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Ammonia mass-balance

This document provides information for modeling a natural gas processing facility, including: - Natural gas composition and operating parameters for primary and secondary reforming, shift conversion, CO2 removal, and methane production. - Chemical reactions and conversion rates for each unit operation. - Stream tables showing flow rates and compositions entering and leaving each unit. - The goal is to produce sweetened pipeline quality methane while maximizing hydrogen production.

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

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Ammonia mass-balance

  • 1.
    Cells for Input Cellsfor Auto calcs Natural Gas Composition (mol%) Methane 92 Ethane 2 Propane 2 Butane 1 Nitrogen 2 Carbondioxide 1 Total 100 Pressure 900 Temperature 120 Basis 100 Desired Production Rate 3000 Stream Factor 345 Operating hours 8280 Max. Hydrocarbon conc. in Steam reformer outlet gas 0.50% Steam to hydrocarbon ratio in Primary Reformer 3
  • 2.
    ells for Input ellsfor Auto calcs psig °F lbmol/hr of Natural Gas Feed Tonnes/day days hours
  • 3.
    Primary Reformer Temperature 727 Pressure900 psig Pressure Drop 10 psig HC to Steam Ratio 3 Natural Gas Steam Reactions in Primary Reformer Reaction 1 CH4 + H2O = CO + 3H2 75% Reaction 2 C2H6 + 2H2O = 2CO + 5H2 100% Reaction 3 C3H8 + 3H2O = 3CO + 7H2 100% Reaction 4 C4H10 + 4H2O = 4CO + 9H2 100% Reaction 5 CO+H2O = CO2 + H2 40% Components Mol. Wt Stream 1 (Natural Gas) Mol% Methane 16 92 92 1472 Ethane 30 2 2 60 Propane 44 2 2 88 Butane 58 1 1 58 Nitrogen 28 2 2 56 Carbon dioxide 44 1 1 44 Carbon monoxide 28 - - - Hydrogen 2 - - - Oxygen 32 - - - Steam 18 - - - Total 100 100 1778 Total Primary Reformer Inlet 7016 lb/hr CO Production Reaction 1 69 lbmol/hr Reaction 2 4 lbmol/hr Reaction 3 6 lbmol/hr Reaction 4 4 lbmol/hr Total 83 lbmol/hr CO Consume °C Mole Flow (mol/hr) Mass Flow (lb/hr) 1 2
  • 4.
    Reaction 5 33.2lbmol/hr CO2 Produced Reaction 5 33.2 lbmol/hr H2 Produced Reaction 1 207 lbmol/hr Reaction 2 10 lbmol/hr Reaction 3 14 lbmol/hr Reaction 4 9 lbmol/hr Reaction 5 33.2 lbmol/hr Total 273.2 lbmol/hr Steam consumption Reaction 1 69 lbmol/hr Reaction 2 4 lbmol/hr Reaction 3 6 lbmol/hr Reaction 4 4 lbmol/hr Reaction 5 33.2 lbmol/hr Total 116.2 lbmol/hr
  • 5.
    Secondary Reformer Exit Temperature1000 Pressure 890 Pressure Drop 10 Air Reactions in Secondary Reform based on CH4 Reaction 1 CH4 + H2O = CO + 3H2 based on C2H6 Reaction 2 CH4 + 2O2 = CO2 + 2H2O based on C3H8 Reaction 3 2CO + O2 = 2CO2 based on C4H10 Reaction 4 CH4 + 2CO + 3O2 = 3CO2 + 2H2 based on CO Stream 2 (Steam) Stream 3 Mol% Mol% - - - 4.13 23.00 - - - 0.00 0.00 - - - 0.00 0.00 - - - 0.00 0.00 - - - 0.36 2.00 - - - 6.14 34.20 - - - 8.94 49.80 - - - 49.05 273.20 - - - - - 100 291 5238 31.38 174.8 100 291 5238 100 557 Total Secondary Reformer Inlet Nitrogen in 113.83 Total air 144.09 O2 with Air 30.26 CH4 Consumption Reaction 4 10.09 Reaction 1 10.98 Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Primary Reformer Secondary Reformer 4 3 5
  • 6.
    CO Production Reaction 110.98 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
  • 7.
    psig psig Reactions in SecondaryReformer CH4 + H2O = CO + 3H2 85% based on remaining CH4 after Reaction 4 CH4 + 2O2 = CO2 + 2H2O 2CO + O2 = 2CO2 CH4 + 2CO + 3O2 = 3CO2 + 2H2O 100% based on O2 eam 3 Stream 4 (Air) Stream 5 Mol% Mol% 368.00 - - - 0.27 0.00 - - - - 0.00 - - - - 0.00 - - - - 56.00 79 113.83 3187.33 16.25 1504.80 - - - 9.04 1394.40 - - - 5.70 546.40 - - - 42.94 - 21 30.26 968.30 0.00 3146.4 - - - 25.81 7016 100 144.09 4155.64 100 11171.64 lb/hr lbmol/hr lbmol/hr lbmol/hr lbmol/hr lbmol/hr °C Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr)
  • 8.
  • 9.
    after Reaction 4 Stream5 1.94 30.99 - - - - - - 115.83 3243.33 64.46 2836.22 40.60 1136.90 306.13 612.26 0.00 0.00 184.00 3311.94 712.96 11171.64 Mole Flow (mol/hr) Mass Flow (lb/hr)
  • 11.
    High Temperature ShiftConverter Temperature 400 Pressure 880 psig Pressure Drop 10 psig SR outlet stream Reactions in HTS Reaction 1 CO+H2O = CO2 + H2 80% Components Mol. Wt Stream 5 (SR outlet) Mol% Methane 16 0.27 1.94 30.99 Nitrogen 28 16.25 115.83 3243.33 Carbon dioxide 44 9.04 64.46 2836.22 Carbon monoxide 28 5.70 40.60 1136.90 Hydrogen 2 42.94 306.13 612.26 Steam 18 25.81 184.00 3311.94 Total 100 713.0 11171.6 CO Consume Reaction 1 32.48 lbmol/hr CO2 Produced Reaction 1 32.48 lbmol/hr H2 Produced Reaction 1 32.48 lbmol/hr Steam Consume Reaction 1 32.48 lbmol/hr °C Mole Flow (mol/hr) Mass Flow (lb/hr) 5
  • 12.
    Low Temperature Shiftconverter Exit Temperature 200 Pressure 870 Pressure Drop 10 Reactions in LTS based on CO Reaction 1 CO+H2O = CO2 + H2 Stream 6 (HTS outlet) Stream 7 (LTS outlet) Mol% Mol% 0.27 1.94 30.99 0.27 1.94 16.25 115.83 3243.33 16.25 115.83 13.60 96.94 4265.46 14.51 103.44 1.14 8.12 227.38 0.23 1.62 47.49 338.61 677.22 48.41 345.11 21.25 151.51 2727.25 20.34 145.02 100 712.96 11171.64 100 712.96 CO Consume Reaction 1 6.50 lbmol/hr CO2 Produced Reaction 1 6.50 lbmol/hr H2 Produced Reaction 1 6.50 lbmol/hr Steam Consume Reaction 1 6.50 lbmol/hr Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) HTS LTS 6 7
  • 13.
    psig psig 80% based onCO (LTS outlet) 30.99 3243.33 4551.31 45.48 690.22 2610.31 11171.64 °C Mass Flow (lb/hr)
  • 14.
    Cooler Separator Temperature 120 Pressure860 psig LTS outlet stream Pressure Drop 10 psig Assumptions: Water Condensed 100% CO2 Solubility in Water 0% Components Mol. Wt Stream 8 (LTS outlet) Mol% Methane 16 0.27 1.94 30.99 Nitrogen 28 16.25 115.83 3243.33 Carbon dioxide 44 14.51 103.44 4551.31 Carbon monoxide 28 0.23 1.62 45.48 Hydrogen 2 48.41 345.11 690.22 Steam 18 20.34 145.02 2610.31 Total 100 713.0 11171.6 CO2 Removal Temperature 120 Stream from Pressure 850 psig Cooler Separator Pressure Drop 10 psig Lean Solvent Assumptions: Solvent Used K2CO3 Solvent Loading 2 lbmol of Acid gas /lbmol of pure solvent Solution Strength 80% by weight Components Mol. Wt Stream 9 (Feed Gas) Mol% Methane 16 0.34 1.94 30.99 Nitrogen 28 20.40 115.83 3243.33 Carbon dioxide 44 18.21 103.44 4551.31 Carbon monoxide 28 0.29 1.62 45.48 Hydrogen 2 60.76 345.11 690.22 Potassium Carbonate 138 0.00 0.00 0.00 Water 18 0.00 0.00 0.00 Total 100.00 567.9 8561.3 °C Mole Flow (mol/hr) Mass Flow (lb/hr) °C Mole Flow (mol/hr) Mass Flow (lb/hr) 8 9 11
  • 15.
    Total Mass in17482.93 lb/hr Total Mass out 17482.93 lb/hr
  • 16.
    Stream 9 Stream10 (Condensed Water) Mol% Mol% 0.34 1.94 30.99 0.00 0.00 20.40 115.83 3243.33 0.00 0.00 18.21 103.44 4551.31 0.00 0.00 0.29 1.62 45.48 0.00 0.00 60.76 345.11 690.22 0.00 0.00 0.00 0.00 0.00 100.00 145.02 100 567.94 8561.33 100 145.02 11171.64 Treated Gas Rich Solvent Stream 11 (Lean Solvent) Stream 12 (Treated Gas) Mol% Mol% 0.00 0.00 0.00 0.42 1.94 0.00 0.00 0.00 24.94 115.83 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.35 1.62 0.00 0.00 0.00 74.30 345.11 34.29 51.72 7137.28 0.00 0.00 65.71 99.13 1784.32 0.00 0.00 100.00 150.85 8921.60 100 464.50 Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Cooler Condenser 9 10 CO2 Removal 13 12
  • 18.
    ondensed Water) 0.00 0.00 0.00 0.00 0.00 2610.31 2610.31 (Treated Gas)Stream 13 (Rich Solvent) Mol% 30.99 0.00 0.00 0.00 3243.33 0.00 0.00 0.00 0.00 40.68 103.44 4551.31 45.48 0.00 0.00 0.00 690.22 0.00 0.00 0.00 0.00 20.34 51.72 7137.28 0 38.98 99.13 1784.32 4010.02 100 254.29 13472.91 Mass Flow (lb/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr)
  • 20.
    Methanator Temperature 400 Pressure 840psig Pressure Drop 10 psig From CO2 Removal Unit Reactions in Methanator Reaction 1 CO+3H2 = CH4 +H2O 100% Components Mol. Wt Stream 12 (CO2 Removal outlet) Mol% Methane 16 0.42 1.94 30.99 Nitrogen 28 24.94 115.83 3243.33 Carbon monoxide 28 0.35 1.62 45.48 Hydrogen 2 74.30 345.11 690.22 Steam 18 0.00 0.00 0.00 Total 100 464.5 4010.0 CO Consume Reaction 1 1.62 lbmol/hr H2 Consume Reaction 1 4.87 lbmol/hr CH4 Produced Reaction 1 1.62 lbmol/hr Steam Produced Reaction 1 1.62 lbmol/hr °C Mole Flow (mol/hr) Mass Flow (lb/hr) 12
  • 21.
    based on CO Stream14 (Methanator outlet) Stream 16 Mol% Mol% 0.77 3.56 56.98 0.77 3.56 25.11 115.83 3243.33 25.20 115.83 0.00 0.00 0.00 0.00 0.00 73.76 340.24 680.47 74.02 340.24 0.35 1.62 29.23 0.00 0.00 100 461.25 4010.02 100 459.63 Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Methanator Cooler and Separator 14 16 15
  • 22.
    Knock out water eam16 Stream 15 (Knock out Water) Mol% 56.98 0.00 0.00 0.00 3243.33 0.00 0.00 0.00 0.00 0.00 0.00 0.00 680.47 0.00 0.00 0.00 0 100.00 1.62 29.23 3980.78 100 1.62 29.23 Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr)
  • 23.
    Ammonia Conversion Loop Temperature400 Pressure 840 psig Pressure Drop 10 psig From Methanator Reactions in Ammonia Converter Reaction 1 N2+3H2 = 2NH3 75% Iteration No. 1 Components Mol. Wt Stream 16 (Methanator Outlet) Mol% Methane 16 0.77 3.56 56.98 Nitrogen 28 25.20 115.83 3243.33 Hydrogen 2 74.02 340.24 680.47 Ammonia 17 0.00 0.00 0.00 Total 100 459.6 3980.8 H2 Consume Calculations for Purge stream 20 Rate Reaction 1 255.18 lbmol/hr Feed Stream Flow N2 Consume Feed Stream Inert Reaction 1 85.06 lbmol/hr Required Inert Conc. NH3 Produced Purge Stream 20 flow Reaction 1 170.12 lbmol/hr Recycle Stream 21 Flow Iteration No. 2 Components Mol. Wt Stream 16 (Methanator Outlet) Mol% Methane 16 0.78 3.58 57.31 Nitrogen 28 25.20 116.01 3248.31 Hydrogen 2 74.02 340.73 681.45 Ammonia 17 0.00 0.00 0.00 Total 100 460.3 3987.1 H2 Consume Calculations for Purge stream 20 Rate Reaction 1 255.55 lbmol/hr Feed Stream Flow °C Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) 16 21
  • 24.
    N2 Consume FeedStream Inert Reaction 1 85.18 lbmol/hr Required Inert Conc. NH3 Produced Purge Stream 20 flow Reaction 1 170.36 lbmol/hr Recycle Stream 21 Flow Iteration No. 3 Components Mol. Wt Stream 16 (Methanator Outlet) Mol% Methane 16 0.78 3.59 57.40 Nitrogen 28 25.20 116.06 3249.76 Hydrogen 2 74.02 340.87 681.74 Ammonia 17 0.00 0.00 0.00 Total 100 460.5 3988.9 H2 Consume Calculations for Purge stream 20 Rate Reaction 1 255.65 lbmol/hr Feed Stream Flow N2 Consume Feed Stream Inert Reaction 1 85.22 lbmol/hr Required Inert Conc. NH3 Produced Purge Stream 20 flow Reaction 1 170.44 lbmol/hr Recycle Stream 21 Flow Iteration No. 4 Components Mol. Wt Stream 16 (Methanator Outlet) Mol% Methane 16 0.78 3.59 57.43 Nitrogen 28 25.20 116.08 3250.19 Hydrogen 2 74.02 340.91 681.83 Ammonia 17 0.00 0.00 0.00 Total 100 460.6 3989.4 H2 Consume Calculations for Purge stream 20 Rate Reaction 1 255.68 lbmol/hr Feed Stream Flow N2 Consume Feed Stream Inert Reaction 1 85.23 lbmol/hr Required Inert Conc. NH3 Produced Purge Stream 20 flow Reaction 1 170.46 lbmol/hr 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 Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr)
  • 25.
    Scale up FactorCalculations 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.
  • 26.
    Recycle Stream based onH2 Stream 17 (Converter outlet) Stream 18 Mol% Mol% 1.23 3.56 56.98 2.98 3.56 10.63 30.77 861.68 25.78 30.77 29.38 85.06 170.12 71.24 85.06 58.76 170.12 2892.01 0.00 0.00 100 289.51 3980.78 100 119.39 stream 20 Rate Purge Stream 20 459.6 lbmol/hr Mol% 0.77 mol% Methane 2.98 3.54 3 mol% Nitrogen 25.78 30.60 118.71 lbmol/hr Hydrogen 71.24 84.57 0.69 lbmol/hr 100.00 118.71 Stream 17 (Converter outlet) Stream 18 Mol% Mol% 1.24 3.58 57.31 2.99 3.58 10.63 30.83 863.22 25.78 30.83 29.38 85.18 170.36 71.23 85.18 58.75 170.36 2896.18 0.00 0.00 100 289.96 3987.07 100 119.59 stream 20 Rate Purge Stream 20 460.3 lbmol/hr Mol% Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mole Flow (mol/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mole Flow (mol/hr) Ammonia Converter Cooler and Ammonia Separator 17 18 19 20
  • 27.
    0.78 mol% Methane2.99 3.58 3 mol% Nitrogen 25.78 30.78 119.39 lbmol/hr Hydrogen 71.23 85.04 0.20 lbmol/hr 100.00 119.39 Stream 17 (Converter outlet) Stream 18 Mol% Mol% 1.24 3.59 57.40 3.00 3.59 10.63 30.85 863.67 25.78 30.85 29.38 85.22 170.44 71.22 85.22 58.75 170.44 2897.41 0.00 0.00 100 290.09 3988.91 100 119.65 stream 20 Rate Purge Stream 20 460.5 lbmol/hr Mol% 0.78 mol% Methane 3.00 3.59 3 mol% Nitrogen 25.78 30.83 119.59 lbmol/hr Hydrogen 71.22 85.18 0.06 lbmol/hr 100.00 119.59 Stream 17 (Converter outlet) Stream 18 Mol% Mol% 1.24 3.59 57.43 3.00 3.59 10.63 30.85 863.80 25.78 30.85 29.38 85.23 170.46 71.22 85.23 58.75 170.46 2897.76 0.00 0.00 100 290.12 3989.45 100 119.67 stream 20 Rate Purge Stream 20 460.6 lbmol/hr Mol% 0.78 mol% Methane 3.00 3.59 3 mol% Nitrogen 25.78 30.85 119.65 lbmol/hr Hydrogen 71.22 85.22 0.02 lbmol/hr 100.00 119.65 d after that all the stream should be purged. Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mole Flow (mol/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mole Flow (mol/hr)
  • 28.
    2897.76 lb/hr 31.6 Tonnes/day 95.1 hedesired production rate.
  • 29.
    Purge Stream Liquid Ammonia eam18 Stream 19 (Liquid Ammonia) Mol% 56.98 0.00 0.00 0.00 861.68 0.00 0.00 0.00 170.12 0.00 0.00 0.00 0 100.00 170.12 2892.01 1088.78 100 170.12 2892.01 Stream 20 Recycle Stream 21 Mol% 56.65 2.98 0.02 0.33 856.71 25.78 0.18 4.97 169.14 71.24 0.49 0.98 1082.49 100.00 0.69 6.28 eam 18 Stream 19 (Liquid Ammonia) Mol% 57.31 0.00 0.00 0.00 863.22 0.00 0.00 0.00 170.36 0.00 0.00 0.00 0 100.00 170.36 2896.18 1090.89 100 170.36 2896.18 Stream 20 Recycle Stream 21 Mol% Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr)
  • 30.
    57.21 2.99 0.010.10 861.76 25.78 0.05 1.46 170.08 71.23 0.14 0.29 1089.04 100.00 0.20 1.84 eam 18 Stream 19 (Liquid Ammonia) Mol% 57.40 0.00 0.00 0.00 863.67 0.00 0.00 0.00 170.44 0.00 0.00 0.00 0 100.00 170.44 2897.41 1091.51 100 170.44 2897.41 Stream 20 Recycle Stream 21 Mol% 57.38 3.00 0.00 0.03 863.24 25.78 0.02 0.42 170.35 71.22 0.04 0.08 1090.97 100.00 0.06 0.53 eam 18 Stream 19 (Liquid Ammonia) Mol% 57.43 0.00 0.00 0.00 863.80 0.00 0.00 0.00 170.46 0.00 0.00 0.00 0 100.00 170.46 2897.76 1091.69 100 170.46 2897.76 Stream 20 Recycle Stream 21 Mol% 57.42 3.00 0.00 0.01 863.68 25.78 0.00 0.12 170.43 71.22 0.01 0.02 1091.53 100.00 0.02 0.15 Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr) Mass Flow (lb/hr) Mole Flow (mol/hr) Mass Flow (lb/hr)
  • 32.