presentation memos

7/29/2019 Presentation Memos

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USE OF SHORTCUT AND SIMULATION TOOLS TO THE

PRELIMINARY DESIGN OF A AMMONIA PRODUCTION PLANT

Project MEMOS

Chemical Process Systems Design Diseo de Procesos Qumicos


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Index

I. Objectives and Methodology

II. Synthesis

III. Analysis

IV. Economic evaluation

V. Highlights

Index


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The Technology Division has requested a preliminary design and economic

evaluation to establish the feasibility ofmanufacturing NH3 in a new facility.

1.- Literature review and quick preliminary screening to select a candidateprocessSynthesisMEMO 1

2.- Determine a preliminary mass and energy balance AnalysisMEMO 2

3.- Determinean economic evaluation of your selected flowsheet EvaluationMEMO 3

The purpose of this initial phase is to establish the economic potential of theprocess and to identify other promising alternatives. Following his study, thegroup reports findings in a oral presentation during the last week of January.

To meet this deadline, please submit your memos by the following dates:

Last week of October: Literature review and Synthesis alternativesFirst week of December: Mass and Energy BalanceThird week January: Economic evaluation

I.Objectives&

Methodology


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- Request to the Design Group from the Chemicals Division of UC Corporation.- Guidelines to Memo #.

- Memo # submission.

+ Grading and Comments to Memo #.

+ Oral Presentation of global project.

I.Objectives&

Methodology


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1. Preliminary Design2. Basic Engineering3. Final Design or

Detailed Engineering

Shortcut Tools Simulation

Linear modelsIdeal thermodynamic

Modular modeEq-Oriented mode

Modular methods Process evaluator

Guthrie, Ulrich, Lang Icarus Process Evaluator (IPE)

Conceptgeneration

Alternativegeneration

Comparison &optimization

ABSTRACTDESCRIPTION

Detaileddescription

Analysis

Evaluation

Analysis

Economic Evaluation

Rigorous Analysis

Costs estimations

Complex models

I.Objectives&

Methodology



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II. Synthesis

II.Synt

hesis

II. Synthesis of Alternatives. MEMO 1


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Ammonia Process Synthesis

Uses: Fertilizers (80%):

Ammonium nitrate. Ammonium salts andUrea

HNO3 production. Explosives Nylon Cryogenic Gas Liquid Refrigerant Cleaning domestic products

Alternatives processes to produce NH3 Raw materials

Three Licenses: Braun ICI Kellog

Ammonia: Haber-Bosch Process characteristics:

- Gas phase direct reaction nitrogen andhydrogen.

- Exothermic reaction.- Slow reaction High activation energy- Pressure effect

II.Synt

hesis


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Product

Steam

Air

Natural Gas

REFORMERCOMPRESSION CONVERSION

Water Water

CO2

Gas stream

SHIFT &

NETHANATION

KELLOG PROCESS

Natural Gas

Air

Water steam

Water

CO2

Product NH3 + (N2+H2+CH4+Ar)

Gas stream (NH3+N2+H2+CH4+Ar)

REFORMADO

CON VAPOR

II.Synt

hesis

Input-Output process diagrams


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III. Analysis

III.Ana

lysis

III. Analysis of a specified NH3 production process

flowsheet. MEMO 2


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Analysis of the preliminary design of NH3 manufacturing NH3 to obtain 1500 mol/ h NH3with > 98% NH3 purity using shortcuttools based on linear mass balances:

Assumptions to simplify and reduce calculations Main characteristics:

Ideal thermodynamic behaviour Unit process calculations Linear equations

Mixer

Separator

Reactor

Flash

Linear Coefficient

-

SplitFraction

Split fraction

Conversion

stoichiometric

coeff.

III.Ana

lysis

III. Analysis


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Design specifications: Raw materials and products

Properties. Antoine equation

Kellog process. NH3 production of 1500 mol/ h with > 98% NH3 purity

Raw materials and products

- [P] = mm Hg

- [T] = K

A B C

Nitrogen 14,93 588,72 -6,60Methane 15,22 897,84 -7,16Argn 15,23 700,51 -5,84Ammonia 16,95 2132,50 -32,98Hydrogen 13,63 164,90 3,19

Antoine eq.

Water 18,31 3826,36 -45,47

III.Analysis


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P: 300-350 psi

CATALYTIC REFORMING

Steam / Hydrocarbon ratio= 6

= 0.935

= 1

= 0.128

= 0.152

Reaction in R2:

= 0.58

= 0.9999

= 1

= 1

= 1

= 0.69

Reaction in R1:

III.Ana

lysis


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SHIFT and METHANATION

Reaction in R3:

Reaction in R4:

Reaction in R5:=1

=1

= 0.584

=0.01). The remaining components by head

F3 Separator: =(1-0.99), Isotherm.=0.73, Isotherm

= 0.85

= 0.955

Separator F1:- Vapor fraction

- Decrease of 2 psig- Water Bottoms Separation of 99%

=0.999F2 Separator:

F4 Separator:Agua

T (F) 100

P (psi) 280

Q (lbmol/hr) 1000

R3

R4

R5

HX2HX3

F1

F2

F3

F4

H4 H5

H6

H7

Agua

CO2T = 100F

T = 750F

T = 675F

T = 690F

T = 400FT = 675F

T =100F

T =100F

P = 250-300 psi

T,P

III.Ana

lysis


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COMPRESSION

Pin / Pout = 260 /4960

F5 Separator: =0.5

F6 Separator: =0

F6 Separator: =0.5

III.Ana

lysis


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AMMONIA SYNTHESIS

R6 conversion reaction:0.5N

2

+ 1.5 H2

NH3

F8 partial condenser:

Tin = 70F; Pin = 4915psi

Partial condenser F9:Tin = 430F; Pin = 4744psi

F10 Separator:Tout = 78.9F; Pout = 364psi

P = 4800 psi; T = 560F

[inerts]< 12%

=0.27

=0.6

=0.37

F9

F8

F10R6

C4

HX4

HX5

M1

M2

SP1

T = 95FP = 4960 psi T = 40F

T =85F

T = 560FP = 4800 psi

T = 920FP = 4750psi

T = 100FP = 4960 psi T = 79F

P = 350psi

T = 79FP = 350psi

T = 79FP= 4600psi

T = 70F

III.Ana

lysis


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Specify split

fraction of key

components

Global Mass

Balance

Sizing

Fixed P and T

P y T

Determine the

coefficients of the

linear modules

Costs

Specifications

and restrictions

Fenske eq.

Kremser eq.

Antoine eq.

Equilibrium eq.

(Bubble anddew point)

T, P

restrictions

General Algorithm for process analysis

III.Ana

lysis


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Flowsheet

Natural Gas

Steam

Air

R1 R2

HX1

R4R3

R5

HX2 HX3

F1 F2

F3

F4

Water

CO2

F5 F6 F7

C3C2

Water

C1

Gas stream

F10

F9

F8

C4

HX5

HX4

M1

M2

Product

Purge

R6

III.Ana

lysis


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Steps

Desulfurization Steam reforming Steam / HC:6/1

CATALYTIC REFORMING

R4R3

R5

HX2 HX3

F1 F2

F3

F4

Water

CO2SHIFT and METHANATION

HT/LT Shift Purification:

CO2 (MEA plant)

Water

Methanation

Natural Gas

Steam

Air

R1 R2

HX1

70% HC

Reformed

Ethane, propane, butane andpentane react completely

Carbonoxides

elimination

PhysicalAbsorption

by MEA

Ni Catalyst

ShiftReactors

III.Ana

lysis


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Steps

3 steps Compression.

Condenaste water elimination Pressure increase

Pin : 350 psi Pout: 4960 psi

COMPRESSION

C1

CONVERSION

Ammonia conversion Liquid ammonia separation

F5 F6 F7

C3C2

Water

C1

Gas stream

F10

F9

F8

C4

HX5

HX4

M1

M2

Product

Purge

R6

60% liquid

NH3

37%liquid

NH3

Fe and RucatalystII

I.Ana

lysis


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Shortcut Tools

Stage 1)

Operation conditions as P, T, split fractions andlinear model coefficients, to each equipment

Stage 2)

Global mass balance solving, obtaining flows, P andT forall process streams.

Steps

Catalytic Reforming Shift and Methanation Compression Conversion

(recycle)

1. Iterations2. Equations system

Equipments: 37

Streams: 56

Components: 13

III.Ana

lysis

Process Analysis: General Algorithm

Specify split fractions of thekey components

Global mass balance

SIZING

P , T specify

P and T

Determine coefficients for linearmodels in each unit: k/n, , ,

COSTS

Specificationsand/or

restrictions

Fenske,

Kremser,Antoine

equations

Equilibrium

equations(Bubble

point, dew

point)

T, P restrictions


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Results Comparison

Anl

isis

SHORTCUT TOOLS SIMULATION (SMS)

Flow: 143,5 lbmol/hr Purity: 29,9% ammonia

Flow: 62,3 lbmol/hr Purity: 45,6% ammonia

F8 F9 F10

H2 0.995 0.971 0.879

N2 0.993 0.967 0.857

Ar 0.992 0.964 0.846

CH4 0.983 0.932 0.730

NH3 0.600 0.370 0.090

Product Stream Flow: 1365 lbmol/hr Purity: 96,5% ammonia

Flow: 1549 lbmol/hr Purity: 99,3% ammonia

Splitt Fractions

F8 F9 F10

H2 0.999 0.998 0.925

N2 0.999 0.997 0.854

Ar 0.986 0.981 0.575

CH4 0.999 0.993 0.677

NH3 0.575 0.378 0.018

Gas Stream

Q

(lbmol/hr)

Gas Stream Product

Stream

H2

213,195 29,467

N270,844 11,856

Ar 8,109 1,475

CH4

12,785 4,717

NH3 130,338 1317,862

Total 435,27 1365,378

Q

(lbmol/hr)

Gas Stream Product

Stream

H2

14,087 1,140

N2

6,023 1,030

Ar 10,432 7,726

CH4

3,320 1,584

NH3 28,420 1538,395

Total 62,828 1549,874

Mass Balance:

Equipment, Streams, Components, Global.


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Analysis

Energy balance

Enthalpies for Vapor Mixtures

Enthalpies for Liquid Mixtures

Heat Exchange

Reactors

Heat

Exchangers


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III. Economic Evaluation. MEMO 3

IV.Evaluation


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Guthries modular method

1. Equipment Base Cost for basic configurationin 1968 prices (carbon steel material and

basic design): BC

2. Module Factor associated to Base Cost. MF3. Modification of BC by the material and

pressure factors, MPF.

Fp up to 1000psi4. Updated Cost by Updated Factor. UF

Williams Equation

ModuleFactor

BC

MF2 Up to 200.000$

MF4 200.000$ a 400.000$

MF6 400.000$ a 600.000$

MF8 600.000$ a 800.000$

MF10 800.000$ a 1.000.000$

Bare Module Cost (BMC) = BC (UF)(MPF+MF-1)

IV.Evaluation


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Ulrichs modular method

Equipment purchase

price

Pressure Factor

Fp

Factor Base

Modular

Material Factor

FmDesign Factor

Fd

UF

Total Cost =

Cp

Fbm

IV.Evaluation


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Icarus

Data conversion to the

simulator to IPE

Reports

Projection of the

data in ICARUS

Starting

data

Sizing

Projection

data

Additional project

Specifications

Project

economicevaluation

IV.Evaluation


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Total Equipment Costs

Total Costs: Guthrie: 17,4 Mill $ Ulrich: 17,7 Mill $ Icarus: 22,2 Mill $

The contribution of each equipmentgroup are different

Coefficient of Variation CV (%)

EQUIPMENT G-U G-I I-U

FLASH 37,8 81,1 51,1

EXCHANGER 38,5 59,3 87,8

REACTOR 31,4 39,5 66,7

COMPRESSOR 21,6 27,1 47,3

TOTAL 1,3 17,0 15,7

IV.Evaluation


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Pressure Vessels

Pressure < 1000 psi High weight to the pressure Oversizing

IV.Evaluation


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Heat Exchanger

Icarus > Gurthrie > Ulrich

IV.Evaluation


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Reactors

Modular Methods Pressure vessels Icarus

Reactor

Equal sizing

Not possible sizing reactors by Icarus

Introduction of D and L previously hand calculated

Differences in Total Costs

Installation Costs

SIZING

COST STIMATIONS

IV.Evaluation


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Compressors

Higher contribution in modular methods. Lower differences

G-U: 21,6% G-I: 27,1% U-I: 47,3%

IV.Evaluation


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GLOBAL COST ESTIMATES: Costs related to the process

CAPITAL INVESTMENT or CAPITAL COST (Inversion de Capital). []Fixed Capital (Capital Fijo o Inmovilizado)

Working Capital (Capital Circulante)

Startup Cost (Coste de Arranque)

MANUFACTURING COSTS (Costes de fabricacion). [/t]Direct Costs (Costes de Fabricacin Directos)

Fixed Costs (Costes de Fabricacin Fijos):

General Expenses (Gastos Generales):.

IV.Evaluation

Cost estimates


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Economic Assessment

DiferentialCash Flow

NPV and IRR Intangible aspects

Payback Period -PBP

Combined Analysis

Environmental Assessment

Technical Assessment

10 years

3-10 years

Profitability Measures

IV.Evaluation


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Highlights

IV.Highlights

SHOW and EXPLAIN- Tools used- Assumptions made

- Problems encountered- Results obtained

REMEMBER

- Open-ended project

- Reasoning solutions

IN A

- Applied professional engineering

- Creativity

- Working Group

- Decision making

.. CONTEXT

DONT FORGET- Discussion of results

- Recommendations on the viability of the process

- Other recommendations

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