Report Mini Project-Group 1

FACULTY OF CHEMICAL ENGINEERING
PLANT DESIGN & ECONOMICS (CPE 604)
MINI PROJECT DESIGN
PRODUCTION OF METHANOL
GROUP: EH220 5A (GROUP 1)
PREPARED FOR:
IR. NORMADYZAH AHMAD
PREPARED BY:
NO NAME MATRIC NUMBER
1 ZIKRY AKMAL BIN AZHAR 2018272666
2 NUR HAZIAH BINTI HASSAN 2018659858
3 ELYA MAISARAH BINTI MUSA 2018435654
4 HAMIZAH IZZATI BINTI ABU BAKAR 2018438736
5 NURSHAFIQAH BALQIS BINTI MOHD ADZHAR 2018660112

Table of Contents
CHAPTER 1: PROCESS BACKGROUND AND SELECTION ........................................ 1

1.1 INTRODUCTION ............................................................................................................ 1
1.2 LITERATURE REVIEW ON PROCESS DETAILS ...................................................... 2
1.3 PRODUCT SPECIFICATION ......................................................................................... 4
1.4 PROCESS SELECTION .................................................................................................. 9
CHAPTER 2: MARKET DEMAND ANALYSIS .............................................................. 14
2.1 GLOBAL MARKET DEMAND ANALYSIS .............................................................. 14
2.2 MARKET AND DEMAND IN MALAYSIA ............................................................... 16
2.3 SITE SELECTION ......................................................................................................... 17
CHAPTER 3: MATERIAL BALANCE .............................................................................. 24
3.1 BLOCK FLOW DIAGRAM FOR METHANOL PROCESS ....................................... 24
3.2 PROCESS FLOW DIAGRAM FOR METHANOL PROCESS.................................... 25
3.3 MASS BALANCE CALCULATION ............................................................................ 26
CHAPTER 4: ENERGY BALANCE ................................................................................... 45
4.1 ENERGY BALANCE CALCULATION ...................................................................... 45
CHAPTER 5: EQUIPMENT SIZING AND DESIGN ....................................................... 77
CHAPTER 6: CAPITAL COST ESTIMATION ................................................................ 93
6.1 BARE MODULE COST CALCULATION FOR EQUIPMENT.................................. 93
6.2 GRASSROOT .............................................................................................................. 106
6.3 LAND COST................................................................................................................ 107
CHAPTER 7: OPERATING COST ESTIMATION ....................................................... 108
7.1 COST OF UTILITIES .................................................................................................. 108
7.2 COST OF RAW MATERIALS ................................................................................... 112
7.3 COST OF OPERATING LABOUR ............................................................................ 113
7.4 COST OF WASTE TREATMENT.............................................................................. 115
7.5 REVENUE ................................................................................................................... 116
7.6 WORKING CAPITAL ................................................................................................. 116
CHAPTER 8: PROFITABILITY ANALYSIS ................................................................. 118
REFERENCES..................................................................................................................... 125
CHAPTER 1: PROCESS BACKGROUND AND SELECTION
1.1 INTRODUCTION
One of the most significant feedstocks for the chemical, petrochemical and energy
industries is methanol. Easily accessible and widely spread resources, relatively low impurity
levels and low prices make natural gas the main feedstock for the manufacture of methanol.
Growing demand for bulk chemicals leads to an ever-increasing single plant capacity, with
indirect synthesis routes limiting bio-resource production and other sustainable alternatives by
reforming methane. Most methanol is syngas-based. Although most of methanol synthesis is
based on natural gas as feedstock, coal-derived syngas is also used coal, solid feedstocks to
generate 9% of methanol production worldwide. Usually, the existing world-class methanol
plants are in the range of 2,000 to 2,500 metric tonnes per day.
The characteristics of methanol as a liquid fuel at room temperature and the various
sources from which methanol can be extracted make it an attractive alternative fuel for vehicles,
trucks and buses. As the most important alcohol, due to its efficient combustion, ease of
distribution and wide availability around the world, methanol is an economical alternative
transportation fuel. Methanol is a high in octane fuel that in spark ignition engines allows for
very efficient and powerful performance. Methanol optimised engines could provide a 50
percent gain in energy-based performance over a conventional gasoline engine in a light-duty
vehicle.
Methanol is a near ideal cooking fuel. Upon burning, it does not form black smoke
because one carbon atom is preoxygenated. It can only add more oxygen and become carbon
dioxide, which in the process releases heat. Methanol is burned with air in an open flame, it
burns without any by-products in the stove. Methanol can be burned under no pressure in a
properly built stove with a heat delivery per burner comparable to an LPG stove. As one of the
largest derivatives of methanol, Formaldehyde is primarily used for the manufacture of amino
and phenolic resins used in the manufacturing of wood-based items. These are mature markets
for formaldehyde in North America and Western Europe with GDP-related growth, but growth
in Eastern Europe and Asia, especially China, has been above average.
1
1.2 LITERATURE REVIEW ON PROCESS DETAILS
Synthesis gas via CO and CO2 hydrogenation
Most methanol currently comes from the catalytic conversion of synthesis gas (syngas) that is
typically produced by natural gas steam reforming. Syngas, a hydrogen, CO and CO2 mixture,
is converted into methanol at temperatures of 200 -300℃and pressures of 50 - 100 bar on
copper and zinc oxide (Cu / ZnO)-based catalysts.
Three equilibrium reactions can describe the methanol synthesis process:
𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 (1)
𝐶𝑂 + 2𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 (2)
𝐶𝑂2 + 𝐻2 ↔ 𝐶𝑂 + 𝐻2 𝑂 (3)
By directly hydrogenating pure CO2 with H2 with high selectivity on standard Cu / ZnO-based
catalysts, methanol can be developed as an alternative to syngas. In addition to thermodynamic
constraints, due to increased water formation, methanol synthesis from pure CO2 is difficult.
Water is formed both as a by-product of CO2 hydrogenation (Equation (1)) and as a reverse-
water gas shift reaction (reverse of Equation (3)) in the absence of CO. Increased water
formation contributes to kinetic inhibition of the Cu / ZnO catalysts and accelerated
deactivation.
Direct Hydrogenation of CO2
Methanol can be derived from syngas, a combination of CO, CO2 and H2 at 50 - 100 bar and
250-300℃ in industrial applications, using copper and zinc-based catalysts. These catalysts
were also active at 200℃ and are selective towards H2 and CO2 formation. The foundation of
the methanol economy is alternate routes and their use as fuel and chemistry. Methanol can be
produced using common catalysts such as CuO /ZnCO2 / ZnO from CO2 and H2. Studies show
that the equilibrium yield of methanol from CO2 is slightly less than 40 % at 200℃ and 50 bar,
whereas the yield from a CO2 and CO mixture is greater than 80 % at the same conditions.
2
There are also some thermodynamic limits to the development of methanol from pure CO2 and
H2, as shown by Zachopoulos and Heracleous, indicating the removal of water by sorbents. In
fact, through CO2 hydrogenation, water inhibits the reaction rate of methanol formation. In
particular, water generated from reverse water gas shift significantly reduces the rate of
methanol synthesis by eliminating the reaction of methanol formation. Chemical reaction that
involves:
𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 (1)
𝐶𝑂2 + 𝐻2 ↔ 𝐶𝑂 + 𝐻2 𝑂 (2)
Synthesis from Biomass
Mixtures of CO and H2 with syngas are needed to produce methanol and hydrogen. A series of
processes to convert the biomass to gasses that achieved the conditions to proceed to the
methanol reactor. First, pre-treatment of feedstock technique is drying. In order to reduce the
heat required for the gasification and the moisture in product gas, the fuel is dried to 15 % or
at minimum 10%. It roughly consumed 10% of energy content in the feedstock. Two ways that
can be done for drying is either with steam or flue gas. The heat that exists from flue gas in
steam generators is used to dry the incoming biomass After pre-treatment, the conversion by
gasification into bio syngas and eventually synthesising the required products. There are two
ways of gasification:
• Low temperature, 800 – 1000℃ where and CO only contains 50% energy, while the
balances contained in and higher hydrocarbon compounds.
• High temperature, higher temperature than 1200℃, all biomass completely converted
to bio syngas
The biomass in the gasifier is converted into gases of CO, H2O, CO2, H2, CH4. Impurities
coming from the gasoline are also present in the gasses such as nitrogen and sulphur
compounds. The final product depends on the contact form of feedstock gas and process
conditions.
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1.3 PRODUCT SPECIFICATION
Thermodynamics and Kinetics of Methanol
Methanol, also known as methyl alcohol, carbinol, wood alcohol, wood naphtha or wood
spirits, is a chemical compound with chemical formula. It is the simplest alcohol, and is a
light, volatile, colourless, flammable, poisonous liquid with a distinctive odour that is
somewhat milder than ethanol.
Table 1.3.1: Physical Properties of Methanol
Molecular weight 32.04 kg/kmol
Saturated liquid density = AB (1+(1-T/C) D(kg/m3)
A= 54.566, B= 0.233211, C= 513.16, D = 0.208875

with range of T between 181 - 513 K
Boiling point 65 ℃
Melting point -97.7 ℃
Critical temperature 512.6 K
Critical pressure 81 bar abs
Heat of formation -201.3 Mj/kmol
Gibbs free energy -162.62 Mj/kmol
Heat of combustion 726.1 kJ/mole
Heat of vaporization H= A exp (-a Tr)(1- Tr)b
A= 45.3 kJ/mol, a = - 0.31, b = 0.4241, Tc = 512.6 K, Tr= T/ Tc

with range of T between 298 - 477 K
Viscosity log (viscosity) = a (1/T – 1/b)

a = 555.3, b = 260.6
Viscosity: mNs/m2, T: K
4
Heat capacity Cp = a + b(T) + c(T2) + d(T3)
a = 21.152, b = 0.07092, c = 2.59E-05, d = -2.85E-08

Cp: kJ/kmol.K, T: K
Vapour pressure ln (P) = a – b(T + c)
a = 18.5875, b = 3626.55, c = -34.29

P: mmHg, T: K
with range of T between 275.15 - 364.15 K
Table 1.3.2: Chemical Composition Percentage in Methanol
Carbon 37.5 %
Hydrogen 12.5 %
Oxygen 50 %
Table 1.3.3: Chemical Properties of Methanol
Combustion of Burns with pale blue, non-luminous flame and produced carbon
methanol dioxide and steam:
Oxidation of Oxidized with acidified Potassium Dichromate, or Potassium

methanol Permanganate and formed Formaldehyde:
Dehydrogenation of Oxidized by passing its vapor through copper, Cu heated up to 300

methanol ℃ and produced Formaldehyde:
Dehydration of Methanol does not undergo dehydration reaction, thus, react with
methanol sulphuric acid, formed dimethyl sulphate:
5
Methanol was produced from synthesis gas through 𝐶uO/ZnO, CuO/ZnO/Al2O3 or
CuO/ZnO/Cr2O3 as a catalyst. The carbon source for methanol can be either CO2 or CO.
Methanol synthesis takes place through three main reactions:
CO2 + 3H2 ⇌ CH3OH + H2O ∆ 𝐻𝑅 = −49.2 𝑘𝐽/𝑚𝑜𝑙
𝐶𝑂 + 2H2 ⇌ CH3OH ∆ 𝐻𝑅 = −90.8 𝑘𝐽/𝑚𝑜𝑙
CO2 + H2 ⇌ 𝐶𝑂 + H2O ∆ 𝐻𝑅 = 41.6 𝑘𝐽/𝑚𝑜l
The most effective for this are CuO/ZnO -based catalysts. The mechanism is further improved
through the supports and promoters because of its high activity, selectivity and stability. The
literature is separated on which of the above reactions directly leads to synthesizing methanol.
The methanol synthesis kinetic models consist of four categories. The first category (Fig. 1,
Type 1) is assumed in the models of Takagawa et al. (1987), Graaf et al. (1988) and Seidel et
al. (2018). CO and CO2 are assumed to be formed of methanol. They also include reverse water
gas shift (RWGS) reaction rate.
Graaf et al. (1988)

483 - 518 K, 15 - 50 bar;
The second type (Fig.2, Type 2) as assumed by Klier et al. (1982), McNeil et al. (1989) and
Ma et al. (2009), the formation of methanol consists of CO and CO2. In this case, the key
reaction is two hydrogenation reactions, thus the rate reaction of RGWS is not put in the
consideration and CO2 cannot be directly processed to form CO.
6
McNeil et al. (1989)
483 – 513 K, 2.89 – 4.38 MPa;
As for the third type (Fig.3, Type 3), CO2 Hydrogenation reaction as the main reaction towards
methanol formation was considered by Skrzypek et al. (1991), Askgaard et al. (1995), Kubota
et al. (2001) and Vanden Bussche and Froment (1996). Bussche and Froment conducted an
experiment and created a steady state kinetic model by assuming that CO2 the major source in
methanol formation. Their experiment includes the effect of pressure, temperature and gas
composition on production rates of methanol that are beyond their own conditions. Although
CO can be produced by the reaction of RGWS, it's assumed that the reaction did not convert to
methanol directly.
Askgaard et al. (1995)

83-563 K, 1 – 4 bar:
The last group (Fig. 4, Type 4) by Villa et al. (1985) assumed CO as the main carbon source
for the formation of methanol. Based on the scheme, methanol was derived from only CO and
a term for CO2 adsorption was added because CO2 adsorbs were strong at high concentrations.
7
Villa et al. (1985)
Figure 1.1: Four Types of Network Reaction of Methanol Synthesis.
The studies on kinetics may vary to the conditions of reactions such as temperature and
pressure, feed that is used and catalyst. Some of the derive models take CO and H2 as
consideration to derive the rate expressions while other authors take CO2 into account.
Different authors use different basics of rate expression because differences of assumed
limiting conditions and this leads to a variety of kinetic equations. Other than that, some of the
authors study the limit of thermodynamics while others study mass transfer as limitations in
this process.
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1.4 PROCESS SELECTION
There are several ways of producing methanol in industry, and all of the processes have their
own advantages and disadvantages. In this section, we consider three methods of methanol
production which are:
1) Synthesis gas via CO and CO2 hydrogenation

2) Direct CO2 hydrogenation
3) Synthesis from biomass
Selection Criteria
1) Production process
Synthesis gas via CO and CO2 hydrogenation

Generally, in industrial applications, methanol conventionally can be produced from
synthesis gas (syngas) via hydrogenation of CO and CO2 and reversed water-gas shift
reaction. Composition of syngas consists mixture of CO, CO2, H2, CH4, and N2. Suitable
operating conditions for this process are at temperature around 250℃-300℃ with pressure
between 50-100 bar. Copper and zinc-based catalyst commonly used in this process because
it is already active at 200℃ and selective towards the formation of CO2 and H2 (Leonzio,
2018). Methanol production consists of three fundamental steps which are natural gas
reforming to produce syngas, conversion of syngas into crude methanol and distillation of
crude methanol. Chemical reaction involved;
𝐶𝑂 + 2𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 (𝟏)

𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 (𝟐)
𝐶𝑂2 + 𝐻2 ↔ 𝐶𝑂 + 𝐻2 𝑂 (𝟑)
Equation (1) and (2) represent exothermic hydrogenation process of CO and CO2, while
equation (3) represents the water-gas shift (WGS) process activated by catalyst. Methanol
synthesis from syngas is highly exothermic therefore, the reactor vessel is prioritized to be
equipped with the excess heat generated removal.
9
Direct CO2 hydrogenation
This method produced methanol from direct hydrogenation of CO2 (using pure CO2 and H2)
with high selectivity of conventional catalyst (Cu/ZnO/Al2O3). However, the reaction rate is
slower than manufacturing methanol from syngas. Suitable operating conditions for this
process are at temperature 250℃ and pressure of 30 bar. Chemical reaction involved;
𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 (𝟏)

𝐶𝑂2 + 𝐻2 ↔ 𝐶𝑂 + 𝐻2 𝑂 (𝟐)
In terms of thermodynamic limitation, methanol production from pure CO2 is complicated

because water formation was increased. The absence of CO result in production of water by-
product in equation (1) and by reverse water-gas shift reaction in equation (2). Higher
formation of water in equation (1) and (2) leads to kinetic inhibition and caused deactivation
of Zinc/Copper-based catalyst (Harri Nieminen, 2019).
Synthesis from biomass
This process involved synthesis gas from biomass. Biomass will be converted into mixture
of CO, CO2, H2O, H2 and other light hydrocarbons. However, solid biomass needs to undergo
chipping process first (in the pre-treatment section) because necessary fuel size for fluidized
bed gasification is between 0 to 50 mm. Approximately 100kJ/kg of total energy required to
chipping of wet biomass. Then it needs to dry around 10-15% depends on gasifier type using
rotary drum dryer or direct/indirect steam. However, impurities contained in gasification
process of raw synthesis gas. The impurities can affect the catalyst activity in reformer,
reactor and also can cause corrosion in equipment such as heat exchanger, compressor and
turbine (Mphoswa, 2015).
Methanol production consists of several fundamental steps such as feed preparation,

gasification, synthesis gas modification and methanol synthesis and purification. Chemical
reaction involved;
𝐶𝑂 + 2𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 (𝟏)
𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 (𝟐)
𝐶𝑂2 + 𝐻2 ↔ 𝐶𝑂 + 𝐻2 𝑂 (𝟑)
10
2) Raw material availability
Synthesis gas via CO and Direct CO2 hydrogenation Synthesis from biomass
CO2 hydrogenation
Syngas Carbon dioxide, CO2 Solid biomass
Syngas is a mixture of gas Carbon dioxide can be Biomass feedstock can be
consists of CO, CO2, H2, CH4, extracted from flue gas. from forest product waste,
and N2. Syngas can be Method to separate CO2 agricultural residues, organic
produced from gasification conventionally include waste or municipal solid
of many sources such as chemical absorption with waste and others. In
natural gas, coal, biomass monoethanolamine (MEA) Malaysia, minimum of 168
and petroleum distillate solvent, cryogenic million tonnes of biomass
through the process of fractionation and absorption waste produced annually.
thermochemical. using molecular sieves Generally, 94% of biomass
(Mustafa J, 2016). However, feedstock is palm oil waste
the equipment needed is while the remaining
complex, consumed high contribute by agricultural
energy and required high and forest by-products such
cost. as 4% of wood residues, 1%
of rice and 1% of sugarcane
industry waste.
Copper-based Catalyst
Copper-based catalyst prepared by composing metal oxide that contained copper oxide based
on several steps. First, slurry solution containing precipitate of catalyst obtained by
contacting acidic metal salt solution (containing copper) with precipitant solution. Then,
precipitate in slurry solution being washed thus, keeping the suspended state.
Zinc-based Catalyst
This catalyst being produced from by coprecipitation with solution of sodium carbonate from
solution mixture of corresponding metal nitrate, followed by several steps such as ageing in
the mother liquor, drying, calcination and reduction.
11
3) Production yield
CO2 hydrogenation
Equilibrium yield to produce Equilibrium yield to produce Methanol synthesis has
methanol from CO and CO2 methanol from CO2 at similar process with
at condition 200℃ and condition 200℃ and pressure synthesis from natural gas.
pressure 50 bar is greater 50 bar is less than 40%.
than 80%.
4) Operating cost
CO2 hydrogenation
Total operating cost using Methanol from biomass or CO2 is at least 2-3 times more
natural gas stated by expensive that syngas via CO and CO2 hydrogenation due to
PETRONAS in 2017 is utilities needed.
around 1,391 MYR million.
5) Energy efficiency
CO2 hydrogenation
Energy efficiency is 75% and Energy efficiency is 46% and Energy efficiency is 51% and
emits around 0.5 to 1.6 kg emits 0.8 kg CO2/kg emits 0.2 kg CO2/kg
CO2/kg methanol. methanol. methanol.
12
Screening Method
Process
Synthesis Gas via Direct CO2 Synthesis from
CO and CO2 Hydrogenation Biomass
Criteria Hydrogenation
Production process + 0 -
Raw material + + +
availability
Production yield + 0 0
Operating cost + - -
Energy efficiency - 0 0
Total score 3 0 -1
Rank 1 2 3
+ = better than, 0 = same as, - = worse than
Scoring Method
Process
Synthesis Gas via Direct CO2
Criteria Weight (%) CO and CO2 Hydrogenation
Hydrogenation
Production process 25 4 3
Raw material availability 25 3 2
Production yield 20 4 3
Operating cost 20 5 3
Energy efficiency 10 3 4
Total score 100 3.85 2.85
Rank 1 2
1 = much worse than reference, 2 = worse than reference, 3 = same as reference, 4 = better than
reference, 5 = much better than reference
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CHAPTER 2: MARKET DEMAND ANALYSIS
2.1 GLOBAL MARKET DEMAND ANALYSIS
Methanol is a colourless liquid formed basically by natural gas or coal. Methanol is a

commodity product that can be used either directly or further refined to manufacture a broad
range of chemicals that are eventually used in many industries. According to HIS Markit, the
markets for methanol are distorted but formaldehyde synthesis remains the single biggest outlet
for methanol. Development of olefins, methyl tert-butyl ether / methyl tert-amyl ether (MTBE),
gasoline blending materials, and dimethyl ether (DME) are other major outlets. Several distinct
market forces, including fuel costs, fuel use, environmental policies, chemical demand, and
plastic use, affect the trend of methanol demand.
Figure 2.1.1: World Consumption of Methanol in 2019
Based on the chart above, we can see that China dominates the production of methanol.
With respect to both methanol capacity and demand, China has emerged as the dominant
country due to its rapid economic growth. In 2000, China accounted for just 12% of global
methanol demand. Methanol demand for fuel applications has slowed recently, mainly due to
decreasing demand for fuel applications, but the gap has been filled by new developments
within the chemical industry such as light olefins production, as well as expanded demand into
energy applications, such as DME and direct gasoline blending. Global methanol consumption
14
is projected to increase further during 2019. By 2019, Chinese methanol consumption had
increased to 64% of global demand.
Figure 2.1.2: Methanol Demand by End Use
With respect to demand, the industry will face more moderate growth rates as direct
gasoline blending has matured and the feverish pace of MTO projects starts to moderate. With
MTO, overall demand will grow at an average annual growth rate of almost 7% over the next
five years due to becoming the second largest methanol derivative.
15
2.2 MARKET AND DEMAND IN MALAYSIA
Sarawak Petchem is the largest producer of methanol in the Asia-Pacific region and the
fourth largest in the world, with an annual production capacity of 2.4 million tonnes per year.
The plant is expected to come on stream in 2022 and Petroliam Nasional Bhd (Petronas) will
receive 140 million standard cubic feet of natural gas feedstock per day. According to, Petronas
Chemicals chairman, the collaboration of Sarawak Petchem and Petronas Chemicals will be
able to boost the supply of methanol to its Increasing demand in the Asia-Pacific region,
particularly in Southeast Asia, China, South Korea, Taiwan, Japan and India, where the
growing middle class is contributing to higher petrochemical product consumption,
Figure 2.2.1: The Growth Demand of Methanol in Year of 2018
Raw Material Market Price
Syngas $ 0.023/𝑘𝑔 (MYR 0.093/𝑘𝑔)

Data based on Gasification and Technologies Conference, 2017, Market 2016
Production Market Price
Methanol $ 295 per metric tonnes (MYR 1,185.90)

Data based on Methanex 2020
16
Market and Demand of Methanol in Malaysia Year of 2018
Methanol Production Market Demands
83,000,000 metric tonnes 89,150,000 metric tonnes
Data collected based on Maybank IB Research 2018
89,150,000 metric tonnes – 83,000,000 metric tonnes = 6,150,000 metric tonnes
After calculation, we contributed 123,000 tonnes to full fill the demand supply about 2%:
6,150,000 𝑚𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛𝑛𝑒𝑠 × 0.02 = 123,000 𝑚𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛𝑛𝑒𝑠
Assumed the factory runs 365 days per year, our productions per day:
𝑡𝑜𝑛𝑛𝑒𝑠 1𝑦𝑒𝑎𝑟
123,000 𝑚𝑒𝑡𝑟𝑖𝑐 × = 𝟑𝟑𝟔. 𝟗𝟖𝟔 𝒎𝒆𝒕𝒓𝒊𝒄 𝒕𝒐𝒏𝒏𝒆𝒔/𝒅𝒂𝒚
𝑦𝑒𝑎𝑟 365 𝑑𝑎𝑦
17
2.3 SITE SELECTION
A good site location is important for plant good performance and quality. Criteria should be
considered such as raw material availability, market availability, transport facilities, utilities,
labour supply, infrastructure & services and safety. In fact, wrong location decision will give
negative impacts for a long period of time. There are three possible places that have been
decided for the site selection:
1) Petroleum Petronas Industrial Area Kerteh, Terengganu

2) Pasir Gudang Industrial Area, Johor
3) Gebeng Industrial Park, Balok, Pahang
Selection Criteria
1) Raw material availability
Kerteh, Terengganu Pasir Gudang, Johor Gebeng, Pahang
• The most important considerations in site selection are plant must be located near to
the raw material source as it will help reduce the transportation cost of raw material.
Syngas supplier: Syngas supplier: Syngas supplier:

➢ Petronas Integrated ➢ Petronas Gas Berhad ➢ BASF Petronas
Petrochemical Pasir Gudang Chemical Sdn Bhd
Complex (IPC)
3.5 km from Petroleum 3 km from Pasir Gudang 3.8 km from Gebeng
Petronas Industrial Area Industrial Area Industrial Park.
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2) Market availability

• In order to have good selling products to the consumers, plant should be located close
to the potential market in which there is a lot of companies that highly demands in
our products. In this case, it will reduce transportation cost and generate more profits
to the company.
• Petronas Acetyls Sdn • Not available ➢ Petronas Chemical
Bhd (BPPA) MTBE Sdn Bhd
3) Transport facilities

• Plant should be located near to at least two forms of major transportation. Plant must
be easy to access for transporting either raw materials sources or the product logistic.
Good transport facilities will ease product distribution and to minimize cost of
transportation, time and energy.
Road: Road: Road:
➢ East Coast Highway ➢ Pasir Gudang ➢ East Coast Highway
Highway
➢ Senai-Desaru
Expressway
Ports: Ports: Port:

➢ Kerteh Port ➢ Johor Port ➢ Kuantan Port
➢ Kuantan Port ➢ Tanjong Langsat Port (Railway linking
(Railway linking ➢ Tanjong Pelepas Port Kerteh, Gebeng and
Kerteh, Gebeng and Kuantan Port)
Kuantan Port)
Airport: Airport: Airport:

➢ Kerteh Airport ➢ Senai International ➢ Kuantan Airport
Airport
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4) Utilities

• A chemical plant must be supply with good utilities to ensure the production process
run smoothly. Common utilities such as water, electric power, steam and fuel.
Energy supply: Energy supply: Energy supply:
➢ Tenaga Nasional ➢ Tenaga Nasional ➢ Tenaga Nasional
Berhad (TNB) Berhad (TNB) Berhad (TNB)
Water supply: Water supply: Water supply:

➢ Syarikat Air ➢ Syarikat Air Johor ➢ Pengurusan Air
Terengganu Sdn Bhd Sdn Bhd Pahang Berhad
5) Labour supply

• The availability of skilled manpower usually brought from outside area is important
to help in plant maintenance and to run the process unit. Institution is one of the
platforms to get continuous workforce for skilled manpower. Besides, current
population in the area also important to ensure continuous labour availability.
Current population in Current population in Johor: Current population Pahang:
Terengganu: ➢ 3.76 million (statistic ➢ 1.67 million (statistic
➢ 1.25 million (statistic 2019) 2019)
2019)
Institution: Institution: Institution:

➢ Institut Teknologi ➢ Politeknik Ibrahim ➢ Institut Latihan
Petroluem Petronas Sultan Perindustrian
(INSTEP) ➢ Institut Latihan Kuantan
Perindustrian Pasir
Gudang
20
6) Infrastructure & services

• The availability of infrastructural facilities plays a role in deciding site location. Plant
should be located near to the infrastructure facilities such as hospital or clinic, town
infrastructure and fire brigade station.
Medical Centre: Medical Centre: Medical Centre:
➢ Dungun Hospital ➢ Penawar Pusat ➢ Tengku Ampuan
➢ Kemaman Hospital Bandar Pasir Gudang Afzan Hospital
Hospital ➢ KPJ Pahang
➢ Wakaf Pasir Gudang Speacilist Hospital
Hospital
➢ KPJ Pasir Gudang
Specialist Hospital
Fire & Rescue Station: Fire & Rescue Station: Fire & Rescue Station:
➢ Kerteh Fire & Rescue ➢ Pasir Gudang Fire ➢ Petronas Emergency
Station and Rescue Station Response Centre
➢ Central Emergency (ERC) Gebeng
& Fire Services ➢ Gebeng Fire &
Response (CESF) Rescue Station
Kerteh
7) Safety

Public safety
• Plant should be located within the industrial area with lowest population and far from
residential area to avoid any unforeseen incident or pollution that might be harmful
to human health.
Plant located near to Plant located at Pasir Gudang Plant located at Gebeng
Petroluem Petronas Industrial Area, Johor. Industrial Park, Balok
Industrial Area, Kerteh. Pahang.
21
Environmental safety
• In order to avoid any pollution, plant should be provided with a good waste
management. Effluent disposal must be treated carefully with the aid of any special
facilities to prevent any inconvenience to the environment.
➢ Aldwich Enviro ➢ Vast Evolve Sdn Bhd ➢ Environment
Management, Teluk Technology Park -
Kalong Incorporating a
training centre, waste
collection and
processing centre.
Act as raw material
management and
storage facilities,
maintenance and
servicing facilities.
Screening Method
Location
Kerteh, Pasir Gudang, Gebeng, Pahang
Criteria Terengganu Johor
Raw material + 0 +
availability
Market availability + - +
Transport facilities + + 0
Utilities + + +
Labour supply 0 0 0
Infrastructure & service 0 0 0
Safety + + +
Total score 5 3 4
Rank 1 3 2
+ = better than, 0 = same as, - = worse than
22
Scoring Method
Location
Criteria Weight (%) Kerteh, Gebeng, Pahang
Terengganu
Raw material availability 20 5 5
Market availability 20 5 5
Transport facilities 15 5 4
Utilities 15 5 5
Labour supply 10 4 4
Infrastructure & service 10 3 4
Safety 10 5 5
Total score 100 4.7 4.65
Rank 1 2
1 = much worse than reference, 2 = worse than reference, 3 = same as reference, 4 = better than
reference, 5 = much better than reference
23
CHAPTER 3: MATERIAL BALANCE
3.1 BLOCK FLOW DIAGRAM FOR METHANOL PRODUCTION PROCESS
Figure 3.1.1: Block Flow Diagram (BFD) for Methanol Process

24
3.2 PROCESS FLOW DIAGRAM FOR METHANOL PRODUCTION PROCESS
Figure 3.2.1: Process Flow Diagram (PFD) for Methanol Process
25
3.3 MASS BALANCE CALCULATION
Based on market demand analysis on Methanol, the demand of methanol per year is about
89,150,000 metric tonnes. However, the production of methanol per year is about 83,000,000
metric tonnes. There are about 6,150,000 metric tonnes shortage on methanol demand in
Malaysia. So, we decided to contribute 123,000 tonnes of methanol per year to fulfil the
demand supply for about 2%.
𝑡𝑜𝑛𝑛𝑒𝑠 1 𝑦𝑒𝑎𝑟 1000 𝑘𝑔

Methanol production = 123000 × 8760 ℎ𝑟 × 1 𝑡𝑜𝑛𝑛𝑒 = 𝟏𝟒𝟎𝟒𝟏𝒌𝒈/𝒉𝒓
𝑦𝑒𝑎𝑟
𝑘𝑔 1 𝑘𝑚𝑜𝑙
Molar flowrate of methanol produced = 14041 ℎ𝑟 × 32.04 𝑘𝑔 = 𝟒𝟑𝟖. 𝟐𝟑𝟑𝒌𝒎𝒐𝒍/𝒉𝒓
• Mass Balance on Methanol Reactor, R-101
S3 S4
Inlet Outlet
R-101
There are two independent reversible reactions considered in the reactor which are
hydrogenation of carbon monoxide and the reverse water gas shift. The kinetics of the reactions
are shown below:
CO + 2H2 ↔ CH3OH ---------------- (main reaction)
CO2 + 3H2 ↔ CH3OH + H2O ------ (main reaction)
CO2 + H2 ↔ CO + H2O ------------ (side reaction)
26
The mass flowrate for the basis of inlet and outlet stream is taken from the journal. (Methanol
Production from Syngas)
Stream 3 Stream 4
Mass Outlet Mass

Component Composi Inlet Basis Inlet Actual Compos Outlet Basis
Flowrate Inlet Actual Flowrate
tion (kg/h) (kmol/h) ition (kg/h)
(kg/h) (kmol/h) Outlet (kg/h)
CO 0.076 2796.400 908.8600 25448.0799 0.0630 2313.2000 751.8148 21050.8140
CO2 0.445 16344.100 3380.3685 148736.2132 0.3892 14293.1000 2956.1704 130071.4979
H2 0.069 2540.300 11558.7460 23117.4921 0.0596 2188.9000 9959.8233 19919.6467
H 2O 0.003 97.300 49.1922 885.4592 0.0255 936.8000 473.6201 8525.1610
CH3OH 0.018 653.300 185.7883 5945.2260 0.0735 2699.3000 767.6387 24564.4398
N2 0.036 1315.800 427.6491 11974.1747 0.0358 1315.8000 427.6491 11974.1747
CH4 0.353 12981.400 7383.4147 118134.6344 0.3534 12981.4000 7383.4147 118134.6344
Total 1.000 36728.6000 23894.0190 334241.2790 1.000 36728.5000 22720.1311 334240.3686
*The mass flow of outlet Methanol is set to be 24564.4398 kg/h
Scale-up factor: (based on the mass flowrate of Methanol at the outlet stream:
𝑘𝑔
(24564.4398 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑚𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑)
ℎ
Scale-up factor = 𝑘𝑔
(2699.3000 𝑜𝑓 𝑏𝑎𝑠𝑖𝑠 𝑚𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑎𝑡 𝑡ℎ𝑒 𝑜𝑢𝑡𝑙𝑒𝑡)
ℎ
= 9.1003
Actual flowrate at the inlet:
𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑚𝑜𝑙
ṁ𝐶𝑂 = 9.1003 × 2796.4 = 25448.0789 ÷ 28 = 908.86
ℎ ℎ 𝑘𝑚𝑜𝑙 ℎ
ṁ𝐶𝑂2 = 9.1003 × 16344.1 = 148736 ÷ 44 = 3380.3685
ṁ𝐻2 = 9.1003 × 2540.3 = 23117.4921 ÷2 = 11559.7460
ṁ𝐻2𝑂 = 9.1003 × 97.3 = 885.4592 ÷ 18 = 49.1922
ṁ𝐶𝐻3𝑂𝐻 = 9.1003 × 653.3 = 5945.226 ÷ 32 = 185.7883
27
ṁ𝑁2 = 9.1003 × 1315.8 = 11974.1447 ÷ 28 = 427.6491
ṁ𝐶𝐻4 = 9.1003 × 12981.4 = 118134.6344 ÷ 16 = 7383.4147
Actual flowrate at the outlet:
ṁ𝐶𝑂 = 9.1003 × 2313.2 = 21050.8140 ÷ 28 = 751.8148
ṁ𝐶𝑂2 = 9.1003 × 14293.1 = 130071.4979 ÷ 44 = 2956.1704
ṁ𝐻2 = 9.1003 × 2188.9 = 19919.6467 ÷2 = 9959.8233
ṁ𝐻2𝑂 = 9.1003 × 936.8 = 8525.1610 ÷ 18 = 473.6201
ṁ𝑁2 = 9.1003 × 1315.8 = 11974.1447 ÷ 28 = 427.6491
ṁ𝐶𝐻4 = 9.1003 × 12981.4 = 118134.6344 ÷ 16 = 7383.4147
Single Pass Conversion (SPC):
*CO is the limiting reactant for the reaction
𝐶𝑂 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛

𝑆𝑃𝐶𝐶𝑂 =
𝐶𝑂 𝑓𝑒𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
𝐶𝑂 (𝑆𝑡𝑟𝑒𝑎𝑚 3−𝑆𝑡𝑟𝑒𝑎𝑚 4)
=
𝐶𝑂2 𝑆𝑡𝑟𝑒𝑎𝑚 3
(3380.3685−2956.1704) 𝑘𝑚𝑜𝑙/ℎ
=
3380.3685 𝑘𝑚𝑜𝑙/ℎ
=17.3%
28
Overall Conversion (OC):
𝐶𝑂 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑝𝑟𝑜𝑐𝑒𝑠𝑠

𝑂𝐶𝐶𝑂 =
𝐶𝑂 𝑓𝑒𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑝𝑟𝑜𝑐𝑒𝑠𝑠
𝐶𝑂 (𝑆𝑡𝑟𝑒𝑎𝑚 1−𝑆𝑡𝑟𝑒𝑎𝑚 11)

=
𝐶𝑂2 𝑆𝑡𝑟𝑒𝑎𝑚 1
(224.7774−67.7322) 𝑘𝑚𝑜𝑙/ℎ
=
224.7774 𝑘𝑚𝑜𝑙/ℎ
=70%
Mass Flowrate inlet = Mass Flowrate Outlet
ṁ stream 3 = ṁ stream 4
334241.2786 𝑘𝑔/ℎ = 334240.3686 𝑘𝑔/ℎ
29
• Mass Balance on Flash Drum, V-101 S6
ṁCO kg CO/h
ṁCO2 kg CO2/h
ṁH2 kg H2/h
ṁH2O kg H2O/h
S5
ṁCH3OH kg CH3OH/h
V-101
21050.8140 kg CO/h ṁN2 kg N2/h
130071.4979 kg CO2/h ṁCH4 kg CH4/h
19919.6467 kg H2/h
8525.1610 kg H2O/h
24564.4398 kg CH3OH/h
S8
11974.1747 kg N2/h
118134.6344 kg CH4/h ṁCO kg CO/h
ṁCO2 kg CO2/h
ṁH2 kg H2/h
ṁH2O kg H2O/h
ṁCH3OH kg CH3OH/h
ṁN2 kg N2/h
ṁCH4 kg CH4/h
The mass composition of Stream 6 is taken from the journal. (Methanol Production from
Syngas)
Stream Stream 5 Stream 6 Stream 8
Number
Component Composition Flowrate Composition Flowrate Composition Flowrate
(kg/h) (kg/h) (kg/h)
CO 0.0630 21050.8140 0.0684 19154.3114 0.0349 1896.5025

CO2 0.3892 130071.4979 0.4196 117447.5618 0.2322 12623.9362
H2 0.0596 19919.6467 0.0648 18125.9775 0.0330 1793.6691
H2O 0.0255 8525.1610 0.0031 867.2586 0.1409 7657.9025
CH3OH 0.0735 24564.4398 0.0212 5945.2260 0.3425 18619.2138
N2 0.0358 11974.1747 0.0389 10894.8792 0.0199 1079.2956
CH4 0.3534 118134.6344 0.3839 107447.2421 0.1966 10687.3923
Total 1.0000 334240.3686 1.0000 279882.4566 1.0000 54357.9120
30
Mass flow CH3OH outlet (Stream 6) = Mass flow CH3OH inlet of reactor (Stream 3)
At Stream 6:
𝑘𝑔 𝑘𝑔
ṁ𝐶𝐻3𝑂𝐻 (𝑆6) = ṁ𝐶𝐻3𝑂𝐻 (𝑆3) = 5945.2260 ÷ 32 = 185.7883 𝑘𝑚𝑜𝑙/ℎ
ℎ 𝑘𝑚𝑜𝑙
ṁ𝐶𝐻3𝑂𝐻 5945.2260 𝑘𝑔/ℎ
ṁ𝐶𝑂 = × 𝑥𝐶𝑂 = × 0.0684 = 19154.3114 𝑘𝑔/ℎ
𝑥𝐶𝐻3𝑂𝐻 0.0212
𝑘𝑔 𝑘𝑔
ṅ𝐶𝑂 = 19154.3114 ÷ 28 = 19154.3114 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐶𝐻3𝑂𝐻 5945.2260 𝑘𝑔/ℎ

ṁ𝐶𝑂2 = × 𝑥𝐶𝑂2 = × 0.4196 = 117447.5618 𝑘𝑔/ℎ
𝑥𝐶𝐻3𝑂𝐻 0.0212
𝑘𝑔 𝑘𝑔
ṅ𝐶𝑂2 = 117447.5618 ÷ 44 = 2669.2628 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐶𝐻3𝑂𝐻 5945.2260 𝑘𝑔/ℎ

ṁ𝐻2 = × 𝑥𝐻2 = × 0.0648 = 18125.9775 𝑘𝑔/ℎ
𝑥𝐶𝐻3𝑂𝐻 0.0212
𝑘𝑔 𝑘𝑔
ṅ𝐻2 = 18125.9775 ÷2 = 9062.9888 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐶𝐻3𝑂𝐻 5945.2260 𝑘𝑔/ℎ

ṁ𝐻2𝑂 = × 𝑥𝐻2𝑂 = × 0.0031 = 867.2586 𝑘𝑔/ℎ
𝑥𝐶𝐻3𝑂𝐻 0.0212
𝑘𝑔 𝑘𝑔
ṅ𝐻2𝑂 = 867.2586 ÷ 16 = 48.1810 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐶𝐻3𝑂𝐻 5945.2260 𝑘𝑔/ℎ

ṁ𝑁2 = × 𝑥𝑁2 = × 0.0389 = 10894.8792 𝑘𝑔/ℎ
𝑥𝐶𝐻3𝑂𝐻 0.0212
𝑘𝑔 𝑘𝑔
ṅ𝑁2 = 10894.8792 ÷ 28 = 389.1028 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐶𝐻3𝑂𝐻 5945.2260 𝑘𝑔/ℎ

ṁ𝐶𝐻4 = × 𝑥𝐶𝐻4 = × 0.3839 = 107447.2421 𝑘𝑔/ℎ
𝑥𝐶𝐻3𝑂𝐻 0.0212
𝑘𝑔 𝑘𝑔
ṅ𝐶𝐻4 = 107447.2421 ÷ 16 = 6715.4526 𝑘𝑚𝑜𝑙/ℎ
31
At Stream 8:
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑖𝑛𝑙𝑒𝑡 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑜𝑢𝑡𝑙𝑒𝑡
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑎𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 5 = (𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑎𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 6 + 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑎𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 8)
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑎𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 8 = (𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑎𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 5 − 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑎𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 6)
ṁ𝐶𝑂 = ṁ𝐶𝑂 (𝑆5 − 𝑆6) = 21050.8140 − 19154.3114 = 1896.5025 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐶𝑂 = 1896.5025 ÷ 28 = 67.7322 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐶𝑂2 = ṁ𝐶𝑂2 (𝑆5 − 𝑆6) = 130071.4979 − 117447.5618 = 12623.9362 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐶𝑂2 = 12623.9362 ÷ 44 = 286.9076 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐻2 = ṁ𝐻2 (𝑆5 − 𝑆6) = 19919.6467 − 18125.9775 = 1793.6691 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐻2 = 1993.6691 ÷2 = 896.8346 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐻2𝑂 = ṁ𝐻2𝑂 (𝑆5 − 𝑆6) = 8525.1610 − 867.2586 = 7657.9025 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐻2𝑂 = 7657.9025 ÷ 18 = 425.4390 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐶𝐻3𝑂𝐻 = ṁ𝐶𝐻3𝑂𝐻 (𝑆5 − 𝑆6) = 24564.4398 − 5945.2260 = 18619.2138 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐶𝐻3𝑂𝐻 = 18619.2138 ÷ 32 = 581.8504 𝑘𝑚𝑜𝑙/ℎ
ṁ𝑁2 = ṁ𝑁2 (𝑆5 − 𝑆6) = 11974.1747 − 10894.8792 = 1079.2956 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝑁2 = 1079.2956 ÷ 28 = 38.5463 𝑘𝑚𝑜𝑙/ℎ
ṁ𝐶𝐻4 = ṁ𝐶𝐻4 (𝑆5 − 𝑆6) = 118134.6344 − 107447.2421 = 10687.3923 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐶𝐻4 = 10687.3923 ÷ 16 = 667.9620 𝑘𝑚𝑜𝑙/ℎ
ṁ𝑇𝑜𝑡𝑎𝑙 = ṁ𝐶𝐻4 + ṁ𝑁2 + ṁ𝐶𝐻3𝑂𝐻 + ṁ𝐻2𝑂 + ṁ𝐻2 + ṁ𝐶𝑂2 + ṁ𝐶𝑂 = 54357.9120 𝑘𝑔/ℎ
32
ṁ𝐶𝑂 1896.5025 𝑘𝑔/ℎ
𝑥𝐶𝑂 = = = 0.0349
ṁ𝑇𝑜𝑡𝑎𝑙 54357.9120 𝑘𝑔/ℎ
ṁ𝐶𝑂2 12623.9362 𝑘𝑔/ℎ

𝑥𝐶𝑂2 = = = 0.2322
ṁ𝐻2 1793.6691 𝑘𝑔/ℎ

𝑥𝐻2 = = = 0.0330
ṁ𝐻2𝑂 7657.9025 𝑘𝑔/ℎ

𝑥𝐻2𝑂 = = = 0.1409
ṁ𝐶𝐻3𝑂𝐻 18619.2138 𝑘𝑔/ℎ

𝑥𝐶𝐻3𝑂𝐻 = = = 0.3425
ṁ𝑁2 1079.2956 𝑘𝑔/ℎ

𝑥𝑁2 = = = 0.0199
ṁ𝐶𝐻4 10687.3923 𝑘𝑔/ℎ

𝑥𝐶𝐻4 = = = 0.1966
ṁ stream 5 = ṁ stream 6 + ṁ stream 8
334240.3686 𝑘𝑔/ℎ = 334240.3686 𝑘𝑔/ℎ
Mole flowrate for every stream:
Molar flowrate (kmol/h)

Component
Stream 5 Stream 6 Stream 8
CO 751.8148 684.0826 67.7322
CO2 2956.1704 2669.2628 286.9076
H2 9959.8233 9062.9888 896.8346
H2O 473.6201 48.1810 425.4390
CH3OH 767.6387 185.7883 581.8504
N2 427.6491 389.1028 38.5463
CH4 7383.4147 6715.4526 667.9620
TOTAL 22720.1311 19754.8589 2965.2722
33
• Mass Balance on Distillation Column, T-101
S10
ṁCO kg CO/h
ṁCO2 kg CO2/h
ṁH2 kg H2/h
ṁH2O kg H2O/h
S9 ṁCH3OH kg CH3OH/h
T-101 ṁN2 kg N2/h
1896.5025 kg CO/h ṁCH4 kg CH4/H
12623.9362 kg CO2/h
1793.6691 kg H2/h
7657.9025kg H2O/h
18619.2138 kg CH3OH/h S12
1079.2956kg N2/h
ṁH2O kg H2O/h
10687.3923 kg CH4/H
ṁCH3OH kg CH3OH/h
79.899 kg CH4/H
The mass flow of Methanol and Water at Stream 10 is taken from the journal. (Methanol
Production from Syngas)
Number
Composition Flowrate Composition Flowrate Composition Flowrate
Component (kg/h) (kg/h) (kg/h)
CO 0.0349 1896.5025 0.0577 1896.5025 - -
CO2 0.2322 12623.9362 0.3841 12623.9362 - -
H2 0.0330 1793.6691 0.0546 1793.6691 - -
H2O 0.1409 7657.9025 0.0086 281.6460 0.3433 7376.2565
CH3OH 0.3425 18619.2138 0.1371 4506.3284 0.6567 14112.8854
N2 0.0199 1079.2956 0.0328 1079.2956 - -
CH4 0.1966 10687.3923 0.3252 10687.3923 - -
Total 1.0000 54357.9120 1.0000 32868.7702 1.0000 21489.1418
34
At Stream 10
Carbon Monoxide Balance:
(ṁCO)in = (ṁCO)out
(ṁCO)out = 1896.5025 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅCO = 1896.5025 ÷ 28 𝑘𝑚𝑜𝑙 = 67.7322 𝑘𝑚𝑜𝑙/ℎ
ℎ
Carbon Dioxide Balance:
(ṁCO2)in = (ṁCO2)out
(ṁCO2)out = 12623.9362 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅCO2 = 12623.9362 ÷ 44 𝑘𝑚𝑜𝑙 = 286.9076 𝑘𝑚𝑜𝑙/ℎ
ℎ
Hydrogen Balance:
(ṁH2)in = (ṁH2)out
(ṁH2)out = 1793.6691 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅH2 = 1793.6691 ÷ 2 𝑘𝑚𝑜𝑙 = 896.8346 𝑘𝑚𝑜𝑙/ℎ
ℎ
Nitrogen Balance:
(ṁN2)in = (ṁN2)out
(ṁN2)out = 1079.2956 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅN2 = 1079.2956 ÷ 28 𝑘𝑚𝑜𝑙 = 38.5463 𝑘𝑚𝑜𝑙/ℎ
ℎ
Methane Balance:
(ṁCH4)in = (ṁCH4)out
(ṁCH4)out = 10687.3923 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅCH4 = 10687.3923 ÷ 16 𝑘𝑚𝑜𝑙 = 667.9620 𝑘𝑚𝑜𝑙/ℎ
ℎ
𝑘𝑔 𝑘𝑔
ṅH2O = 281.6460 ÷ 18 𝑘𝑚𝑜𝑙 = 15.6470 𝑘𝑚𝑜𝑙/ℎ
ℎ
𝑘𝑔 𝑘𝑔
ṅCH3OH = 4506.3284 ÷ 32 𝑘𝑚𝑜𝑙 = 140.8228 𝑘𝑚𝑜𝑙/ℎ
ℎ
35
ṁ𝑇𝑜𝑡𝑎𝑙 = ṁ𝐶𝐻4 + ṁ𝑁2 + ṁ𝐶𝐻3𝑂𝐻 + ṁ𝐻2𝑂 + ṁ𝐻2 + ṁ𝐶𝑂2 + ṁ𝐶𝑂 = 32868.7702 𝑘𝑔/ℎ
ṁ𝐶𝑂 1896.5025 𝑘𝑔/ℎ

𝑥𝐶𝑂 = = = 0.0577
ṁ𝐶𝑂2 12623.9362 𝑘𝑔/ℎ

𝑥𝐶𝑂2 = = = 0.3841
ṁ𝐻2 1793.6691 𝑘𝑔/ℎ

𝑥𝐻2 = = = 0.0546
ṁ𝐻2𝑂 281.6460 𝑘𝑔/ℎ

𝑥𝐻2𝑂 = = = 0.0086
ṁ𝐶𝐻3𝑂𝐻 4506.3284 𝑘𝑔/ℎ

𝑥𝐶𝐻3𝑂𝐻 = = = 0.1371
ṁ𝑁2 1079.2956 𝑘𝑔/ℎ

𝑥𝑁2 = = = 0.0328
ṁ𝐶𝐻4 10687.3923 𝑘𝑔/ℎ

𝑥𝐶𝐻4 = = = 0.3252
At Stream 12:
ṁ𝐻2𝑂 = ṁ𝐻2𝑂 (𝑆9 − 𝑆10) = 7657.9025 − 281.6460 = 7376.2565 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐻2𝑂 = 7376.2565 ÷ 18 = 409.7920 𝑘𝑚𝑜𝑙/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐶𝐻3𝑂𝐻 = 14112.8854 ÷ 32 = 441.0277 𝑘𝑚𝑜𝑙/ℎ
36
ṁ𝑇𝑜𝑡𝑎𝑙 = ṁ𝐶𝐻3𝑂𝐻 + ṁ𝐻2𝑂 = 21489.1418 𝑘𝑔/ℎ
ṁ𝐻2𝑂 7376.2565 𝑘𝑔/ℎ

𝑥𝐻2𝑂 = = = 0.3433
ṁ𝐶𝐻3𝑂𝐻 14112.8854 𝑘𝑔/ℎ

𝑥𝐶𝐻3𝑂𝐻 = = = 0.6567
54357.9120 𝑘𝑔/ℎ = 54357.9120 𝑘𝑔/ℎ

Component
CO 67.7322 67.7322 -
CO2 286.9076 286.9076 -
H2 896.8346 896.8346 -
H2O 425.4390 15.6470 409.7920
CH3OH 581.8504 140.8228 441.0277
N2 38.5463 38.5463 -
CH4 667.9620 667.9620 -
TOTAL 2965.2722 2114.4525 850.8197
37
• Mass Balance on Distillation Column, T-102
S13
ṁH2O kg H2O/h
ṁCH3OH kg CH3OH/h
S12
T-102
7376.2565 kg H2O/h
14112.8854 kg CH3OH/h
S14
ṁH2O kg H2O/h
ṁCH3OH kg CH3OH/h

Number
(kg/h) (kg/h) (kg/h)
Component
CO - - - - - -
CO2 - - - - - -
H2 - - - - - -
H2O 0.3433 7376.2565 0.0007 9.8356 0.9907 7648.0668

CH3OH 0.6567 14112.8854 0.9993 14041.0907 0.0093 71.7947
N2 - - - - - -
CH4 - - - - - -
Total 1.0000 21489.1418 1.0000 14050.9263 1.0000 7719.8615
38
At Stream 13:
ṁ𝐶𝐻3𝑂𝐻 = 𝑀𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑑𝑒𝑚𝑎𝑛𝑑 = 14041.0907 𝑘𝑔/ℎ
𝑥𝐶𝐻3𝑂𝐻 = 0.9993
𝑘𝑔 𝑘𝑔
ṅ𝐶𝐻3𝑂𝐻 = 14041.0907 ÷ 32 = 438.7841 𝑘𝑚𝑜𝑙/ℎ
𝑥𝐻2𝑂 = 1 − 0.9993 = 0.0007
ṁ𝐶𝐻3𝑂𝐻 14041.0907
ṁ𝐻2𝑂 = × 𝑥𝐻2𝑂 = × 0.0007 = 9.8356 𝑘𝑔/ℎ
𝑥𝐶𝐻3𝑂𝐻 0.9993
𝑘𝑔 𝑘𝑔
ṅ𝐻2𝑂 = 9.8356 ÷ 18 = 0.5464 𝑘𝑚𝑜𝑙/ℎ
At Stream 14:
ṁ𝐻2𝑂 = ṁ𝐻2𝑂 (𝑆12 − 𝑆13) = 7376.2565 − 9.8356 = 7366.4208 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐻2𝑂 = 7366.4208 ÷ 18 = 409.2456 𝑘𝑚𝑜𝑙/ℎ
𝑘𝑔 𝑘𝑔
ṅ𝐶𝐻3𝑂𝐻 = 71.7947 ÷ 32 = 2.2436 𝑘𝑚𝑜𝑙/ℎ
ṁ𝑇𝑜𝑡𝑎𝑙 = ṁ𝐶𝐻3𝑂𝐻 + ṁ𝐻2𝑂 = 7437.2155 𝑘𝑔/ℎ
ṁ𝐻2𝑂 7366.4208 𝑘𝑔/ℎ

𝑥𝐻2𝑂 = = = 0.9907
ṁ𝐶𝐻3𝑂𝐻 71.7947 𝑘𝑔/ℎ

𝑥𝐶𝐻3𝑂𝐻 = = = 0.0093
39
21489.1418 𝑘𝑔/ℎ = 21489.1418 𝑘𝑔/ℎ

Component
CO - - -
CO2 - - -
H2 - - -
H2O 409.7920 0.5464 409.2456
CH3OH 441.0277 438.7841 2.2436

N2 - - -
CH4 - - -
TOTAL 805.8197 439.3305 411.4892
40
• Mass Balance on Mixing point
S2 S3
ṁCO kg CO/h
25448.0789 kg CO/h
ṁCO2 kg CO2/h
S7 148736.2132 kg CO2/h
ṁH2 kg H2/h
23117.4921 kg H2/h
19154.3114 kg CO/h
ṁH2O kg H2O/h
885.4592 kg H2O/h
117447.5618 kg CO2/h
ṁCH3OH kg CH3OH/h
5945.2260 kg CH3OH/h
18125.9775 kg H2/h
ṁN2 kg N2/h
11974.1747 kg N2/h
867.2586 kg H2O/h
ṁCH4 kg CH4/h
118134.6344 kg CH4/h
5945.2260 kg CH3OH/h
10894.8792 kg N2/h
107447.2421 kg CH4/h

Number
Component (kg/h) (kg/h) (kg/h)
CO 0.1158 6293.7675 0.0684 19154.3114 0.0761 25448.0789
CO2 0.5756 31288.6515 0.4196 117447.5618 0.4450 148736.2132
H2 0.0918 4991.5146 0.0648 18125.9775 0.0692 23117.4921
H2O 0.0003 18.2006 0.0031 867.2586 0.0026 885.4592
CH3OH - - 0.0212 5945.2260 0.0178 5945.2260
N2 0.0199 1079.2956 0.0389 10894.8792 0.0358 11974.1747
CH4 0.1966 10687.3923 0.3839 107447.2421 0.3534 118134.6344
Total 1.0000 54358.8220 1.0000 279882.4566 1.0000 334241.2786
41
Carbon Monoxide Balance:
(ṁCO)in = (ṁCO)out
(ṁCO)in = 25448.0789 − 19154.3114 = 6293.7675 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅCO = 6293.7675 ℎ
÷ 28 𝑘𝑚𝑜𝑙 = 224.7774 𝑘𝑚𝑜𝑙/ℎ
Carbon Dioxide Balance:
(ṁCO2)in = (ṅCO2)out
(ṁCO2)in = 148736.2132 − 117447.5618 = 31288.6515 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅCO2 = 31288.6515 ℎ
÷ 44 𝑘𝑚𝑜𝑙 = 711.1057 𝑘𝑚𝑜𝑙/ℎ
Hydrogen Balance:
(ṁH2)in = (ṁH2)out
(ṁH2)in = 23117.4921 − 18125.9775 = 4991.5146 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅH2 = 4991.5146 ℎ
÷ 2 𝑘𝑚𝑜𝑙 = 2495.7573 𝑘𝑚𝑜𝑙/ℎ
Water Balance:
(ṁH2O)in = (ṁH2O)out
(ṁH2O)in = 885.4592 − 867.2586 = 18.2006 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅH2O =18.2006 ℎ
÷ 18 𝑘𝑚𝑜𝑙 = 1.0111 𝑘𝑚𝑜𝑙/ℎ
Methanol Balance:
(ṁCH3OH)in = (ṁCH3OH)out
(ṁCH3OH)in = 5945.2260 − 5945.2260 = 0 𝑘𝑔/ℎ
42
Nitrogen Balance:
(ṁN2)in = (ṁN2)out
(ṁN2)in = 11974.1747 − 10894.8792 = 1079.2956 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅN2 = 1079.2956 ℎ
÷ 28 𝑘𝑚𝑜𝑙 = 38.5463 𝑘𝑚𝑜𝑙/ℎ
Methane Balance:
(ṁCH4)in = (ṅCH4)out
(ṁCH4)in = 118134.6344 − 107447.2421 = 10687.3923 𝑘𝑔/ℎ
𝑘𝑔 𝑘𝑔
ṅCH4 = 10687.3923 ℎ
÷ 16 𝑘𝑚𝑜𝑙 = 667.9620 𝑘𝑚𝑜𝑙/ℎ
ṁ stream 2 + ṁ stream 7 = ṁ stream 3
334241.2786 𝑘𝑔/ℎ = 334241.2786 𝑘𝑔/ℎ

Component
CO 224.7774 684.0826 684.0826
CO2 711.1057 2669.2628 2669.2628
H2 2495.7573 9062.9888 9062.9888
H2O 1.0111 48.1810 48.1810
CH3OH 0.0000 185.7883 185.7883
N2 38.5463 389.1028 389.1028
CH4 667.9620 6715.4526 6715.4526
TOTAL 4139.1598 19754.8589 19754.8589
43
Stream
1 2 3 4 5 6 7
Number
Temperature 25.00 25.00 206.30 252.50 110.00 65.00 50.00
(°C)
Pressure 10.00 70.00 70.00 69.00 14.00 40.00 70.00
(bar)
Vapor 1.000 1.000 1.000 1.000 1.000 1.000 1.000
Fraction
Mass Flow 54358.824 54358.824 334241.279 334240.368 334240.368 279882.456 279882.456
(kg/h) 0 6 6 6 6
Mole Flow 4139.1599 4139.1599 23894.0190 22720.1311 22720.1311 19754.8589 19754.8589
(kmol/h)
Component Flowrates (kmol/h)
Carbon 224.7774 224.7774 908.8600 751.8148 751.8148 684.0826 684.0826
Monoxide
Carbon 711.1057 711.1057 3380.3685 2956.1704 2956.1704 2669.2628 2669.2628
Dioxide
Hydrogen 2495.7572 2495.7572 11558.7460 9959.8233 9959.8233 9062.9888 9062.9888
Water 1.0112 1.0112 49.1922 473.6201 473.6201 48.1810 48.1810
Methanol - - 185.7883 767.6387 767.6387 185.7883 185.7883
Nitrogen 38.5463 38.5463 427.6491 427.6491 427.6491 389.1028 389.1028
Methane 667.9621 667.9621 7383.4147 7383.4147 7383.4147 6715.4526 6715.4526
Stream
8 9 10 11 12 13 14
Number
Temperature 50.00 50.00 18.00 18.00 143.70 138.60 178.60
(°C)
Pressure 40.00 12.00 11.00 11.00 11.00 11.00 11.00
(bar)
Vapor 0.000 0.000 1.000 1.000 0.000 1.000 0.000
Fraction
Mass Flow 54357.912 54357.912 32868.7702 32868.7702 21489.1418 14050.9263 7719.8615
(kg/h) 0 0
Mole Flow 2965.2722 2965.2722 2114.4525 2114.4525 805.8197 439.3305 411.4892
(kmol/h)
Carbon 67.7322 67.7322 67.7322 67.7322 - - -
Monoxide
Carbon 286.9076 286.9076 286.9076 286.9076 - - -
Dioxide
Hydrogen 896.8346 896.8346 896.8346 896.8346 - - -
Water 425.4390 425.4390 15.6470 15.6470 409.7920 0.5464 409.2456
Methanol 581.8504 581.8504 140.8228 140.8228 441.0277 438.7841 2.2436
Nitrogen 38.5463 38.5463 38.5463 38.5463 - - -
Methane 667.9620 667.9620 667.9620 667.9620 - - -
44
CHAPTER 4: ENERGY BALANCE
4.1 ENERGY BALANCE CALCULATION

• Energy Balance on Heat Exchanger, E-101
S2 S3
E-101
T = 25℃ T = 206.3℃
P = 70 bar P = 70 bar
vapour vapour
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒𝑠: 𝐶𝑂( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐶𝑂2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐻2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟) , 𝑁2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ),
Substances 𝑛̇ 𝑖𝑛 ̂𝑖𝑛
𝐻 𝑛̇ 𝑜𝑢𝑡 ̂𝑜𝑢𝑡
𝐻
(mol/h) (kJ/mol) (mol/h) (kJ/mol)
𝐻2 2495757 H1 11558746 H7
𝑁2 38546 H2 427649.1 H8
𝐶𝑂2 711106 H3 3380368.5 H9
𝐶𝑂 224777 H4 908860 H10
𝐻2 𝑂 1011 H5 49192.2 H11
𝐶𝐻4 667962 H6 7383414.7 H12
𝐶𝐻3 𝑂𝐻 - - 185788.3 H13
𝐶𝐻4 ( 𝑣, 25℃, 1 𝑏𝑎𝑟) , 𝐻2 𝑂( 𝑣, 25, 1 𝑏𝑎𝑟 ), 𝐶𝐻3 𝑂𝐻 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 )
𝐻2 (v, 25℃, 1 bar) → 𝐻2 ( v, 25℃, 70 bar)
H1 = ∆𝑃 ← 𝑎𝑠𝑠𝑢𝑚𝑒 𝑖𝑑𝑒𝑎𝑙 𝑔𝑎𝑠

= 0kJ/mol
𝑁2 (v, 25℃, 1 bar) → 𝑁2 ( v, 25℃, 70 bar)
= 0kJ/mol
45
𝐶𝑂2(v, 25℃, 1 bar) → 𝐶𝑂2 ( v, 25℃, 70 bar)
= 0kJ/mol
𝐶𝑂(v, 25℃, 1 bar) → 𝐶𝑂( v, 25℃, 70 bar)
= 0kJ/mol
𝐻2 𝑂(v, 25℃, 1 bar) → 𝐻2 𝑂( v, 25℃, 70 bar)
= 0kJ/mol
𝐶𝐻4 (v, 25℃, 1 bar) → 𝐶𝐻4 ( v, 25℃, 70 bar)

= 0kJ/mol
𝐻2 (v, 25℃, 1 bar) → 𝐻2 ( v, 206.3℃, 1 bar) → 𝐻2 ( v, 206.3℃, 70 bar)
H7 = ∆𝑇 + ∆𝑃 ← 𝑎𝑠𝑠𝑢𝑚𝑒 𝑖𝑑𝑒𝑎𝑙 𝑔𝑎𝑠, 𝐻 = 0

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 5.240kJ/mol
𝑁2 (v, 25℃, 1 bar) → 𝑁2 ( v, 206.3℃, 1 bar) → 𝑁2 ( v, 206.3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 5.319kJ/mol
46
𝐶𝑂2(v, 25℃, 1 bar) → 𝐶𝑂2 ( v, 206.3℃, 1 bar) → 𝐶𝑂2( v, 206.3℃, 70 bar)

206.3
=∫25 𝐶𝑃 𝑑𝑇 + 0
= 7.353kJ/mol
𝐶𝑂(v, 25℃, 1 bar) → 𝐶𝑂( v, 206.3℃, 1 bar) → 𝐶𝑂( v, 206.3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 5.344kJ/mol
𝐻2 𝑂(v, 25℃, 1 bar) → 𝐻2 𝑂( v, 206.3℃, 1 bar) → 𝐻2 𝑂( v, 206.3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 6.231kJ/mol
𝐶𝐻4 (v, 25℃, 1 bar) → 𝐶𝐻4 ( v, 206.3℃, 1 bar) → 𝐶𝐻4 ( v, 206.3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 7.373kJ/mol
𝐶𝐻3 𝑂𝐻(v, 25℃, 1 bar) → 𝐶𝐻3 𝑂𝐻( v, 206.3℃, 1 bar) → 𝐶𝐻3 𝑂𝐻( v, 206,3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 9.465kJ/mol
47
𝑄̇ = ∆𝐻̇ = ∑ 𝑛̇ 𝑜𝑢𝑡 𝐻
̂𝑜𝑢𝑡 - ∑ 𝑛̇ 𝑖𝑛 𝐻
̂𝑖𝑛
= [(11558746 × 5.240) + (427649.1 × 5.319) + (3380368.5 × 7.353) + (908860 × 5.344)

+ (49192.2 × 6.231) + (7383414.7 × 7.373) + (185788.3 × 9.465)] kJ/h – 0kJ/h
𝑘𝐽 1ℎ
= 149058211.5 × 3600𝑠
ℎ
= 41405.059kW
48
• Energy Balance on Methanol Synthesis Reactor, R-101
S3 S4
R-101
T = 206.3℃ T = 252.5℃
P = 70 bar P = 69 bar
vapour vapour
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒𝑠: 𝐶𝑂( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐶𝑂2( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐻2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ),

𝐻2 𝑂( 𝑣, 25, 1 𝑏𝑎𝑟 ), 𝐶𝐻3 𝑂𝐻 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝑁2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐶𝐻4 ( 𝑣, 25℃, 1 𝑏𝑎𝑟)
𝐻
𝐻2 11558746 H1 9959823.3 H8
𝑁2 427649.1 H2 427649.1 H9
𝐶𝑂2 3380368.5 H3 2956170.4 H10
𝐶𝑂 908860 H4 751814.8 H11
𝐻2 𝑂 49192.2 H5 473620.1 H12
𝐶𝐻4 7383414.7 H6 7383414.7 H13
𝐶𝐻3 𝑂𝐻 185788.3 H7 767638.7 H14
H1 = ∆𝐻𝑓° + ∆𝑇 + ∆𝑃 ← 𝑎𝑠𝑠𝑢𝑚𝑒 𝑖𝑑𝑒𝑎𝑙 𝑔𝑎𝑠, 𝐻 = 0

206.3
= 0 + ∫25 𝐶𝑃 𝑑𝑇 + 0
= 5.240kJ/mol

206.3
= 0 + ∫25 𝐶𝑃 𝑑𝑇 + 0
= 5.319kJ/mol
49
𝐶𝑂2(v, 25℃, 1 bar) → 𝐶𝑂2 ( v, 206.3℃, 1 bar) → 𝐶𝑂2( v, 206.3℃, 70 bar)

393.5𝑘𝐽 206.3
=− + ∫25 𝐶𝑃 𝑑𝑇 + 0
𝑚𝑜𝑙
= - 386.147kJ/mol

110.52𝑘𝐽 206.3
=− + ∫25 𝐶𝑃 𝑑𝑇 + 0
𝑚𝑜𝑙
= - 105.176kJ/mol

241.83𝑘𝐽 206.3
=− + ∫25 𝐶𝑃 𝑑𝑇 + 0
𝑚𝑜𝑙
= - 235.599kJ/mol

74.85𝑘𝐽 206.3
= 𝑚𝑜𝑙
+ ∫25 𝐶𝑃 𝑑𝑇 + 0
= 82.223kJ/mol
𝐶𝐻3 𝑂𝐻(v, 25℃, 1 bar) → 𝐶𝐻3 𝑂𝐻( v, 206.3℃, 1 bar) → 𝐶𝐻3 𝑂𝐻( v, 206,3℃, 70 bar)
H7 =∆𝐻𝑓° + ∆𝑇 + ∆𝑃 ← 𝑎𝑠𝑠𝑢𝑚𝑒 𝑖𝑑𝑒𝑎𝑙 𝑔𝑎𝑠, 𝐻 = 0

201.2𝑘𝐽 206.3
= + ∫25 𝐶𝑃 𝑑𝑇 + 0
𝑚𝑜𝑙
= 210.665kJ/mol
50

252.5
= 0 + ∫25 𝐶𝑃 𝑑𝑇 + 0
= 6.580kJ/mol

252.5
= 0 + ∫25 𝐶𝑃 𝑑𝑇 + 0
= 6.695kJ/mol
𝐶𝑂2(v, 25℃, 1 bar) → 𝐶02 ( v, 252.5℃, 1 bar) → 𝐶02 ( v, 252.5℃, 69 bar)

393.5𝑘𝐽 252.5
=− + ∫25 𝐶𝑃 𝑑𝑇 + 0
𝑚𝑜𝑙
= - 384.096kJ/mol

110.52𝑘𝐽 252.5
=− + ∫25 𝐶𝑃 𝑑𝑇 + 0
𝑚𝑜𝑙
= - 103.787kJ/mol

241.83𝑘𝐽 252.5
=− + ∫25 𝐶𝑃 𝑑𝑇 + 0
𝑚𝑜𝑙
= - 232.826kJ/mol
51

74.85𝑘𝐽 252.5
= + ∫25 𝐶𝑃 𝑑𝑇 + 0
𝑚𝑜𝑙
= 84.390kJ/mol
𝐶𝐻3 𝑂𝐻(v, 25℃, 1 bar) → 𝐶𝐻3 𝑂𝐻( v, 252.5℃, 1 bar) → 𝐶𝐻3 𝑂𝐻( v, 252.5℃, 69 bar)
H14 =∆𝐻𝑓° + ∆𝑇 + ∆𝑃 ← 𝑎𝑠𝑠𝑢𝑚𝑒 𝑖𝑑𝑒𝑎𝑙 𝑔𝑎𝑠, 𝐻 = 0

201.2𝑘𝐽 252.5
= + ∫25 𝐶𝑃 𝑑𝑇 + 0
𝑚𝑜𝑙
= 213.478kJ/mol
𝑄̇ = ∆𝐻̇ = ∑ 𝑛̇ 𝑜𝑢𝑡 𝐻
̂𝑜𝑢𝑡 − ∑ 𝑛̇ 𝑖𝑛 𝐻
̂𝑖𝑛
= [ (9959823.3 × 6.580) + (427649.1 × 6.695) + (2956170.4 × - 384.096) + (751814.8 × -

103.787) + (473620.1 × - 232.826) + (7383414.7 × 84.390) + (767638.7 × 213.478)] –
[(11558746 × 5.240) + (427649.1 × 5.319) + (3380368.5 × - 386.147) + (908860 × -
105.176) + (49192.2 × - 235.599) + (7383414.7 × 82.223) + (185788.3 × 210.665)
𝑘𝐽 1ℎ
= 235037140.9 × 3600𝑠
ℎ
= 65288.095kW
52
• Energy Balance on Cooler, E-102
S4 S5
E-102
T = 252.5℃ T = 110℃
P = 69 bar P = 14 bar
vapour vapour
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒𝑠: 𝐶𝑂( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐶𝑂2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐻2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐻2 𝑂( 𝑣, 25, 1 𝑏𝑎𝑟 ),
𝐶𝐻3 𝑂𝐻 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝑁2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐶𝐻4 ( 𝑣, 25℃, 1 𝑏𝑎𝑟)
𝐻
𝐻2 9959823.3 H1 9959823.3 H8
𝑁2 427649.1 H2 427649.1 H9
𝐶𝑂2 2956170.4 H3 2956170.4 H10
𝐶𝑂 751814.8 H4 751814.8 H11
𝐻2 𝑂 473620.1 H5 473620.1 H12
𝐶𝐻4 7383414.7 H6 7383414.7 H13
𝐶𝐻3 𝑂𝐻 767638.7 H7 767638.7 H14
𝐻2 (v, 25℃, 1 bar) → 𝐻2 (v, 252.5℃, 1 bar) → 𝐻2 (v, 252.5℃, 69 bar)

252.5
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 6.580kJ/mol
𝑁2 (v, 25℃, 1 bar) → 𝑁2 (v, 252.5℃, 1 bar) → 𝑁2 (v, 252.5℃, 69 bar)

252.5
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 6.695kJ/mol
53
𝐶𝑂2(v, 25℃, 1 bar) → 𝐶02 (v, 252.5℃, 1 bar) → 𝐶02 (v, 252.5℃, 69 bar)

252.5
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 9.404kJ/mol
𝐶𝑂(v, 25℃, 1 bar) → 𝐶𝑂(v, 252.5℃, 1 bar) → 𝐶𝑂(v, 252.5℃, 69 bar)

252.5
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 6.733kJ/mol
𝐻2 𝑂(v, 25℃, 1 bar) → 𝐻2 𝑂(v, 252.5℃, 1 bar) → 𝐻2 𝑂(v, 252.5℃, 69 bar)

252.5
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 9.004kJ/mol
𝐶𝐻4 (v, 25℃, 1 bar) → 𝐶𝐻4 (v, 252.5℃, 1 bar) → 𝐶𝐻4 (v, 252.5℃, 69 bar)

252.5
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 9.540kJ/mol
𝐶𝐻3 𝑂𝐻(v, 25℃, 1 bar) → 𝐶𝐻3 𝑂𝐻(v, 252.5℃, 1 bar) → 𝐶𝐻3 𝑂𝐻(v, 252.5℃, 69 bar)

252.5
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 12.278kJ/mol
54
𝐻2 (v, 25℃, 1 bar) → 𝐻2 (v, 110℃, 1 bar) → 𝐻2 (v, 110℃, 14 bar)

110
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 2.453kJ/mol
𝑁2 (v, 25℃, 1 bar) → 𝑁2 (v, 110℃, 1 bar) → 𝑁2 (v, 110℃, 14 bar)

110
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 2.480kJ/mol
𝐶𝑂2(v, 25℃, 1 bar) → 𝐶𝑂2 (v, 110℃, 1 bar) → 𝐶𝑂2(v, 110℃, 14 bar)

110
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 3.300kJ/mol
𝐶𝑂(v, 25℃, 1 bar) → 𝐶𝑂(v, 110℃, 1 bar) → 𝐶𝑂(v, 110℃, 14 bar)

110
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 2.486kJ/mol
𝐻2 𝑂(v, 25℃, 1 bar) → 𝐻2 𝑂(v, 110℃, 1 bar) → 𝐻2 𝑂(v, 110℃, 14 bar)

110
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 2.887kJ/mol
55
𝐶𝐻4 (v, 25℃, 1 bar) → 𝐶𝐻4 (v, 110℃, 1 bar) → 𝐶𝐻4 (v, 110℃, 14 bar)

110
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 3.232kJ/mol
𝐶𝐻3 𝑂𝐻(v, 25℃, 1 bar) → 𝐶𝐻3 𝑂𝐻(v, 110℃, 1 bar) → 𝐶𝐻3 𝑂𝐻(v, 110℃, 14 bar)

110
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 4.117kJ/mol
𝑄̇ = ∆𝐻̇ = ∑ 𝑛̇ 𝑜𝑢𝑡 𝐻
̂𝑖𝑛
= [(9959823.3 × 2.453) + (427649.1 × 2.480) + (2956170.4 × 3.300) + (751814.8 × 2.486)

+ (473620.1 × 2.887) + (7383414.7 × 3.232) + (767638.7 × 4.117)] - [ (9959823.3 × 6.580)
+ (427649.1 × 6.695) + (2956170.4 × 9.404) + (751814.8 × 6.733) + (473620.1 × 9.004) +
(7383414.7 × 9.540) + (767638.7 × 12.278)]
𝑘𝐽 1ℎ
= −119880566.8 × 3600𝑠
ℎ
= -33300.15745kW
56
• Energy Balance on Mixing Point
S2 S3
T = 25℃ T = 206.3℃
P = 70 bar P = 70 bar
vapour vapour
T = 50℃
S7
P = 70 bar
vapour
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒𝑠: 𝐶𝑂( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐶𝑂2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐻2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐻2 𝑂( 𝑣, 25, 1 𝑏𝑎𝑟 ),
𝐶𝐻3 𝑂𝐻 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝑁2 ( 𝑣, 25℃, 1 𝑏𝑎𝑟 ), 𝐶𝐻4 ( 𝑣, 25℃, 1 𝑏𝑎𝑟)
Components Stream 2 Stream 7 Stream 3

𝑛̇ 𝑖𝑛 ̂𝑖𝑛
𝐻 𝑛̇ 𝑖𝑛 ̂𝑖𝑛
𝐻
(mol/h) (kJ/mol) (kmol/h) (kJ/mol) (kmol/h) (kJ/mol)
𝐻2 2495757 H1 9062988.8 H7 11558746 H14
𝑁2 38546 H2 389102.8 H8 427649.1 H15
𝐶𝑂2 711106 H3 2669262.8 H9 3380368.5 H16
𝐶𝑂 224777 H4 684082.6 H10 908860 H17
𝐻2 𝑂 1011 H5 48181 H11 49192.2 H18
𝐶𝐻4 667962 H6 6715452.6 H12 7383414.7 H19
𝐶𝐻3 𝑂𝐻 - - 185788.3 H13 185788.3 H20
𝐻2 (v, 25℃, 1 bar) → 𝐻2 (v, 25℃, 70 bar)
= 0kJ/mol
𝑁2 (v, 25℃, 1 bar) → 𝑁2 (v, 25℃, 70 bar)

= 0kJ/mol
57
𝐶𝑂2(v, 25℃, 1 bar) → 𝐶𝑂2 (v, 25℃, 70 bar)
= 0kJ/mol
𝐶𝑂(v, 25℃, 1 bar) → 𝐶𝑂(v, 25℃, 70 bar)
= 0kJ/mol
𝐻2 𝑂(v, 25℃, 1 bar) → 𝐻2 𝑂(v, 25℃, 70 bar)

= 0kJ/mol
𝐶𝐻4 (v, 25℃, 1 bar) → 𝐶𝐻4 (v, 25℃, 70 bar)

= 0kJ/mol
𝐻2 (v, 25℃, 1 bar) → 𝐻2 (v, 50℃, 1 bar) → 𝐻2 (v, 50℃, 70 bar)
H7 = ∆𝑇 + ∆𝑃 ← 𝑎𝑠𝑠𝑢𝑚𝑒 𝑖𝑑𝑒𝑎𝑙 𝑔𝑎𝑠

50
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 0.721kJ/mol
𝑁2 (v, 25℃, 1 bar) → 𝑁2 (v, 50℃, 1 bar) → 𝑁2 (v, 50℃, 70 bar)

50
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 0.727kJ/mol
58
𝐶𝑂2(v, 25℃, 1 bar) → 𝐶𝑂2 (v, 50℃, 1 bar) → 𝐶𝑂2(v, 50℃, 70 bar)

50
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 0.941kJ/mol
𝐶𝑂(v, 25℃, 1 bar) → 𝐶𝑂(v, 50℃, 1 bar) → 𝐶𝑂(v, 50℃, 70 bar)

50
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 0.728kJ/mol
𝐻2 𝑂(v, 25℃, 1 bar) → 𝐻2 𝑂(v, 50℃, 1 bar) → 𝐻2 𝑂(v, 50℃, 70 bar)

50
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 0.843kJ/mol
𝐶𝐻4 (v, 25℃, 1 bar) → 𝐶𝐻4 (v, 50℃, 1 bar) → 𝐶𝐻4 (v, 50℃, 70 bar)

50
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 0.909kJ/mol
𝐶𝐻3 𝑂𝐻(v, 25℃, 1 bar) → 𝐶𝐻3 𝑂𝐻(v, 50℃, 1 bar) → 𝐶𝐻3 𝑂𝐻(v, 50℃, 70 bar)

50
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 1.150kJ/mol
𝐻2 (v, 25℃, 1 bar) → 𝐻2 (v, 206.3℃, 1 bar) → 𝐻2 (v, 206.3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
59
= 5.240kJ/mol
𝑁2 (v, 25℃, 1 bar) → 𝑁2 (v, 206.3℃, 1 bar) → 𝑁2 (v, 206.3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 5.319kJ/mol
𝐶𝑂2(v, 25℃, 1 bar) → 𝐶𝑂2 (v, 206.3℃, 1 bar) → 𝐶𝑂2(v, 206.3℃, 70 bar)

206.3
=∫25 𝐶𝑃 𝑑𝑇 + 0
= 7.353kJ/mol
𝐶𝑂(v, 25℃, 1 bar) → 𝐶𝑂(v, 206.3℃, 1 bar) → 𝐶𝑂(v, 206.3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 5.344kJ/mol
𝐻2 𝑂(v, 25℃, 1 bar) → 𝐻2 𝑂(v, 206.3℃, 1 bar) → 𝐻2 𝑂(v, 206.3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 6.231kJ/mol
𝐶𝐻4 (v, 25℃, 1 bar) → 𝐶𝐻4 (v, 206.3℃, 1 bar) → 𝐶𝐻4 (v, 206.3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 7.373kJ/mol
60
𝐶𝐻3 𝑂𝐻(v, 25℃, 1 bar) → 𝐶𝐻3 𝑂𝐻(v, 206.3℃, 1 bar) → 𝐶𝐻3 𝑂𝐻(v, 206,3℃, 70 bar)

206.3
= ∫25 𝐶𝑃 𝑑𝑇 + 0
= 9.465kJ/mol
𝑄̇ = ∆𝐻̇ = ∑ 𝑛̇ 𝑜𝑢𝑡 𝐻
̂𝑖𝑛
= [(11558746 × 5.240) + (427649.1 × 5.319) + (3380368.5 × 7.353) + (908860 × 5.344) +

(49192.2 × 6.231) + (7383414.7 × 7.373) + (185788.3 × 9.465)] – [(9062988.8 × 0.721) +
(389102.8× 0.727) + (2669262.8× 0.941) + (684082.6 × 0.728) + (48181× 0.843) +
(6715452.6× 0.909) + (185788.3 × 1.150)]
𝑘𝐽 1ℎ
= 132872510.835 ℎ × 3600𝑠
= 36909.031kW
61
• Energy Balance on Flash Drum, V-101
S6
T=65℃
P=40bar
S5 vapour
V-101
T=110℃
P=14bar
vapour
S8
T=50℃
P=40bar
Mixture of vapour and
liquid

Substances
n in H in n out H out n out H out
CO(g) 751.8148 𝐻1𝑎 684.0826 𝐻1𝑏 67.7322 𝐻1𝑐
CO2 (g) 2956.1704 𝐻2𝑎 2669.2628 𝐻2𝑏 286.9076 𝐻2𝑐
H2 (g) 9959.8233 𝐻3𝑎 9062.9888 𝐻3𝑏 896.8346 𝐻3𝑐
H2O (g) 473.6201 𝐻4𝑎 48.1810 𝐻4𝑏 - -
H2O (l) - - - - 425.4390 𝐻4𝑐
CH3OH (g) 767.6387 𝐻5𝑎 185.7883 𝐻5𝑏 - -
CH3OH (l) - - - - 581.8504 𝐻5𝑐
N2 (g) 427.6491 𝐻6𝑎 389.1028 𝐻6𝑏 38.5463 𝐻6𝑐
CH4 (g) 7383.4147 𝐻7𝑎 6715.4526 𝐻7𝑏 667.9620 𝐻7𝑐
T and P 110℃ and 14 bar 65℃ and 40 bar 65℃ and 40 bar
Unit: n (kmol/h), H (kJ/mol)
62
Density at 25℃ and 1 atm
Calculate 𝑉̂ ,
𝑘𝐽
𝑉̂ (𝑚𝑜𝑙 ) = 1.013 × 10−4 [(Molecular weight) (∆P) / (Specific Gravity)]
For gas phase, we assume as ideal gas, ∆H = 𝑉̂ 𝑃 = 0
Substances Molecular weight (g/mol) Specific gravity (𝑔/𝑐𝑚3 )

H2 O (l) 18.01 1
CH3 OH (l) 32.04 0.764
Reference state: CO(g), CO2 (g), H2 (g), N2 (g), CH4 (g), H2O (l), and CH3OH (l) at 1 atm
and 25℃
Stream 5
Calculate 𝐻1𝑎 ;
𝐶𝑂(𝑣, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝑂(𝑣, 110℃, 1 𝑎𝑡𝑚) → 𝐶𝑂 (𝑣, 110℃, 13.817 𝑎𝑡𝑚)
110
𝐻1𝑎 = ∫25 (28.95 × 10−3 ) + (0.4110 × 10−5 )T + (0.3548 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝑂
= 2.4859 + 0
= 2.4859 kJ/mol
𝐶𝑂2 (𝑣, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝑂2 (𝑣, 110℃, 1 𝑎𝑡𝑚) → 𝐶𝑂2 (𝑣, 110℃, 13.817 𝑎𝑡𝑚)
110
𝐻2𝑎 =∫25 ( 36.111 × 10−3 ) + (4.233 × 10−5 )T − (2.887 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝑂2
= 3.2996 + 0
= 3.2996 kJ/mol
𝐻2 (𝑣, 25℃, 1 𝑎𝑡𝑚) → 𝐻2 (𝑣, 110℃, 1 𝑎𝑡𝑚) → 𝐻2 (𝑣, 110℃, 13.817 𝑎𝑡𝑚)
110
𝐻3𝑎 = ∫25 (28.84 × 10−3 ) + (0.00765 × 10−5 )T + (0.3288 × 10−8 )𝑇 2 dT + 𝑉̂𝐻2
= 2.4533 + 0
= 2.4533 kJ/mol
63
𝐻2 𝑂 (𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂 (𝑙, 100℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂 (𝑣, 100℃, 1 𝑎𝑡𝑚) →
𝐻2 𝑂 (𝑣, 110℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂 (𝑣, 110℃, 13.817 𝑎𝑡𝑚)
100 110
𝐻4𝑎 = ∫25 (75.4 × 10−3 ) dT + (𝐻𝑣)𝐻2 𝑂 + ∫100 (33.46 × 10−3 ) + (0.688 × 10−5 )𝑇 +
(0.7604 × 10−8 )𝑇 2 dT + 𝑉̂𝐻 𝑂
2
= 5.6550 + 40.6560 + 0.3427 + 0
= 46.6537 kJ/mol
𝐶𝐻3 𝑂𝐻 (𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻 (𝑙, 64.7℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻 (𝑣, 64.7℃, 1 𝑎𝑡𝑚) →
𝐶𝐻3 𝑂𝐻 (𝑣, 110℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻 (𝑣, 110℃, 13.817 𝑎𝑡𝑚)
64.7 110
𝐻5𝑎 = ∫25 (75.86 × 10−3 ) + (16.83 × 10−5 )T dT + 𝐻𝑣𝐶𝐻3 𝑂𝐻 + ∫64.7 (42.93 × 10−3 ) +
(8.301 × 10−5 )T − (1.87 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝐻 𝑂𝐻
3
= 3.3113 + 35.2700 + 2.2732 + 0
= 40.8545 kJ/mol
𝑁2 (𝑣, 25℃, 1 𝑎𝑡𝑚) → 𝑁2 (𝑣, 110℃, 1 𝑎𝑡𝑚) → 𝑁2 (𝑣, 110℃, 13.817 𝑎𝑡𝑚)
110
𝐻6𝑎 =∫25 (29 × 10−3 ) + (0.2199 × 10−5 )T + (0.5723 × 10−8 )𝑇 2 dT + 𝑉̂𝑁2
= 2.4801 + 0
= 2.4801 kJ/mol
𝐶𝐻4 (𝑣, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝐻4 (𝑣, 110℃, 1 𝑎𝑡𝑚) → 𝐶𝐻4 (𝑣, 110℃, 13.817 𝑎𝑡𝑚)
110
𝐻7𝑎 = ∫25 (34.31 × 10−3 ) + (5.649 × 10−5 )T + (0.3661 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝐻4
= 3.2421 + 0
= 3.2421 kJ/mol
64
Stream 6
Calculate 𝐻1𝑏 ;
65
𝐻1𝑏 = ∫25 (28.95 × 10−3 ) + (0.4110 × 10−5 )T + (0.3548 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝑂
= 1.1657 + 0
= 1.1657 kJ/mol
65
𝐻2𝑏 =∫25 ( 36.111 × 10−3 ) + (4.233 × 10−5 )T − (2.887 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝑂2
= 1.5181 + 0
= 1.5181 kJ/mol
65
𝐻3𝑏 = ∫25 (28.84 × 10−3 ) + (0.00765 × 10−5 )T + (0.3288 × 10−8 )𝑇 2 dT + 𝑉̂𝐻2
= 1.1540 + 0
= 1.1540 kJ/mol
𝐻2 𝑂 (𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂 (𝑙, 100℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂 (𝑣, 100℃, 1 𝑎𝑡𝑚) →
𝐻2 𝑂 (𝑣, 100℃, 39.477 𝑎𝑡𝑚) → 𝐻2 𝑂 (𝑣, 65℃, 39.477 𝑎𝑡𝑚)
100 65
𝐻4𝑏 = ∫25 (75.4 × 10−3 )dT + (𝐻𝑣)𝐻2𝑂 + + 𝑉̂𝐻2𝑂 + ∫100(33.46 × 10−3 ) +
(0.688 × 10−5 )𝑇 + (0.7604 × 10−8 )𝑇 2 dT
= 5.6550 + 40.656 + 0 – 1.1928
= 45.1182 kJ/mol
65
𝐶𝐻3 𝑂𝐻 (𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻 (𝑙, 64.7℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻 (𝑣, 64.7℃, 1 𝑎𝑡𝑚) →
𝐶𝐻3 𝑂𝐻 (𝑣, 64.7℃, 39.477 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻 (𝑣, 65℃, 39.477 𝑎𝑡𝑚)
64.7
𝐻5𝑏 = ∫25 (75.86 × 10−3 ) + (16.83 × 10−5 )T dT + 𝐻𝑣𝐶𝐻3 𝑂𝐻 + 𝑉̂𝐶𝐻3𝑂𝐻 +
65
∫64.7 (42.93 × 10−3 ) + (8.301 × 10−5 )T − (1.87 × 10−8 )𝑇 2 dT
= 3.3113 + 35.270 + 0 + 0.0144
= 38.5957 kJ/mol
65
𝐻6𝑏 =∫25 (29 × 10−3 ) + (0.2199 × 10−5 )T + (0.5723 × 10−8 )𝑇 2 dT + 𝑉̂𝑁2
= 1.1605 + 0
= 1.1605 kJ/mol
65
𝐻7𝑏 = ∫25 (34.31 × 10−3 ) + (5.649 × 10−5 )T + (0.3661 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝐻4
= 1.4744 + 0
= 1.4744 kJ/mol
Stream 8
Calculate 𝐻1𝑐 ;
50
𝐻1𝑐 = ∫25 (28.95 × 10−3 ) + (0.4110 × 10−5 )T + (0.3548 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝑂
= 0.7277 + 0
= 0.7277 kJ/mol
66
50
𝐻2𝑐 =∫25 ( 36.111 × 10−3 ) + (4.233 × 10−5 )T − (2.887 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝑂2
= 0.9414 + 0
= 0.9414 kJ/mol
50
𝐻3𝑐 = ∫25 (28.84 × 10−3 ) + (0.00765 × 10−5 )T + (0.3288 × 10−8 )𝑇 2 dt + 𝑉̂𝐻2
= 0.7212 + 0
= 0.7212 kJ/mol
𝐻2 𝑂 (𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂 (𝑙, 50℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂 (𝑙, 50℃, 39.477 𝑎𝑡𝑚)
50
𝐻4𝑐 = ∫25 (75.4 × 10−3 )dT + 𝑉̂𝐻2𝑂
= 1.8850 + 1.013 × 10−4 [(18.01) (39.477 − 1) / (1)]
= 1.8850 + 0.0039
= 1.8889 kJ/mol
𝐶𝐻3 𝑂𝐻 (𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻 (𝑙, 50℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻 (𝑙, 50℃, 39.477 𝑎𝑡𝑚)
50
𝐻5𝑐 = ∫25 (75.86 × 10−3 ) + (16.83 × 10−5 )T dT + 𝑉̂𝐶𝐻3𝑂𝐻
= 2.0543 + 1.013 × 10−4 [(32.04) (39.477 − 1) / (0.764)]
= 2.0543 + 0.1635
= 2.0987 kJ/mol
67
50
𝐻6𝑐 =∫25 (29 × 10−3 ) + (0.2199 × 10−5 )T + (0.5723 × 10−8 )𝑇 2 dT + 𝑉̂𝑁2
= 0.7273 + 0
= 0.7273 kJ/mol
−161.6
𝐻7𝑐 = ∫25 (34.31 × 10−3 ) + (5.649 × 10−5 )T + (0.3661 × 10−8 )𝑇 2 dT + 𝑉̂𝐶𝐻4
= 0.9108 + 0
= 0.9108 kJ/mol
Stream 5;
∑ Hin(n in) = (751.8148)(2.4859) + (2956.1704)(3.2996) + (9959.8233)(2.4533) +
(473.6201)(46.6537) + (767.6387)(40.8545) + (427.6491)(2.4801) + (7383.4147)(3.2421)
= 114,513,557.4254 kJ/h
Stream 6;
∑ H out(n out) = (684.0826)(1.1657) + (2669.2628)( 1.5181) + (9062.9888)( 1.1540) +
(48.1810)(45.1182) + (185.7883)(38.5957) + (389.1028)( 1.1605) + (6715.4526)(1.4744)
= 35,005,618.6161 kJ/h
Stream 8;
∑ H out(n out) = (67.7322)( 0.7277) + (286.9076)(0.9414) + (896.8346)(0.7212) +
(425.4390)(1.8889) + (581.8504)(2.0987) + (38.5463)(0.7273) + (667.9620)(0.9108)
= 3,627,336.3253 kJ/h
𝑄 = ∑ H out(n out) − ∑ H in(n in)
= (35,005,618.6161 + 3,627,336.3253) – (114,513,557.4254)

= - 75,880.60 × 𝟏𝟎𝟑 kJ/h
68
• Energy Balance on Distillation Column, T-101
S10
T = 18oC
P = 11 bar
S9 vapour
T-101
T= 50oC
P = 12 bar
Mixture of S12
vapour and
liquid
T = 143.70oC
P = 11 bar
liquid
Substances Stream 9 Stream 10 Stream 12

nin Hin nin Hin nin Hin
CO (g) 67.7322 H9a 67.7322 H11a - -
CO2 (g) 289.9076 H9b 289.9076 H11b - -
H2 (g) 896.8346 H9c 896.8346 H11c - -
N2 (g) 38.5463 H9d 38.5463 H11d - -
CH4 (g) 667.9620 H9e 667.9620 H11e - -
H2O (l) 425.4390 H9f 15.6470 H11f 409.7920 H12a
CH3OH (l) 581.8504 H9g 140.8228 H11g 441.0277 H12b
Unit: n (kmol/h), H (kJ/mol)
69
Calculate 𝑉̂ ∆𝑃 for pressure change,
𝑉̂ ∆𝑃 = 1.013−4 × (𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡) × ∆𝑃/(𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑔𝑟𝑎𝑣𝑖𝑡𝑦)
For gas phase, assume as ideal gas ∆H = 𝑉̂ ∆𝑃 = 0
Substances Molecular weight (g/mol) Specific Gravity

H2O 18.016 1
CH3OH 32.04 0.792
Reference state: CO (g), CO2 (g), N2 (g), CH4 (g), H2O (l), CH3OH (l) at T = 25℃, P = 1 atm
Stream 9,
𝐶𝑂(𝑣, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝑂(𝑣, 50℃, 1 𝑎𝑡𝑚) → 𝐶𝑂(𝑣, 50℃, 11.84 𝑎𝑡𝑚)
50
𝐻9𝑎 = ∫25 (28.95 × 10−3 + 0.4110 × 10−5 𝑇 + 0.3548 × 10−8 𝑇 2 )𝑑𝑇 + 𝑉̂ ∆𝑃𝐶𝑂
= 0.7238 + 0
= 0.7238 kJ/mol
50
𝐻9𝑏 = ∫25 (36.11 × 10−3 + 4.233 × 10−5 𝑇 − 2.887 × 10−8 𝑇 2 )𝑑𝑇 + 𝑉̂ ∆𝑃𝐶𝑂2
= 0.9028 + 0
= 0.9028 kJ/mol
𝐻2 (𝑣, 25℃, 1 𝑎𝑡𝑚) → 𝐻2 (𝑣, 50℃, 1 𝑎𝑡𝑚) → 𝐻(𝑣, 50℃, 11.84 𝑎𝑡𝑚)
50
𝐻9𝑐 = ∫25 (28.84 × 10−3 + 0.00765 × 10−5 𝑇 + 0.3288 × 10−8 𝑇 2 )𝑑𝑇 + 𝑉̂ ∆𝑃𝐻2
= 0.7210 + 0
= 0.7210 kJ/mol
50
𝐻9𝑑 = ∫25 (29.00 × 10−3 + 0.2199 × 10−5 𝑇 + 0.5723 × 10−8 𝑇 2 )𝑑𝑇 + 𝑉̂ ∆𝑃𝑁2
= 0.7250 + 0
= 0.7250 kJ/mol
70
50
𝐻9𝑒 = ∫25 (34.31 × 10−3 + 5.469 × 10−5 𝑇 + 0.3661 × 10−8 𝑇 2 )𝑑𝑇 + 𝑉̂ ∆𝑃𝐶𝐻4
= 0.8578 + 0
= 0.8578 kJ/mol
𝐻2 𝑂(𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂(𝑙, 50℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂(𝑙, 50℃, 11.84 𝑎𝑡𝑚)
50
𝐻9𝑓 = ∫25 75.40 × 10−3 𝑑𝑇 + 𝑉̂ ∆𝑃𝐻2𝑂
= 1.8850 + 0.0198
= 1.9048 kJ/mol
𝐶𝐻3 𝑂𝐻(𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻(𝑙, 50℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻(𝑙, 50℃, 11.84 𝑎𝑡𝑚)
50
𝐻9𝑔 = ∫25 (75.86 × 10−3 + 16.83 × 10−5 𝑇)𝑑𝑇 + 𝑉̂ ∆𝑃𝐶𝐻3𝑂𝐻
= 1.8965 + 0.0444
= 1.9409 kJ/mol
Stream 11,
𝐶𝑂(𝑣, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝑂(𝑣, 18℃, 1 𝑎𝑡𝑚) → 𝐶𝑂(𝑣, 18℃, 10.86 𝑎𝑡𝑚)
18
𝐻11𝑎 = ∫25 (28.95 × 10−3 + 0.4110 × 10−5 𝑇 + 0.3548 × 10−8 𝑇 2 ) 𝑑𝑇 + 𝑉̂ ∆𝑃𝐶𝑂
= -0.2027 + 0
= -0.2027 kJ/mol
18
𝐻11𝑏 = ∫25 (36.11 × 10−3 + 4.233 × 10−5 𝑇 − 2.887 × 10−8 𝑇 2 ) 𝑑𝑇 + 𝑉̂ ∆𝑃𝐶𝑂2
= -0.2528 + 0
= -0.2528 kJ/mol
71
18
𝐻11𝑐 = ∫25 (28.84 × 10−3 + 0.00765 × 10−5 𝑇 + 0.3288 × 10−8 𝑇 2 ) 𝑑𝑇 + 𝑉̂ ∆𝑃𝐻2
= -0.2019 + 0
= -0.2019 kJ/mol
18
𝐻11𝑑 = ∫25 (29.00 × 10−3 + 0.2199 × 10−5 𝑇 + 0.5723 × 10−8 𝑇 2 ) 𝑑𝑇 + 𝑉̂ ∆𝑃𝑁2
= -0.2030 + 0
= -0.2030 kJ/mol
18
𝐻11𝑔 = ∫25 (34.31 × 10−3 + 5.469 × 10−5 𝑇 + 0.3661 × 10−8 𝑇 2 ) 𝑑𝑇 + 𝑉̂ ∆𝑃𝐶𝐻4
= -0.2402 + 0
= -0.2402 kJ/mol
𝐻2 𝑂(𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂(𝑙, 18℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂(𝑙, 18℃, 10.86 𝑎𝑡𝑚)
18
𝐻11𝑓 = ∫25 75.40 × 10−3 𝑑𝑇 + 𝑉̂ ∆𝑃𝐻2𝑂
= -0.5278 + 0.0179
= -0.5099 kJ/mol
𝐶𝐻3 𝑂𝐻(𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻(𝑙, 18℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻(𝑙, 18℃, 10.86 𝑎𝑡𝑚)
18
𝐻11𝑓 = ∫25 (75.86 × 10−3 + 16.83 × 10−5 𝑇)𝑑𝑇 + 𝑉̂ ∆𝑃𝐶𝐻3𝑂𝐻
= -0.5310 + 0.0404
= -0.4906 kJ/mol
72
Stream 12,
𝐻2 𝑂(𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂(𝑙, 100℃, 1𝑎𝑡𝑚) → 𝐻2 𝑂(𝑣, 100℃, 1 𝑎𝑡𝑚) →

𝐻2 𝑂(𝑣, 143.70℃, 1 𝑎𝑡𝑚) → 𝐻2 𝑂(𝑣, 143.70℃, 10.86 𝑎𝑡𝑚)
100 143.70
𝐻12𝑎 = ∫25 (75.40 × 10−3 ) 𝑑𝑇 + 40.656 + ∫100 (33.46 × 10−3 + 0.6880 × 10−5 𝑇 +
0.7604 × 10−8 𝑇 2 )𝑑𝑇 + 𝑉̂ ∆𝑃𝐻2𝑂
= 5.6550 + 40.656 + 1.4622 + 0

= 47.7732 kJ/mol
𝐶𝐻3 𝑂𝐻(𝑙, 25℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻(𝑙, 64.7℃, 1𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻(𝑣, 64.7℃, 1 𝑎𝑡𝑚) →
𝐶𝐻3 𝑂𝐻(𝑣, 143.70℃, 1 𝑎𝑡𝑚) → 𝐶𝐻3 𝑂𝐻(𝑣, 143.70℃, 10.86 𝑎𝑡𝑚)
64.7 143.70
𝐻12𝑏 = ∫25 (75.86 × 10−3 + 16.83 × 10−5 𝑇)𝑑𝑇 + 35.27 + ∫64.7 (42.93 × 10−3 +
8.301 × 10−5 𝑇 − 1.87 × 10−8 𝑇 2 )𝑑𝑇 + 𝑉̂ ∆𝑃𝐶𝐻3𝑂𝐻
= 3.0116 + 35.27 + 3.3915 + 0

= 41.6731 kJ/mol
Stream 9;
∑ Hin(n in) = (0.7238)(67 732.2) + (0.9028)(289 907.6) + (0.7210)(896 834.6) +
(0.7250)(38 546.3) + (0.8578)(667 962.0) + (1.9048)(425 439.0) + (1.9409)(581 850.4)
= 3,497,984.41 kJ/h
Stream 11;
∑ H out(n out) = (-0.2027)(67 732.2) + (-0.2528)(289 907.6) + (-0.2019)(896 834.6) + (-
0.2030)(38 546.3) + (-0.2402)(667 962.0) + (-0.5099)(15 647.0) + (-0.4906)(140 822.8)
= -513,424.31 kJ/h
Stream 12;
∑ H out(n out) = (47.7732)( 409 792.0) + (41.6731)(441 027.7)
= 37,956,066.62 kJ/h
𝑄 = ∑ H out(n out) − ∑ H in(n in)
= (-513,424.31 +37,956,066.62) – (3,497,984.41)

= 33,943.66 × 𝟏𝟎𝟑 kJ/h
73
• Energy Balance on Distillation Column, T-102
S13
T = 138.6 °C
P = 11 bar
vapour
S12
T-102
T = 143.7 °C
P = 11 bar
liquid
S14
T = 178.6 °C
P = 11 bar
liquid
Component Stream 11 Stream 12 Stream 13
ńin Ĥin ńout Ĥout ńout Ĥout

(kmol/h) (kJ/mol) (kmol/h) (kJ/mol) (kmol/h) (kJ/mol)
H2O 425.4390 Ĥ1 = 0 0.5464 Ĥ3 = 38.6885 424.8926 Ĥ5 = 2.6315
CH3OH 441.0277 Ĥ2 = 0 438.7841 Ĥ4 = 33.0583 2.2436 Ĥ6 = 2.6475
Density at 25°C and 1.01325 bar

Calculate 𝑉̂ ∆𝑃 for pressure change,
𝑘𝐽
𝑉̂ 𝛥𝑃 (𝑚𝑜𝑙 )= 1.013 × 10−4 [(Molecular weight) (∆P) / (Specific Gravity)]
74
For gas phase, assume as ideal gas, ∆H = 𝑉̂ 𝛥𝑃 = 0
Substances Molecular weight (g/mol) Specific Gravity
H2O 18.016 1
CH3OH 32.04 0.792
By taking the inlet stream as references point: H2O (l), and CH3OH (l) at 11 bar and
143.7℃
Ḣ1 = 0 kJ/mol, Ḣ2 = 0 kJ/mol → Ḣin = 0 kJ/mol
Stream 12
Calculate Ḣ3:
𝐻2 𝑂(𝑙, 143.7℃, 11 𝑏𝑎𝑟) → 𝐻2 𝑂(𝑙, 100℃, 11 𝑏𝑎𝑟) → 𝐻2 𝑂(𝑣, 100℃, 1.01325 𝑏𝑎𝑟) →
𝐻2 𝑂(𝑣, 138.6℃, 1.01325 𝑏𝑎𝑟) → 𝐻2 𝑂(𝑣, 138.6℃, 11 𝑏𝑎𝑟)
100 138.6
Ḣ3 = ∫143.7(0.0754)𝑑𝑇 + (𝐻𝑣 )𝐻2𝑂 + 𝑉̂ ∆𝑃𝐻2𝑂 + ∫100 ( 0.03346) + (0.688 × 10−5 )𝑇 +
(0.7604 × 10−8 )𝑇 2 𝑑𝑇 + 𝑉̂ ∆𝑃𝐻2𝑂
Ḣ3 =−3.295 + 40.656 + 0 + 1.3275 + 0 = 𝟑𝟖. 𝟔𝟖𝟖𝟓 𝒌𝑱/𝒎𝒐𝒍
Calculate Ḣ4:
𝐶𝐻3 𝑂𝐻(𝑙, 143.7℃, 11 𝑏𝑎𝑟) → 𝐶𝐻3 𝑂𝐻(𝑙, 64.7℃, 11 𝑏𝑎𝑟) →

𝐶𝐻3 𝑂𝐻(𝑣, 64.7℃, 1.01325 𝑏𝑎𝑟) → 𝐶𝐻3 𝑂𝐻(𝑣, 138.6℃, 1.01325 𝑏𝑎𝑟) →
𝐶𝐻3 𝑂𝐻(𝑣, 138.6℃, 11 𝑏𝑎𝑟)
64.7
Ḣ4 = ∫143.7(0.07586) + (16.83 × 10−5 )𝑇 𝑑𝑇 + (𝐻𝑣 )𝐶𝐻3𝑂𝐻 + 𝑉̂ ∆𝑃𝐶𝐻3𝑂𝐻 +
138.6
∫64.7 ( 0.04293) + (8.301 × 10−5 )𝑇 − (1.87 × 10−8 )𝑇 2 𝑑𝑇 + 𝑉̂ ∆𝑃𝐻2𝑂
Ḣ4 = −5.9929 + 35.27 + 0 + 3.7812 + 0 = 𝟑𝟑. 𝟎𝟓𝟖𝟑 𝒌𝑱/𝒎𝒐𝒍
75
Stream 13
Calculate Ḣ5:
𝐻2 𝑂(𝑙, 143.7℃, 11 𝑏𝑎𝑟) → 𝐻2 𝑂(𝑙, 178.6℃, 11 𝑏𝑎𝑟)
178.6
Ḣ5 = ∫143.7 ( 0.0754)𝑑𝑇
Ḣ5 = 𝟐. 𝟔𝟑𝟏𝟓 𝒌𝑱/𝒎𝒐𝒍
Calculate Ḣ6:
𝐶𝐻3 𝑂𝐻(𝑙, 143.7℃, 11 𝑏𝑎𝑟) → 𝐶𝐻3 𝑂𝐻(𝑙, 178.6℃, 11 𝑏𝑎𝑟)
178.6
Ḣ6 = ∫143.7 ( 0.07586)𝑑𝑇
Ḣ6 = 𝟐. 𝟔𝟒𝟕𝟓 𝒌𝑱/𝒎𝒐𝒍
Q = ΔḢ = ΣḢout - ΣḢin = ΣṅoutĤout – ΣṅinĤin = ΣṅoutĤout
𝑚𝑜𝑙 38.6885𝑘𝐽 103 𝑚𝑜𝑙 33.0583𝑘𝐽

= [(0.5464 × 103 )( )(438.7841 × )( )] + [(424.8926 ×
ℎ 𝑚𝑜𝑙 ℎ 𝑚𝑜𝑙
103 𝑚𝑜𝑙 𝑘𝐽 103 𝑚𝑜𝑙 2.6475𝑘𝐽
) (2.6315 𝑚𝑜𝑙) + (2.2436 × )( )]
ℎ ℎ 𝑚𝑜𝑙
Q = 21139.3964 + (145.05 x 105) + (111.81 x 104) + 5939.931
Q = 1565.018 x 104 kJ/h
76
CHAPTER 5: EQUIPMENT DESIGN AND SIZING
Heuristic for Reactor R-101
Stream Number 3 4
o
Temperature ( C) 206.30 252.50
Pressure (bar) 70.00 69.00
Vapor Fraction 1.000 1.000
Mass Flow (kg/h) 334241.2786 334240.3686
Mole Flow (kmol/h) 23894.0187 22720.1311
Carbon Monoxide 908.8600 751.8148
Carbon Dioxide 3380.3685 2956.1704
Hydrogen 11558.7460 9959.8233
Water 49.1922 473.6201
Methanol 185.7883 767.6387
Nitrogen 427.6491 427.6491
Methane 7383.4147 7383.4147
CO2 + 3H2 ↔ CH3OH + H2O ------ (main reaction)
Rate law for this reaction, -rA = kCACB
Find specific rate constant, k
Diameter reactor= 2.5 m
Length reactor = 3.5 m
𝜋𝐷 2 𝐿 𝜋(2.5)2 (3.5) 1000𝐿

Volume reactor = = = 17.18𝑚3 × = 17180 𝐿
4 4 1𝑚3
77
From the stream table
Assume the entering reactant is pure gas, so 𝑌𝐴𝑂 = 1 and Carbon dioxide as limiting reactant
FAO = 3380.3685 kmol/hr
FBO = 11558.7460 kmol/hr
𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑖𝑛 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛

Single pass conversion, X = 𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑓𝑒𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
11558.746−9959.8233
X= 11558.7460
X = 0.1383
Assume reactant enter the reactor is a pure gas thus, yAO = 1
𝑦ᴀᴏ𝑃ᴏ (1)(70 𝑎𝑡𝑚)

CAO = = 𝐿.𝑎𝑡𝑚 = 1.779 mol/L
𝑅𝑇ᴏ 0.08205 (206.30+273.15)𝐾
𝑚𝑜𝑙.𝐾
Concentration carbon dioxide, CA and hydrogen, CB
𝐶ᴀᴏ(1−𝑋)
CA = 1+ ℰ𝑋
𝐶ᴀᴏ(Ѳ𝐴−1)
CB = 1+ ℰ𝑋
ε = yAOδ
𝑑 𝑐 𝑏
δ=𝑎+𝑎−𝑎−1
δ = 1+ 1 – 3 – 1 = -2
ε = yAOδ = (1)(-2) = -2
𝑘𝑚𝑜𝑙
𝐹𝐵𝑜 11558.7460
ѲB = 𝐹𝐴ᴏ = ℎ𝑟
𝑘𝑚𝑜𝑙 = 3.419
3380.3685
ℎ𝑟
1.779(1−0.1383)
CA = 1+ (−2)(0.1383) = 2.1191 𝑚𝑜𝑙/𝐿
1.779(3.419−1)
CB = 1+ (−2)(0.1383) = 5.9489 𝑚𝑜𝑙/𝐿
78
𝐹𝑎𝑜𝑋 𝐹𝑎𝑜𝑋
From this equation, V = rearranged it into this equation -rA = , then substitute value
−𝑟𝐴 𝑉
of FAO, X and V.
𝑘𝑚𝑜𝑙
𝐹𝑎𝑜𝑋 3380.3685 (0.1383)
ℎ𝑟
-rA = = = 0.0272 kmol/L.hr
𝑉 17180 𝐿
𝑚𝑜𝑙
−𝑟𝐴 27.2122
𝑘= = 𝐿. ℎ𝑟 = 2.1586 𝐿/𝑚𝑜𝑙. ℎ𝑟
𝐶𝐴 𝐶𝐵 (2. .1191)(5.9489)
Insert all information into this table.
X CA CB -rA FAO/-rA
0.01 1.7972 4.3912 0.001968 1717666.921
0.02 1.8161 4.4827 0.003935 859051.7154
0.04 1.8563 4.6776 0.007870 429525.8577
0.06 1.9003 4.8902 0.011806 286326.3171
0.08 1.9484 5.1231 0.015741 214749.2853
0.1383 2.1191 5.9489 0.027212 124223.4492
Volume reactor
𝒅𝑿
V = FAO ∫ −𝒓𝑨
Using formula Simpson’s one third rule,
ℎ
V = ∫ f(x) dx = 3[f(x1) + 4f(x2) + f(x3)]
h = 0.04-0.01
h = 0.03
0.03
V= [1717666.921+ 4(859051.7154) + 429525.8577]
3
V = 55833.9964 L
79
Using formula Simpson’s one third rule,
ℎ
V = ∫ f(x) dx = 3[f(x1) + 4f(x2) + f(x3)]
h = 0.1383-0.06
h = 0.0783
0.0783
V= [286326.3171+ 4(214749.2853) + 124223.4492]
3
V = 33135.1743 L
Volume total, VT
VT = 55833.9964 L + 33135.1743 L
0.001 𝑚3
VT = 88969.1707 L x 1𝐿
VT = 88.97 m3
For Height and Diameter of reactor, it has been scales up from the references.
D = 3.5 m & L = 9.2474 m
Based on heuristic, L/D = 2.5
L/D = 9.2474/ 3.5 = 2.64
Therefore, it consistent with heuristic.
80
Heuristic for Heat Exchanger, E-101
Rule 1: Set F= 0.9 for shell-and-tube exchangers with no phase changes, 𝑞 = 𝑈𝐴𝐹∆𝑇𝑙𝑚 ,
when ∆𝑇 at exchanger ends differ greatly, reconfigure if F is less than 0.85
Rule 6: minimum temperature approach is 10 ℃ for fluids
∆𝑇 = 206.30 − 38 = 168 ℃, does not violated Rule 6
Rule 7: Cooling water inlet is 30 ℃, maximum outlet 45 ℃
Rule 8: Heat transfer coefficient for estimating purposes, (𝑊 ⁄𝑚2 . ℃): water to liquid 850
𝑈 = 850 𝑊 ⁄𝑚2 . ℃
From energy balance E-101,
𝑄 = 41,405.059 𝑘𝑊
Assume the flow is counter current flow,
(𝑇ℎ2 − 𝑇𝑐2 ) − (𝑇ℎ1 − 𝑇𝑐1 )

∆𝑇𝑙𝑚 =
(𝑇 − 𝑇𝑐2 )
𝑙𝑛 ℎ2
(𝑇ℎ1 − 𝑇𝑐1 )
(206.30 − 30) − (40 − 25)

∆𝑇𝑙𝑚 = = 65.45 ℃
206.30 − 30
𝑙𝑛
40 − 25
Calculate Area,
𝑄 41,405,059
𝐴= = = 826.95 𝑚2
𝑈∆𝑇𝑙𝑚 𝐹 (850)(65.45)(0.9)
Therefore, it consistent with heuristic
81
Heuristic for Compressor, C-101
𝑎
Rule 2: Theoretical reversible adiabatic power = 𝑚𝑧1 𝑅𝑇1 [({𝑃2 ⁄𝑃1 } − 1)]/𝑎 where 𝑇1 is inlet
𝑘−1
Temperature, R= gas constant, 𝑧1 = compressibility, m=molar flow rate, 𝑎 = ,
𝑘
𝐶𝑝
𝑘= 𝐶𝑣
Assume 𝑘 = 1.41, corresponds to a compression ratio of 4
𝑎 = 0.2908
𝐹𝑙𝑜𝑤 = 54 358.822 𝑘𝑔⁄ℎ
𝑚𝑤 = 167.13 𝑘𝑔⁄𝑘𝑚𝑜𝑙
1 1
𝑚𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 = 54,358.822 × ( )×( )
167.13 3600
= 0.0903 𝑘𝑚𝑜𝑙 ⁄𝑠
𝑎
𝑊𝑟𝑒𝑣 𝑎𝑑𝑖𝑎𝑏 = 𝑚𝑧1 𝑅𝑇1 [({𝑃2 ⁄𝑃1 } − 1)]/𝑎
(0.0903)(1)(8.314)(298)[(70⁄10)0.2908 − 1]
=
0.2908
= 585.45 𝑘𝑊
Rule 6: Efficiencies of reciprocating compressors: 80-85% at compression ratios 3-6
𝑊𝑎𝑐𝑡 = 585.45 (0.8) = 486.36 𝑘𝑊
Therefore, it consistent with heuristic
82
Heuristic for Flash Drum, V-101
Rule 3 → Vertical vessel

Rule 4 → L/D between 2.5 and 5 with optimum at 3.0
Rule 5 → Liquid holdup time is 5 min based on ½ volume of vessel
Rule 9 → Gas velocity u is given by
𝜌
𝑢 = 𝑘√𝜌 𝑙 − 1 𝑚/𝑠
𝑣
Where k=0.0305 for vessels without mesh entrainers.

Rule 12 → Good performance obtained at 30%-100% of u from Rule 9, typical value is 75%
From mass balance calculation:

Vapor flow = Stream 6 = 279882.457 kg/h, P = 40 bar, T = 65°C = 323K
Liquid flow = Stream 8 = 54357.912 kg/h, P = 40 bar, T = 50°C = 338K
Density of vapor mixture, ρv:

The mixture vapor is assumed to be ideal so that PV=nRT can be apply.
ṅ𝐶𝑂 ṅ ṅ𝐻2 ṅ
𝑀𝑊𝑎𝑣𝑔 = (ṅ ) (𝑀𝑊𝐶𝑂 ) + (ṅ 𝐶𝑂2 ) (𝑀𝑊𝐶𝑂2 ) + (ṅ ) (𝑀𝑊𝐻2 ) + (ṅ 𝐻2𝑂 ) (𝑀𝑊𝐻2𝑂 ) +
𝑇𝑜𝑡𝑎𝑙 𝑇𝑜𝑡𝑎𝑙 𝑇𝑜𝑡𝑎𝑙 𝑇𝑜𝑡𝑎𝑙
ṅ𝐶𝐻3𝑂𝐻 ṅ𝑁2 ṅ𝐶𝐻4
(ṅ ) (𝑀𝑊𝐶𝐻3𝑂𝐻 ) + (ṅ ) (𝑀𝑊𝑁2 ) + (ṅ ) (𝑀𝑊𝐶𝐻4 )
𝑇𝑜𝑡𝑎𝑙 𝑇𝑜𝑡𝑎𝑙 𝑇𝑜𝑡𝑎𝑙
684.0826 2669.2628 9062.9888 48.2810

𝑀𝑊𝑎𝑣𝑔 = (19754.8589) (28) + (19754.8589) (44) + (19754.8589) (2) + (19754.8589) (18) +
185.7883 389.1028 6715.4526
(19754.8589) (32) + (19754.8589) (28) + (19754.8589) (16)
𝑀𝑊𝑎𝑣𝑔 = 14.1678 𝑘𝑔/𝑘𝑚𝑜𝑙
(4 × 106 𝑃𝑎)(14.1678 𝑔/𝑚𝑜𝑙) 𝑔

𝜌𝑣 = −1 −1
= 20166.7395 3 = 20.166 𝑘𝑔/𝑚3
(8.314 𝐽 𝑚𝑜𝑙 𝐾 )(338 𝐾) 𝑚
83
Density of liquid mixture, ρl:
The density of liquid mixture is obtained from Interpolation of density value from Textbook
Perrys Chemical Engineers Handbook 8th Edition:
Component Density (kg/m3)
CO 42.5257
CO2 106.6552
H2 2.4007
H2O 983.9208
CH3OH 763.6105
N2 304.1740
CH4 25.9080
Total 2229.1948
𝜌𝑙 = 2320.6943 𝑘𝑔/𝑚3 , 𝜌𝑣 = 20.166 𝑘𝑔/𝑚3
From Rule 9:
𝜌𝑙 2320.6943
𝑢 = 𝑘√ − 1 = (0.0305) (√ − 1) = 0.3258 𝑚/𝑠
𝜌𝑣 20.166
From Rule 12:

𝑢𝑎𝑐𝑡 = (0.75)(0.3258) = 0.2443 𝑚/𝑠
The mass flowrate of vapor: 𝑢𝜌𝑣 𝝅𝐷2 /4

𝑢𝜌𝑣 𝝅𝐷2 𝑘𝑔
= 77.7451
4 𝑠
(77.7451)(4)
𝐷=√ = 4.53 𝑚
(0.2443)(20.166)𝜋
From Rule 5:
The volume of the liquid, 0.5𝐿𝜋𝐷2 /4
0.5𝐿𝜋𝐷2 (0.5)(𝜋)(4.53)2 𝐿
= = 8.0514𝐿 𝑚3
4 4
84
5 min liquid flow:
60 𝑠 𝑘𝑔 1ℎ 1
5 𝑚𝑖𝑛 × × 54375.912 × × = 2.0327 𝑚3
1 𝑚𝑖𝑛 ℎ 3600 𝑠 2229.1948 𝑘𝑔/𝑚3
8.0514𝐿 = 2.0327
𝐿 = 0.25 𝑚
From Rule 4: L/D should be in the range of 2.5 to 5

𝐿 0.25
= = 0.0558
𝐷 4.53
Because it is out of range, change to 𝐿 = 2.5𝐷 = (2.5)(4.53) = 11.32 𝑚
Based on the heuristic, V-101 should be a vertical vessel with D = 4.53 m and L = 11.32 m.
Therefore, the diameter and length of the vessel is not consistent with heuristic.
85
Heuristic for Distillation Column, T-101
Stream Feed Overhead Bottom

Temperature (℃) 50 18 143.7
Pressure (bar) 12 11 11
Vapour composition 0 1 0
Total flow (kg/h) 54357.9120 32868.7702 21489.1418
Total flow (kmol/h) 2965.2722 2114.4525 805.8197
Component flow rates (kmol/h)
Carbon Monoxide 67.7322 67.7322 -
Carbon Dioxide 286.9076 286.9076 -
Hydrogen 896.8346 896.8346 -
Water 425.4390 15.6470 425.4390
Methanol 581.8504 140.8228 441.0277
Nitrogen 38.5463 38.5463 -
Methane 667.9620 667.9620 -
By taking methanol as light key component and water as the heavy key component;
140.8228 441.0277
𝑋𝑜𝑣ℎ𝑑 = 2114.4525 = 0.067 𝑋𝑏𝑜𝑡 = 850.8197 = 0.518
Rule 2 (Table 11.13): Relative volatility

Antoine equation used to find vapor pressure for each component;
𝐵
𝑖
𝑙𝑜𝑔10 𝑃𝑖 (𝑚𝑚𝐻𝑔) = 𝐴𝑖 − 𝑇(℃)+𝐶 where P in mmHg and T in ℃
𝑖
Temperature overhead = 18℃

1574.99
𝑙𝑜𝑔10 𝑃1𝑠𝑎𝑡 (𝑚𝑒𝑡ℎ𝑎𝑛𝑜𝑙) = 8.07247 −
18 + 238.86
𝑃1𝑠𝑎𝑡 = 87.2497 𝑚𝑚𝐻𝑔 = 0.1163 𝑏𝑎𝑟
1657.462
𝑙𝑜𝑔10 𝑃2𝑠𝑎𝑡 (𝑤𝑎𝑡𝑒𝑟) = 7.94917 −
18 + 227.02
𝑃2𝑠𝑎𝑡 = 15.2958 𝑚𝑚𝐻𝑔 = 0.0204 𝑏𝑎𝑟
𝑃1𝑠𝑎𝑡 0.1163
𝛼𝑜𝑣ℎ𝑑 = = = 5.701
𝑃2𝑠𝑎𝑡 0.0204
86
Temperature bottom = 143.7℃
1574.99
𝑙𝑜𝑔10 𝑃1𝑠𝑎𝑡 (𝑚𝑒𝑡ℎ𝑎𝑛𝑜𝑙) = 8.07247 −
143.7 + 238.86
𝑃1𝑠𝑎𝑡 = 9 025.9908 𝑚𝑚𝐻𝑔 = 12.0336
1657.462
𝑙𝑜𝑔10 𝑃2𝑠𝑎𝑡 (𝑤𝑎𝑡𝑒𝑟) = 7.94917 −
143.7 + 227.02
𝑃2𝑠𝑎𝑡 = 3 007.7598 𝑚𝑚𝐻𝑔 = 4.0100 𝑏𝑎𝑟
𝑃1𝑠𝑎𝑡 12.0336
𝛼𝑏𝑜𝑡𝑡𝑜𝑚 = 𝑠𝑎𝑡 = = 3.001
𝑃2 4.0100
𝛼 𝑔𝑒𝑜𝑚 𝑎𝑣𝑒 = (5.701 × 3.001)0.5 = 4.136
Fenske equation used to find the minimum number of trays;
𝐿𝐾 𝐻𝐾
𝑙𝑛 [(𝐻𝐾𝐷 ) ( 𝐿𝐾𝐵 )]
𝐷 𝐵
𝑁 𝑚𝑖𝑛 =
ln 𝛼𝑎𝑣𝑒
140.8228 409.7920
𝑙𝑛 [( ) × (441.0277)]
𝑁 𝑚𝑖𝑛 = 15.6470 = 1.496
ln 4.136
Rule 6 (Table 11.13): Rule 6 (Table 11.13): 𝑁𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 = 2𝑁𝑚𝑖𝑛 = 2(1.496) = 2.992
Rule 9 (Table 11.13): Safety factor of 10% on number of trays
Tray efficiency, 𝜀 = 60%
2.992
𝑁 𝑎𝑐𝑡𝑢𝑎𝑙 = × 1.1 = 5.5 = 6 𝑡𝑟𝑎𝑦𝑠
0.6
(𝐹/𝐷)
𝑅 𝑚𝑖𝑛 =
(𝛼 − 1)
(2 965.2722⁄2 114.4525)
𝑅 𝑚𝑖𝑛 = = 0.447
(4.136 − 1)
87
Rule 5 (Table 11.13): The optimum reflux in the range of (1.2 – 1.5) Rmin
1.2𝑅𝑚𝑖𝑛 = 1.2 × 0.447 = 0.536

1.5𝑅𝑚𝑖𝑛 = 1.5 × 0.447 = 0.671
Rule 2 (Table 11.14): Vapor factor 𝐹𝑠 = 𝑢𝜌𝑣0.5 = 1.2 → 1.5 m/s (kg/m3)0.5
ṅ𝐶𝑂 ṅ𝐶𝑂2 ṅ𝐻2 ṅ𝐻2𝑂

𝑀𝑊𝑎𝑣𝑔 = ( ) (𝑀𝑊𝐶𝑂 ) + ( ) (𝑀𝑊𝐶𝑂2 ) + ( ) (𝑀𝑊𝐻2 ) + ( ) (𝑀𝑊𝐻2𝑂 )
ṅ 𝑇𝑜𝑡𝑎𝑙 ṅ 𝑇𝑜𝑡𝑎𝑙 ṅ 𝑇𝑜𝑡𝑎𝑙 ṅ 𝑇𝑜𝑡𝑎𝑙
ṅ𝐶𝐻3𝑂𝐻 ṅ𝑁2 ṅ𝐶𝐻4
+( ) (𝑀𝑊𝐶𝐻3𝑂𝐻 ) + ( ) (𝑀𝑊𝑁2 ) + ( ) (𝑀𝑊𝐶𝐻4 )
ṅ 𝑇𝑜𝑡𝑎𝑙 ṅ 𝑇𝑜𝑡𝑎𝑙 ṅ 𝑇𝑜𝑡𝑎𝑙
67.7322 286.9076 896.8346
𝑀𝑊𝑎𝑣𝑔 = ( ) (28) + ( ) (44) + ( ) (2)
2114.4525 2114.4525 2114.4525
15.6470 140.8228 38.5463
+( ) (18) + ( ) (32) + ( ) (28)
2114.4525 2114.4525 2114.4525
667.9620
+( ) (16)
2114.4525
𝑀𝑊𝑎𝑣𝑔 = 15.5448 𝑘𝑔/𝑘𝑚𝑜𝑙
(1.1 × 106 𝑃𝑎)(15.5448 𝑔/𝑚𝑜𝑙) 𝑔

𝝆𝒗 = −1 −1
= 7,067.65 3 = 𝟕. 𝟎𝟔𝟕 𝒌𝒈/𝒎𝟑
(8.314 𝐽 𝑚𝑜𝑙 𝐾 )(291 𝐾) 𝑚
𝐹𝑠
𝑢=
𝜌𝑣 0,5
1.2 1.5
𝑢 = 7.0670.5 = 0.451 𝑚/𝑠 , 𝑢 = 7.0670.5 = 0.564 𝑚/𝑠
Vapor flowrate (overhead stream) = 32868.7702 kg/h

32 868.7702 𝑘𝑔/ℎ
𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 = 3
= 4 651.022 𝑚3 /ℎ
7.067 𝑘𝑔/𝑚
4 651.022 𝑚3 1ℎ 𝑚3
𝑣= × = 1.292
ℎ 3600 𝑠𝑒𝑐 𝑠
88
To find diameter,
4𝑣 0.5
𝐷𝑡𝑜𝑤𝑒𝑟 = ( )
𝜋𝑢
4×1.292 0.5 4×1.292 0.5

𝐷𝑡𝑜𝑤𝑒𝑟 = (𝜋×0.451) = 1.91 𝑚 , 𝐷𝑡𝑜𝑤𝑒𝑟 = (𝜋×0.564) = 2.92 𝑚
To find height,
𝐻 = (0.5 × 6 𝑡𝑟𝑎𝑦𝑠) + 3 = 6 𝑚
𝐻 = (0.6 × 6 𝑡𝑟𝑎𝑦𝑠) + 3 = 6.6 𝑚
Rule 14 (Table 11.13): Limit tower height to about 53 m and L/D < 30
𝐿 6
= = 3.141 𝑚
𝐷 1.91
𝐿 6.6
= = 2.260 𝑚
𝐷 2.92
Tower Diameter 1.91 – 2.92 m

Reflux Ratio, R 0.536 – 0.671
Number of Trays 6
Height Tower, L 6 - 6.6 m
89
Heuristic for Distillation Column, T-102
Stream Feed Overhead Bottom
Temperature (℃) 143.7 138.6 178.6
Pressure (kPa) 1100 1100 1100
Vapour fraction 0 1 0
Total flow (kg/h) 21770.7878 14050.9263 7719.8615
Total flow (kmol/h) 850.8197 439.3305 411.4892
Component flow rates (kmol/h)
Methanol (𝐶𝐻3 𝑂𝐻) 441.0277 438.7841 2.2436
Water (𝐻2 𝑂) 409.7920 0.5464 409.2456
By taking methanol as light key component and water as the heavy key component;
438.7841 2.2436
𝑥𝑜𝑣ℎ𝑑 = = 0.9988 𝑥𝑏𝑜𝑡 = = 0.0055
439.3305 411.4892
Rule 2 (Table 11.13): Relative volatility
Temperature overhead = 138.6 oC
𝐵 𝐵
𝑙𝑜𝑔𝑃1 𝑠𝑎𝑡 𝑜𝑣ℎ𝑑 = A − 𝑙𝑜𝑔𝑃2 𝑠𝑎𝑡 𝑜𝑣ℎ𝑑 = A −
𝑇+𝐶 𝑇+𝐶
1574.99 1657.462
= 8.07247 − 138.6+238.86
= 7.94917 −
138.6+227.02
= 3.8999 = 3.4159
𝑃1 𝑠𝑎𝑡 𝑜𝑣ℎ𝑑 = 7940.8854 𝑃2 𝑠𝑎𝑡 𝑜𝑣ℎ𝑑 = 2605.4252
𝑃1 𝑠𝑎𝑡 𝑜𝑣ℎ𝑑
𝛼0𝑣ℎ𝑑 = = 3.05
𝑃2 𝑠𝑎𝑡 𝑜𝑣ℎ𝑑
Temperature bottom = 178.6 oC

𝐵 𝐵
𝑙𝑜𝑔𝑃1 𝑠𝑎𝑡 𝑏𝑜𝑡 = A − 𝑙𝑜𝑔𝑃2 𝑠𝑎𝑡 𝑏𝑜𝑡 = A −
𝑇+𝐶 𝑇+𝐶
1574.99 1657.462
= 8.07247 − 178.6+238.86
= 7.94917 −
178.6+227.02
= 4.2997 = 3.8629
𝑃1 𝑠𝑎𝑡 𝑏𝑜𝑡 = 19937.8074 𝑃2 𝑠𝑎𝑡 𝑏𝑜𝑡 = 7293.3443
90
𝑃1 𝑠𝑎𝑡 𝑏𝑜𝑡
𝛼𝑏𝑜𝑡 = = 2.73
𝑃2 𝑠𝑎𝑡 𝑏𝑜𝑡
𝛼𝑔𝑒𝑜𝑚 𝑎𝑣𝑒 = (𝛼𝑜𝑣ℎ𝑑 𝛼𝑏𝑜𝑡 )0.5 = 2.89
Rule 7: 𝑁𝑚𝑖𝑛 = ln{ [𝑥/(1 – 𝑥)]𝑜𝑣ℎ𝑑 /[𝑥/(1 – 𝑥)]𝑏𝑜𝑡 }/ ln α

𝑁𝑚𝑖𝑛 = ln{ [0.9988/(1 – 0.9988)]/[0.0055/(1 – 0.0055)]}/ln (2.89)
𝑁𝑚𝑖𝑛 = 11.2
Rule 6 (Table 11.13): Optimum number of stages approximately 2 𝑁𝑚𝑖𝑛

𝑁𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 ≈ (2)(11.2) = 22.4
Rule 9 (Table 11.13): Use a safety factor of 10% on number of trays.

Rule 4 (Table 11.13): 𝜀𝑡𝑟𝑎𝑦 = 60 – 90 %
𝜀𝑡𝑟𝑎𝑦 = 0.6
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 ≈ (22.4/0.6)(1.1) = 41 trays
Rule 8 (Table 11.13): 𝑅𝑚𝑖𝑛 = {F/D}/(α – 1)

𝑅𝑚𝑖𝑛 = {850.8197/411.4892}/(2.89 – 1) = 1.09
Rule 5 (Table 11.13): Optimum reflux in the range of 1.2–1.5 𝑅𝑚𝑖𝑛

Range of R = (1.2 →1.5) 𝑅𝑚𝑖𝑛 = 1.31 → 1.64
Rule 2 (Table 11.14): 𝐹𝑠 = u𝜌𝑣0.5 = 1.2 → 1.5m/s (𝑘𝑔/𝑚3)0.5

Assume ideal gas,
PV = 𝑛𝑅𝑇
Methanol molecular weight = 32.04g/mol
Water molecular weight = 18.02g/mol
438.7841 2.2436
Molecular weight average = (32.04) + (18.02)
439.3305 411.4892
= 32.1g/mol
91
32.1𝑔
1100000𝑃𝑎 ( )
𝑚𝑜𝑙
𝜌𝑣 = = 10318.399g/m3
8.314(138.6+273𝐾)
𝜌𝑣 = 10.32kg/m3
u = (1.2 → 1.5)/10.320.5 = 0.37 → 0.47 m/s
Vapour flow rate = 14050.9263kg/h
14050.9263kg/h 1361.524𝑚3/ℎ
Vol. flow rate, v = = = 0.38m3/s
10.32kg/m3 3600𝑠
To find diameter,
𝐷𝑡𝑜𝑤𝑒𝑟 = [4𝑣/𝜋𝑢]0.5 = [(4)(0.38)/(3.142)/(0.37 → 0.47)]0.5 = 1.14 – 1.01 m
To find height,
L = (tray spacing × no of trays) + 3 = [(0.5 - 0.6)× 41] + 3 = 23.5 – 27.6 m
Rule 3: 𝛥𝑃𝑡𝑟𝑎𝑦 = 0.007 bar
𝛥𝑃𝑡𝑜𝑤𝑒𝑟 = (𝑁𝑎𝑐𝑡𝑢𝑎𝑙 )( 𝛥𝑃𝑡𝑟𝑎𝑦 ) = (41)(0.007) = 0.29 bar
Rule 14: 𝐿𝑚𝑎𝑥 = 53 m and L/D < 30

L/D = 27.6/1.01 = 27.33 < 30
Therefore, it is consistent with heuristic.
Tower Diameter 1.14 – 1.01 m

Reflux Ratio, R 1.31 – 1.64
Number of Trays 41
Pressure Drop, 𝛥𝑃𝑡𝑜𝑤𝑒𝑟 0.29 bar
Height Tower, L 23.5 – 27.6 m
92
CHAPTER 6: CAPITAL COST ESTIMATION
6.1 Bare Module Cost Calculation for Equipment
Reactor, R-101
Equipment number Capacity/Size Material of Operating pressure
construction (barg)
R-101 V = 88.97 m3 Stainless steel 70
CEPCI : 2019 = 619.2 , 2001 = 394
R-101
From Table A.1, the type of reactor was Reactor jacketed and non-agitated.
K1 = 3.3496
K2 = 0.7235
K3 = 0.0025
log10 Cp° (2001) = K1 + K2 log(A) + K3 [log(A)]2, where A = Volume, m3
log10 Cp° (2001) = 3.3496 + 0.7235log (88.97) + 0.0025(log [88.97]2)
log10 Cp° (2001) = 4.769376614
Cp° (2001) = $ 58,799.90
From Figure A.7, Reactor jacketed and non-agitated, the value of FBM = 4
For 2001
CBM (2001) = Cp°FBM
CBM (2001) = $ 58,799.90 x 4
CBM (2001) = $ 235,199.6
For 2019
CBM (2019) = $ 235,199.6 x (619.2/394)
CBM (2019) = $ 369,633.48
°
𝐶BM,2019 = ($ 58,799.90) x (619.2/394)
°
𝐶BM,2019 = $ 92,408.37
93
Flash Drum, V-101
Material of construction Stainless steel

Length/Height 11.32 m
Diameter 4.53 m
Operating Pressure 40 bar
Volume of the vessel:

𝜋𝐷2 𝐿 𝜋 × (4.53 𝑚)2 × 11.32 𝑚
𝑉= = = 4.07𝑚3
4 4
From Table A.1, (In Textbook Analysis, Synthesis and Design of Chemical Processes 5th
Edition) the type of V-101 is vertical process vessel.
K1 = 3.4974 K2 = 0.4485 K3 = 0.1074
By using Equation A.1:

𝑙𝑜𝑔10 𝐶 𝑜 𝑝 = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 (𝐴) + 𝐾3 [𝑙𝑜𝑔10 (𝐴)]2
𝑙𝑜𝑔10 𝐶 𝑜 𝑝 = 3.4974 + 0.4485 (𝑙𝑜𝑔10 4.07) + 0.1074(𝑙𝑜𝑔10 4.07)2
𝐶 𝑜 𝑝 (2001) = $ 6,462.96
This equation used to find Bare Module Cost, 𝐶𝐵𝑀 for vessel;
𝐶𝐵𝑀 = 𝐶𝑃° 𝐹𝐵𝑀 = 𝐶𝑃° (𝐵1 + 𝐵2 𝐹𝑀 𝐹𝑃 )
From Table A.3, for vertical process vessels;
- Identification Number = 20
- Material of construction = Stainless Steel
From Figure A.18, Fm = 3.1
B1 = 2.25 B2 = 1.82
94
By using Equation A.2, find pressure factor, Fp for process vessels:
𝑃𝐷
[ + 𝐶𝐴]
2(850 − 0.6(𝑃))
𝐹𝑃,𝑣𝑒𝑠𝑠𝑒𝑙 =
𝑡𝑚𝑖𝑛
(40)(4.53)
[ + 0.00315]
2(850 − 0.6(40))
𝐹𝑃,𝑣𝑒𝑠𝑠𝑒𝑙 = = 17.90
0.0063

𝐶𝐵𝑀 (2001) = 𝐶𝑃° 𝐹𝐵𝑀 = $ 6,314.56(2.25 + [(1.82)(3.1)(14.425)])
𝐶𝐵𝑀(2001) = $ 667,343.69
For minimum standard with Carbon steel for vessel wall,

FP = 1.0 and FM = 1.0
°
𝐶𝐵𝑀(2001) = 𝐶𝑃° 𝐹𝐵𝑀 = 𝐶𝑃° (𝐵1 + 𝐵2 𝐹𝑀 𝐹𝑃 )
°
𝐶𝐵𝑀(2001) = 𝐶𝑃° 𝐹𝐵𝑀 = $ 6,462.96(2.25 + [(1.82)(1)(1)])
°
𝐶𝐵𝑀(2001) = $ 26,304.24
For 2019:
607.5
𝐶𝑝° (2019) = $ 6,314.56 × ( 394 )
𝐶𝑝° (2019) = $ 9,965.09

𝐶𝐵𝑀 (2019) = 𝐶𝑃° 𝐹𝐵𝑀 = $ 9,965.09(2.25 + [(1.82)(3.1)(20.92)])
𝐶𝐵𝑀(2019) = $ 1,028,962.67
°
𝐶𝐵𝑀(2019) = 𝐶𝑃° 𝐹𝐵𝑀 = $ 9,965.09(2.25 + [(1.82)(1)(1)])
°
𝐶𝐵𝑀(2019) = $ 40,557.93
95
Gas Scrubber, V-102
Material of Construction Stainless steel

Height 1.83m
Diameter 0.31 m
Operating Pressure 11 barg
Volume = π𝐷2 L/4 = (3.142)(0.31)2(1.83)/4 = 0.138 m3
From Table A.1for vertical process vessel,
𝐾1 = 3.4974 𝐾2 = 0.4485 𝐾3 = 0.1074
From Equation (A.1),
𝑙𝑜𝑔10 𝐶𝑝𝑜 (2001) = 3.4974 + 0.4485𝑙𝑜𝑔10(0.138) + 0.1074{𝑙𝑜𝑔10 (0.138)}2 = 3.1911
𝐶𝑝𝑜 (2001) = 103.1911 = $1552.74

607.5
𝐶𝑝𝑜 (2019) = $1552.74 × ( 394 ) = $2394.14
From Table A.4,
𝐵1 = 2.25 𝐵2 = 1.82
From Table A.3, identification number for stainless steel vertical vessel = 20
From Figure A.18,
𝐹𝑀 = 3.11
(𝑃 + 1)𝐷
+ 𝐶𝐴
(2)[(944)(0.9) − 0.6(𝑃 + 1)]
𝐹𝑝 =
𝑡𝑚𝑖𝑛
(11 + 1) × 0.31
+ 0.00315
(2)[(944)(0.9) − 0.6(11 + 1)]
𝐹𝑝 =
0.0063
𝐹𝑝 = 0.851
96
From equation A.3;
𝐹𝐵𝑀 = 𝐵1 + 𝐵2 𝐹𝑚 𝐹𝑝
𝐹𝐵𝑀 = 2.25 + (1.82 × 3.11 × 0.851)
𝐹𝐵𝑀 = 7.07
𝐶𝐵𝑀 = 𝐶𝑝𝑜 𝐹𝐵𝑀
Bare Module Cost for tower (2019)
𝐶𝐵𝑀 (2019) = $2394.14 × 7.07
𝐶𝐵𝑀 (2019) = $16926.57
For minimum standard with carbon steel for tower

𝑜 (2019)
𝐶𝐵𝑀 = $2394.14 × [2.25 + 1.82(1)(1)]
𝑜 (2019)
𝐶𝐵𝑀 = $9744.15
97
Distillation Column, T-101

Type of trays Sieve tray
No of trays 6 Stainless steel
Height 6.6 m
Diameter 0.422 m
For tower
𝜋𝐷2 𝐿 𝜋 × (2.92 𝑚)2 × 6.6 𝑚

𝑉𝑜𝑙𝑢𝑚𝑒 = =
4 4
𝑉𝑜𝑙𝑢𝑚𝑒 = 44.20 𝑚3
From Table A.1, equipment data for tower tray and packed;
K1 = 3.4974 K2 = 0.4485 K3 = 0.1074
From equation A.1;

𝑙𝑜𝑔10 𝐶 𝑜 𝑝 = 3.4974 + 0.4485 (𝑙𝑜𝑔10 44.20) + 0.1074(𝑙𝑜𝑔10 44.20)2
𝑜
𝐶𝑝(2001) = $ 33,585.22
This equation used to find Bare Module Cost, 𝐶𝐵𝑀 for tower;
B1 = 2.25 B2 = 1.82
From Table A.3, stainless steel vertical tower;
98
Identification number = 20
From Figure A.18, Fm = 3.1
Fp calculated using this equation;
𝑃𝐷
+ 𝐶𝐴
2[850 − 0.6(𝑃)]
𝐹𝑝,𝑣𝑒𝑠𝑠𝑒𝑙 =
𝑡𝑚𝑖𝑛
(12)(2.92)
+ 0.00315
2[850 − 0.6(12)]
𝐹𝑝 =
0.0063
𝐹𝑝 = 3.795
For tower (2019)
°
𝐶𝑝(2019) = $ 33,585.22 x (607.5/394)
°
𝐶𝑝(2019) = $ 51,784.32
𝐶𝐵𝑀(2019) = 𝐶𝑃° (𝐵1 + 𝐵2 𝐹𝑀 𝐹𝑃 )
𝐶𝐵𝑀(2019) = $ 51,784.32(2.25 + [(1.82)(3.10)(3.795)])
𝐶𝐵𝑀(2019) = $ 1,225,288.99
For minimum standard with Carbon steel for tower,

°
𝐶𝐵𝑀(2019) = $ 51,784.32 [2.25 + 1.82 (1) (1)]
°
𝐶𝐵𝑀(2019) = $ 210,762.18
99
For trays
𝜋𝐷2 𝜋 × (2.92)2
𝐴𝑟𝑒𝑎 = =
4 4
𝐴𝑟𝑒𝑎 = 6.70 𝑐𝑚2
From Table A.1, equipment data for sieve trays;
K1 = 2.9949 K2 = 0.4465 K3 = 0.3961
From equation A.1;

𝑙𝑜𝑔10 𝐶 𝑜 𝑝 = 2.9949 + 0.4465(𝑙𝑜𝑔10 6.70) + [0.3961 (𝑙𝑜𝑔10 6.70)2 ]
𝑜
𝐶𝑝(2001) = $ 4,305.67
Number of trays = 6, Since N < 20;
𝑙𝑜𝑔10 𝐹𝑞 = 0.4771 + 0.0851(𝑙𝑜𝑔10 𝑁) − 0.3473 (𝑙𝑜𝑔10 𝑁)2
𝑙𝑜𝑔10 𝐹𝑞 = 0.4771 + [0.0851 (𝑙𝑜𝑔10 6)] − [0.3473 (𝑙𝑜𝑔10 6)2 ]
𝐹𝑞 = 2.153
From Table A.6, stainless steel sieve trays;
From Figure A.19, FBM = 1.8
100
For trays (2019)
𝑜
𝐶𝑝(2019) = $ 4,305.67 x (607.5/394)
𝑜
𝐶𝑝(2019) = $ 6,638.82
𝑜
𝐶𝐵𝑀(2019) = 𝐶𝑝(2019) 𝑁𝐹𝐵𝑀 𝐹𝑞
𝐶𝐵𝑀(2019) = $ 6,638.82 × 6 × 1.8 × 2.153
𝐶𝐵𝑀(2019) = $ 154,368.49
For minimum standard with Carbon steel for trays,

FBM = 1.0
° 𝑜 𝑜
𝐶𝐵𝑀(2019) = 𝐶𝑝(2019) 𝑁𝐹𝐵𝑀 𝐹𝑞
°
𝐶𝐵𝑀(2019) = $ 6,638.82 × 6 × 1 × 2.153
°
𝐶𝐵𝑀(2019) = $ 85,760.28
For tower plus trays,
𝐶𝐵𝑀(2019) = $ 1,225,288.99 + $ 154,368.49
𝐶𝐵𝑀(2019) = $ 1,379,657.48
°
𝐶𝐵𝑀(2019) = $210,762.18 + $ 85,760.28
°
𝐶𝐵𝑀(2019) = $ 296,522.46
101
Distillation Column, T-102
Type of trays Sieve tray
No of trays 41 Stainless steel
Height 27.6 m
Diameter 1.57 m
For the tower,
Volume = π𝐷2 L/4 = (3.142)(1.01)2(27.6)/4 = 22.12 m3
From Table A.1,
𝐾1 = 3.4974 𝐾2 = 0.4485 𝐾3 = 0.1074
From Equation (A.1),

𝑜
𝑙𝑜𝑔10 𝐶𝑝(2001) = 3.4974 + 0.4485𝑙𝑜𝑔10(22.12) + 0.1074{𝑙𝑜𝑔10 (22.12)}2 = 4.2948
𝑜
𝐶𝑝(2001) = 104.2948 = $19,715.15
𝑜 607.5
𝐶𝑝(2019) = $19,715.15× ( 394 ) = $30,398.36
From Table A.4,
𝐵1 = 2.25 𝐵2 = 1.82
From Table A.3, identification number for stainless steel vertical vessel = 20
From Figure A.18,
𝐹𝑀 = 3.11
(𝑃 + 1)𝐷
+ 𝐶𝐴
(2)[(944)(0.9) − 0.6(𝑃 + 1)]
𝐹𝑝 =
𝑡𝑚𝑖𝑛
(11 + 1) × 1.01
+ 0.00315
(2)[(944)(0.9) − 0.6(11 + 1)]
𝐹𝑝 =
0.0063
𝐹𝑝 = 1.642
102
From equation A.3;
𝐹𝐵𝑀 = 𝐵1 + 𝐵2 𝐹𝑚 𝐹𝑝
𝐹𝐵𝑀 = 2.25 + (1.82 × 3.11 × 1.642)
𝐹𝐵𝑀 = 11.54
𝐶𝐵𝑀 = 𝐶𝑝𝑜 𝐹𝐵𝑀
Bare Module Cost for tower (2019)
𝐶𝐵𝑀 (2019) = $30,398.36 × 11.54
𝐶𝐵𝑀 (2019) = $350,797.07
For minimum standard with carbon steel for tower

𝑜 (2019)
𝐶𝐵𝑀 = $30,398.36 × [2.25 + 1.82(1)(1)]
𝑜 (2019)
𝐶𝐵𝑀 = $123,721.33
For the trays,
𝜋𝐷2 𝜋 × (1.01)2
𝐴𝑟𝑒𝑎 = =
4 4
𝐴𝑟𝑒𝑎 = 0.80 𝑚2
From Table A.1, equipment data for sieve trays;

K1 = 2.9949 K2 = 0.4465 K3 = 0.3961
From equation A.1;
𝑙𝑜𝑔10 𝐶𝑝𝑜 (2001) = 𝐾1 + 𝐾2 (𝑙𝑜𝑔10 𝐴) + 𝐾3 [(𝑙𝑜𝑔10 𝐴)2 ]
𝑙𝑜𝑔10 𝐶𝑝𝑜 (2001) = 2.9949 + 0.4465(𝑙𝑜𝑔10 0.80) + [0.3961 (𝑙𝑜𝑔10 0.80)2 ]
𝐶𝑝𝑜 (2001) = $ 902.30

607.5
𝐶𝑝𝑜 (2019) = $ 902.30 × ( 394 ) = $1391.24
103
Number of trays = 41, Since N > 20;
𝐹𝑞 = 1
From Table A.6, stainless steel sieve trays;

From Figure A.19, FBM = 1.8
Equation from Table A.5;

Bare Module Cost for trays (2019)
𝐶𝐵𝑀 (2019) = 𝐶 𝑜 𝑝(2019)𝑁𝐹𝐵𝑀 𝐹𝑞
𝐶𝐵𝑀 (2019) = $1391.24 × 41 × 1.8 × 1
𝐶𝐵𝑀 (2019) = $102,673.51
For minimum standard with carbon steel for trays

𝑜 (2019))
𝐶𝐵𝑀 = $1391.24 × 41 × 1 × 1
𝑜 (2019)
𝐶𝐵𝑀 = $57,040.84
Total Bare Module Cost (2019)
𝐶𝐵𝑀 (2019) = $350,797.07 + $102,673.51
𝐶𝐵𝑀 (2019) = $453,470.58
Total minimum standard

𝑜 (2019)
𝐶𝐵𝑀 = $123,721.33 + $57,040.84
𝑜 (2019)
𝐶𝐵𝑀 = $180,762.17
104
1 United States Dollar = 4.04 Malaysian Ringgit (17 /1/ 2021)
Equipment Description CBM,2019 ($) C°BM,2019 ($)
C-101 Compressor 1 823,000.00 823,000.00

C-102 Compressor 2 787,000.00 787,000.00
E-101 Heat Exchanger 663,000.00 579,000.00
R-101 Methanol synthesis reactor 369,633.48 92,408.37
E-102 Cooler 288,000.00 252,000.00
V-101 Flash drum 1,028,962.67 40,557.93
T-101 Distillation column 1 1,379,657.48 296,522.46
E-103 Condenser 1 107,000.00 105,000.00
E-104 Reboiler 1 425,000.00 419,000.00
V-102 Gas scrubber 16,926.57 9,744.15
T-102 Distillation column 2 453,470.58 180,762.17
E-105 Condenser 2 93,500.00 92,400.00
E-106 Reboiler 2 147,000.00 146,000.00
TOTAL 65,82,150.78 3,823,395.08
Table 6.1: Summary of Bare Module Cost of the Equipment
105
6.2 Grassroot Cost
𝑛 𝑛
𝐶𝑇𝑀 = ∑ 𝐶𝑇𝑀,𝑖 = 1.18 ∑ 𝐶𝐵𝑀,𝑖

𝑖=1 𝑖=1
𝐶𝑇𝑀 = 1.18(6582150.78)
𝐶𝑇𝑀 = $ 7,766,937.92
𝑛
o
𝐶𝐺𝑅 = 𝐶𝑇𝑀 + 0.50 ∑ 𝐶𝐵𝑚,𝑖
𝑖=1
𝐶𝐺𝑅 = $ 7,766,937.92 + (0.50)($ 3,823,395.08)

𝐶𝐺𝑅 = $ 9,678,635.46
Fixed Capital Investment (FCIL) = 𝐶𝐺𝑅

Fixed Capital Investment (FCIL) = $ 𝟗, 𝟔𝟕𝟖, 𝟔𝟑𝟓. 𝟒𝟔 (RM 39,101,687.26)
106
6.3 Land Cost
Figure 6.3.1: Kerteh Industrial Land
Figure 6.3.2: Main road near Kerteh Industrial Land
The total land area size is 24 acres at RM 19.5 million with RM 18 per sqft (EdgeProp, 2020).
This industrial land located near to Petroleum Penapisan Kerteh and accessible via Jalan
Kemaman – Kuantan, Kerteh Terengganu. The site is almost flat in terrain and equipped with
electricity (TNB) power station.
107
CHAPTER 7: OPERATING COST ESTIMATION
Manufacturing Cost
In estimation in manufacturing cost, we need to consider three important things, which

are direct cost, fixed cost, and general expenses. Direct cost is basically determined by cost of
raw materials, waste treatment, utilities, operating labour, and many more. For fixed cost
usually consists of cost in rent, local taxes and insurance, and depreciation. Meanwhile in
general expenses, the administration, distribution and selling costs of products, consultant fee
are several things that need to be considered. For estimation of manufacturing cost in this
plant, we considered the fixed capital investment, cost of operating labour, cost of utilities and
cost of raw materials.
7.1 Utilities cost
Equipment Utility used Actual used Annal Utility Cost

(kW) ($/year)
E-101 High pressure steam 1725.211 1484632.74
E-102 Cooling water 1387.507 23883.22
E-103 Cooling water 383.449 6598.37
E-105 Cooling water 6405.09 110240.56
C-101 Electricity 468.360 564139.62
C-102 Electricity 595.800 765483.84
TOTAL 9,801,536.93
TOTAL (RM) 39,598,209.20
Utilities for Heat Exchanger

The electric distribution cost for industrial consumer is $0.0976/kWh in 2019 (Tenaga
Nasional Berhad, n.d.)
Stream factor = 365 days plant operation / 365 days
=1
Tariff TnB (2019) = 39.45 sen/kW = $ 0.0976 /𝑘𝑊
108
E-101 (HP steam)
Duty = Q = 1725.211 kW, P = 70 barg (high pressure)
Cost of High-Pressure steam from 2001 = $17.70/GJ
𝐺𝐽
𝑄 = 1725.211 𝑥
277.8 𝑘𝑊
𝐺𝐽
𝑄 = 6.21
ℎ
𝐺𝐽 24 ℎ $ 365 𝑑 607.5
𝑌𝑒𝑎𝑟𝑙𝑦 𝑐𝑜𝑠𝑡 = 6.21 𝑥 𝑥 17.70 𝑥 𝑥1𝑥
ℎ 𝑑 𝐺𝐽 𝑦𝑒𝑎𝑟 394
$ 1484632.74
𝑌𝑒𝑎𝑟𝑙𝑦 𝑐𝑜𝑠𝑡 =
𝑦𝑒𝑎𝑟
E-102 (cooling water)

Duty = Q = 1387.507 kW
Cost of Cooling water from 2001 = $0.354/GJ
𝐺𝐽
𝑄 = 1387.507 𝑥
277.8 𝑘𝑊
𝐺𝐽
𝑄 = 4.995
ℎ
𝐺𝐽 24 ℎ $ 365 𝑑 607.5
$ 23883.22
𝑦𝑒𝑎𝑟

Duty = Q = 383.449 kW
𝐺𝐽
𝑄 = 383.449 𝑥
277.8 𝑘𝑊
𝐺𝐽
𝑄 = 1.38
ℎ
𝐺𝐽 24 ℎ $ 365 𝑑 607.5
$ 6598.37
𝑦𝑒𝑎𝑟
109
E-104 (HP steam)
Duty = Q = 1381.944 kW, P = 10 barg (medium pressure)
Cost from 2001 = $14.19/GJ
𝐺𝐽
𝑄 = 1381.944 𝑘𝑊 𝑥
277.8 𝑘𝑊
𝐺𝐽
𝑄 = 4.97
ℎ
𝐺𝐽 24 ℎ $ 365 𝑑 607.5
$ 952561.34
𝑦𝑒𝑎𝑟

Duty = Q = 6405.09 kW
𝐺𝐽
𝑄 = 6405.09 kW 𝑥
277.8 𝑘𝑊
𝐺𝐽
𝑄 = 23.056
ℎ
𝐺𝐽 24 ℎ $ 365 𝑑 607.5
$ 110240.56
𝑦𝑒𝑎𝑟
E-106 (HP steam)

Duty = Q = 854.282 kW, P = 10 barg (medium pressure)
Cost from 2001 = $14.19 /GJ
𝐺𝐽
𝑄 = 8542.82 𝑘𝑊 𝑥
277.8 𝑘𝑊ℎ
𝐺𝐽
𝑄 = 30.752
ℎ
𝐺𝐽 24 ℎ $ 365 𝑑 607.5
$ 5893997.24
𝑦𝑒𝑎𝑟
110
Utilities for compressor
C-101
Power = P = 468.36 kW. Efficiency = 80%
Electric power = P/Efficiency = / 0.75
= 585.45 kW
$ 24 ℎ 365𝑑𝑎𝑦𝑠
𝑌𝑒𝑎𝑟𝑙𝑦 𝑐𝑜𝑠𝑡 = 585.45 𝑘𝑊 𝑥 0.0976 𝑥 𝑥
𝑘𝑊ℎ 𝑑 𝑦𝑒𝑎𝑟
$ 500,545.70
𝑦𝑒𝑎𝑟
C-102
Power = P = 595.800 kW. Efficiency = 75%
Electric power = P/Efficiency = 595.800 / 0.75
= 794.4 kW
$ 24 ℎ 365 𝑑𝑎𝑦𝑠
𝑌𝑒𝑎𝑟𝑙𝑦 𝑐𝑜𝑠𝑡 = 794.4 𝑘𝑊 𝑥 0.0976 𝑥 𝑥 𝑥1
𝑘𝑊ℎ 𝑑 𝑦𝑒𝑎𝑟
$ 679,192.93
𝑦𝑒𝑎𝑟
Therefore, the total cost of utilities is $ 9,801,536.93per year ( RM 39,598,209.20 /year)
111
7.2 Cost of Raw Material
Estimation of Raw Material Price Annually

Raw Material Flowrate (𝑘𝑔⁄𝑦𝑒𝑎𝑟) Cost ($) Total cost ($)
Syngas 476,183,298 0.023/kg 10,952,215.85
Source: Gasification and Technologies Conference, 2017
Reported by Gasification and Technologies Conference (2017), the market-controlled price

for syngas in year of 2016 was $5.30 per MMBTU in Malaysia
Flowrate of syngas (𝑘𝑔⁄𝑦𝑒𝑎𝑟);

𝑘𝑔 ℎ𝑟 𝑑𝑎𝑦 𝑘𝑔
54,358.824 (24 ) (365 ) = 476,183,298
ℎ𝑟 𝑑𝑎𝑦 𝑦𝑒𝑎𝑟 𝑦𝑒𝑎𝑟
Change unit MMBTU to kg;

228.8 𝑘𝑔
1 𝑀𝑀𝐵𝑇𝑈 ( ) = 228.8 𝑘𝑔
1 𝑀𝑀𝐵𝑇𝑈
Cost syngas ($/kg);

$ 5.30 𝑚3 $ 0.023
( )( )=
228.8 𝑘𝑔 0.95 𝑘𝑔 𝑘𝑔
Cost syngas ($/year);

𝑘𝑔 $ 0.023 $ 10,952,215.85
476,183,298 ( )=
𝑦𝑒𝑎𝑟 𝑘𝑔 𝑦𝑒𝑎𝑟
Therefore, total cost for raw material is $10,952,215.85 per year (RM 44,246,952.03/year).
112
7.3 Cost of Operating Labour
Estimation cost of operating labour for the production of methanol.

- The annual operation of the plant is 365 days per year.
- The working period for a single operator is 49 weeks per year (3 weeks’ time off for
vacation and sick leave) with five 8-hour shifts per week.
Equipment Number of Equipment Nnp

Compressors 2 2
Exchangers 6 6
Fired Heater 0 0
Pumps* 0 -
Reactors 1 1
Towers 2 2
Vessels* 2 -
TOTAL 11
P = 0, because methanol is not solid

0.5
𝑁𝑂𝐿 = (6.29 + 31.7𝑃2 + 0.23𝑁𝑛𝑝 )
𝑁𝑂𝐿 = (6.29 + 31.7(0)2 + 0.23(11))0.5
𝑁𝑂𝐿 = 2.97
Number of shifts per operator per year:
= (49 𝑤𝑒𝑒𝑘𝑠/𝑦𝑒𝑎𝑟) × (5 𝑠ℎ𝑖𝑓𝑡𝑠/𝑤𝑒𝑒𝑘) = 245 𝑠ℎ𝑖𝑓𝑡𝑠 𝑝𝑒𝑟 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟
Number of operating shifts per year:
= (365 𝑑𝑎𝑦𝑠/𝑦𝑒𝑎𝑟) × (3 𝑠ℎ𝑖𝑓𝑡𝑠/𝑑𝑎𝑦) = 1095 𝑠ℎ𝑖𝑓𝑡𝑠/𝑦𝑒𝑎𝑟
Number of operators needed for a single unit:

(1095 𝑠ℎ𝑖𝑓𝑡𝑠/𝑦𝑒𝑎𝑟)
= (245 𝑠ℎ𝑖𝑓𝑡𝑠 𝑝𝑒𝑟 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟) = 4.5 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠 𝑓𝑜𝑟 𝑎 𝑠𝑖𝑛𝑔𝑙𝑒 𝑠ℎ𝑖𝑓𝑡
113
Number of operating labours:
= (2.97)(4.5 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠 𝑓𝑜𝑟 𝑎 𝑠𝑖𝑛𝑔𝑙𝑒 𝑠ℎ𝑖𝑓𝑡)
= 13.37 ≈ 14 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠
Cost of Operating Labour, COL:

Average base salary for an operator in Malaysia is RM13.14 per hour (How much does a
plant operator make in Malaysia, Jan 2021)
8ℎ 343𝑑𝑎𝑦𝑠 49𝑤𝑒𝑒𝑘𝑠
(𝑅𝑀13.14/ℎ) × × × = 𝑅𝑀360982.08 /𝑦𝑒𝑎𝑟
𝑑𝑎𝑦 49𝑤𝑒𝑒𝑘𝑠 𝑦𝑒𝑎𝑟
𝐶𝑂𝐿 = 𝑅𝑀360982.08/𝑦𝑒𝑎𝑟 × 14 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠 = 𝑅𝑀5,053,749 /𝑦𝑒𝑎𝑟

= $1,250,928 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟
Therefore, total cost for operating labour is $ 1,250,928 per year (RM 5,053,749/year).
114
7.4 Cost of Waste Treatment
The wastewater produced at the end of the process of methanol production need to be treated
before it is being discharge to the lake or river so that it can comply with the Environmental
Quality Act (1974). There are a few parameters that need to be highlighted to meet the standard
limit of Third Schedule in Environmental Quality (Sewage and Industrial Effluents)
Regulations 1978 which are the temperature, Ph, free chlorine, BOD, COD, Sulfide, Suspended
solids, Lead, Copper and other metals.
Based on Table 8.3 in the textbook Analysis, Synthesis and Design of Chemical Processes 5th
Edition (pg 247):
The wastewater treatment should be the secondary class which include filtration and activated
sludge. The cost for this type of wastewater treatment is $43/1000 m3.
Treatment Flowrate (kg/year) Cost ($) Total Cost ($)

Wastewater 67,625,985.35 $43/1000 m3 2907.92
Flowrate (𝑘𝑔⁄𝑦𝑒𝑎𝑟);
𝑘𝑔 ℎ𝑟 𝑑𝑎𝑦 𝑘𝑔
7719.8615 (24 ) (365 ) = 67,625,986.35
ℎ𝑟 𝑑𝑎𝑦 𝑦𝑒𝑎𝑟 𝑦𝑒𝑎𝑟
Cost of waste treatment ($/year):
$ 43 𝑚3 $ 0.000043
( 3
) ( )=
1000𝑚 1000 𝑘𝑔 𝑘𝑔
𝑘𝑔 $ 0.000043 $ 2907.92
67,625,986.35 ( )=
𝑦𝑒𝑎𝑟 𝑘𝑔 𝑦𝑒𝑎𝑟
Therefore, total cost for waste treatment is $ 2,907.92 per year (RM 11747.99/year).
115
7.5 Projected Revenue per Year
The revenue per year for the plant will be based on the current price of the product,
methanol which costs $295/tonne. The methanol produce at the end of the process is
123,000tonne/year. Shown below are the calculations for the revenue per year.
Projected
Price Price Amount
Product Revenue
($/Tonne) (RM/Tonne) (Tonne/Year)
(RM/Year)
Methanol 295 1,191.8 123,000 146,591,400
TOTAL = RM 146,591,400.00
Thus, the projected revenue/year, R = RM 146,591,400
7.6 Working Capital
Working Capital is based on 20% from fixed capital investment (FCIL).

Working Capital = (0.2)($ 9678635.46)
= $ 1,935,727.09
= RM 7,820,337.45
116
Summary of Manufacturing Cost
From the research that we have done on the raw material cost, there are a lot of
different price from different countries. The research was done in order to get the best price with
high purity of substances. Based on that, we have decided to use the import raw material from other
country because it is more affordable. In order to gain profit for the company, it is right for us to
choose best raw materials but with the lower price.
In calculating the utilities cost, we have made decision to focus on finding the
utilities for heat exchanger and compressor. The tariff or electricity distribution is based on the
Tenaga Nasional Berhad and some references are from the Analysis, Synthesis and Design of
Chemical Processes book. The based year of 2001 (from the textbook) have been multiplied
with the value of CEPCI to get the estimation cost for the current year.
Factors used in calculation of cost of manufacturing (COMd)
COMd = 0.18FCI + 2.76COL + 1.23(CUT + CWT + CRM)
Convert dollar, $ to Ringgit Malaysia, RM:

Cost (RM)
FCI 58,601,687.26
COL 5,053,749.00
CUT 39,598,209.20
CWT 11,747.9968
CRM 44,246,952.03
COMd 127,640,649.3
Table 7: Table calculation for COMd
117
CHAPTER 8: PROFITABILITY ANALYSIS
Table 8.1: Information of project life, interest rate and taxation rate
Project Life (Years after start-up) 10 years

Construction period 2 years
Distribution of Fixed Capital Investment (FCI)
End of year one 60%
End of year two 40%
Internal Investment Rate, i = 10% = 0.10
Taxation Rate, t = 0.24
Table 8.2: Information for calculation non-discounted and discounted profitability
Cost (MYR) Cost (in Million)

Land Cost 19,500,000 19.5
Fixed Capital Investment (FCI) 39101687.26 39.10168726
Working capital 7820337.452 7.820337452
Revenue 146591400 146.5914
Cost of Manufacturing (COM) 127640649.3 127.6406493
118
(R - COM - Non- Discounted
End of year dk) x (1-t) + discounted Discounted Cumulative
(k) Investment dk FCI - ∑dk R COMd dk Cash Flow Cash Flow Cash Flow Cash Flow
39.1016872
0 -19.5 6 -19.5 -19.5 -19.5 -19.5
- 39.1016872 - - - -
1 23.46101236 6 23.46101236 42.96101236 21.32819305 40.82819305
- 39.1016872 - - - -
2 23.46101236 6 23.46101236 66.42202471 19.38926641 60.21745946
7.82033745 31.2813498 146.591 127.640649 16.2794515 - -
3 2 1 4 3 2 16.27945152 50.14257319 12.23099288 47.98646658
7.82033745 23.4610123 146.591 127.640649 16.2794515 - -
4 2 6 4 3 2 16.27945152 33.86312167 11.11908443 36.86738215
7.82033745 146.591 127.640649 16.2794515 - -
5 2 15.6406749 4 3 2 16.27945152 17.58367015 10.10825858 26.75912357
7.82033745 7.82033745 146.591 127.640649 16.2794515 - -
6 2 2 4 3 2 16.27945152 1.304218632 9.189325979 17.56979759
7.82033745 146.591 127.640649 16.2794515 -
7 2 4 3 2 16.27945152 14.97523289 8.353932708 9.215864886
146.591 127.640649 14.4025705 -
8 4 3 3 14.40257053 29.37780342 6.718905447 2.496959439
146.591 127.640649 14.4025705
9 4 3 3 14.40257053 43.78037395 6.108095861 3.611136421
146.591 127.640649 14.4025705
10 4 3 3 14.40257053 58.18294448 5.552814419 9.16395084
146.591 127.640649 14.4025705
11 4 3 3 14.40257053 72.58551501 5.048013108 14.21196395
146.591 127.640649 14.4025705
12 27.32033745 4 3 3 41.72290798 114.308423 13.29420429 27.50616824
119
Non-Discounted Cash Flow
Non-discounted cash flow diagram

140
120
100
80
60
40
20
0
-20 0 1 2 3 4 5 6 7 8 9 10 11 12
-40
-60
-80
Figure 8.1: Cumulative cash flow diagram for non-discounted after-tax cash flows
Non-Discounted Profitability Criteria
I. Payback period = PBP
By using direct interpolation, find the payback period for non-discounted cash flow.
PBP = Highest negative value of cumulative non-discounted cash flow + FCIL
where,
FCIL = 39.10168726 million
Interpolate to get the value of PBP:

Table 8.2: Table of interpolation between year 0 and year 1
Years Cumulative cash flow

4 32.55890304
X 39.10168726
5 48.83835456
48.83835456−(32.55890304) 5−4
=
48.83835456−(39.10168726) 5−𝑋
120
X = 4.40 years
Then, value X minus with construction period

X = 4.40 – 2
X = 2.40 years
Payback period non-discounted cash flow = 2.40 years
II. Cumulative Cash Position, CCP

CCP = Net present value (NPV)
NPV = Cumulative non-discounted cash position at the end of the project
CCP = 114.308423 million
III. Cumulative Cash Ratio, CCR

𝑆𝑢𝑚 𝑜𝑓 𝑎𝑙𝑙 𝑃𝑜𝑠𝑖𝑡𝑖𝑣𝑒 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤𝑠 𝐶𝐶𝑃
CCR = =1+
𝑆𝑢𝑚 𝑜𝑓 𝑎𝑙𝑙 𝑁𝑒𝑔𝑎𝑡𝑖𝑣𝑒 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤𝑠 𝐿𝑎𝑛𝑑+𝑊𝐶+𝐹𝐶𝐼𝐿
where,
CCP = 114.308423 million
Land = 19.5 million
Working capital, WC = 7.820337452 million
FCIL = 39.10168726 million
140.984423
CCR = 1 +
19.5 +7.820337452 +39.10168726
CCR = 2.720941563 million
IV. Rate of return on investment, ROROI

𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐴𝑛𝑛𝑢𝑎𝑙 𝑁𝑒𝑡 𝑃𝑟𝑜𝑓𝑖𝑡 𝑆𝑙𝑜𝑝𝑒 𝑜𝑓 𝑙𝑖𝑛𝑒 1
ROROI = = −
𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 (𝐹𝐶𝐼𝐿) (𝐹𝐶𝐼) 𝑛
16.58284455 1
ROROI = −
(39.10168726) 10
ROROI = 0.3241 or 32.41%

ROROI ≈ 32.41 %
121
Discounted Cash Flow
Discounted Cumulative Cash Flow

40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12
-10
-20
-30
-40
-50
-60
-70
Figure 8.2: Cumulative cash flow diagram for discounted after-tax cash flows
Discounted Profitability Criteria
I. Payback period = PBP (Use direct interpolation)
Find the payback period for discounted cash flow by find the discounted fixed capital
investment (FCIL)
23.46101236 15.6406749
Discounted FCIL =
(1+0.1)1
+ (1+0.1)2
Discounted FCIL = 34.25437066
Interpolate to get the value of PBP:

Table 8.4: Table interpolation between year 5 and year 6
Years Cumulative cash flow

5 33.45833589
X 34.25437066
6 42.64766187
122
42.64766187−(33.45833589) 6−5
=
42.64766187−(34.25437066) 6−𝑋
X = 5.09 years
Then, value X minus with construction period

X = 5.09 – 2
X = 3.09 years
Payback period discounted cash flow = 3.09 years
II. Present Value Ratio (PVR)

∑ 𝑝𝑜𝑠𝑖𝑡𝑖𝑣𝑒 𝑑𝑖𝑠𝑐𝑜𝑢𝑛𝑡𝑒𝑑 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤𝑠
𝑃𝑟𝑒𝑠𝑒𝑛𝑡 𝑉𝑎𝑙𝑢𝑒 𝑅𝑎𝑡𝑖𝑜(𝑃𝑉𝑅) =
∑ 𝑛𝑒𝑔𝑎𝑡𝑖𝑣𝑒 𝑑𝑖𝑠𝑐𝑜𝑢𝑛𝑡𝑒𝑑 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤𝑠
87.72
𝑃𝑟𝑒𝑠𝑒𝑛𝑡 𝑉𝑎𝑙𝑢𝑒 𝑅𝑎𝑡𝑖𝑜(𝑃𝑉𝑅) =
60.22
PVR = 1.46
III. Net Present value, NPV

NPV = Cumulative non-discounted cash position at the end of the project
NPV = 27.50616824 million
IV. Discounted cash flow rate of return, DCFROR

DCFROR = Interest or discount rate for which the NPV of the project is equal to zero
(NPV = 0)
Assume interest rate, i = 0.10

Find new discounted cash flow and cumulative discounted cash flows using new
interest rate.
−19.5
Discounted cash flow = = -19.5 million
(1+0.10)0
123
Table of discounted cash flow and cumulative discounted cash flow
Discounted
Discounted Cumulative Cash
Cash Flow Flow
-19.5 -19.5
-21.32819305 -40.82819305
-19.38926641 -60.21745946
12.23099288 -47.98646658
11.11908443 -36.86738215
10.10825858 -26.75912357
9.189325979 -17.56979759
8.353932708 -9.215864886
6.718905447 -2.496959439
6.108095861 3.611136421
5.552814419 9.16395084
5.048013108 14.21196395
13.29420429 27.50616824
Then, interpolate value of NPV at interest rate, i = 0.10
Table 8.5: Interpolation between interest rate, i of 0.1 and 0.2
i NPV
0.1 27.50616824
X 0
0.18 -1.78191507
27.50616824−(−1.78191507) 0.10−0.18
=
27.50616824−0 0.10−𝑋
X = 0.1751
DCFROR = 0.1751
DCFROR = 17.51 %
124
REFERENCES
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http://www.bursamarketplace.com/mkt/tools/research/ch=research&pg=research&ac=
564513&bb=576472
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Institute|www.methanol.org. https://www.methanol.org/energy/
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Liquid-Phase Process with Alcoholic Solvents: A Techno-Economic Analysis.
Processes, 7(7), 405. https://doi.org/10.3390/pr7070405
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plant. (2018, December 14). The Edge Markets.
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produced-sarawak-petchems-bintulu-plant
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127

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FACULTY OF CHEMICAL ENGINEERING

PLANT DESIGN & ECONOMICS (CPE 604)

MINI PROJECT DESIGN

GROUP: EH220 5A (GROUP 1)

IR. NORMADYZAH AHMAD

NO NAME MATRIC NUMBER

1 ZIKRY AKMAL BIN AZHAR 2018272666

2 NUR HAZIAH BINTI HASSAN 2018659858

3 ELYA MAISARAH BINTI MUSA 2018435654

4 HAMIZAH IZZATI BINTI ABU BAKAR 2018438736

5 NURSHAFIQAH BALQIS BINTI MOHD ADZHAR 2018660112

CHAPTER 1: PROCESS BACKGROUND AND SELECTION ........................................ 1

Synthesis gas via CO and CO2 hydrogenation

Three equilibrium reactions can describe the methanol synthesis process:

𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 (1)

𝐶𝑂 + 2𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 (2)

Direct Hydrogenation of CO2

𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 (1)

Synthesis from Biomass

Thermodynamics and Kinetics of Methanol

Table 1.3.1: Physical Properties of Methanol

Molecular weight 32.04 kg/kmol

Saturated liquid density = AB (1+(1-T/C) D(kg/m3)

A= 54.566, B= 0.233211, C= 513.16, D = 0.208875

Melting point -97.7 ℃

Critical temperature 512.6 K

Critical pressure 81 bar abs

Heat of formation -201.3 Mj/kmol

Gibbs free energy -162.62 Mj/kmol

Heat of combustion 726.1 kJ/mole

Heat of vaporization H= A exp (-a Tr)(1- Tr)b

A= 45.3 kJ/mol, a = - 0.31, b = 0.4241, Tc = 512.6 K, Tr= T/ Tc

Viscosity log (viscosity) = a (1/T – 1/b)

a = 21.152, b = 0.07092, c = 2.59E-05, d = -2.85E-08

Vapour pressure ln (P) = a – b(T + c)

a = 18.5875, b = 3626.55, c = -34.29

Table 1.3.2: Chemical Composition Percentage in Methanol

Table 1.3.3: Chemical Properties of Methanol

Oxidation of Oxidized with acidified Potassium Dichromate, or Potassium

Dehydrogenation of Oxidized by passing its vapor through copper, Cu heated up to 300

CO2 + 3H2 ⇌ CH3OH + H2O ∆ 𝐻𝑅 = −49.2 𝑘𝐽/𝑚𝑜𝑙

𝐶𝑂 + 2H2 ⇌ CH3OH ∆ 𝐻𝑅 = −90.8 𝑘𝐽/𝑚𝑜𝑙

CO2 + H2 ⇌ 𝐶𝑂 + H2O ∆ 𝐻𝑅 = 41.6 𝑘𝐽/𝑚𝑜l

Graaf et al. (1988)

Askgaard et al. (1995)

Figure 1.1: Four Types of Network Reaction of Methanol Synthesis.

1) Synthesis gas via CO and CO2 hydrogenation

Synthesis gas via CO and CO2 hydrogenation

𝐶𝑂 + 2𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 (𝟏)

𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 (𝟏)

In terms of thermodynamic limitation, methanol production from pure CO2 is complicated

Methanol production consists of several fundamental steps such as feed preparation,

2.1 GLOBAL MARKET DEMAND ANALYSIS

Methanol is a colourless liquid formed basically by natural gas or coal. Methanol is a

Figure 2.1.1: World Consumption of Methanol in 2019

Figure 2.1.2: Methanol Demand by End Use

Figure 2.2.1: The Growth Demand of Methanol in Year of 2018