The document presents a case study on the integration of ammonia and methanol flowsheets to enhance profitability and minimize risks. It includes detailed descriptions of conventional process designs, equipment lists, and a series of integration flowsheets that optimize various stages of production. Additionally, material balance tables provide insight into component flow rates, temperatures, and pressures throughout the processes.

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

3. Conventional Ammonia Plant Flow Sheet

4. Conventional Methanol Plant Flow Sheet

5. Superstructure Block Diagram

6. Process Design Tools

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

14. 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

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