MATERIAL BALANCE

Prepared by : Santunu Pathy(chemical engineering)

Aim for the production of BaCO3 is 100 tons/day

Rawmaterial required: Product produced :

Barytes = 6211.2243953587 (purity) = 0.93772977 Kg/hr BaCO3 = 100 tons/day
Coke = 985.34578402367 (purity) = 0.80 Kg/hr
Sulfur = 15.71136 tons/day
CaCO3 = 259.092206777 Kg/hr Gypsum = 10.6953262957544 tons/day
MEA = 965.79233224682 Kg/hr CO2 = 28.3299084125734 tons/day

MATERIAL BALANCE FOR DRYER

Basis:
required product = 100 tons/day
losses = 0.2% 0.002

product outlet = 100.2 tons/day

outlet moisture = 0.10%
product quality = 98.50% BaCO3
dryer capacity = 1800 Kg/hr WATER
product flow rate = 4175 Kg/hr
dryer gas flow rate = 14000 Kg/hr

stream1= feed inlet product composition: dryer entry moisture = 25%

stream2= product outlet BaCO3 98.50% PBF entry moisture = 40%
stream3= hot gas in H2O 0.01% RVF entry moisture = 55%
stream4= hot gas out SrCO3 0.01% setteling entry water content = 86%
dryer outlet gas analaysis Fe2O3 0.02%
dryer outlet gas analaysis CaCO3 0.001%
CO2 0.02 SiO2 0.001%
O2 0.175 BaS 1%
 moisture 0.053 others 0.46%
N2 0.752 100.00%
BaCO3 0.01
C + O2 = CO2
12 32 44
490 673.75
0.035 0.048125

stream1 stream 2 stream 3

components molecular weight Wt% Kg/hr Mols/hr Wt% Kg/hr Mols/hr Wt% Kg/hr Mols/hr
BaCO3 197 98.50% 4112.375 20.875 73.5100% 4112.375 20.875 0 0 0
H2O 18 0.01% 0.4175 0.02319444 25% 1398.57672426 77.6987069030669 0 0 0
SrCO3 147 0.01% 0.4175 0.00284014 0.01% 0.4175 0.00284013605442 0 0 0
Fe2O3 100 0.02% 0.835 0.00835 0.02% 0.835 0.00835 0 0 0
CaCO3 100 0.001% 0.04175 0.0004175 0.001% 0.04175 0.0004175 0 0 0
SiO2 70 0.001% 0.04175 0.00059643 0.001% 0.04175 0.00059642857143 0 0 0
BaS 169 1% 41.75 0.24704142 1% 41.75 0.24704142011834 0 0 0
others 0.46% 19.1215 0.46% 19.1215 0 0 0
CO2 44 0 0 0 0 0 0 0.014 196 4.454545
O2 32 0 0 0 0 0 0 0.21 2940 32
N2 28 0 0 0 0 0 0 0.776 10864 500
Total 905 1 4175 21.1574399 1 5573.15922426 98.8329523878111 1 14000 536.4545

MATERIAL BALANCE FOR CARBONATION

 BaS + H2O + CO2 = BaCO3 + H2S
169 18 44 197 34

SrO2 + CO2 = SrCO3 + 0.5 O2

108 44 136 16

STREAM-1: BaS liquor inlet 32445.1061 33667.5461

STREAM-2: CO2 inlet 1102.2
STREAM-3: Acid gas outlet 1222.44
STREAM-4: BaSO3 slurry outlet 32565.3461 33667.5461

liquor inlet concentration = 0.1096142197017

BaCO3 outlet concentration = 0.1251

moisture in the water gas= 0.08 8.00%

MB:
2+4 33667.546
1+3 33667.546

WB:
2+4 28975.264
1+3+reaction 28975.264
 0.230273224043716 0.76972677596
streams 1 2 3
component molecular weight wt% Kg/hr mols/hr wt% Kg/hr mols/hr wt% Kg/hr mols/hr
BaS 169 1.000% 41.75 0.24704142 0 0 0 0 0 0
CO2 44 0 0 0 1 1102.2 25.05 0.150273224043716 183.7 4.175
H2S 34 0 0 0 0 0 0 0.769726775956284 709.75 20.875
BaCO3 197 12.510% 4112.375 20.875 0 0 0 0 0 0
H2O 18 86% 28270.5236 1570.58464 0 0 0 0.08 328.99 18.27722
SrCO3 148 0.010% 0.4175 0.00282095 0 0 0 0 0 0
Fe2O3 160 0.020% 0.835 0.00521875 0 0 0 0 0 0
CaCO3 100 0.001% 0.04175 0.0004175 0 0 0 0 0 0
SiO2 60 0.001% 0.04175 0.00069583 0 0 0 0 0 0
OTHERS 0.458% 19.1215 0 0 0 0 0 0 0
TOTAL 1 32445.1061 1591.71584 1 1102.2 25.05 1 1222.44 43.32722

BaS + H2O + CO2 = BaCO3 + H2S + BaS + CO2

169 18 44 197 34 169 44
3527.875 375.75 918.5 4112.375 709.75 41.75 183.7

CONVERSION 0 =.9883041 98.83%

EXCESS USED FOR GOOD CONVERSION = 20% = 0.2
Actual CO2 used = 1102.2

MATERIAL BALANCE FOR CLAUS PLANT

WB:
1+12+reaction 704.74
 3+10+11 704.74

MB:
1+12 2812.916
3+10+11 2812.916

Stream1 acid gas inlet stream7 rest gas for LB-2 n condenser-2
stream2 acid gas with out moisture stream8 stream to catalytic process
stream3 condensed water stream9 sulpher recovery-3
stream4 rest gas for LB n condenser stream10 flue gas to chimini
stream5 sulpher recovery-1 stream11 total sulpher recovery
stream6 sulpher recovery-2

Streams 1 2 3
components Mol. Wt. wt% Kg/hr mols/hr wt% Kg/hr mols/hr wt% Kg/hr
H2S 34 0.76972678 709.75 20.875 0.79439252336 709.75 20.875 0 0
CO2 44 0.15027322 183.7 4.175 0.20560747664 183.7 4.175 0 0
H2O 18 0.08 328.99 18.277222 0 0 0 1 328.99
N2 28 0 0 0 0 0 0 0 0
O2 32 0 0 0 0 0 0 0 0
S 32 0 0 0 0 0 0 0 0
Total 1 1222.44 43.327222 1 893.45 25.05 1 328.99
SO2 64 0 0 0 0 0 0 0 0

2483.92619047619
2483.92619047619

3H2S + 1.5 O2 = 0.5 S6 + 3H2O

102 48 96 54
considering 60% reaction in main burner 709.75 334 668 375.75
MB 425.85 200.4 400.8 225.45
LB-1 141.95 66.8 133.6 75.15
 LB-2 127.755 60.12 120.24 67.635
CC 14.195 6.68 13.36 7.515

conversion in MB = 60% 2H2S + SO2 =

Conversion in LB-1 = 20% 68 64
Conversion in LB-2 = 18%
conversion in Catalytic chamber = 2%
MATERIAL BALANCE FOR LEACHING PLANT

M.B.: 3+4
1+2

W.B.: 3+4
1+2

leac liq g

Streams 1 2 3
components MOL WT WT% Kg/hr mols/hr WT% Kg/hr mols/hr WT% Kg/hr
BaS 169 0.10961422 3569.625 21.122041 18% 180 1.06508875739645 0.76284847337 3749.625
BaCO3 197 0 0 0 0 0 0 0 0
H2O 18 0.88975758 28975.2636 1609.7369 20% 200 11.1111111111111 0 0
SrCO3 148 1.282E-05 0.4175 0.0028209 2.00% 20 0.135135135135135 0.00415387104 20.4175
Fe2O3 160 2.5641E-05 0.835 0.0052188 2.00% 20 0.125 0.00423881 20.835
CaCO3 100 1.282E-06 0.04175 0.0004175 2.00% 20 0.2 0.00407742598 20.04175
SiO2 60 1.282E-06 0.04175 0.0006958 19% 190 3.16666666666667 0.0386633487 190.0418
BaSO4 233 0 0 0 25.00% 250 1.07296137339056 0.05086165106 250
Coke 0 0 0 12% 120 120 0.02441359251 120
waste 0.00058717 19.1215 0 0.34435349397 525.212123909024 0.11074282735 544.3336
total 1 32565.3461 1630.8681 114% 1525.21212390902 136.8759630437 1 4915.295
< total amt will be taken as the bottom due to the composition is

waste flow rate is consider to be = 1000 kg/hr 0.04750593824228 34290.56

 actual waste flow rate = 1525.21212
composition is in dry basis so water is not considered 34090.56
water in waste = 20%
BaSO4 in waste = 25%
BaS in waste = 18% 2BaSO4 + 5C + 0.5O2 = 2BaS +
coke = 12% 466 60 16 338
SrCO3 in waste = 2% 5169.60133136095 665.613905325444 3749.625
Fe2O3 in waste = 2%
CaCO3 in waste = 2% 5419.60133136095 785.613905325444 3749.625
SiO2 in waste = 19% for kiln conversion = 0.95387114573
100%

MATERIAL BALANCE FOR KILN SECTION

flue gas at the outlet = 6990.6218 Kg/Hr

Density of the flue gas = 1.4148 Kg/m3(As per FGD design)

Flue gas flow rate = 8548.0462 Nm3/Hr

M.B.: 2 11906.91643166
1+3 11906.91643166

W.B. 2 30
1+3 30

Streams 1 2 3
components mol wt. WT% Kg/hr mols/hr WT% Kg/hr mols/hr WT% Kg/hr mols/hr
 BaS 169 0.762693306004 3749.625 22.18713 0 0 0 0.002145731869427 15 0.08876
Al2O3 102 0 0 0 0 0 0 0 0 0
SrCO3 148 0.004153026123 20.4175 0.1379561 0.001715 20.4175 0.137956081081 0 0 0
Fe2O3 160 0.004237947803 20.835 0.1302188 0.002625 31.2525 0.195328125 0 0 0
CaCO3 100 0.00407659661 20.04175 0.2004175 0.001683 20.04175 0.2004175 0 0 0
SiO2 60 0.038655484371 190.04175 3.1673625 0.023941 285.062625 4.75104375 0 0 0
H2O 18 0 0 0 0.00252 30 1.666666666667 0.004291463738853 30 1.66667
BaSO4 233 0.050851305531 250 1.0729614 0.489165 5824.45002 24.99763957236 0 0 0
coke 12 0.024408626655 120 10 0.082754 985.345784 82.11214866864 0 0 0
FO 0 0 0 0 0.020576 245 0 0 0 0
CO2 44 0 0 0 0 0 0 0.452738554715909 3164.9240138 71.9301
SO2 64 0 0 0 0 0 0 0.02635578809844 184.24334704 2.8788
CO 28 0 0 0 0 0 0 0.004461154309474 31.186242604 1.11379
O2 32 0 0 0 0.0783819 933.287198 29.16522493682 0.003773720096079 26.38065 0.8244
N2 28 0 0 0 0.2948654 3510.937554 125.3906269393 0.50223537345512 3510.9375543 125.391
H2 2 0 0 0 0 0 0 0.003855164925403 26.95 13.475
waste 0.1107203016804 544.33362 0.0016059 19.1215 0.000143048791295 1 0
total 1.00 4916.29462 36.8960464 1.00 11906.9164317 268.6170522398 1.00 6990.6218078 217.368

2BaSO4 + 5C + 0.5O2 = 2BaS + 4CO2 + CO + unreacted BaSO4

466 60 16 338 176 28 233
5190.2818 668.27663 178.207100592 3764.625 1960.27810650888 311.862426036

8101.01803046721 5440.2818 788.27663 178.207100592 3764.625 1960.27810650888 311.862426036 250

8101.01803046721
Fuel oil flow rate = 250 Lit/hr = 245000 245 kg/hr
19.706915680473 coke flow rate = 985.345784024 Kg/Hr
for kiln conversion = 0.95404649815
S.G. of fuel oil = 0.98
Purity of BaSO4 = 0.93772976947 94%
Baryte flow rate = 6211.22439536 Kg/Hr 5827.05617973373
Sulphur in coke= 0.03 3%
Purity of coke = 0.80 80%
ash with coke= 0.09 9%
water with coke = 0.02 2% Carbon in the FO
V.M. in coke = 0.06 6%
1 100%
water added in coke = 30 Kg/hr Sulphur in fuel n coke = 39.3603735207 Kg/Hr C +
BaS in flue gas = 15 Kg/Hr 12
Extra BaSO4 required for other reactions = 384.168216 208.25
Actal BaSO4 required = 5824.4500203587
H2S in gas stream = 0
S + O2 = SO2
32 32 64
For controling CO emission 39.3603735207101 39.3603735207101 78.7207470414
CO + 0.5 O2 = CO2 +
28 16 44 BaSO4 + Fe2O3 = BaO.Fe2O3 + SO2 +
311.8624260355 178.207101 490.069527 233 160 313 64
For conversion= 90% 280.67618343195 160.386391 441.062574 15.170484375 10.4175 20.379234375 4.167

BaSO4 + Al2O3 = BaO.Al2O3 + SO2 +

233 102 255 64
0 0 0 0

BaSO4 + SiO2 = BaSiO3 + SO2 +

233 60 213 64
368.99773125 95.020875 337.32410625 101.3556

3BaSO4 + Fe2O3 + Al2O3 + SiO2 = BaO.Fe2O3 + BaO.Al2O3 + BaSiO3 + 4SO2 +

699 160 102 60 313 255 213 256

NOTE: Hence it can be said that for the reaction only 4444.2248 Kg/Hr air required, but for the good combustion and maintaining the temperature we are providing s

MATERIAL BALANCE FOR FGD SECTION

STREAMS NAME
1 FLUE GAS INLET
2 FLUE GAS OUTLET
3 BaS LIQUOR OUTLET
4 WATER INLET
gas flow rate to the FGD section 4929.91665 m3/hr
gas density = 1.418 Kg/m3 M.B. 1+4 7327.06131205
gas flow rate = 6990.62181 Kg/hr 2+3 7327.06131205
dust flow rate = 15 Kg/hr
dust composition W.B. 1+4 93.2731944397
BaSO4 = 82% 2+3+WATER IN GYPSUM 93.2731944397
BaS = 5%
acid soluble = 6%
 coke = 4%
others = 3%
total = 100%
1 2 3
components mol wt. WT% Kg/hr mols/hr WT% Kg/hr mols/hr WT% Kg/hr mols/hr
Dust 169 0.002146038858 15 0 0 0 0 0.032563489341626 15 0.08876
CaCO3 100 0 0 0 0 0 0 0 0 0
Gypsum 172 0 0 0 0 0 0 0.967436510658374 445.63859566 2.59092
H2O 18 0.0042920777154 30 1.66666667 0 0 0 0 0 0
CO2 44 0.4528033276846 3164.92401 71.9300912 0.4775303 3278.92458479 74.5210132906497 0 0 0
SO2 64 0.0263595588015 184.243347 2.8788023 0.0026833 18.4243347041 0.287880229752 0 0 0
CO 28 0.0044617925635 31.1862426 1.1137944 0.0045418 31.1862426036 1.113794378698 0 0 0
O2 32 0.0037742599994 26.38065 0.8243953 0 0 0 0 0 0
N2 28 0.5023072278969 3510.93755 125.39063 0.5113198 3510.9375543 125.3906269393 0 0 0
H2 2 0.003855716481 26.95 13.475 0.0039249 26.95 13.475 0 0 0
total 1 6989.62181 217.27938 1 6866.4227164 214.7883148384 1 460.638595656 2.67968

CaCO3 + SO2 = CaSO3 + CO2

CaSO3 + 0.5 O2 = CaSO4
2H2O + CaCO3 + SO2 + 0.5 O2 = CaSO4.2H2O+ CO2 7327.061
36 100 64 16 172 44 7327.061
103.6368827108 287.88023 184.243347 46.060837 495.153995174 126.667301090976
2H2O + CaCO3 + SO2 + 0.5 O2 = CaSO4.2H2O + CO2
36 100 64 16 172 44
for conversion = 90% 93.2731944 259.092207 165.81901 41.4547530843 445.638595656435 114.000570981879
103.636883 287.88023 184.24335 46.0608367604 495.153995173817 126.667301090976

MATERIAL BALANCE FOR CO2 SECTION

M.B.: 1+2+5+8 16305.286362963
3+6+9+10 16305.286362963

W.B. 1+2+5+8 965.79233224682

3+6+9+10 965.79233224682

Note: since we are maintaining the damper opening to the chiminiat the FGD top, for that we may consider the outlet gas going to be = 60%
Gas flow rate = 2746.5690865583

STREAMS 1 2 3
COMPONENTS MOL.WT. WT% Kg/hr mols/hr WT% Kg/hr mols/hr WT% Kg/hr mols/hr
MEA 61 0 0 0 0 0 0 0 0 0
NAOH 106 0 0 0 1 4.606083676 0.043453619585 0 0 0
H2O 18 0 0 0 0 0 0 0 0 0
NaHSO3 104 0 0 0 0 0 0 1 11.9758175577 0.115152
CO2 44 0.4775302541393 1311.56983 29.8084053 0 0 0 0 0 0
SO2 64 0.0026832508666 7.36973388 0.11515209 0 0 0 0 0 0
CO 28 0.0045418471731 12 0.44551775 0 0 0 0 0 0
O2 32 0 0 0 0 0 0 0 0 0
N2 28 0.5113197511007 1404.37502 50.1562508 0 0 0 0 0 0
H2 2 0.0039248967203 10.78 5.39 0 0 0 0 0 0
waste 0 0 0 0 0 0 0 0 0
total 1 2746.56909 1 4.60608367604 1 11.9758175577 0.115152
2751.17517023428
2751.17517023428
 NaOH + SO2 = NaHSO3
40 64 104
4.60608368 7.3697339 11.9758175577

2H2O + MEA + CO2 = H3O+ + MEACOO- + OH-

36 61 44 19 105 17
1073.1025913854 1818.31272 1311.56983 566.3597 3129.88255821 506.742890376418

for conversion = 90% 965.79233224682 1636.48145 1180.41285 509.72373 2816.89430239 456.068601338776

Inlet concentration of MEA = 13%

MEA required = 12588.318860482 Kg/Hr

NOTE: THE STREAM : 8 IS NOT CONSIDERED, BECAUSE IT IS A MATERIAL BALANCE AND ENERGY CALCULATIONS ARE NOT INCLUDED IN IT.
M.B. 9+3 46445.106
 8+6+4+1+10 46445.106

W.B. 9 28270.523581
4+6+8+10 28270.106081

stream 4 stream 5 stream 6 stream 7 stream 8

Wt% Kg/hr Mols/hr Wt% Kg/hr Mols/hr Wt% Kg/hr Mols/hr Wt% Kg/hr Mols/hr Wt% Kg/hr Mols/hr Wt%
0 0 0 58.5100% 4112.375 20.875 0 0 0 43.5100% 4112.375 20.875 0 0 0 12.510%
0.0998685 1398.15922426 77.6755125 40% 2811.3998 156.1888756 1 1412.823036 78.490169 55% 5198.36 288.797754 1 2387 132.609 86.000%
0 0 0 0.01% 0.4175 0.0028401361 0 0 0 0.01% 0.4175 0.00284014 0 0 0 0.010%
0 0 0 0.02% 0.835 0.00835 0 0 0 0.02% 0.835 0.00835 0 0 0 0.020%
0 0 0 0.001% 0.04175 0.0004175 0 0 0 0.001% 0.04175 0.0004175 0 0 0 0.001%
0 0 0 0.001% 0.04175 0.0005964286 0 0 0 0.001% 0.04175 0.00059643 0 0 0 0.001%
0 0 0 1% 41.75 0.2470414201 0 0 0 1% 41.75 0.24704142 0 0 0 1.000%
0 0 0 0.46% 19.1215 0 0 0 0 0.46% 19.1215 0 0 0 0 0.458%
0.048125 673.75 15.3125 0 0 0 0 0 0 0 0 0 0 0 0 0%
0.175 2450 76.5625 0 0 0 0 0 0 0 0 0 0 0 0 0%
0.776875 10876.25 388.4375 0 0 0 0 0 0 0 0 0 0 0 0 0%
1 15398.1592243 557.988012 100.00% 6985.9823 177.32312108 1 1412.823036 78.490169 100% 9372.942 309.932 1 2387 132.609 100%
 4
wt% Kg/hr mols/hr
0.1096142 3569.625 21.1220414
0 0 0
0 0 0
0 0 0
0.8897576 28975.2635811 1609.73687
1.282E-05 0.4175 0.00282095
2.564E-05 0.835 0.00521875
1.282E-06 0.04175 0.0004175
1.282E-06 0.04175 0.00069583
0.0005872 19.1215 0
1 32565.3460811 1630.86806

8.33333333333
7.5
 12 4 5 6 7
mols/hr wt% Kg/hr mols/hr wt% Kg/hr mols/hr wt% Kg/hr mols/hr wt% Kg/hr mols/hr wt% Kg/hr mols/hr
0 0 0 0 0.1362856 283.9 8.35 0 0 0 0 0 0 0.07281 141.95 4.175
0 0 0 0 0.0881848 183.7 4.175 0 0 0 0 0 0 0.09423 183.7 4.175
18.277222 0 0 0 0.1082268 225.45 12.525 0 0 0 0 0 0 0.15419 300.6 16.7
0 0.79 1256.47619 44.8741497 0.6031685 1256.4761905 44.8741497 0 0 0 0 0 0 0.6445 1256.48 44.87415
0 0.21 334 10.4375 0.0641344 133.6 4.175 0 0 0 0 0 0 0.03426 66.8 2.0875
0 0 0 0 0 0 0 1 400.8 12.525 1 133.6 4.175 0 0 0
18.277222 1 1590.47619 55.3116497 1 2083.1261905 74.0991497 1 400.8 12.525 1 133.6 4.175 1 1949.53
0 0 0 0 0.0855125 178.13333333 2.78333333 0 0 0 0 0 0 0.04569 89.0667 1.3916667

1949.53
1949.53

3 H2S + 1.5 O2 = 2H2S + SO2 + H2O

102 48 68 64 18
709.75 445.33333
425.85 267.2
141.95 89.066667
 127.755 80.16
14.195 8.9066667

0.5 S6 + 2H2O
96 36

34090.558
34090.558

29175.264
29175.264

leac liq gpl = 0.12235107971

4
mols/hr WT% Kg/hr mols/hr
22.18713 0 0 0
0 0 0 0
0 1 29175.2636 1620.84798
0.1379561 0 0 0
0.1302188 0 0 0
0.2004175 0 0 0
3.1673625 0 0 0
1.0729614 0 0 0
0 0
0 0
26.896046 1 29175.2636 1620.84798
e composition is given in dry basis
4CO2 + CO + unreacted BaSO4 + unburnt coke
176 28 233 12

250 120
 11906.9164317
11906.9164317

0.00

unreacted BaSO4 + O2 + unburnt coke

32 12

0 120

FO composition :
C= 85%
H2= 11%
S= 4%

100%

Carbon in the FO for increasing the temperature inside the kiln:

 O2 = CO2
32 44
555.33333 763.583333333

0.5 O2
16
1.04175

0.5 O2
16
0

0.5 O2
16
25.3389

1.5 O2
48

we are providing sufficient air flow.

 4
WT% Kg/hr mols/hr
0 0 0
0.767818 259.09220678 2.5909221
0 0 0
0.1875097 63.2731944397 3.51517747
0 0 0
0 0 0
0 0 0
0.044672 15.0741030843 0.4710657
0 0 0
0 0 0
1 337.439504301 6.5771653
 4 5 6 7 8
WT% Kg/hr mols/hr WT% Kg/hr mols/hr WT% Kg/hr mols/hr WT% Kg/hr mols/hr WT% Kg/hr mols/hr WT%
0 0 0 0.1207369 1636.481 26.82756478 0 0 0 0.191176 2816.89 46.178595 0
0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0.07125457 965.79233 53.655129569 0 0 0 14734.524 965.7923 53.6551296 0
0 0 0 0 0 0 0 0 0 0 0 0 0
0.478815 1311.56983392 29.8084053 0 0 0 0.08414044 131.1569834 2.9808405 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 0
0.0045541 12 0.44551775 0 0 0 0.0080027 12 0.4455178 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
0.5126954 1404.37502172 50.1562508 0 0 0 0.90094123 1404.375022 50.156251 0 0 0 0
0.0039355 10.78 5.39 0 0 0 0.00691564 10.78 5.39 0 0 0 0
0 0 0 0.80800853 10951.837 0 0 0 0 0.7432773 10951.84 0 0
1 2739.19935268 85.8001738 1 13554.111 80.482694354 1 1558.786502 14735.458 14734.52 1
16293.310545 14734.524
16293.310545 14734.524
stream 9 stream 10
Kg/hr Mols/hr Wt% Kg/hr Mols/hr
4112.375 20.875 0 0 0
28270.52358 1570.585 1 23072.164 1281.787
0.4175 0.00284 0 0 0
0.835 0.00835 0 0 0
0.04175 0.000418 0 0 0
0.04175 0.000596 0 0 0
41.75 0.247041 0 0 0
19.1215 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
32445.10608 1591.719 1 23072.164 1281.787
 8 9 10 11
wt% Kg/hr mols/hr wt% Kg/hr mols/hr wt% Kg/hr mols/hr wt% Kg/hr mols/hr
0.007759857 14.195 0.4175 0 0 0 0 0 0 0 0 0
0.100421684 183.7 4.175 0 0 0 0.10042 183.7 4.175 0 0 0
0.20129983 368.235 20.4575 0 0 0 0.20541 375.75 20.88 0 0 0
0.68686693 1256.476 44.87415 0 0 0 0.68687 1256.48 44.87 0 0 0
0.003651698 6.68 0.20875 0 0 0 0 0 0 0 0 0
0 0 0 1 120.24 3.7575 0.0073 13.36 0.418 1 654.64 20.46
1 1829.286 70.1329 1 120.24 3.7575 1 1829.29 70.34 1 654.64 20.46
0.043820371 80.16 1.2525 0 0 0 0.00487 8.90667 0.139 0 0 0
15711.4 Kg/day
15.7114 tons/day
 9 10
Kg/hr mols/hr WT% Kg/hr mols/hr
0 0 0.120737 1636.481 26.8276
0 0 0 0 0
0 0 0.0712546 965.79233 53.65513
0 0 0 0 0
1180.412851 26.82756 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0.8080085 10951.837 0
1180.412851 26.82756 1 13554.111 80.48269
 Waste heat boiler tubes calculation
The gas flow rate at the outlet of the dust chamber is = 8548.04617430679 Nm3/Hr
6990.62180775101 Kg/Hr

By considering excess air to be = 10% 9402.85079173747 Nm3/Hr

7689.68398852611 Kg/Hr
By considering the following tube dimensions we have;
Tube ID = 2.284 Inch 0.0571 M
Tube OD = 2.50 Inch 0.0635 M
Thickness = 3.20 mm 0.0032 M
Tube length = 2500.00 M 2.50 M

The gas composition as per the mail is:

COMPONENTS % V/V Mol Wt. H 800'K H 480'K

CO2 18.00% 44 22806 7416 KJ/KgMol
O2 2.00% 32 15835 5463 KJ/KgMol
N2 70.50% 28 15046 3780 KJ/KgMol
H2O 8.00% 18 18002 6222 KJ/KgMol
SO2 0.50% 64 23721 7831 KJ/KgMol
CO 1.00% 44 15177 5335 KJ/KgMol
NO2 0.00% 46 22136 5450 KJ/KgMol

Assumptions: There is no chemical reaction takes place during the heat exchanging

Design datas available as per the material balance and design.

Hot Side Cold side units

Gas flow rate = 9402.85079173747 Gas flow rate = 9402.85079174 m3/Hr
inlet temperature= 823 inlet temperature= 308 . 'K
out let temperature = 473 out let temperature = 633 . 'K
Density of the gas= 1.4148 Density of the gas= 1.208 Kg/M3
Cp = 1.141 Cp = 1.005 KJ/Kg(inlet temp)
0.02 1.055 KJ/Kg(outlet temp)

Heat content in the output gas = MCp dT

3070875.3008179 KJ/Hr
853020.916893862 W
By calculating the enthalpy according to the mail for the flue gas compounds.

Sensible Heat capacity of hot air at the inlet temperature:

QCO2 = 717426.544264063 KJ/Hr
QO2 76103.8412239444 KJ/Hr
QN2 2913135.16537184 KJ/Hr
QH2O 615243.071828654 KJ/Hr
QSO2 14250.5463977991 KJ/Hr
QCO 26524.1667940593 KJ/Hr
QNO2 0 KJ/Hr
Qtotal = 4362683.33588036 KJ/Hr

Sensible Heat capacity of hot air at the outlet temperature:

QCO2 = 233291.030968267 KJ/Hr
QO2 26255.4647683238 KJ/Hr
QN2 731865.673607973 KJ/Hr
QH2O 212645.394562709 KJ/Hr
QSO2 4704.52463391781 KJ/Hr
QCO 9323.74183608791 KJ/Hr
QNO2 0 KJ/Hr
Qtotal = 1218085.83037728 KJ/Hr

Total heat recovery = (Heat at the hot air inlet) - (Heat at the hot air outlet)
3144597.50550308 KJ/Hr
873499.307084189 W

Let us consider for the ideal case which is the total heat recovered to be supplied to the cooling medium itself and there is no heat loss.

LMTD = 177.206183704371
U= 60 W/M2K(varies from 60-180) 10632.371022

As per the assumption we have,

Qcold air = Qhot air

UA(LMTD) = 853020.916893862 873499.307084
A= 80.2286634945103 M2 82.1547052163 M2

Tube details:
Tube ID = 2.284 Inch 0.0571 M
Tube OD = 2.5 Inch 0.0635 M
Thickness = 3.2 mm 0.0032 M
Tube length = 2500 M 2.5 M

The heat transfer area should be outer surface of the tubes:

heat transfer Area of each tube = 0.49863375 M2
Number of tubes = N= 160.896977981355 164.75961608

The gas velocity = Q/A

22826.0884562228 M/Hr
6.34058012672856 M/Sec