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SYNGAS Process Integration

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Gerard B. Hawkins
Gerard B. Hawkins

SYNGAS Process Integration Ammonia / Methanol Flowsheet Integration “Reducing Risk and Increasing Profitability” Contents Conventional Ammonia Plant Flow Sheet Conventional Methanol Plant Flow Sheet Superstructure Block Diagram Process Design Tools Pi Algorithm Approach Ammonia / Methanol Flow Sheet Integration: Case Study#72514GB/H Equipment List Integration Flowsheet 1: Feed Preparation (HDS) Integration Flowsheet 2: Feed Preparation (Saturator Circuit) Integration Flowsheet 3: Pre-reformer, AGHR, ATR Integration Flowsheet 4: Isothermal Shift Integration Flowsheet 5: CO2 Removal Stream Component - Material Balances Table 1 Table 2 Table 3

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Ammonia / Methanol Flowsheet Integration “Reducing Risk and Increasing Profitability” Case Study #72514GB/H
Contents Conventional Ammonia Plant Flow Sheet Conventional Methanol Plant Flow Sheet Superstructure Block Diagram Process Design Tools Pi Algorithm Approach Ammonia / Methanol Flow Sheet Integration: Case Study#72514GB/H Equipment List Integration Flowsheet 1: Feed Preparation (HDS) Integration Flowsheet 2: Feed Preparation (Saturator Circuit) Integration Flowsheet 3: Pre-reformer, AGHR, ATR Integration Flowsheet 4: Isothermal Shift Integration Flowsheet 5: CO2 Removal Stream Component - Material Balances Table 1 Table 2 Table 3
Conventional Ammonia Plant Flow Sheet
Conventional Methanol Plant Flow Sheet
Superstructure Block Diagram
Process Design Tools
PFD SIM - in Excel
Ammonia / Methanol Flow Sheet Integration Case Study#72514GB/H
Equipment List Tag Description B-101 HDS Fired Heater B-301 Pre-reformer Fired Heater E-101 HDS Interchanger E-301 AGHR Interchanger E-401 HT Saturator Water Heater E-402 NH3 Syngas Saturator Water Heater E-403 NH3 Syngas Cooler E-404 MeOH Syngas Saturator Water Heater E-405 MeOH Syngas Cooler J-201 Cool Saturator Water Pump J-202 Hot Saturator Water Pump K-101 Natural Gas Compressor R-101 HDS R-102A H2S Absorber 1 R-102B H2S Absorber 2 R-301 Pre-reformer R-302 AGHR R-303 ATR R-401 Isothermal Shift T-201 Saturator V-401 NH3 Syngas KO Pot V-402 MeOH Syngas KO Pot X-501 CO2 Removal X-502 Cold Box
To Saturator Natural Gas H2 Recycle from CO2 Removal S-414 S-101 K-101 B-101 E-101 S-107 R-101 R-102A R-102B Integration Flowsheet 1: Feed Preparation (HDS)
S-107 S-203S-201 MP Steam To FXC Water from E-401 To E-401 Mixed Feed to Reformer Process Condensate To E-402 J-201 J-202 From HDS S-202 T-201 Integration Flowsheet 2: Feed Preparation (Saturator Circuit)
Fuel Gas O2 from ASU R-301 R-302 R-303 E-301 S-203 Mixed Gas from Saturator S-301 Reform Gas to E-401 S-307 S-308 S-302 B-301 S-203 From FC S-304 S-305 Integration Flowsheet 3: Pre-reformer, AGHR, ATR
From FCV Water to Saturator E-403 To CO2 Removal S-401 S-308 E-402 S-408 V-401 From 201 S-415 E-401 S-404 S-405 Reform Gas from E-301 From J-202 R-301 From Co2 Removal E-405E-404 MeOH Syngas S-420 V-402 S-410 Integration Flowsheet 4: Isothermal Shift
S-414 S-410 S-411 S-501 S-408 N2 from ASU Fuel Gas S-508 S-502 X-502 X-501 From V-401 CO Product NH3 Syngas S-509 H2 R/C to HDS To MeOH Syngas Integration Flowsheet 5: CO2 Removal
Name S-101 S-107 S-201 S-202 S-203 S-301 S-302 Temperature (C) 27 154.3 223.8 350 260.3 400 504.2 Pressure (bar) 22 52.2 51.7 55 51.7 51.1 50.3 Molar Flow (kgmole/h) 10360 10587.3 22437.5 9317.5 31755 31755 31755 Mass Flow (kg/h) 172113 172942 386425 167856 554281 554281 554281 Hydrogen 0.000% 2.005% 0.946% 0.000% 0.668% 0.668% 0.668% CO 0.000% 0.121% 0.057% 0.000% 0.040% 0.040% 0.040% CO2 0.640% 0.626% 0.296% 0.000% 0.209% 0.209% 0.209% Methane 96.570% 94.514% 44.597% 0.000% 31.512% 31.512% 31.512% Ethane 2.710% 2.652% 1.251% 0.000% 0.884% 0.884% 0.884% Propane 0.010% 0.010% 0.005% 0.000% 0.003% 0.003% 0.003% Nitrogen 0.070% 0.071% 0.033% 0.000% 0.024% 0.024% 0.024% Methanol 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% H2O 0.000% 0.000% 52.815% 100.000% 66.660% 66.660% 66.660% Oxygen 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% Argon 0.000% 0.002% 0.001% 0.000% 0.001% 0.001% 0.001% Stream Component: Material Balances Table 1
S-303 S-304 S-305 S-307 S-308 S-401 S-402 S-404 S-405 450 40 1050 580 460.5 220 220 220 252.7 49.3 45.8 42.8 42.3 41.9 41.3 41.3 41.3 39.8 32843.6 4913.8 52509.3 52444 52444 52444 21711 4511 26222.4 554281 157338 711619 711619 711619 711619 294600 61210 355809 6.426% 0.000% 45.832% 45.280% 45.280% 45.280% 45.280% 45.280% 56.638% 0.027% 0.000% 14.392% 14.770% 14.770% 14.770% 14.770% 14.770% 3.413% 1.871% 0.000% 5.475% 5.059% 5.059% 5.059% 5.059% 5.059% 16.416% 30.529% 0.000% 0.416% 0.479% 0.479% 0.479% 0.479% 0.479% 0.479% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.023% 0.500% 0.061% 0.061% 0.061% 0.061% 0.061% 0.061% 0.061% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 61.124% 0.000% 33.777% 34.304% 34.304% 34.304% 34.304% 34.304% 22.946% 0.000% 99.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.001% 0.500% 0.047% 0.047% 0.047% 0.047% 0.047% 0.047% 0.047% Name Temperature (C) Pressure (bar) Molar Flow (kgmole/h) Mass Flow (kg/h) Hydrogen CO CO2 Methane Ethane Propane Nitrogen Methanol H2O Oxygen Argon Stream Component: Material Balances Table 2
S-408 S-410 S-411 S-414 S-415 S-420 S-501 S-502 S-508 S-509 45 45 45 45 220 45 0 45.3 28.8 31.7 38.4 37.9 37.9 37.9 41.3 37.9 50 37.9 37.9 37.9 20253.9 109.8 15563.5 227.2 26222 17378.6 4998.6 832 735.1 18995 247979 400 56732 828 355809 194736 140025 23304 11709 161744 73.328% 93.405% 93.405% 93.405% 45.280% 68.910% 0.000% 0.000% 39.549% 75.001% 4.418% 5.627% 5.627% 5.627% 14.770% 22.316% 0.000% 100.000 % 5.956% 0.000% 21.195% 0.000% 0.000% 0.000% 5.059% 7.594% 0.000% 0.000% 0.000% 0.000% 0.620% 0.790% 0.790% 0.790% 0.479% 0.727% 0.000% 0.000% 16.717% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.079% 0.101% 0.101% 0.101% 0.061% 0.093% 100.000 % 0.000% 36.131% 24.999% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.299% 0.000% 0.000% 0.000% 34.304% 0.287% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.061% 0.078% 0.078% 0.078% 0.047% 0.072% 0.000% 0.000% 1.647% 0.000% Name Temperature (C) Pressure (bar) Molar Flow (kgmole/h) Mass Flow (kg/h) Hydrogen CO CO2 Methane Ethane Propane Nitrogen Methanol H2O Oxygen Argon Stream Component: Material Balances Table 3
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SYNGAS Process Integration

  • 1. Ammonia / Methanol Flowsheet Integration “Reducing Risk and Increasing Profitability” Case Study #72514GB/H
  • 2. Contents Conventional Ammonia Plant Flow Sheet Conventional Methanol Plant Flow Sheet Superstructure Block Diagram Process Design Tools Pi Algorithm Approach Ammonia / Methanol Flow Sheet Integration: Case Study#72514GB/H Equipment List Integration Flowsheet 1: Feed Preparation (HDS) Integration Flowsheet 2: Feed Preparation (Saturator Circuit) Integration Flowsheet 3: Pre-reformer, AGHR, ATR Integration Flowsheet 4: Isothermal Shift Integration Flowsheet 5: CO2 Removal Stream Component - Material Balances Table 1 Table 2 Table 3
  • 7. PFD SIM - in Excel
  • 8. Ammonia / Methanol Flow Sheet Integration Case Study#72514GB/H
  • 9. Equipment List Tag Description B-101 HDS Fired Heater B-301 Pre-reformer Fired Heater E-101 HDS Interchanger E-301 AGHR Interchanger E-401 HT Saturator Water Heater E-402 NH3 Syngas Saturator Water Heater E-403 NH3 Syngas Cooler E-404 MeOH Syngas Saturator Water Heater E-405 MeOH Syngas Cooler J-201 Cool Saturator Water Pump J-202 Hot Saturator Water Pump K-101 Natural Gas Compressor R-101 HDS R-102A H2S Absorber 1 R-102B H2S Absorber 2 R-301 Pre-reformer R-302 AGHR R-303 ATR R-401 Isothermal Shift T-201 Saturator V-401 NH3 Syngas KO Pot V-402 MeOH Syngas KO Pot X-501 CO2 Removal X-502 Cold Box
  • 10. To Saturator Natural Gas H2 Recycle from CO2 Removal S-414 S-101 K-101 B-101 E-101 S-107 R-101 R-102A R-102B Integration Flowsheet 1: Feed Preparation (HDS)
  • 11. S-107 S-203S-201 MP Steam To FXC Water from E-401 To E-401 Mixed Feed to Reformer Process Condensate To E-402 J-201 J-202 From HDS S-202 T-201 Integration Flowsheet 2: Feed Preparation (Saturator Circuit)
  • 12. Fuel Gas O2 from ASU R-301 R-302 R-303 E-301 S-203 Mixed Gas from Saturator S-301 Reform Gas to E-401 S-307 S-308 S-302 B-301 S-203 From FC S-304 S-305 Integration Flowsheet 3: Pre-reformer, AGHR, ATR
  • 13. From FCV Water to Saturator E-403 To CO2 Removal S-401 S-308 E-402 S-408 V-401 From 201 S-415 E-401 S-404 S-405 Reform Gas from E-301 From J-202 R-301 From Co2 Removal E-405E-404 MeOH Syngas S-420 V-402 S-410 Integration Flowsheet 4: Isothermal Shift
  • 15. Name S-101 S-107 S-201 S-202 S-203 S-301 S-302 Temperature (C) 27 154.3 223.8 350 260.3 400 504.2 Pressure (bar) 22 52.2 51.7 55 51.7 51.1 50.3 Molar Flow (kgmole/h) 10360 10587.3 22437.5 9317.5 31755 31755 31755 Mass Flow (kg/h) 172113 172942 386425 167856 554281 554281 554281 Hydrogen 0.000% 2.005% 0.946% 0.000% 0.668% 0.668% 0.668% CO 0.000% 0.121% 0.057% 0.000% 0.040% 0.040% 0.040% CO2 0.640% 0.626% 0.296% 0.000% 0.209% 0.209% 0.209% Methane 96.570% 94.514% 44.597% 0.000% 31.512% 31.512% 31.512% Ethane 2.710% 2.652% 1.251% 0.000% 0.884% 0.884% 0.884% Propane 0.010% 0.010% 0.005% 0.000% 0.003% 0.003% 0.003% Nitrogen 0.070% 0.071% 0.033% 0.000% 0.024% 0.024% 0.024% Methanol 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% H2O 0.000% 0.000% 52.815% 100.000% 66.660% 66.660% 66.660% Oxygen 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% Argon 0.000% 0.002% 0.001% 0.000% 0.001% 0.001% 0.001% Stream Component: Material Balances Table 1
  • 16. S-303 S-304 S-305 S-307 S-308 S-401 S-402 S-404 S-405 450 40 1050 580 460.5 220 220 220 252.7 49.3 45.8 42.8 42.3 41.9 41.3 41.3 41.3 39.8 32843.6 4913.8 52509.3 52444 52444 52444 21711 4511 26222.4 554281 157338 711619 711619 711619 711619 294600 61210 355809 6.426% 0.000% 45.832% 45.280% 45.280% 45.280% 45.280% 45.280% 56.638% 0.027% 0.000% 14.392% 14.770% 14.770% 14.770% 14.770% 14.770% 3.413% 1.871% 0.000% 5.475% 5.059% 5.059% 5.059% 5.059% 5.059% 16.416% 30.529% 0.000% 0.416% 0.479% 0.479% 0.479% 0.479% 0.479% 0.479% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.023% 0.500% 0.061% 0.061% 0.061% 0.061% 0.061% 0.061% 0.061% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 61.124% 0.000% 33.777% 34.304% 34.304% 34.304% 34.304% 34.304% 22.946% 0.000% 99.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.001% 0.500% 0.047% 0.047% 0.047% 0.047% 0.047% 0.047% 0.047% Name Temperature (C) Pressure (bar) Molar Flow (kgmole/h) Mass Flow (kg/h) Hydrogen CO CO2 Methane Ethane Propane Nitrogen Methanol H2O Oxygen Argon Stream Component: Material Balances Table 2
  • 17. S-408 S-410 S-411 S-414 S-415 S-420 S-501 S-502 S-508 S-509 45 45 45 45 220 45 0 45.3 28.8 31.7 38.4 37.9 37.9 37.9 41.3 37.9 50 37.9 37.9 37.9 20253.9 109.8 15563.5 227.2 26222 17378.6 4998.6 832 735.1 18995 247979 400 56732 828 355809 194736 140025 23304 11709 161744 73.328% 93.405% 93.405% 93.405% 45.280% 68.910% 0.000% 0.000% 39.549% 75.001% 4.418% 5.627% 5.627% 5.627% 14.770% 22.316% 0.000% 100.000 % 5.956% 0.000% 21.195% 0.000% 0.000% 0.000% 5.059% 7.594% 0.000% 0.000% 0.000% 0.000% 0.620% 0.790% 0.790% 0.790% 0.479% 0.727% 0.000% 0.000% 16.717% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.079% 0.101% 0.101% 0.101% 0.061% 0.093% 100.000 % 0.000% 36.131% 24.999% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.299% 0.000% 0.000% 0.000% 34.304% 0.287% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.061% 0.078% 0.078% 0.078% 0.047% 0.072% 0.000% 0.000% 1.647% 0.000% Name Temperature (C) Pressure (bar) Molar Flow (kgmole/h) Mass Flow (kg/h) Hydrogen CO CO2 Methane Ethane Propane Nitrogen Methanol H2O Oxygen Argon Stream Component: Material Balances Table 3