The document is a project report submitted by a group of students to analyze regeneration processes for a coked catalyst. It summarizes that:
1) The students calculated it would take 10.452 hours for hydrogen gas at 1000 K and 1.1 bar to remove 95% of carbon from a coked catalyst, longer than the company's shutdown time.
2) Adding hydrogen recycle increases time to 19.631 hours but reduces hydrogen needs. Using steam instead of hydrogen reduces time to just 1.062 hours.
3) The students recommend the company use steam instead of hydrogen for greater efficiency and reduced costs and downtime, while addressing necessary safety precautions for products like carbon monoxide and carbon dioxide.
The Principles required to understand Distillation, Absorption, Stripping, Flashing, Gas Treating, Scrubbing and more!
Introduction:
This course covers all the theory required to understand the basic principles behind Unit Operations that are based on Mass Transfer. Most of these Unit Operations (Equipments) are used in Process Separation Technologies in the Industry.Common examples are Distillation, Absorption and Scrubbing.
This course is required for the following:
Flash Distillation
Gas Absorption & Stripping
Simple Distillation
Batch Distillation
Binary Distillation
Fractional Distillation
Scrubbers
Gas Treating
Sprayers / Spray Towers
Bubble Columns / Sparged Vessels
Agitation Vessels
Packed Towers
Tray Towers
We will cover:
Mass Transfer Basics
Diffusion, Convection
Flux & Fick's Law
The Concept of Equilibrium & Phases
Gibbs Phase Rule
Vapor Pressure
Equilibrium Vapor-Liquid Diagrams (T-xy, P-xy, XY)
Equilibrium Curves
Dew Point, Bubble Point
Volatility (Absolute & Relative)
K-Values
Ideal Cases vs. Real Cases
Henry's Law
Raoult's Law
Deviations of Ideal Cases (Positive and Negative)
Azeotropes
Solubility of Gases in Liquids
Interphase Mass Transfer and its Theories
Two Film Theory
Mass Transfer Coefficients (Overall vs Local)
Getting Vapor-Liquid and Solubility Data
Solved-Problem Approach:
All theory is backed with:
Exercises
Solved problems
Proposed problems
Homework
Case Studies
Individual Study
At the end of the course:
You will be able to understand the mass transfer concepts behind various Unit Operations involving Vapor - Liquid Interaction.
You will be able to apply this theory in further Unit Operations related to Mass Transfer Vapor - Liquid, which is one of the most common interactions found in the industry.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating. There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
Microbial catalysis of syngas fermentation into biofuels precursors - An expe...Pratap Jung Rai
Search for environment-friendly sustainable energy sources is of global interest due to continuous depletion of fossil fuels resources and excessive carbon dioxide emissions. Syngas fermentation is one of the promising sustainable alternative for liquid biofuel and chemical production from energy content wastes/byproducts. This study mainly focuses on acetic acid and ethanol production via fermentation, using hydrogen and carbon dioxide as substrates to mimic syngas. A laboratory scale, batch fermentation was performed at different headspace pressure ranged from 0.29 to 1.51 bar, 1200 rpm stirrer speed, and 22±1.4ºC.
Formation of acetic acid and ethanol were found significant. The maximum acetic acid concentration 68 mmol/L was obtained at 1176 hours and 1.12 bar headspace pressure. However, maximum ethanol concentration of 15 pA*s was found at 1297 hours and 1.51 bar headspace pressure. Ethanol consumption was observed during first 553 hours. Maximum H2 consumption rate was 0.153 mmol/h•gVS during 478-527 hours at 1.12 bar headspace pressure, which was 51 times higher than that obtained during first 71 hours at 0.29 bar headspace pressure (0.003 mmol/h• gVS). The total consumed hydrogen gas measure as COD (CODHydrogen) was equivalent to the increase in bulk liquid COD, 11.02 gCOD and 11.44 gCOD; in which 68% of CODHydrogen was converted to acetic acid (7.44 gCOD). A significant influence of headspace pressure and dissolved hydrogen concentration were observed on the volumetric mass (H2) transfer coefficient (kLa) and the solubility of hydrogen in the inoculum (CH). The maximum kLa and CH of 0.082 h-1 (R2 = 0.995) and 1.2 10-3 mol/L were found at 1.12 bar headspace pressure and 89 mmol/L dissolved hydrogen concentration, respectively. The calculated biomass yields ranged from 0.001-0.066 and 0.001-0.059 gVSS/gCOD, for acetic acid and ethanol formation, respectively, when the assumption of free energy efficiency use in growth was changed from 0.1 to 1.
Acetic acid and ethanol were dominant final product whereas other organic acids were almost constant and insignificant throughout the experiment. This implies that the microbial fermentation of hydrogen and carbon dioxide at headspace pressure ranged from 0.29-1.51 bar, 1200 rpm stirrer speed, and 22±1.4ºC, can be performed with digested food waste sludge for efficient acetic acid and ethanol production.
Adsorption of hydrogen sulfide using palm shell activated carboneSAT Journals
Abstract Removing H2S from biogas that is produced from anaerobic digestion of palm oil mill effluent is a crucial step in order for the biogas to be utilized as a source of energy. In this study, palm shell activated carbon (PSAC) prepared by steam activation was used to adsorb H2S from simulated biogas. The parameters studied were H2S concentration, adsorption temperature and space velocity. The effect of these parameters towards breakthrough adsorption capacity was studied using statistical analysis with Design Expert Software. H2S concentration and space velocity were found to be significant in affecting the breakthrough adsorption capacity.Adsorption temperature on its own was found not to have significant effect on the breakthrough adsorption capacity but its interaction with other parameters was found to be significant. Characterization of fresh and spent PSAC confirmed and provided further information on the adsorption of sulfur species on PSAC pore surface. Keywords: Activated carbon; Biogas; Hydrogen sulfide; Adsorption
The Principles required to understand Distillation, Absorption, Stripping, Flashing, Gas Treating, Scrubbing and more!
Introduction:
This course covers all the theory required to understand the basic principles behind Unit Operations that are based on Mass Transfer. Most of these Unit Operations (Equipments) are used in Process Separation Technologies in the Industry.Common examples are Distillation, Absorption and Scrubbing.
This course is required for the following:
Flash Distillation
Gas Absorption & Stripping
Simple Distillation
Batch Distillation
Binary Distillation
Fractional Distillation
Scrubbers
Gas Treating
Sprayers / Spray Towers
Bubble Columns / Sparged Vessels
Agitation Vessels
Packed Towers
Tray Towers
We will cover:
Mass Transfer Basics
Diffusion, Convection
Flux & Fick's Law
The Concept of Equilibrium & Phases
Gibbs Phase Rule
Vapor Pressure
Equilibrium Vapor-Liquid Diagrams (T-xy, P-xy, XY)
Equilibrium Curves
Dew Point, Bubble Point
Volatility (Absolute & Relative)
K-Values
Ideal Cases vs. Real Cases
Henry's Law
Raoult's Law
Deviations of Ideal Cases (Positive and Negative)
Azeotropes
Solubility of Gases in Liquids
Interphase Mass Transfer and its Theories
Two Film Theory
Mass Transfer Coefficients (Overall vs Local)
Getting Vapor-Liquid and Solubility Data
Solved-Problem Approach:
All theory is backed with:
Exercises
Solved problems
Proposed problems
Homework
Case Studies
Individual Study
At the end of the course:
You will be able to understand the mass transfer concepts behind various Unit Operations involving Vapor - Liquid Interaction.
You will be able to apply this theory in further Unit Operations related to Mass Transfer Vapor - Liquid, which is one of the most common interactions found in the industry.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating. There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
Microbial catalysis of syngas fermentation into biofuels precursors - An expe...Pratap Jung Rai
Search for environment-friendly sustainable energy sources is of global interest due to continuous depletion of fossil fuels resources and excessive carbon dioxide emissions. Syngas fermentation is one of the promising sustainable alternative for liquid biofuel and chemical production from energy content wastes/byproducts. This study mainly focuses on acetic acid and ethanol production via fermentation, using hydrogen and carbon dioxide as substrates to mimic syngas. A laboratory scale, batch fermentation was performed at different headspace pressure ranged from 0.29 to 1.51 bar, 1200 rpm stirrer speed, and 22±1.4ºC.
Formation of acetic acid and ethanol were found significant. The maximum acetic acid concentration 68 mmol/L was obtained at 1176 hours and 1.12 bar headspace pressure. However, maximum ethanol concentration of 15 pA*s was found at 1297 hours and 1.51 bar headspace pressure. Ethanol consumption was observed during first 553 hours. Maximum H2 consumption rate was 0.153 mmol/h•gVS during 478-527 hours at 1.12 bar headspace pressure, which was 51 times higher than that obtained during first 71 hours at 0.29 bar headspace pressure (0.003 mmol/h• gVS). The total consumed hydrogen gas measure as COD (CODHydrogen) was equivalent to the increase in bulk liquid COD, 11.02 gCOD and 11.44 gCOD; in which 68% of CODHydrogen was converted to acetic acid (7.44 gCOD). A significant influence of headspace pressure and dissolved hydrogen concentration were observed on the volumetric mass (H2) transfer coefficient (kLa) and the solubility of hydrogen in the inoculum (CH). The maximum kLa and CH of 0.082 h-1 (R2 = 0.995) and 1.2 10-3 mol/L were found at 1.12 bar headspace pressure and 89 mmol/L dissolved hydrogen concentration, respectively. The calculated biomass yields ranged from 0.001-0.066 and 0.001-0.059 gVSS/gCOD, for acetic acid and ethanol formation, respectively, when the assumption of free energy efficiency use in growth was changed from 0.1 to 1.
Acetic acid and ethanol were dominant final product whereas other organic acids were almost constant and insignificant throughout the experiment. This implies that the microbial fermentation of hydrogen and carbon dioxide at headspace pressure ranged from 0.29-1.51 bar, 1200 rpm stirrer speed, and 22±1.4ºC, can be performed with digested food waste sludge for efficient acetic acid and ethanol production.
Adsorption of hydrogen sulfide using palm shell activated carboneSAT Journals
Abstract Removing H2S from biogas that is produced from anaerobic digestion of palm oil mill effluent is a crucial step in order for the biogas to be utilized as a source of energy. In this study, palm shell activated carbon (PSAC) prepared by steam activation was used to adsorb H2S from simulated biogas. The parameters studied were H2S concentration, adsorption temperature and space velocity. The effect of these parameters towards breakthrough adsorption capacity was studied using statistical analysis with Design Expert Software. H2S concentration and space velocity were found to be significant in affecting the breakthrough adsorption capacity.Adsorption temperature on its own was found not to have significant effect on the breakthrough adsorption capacity but its interaction with other parameters was found to be significant. Characterization of fresh and spent PSAC confirmed and provided further information on the adsorption of sulfur species on PSAC pore surface. Keywords: Activated carbon; Biogas; Hydrogen sulfide; Adsorption
FULL COURSE:
https://courses.chemicalengineeringguy.com/p/flash-distillation-in-chemical-process-engineering/
Introduction:
Binary Distillation is one of the most important Mass Transfer Operations used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas, Liquid-Liquid and the Gas-Liquid mass transfer interaction will allow you to understand and model Distillation Columns, Flashes, Batch Distillator, Tray Columns and Packed column, etc...
We will cover:
REVIEW: Of Mass Transfer Basics (Equilibrium VLE Diagrams, Volatility, Raoult's Law, Azeotropes, etc..)
Distillation Theory - Concepts and Principles
Application of Distillation in the Industry
Equipment for Flashing Systems such as Flash Drums
Design & Operation of Flash Drums
Material and Energy Balances for flash systems
Adiabatic and Isothermal Operation
Animations and Software Simulation for Flash Distillation Systems (ASPEN PLUS/HYSYS)
Theory + Solved Problem Approach:
All theory is taught and backed with exercises, solved problems, and proposed problems for homework/individual study.
At the end of the course:
You will be able to understand mass transfer mechanism and processes behind Flash Distillation.
You will be able to continue with Batch Distillation, Fractional Distillation, Continuous Distillation and further courses such as Multi-Component Distillation, Reactive Distillation and Azeotropic Distillation.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating.
There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Selection of amine solvents for CO2 capture from natural gas power plant - presentation by Jiafei Zhang in the Natural Gas CCS session at the UKCCSRC Cardiff Biannual Meeting, 10-11 September 2014
Selection of amine solvents for CO2 capture from natural gas power plant - presentation by Jiafei Zhang of Imperial College London at the UKCCSRC Natural Gas CCS Network Meeting at GHGT-12, Austin, Texas, October 2014
Flue gas desulfurization is commonly known as FGD and is the technology used for removing sulfur dioxide (SO2) from the exhaust combustion flue gases of power plants that burn coal or oil to produce steam for the turbines that drive their electricity generators.
Application and development trend of flue gas desulfurization (fgd) process a...hunypink
In 1927, the limestone desulfurization process was first applied in the Barthes and Bansside Power Plants (total
120MW) beside the Thames River in UK to protect high-rise building in London. Up to now, over 10 desulfurization processes have been launched and applied. Based on the desulfurizing agent being used, there include calcium process (limestone/lime), ammonia process, magnesium process, sodium process, alkali alumina process, copper oxide/zinc process, active carbon process, ammonium dihydrogen phosphate process, etc. The calcium process is commercially available and widely used in the world, i.e. more than 90%. Flue gas desulfurization processes, survey made by the coal research institute under the International Energy Agency shows that the wet-process desulfurization accounts for 85% of total installed capacity of flue gas desulfurization units across the world. The wet-process desulfurization is mainly applied in countries, like Japan (98%), USA (92%), Germany (90%), etc. The limestone-gypsum wet desulfurization process, the most mature technology, the most applications, the most reliable operation in the world, may have rate of desulfurization of more than 90%. Currently, the flue gas desulfurization technology used at thermal power plants at home and abroad tends to be higher rate of desulfurization, bigger installed capacity, more advanced technology, lower investment, less land acquisition, lower operation cost, higher level of automation, more excellent reliability, etc. This paper briefs current situations and trends of flue gas desulfurization technology also append short descript of different type of FDG and their category.
Manpower has partnered with one of North America’s leading manufacturers and innovators in Cornwall, ON. Let our Talent Placement Specialists guide you seamlessly into your long term, rewarding career as an Electrician.
PRAN-RFL Group is the growing and largest FMCG and also daily Household necessary plastic manufacturer in Asian countries. please check the attach file for more details
FULL COURSE:
https://courses.chemicalengineeringguy.com/p/flash-distillation-in-chemical-process-engineering/
Introduction:
Binary Distillation is one of the most important Mass Transfer Operations used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas, Liquid-Liquid and the Gas-Liquid mass transfer interaction will allow you to understand and model Distillation Columns, Flashes, Batch Distillator, Tray Columns and Packed column, etc...
We will cover:
REVIEW: Of Mass Transfer Basics (Equilibrium VLE Diagrams, Volatility, Raoult's Law, Azeotropes, etc..)
Distillation Theory - Concepts and Principles
Application of Distillation in the Industry
Equipment for Flashing Systems such as Flash Drums
Design & Operation of Flash Drums
Material and Energy Balances for flash systems
Adiabatic and Isothermal Operation
Animations and Software Simulation for Flash Distillation Systems (ASPEN PLUS/HYSYS)
Theory + Solved Problem Approach:
All theory is taught and backed with exercises, solved problems, and proposed problems for homework/individual study.
At the end of the course:
You will be able to understand mass transfer mechanism and processes behind Flash Distillation.
You will be able to continue with Batch Distillation, Fractional Distillation, Continuous Distillation and further courses such as Multi-Component Distillation, Reactive Distillation and Azeotropic Distillation.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating.
There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Selection of amine solvents for CO2 capture from natural gas power plant - presentation by Jiafei Zhang in the Natural Gas CCS session at the UKCCSRC Cardiff Biannual Meeting, 10-11 September 2014
Selection of amine solvents for CO2 capture from natural gas power plant - presentation by Jiafei Zhang of Imperial College London at the UKCCSRC Natural Gas CCS Network Meeting at GHGT-12, Austin, Texas, October 2014
Flue gas desulfurization is commonly known as FGD and is the technology used for removing sulfur dioxide (SO2) from the exhaust combustion flue gases of power plants that burn coal or oil to produce steam for the turbines that drive their electricity generators.
Application and development trend of flue gas desulfurization (fgd) process a...hunypink
In 1927, the limestone desulfurization process was first applied in the Barthes and Bansside Power Plants (total
120MW) beside the Thames River in UK to protect high-rise building in London. Up to now, over 10 desulfurization processes have been launched and applied. Based on the desulfurizing agent being used, there include calcium process (limestone/lime), ammonia process, magnesium process, sodium process, alkali alumina process, copper oxide/zinc process, active carbon process, ammonium dihydrogen phosphate process, etc. The calcium process is commercially available and widely used in the world, i.e. more than 90%. Flue gas desulfurization processes, survey made by the coal research institute under the International Energy Agency shows that the wet-process desulfurization accounts for 85% of total installed capacity of flue gas desulfurization units across the world. The wet-process desulfurization is mainly applied in countries, like Japan (98%), USA (92%), Germany (90%), etc. The limestone-gypsum wet desulfurization process, the most mature technology, the most applications, the most reliable operation in the world, may have rate of desulfurization of more than 90%. Currently, the flue gas desulfurization technology used at thermal power plants at home and abroad tends to be higher rate of desulfurization, bigger installed capacity, more advanced technology, lower investment, less land acquisition, lower operation cost, higher level of automation, more excellent reliability, etc. This paper briefs current situations and trends of flue gas desulfurization technology also append short descript of different type of FDG and their category.
Manpower has partnered with one of North America’s leading manufacturers and innovators in Cornwall, ON. Let our Talent Placement Specialists guide you seamlessly into your long term, rewarding career as an Electrician.
PRAN-RFL Group is the growing and largest FMCG and also daily Household necessary plastic manufacturer in Asian countries. please check the attach file for more details
Palestra “Solução de pagamentos de pedágio, sem aumento nos custos", com Wagner Muradian, diretor comercial da MoveMais, realizada no dia 14 de fevereiro.
Peter Styring (University of Sheffield) presenting 'Carbon Dioxide Utilisation as a Direct Air Capture Driver' at the UKCCSRC/IMechE/CO2Chem Air Capture Workshop on 20th February 2015 in London
PRESENTATION ON PLANT DESIGN FOR MANUFACTURING OF HYDROGENPriyam Jyoti Borah
Steam reforming or steam methane reforming is a method for producing syngas (hydrogen and carbon monoxide) by reaction of hydrocarbons with water. Commonly natural gas is the feedstock. The main purpose of this technology is hydrogen production.The reaction is conducted in a reformer vessel where a high pressure mixture of steam and methane are put into contact with a nickel catalyst. Catalysts with high surface-area-to-volume ratio are preferred because of diffusion limitations due to high operating temperature. Examples of catalyst shapes used are spoked wheels, gear wheels, and rings with holes. Additionally, these shapes have a low pressure drop which is advantageous for this application.
From CO2 to Coal: Turning Back the ClockDon Basile
Over the much longer term, global warming could cause countless animal extinctions and even threaten the very existence of mankind itself. Thankfully, several leading solutions are being developed that could rewind the CO2 emissions clock. While scrubbing carbon dioxide from the air might seem impossible, it is very close to becoming a reality.
Elizabeth Towle Coked Catalyst Regeneration Project
1. Coked Catalyst Regeneration Project
A Project Report for ChE 2013
submitted to the Faculty of the
Department of Chemical Engineering
Worcester Polytechnic Institute
Worcester, MA 01609
March 4, 2016
The Not Coal Group
“What’s that rock? It’s coal.”
_____________________
Benjamin Drury
_____________________
Weiran Gao
_____________________
Natalie Thompson
_____________________
Elizabeth Towle
2. To: Dr. M. Timko
From: B. Drury, W. Gao, N. Thompson, E. Towle
Subject: Reaction Equilibria Project
Introduction
The ThermoChem Company runs a process to catalytically crack hydrocarbons, but must
periodically shut down their cracking process and pass H2 gas through a reactor to regenerate a
catalyst that has been “coked” by carbon. This process begins when the catalyst has been coked
with carbon weighing 10% of the catalyst. Hydrogen gas is passed over the carbon at 1000 K, 1.1
bar for nine hours with the expectation of recovering 95% of the carbon. It is the mission of this
report to verify that after the given nine hours that no carbon remains coked upon the catalyst.
This report also endeavors to calculate the viability of recycling H2 while recovering methane.
Further, at the suggestion of our esteemed college Clem Chem, we have also analyzed a process
using steam instead of pure hydrogen to recover CH4 from the coked carbon. These various
processes will be evaluated for their viability.
Methodology
We considered a method involving the conversion of carbon to methane. Carbon recovery occurs
when 105,000 lbs of catalyst have been coked with 10,500 lbs of carbon, which is equivalent to
867 lbmol. Hydrogen is passed through at 1000 lbmol/hr of pure hydrogen gas.
Further, we considered the recovery of hydrogen and methane gas from the conversion. The total
feed was still 1000 lbmol/hr, although methane was returned to the feed at no more than 4 mol%.
This percentage was maintained by a purge on the recycle stream.
We also considered the effect of using steam instead of hydrogen gas and what changes that
would bring upon the overall conversion and recovery. This process produces hydrogen, carbon
monoxide, and carbon dioxide, in addition to methane. It will be evaluated for its time and cost
efficiency compared to the use of hydrogen, as well as its yield of methane and the health and
safety issues it creates.
The process was assumed to be 100% efficient and to reach equilibrium in the reactor. Further, it
was assumed that neither hydrogen nor any other gas was dissolved into the liquid methane.
Especially at this low pressure, this is not likely an oversimplification, and there is very low
solubility of hydrogen in methane, and should not significantly affect the results. As the pressure
was only 1.1 bar, it was assumed all gases behave ideally.
MathCad was used for necessary calculations.
3. Results and Discussion
Hydrogen Feed without Recycle
It was calculated that it would take 10.452 hours to remove 95% of the carbon from the reactor.
The details of these calculations can be found in Appendices 1 and 2. This data proves that the
ThermoChem Company has not been shutting down the cracking process long enough to
preserve the reduced state of the carbon. One possibility for this discrepancy between the
expected time that ThermoChem was using and the calculated time we found, is that we used the
Van’t Hoff equation and assumed ΔH is a function of T while ThermoChem might have assumed
ΔH is constant. Because we assumed ΔH is a function of T and used mathcad, our calculated
values can be adapted to account for a different flow rate, pressure, and temperature. One
possible source of error could be failing to take into consideration the poynting factor. With
such a low pressure, we assumed that it would be one but no system is ever ideal so this
assumption could allow for a small margin of error.
4. Hydrogen Feed with Recycle
By adding a recycle, the time to remove 95% of the carbon increases to 19.631 hours, over twice
the original allotted time of 9 hours. However, it reduces the amount of hydrogen necessary to
273 lbmol/hr from 1000 lbmol/hour. This will reduce the costs of H2, from about 105
lbmol over
10 hours to 5400 lbmol over 19 hours, but the additional 9 hours needed every time carbon is to
be recovered will detract from the productivity of the plant. One reason this takes so long might
be that the recycle stream contains a bit of the product, CH4 which is not advantageous for the
equilibrium reaction to shift to the right. This could be addressed by purging more methane from
the stream, although this would also reduce the amount of H2 recycled. It can be generalized that
any amount of recycle will decrease the H2 costs but increase the required time. The potential
sources of error include potentially flawed assumptions. The process was assumed to be 100%
efficient and to reach equilibrium in the reactor. Further, it was assumed that no hydrogen was
dissolved into the liquid methane. Especially at this low pressure, this is not likely an
oversimplification, and there is very low solubility of hydrogen in methane, and should not
significantly affect the results. As the pressure was only 1.1 bar, it was assumed all gases behave
ideally.
5. Steam Feed, No Recycle
If 1000 lbmol/hr of steam is used instead of hydrogen, the process of removing 95% carbon from
the catalyst takes only 1.062 hours. This would reduce the downtime of the plant, as well as
significantly reducing the cost of materials. steam is much cheaper than hydrogen, and 1088
lbmol of steam is much more by weight than the amount of hydrogen needed to run the recycle,
and significantly less than the current practice uses. These results can be extended to generalize
that using steam instead of hydrogen will be more efficient to remove carbon from a catalyst.
This efficiency stems from multiple reactions happening at the same time, pushing the
equilibrium in a favorable direction. This practice is extremely time and cost efficient, but does
however create exhausts like CO2 and CO. As will be addressed more later, these gases have
toxic effects on both humans and the environment, and all necessary precautions should be taken.
The potential sources of error include potentially flawed assumptions. The process was assumed
to be 100% efficient and to reach equilibrium in the reactor. As the pressure was only 1.1 bar, it
was assumed all gases behave ideally. We are confident in these results, and they are very
reliable.
6. Health and safety
The chemicals used in our processes are thankfully not incredibly harmful. Carbon should not be
ingested and hydrogen and methane shouldn’t be allowed to reach more than 10% concentration
in the volume they are contained in, as if oxygen contaminates the feed there is a possibility of
fire and explosions. Carbon monoxide is toxic and has the ability to form potentially explosive
chemicals when introduced into the atmosphere. Carbon dioxide can cause asphyxiation if
concentrations greater than or equal to 10% are inhaled. In regards to the amount of carbon
dioxide being created, it is recommended that this company capture, recycle, or convert the
carbon dioxide into a more environmentally friendly compound before being released into the
atmosphere.
7. Conclusion and Recommendations
Upon completion of our studious research and calculations we determined that the ThermoChem
Company has not been passing hydrogen gas through the reactor long enough for all of the
carbon to be converted to methane. Further, we would like to recommend Clem Chem’s
proposed idea of using steam instead of hydrogen, as it will reduce downtime and material costs.
With the necessary health and safety precautions, this can be a significantly more economically
viable option, increasing production by the ThermoChem Company. Without equations for the
costs of time, supplies, and waste removal, it is impossible to say with absolute certainty that this
will be the most cost effective method, but we are nevertheless confident in our analysis that
using steam instead of hydrogen for just 1.088 hours will be the best way to remove carbon from
the catalyst.
8. References
MSDS C
"Material Safety Data Sheet." Actp-12-18-2013. Cleartech, 19 Dec. 2013. Web. 2 Mar. 2016.
<http://www.dynamicaqua.com/msds/activatedcarbon.pdf>.
MSDS H2
"Material Safety Data Sheet." Hydrogen. Air Products, June 1994. Web. 2 Mar. 2016.
<http://avogadro.chem.iastate.edu/MSDS/hydrogen.pdf>.
MSDS CH4
"Material Safety Data Sheet." Methane. Air Products, July 1999. Web. 3 Mar. 2016.
<http://avogadro.chem.iastate.edu/msds/methane.pdf>.
MSDS H2O
"Material Safety Data Sheet Water MSDS." Msds.php. Science Lab.com, 21 May 2013. Web. 3
Mar. 2016. <http://www.sciencelab.com/msds.php?msdsId=9927321>.
MSDS CO
"Safety Data Sheet Carbon Monoxide." 001014.pdf. Airgas, 12 May 2015. Web. 3 Mar. 2016.
<https://www.airgas.com/msds/001014.pdf>.
MSDS CO2
"Material Safety Data Sheet." Carbon Dioxide. Air Products, Sept. 1998. Web. 3 Mar. 2016.
<http://avogadro.chem.iastate.edu/MSDS/carbon_dioxide.pdf>.