Ammonia Mass Balance
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View Ammonia Mass Balance as PDF for free.
More details
- Words: 2,393
- Pages: 34
Cells for Input Cells for Auto calcs
Natural Gas Composition (mol%) Methane Ethane Propane Butane Nitrogen Carbondioxide Total
92 2 2 1 2 1 100
Pressure Temperature Basis Desired Production Rate
900 120 100 3000
Stream Factor Operating hours
345 8280
Max. Hydrocarbon conc. in Steam reformer outlet gas Steam to hydrocarbon ratio in Primary Reformer
0.50% 3
ells for Input ells for Auto calcs
psig °F lbmol/hr of Natural Gas Feed Tonnes/day days hours
Primary Reformer 727 °C 900 psig 10 psig 3
Temperature Pressure Pressure Drop HC to Steam Ratio
Natural Gas Steam
Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5
Reactions in Primary Reformer CH4 + H2O = CO + 3H2 C2H6 + 2H2O = 2CO + 5H2 C3H8 + 3H2O = 3CO + 7H2 C4H10 + 4H2O = 4CO + 9H2 CO+H2O = CO2 + H2
1
2
75% 100% 100% 100% 40%
Stream 1 (Natural Gas) Components
Mol. Wt
Total
Mol% 92 2 2 1 2 1 100
Total Primary Reformer Inlet
7016
Methane Ethane Propane Butane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Oxygen Steam
CO Production Reaction 1 Reaction 2 Reaction 3 Reaction 4 Total CO Consume
16 30 44 58 28 44 28 2 32 18
69 lbmol/hr 4 lbmol/hr 6 lbmol/hr 4 lbmol/hr 83 lbmol/hr
Mole Flow (mol/hr) 92 2 2 1 2 1 100 lb/hr
Mass Flow (lb/hr) 1472 60 88 58 56 44 1778
Reaction 5
33.2 lbmol/hr
CO2 Produced Reaction 5
33.2 lbmol/hr
H2 Produced Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5 Total
207 lbmol/hr 10 lbmol/hr 14 lbmol/hr 9 lbmol/hr 33.2 lbmol/hr 273.2 lbmol/hr
Steam consumption Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5 Total
69 lbmol/hr 4 lbmol/hr 6 lbmol/hr 4 lbmol/hr 33.2 lbmol/hr 116.2 lbmol/hr
Secondary Reformer Exit Temperature Pressure Pressure Drop 3
Primary Reformer 4
1000 890 10
Secondary Reformer Air
based on CH4 based on C2H6 based on C3H8 based on C4H10 based on CO
Reaction 1 Reaction 2 Reaction 3 Reaction 4
Stream 2 (Steam) Mol% 100 100
Mole Flow (mol/hr) 291 291
5
Reactions in Secondary Reform CH4 + H2O = CO + 3H2 CH4 + 2O2 = CO2 + 2H2O 2CO + O2 = 2CO2 CH4 + 2CO + 3O2 = 3CO2 + 2H2
Stream 3 Mass Flow (lb/hr) 5238 5238
Mol% 4.13 0.00 0.00 0.00 0.36 6.14 8.94 49.05 31.38 100
Mole Flow (mol/hr) 23.00 0.00 0.00 0.00 2.00 34.20 49.80 273.20 174.8 557
Total Secondary Reformer Inlet Nitrogen in Total air O2 with Air CH4 Consumption Reaction 4 Reaction 1
113.83 144.09 30.26
10.09 10.98
CO Production Reaction 1
10.98
CO Consumption Reaction 4
20.17
CO2 Production Reaction 4
30.26
H2 production Reaction 1
32.93
Steam Consumption Reaction 1
10.98
Steam Production Reaction 4
20.17
°C psig psig
Reactions in Secondary Reformer CH4 + H2O = CO + 3H2 CH4 + 2O2 = CO2 + 2H2O 2CO + O2 = 2CO2 CH4 + 2CO + 3O2 = 3CO2 + 2H2O
eam 3
85% based on remaining CH4 after Reaction 4
100% based on O2
Stream 4 (Air) Mass Flow (lb/hr) 368.00 0.00 0.00 0.00 56.00 1504.80 1394.40 546.40 3146.4 7016
Mol% 79 21 100
Mole Flow (mol/hr) 113.83 30.26 144.09
11171.64 lb/hr lbmol/hr lbmol/hr lbmol/hr
lbmol/hr lbmol/hr
Stream 5 Mass Flow (lb/hr) 3187.33 968.30 4155.64
Mol% 0.27 16.25 9.04 5.70 42.94 0.00 25.81 100
lbmol/hr
lbmol/hr
lbmol/hr
lbmol/hr
lbmol/hr
lbmol/hr
after Reaction 4
Stream 5 Mole Flow (mol/hr) 1.94 115.83 64.46 40.60 306.13 0.00 184.00 712.96
Mass Flow (lb/hr) 30.99 3243.33 2836.22 1136.90 612.26 0.00 3311.94 11171.64
High Temperature Shift Converter 400 °C 880 psig 10 psig
Temperature Pressure Pressure Drop
SR outlet stream 5 Reactions in HTS CO+H2O = CO2 + H2
Reaction 1
80%
Stream 5 (SR outlet) Components
Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Steam Total CO Consume Reaction 1 CO2 Produced Reaction 1 H2 Produced Reaction 1 Steam Consume Reaction 1
Mol. Wt 16 28 44 28 2 18
Mol% 0.27 16.25 9.04 5.70 42.94 25.81 100
32.48 lbmol/hr 32.48 lbmol/hr 32.48 lbmol/hr 32.48 lbmol/hr
Mole Flow (mol/hr) 1.94 115.83 64.46 40.60 306.13 184.00 713.0
Mass Flow (lb/hr) 30.99 3243.33 2836.22 1136.90 612.26 3311.94 11171.6
Low Temperature Shift converter Exit Temperature Pressure Pressure Drop
200 870 10
6
7 LTS
HTS
based on CO
Reactions in LTS CO+H2O = CO2 + H2
Reaction 1
Stream 6 (HTS outlet) Mol% 0.27 16.25 13.60 1.14 47.49 21.25 100
Mole Flow (mol/hr) 1.94 115.83 96.94 8.12 338.61 151.51 712.96 CO Consume Reaction 1 CO2 Produced Reaction 1 H2 Produced Reaction 1 Steam Consume Reaction 1
Stream 7 (LTS outlet) Mass Flow (lb/hr) 30.99 3243.33 4265.46 227.38 677.22 2727.25 11171.64
Mol% 0.27 16.25 14.51 0.23 48.41 20.34 100
6.50 lbmol/hr 6.50 lbmol/hr 6.50 lbmol/hr 6.50 lbmol/hr
Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 145.02 712.96
°C psig psig
80% based on CO
(LTS outlet) Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 2610.31 11171.64
Cooler Separator 120 °C 860 psig 10 psig
Temperature Pressure Pressure Drop Assumptions: Water Condensed CO2 Solubility in Water
LTS outlet stream 8
100% 0% Stream 8 (LTS outlet)
Components
Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Steam
Mol. Wt Mol% 0.27 16.25 14.51 0.23 48.41 20.34 100
16 28 44 28 2 18
Total
Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 145.02 713.0
Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 2610.31 11171.6
Stream from Cooler Separator
9
CO2 Removal 120 °C 850 psig 10 psig
Temperature Pressure Pressure Drop
Lean Solvent Assumptions: Solvent Used Solvent Loading Solution Strength
11
K2CO3 2 lbmol of Acid gas /lbmol of pure solvent 80% by weight Stream 9 (Feed Gas)
Components
Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Potassium Carbonate Water Total
Mol. Wt 16 28 44 28 2 138 18
Mol% 0.34 20.40 18.21 0.29 60.76 0.00 0.00 100.00
Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 0.00 0.00 567.9
Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 0.00 0.00 8561.3
Total Mass in Total Mass out
17482.93 lb/hr 17482.93 lb/hr
9
Cooler Condenser 10
Stream 9 Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 0.00 567.94
Mol% 0.34 20.40 18.21 0.29 60.76 0.00 100
Stream 10 (Condensed Water) Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 0.00 8561.33
Mol% 0.00 0.00 0.00 0.00 0.00 100.00 100
Mole Flow (mol/hr) 0.00 0.00 0.00 0.00 0.00 145.02 145.02
11171.64
12
Treated Gas
CO2 Removal 13
Rich Solvent
Stream 11 (Lean Solvent) Mol% 0.00 0.00 0.00 0.00 0.00 34.29 65.71 100.00
Mole Flow (mol/hr) 0.00 0.00 0.00 0.00 0.00 51.72 99.13 150.85
Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 0.00 7137.28 1784.32 8921.60
Stream 12 (Treated Gas) Mol% 0.42 24.94 0.00 0.35 74.30 0.00 0.00 100
Mole Flow (mol/hr) 1.94 115.83 0.00 1.62 345.11 0.00 0.00 464.50
ondensed Water) Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 0.00 2610.31 2610.31
(Treated Gas) Mass Flow (lb/hr) 30.99 3243.33 0.00 45.48 690.22 0.00 0 4010.02
Stream 13 (Rich Solvent) Mol% 0.00 0.00 40.68 0.00 0.00 20.34 38.98 100
Mole Flow (mol/hr) 0.00 0.00 103.44 0.00 0.00 51.72 99.13 254.29
Mass Flow (lb/hr) 0.00 0.00 4551.31 0.00 0.00 7137.28 1784.32 13472.91
Methanator 400 °C 840 psig 10 psig
Temperature Pressure Pressure Drop
From CO2 Removal Unit 12 Reactions in Methanator CO+3H2 = CH4 +H2O
Reaction 1
100%
Stream 12 (CO2 Removal outlet) Components
Methane Nitrogen Carbon monoxide Hydrogen Steam Total CO Consume Reaction 1 H2 Consume Reaction 1 CH4 Produced Reaction 1 Steam Produced Reaction 1
Mol. Wt 16 28 28 2 18
Mol% 0.42 24.94 0.35 74.30 0.00 100
1.62 lbmol/hr 4.87 lbmol/hr 1.62 lbmol/hr 1.62 lbmol/hr
Mole Flow (mol/hr) 1.94 115.83 1.62 345.11 0.00 464.5
Mass Flow (lb/hr) 30.99 3243.33 45.48 690.22 0.00 4010.0
14
Cooler and Separator
Methanator
16
15 based on CO Stream 14 (Methanator outlet) Mol% 0.77 25.11 0.00 73.76 0.35 100
Mole Flow (mol/hr) 3.56 115.83 0.00 340.24 1.62 461.25
Mass Flow (lb/hr) 56.98 3243.33 0.00 680.47 29.23 4010.02
Stream 16 Mol% 0.77 25.20 0.00 74.02 0.00 100
Mole Flow (mol/hr) 3.56 115.83 0.00 340.24 0.00 459.63
Knock out water
eam 16
Stream 15 (Knock out Water) Mass Flow (lb/hr) 56.98 3243.33 0.00 680.47 0 3980.78
Mol% 0.00 0.00 0.00 0.00 100.00 100
Mole Flow (mol/hr) 0.00 0.00 0.00 0.00 1.62 1.62
Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 29.23 29.23
Ammonia Conversion Loop 400 °C 840 psig 10 psig
Temperature Pressure Pressure Drop
21 From Methanator 16
Reaction 1
Reactions in Ammonia Converter N2+3H2 = 2NH3
75%
Iteration No. 1 Stream 16 (Methanator Outlet) Components
Methane Nitrogen Hydrogen Ammonia
Mol. Wt Mol% 0.77 25.20 74.02 0.00 100
16 28 2 17
Total H2 Consume
Mole Flow (mol/hr) 3.56 115.83 340.24 0.00 459.6
Mass Flow (lb/hr) 56.98 3243.33 680.47 0.00 3980.8
Calculations for Purge stream 20 Rate
Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1
255.18 lbmol/hr
Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow
85.06 lbmol/hr 170.12 lbmol/hr
Iteration No. 2 Stream 16 (Methanator Outlet) Components
Methane Nitrogen Hydrogen Ammonia Total
Mol. Wt 16 28 2 17
Mol% 0.78 25.20 74.02 0.00 100
H2 Consume Reaction 1
Mole Flow (mol/hr) 3.58 116.01 340.73 0.00 460.3
Mass Flow (lb/hr) 57.31 3248.31 681.45 0.00 3987.1
Calculations for Purge stream 20 Rate 255.55 lbmol/hr
Feed Stream Flow
N2 Consume Reaction 1 NH3 Produced Reaction 1
Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow
85.18 lbmol/hr 170.36 lbmol/hr
Iteration No. 3 Stream 16 (Methanator Outlet) Components
Methane Nitrogen Hydrogen Ammonia
Mol. Wt Mol% 0.78 25.20 74.02 0.00 100
16 28 2 17
Total H2 Consume
Mole Flow (mol/hr) 3.59 116.06 340.87 0.00 460.5
Mass Flow (lb/hr) 57.40 3249.76 681.74 0.00 3988.9
Calculations for Purge stream 20 Rate
Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1
255.65 lbmol/hr
Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow
85.22 lbmol/hr 170.44 lbmol/hr
Iteration No. 4 Stream 16 (Methanator Outlet) Components
Methane Nitrogen Hydrogen Ammonia Total
Mol. Wt 16 28 2 17
Mol% 0.78 25.20 74.02 0.00 100
H2 Consume Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1
Mole Flow (mol/hr) 3.59 116.08 340.91 0.00 460.6
Mass Flow (lb/hr) 57.43 3250.19 681.83 0.00 3989.4
Calculations for Purge stream 20 Rate 255.68 lbmol/hr 85.23 lbmol/hr 170.46 lbmol/hr
Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow
Note: This indicates that at the start-up, until the system get stabilized, recycle is required after that all the stream sh
Scale up Factor Calculations NH3 production based on 100 lbmol/hr of Natural Gas Feed Scale up Factor All the stream flow should be multiplied by this factor to get the desired production rate.
20
Recycle Stream
17
Ammonia Converter
Cooler and Ammonia Separator
18
19 based on H2
Stream 17 (Converter outlet) Mol% 1.23 10.63 29.38 58.76 100
Mole Flow (mol/hr) 3.56 30.77 85.06 170.12 289.51
Mass Flow (lb/hr) 56.98 861.68 170.12 2892.01 3980.78
Stream 18 Mol% 2.98 25.78 71.24 0.00 100
stream 20 Rate
Mole Flow (mol/hr) 3.56 30.77 85.06 0.00 119.39 Purge Stream 20
459.6 lbmol/hr 0.77 mol% 3 mol% 118.71 lbmol/hr 0.69 lbmol/hr
Methane Nitrogen Hydrogen
Mol% 2.98 25.78 71.24 100.00
Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100
Mole Flow (mol/hr) 3.58 30.83 85.18 170.36 289.96
Mass Flow (lb/hr) 57.31 863.22 170.36 2896.18 3987.07
Mole Flow (mol/hr) 3.54 30.60 84.57 118.71
Stream 18 Mol% 2.99 25.78 71.23 0.00 100
stream 20 Rate
Mole Flow (mol/hr) 3.58 30.83 85.18 0.00 119.59 Purge Stream 20
460.3 lbmol/hr
Mol%
Mole Flow (mol/hr)
0.78 mol% 3 mol% 119.39 lbmol/hr 0.20 lbmol/hr
Methane Nitrogen Hydrogen
2.99 25.78 71.23 100.00
Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100
Mole Flow (mol/hr) 3.59 30.85 85.22 170.44 290.09
Mass Flow (lb/hr) 57.40 863.67 170.44 2897.41 3988.91
3.58 30.78 85.04 119.39
Stream 18 Mol% 3.00 25.78 71.22 0.00 100
stream 20 Rate
Mole Flow (mol/hr) 3.59 30.85 85.22 0.00 119.65 Purge Stream 20
460.5 lbmol/hr 0.78 mol% 3 mol% 119.59 lbmol/hr 0.06 lbmol/hr
Methane Nitrogen Hydrogen
Mol% 3.00 25.78 71.22 100.00
Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100
Mole Flow (mol/hr) 3.59 30.85 85.23 170.46 290.12
Mass Flow (lb/hr) 57.43 863.80 170.46 2897.76 3989.45
Mole Flow (mol/hr) 3.59 30.83 85.18 119.59
Stream 18 Mol% 3.00 25.78 71.22 0.00 100
stream 20 Rate
Mole Flow (mol/hr) 3.59 30.85 85.23 0.00 119.67 Purge Stream 20
460.6 lbmol/hr 0.78 mol% 3 mol% 119.65 lbmol/hr 0.02 lbmol/hr
d after that all the stream should be purged.
Methane Nitrogen Hydrogen
Mol% 3.00 25.78 71.22 100.00
Mole Flow (mol/hr) 3.59 30.85 85.22 119.65
he desired production rate.
2897.76 lb/hr 31.6 Tonnes/day 95.1
Purge Stream
Liquid Ammonia
eam 18
Stream 19 (Liquid Ammonia) Mass Flow (lb/hr) 56.98 861.68 170.12 0 1088.78
Mol% 0.00 0.00 0.00 100.00 100
Stream 20
Mole Flow (mol/hr) 0.00 0.00 0.00 170.12 170.12
Mass Flow (lb/hr) 0.00 0.00 0.00 2892.01 2892.01
Recycle Stream 21 Mass Flow (lb/hr) 56.65 856.71 169.14 1082.49
eam 18
Mol% 2.98 25.78 71.24 100.00
Mole Flow (mol/hr) 0.02 0.18 0.49 0.69
Mass Flow (lb/hr) 0.33 4.97 0.98 6.28
Stream 19 (Liquid Ammonia) Mass Flow (lb/hr) 57.31 863.22 170.36 0 1090.89
Mol% 0.00 0.00 0.00 100.00 100
Stream 20
Mole Flow (mol/hr) 0.00 0.00 0.00 170.36 170.36
Mass Flow (lb/hr) 0.00 0.00 0.00 2896.18 2896.18
Recycle Stream 21 Mass Flow (lb/hr)
Mol%
Mole Flow (mol/hr)
Mass Flow (lb/hr)
57.21 861.76 170.08 1089.04
eam 18
2.99 25.78 71.23 100.00
0.01 0.05 0.14 0.20
0.10 1.46 0.29 1.84
Stream 19 (Liquid Ammonia) Mass Flow (lb/hr) 57.40 863.67 170.44 0 1091.51
Mol% 0.00 0.00 0.00 100.00 100
Stream 20
Mole Flow (mol/hr) 0.00 0.00 0.00 170.44 170.44
Mass Flow (lb/hr) 0.00 0.00 0.00 2897.41 2897.41
Recycle Stream 21 Mass Flow (lb/hr) 57.38 863.24 170.35 1090.97
eam 18
Mol% 3.00 25.78 71.22 100.00
Mole Flow (mol/hr) 0.00 0.02 0.04 0.06
Mass Flow (lb/hr) 0.03 0.42 0.08 0.53
Stream 19 (Liquid Ammonia) Mass Flow (lb/hr) 57.43 863.80 170.46 0 1091.69
Mol% 0.00 0.00 0.00 100.00 100
Stream 20
Mole Flow (mol/hr) 0.00 0.00 0.00 170.46 170.46
Mass Flow (lb/hr) 0.00 0.00 0.00 2897.76 2897.76
Recycle Stream 21 Mass Flow (lb/hr) 57.42 863.68 170.43 1091.53
Mol% 3.00 25.78 71.22 100.00
Mole Flow (mol/hr) 0.00 0.00 0.01 0.02
Mass Flow (lb/hr) 0.01 0.12 0.02 0.15
3980.78
1088.78
Natural Gas Composition (mol%) Methane Ethane Propane Butane Nitrogen Carbondioxide Total
92 2 2 1 2 1 100
Pressure Temperature Basis Desired Production Rate
900 120 100 3000
Stream Factor Operating hours
345 8280
Max. Hydrocarbon conc. in Steam reformer outlet gas Steam to hydrocarbon ratio in Primary Reformer
0.50% 3
ells for Input ells for Auto calcs
psig °F lbmol/hr of Natural Gas Feed Tonnes/day days hours
Primary Reformer 727 °C 900 psig 10 psig 3
Temperature Pressure Pressure Drop HC to Steam Ratio
Natural Gas Steam
Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5
Reactions in Primary Reformer CH4 + H2O = CO + 3H2 C2H6 + 2H2O = 2CO + 5H2 C3H8 + 3H2O = 3CO + 7H2 C4H10 + 4H2O = 4CO + 9H2 CO+H2O = CO2 + H2
1
2
75% 100% 100% 100% 40%
Stream 1 (Natural Gas) Components
Mol. Wt
Total
Mol% 92 2 2 1 2 1 100
Total Primary Reformer Inlet
7016
Methane Ethane Propane Butane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Oxygen Steam
CO Production Reaction 1 Reaction 2 Reaction 3 Reaction 4 Total CO Consume
16 30 44 58 28 44 28 2 32 18
69 lbmol/hr 4 lbmol/hr 6 lbmol/hr 4 lbmol/hr 83 lbmol/hr
Mole Flow (mol/hr) 92 2 2 1 2 1 100 lb/hr
Mass Flow (lb/hr) 1472 60 88 58 56 44 1778
Reaction 5
33.2 lbmol/hr
CO2 Produced Reaction 5
33.2 lbmol/hr
H2 Produced Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5 Total
207 lbmol/hr 10 lbmol/hr 14 lbmol/hr 9 lbmol/hr 33.2 lbmol/hr 273.2 lbmol/hr
Steam consumption Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5 Total
69 lbmol/hr 4 lbmol/hr 6 lbmol/hr 4 lbmol/hr 33.2 lbmol/hr 116.2 lbmol/hr
Secondary Reformer Exit Temperature Pressure Pressure Drop 3
Primary Reformer 4
1000 890 10
Secondary Reformer Air
based on CH4 based on C2H6 based on C3H8 based on C4H10 based on CO
Reaction 1 Reaction 2 Reaction 3 Reaction 4
Stream 2 (Steam) Mol% 100 100
Mole Flow (mol/hr) 291 291
5
Reactions in Secondary Reform CH4 + H2O = CO + 3H2 CH4 + 2O2 = CO2 + 2H2O 2CO + O2 = 2CO2 CH4 + 2CO + 3O2 = 3CO2 + 2H2
Stream 3 Mass Flow (lb/hr) 5238 5238
Mol% 4.13 0.00 0.00 0.00 0.36 6.14 8.94 49.05 31.38 100
Mole Flow (mol/hr) 23.00 0.00 0.00 0.00 2.00 34.20 49.80 273.20 174.8 557
Total Secondary Reformer Inlet Nitrogen in Total air O2 with Air CH4 Consumption Reaction 4 Reaction 1
113.83 144.09 30.26
10.09 10.98
CO Production Reaction 1
10.98
CO Consumption Reaction 4
20.17
CO2 Production Reaction 4
30.26
H2 production Reaction 1
32.93
Steam Consumption Reaction 1
10.98
Steam Production Reaction 4
20.17
°C psig psig
Reactions in Secondary Reformer CH4 + H2O = CO + 3H2 CH4 + 2O2 = CO2 + 2H2O 2CO + O2 = 2CO2 CH4 + 2CO + 3O2 = 3CO2 + 2H2O
eam 3
85% based on remaining CH4 after Reaction 4
100% based on O2
Stream 4 (Air) Mass Flow (lb/hr) 368.00 0.00 0.00 0.00 56.00 1504.80 1394.40 546.40 3146.4 7016
Mol% 79 21 100
Mole Flow (mol/hr) 113.83 30.26 144.09
11171.64 lb/hr lbmol/hr lbmol/hr lbmol/hr
lbmol/hr lbmol/hr
Stream 5 Mass Flow (lb/hr) 3187.33 968.30 4155.64
Mol% 0.27 16.25 9.04 5.70 42.94 0.00 25.81 100
lbmol/hr
lbmol/hr
lbmol/hr
lbmol/hr
lbmol/hr
lbmol/hr
after Reaction 4
Stream 5 Mole Flow (mol/hr) 1.94 115.83 64.46 40.60 306.13 0.00 184.00 712.96
Mass Flow (lb/hr) 30.99 3243.33 2836.22 1136.90 612.26 0.00 3311.94 11171.64
High Temperature Shift Converter 400 °C 880 psig 10 psig
Temperature Pressure Pressure Drop
SR outlet stream 5 Reactions in HTS CO+H2O = CO2 + H2
Reaction 1
80%
Stream 5 (SR outlet) Components
Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Steam Total CO Consume Reaction 1 CO2 Produced Reaction 1 H2 Produced Reaction 1 Steam Consume Reaction 1
Mol. Wt 16 28 44 28 2 18
Mol% 0.27 16.25 9.04 5.70 42.94 25.81 100
32.48 lbmol/hr 32.48 lbmol/hr 32.48 lbmol/hr 32.48 lbmol/hr
Mole Flow (mol/hr) 1.94 115.83 64.46 40.60 306.13 184.00 713.0
Mass Flow (lb/hr) 30.99 3243.33 2836.22 1136.90 612.26 3311.94 11171.6
Low Temperature Shift converter Exit Temperature Pressure Pressure Drop
200 870 10
6
7 LTS
HTS
based on CO
Reactions in LTS CO+H2O = CO2 + H2
Reaction 1
Stream 6 (HTS outlet) Mol% 0.27 16.25 13.60 1.14 47.49 21.25 100
Mole Flow (mol/hr) 1.94 115.83 96.94 8.12 338.61 151.51 712.96 CO Consume Reaction 1 CO2 Produced Reaction 1 H2 Produced Reaction 1 Steam Consume Reaction 1
Stream 7 (LTS outlet) Mass Flow (lb/hr) 30.99 3243.33 4265.46 227.38 677.22 2727.25 11171.64
Mol% 0.27 16.25 14.51 0.23 48.41 20.34 100
6.50 lbmol/hr 6.50 lbmol/hr 6.50 lbmol/hr 6.50 lbmol/hr
Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 145.02 712.96
°C psig psig
80% based on CO
(LTS outlet) Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 2610.31 11171.64
Cooler Separator 120 °C 860 psig 10 psig
Temperature Pressure Pressure Drop Assumptions: Water Condensed CO2 Solubility in Water
LTS outlet stream 8
100% 0% Stream 8 (LTS outlet)
Components
Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Steam
Mol. Wt Mol% 0.27 16.25 14.51 0.23 48.41 20.34 100
16 28 44 28 2 18
Total
Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 145.02 713.0
Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 2610.31 11171.6
Stream from Cooler Separator
9
CO2 Removal 120 °C 850 psig 10 psig
Temperature Pressure Pressure Drop
Lean Solvent Assumptions: Solvent Used Solvent Loading Solution Strength
11
K2CO3 2 lbmol of Acid gas /lbmol of pure solvent 80% by weight Stream 9 (Feed Gas)
Components
Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Potassium Carbonate Water Total
Mol. Wt 16 28 44 28 2 138 18
Mol% 0.34 20.40 18.21 0.29 60.76 0.00 0.00 100.00
Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 0.00 0.00 567.9
Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 0.00 0.00 8561.3
Total Mass in Total Mass out
17482.93 lb/hr 17482.93 lb/hr
9
Cooler Condenser 10
Stream 9 Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 0.00 567.94
Mol% 0.34 20.40 18.21 0.29 60.76 0.00 100
Stream 10 (Condensed Water) Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 0.00 8561.33
Mol% 0.00 0.00 0.00 0.00 0.00 100.00 100
Mole Flow (mol/hr) 0.00 0.00 0.00 0.00 0.00 145.02 145.02
11171.64
12
Treated Gas
CO2 Removal 13
Rich Solvent
Stream 11 (Lean Solvent) Mol% 0.00 0.00 0.00 0.00 0.00 34.29 65.71 100.00
Mole Flow (mol/hr) 0.00 0.00 0.00 0.00 0.00 51.72 99.13 150.85
Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 0.00 7137.28 1784.32 8921.60
Stream 12 (Treated Gas) Mol% 0.42 24.94 0.00 0.35 74.30 0.00 0.00 100
Mole Flow (mol/hr) 1.94 115.83 0.00 1.62 345.11 0.00 0.00 464.50
ondensed Water) Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 0.00 2610.31 2610.31
(Treated Gas) Mass Flow (lb/hr) 30.99 3243.33 0.00 45.48 690.22 0.00 0 4010.02
Stream 13 (Rich Solvent) Mol% 0.00 0.00 40.68 0.00 0.00 20.34 38.98 100
Mole Flow (mol/hr) 0.00 0.00 103.44 0.00 0.00 51.72 99.13 254.29
Mass Flow (lb/hr) 0.00 0.00 4551.31 0.00 0.00 7137.28 1784.32 13472.91
Methanator 400 °C 840 psig 10 psig
Temperature Pressure Pressure Drop
From CO2 Removal Unit 12 Reactions in Methanator CO+3H2 = CH4 +H2O
Reaction 1
100%
Stream 12 (CO2 Removal outlet) Components
Methane Nitrogen Carbon monoxide Hydrogen Steam Total CO Consume Reaction 1 H2 Consume Reaction 1 CH4 Produced Reaction 1 Steam Produced Reaction 1
Mol. Wt 16 28 28 2 18
Mol% 0.42 24.94 0.35 74.30 0.00 100
1.62 lbmol/hr 4.87 lbmol/hr 1.62 lbmol/hr 1.62 lbmol/hr
Mole Flow (mol/hr) 1.94 115.83 1.62 345.11 0.00 464.5
Mass Flow (lb/hr) 30.99 3243.33 45.48 690.22 0.00 4010.0
14
Cooler and Separator
Methanator
16
15 based on CO Stream 14 (Methanator outlet) Mol% 0.77 25.11 0.00 73.76 0.35 100
Mole Flow (mol/hr) 3.56 115.83 0.00 340.24 1.62 461.25
Mass Flow (lb/hr) 56.98 3243.33 0.00 680.47 29.23 4010.02
Stream 16 Mol% 0.77 25.20 0.00 74.02 0.00 100
Mole Flow (mol/hr) 3.56 115.83 0.00 340.24 0.00 459.63
Knock out water
eam 16
Stream 15 (Knock out Water) Mass Flow (lb/hr) 56.98 3243.33 0.00 680.47 0 3980.78
Mol% 0.00 0.00 0.00 0.00 100.00 100
Mole Flow (mol/hr) 0.00 0.00 0.00 0.00 1.62 1.62
Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 29.23 29.23
Ammonia Conversion Loop 400 °C 840 psig 10 psig
Temperature Pressure Pressure Drop
21 From Methanator 16
Reaction 1
Reactions in Ammonia Converter N2+3H2 = 2NH3
75%
Iteration No. 1 Stream 16 (Methanator Outlet) Components
Methane Nitrogen Hydrogen Ammonia
Mol. Wt Mol% 0.77 25.20 74.02 0.00 100
16 28 2 17
Total H2 Consume
Mole Flow (mol/hr) 3.56 115.83 340.24 0.00 459.6
Mass Flow (lb/hr) 56.98 3243.33 680.47 0.00 3980.8
Calculations for Purge stream 20 Rate
Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1
255.18 lbmol/hr
Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow
85.06 lbmol/hr 170.12 lbmol/hr
Iteration No. 2 Stream 16 (Methanator Outlet) Components
Methane Nitrogen Hydrogen Ammonia Total
Mol. Wt 16 28 2 17
Mol% 0.78 25.20 74.02 0.00 100
H2 Consume Reaction 1
Mole Flow (mol/hr) 3.58 116.01 340.73 0.00 460.3
Mass Flow (lb/hr) 57.31 3248.31 681.45 0.00 3987.1
Calculations for Purge stream 20 Rate 255.55 lbmol/hr
Feed Stream Flow
N2 Consume Reaction 1 NH3 Produced Reaction 1
Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow
85.18 lbmol/hr 170.36 lbmol/hr
Iteration No. 3 Stream 16 (Methanator Outlet) Components
Methane Nitrogen Hydrogen Ammonia
Mol. Wt Mol% 0.78 25.20 74.02 0.00 100
16 28 2 17
Total H2 Consume
Mole Flow (mol/hr) 3.59 116.06 340.87 0.00 460.5
Mass Flow (lb/hr) 57.40 3249.76 681.74 0.00 3988.9
Calculations for Purge stream 20 Rate
Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1
255.65 lbmol/hr
Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow
85.22 lbmol/hr 170.44 lbmol/hr
Iteration No. 4 Stream 16 (Methanator Outlet) Components
Methane Nitrogen Hydrogen Ammonia Total
Mol. Wt 16 28 2 17
Mol% 0.78 25.20 74.02 0.00 100
H2 Consume Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1
Mole Flow (mol/hr) 3.59 116.08 340.91 0.00 460.6
Mass Flow (lb/hr) 57.43 3250.19 681.83 0.00 3989.4
Calculations for Purge stream 20 Rate 255.68 lbmol/hr 85.23 lbmol/hr 170.46 lbmol/hr
Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow
Note: This indicates that at the start-up, until the system get stabilized, recycle is required after that all the stream sh
Scale up Factor Calculations NH3 production based on 100 lbmol/hr of Natural Gas Feed Scale up Factor All the stream flow should be multiplied by this factor to get the desired production rate.
20
Recycle Stream
17
Ammonia Converter
Cooler and Ammonia Separator
18
19 based on H2
Stream 17 (Converter outlet) Mol% 1.23 10.63 29.38 58.76 100
Mole Flow (mol/hr) 3.56 30.77 85.06 170.12 289.51
Mass Flow (lb/hr) 56.98 861.68 170.12 2892.01 3980.78
Stream 18 Mol% 2.98 25.78 71.24 0.00 100
stream 20 Rate
Mole Flow (mol/hr) 3.56 30.77 85.06 0.00 119.39 Purge Stream 20
459.6 lbmol/hr 0.77 mol% 3 mol% 118.71 lbmol/hr 0.69 lbmol/hr
Methane Nitrogen Hydrogen
Mol% 2.98 25.78 71.24 100.00
Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100
Mole Flow (mol/hr) 3.58 30.83 85.18 170.36 289.96
Mass Flow (lb/hr) 57.31 863.22 170.36 2896.18 3987.07
Mole Flow (mol/hr) 3.54 30.60 84.57 118.71
Stream 18 Mol% 2.99 25.78 71.23 0.00 100
stream 20 Rate
Mole Flow (mol/hr) 3.58 30.83 85.18 0.00 119.59 Purge Stream 20
460.3 lbmol/hr
Mol%
Mole Flow (mol/hr)
0.78 mol% 3 mol% 119.39 lbmol/hr 0.20 lbmol/hr
Methane Nitrogen Hydrogen
2.99 25.78 71.23 100.00
Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100
Mole Flow (mol/hr) 3.59 30.85 85.22 170.44 290.09
Mass Flow (lb/hr) 57.40 863.67 170.44 2897.41 3988.91
3.58 30.78 85.04 119.39
Stream 18 Mol% 3.00 25.78 71.22 0.00 100
stream 20 Rate
Mole Flow (mol/hr) 3.59 30.85 85.22 0.00 119.65 Purge Stream 20
460.5 lbmol/hr 0.78 mol% 3 mol% 119.59 lbmol/hr 0.06 lbmol/hr
Methane Nitrogen Hydrogen
Mol% 3.00 25.78 71.22 100.00
Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100
Mole Flow (mol/hr) 3.59 30.85 85.23 170.46 290.12
Mass Flow (lb/hr) 57.43 863.80 170.46 2897.76 3989.45
Mole Flow (mol/hr) 3.59 30.83 85.18 119.59
Stream 18 Mol% 3.00 25.78 71.22 0.00 100
stream 20 Rate
Mole Flow (mol/hr) 3.59 30.85 85.23 0.00 119.67 Purge Stream 20
460.6 lbmol/hr 0.78 mol% 3 mol% 119.65 lbmol/hr 0.02 lbmol/hr
d after that all the stream should be purged.
Methane Nitrogen Hydrogen
Mol% 3.00 25.78 71.22 100.00
Mole Flow (mol/hr) 3.59 30.85 85.22 119.65
he desired production rate.
2897.76 lb/hr 31.6 Tonnes/day 95.1
Purge Stream
Liquid Ammonia
eam 18
Stream 19 (Liquid Ammonia) Mass Flow (lb/hr) 56.98 861.68 170.12 0 1088.78
Mol% 0.00 0.00 0.00 100.00 100
Stream 20
Mole Flow (mol/hr) 0.00 0.00 0.00 170.12 170.12
Mass Flow (lb/hr) 0.00 0.00 0.00 2892.01 2892.01
Recycle Stream 21 Mass Flow (lb/hr) 56.65 856.71 169.14 1082.49
eam 18
Mol% 2.98 25.78 71.24 100.00
Mole Flow (mol/hr) 0.02 0.18 0.49 0.69
Mass Flow (lb/hr) 0.33 4.97 0.98 6.28
Stream 19 (Liquid Ammonia) Mass Flow (lb/hr) 57.31 863.22 170.36 0 1090.89
Mol% 0.00 0.00 0.00 100.00 100
Stream 20
Mole Flow (mol/hr) 0.00 0.00 0.00 170.36 170.36
Mass Flow (lb/hr) 0.00 0.00 0.00 2896.18 2896.18
Recycle Stream 21 Mass Flow (lb/hr)
Mol%
Mole Flow (mol/hr)
Mass Flow (lb/hr)
57.21 861.76 170.08 1089.04
eam 18
2.99 25.78 71.23 100.00
0.01 0.05 0.14 0.20
0.10 1.46 0.29 1.84
Stream 19 (Liquid Ammonia) Mass Flow (lb/hr) 57.40 863.67 170.44 0 1091.51
Mol% 0.00 0.00 0.00 100.00 100
Stream 20
Mole Flow (mol/hr) 0.00 0.00 0.00 170.44 170.44
Mass Flow (lb/hr) 0.00 0.00 0.00 2897.41 2897.41
Recycle Stream 21 Mass Flow (lb/hr) 57.38 863.24 170.35 1090.97
eam 18
Mol% 3.00 25.78 71.22 100.00
Mole Flow (mol/hr) 0.00 0.02 0.04 0.06
Mass Flow (lb/hr) 0.03 0.42 0.08 0.53
Stream 19 (Liquid Ammonia) Mass Flow (lb/hr) 57.43 863.80 170.46 0 1091.69
Mol% 0.00 0.00 0.00 100.00 100
Stream 20
Mole Flow (mol/hr) 0.00 0.00 0.00 170.46 170.46
Mass Flow (lb/hr) 0.00 0.00 0.00 2897.76 2897.76
Recycle Stream 21 Mass Flow (lb/hr) 57.42 863.68 170.43 1091.53
Mol% 3.00 25.78 71.22 100.00
Mole Flow (mol/hr) 0.00 0.00 0.01 0.02
Mass Flow (lb/hr) 0.01 0.12 0.02 0.15
3980.78
1088.78
Related Documents
Ammonia Mass Balance
June 2020 6
Ammonia Energy 2520 Balance
November 2019 27
Mass Balance
December 2019 21
Mass Balance
May 2020 7
Ammonia Material 2520 Balance
November 2019 22