Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Scribd Logo
Upload

Welcome to Scribd!

  • 199 views

    Effect of Primary Reformer Steam To Carbon Ratio On Ammonia Plant Efficiency

    Uploaded by

    Manish Gautam
    Changing the steam to carbon ratio (S/C ratio) in an ammonia plant's primary reformer impacts the plant's efficiency. Specifically: 1) Increasing the S/C ratio from 3.61 to 3.71 increases fuel requirements, steam generation, and pressure drops, while decreasing synthesis loop purge rates and secondary reformer methane slip. 2) Decreasing the S/C ratio from 3.71 to 3.61 produces the opposite effects. 3) Calculations estimate that decreasing the S/C ratio by 0.1 would save 0.51 Gcal/hr of heat, equating to annual savings of 0.95 crore rupees with India's current energy costs

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd

    Effect of Primary Reformer Steam To Carbon Ratio On Ammonia Plant Efficiency

    Uploaded by

    Manish Gautam
    199 views2 pages
    Changing the steam to carbon ratio (S/C ratio) in an ammonia plant's primary reformer impacts the plant's efficiency. Specifically: 1) Increasing the S/C ratio from 3.61 to 3.71 increases fuel requirements, steam generation, and pressure drops, while decreasing synthesis loop purge rates and secondary reformer methane slip. 2) Decreasing the S/C ratio from 3.71 to 3.61 produces the opposite effects. 3) Calculations estimate that decreasing the S/C ratio by 0.1 would save 0.51 Gcal/hr of heat, equating to annual savings of 0.95 crore rupees with India's current energy costs

    Original Title

    SC calculation

    Copyright

    © © All Rights Reserved

    Available Formats

    DOCX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Changing the steam to carbon ratio (S/C ratio) in an ammonia plant's primary reformer impacts the plant's efficiency. Specifically: 1) Increasing the S/C ratio from 3.61 to 3.71 increases fuel requirements, steam generation, and pressure drops, while decreasing synthesis loop purge rates and secondary reformer methane slip. 2) Decreasing the S/C ratio from 3.71 to 3.61 produces the opposite effects. 3) Calculations estimate that decreasing the S/C ratio by 0.1 would save 0.51 Gcal/hr of heat, equating to annual savings of 0.95 crore rupees with India's current energy costs

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    199 views2 pages

    Effect of Primary Reformer Steam To Carbon Ratio On Ammonia Plant Efficiency

    Uploaded by

    Manish Gautam
    Changing the steam to carbon ratio (S/C ratio) in an ammonia plant's primary reformer impacts the plant's efficiency. Specifically: 1) Increasing the S/C ratio from 3.61 to 3.71 increases fuel requirements, steam generation, and pressure drops, while decreasing synthesis loop purge rates and secondary reformer methane slip. 2) Decreasing the S/C ratio from 3.71 to 3.61 produces the opposite effects. 3) Calculations estimate that decreasing the S/C ratio by 0.1 would save 0.51 Gcal/hr of heat, equating to annual savings of 0.95 crore rupees with India's current energy costs

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 2

    Effect of Primary Reformer Steam to Carbon ratio on Ammonia plant

    Efficiency
    Steam rate in any ammonia plant should be enough to meet certain requirements which are as
    follow

    1) Steam is one of the reactant in the reforming reaction and water shift reaction therefore it
    should be more than stoichiometric requirement.

    Theoretical requirement of S/C

    S/C 1.5 To prevent carbon formation zone in Primary Reformer tube

    S/C 2 To maintain High temperature shift catalyst in proper reduction state

    2) Condensing steam should be enough to provide heat of regeneration in CO2 removal


    system.

    Change occurring for a steady plant operation by changing S/C ratio by 0.1.

      S/C 3.71 3.61


           
    1) Fuel Requirement Increase Decrease
    2) Synthesis loop purge rate Decrease Increase
    3) Steam generation in HP boiler Increase Decrease
    4) Pressure drop through Front End Increase Decrease
    5) Supply of heat of regeneration in No 2 HPC reboiler Decrease Increase

    Calculation for change in specific energy consumption


    Following are the assumptions taken while doing the calculation for change in specific energy
    consumption
    1) PFD data is considered as base case.
    2) Primary Reformer efficiency is constant while changing the S/C
    3) Cost of energy is considered to be 2400 INR/Mkcal.
    4) Approach to Equilibruim for all catalyst reactor is same.

    Inlet steam to Primary Reformer MT/hr 66.68 64.80


    Inlet steam temperature Kg/cm2G 36 36
    Inlet steam temperature O
    C 245 245
    Enthalpy of steam at inlet kcal/kg 671 671
    Outlet pressure Kg/cm2G 30.4 30.4
    Outlet temperature O
    C 761 761
    Enthaply of steam at outlet kcal/kg 970 970
    Heat duty Gcal/hr 20 19
    heat of regeneration kcal/Nm3 1075 1075
    Steam input to No 2 HPC reboiler MT/hr 9.90 10.08
    Enthalpy of steam to No 2 HPC reboiler kcal/kg 667 667
    Steam Saving MT/hr 1.70
    Heat Saving Gcal/hr 0.51
    Secondary Reformer CH4 slip % 1.05 1.11
    Primary Reformer efficiency % 82 82
    Reformer fuel Flow   3635 3569
    Fuel Saving   66.1
    Speicific Energy Consumption (Gcal/MTNH3) Gcal/MT 0.02
    Speicific Energy Consumption (Gcal/MT Urea) Gcal/MT 0.010
    Cost of Energy Rs/Gcal 2400
    RS/MT of
      Urea 25.13
    Yearly Saving Crore 0.95

    If S/C ratio is changed by 0.1 then energy saving of 0.02 Gcal/MT of NH 3 can be achieved which is
    equivalent to INR 0.95 Crore annually with the current energy cost.

    Please note that there is a source of error.


    1) Change in SC ratio will alter the conversion rate and rate kinetics of Methane reforming in Primary
    Reformer which is not considered in the calculation.
    2) Change in SC ratio will alter the conversion rate for water shift reaction which is not considered in
    the calculation.

    You might also like