presentation memos
TRANSCRIPT
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USE OF SHORTCUT AND SIMULATION TOOLS TO THE
PRELIMINARY DESIGN OF A AMMONIA PRODUCTION PLANT
Project MEMOS
Chemical Process Systems Design Diseo de Procesos Qumicos
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Index
I. Objectives and Methodology
II. Synthesis
III. Analysis
IV. Economic evaluation
V. Highlights
Index
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I. Objectives and Methodology
The Technology Division has requested a preliminary design and economic
evaluation to establish the feasibility ofmanufacturing NH3 in a new facility.
1.- Literature review and quick preliminary screening to select a candidateprocessSynthesisMEMO 1
2.- Determine a preliminary mass and energy balance AnalysisMEMO 2
3.- Determinean economic evaluation of your selected flowsheet EvaluationMEMO 3
The purpose of this initial phase is to establish the economic potential of theprocess and to identify other promising alternatives. Following his study, thegroup reports findings in a oral presentation during the last week of January.
To meet this deadline, please submit your memos by the following dates:
Last week of October: Literature review and Synthesis alternativesFirst week of December: Mass and Energy BalanceThird week January: Economic evaluation
I.Objectives&
Methodology
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I. Objectives and Methodology
- Request to the Design Group from the Chemicals Division of UC Corporation.- Guidelines to Memo #.
- Memo # submission.
+ Grading and Comments to Memo #.
+ Oral Presentation of global project.
I.Objectives&
Methodology
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1. Preliminary Design2. Basic Engineering3. Final Design or
Detailed Engineering
Shortcut Tools Simulation
Linear modelsIdeal thermodynamic
Modular modeEq-Oriented mode
Modular methods Process evaluator
Guthrie, Ulrich, Lang Icarus Process Evaluator (IPE)
Conceptgeneration
Alternativegeneration
Comparison &optimization
ABSTRACTDESCRIPTION
Detaileddescription
Analysis
Evaluation
Analysis
Economic Evaluation
Rigorous Analysis
Costs estimations
Complex models
I.Objectives&
Methodology
I. Objectives and Methodology
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II. Synthesis
II.Synt
hesis
II. Synthesis of Alternatives. MEMO 1
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Ammonia Process Synthesis
Uses: Fertilizers (80%):
Ammonium nitrate. Ammonium salts andUrea
HNO3 production. Explosives Nylon Cryogenic Gas Liquid Refrigerant Cleaning domestic products
Alternatives processes to produce NH3 Raw materials
Three Licenses: Braun ICI Kellog
Ammonia: Haber-Bosch Process characteristics:
- Gas phase direct reaction nitrogen andhydrogen.
- Exothermic reaction.- Slow reaction High activation energy- Pressure effect
II.Synt
hesis
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Product
Steam
Air
Natural Gas
REFORMERCOMPRESSION CONVERSION
Water Water
CO2
Gas stream
SHIFT &
NETHANATION
KELLOG PROCESS
Natural Gas
Air
Water steam
Water
CO2
Product NH3 + (N2+H2+CH4+Ar)
Gas stream (NH3+N2+H2+CH4+Ar)
REFORMADO
CON VAPOR
II.Synt
hesis
Input-Output process diagrams
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III. Analysis
III.Ana
lysis
III. Analysis of a specified NH3 production process
flowsheet. MEMO 2
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Analysis of the preliminary design of NH3 manufacturing NH3 to obtain 1500 mol/ h NH3with > 98% NH3 purity using shortcuttools based on linear mass balances:
Assumptions to simplify and reduce calculations Main characteristics:
Ideal thermodynamic behaviour Unit process calculations Linear equations
Mixer
Separator
Reactor
Flash
Linear Coefficient
-
SplitFraction
Split fraction
Conversion
stoichiometric
coeff.
III.Ana
lysis
III. Analysis
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Design specifications: Raw materials and products
Properties. Antoine equation
Kellog process. NH3 production of 1500 mol/ h with > 98% NH3 purity
Raw materials and products
- [P] = mm Hg
- [T] = K
A B C
Nitrogen 14,93 588,72 -6,60Methane 15,22 897,84 -7,16Argn 15,23 700,51 -5,84Ammonia 16,95 2132,50 -32,98Hydrogen 13,63 164,90 3,19
Antoine eq.
Water 18,31 3826,36 -45,47
III.Analysis
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P: 300-350 psi
CATALYTIC REFORMING
Steam / Hydrocarbon ratio= 6
= 0.935
= 1
= 0.128
= 0.152
Reaction in R2:
= 0.58
= 0.9999
= 1
= 1
= 1
= 0.69
Reaction in R1:
III.Ana
lysis
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SHIFT and METHANATION
Reaction in R3:
Reaction in R4:
Reaction in R5:=1
=1
= 0.584
=0.01). The remaining components by head
F3 Separator: =(1-0.99), Isotherm.=0.73, Isotherm
= 0.85
= 0.955
Separator F1:- Vapor fraction
- Decrease of 2 psig- Water Bottoms Separation of 99%
=0.999F2 Separator:
F4 Separator:Agua
T (F) 100
P (psi) 280
Q (lbmol/hr) 1000
R3
R4
R5
HX2HX3
F1
F2
F3
F4
H4 H5
H6
H7
Agua
CO2T = 100F
T = 750F
T = 675F
T = 690F
T = 400FT = 675F
T =100F
T =100F
P = 250-300 psi
T,P
III.Ana
lysis
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COMPRESSION
Pin / Pout = 260 /4960
F5 Separator: =0.5
F6 Separator: =0
F6 Separator: =0.5
III.Ana
lysis
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AMMONIA SYNTHESIS
R6 conversion reaction:0.5N
2
+ 1.5 H2
NH3
F8 partial condenser:
Tin = 70F; Pin = 4915psi
Partial condenser F9:Tin = 430F; Pin = 4744psi
F10 Separator:Tout = 78.9F; Pout = 364psi
P = 4800 psi; T = 560F
[inerts]< 12%
=0.27
=0.6
=0.37
F9
F8
F10R6
C4
HX4
HX5
M1
M2
SP1
T = 95FP = 4960 psi T = 40F
T =85F
T = 560FP = 4800 psi
T = 920FP = 4750psi
T = 100FP = 4960 psi T = 79F
P = 350psi
T = 79FP = 350psi
T = 79FP= 4600psi
T = 70F
III.Ana
lysis
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Specify split
fraction of key
components
Global Mass
Balance
Sizing
Fixed P and T
P y T
Determine the
coefficients of the
linear modules
Costs
Specifications
and restrictions
Fenske eq.
Kremser eq.
Antoine eq.
Equilibrium eq.
(Bubble anddew point)
T, P
restrictions
General Algorithm for process analysis
III.Ana
lysis
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Flowsheet
Natural Gas
Steam
Air
R1 R2
HX1
R4R3
R5
HX2 HX3
F1 F2
F3
F4
Water
CO2
F5 F6 F7
C3C2
Water
C1
Gas stream
F10
F9
F8
C4
HX5
HX4
M1
M2
Product
Purge
R6
III.Ana
lysis
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Steps
Desulfurization Steam reforming Steam / HC:6/1
CATALYTIC REFORMING
R4R3
R5
HX2 HX3
F1 F2
F3
F4
Water
CO2SHIFT and METHANATION
HT/LT Shift Purification:
CO2 (MEA plant)
Water
Methanation
Natural Gas
Steam
Air
R1 R2
HX1
70% HC
Reformed
Ethane, propane, butane andpentane react completely
Carbonoxides
elimination
PhysicalAbsorption
by MEA
Ni Catalyst
ShiftReactors
III.Ana
lysis
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Steps
3 steps Compression.
Condenaste water elimination Pressure increase
Pin : 350 psi Pout: 4960 psi
COMPRESSION
C1
CONVERSION
Ammonia conversion Liquid ammonia separation
F5 F6 F7
C3C2
Water
C1
Gas stream
F10
F9
F8
C4
HX5
HX4
M1
M2
Product
Purge
R6
60% liquid
NH3
37%liquid
NH3
Fe and RucatalystII
I.Ana
lysis
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Shortcut Tools
Stage 1)
Operation conditions as P, T, split fractions andlinear model coefficients, to each equipment
Stage 2)
Global mass balance solving, obtaining flows, P andT forall process streams.
Steps
Catalytic Reforming Shift and Methanation Compression Conversion
(recycle)
1. Iterations2. Equations system
Equipments: 37
Streams: 56
Components: 13
III.Ana
lysis
Process Analysis: General Algorithm
Specify split fractions of thekey components
Global mass balance
SIZING
P , T specify
P and T
Determine coefficients for linearmodels in each unit: k/n, , ,
COSTS
Specificationsand/or
restrictions
Fenske,
Kremser,Antoine
equations
Equilibrium
equations(Bubble
point, dew
point)
T, P restrictions
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Results Comparison
Anl
isis
SHORTCUT TOOLS SIMULATION (SMS)
Flow: 143,5 lbmol/hr Purity: 29,9% ammonia
Flow: 62,3 lbmol/hr Purity: 45,6% ammonia
F8 F9 F10
H2 0.995 0.971 0.879
N2 0.993 0.967 0.857
Ar 0.992 0.964 0.846
CH4 0.983 0.932 0.730
NH3 0.600 0.370 0.090
Product Stream Flow: 1365 lbmol/hr Purity: 96,5% ammonia
Flow: 1549 lbmol/hr Purity: 99,3% ammonia
Splitt Fractions
F8 F9 F10
H2 0.999 0.998 0.925
N2 0.999 0.997 0.854
Ar 0.986 0.981 0.575
CH4 0.999 0.993 0.677
NH3 0.575 0.378 0.018
Gas Stream
Q
(lbmol/hr)
Gas Stream Product
Stream
H2
213,195 29,467
N270,844 11,856
Ar 8,109 1,475
CH4
12,785 4,717
NH3 130,338 1317,862
Total 435,27 1365,378
Q
(lbmol/hr)
Gas Stream Product
Stream
H2
14,087 1,140
N2
6,023 1,030
Ar 10,432 7,726
CH4
3,320 1,584
NH3 28,420 1538,395
Total 62,828 1549,874
Mass Balance:
Equipment, Streams, Components, Global.
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Analysis
Energy balance
Enthalpies for Vapor Mixtures
Enthalpies for Liquid Mixtures
Heat Exchange
Reactors
Heat
Exchangers
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III. Economic Evaluation. MEMO 3
IV.Evaluation
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Guthries modular method
1. Equipment Base Cost for basic configurationin 1968 prices (carbon steel material and
basic design): BC
2. Module Factor associated to Base Cost. MF3. Modification of BC by the material and
pressure factors, MPF.
Fp up to 1000psi4. Updated Cost by Updated Factor. UF
Williams Equation
ModuleFactor
BC
MF2 Up to 200.000$
MF4 200.000$ a 400.000$
MF6 400.000$ a 600.000$
MF8 600.000$ a 800.000$
MF10 800.000$ a 1.000.000$
Bare Module Cost (BMC) = BC (UF)(MPF+MF-1)
IV.Evaluation
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Ulrichs modular method
Equipment purchase
price
Pressure Factor
Fp
Factor Base
Modular
Material Factor
FmDesign Factor
Fd
UF
Total Cost =
Cp
Fbm
IV.Evaluation
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Icarus
Data conversion to the
simulator to IPE
Reports
Projection of the
data in ICARUS
Starting
data
Sizing
Projection
data
Additional project
Specifications
Project
economicevaluation
IV.Evaluation
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Total Equipment Costs
Total Costs: Guthrie: 17,4 Mill $ Ulrich: 17,7 Mill $ Icarus: 22,2 Mill $
The contribution of each equipmentgroup are different
Coefficient of Variation CV (%)
EQUIPMENT G-U G-I I-U
FLASH 37,8 81,1 51,1
EXCHANGER 38,5 59,3 87,8
REACTOR 31,4 39,5 66,7
COMPRESSOR 21,6 27,1 47,3
TOTAL 1,3 17,0 15,7
IV.Evaluation
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Pressure Vessels
Pressure < 1000 psi High weight to the pressure Oversizing
IV.Evaluation
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Heat Exchanger
Icarus > Gurthrie > Ulrich
IV.Evaluation
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Reactors
Modular Methods Pressure vessels Icarus
Reactor
Equal sizing
Not possible sizing reactors by Icarus
Introduction of D and L previously hand calculated
Differences in Total Costs
Installation Costs
SIZING
COST STIMATIONS
IV.Evaluation
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Compressors
Higher contribution in modular methods. Lower differences
G-U: 21,6% G-I: 27,1% U-I: 47,3%
IV.Evaluation
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GLOBAL COST ESTIMATES: Costs related to the process
CAPITAL INVESTMENT or CAPITAL COST (Inversion de Capital). []Fixed Capital (Capital Fijo o Inmovilizado)
Working Capital (Capital Circulante)
Startup Cost (Coste de Arranque)
MANUFACTURING COSTS (Costes de fabricacion). [/t]Direct Costs (Costes de Fabricacin Directos)
Fixed Costs (Costes de Fabricacin Fijos):
General Expenses (Gastos Generales):.
IV.Evaluation
Cost estimates
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Economic Assessment
DiferentialCash Flow
NPV and IRR Intangible aspects
Payback Period -PBP
Combined Analysis
Environmental Assessment
Technical Assessment
10 years
3-10 years
Profitability Measures
IV.Evaluation
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Highlights
IV.Highlights
SHOW and EXPLAIN- Tools used- Assumptions made
- Problems encountered- Results obtained
REMEMBER
- Open-ended project
- Reasoning solutions
IN A
- Applied professional engineering
- Creativity
- Working Group
- Decision making
.. CONTEXT
DONT FORGET- Discussion of results
- Recommendations on the viability of the process
- Other recommendations