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    Feed Gas Pre-Heater Efficiency Calculation and Enhancement of Ammonia Plant

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    Shahadat Awan
    This document discusses improving the efficiency of a feed gas pre-heater in an ammonia plant. It includes the following sections: scope, literature review, process flow diagram (PFD), energy and material balance calculations, efficiency calculations, design of a fired heater, design of an absorber and stripper, comparison of solvents (Benfield vs MDEA), costing analysis, simulation, and conclusions. Replacing the existing Benfield process with MDEA would save the plant around $60 million annually through reduced steam usage and energy for regeneration.

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    © All Rights Reserved
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    Feed Gas Pre-Heater Efficiency Calculation and Enhancement of Ammonia Plant

    Uploaded by

    Shahadat Awan
    32 views10 pages
    This document discusses improving the efficiency of a feed gas pre-heater in an ammonia plant. It includes the following sections: scope, literature review, process flow diagram (PFD), energy and material balance calculations, efficiency calculations, design of a fired heater, design of an absorber and stripper, comparison of solvents (Benfield vs MDEA), costing analysis, simulation, and conclusions. Replacing the existing Benfield process with MDEA would save the plant around $60 million annually through reduced steam usage and energy for regeneration.

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    Project

    Original Title

    Maryam Saeed Group 12

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    This document discusses improving the efficiency of a feed gas pre-heater in an ammonia plant. It includes the following sections: scope, literature review, process flow diagram (PFD), energy and material balance calculations, efficiency calculations, design of a fired heater, design of an absorber and stripper, comparison of solvents (Benfield vs MDEA), costing analysis, simulation, and conclusions. Replacing the existing Benfield process with MDEA would save the plant around $60 million annually through reduced steam usage and energy for regeneration.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    32 views10 pages

    Feed Gas Pre-Heater Efficiency Calculation and Enhancement of Ammonia Plant

    Uploaded by

    Shahadat Awan
    This document discusses improving the efficiency of a feed gas pre-heater in an ammonia plant. It includes the following sections: scope, literature review, process flow diagram (PFD), energy and material balance calculations, efficiency calculations, design of a fired heater, design of an absorber and stripper, comparison of solvents (Benfield vs MDEA), costing analysis, simulation, and conclusions. Replacing the existing Benfield process with MDEA would save the plant around $60 million annually through reduced steam usage and energy for regeneration.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 10

    Feed Gas Pre-heater Efficiency

    Calculation And Enhancement


    Of Ammonia Plant

    Supervisor : Dr Muhammad Bilal Khan Niazi


    Co-supervisor : Engr Nouman Ahmed

    Group Members:
    Daniyal Ashfaq Maryam Saeed Tahir Gillani
    UPTIL NOW
    ▷ Scope
    ▷ Literature review
    ▷ PFD
    ▷ Energy and material balance
    ▷ Efficiency calculations
    Scope Designing
    PFD
    Process Simulation
    Understanding Literature Material Energy
    Review Balance Balance Costing
    Thesis

    Sep Oct Nov Dec Jan Feb Mar Apr 2017-2018

    2
    Steps to design a fired heater
    Acp = Cold
    Now PlaneEnergy
    applying Area balance on the furnace
    =ctc/do
    1) DESIGN
    Required average
    Now calculate OF
    Flux
    density 5000 BTU/hr
    FIRED HEATER
    = 1.9
    ▷ Using Loeb and Evan’s So from graph
    method
    2) Tube=surface
    18712temperature
    BTU/hr ft^2
    = 12.3 MBTU/hr = 0.9
    ▷ TsDesign
    = 600 F specification

    DESIGN
    Find the value of Tg by
    Surface
    3) Assume 2 xarea of tube
    flux density
    graphParameters Specifications
    Tg = Heater
    1300 F Duty 3908962 BTU/hr
    = 10,000 BTU/hr
    Now Efficiency
    compare the value of 80.2%
    P =Fuel
    partial pressure
    Tg Number
    Assume of
    Heating
    exchange tubes
    Value
    factor 23852 BTU/Lb
    F =L 0.5
    = mean beam length
    Excess Air
    PL
    10000/0.5 15%
    With iterations % error can
    = 20,000
    = Furnace tube
    0.256 * 9.5 Dia = 8 in CTC= 16 in
    be reducedof Y-axis and Ts
    Intersection
    = 2.4 Atm
    = 35 ft L = 35.07 ft
    from
    Overall Graph
    graph = Eg
    fromexchange = F0.5
    1300
    factor = 0.5 3
    ABSORBER AND STRIPPER DESIGN
    STRIPPER DESIGN
    Now calculate
    ▷ LFirstly calculate the Lmin for given
    = liquid flow rate kg/hr
    VGas flow
    = vapor rate.
    flow rate kg/hr
    •Design
    pV = density ofstepsvapor same as absorber
    =m9.816
    pLTemperature
    = density = slope of Kequilibrium line
    385
    of liquid
    Gm/Lm =275800
    Pressure slope Pa
    of operating line
    •Design
    CO2 =in3.34 Summary 0.19
    Unknown
    at
    = flooding
    21.29 ˜=21
    0.16
    CO2Diameter = 3.6 m
    out Kgmol/hr
    = 11698 0.001
    HETP = 1.11m
    L = Lmin * 1.2 Area =
    H = 2707347314 Pa
    LNTU = Kgmol/hr
    = 134038
    11439
    Height = 15.5
    = 1238.77 kg/hr ft^2
    =m
    21*1 Area = 10.4 m^2
    Kgmol/hr
    = 524020 Pa = 21 m Diameter = 3.64 m xn
    At 60% flooding So HETP = 1
    = 743 kg/hr ft^2
    xn = 0.019 4
    COMPARISON OF SOLVENTS
    BENFIELD MDEA
    Circulation rate m3/hr 2150 1270

    Additives Piperazine DEA,V2O5


    Steam required t/hr Nil 44

    Heat Required for 167 669


    regeneration Kcal/m3
    of CO2
    Solution cost per one 29.8 6.98
    charge / million
    Activator Nil DEA degrades
    degradation
    Concentration of 40% 28%
    solution

    5
    COSTING
    Cost of existing unit Cost of new unit

    PCE = $185,568 PCE = $155568


    PPC = $445363 PPC = $373363
    Fixed capital = $623508 Fixed capital = $522708
    Working capital = $31175 Working capital = $31175
    Total investment = $654683 Total investment = $553883

    Solvent cost = $0.52/kg Solvent cost = $1.52/kg


    Steam Required = $399740 Steam Required = Nil
    Energy for Energy for
    regeneration = $6600260 regeneration = $1112843

    Total cost = $400million Total cost = $340 million


    6
    How Is Cost Being Reduced?
    Benfield Process Diagram

    First Second Last

    No heat 40 tons of About 4 times


    exchanger steam saved less energy is
    required for per hour. needed for
    MDEA process
    steam regeneration.
    Diagram

    generation.

    7
    SIMULATION

    8
    HAZOP REPORT

    9
    Conclusions:
    Replacing Benfield with MDEA

    Saves about 40tons of steam per


    hour

    Total annual saving are $60 million

    10

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