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Group 3 FYP 2nd Presentations final.pptx
- 1. Page 01 Group members •2020-CH-255 (Hassnain Faisal) • 2020-CH-275 (Zeeshan Abid) • 2020-CH-229 (Arslan Sheraz) • 2020-Ch-238 (Burhan Bashir) Enhancing Green Ammonia Synthesis Process By Adsorber Based Separation Group Supervisor Dr. Ing Izzat Iqbal Cheema
- 2. Page 02 Overview Methodology MaterialBalance Heat Exchanger Reactor Equipment design Economic analysis Sustainability Adsorber Compressor References Socio Economic consideration Problem statement
- 3. Page 05 Problem Statements •Fossil fuels, central to the world's energy needs, drive economic development but their extraction, processing, and combustion contribute to environmental harm, leading to global warming and adverse economic impacts. Transitioning to sustainable energy sources is crucial for mitigating these effects. • High pressure used in separator. Low pressure in adsorber is maintained to favor the Separation of ammonia. Past Data Analysis
- 4. Page 05 Capacity • Wehave Selected the Capacity of 150MTD • Quaid-e-Azam Solar Park has 400MWh of capacity. • Each ton of Ammonia Production Required 9-10 MW of Electricity Past Data Analysis Quaid-e-Azam Solar Park, Bahawlpur Site Selection
- 5. Page 10 Objectives Design aninnovative ammonia synthesis loop incorporating adsorber instead of separator, aiming for enhances efficiency 01 Optimal Design of multiple stage Reactor , adsorber and heat exchangers for maximum conversion 02 We are capturing ammonia using metal halides because it will be economical and efficient compared to the separator. 03 Perform Economic and Energy Analysis to visualize the efficiency of the system 03
- 6. Page 03 Methodology We useit because we get: • Cost efficiency. • Use less pressure • Overall efficient. • More production. • Less energy consumption. : Absorber instead of Separator:
- 7. Page 04 Process FlowDiagram M1,2,3,4 : Mixer V1,2,3,4 : Valves MCOMP : Multistage compressor S1 : Splitter HX : Heat exchanger REC 1,2,3 : Reactors S2: Splitter ADS: Adsorber STRIP: Stripper COND : Condenser
- 8. Page 05 Material Balance OutOut Out Out H2 in N2 in 1 1 17 2 assum 5 8 9 6 10 11 N2 0 5322.546 5322.546 5322.546 12799.92 23749.69 2374.969 17289.78 19664.74 2374.969 17894.92 20269.89 H2 1146.096 1146.096 1146.096 3980.447 2106.355 210.6355 1315.906 1526.541 210.6355 1144.442 1355.077 Ar 0 96.67416 96.67416 96.67416 96579.04 96663.07 9666.307 77330.46 86996.76 9666.307 86996.76 96663.07 NH3 0 0 0 314.1087 339.0838 33.90838 2350.46 2384.368 33.90838 4536.333 4570.241 Total 1146.096 5419.22 6565.316 6565.316 113673.5 122858.2 12285.82 98286.6 110572.4 12285.82 110572.5 122858.3 Mixer 4 In In In In Mixer 1 Mixer 2 Mixer 3 In In 3 4 5 6 15 16 17 N2 23749.69 18999.75 2374.969 2374.969 18445.6 18.4456 18427.15 H2 2106.355 1685.084 210.6355 210.6355 961.219 0.961219 960.2578 Ar 96663.07 77330.46 9666.307 9666.307 96663.07 96.66307 96566.41 NH3 339.0838 271.267 33.90838 33.90838 339.4214 0.339421 339.082 Total 122858.2 98286.56 12285.82 12285.82 116409.3 116.4093 116292.9 Out Out Spliter 1 Spliter 2 In Out Cold In Cold Out Hot In Hot Out In Out 2 assum 3 4 7 12 13 13 14 N2 23749.69 23749.69 18999.75 18999.75 18445.6 18445.6 18445.6 18445.6 H2 2106.355 2106.355 1685.084 1685.084 961.219 961.219 961.219 961.219 Ar 96663.07 96663.07 77330.46 77330.46 96663.07 96663.07 96663.07 96663.07 NH3 339.0838 339.0838 271.267 271.267 6788.428 6788.428 6788.428 6788.428 Total 122858.2 122858.2 98286.56 98286.56 122858.3 122858.3 122858.3 122858.3 Cooler Heat Exchanger Comprressor In Out In Out In Out 7 8 9 10 11 12 N2 18999.75 17289.78 19664.74 17894.92 20269.89 18445.6 H2 1685.084 1315.906 1526.541 1144.442 1355.077 961.219 Ar 77330.46 77330.46 86996.76 86996.76 96663.07 96663.07 NH3 271.267 2350.46 2384.368 4536.333 4570.241 6788.428 Total 98286.56 98286.6 110572.4 110572.5 122858.3 122858.3 Reactor 1 Reactor 2 Reactor 3 In Out Acc 14 15 0 N2 15767.99 15767.99 0 H2 3343.846 3343.846 0 Ar 1933.442 1933.442 0 NH3 5788.075 289.4038 5498.672 Total 26833.35 21334.68 5498.672 Adsorber
- 9. Page 17 Energy BalanceResults EQUIPMENT UNITS ENTHALPY FLOW (IN) W/Q ENTHALPY FLOW (OUT) Mixer 2 J/hr 83309.44159 83309.44159 Compressor J/hr 65666.0837 11429.2101 54236.8736 Splitter 1 J/hr 350533.1146 350533.1146 Heat Exchanger J/hr 49213485.32 -10208634 59422119.32 Reactor 1 J/hr 30170200.12 -5720848.12 35891048.24 Mixer 3 J/hr 36578161.28 36578161.28 Reactor 2 J/hr 36578161.28 -109635.7714 36687797.05 Mixer 4 J/hr 37374910.09 37374910.09 Reactor 3 J/hr 37374910.09 -6103286.817 43478196.9 Cooler J/hr 5670303.141 -5261097.498 409205.6432 Adsorber J/hr 360154.1415 360154.1415 Energy Balance
- 10. Heat Exchanger Detail Designof Equipments
- 11. Page 07 Heat ExchangerSelection Feature Plate Heat Exchanger Double Pipe Heat Exchanger Shell and Tube Heat Exchanger Construction Plates with flow channels Two concentric pipes Shell with multiple tubes Heat Transfer Area High per unit volume Moderate Moderate to high Pressure Drop Low Moderate Moderate to high (depends on design) Maintenance Easier cleaning due to accessible plates Moderate difficulty More complex cleaning due to tubes Fouling Sensitivity Less prone to fouling Moderately prone to fouling Can be prone to fouling depending on fluids Cost Lower for smaller capacities Lower for low flow rates and pressures Moderate to high Versatility Limited to moderate pressures and temperatures Limited flow rates and pressures Wide range of pressures, temperatures, and flow rates Suitability for: - Clean fluids - Low pressure applications - Sanitary applications - Low flow rates - Low pressures - Viscous fluids - High pressures - High temperatures - Dirty or viscous fluids - Wide range of applications
- 12. Page 08 Design Procedure ColdIn Temp= 100°C Pressure= 30 bar Flow rates in kg/hr N2=16241.69889 H2= 3458.201002 AR=1546.753516 NH3=219.9477668 Total =21466.60118 Cold out Temp= 400°C Pressure= 30 bar Flow rates in kg/hr N2=16241.69889 H2= 3458.201002 AR=1546.753516 NH3=219.9477668 Total =21466.60118 Hot In Temp= 479.13°C Pressure= 30bar Flow rates in kg/hr N2=15767.98538 H2=3343.84587 AR=1933.441895 NH3=5788.075438 Total=26833.34858 Hot out Temp= 223.72°C Pressure= 30bar Flow rates in Kg/hr N2=15767.98538 H2=3343.84587 AR=1933.441895 NH3=5788.075438 Total=26833.34858 Design Specs Heat Exchanger Shell and tube Type BEM Material Carbon Steel Shell passes 1 Tube Passes 1 Pitch Type Triangular Baffle Single Segmental
- 13. Page 09 Background Datafor calculations
- 14. Page 10 Design Stepsand Results Design Sketch
- 15. Page 11 Setting Planand Tube sheet layout on Aspen EDR Specs and Results
- 16. Page 12 Hazop Analysisof HX Guide Word Deviation Parameter Cause Consequence Safeguard More Overheating Temperature Cooling system failure Equipment damage, fire Temperature sensors, emergency cooling system, regular maintenance of cooling system Less Freezing Temperature Heating system failure Equipment damage, process shutdown Temperature sensors, emergency heating system, regular maintenance of heating system Part of Corrosion Material Corrosive process fluid Equipment damage, loss of containment Material selection, corrosion monitoring, regular inspection of equipment for signs of corrosion Abnormal Fouling Flow rate Process fluid contamination Reduced heat transfer, process upset Strainers, regular maintenance and cleaning of equipment Reverse Flow reversal Flow direction Piping configuration or operator error Reduced heat transfer, equipment damage Check valves, operator training on correct handling of equipment Other than Improper installation Equipment installation Errors in equipment installation Equipment damage, safety hazard Quality control of equipment installation, operator training on correct installation procedures
- 17. Page 13 Cost EstimationFor HX Cost Estimation Equipment weight 1100 lbs Installed weight 11988 lbs Surface area 1030 ft2 Purchased cost 15848 $ Operation pressure 3000 kpa Correction factor 1.16 Tube and shell Final cost 18384 $
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- 19. Page 15 Reactor Designand Procedure
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- 24. Page 20 Results Reactor Parametrs Bed1 Bed 2 Bed 3 Vbed (m3) 0.412948 0.989513 2.075206 mcat (kg) 1156.255 2770.637 5810.578 Ltube (m) 0.8 2 4 dtube (m) 0.15 0.15 0.15 N tube 30 30 30 Lreactor (m) 2.076937 3.250151 5.280169 Dreactor (m) 1.276937 1.250151 1.280169 Vreactor (m3) 2.732044 4.091604 6.864727 Space velocity (h-1) 10867.19 14863.3 17483.42 Pressure Drop (atm) 0.249216 0.657704 0.814598
- 25. Page 21 Cost estimation Costestimation Total weight of Shell 6118.629 kg Total weight of heads 3507.98 kg Cost of Reactor 1 27435.71 $ Cost of Reactor 2 31346.87 $ Cost of Reactor 3 40250.8 $ Cost of Catalyst 125613.4 $ Total cost 224646.7 $
- 26. Page 22 Hazop Analysis NodeParameter Guide Word Deviation Consequence Safeguard Reactor Temperature More High temperature Thermal runaway, equipment failure High-temperature alarm, cooling system Reactor Pressure More High pressure Equipment failure, safety valve failure High-pressure alarm, safety valve Reactor Catalyst flow No No catalyst flow Reduced ammonia production Low-flow alarm
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- 28. Page 24 Design andSelection of Compressor Selection Reciprocating Centrifuge Rotary Reciprocating Compression ratio 1.75 Stages Single Multiple Multiple stage Ideal for 1 stage is 1.2-1.4 Compression ratio 1.75 Flow rate 26833.25kg/hr Volume 1.32m2/kg Work 1876 kJ/kg Mass flow rate 5.64kg/sec Power 10 kW Conditions • P1=17.07 bar, P2=30 bar • T=100°C Detail design link • https:// eu.docworkspace.com/d/sIJzp-rFb -8ausQY
- 29. Page 25 Hazop Analysis Guideword Deviation Parameter Cause Consequences Safeguards Less Low Pressure Pressure Compressor failure Impact to reactor Pressure indicator is provided More High Pressure Pressure Failure of pressure relief valve Pipe vibration Pressure indicator is provided No No Flow Flow Line leakage No process gas into the reactor Flow indicator is provided
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- 32. Adsorbent Selection Choose adsorbenttype based on Langmuir Adsorption Isotherm: q= a*m*b*P/1+b*P Calculate mass of adsorbent ( ) and volume (V). 𝑚 Column Dimensions Determine L/D ratio (2-5). Calculate bed diameter (D) and length ( ). 𝐿 Saturation Time Find initial ( ) and final ( o) 𝐶 𝐶 concentrations. Calculate equilibrium loading (Wsat) and superficial velocity ( o). 𝑈 Breakthrough Loading Determine used bed length (Lb) and breakthrough loading (Wb). Overall Mass Transfer Coefficient Calculate internal (Kc internal) and external (Kc external) mass transfer coefficients. Determine overall mass transfer coefficient (Kc) and surface area per unit volume (a). Saturated Bed Length Calculate saturated bed length (L last) Page 27 Design Procedure
- 33. Page 28 Design Calculations T(K) 298 K P (Bar) 28 bar R 8.31E-02 m3.bar.K- 1.mol-1 M.M 10.2818395 1 kmol/kg den 1.16E+01 kg/m3 visc 1.13E-05 N-s/m2 q 0.0586 kg of NH3 / kg of Mgcl2 M of Ads 118527.142 1 kg den of ads 2320 kg/m3 V 51.08928537 m3 Q 2.31E+03 m3/h D 2.533533503 m L 10.13413401 m Hv 11.13413401 m Co 2.51E+00 kg/m3 C 1.25E-01 kg/m3 Wsat 0.27 kg of NH3 / kg of Mgcl2 W 0.0135 kg of NH3 / kg of Mgcl2 V 51.08928537 m3 uo 1.27E-01 m/s t 5.25E+00 h tb 5 h Lb 9.65E+00 m Lub 4.87E-01 m Wb 2.58E-01 kg of NH3 / kg of Mgcl2 kint 8.91E-03 m/s Part Dia 2.00E-07 m porasity 0.005568 - tourasity 2.5 - Diffusivity 1.78E-10 m2/s ke. Int 8.91E-03 m/s Re 5.20E+00 - Sc 2.74E+01 - Sh 9.262672942 - ke. ext 8.25E-03 m/s Kc 4.28E-03 m/s a 2.98E+07 1/m aKc 1.28E+05 1/s vz 5.36E-04 m/s t1 1.86E-03 Lsat 2.68E-03
- 34. Page 29 Hazop Analysis NodeGuide word Parameter Deviation Consequence Safeguard Action Adsorber inlet No Flow Low Incomplete adsorption Flow meter Check flowrate, calibrate flowmeter High Overloading Pressure relief valve Adjust flowrate, install pressure relief valve Adsorber outlet No Pressure Low Decreased efficiency Pressure gauge Monitor pressure, check for leaks High Pressurization Pressure relief valve Adjust pressure, install relief valve Burst disc Install burst disc Emergency shutdown Implement emergency shutdown procedure Adsorbent bed No Temperature Low Reduced adsorption capacity Temperature sensor Monitor temperature, adjust heating High Thermal decomposition Temperature controller Monitor temperature, adjust heating Fire suppression system Install fire suppression system Emergency shutdown Implement emergency shutdown
- 35. Page 30 Cost Estimationof Adsorber Total weight of shell 2800 lb Purchased cost of carbon steel shell 28000lb 11,100 $ Cost of 19 installed 18 inch manholes 39,672 $ Cost of 1 installed 16 inch nozzle inlet 690 $ Cost of 1 installed 16 inch nozzle outlet 828 $ 6 installed 1 inch couple 114 $ Cost of packing material ( Activated carbon) 45 $ Cost of Adsorbent MgCl2 535 $ For Packed bed column following are the conditions , 18 inch man holes, shell ⅝ inch, six 1 inch coupling, flanged nozzles attached each 10 inch, 2 nozzles of 16 inch
- 36. Page 31 Economic Analysis PurchasedEquipment Cost Compressor Reactors Mixers Spliter condensor Pump Stripper Adsorber Stripper Heat Exchanger
- 37. Page 32 Socio EconomicConsiderations Climate Change Mitigation Economic Benefits Cost and Barriers Job creation Market demand Policy and Regulatory Support Future Prospects and Advancements Sustainability considerations
- 38. Page 33 FAUGET UNIVERSITY References 1. ImprovingAbsorbent-Enhanced Ammonia Separation For Efficient Small Scale Ammonia Synthesis Emmanuel Onuoha1 Matthew Kale1 Mahdi Malmali2 Paul Dauenhauer Alon McCormick1,* 2. Department of Chemical Engineering & Materials Science, 421 Washington Ave. SE, University of Minnesota, Minneapolis, MN, USA 55455. 3. Department of Chemical Engineering, 807 Canton Ave, Texas Tech University, Lubbock, TX 794 4. Achieving +95% Ammonia Purity by Optimizing the Absorption and Desorption Conditions of Supported Metal Halides Daniel J. Hrtus, Fouzia Hasan Nowrin, Austin Lomas, Yanick Fotsa, and Mahdi Malmali* 5. Optimizing the Conditions for Ammonia Production Using Absorption Collin Smith, Alon V. McCormick, and E. L. Cussler* 6. Green ammonia project set for launch in UK today Article by Adam Duckett 7. Modeling and Optimal Design of Absorbent Enhanced Ammonia Synthesis by Matthew J. Palys,Alon McCormickORCID,E. L. Cussler andProdromos Daoutidis *ORCID 8. Department of Chemical Engineering and Materials Science, University of Minnesota, Minneapolis, MN 5405, USA 9. Ammonia Synthesis at Low Pressure Edward Cussler, 1 Alon McCormick, 1 Michael Reese, 2 and Mahdi Malmali 1
- 39. Page 34 FOR YOURATTENTION Any Questions? THANK YOU