Conceptual design, process simulation and economic evaluation for the production of synthetic fuels in Argentina

Abstract

This paper presents the design and economic evaluation of an industrial plant for the production of e-fuels, specifically oriented to e-kerosene. The study deals with the conceptual design of the process, focusing on equipment sizing and thermal integration to optimize energy efficiency and kerosene yield. Key components of the plant include the synthesis gas production (reverse water gas shift), the Fischer-Tropsch synthesis unit, the hydrocracking reactor and distillation train. Auxiliary services (cooling water service and steam production and use) are included as well. Both hydrogen (produced electrolytically from wind energy) and carbon dioxide (captured from exhaust gas turbine nearby the plant) are considered as raw materials for the process under study. Results indicate a consumption of 0.8 kg_H2/kg_fuel and 3.1 kg_CO2/kg_fuel with a kerosene yield of ca. 75 %. The economic assessment considers capital and operating expenditures (CAPEX and OPEX), market conditions. Profitability indicators, such as Net Present Value (NPV), Internal Rate of Return (IRR), Payback Period (PBP) and Levelized Cost of Fuel (LCoF), are used to evaluate the plant's financial viability. A sensitivity analyses explores the influence of hydrogen costs and kerosene selling pricing over the internal rate of return.