-44027 National Renewable Energy Laboratory 1617 Cole Boulevard, Golden, Colorado 80401-3393 303-275-3000 • www.nrel.gov Operated for the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy by Midwest Research Institute • Battelle Contract No. DE-AC36-99-GO10337 This publication was reproduced from the best available copy Submitted by the subcontractor and received no editorial review at NREL NOTICE This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. Available electronically at http://www.osti.gov/bridge Available for a processing fee to U.S. Department of Energy and its contractors, in paper, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831-0062 phone: 865.576.8401 fax: 865.576.5728 email: mailto:[email protected] Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 phone: 800.553.6847 fax: 703.605.6900 email: [email protected] online ordering: http://www.ntis.gov/ordering.htm Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste Contents Section Page Executive Summary ..............................................................................................................................ES-1 Introduction and Methodology..................................................................................................................1 Section 1 Fluidized Catalytic Cracking ............................................................................................1-1 1.1 Introduction and Methodology .................................................................................................1-1 1.2 Technology Background...........................................................................................................1-2 1.3 Process Descriptions and Design Assumptions........................................................................1-3 1.3.1 Large Scale (Side-by-Side) FCC .....................................................................................1-8 1.3.2 Small Scale (Stacked) FCC............................................................................................1-10 1.4 Operating Costs and Utility Requirements.............................................................................1-12 Section 2 Natural Gas Reforming .....................................................................................................2-1 2.1 Introduction and Methodology .................................................................................................2-1 2.2 Technology Background...........................................................................................................2-1 2.3 Process Descriptions and Design Assumptions........................................................................2-1 2.3.1 Small Scale SMR Design.................................................................................................2-2 2.3.2 Large Scale SMR Design.................................................................................................2-8 2.4 Operating Costs and Utility Requirements.............................................................................2-14 Section 3 Natural Gas Liquid Expanders.........................................................................................3-1 3.1 Introduction and Methodology .................................................................................................3-1 3.2 Technology Background...........................................................................................................3-1 3.3 Process Descriptions and Design Assumptions........................................................................3-3 3.3.1 Small Scale NGL Expander Design.................................................................................3-3 3.3.2 Large Scale NGL Expander Design.................................................................................3-9 3.4 Operating Costs and Utility Requirements.............................................................................3-14 Section 4 Summary and Conclusions................................................................................................4-1 Appendix A Technology Evaluations....................................................................................................A-1 A.1 Refinery Processes...................................................................................................................A-1 A.2 Claus Sulfur Recovery.............................................................................................................A-5 A.3 Natural Gas Reforming............................................................................................................A-7 A.4 Methanol from Natural Gas.....................................................................................................A-9 A.5 Ammonia Production.............................................................................................................A-11 A.6 Gas-To-Liquids......................................................................................................................A-13 A.7 Natural Gas Liquids Expanders.............................................................................................A-13 A.8 Cryogenic Oxygen Plants ......................................................................................................A-16 A.9 Ethylene and other Olefins Production..................................................................................A-18 Task 1 Final Report ii Cost Estimates of Small Modular Systems United States Department of Energy/National Renewable Energy Laboratory Figures and Tables Figure Page 1-1 Large Scale FCC Design...............................................................................................................1-4 1-2 Small Scale FCC Design...............................................................................................................1-5 2-1 Small Scale SMR Process Flow Diagram.....................................................................................2-3 2-2 Typical Small Scale SMR Reactor Design ...................................................................................2-7 2-3 Large Scale SMR Process Flow Diagram...................................................................................2-10 2-4 Typical Large Scale SMR Reactor Design .................................................................................2-13 2-5 Large Scale SMR Reactor Heat Integration................................................................................2-13 3-1 Small-Scale NGL Expander Process Flow Diagram ....................................................................3-4 3-2 Large-Scale NGL Expander Process Flow Diagram ..................................................................3-11 4-1 SMR Project Costs, Broad Size Range .........................................................................................4-1 A-1 2004 US Refinery Sizes...............................................................................................................A-2 A-2 Typical Claus Plant BFD ............................................................................................................A-6 A-3 Steam Methane Reformer Process Flow, Ammonia Plant...........................................................A-8 A-4 Low Pressure Methanol Process Flow Diagram........................................................................A-10 A-5 Ammonia Production Capacity and Energy Consumption (1960-2010) ...................................A-11 A-6 Ammonia Production Flowsheet................................................................................................A-12