CHAPTER FOUR

Result and Discussion

 CHAPTER FOUR RESULT AND DISCUSSION

4.1 Result of material balance

The material balance have been made in order to calculate the theoretical amount of air
required for complete combustion of inlet gas stream, where it was 1450 kgmol/h, than
the actual inlet air is calculated based on assumed value of excess air (50%). All the
results are shown in table 4.1.

Table 4.1: specification of inlet air

Air specification
o
Temperature ( C) 25
Pressure (bar) 1
Inlet flow rate (kgmol/h) 1450
Composition
O2 21%
N2 79%

Material balance around the reactor CRV-100 is made to calculate the amount of
produced gases, and since the process is taken under steady state condition; the outlet
flow must satisfy the following mole balance equation

Accumulation = out - In + Generation - consumption

Table 4.2:mass around CRV-100

Inlet flow Cons./Gene. Outlet flow

Component
(kgmol/h) (kgmol/h) (kgmol/h)
Hydrogen 83.23413 -83.2341 0
Methane 18.37573 -18.3757 0
Ethane 15.98276 -15.9828 0
Propane 13.28889 -13.2889 0
i-Butane 3.196614 -3.19661 0
n-Butane 4.806964 -4.80696 0
i-Pentane 4.44E-02 -4.44E-02 0
n-Pentane 3.33E-02 -3.33E-02 0
Oxygen 304.5 -253.392 51.10752606
Nitrogen 1145.5 0 1145.5
CO2 0 122.6103 122.6102962
H2O 0 261.573 261.572991
Total 1588.963 -8.172 1580.791

Outflow = In + (Gen. –Cons) = 1588.963 + (-8.172)

Outlet flow = 1580.791 kgmol/h

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 CHAPTER FOUR RESULT AND DISCUSSION

The outlet of reactor CRV-100 is a mixture of flue gas with a composition shown in
table 4.3, where contain mainly water and carbon dioxide with the excess amount of
oxygen and nitrogen.

Table 4.3: specification of CRV-100 produced gas

Mole Molart flow
Component
fraction (kgmol/h)
Hydrogen 0 0
Methane 0 0
Ethane 0 0
Propane 0 0
i-Butane 0 0
n-Butane 0 0
i-Pentane 0 0
n-Pentane 0 0
Oxygen 0.0323 51.10752606
Nitrogen 0.7246 1145.5
CO2 0.776 122.6102962
H2O 0.1655 261.572991
Total 1 1580.791

In order to calculate the amount of steam required to operate the STC, and the amount
of toluene required to operate the ORC, the combined material and energy balance is
required, which will be explained in a while.

4.2 Result of energy balance

1. Energy balance around feed compressors
Since the process is operating at steady state condition, the energy balance around the
gas compressors K-101 and K-102 are done using the adiabatic efficiency 100%, in
order to calculate the power required to increase the gas pressure to 5 bar. The
compressor specifications are shown in table 4.4.

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 CHAPTER FOUR RESULT AND DISCUSSION

Table 4.4: specification of compressors

k-101 K-102
o
Outlet temperature [ C] 131.7 250.5
Adiabatic Head [m] 32885.772 17844.891
Polytropic Head [m] 32885.784 18957.756
Adiabatic Fluid Head [kJ/kg] 322.499 174.999
Polytropic Fluid Head [kJ/kg] 322.499 185.912
Adiabatic Efficiency 100 100
Polytropic Efficiency 100 79.677
Power Consumed [kW] 179.166 2711.370
Polytropic Head Factor 1.003 1.001
Polytropic Exponent 1.237 1.538
Isentropic Exponent 1.237 1.390

2. Energy balance around CRV-100

Since the reaction is exothermic, heat must be removed in order to keep the reactor
temperature within the limit of 1500 oC, where the result shown in table 4.5, and it can
be seen that about 9244 kw of heat must be removed and to achieve that about
1.591x106 kg/h of cooling water is required.

Table 4.5: specification of CRV-100

Reactor temperature [oC] 1500
Heat flow [kw] 9244
Cooling water flow 1.591x106

4.3 Result of scenario 1

In the first scenario, the heat of combustion is directly utilized to operate a steam turbine
cycle STC, where the combined mass and energy balance is performed to calculate the
net output power, amount of working fluid required, and heat must be add and removed,
as well as the operating condition. All the results are shown in table 4.6.

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 CHAPTER FOUR RESULT AND DISCUSSION

Table 4.6: specification of STC in scenario 1

P-100
Outlet pressure [bar] 5
Power Intput [kw] 3.602
K-103
o
Inlet temperature [ C] 200
Outlet temperature [oC] 99.6
Outlet pressure [bar] 1
Power output [kw] 1454
E-100
Outlet temperature [oC] 85
Cooling water flow rate [kg/h] 2.568x106

The main results of the STC is the net output power which calculated to be 1450.4 kw,
and this is achieved by steam flow rate of 2.354x104 kg/h as a working fluid, that enters
the steam turbine at 5 bar and 200 oC.

Since the temperature of stream S4 is high enough to operate an organic rankin cycle
ORC with a toluene as a working fluid, the stream S4 is used to vaporize the toluene in
order to operate the ORC, where the results of that cycle is shown in table 4.7.

Table 4.7: specification of ORC in scenario 1

P-101
Outlet pressure [bar] 5
Power Intput [kw] 6.078
K-104
Inlet temperature [oC] 183
Outlet temperature [oC] 154
Outlet pressure [bar] 1.327
Power output [kw] 351.5
E-103
o
Outlet temperature [ C] 115
Cooling water flow rate [kg/h] 6.917x105

The main results of the ORC is the net output power which calculated to be 345.422
kw, and this is achieved by toluene flow rate of 3.468 x104 kg/h as a working fluid, that
enters the steam turbine at 5 bar and 183 oC.

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 CHAPTER FOUR RESULT AND DISCUSSION

4.4 Result of scenario 2

In the second scenario, the flare gas is used to generate a power in gas turbine, where
the gas is first combusted in a combustion chamber of gas turbine where the power is
generated, and the result of that section is shown in table 4.8

Table 4.8 specification of GT in scenario 2

K-100
o
Inlet temperature [ C] 1500
Outlet temperature [oC] 1104
Outlet pressure [bar] 1
Power output [kw] 6775

Since the outlet stream of gas turbine K-100 is hot, the heat utilized to operate a steam
turbine cycle STC, where the combined mass and energy balance is performed to
calculate the net output power, amount of working fluid required, and heat must be add
and removed, as well as the operating condition. All the results are shown in table 4.9.

Table 4.9: specification of STC in scenario 2

P-100
Outlet pressure [bar] 5
Power Intput [kw] 2.298
K-103
o
Inlet temperature [ C] 200
Outlet temperature [oC] 99.6
Outlet pressure [bar] 1
Power output [kw] 1335
E-100
o
Outlet temperature [ C] 85
Cooling water flow rate [kg/h] 1.927x106

The main results of the STC is the net output power which calculated to be 1332.7 kw,
and this is achieved by steam flow rate of 1.802x104 kg/h as a working fluid, that enters
the steam turbine at 5 bar and 200 oC.

Since the temperature of stream S4 is high enough to operate an organic rankin cycle
ORC with a toluene as a working fluid, the stream S4 is used to vaporize the toluene in
order to operate the ORC, where the results of that cycle is shown in table 4.10.

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 CHAPTER FOUR RESULT AND DISCUSSION

Table 4.10: specification of ORC in scenario 2

P-101
Outlet pressure [bar] 5
Power Intput [kw] 1.482
K-104
o
Inlet temperature [ C] 183
Outlet temperature [oC] 149.5
Outlet pressure [bar] 1.327
Power output [kw] 137.1
E-103
Outlet temperature [oC] 115
Cooling water flow rate [kg/h] 2.209x105

The main results of the ORC is the net output power which calculated to be 135.618
kw, and this is achieved by toluene flow rate of 1.127 x104 kg/h as a working fluid, that
enters the steam turbine at 5 bar and 115 oC.

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 CHAPTER FOUR RESULT AND DISCUSSION

4.4 Comparison between scenarios

In this study, two scenarios are proposed and investigated to reuse the flare gas, where
in the first scenario the net power generated was a negative value means that this
scenario is unpractical. While in the second scenario when gas turbine is add to the
system, the net power generated was positive value, which mean that this scenario is
practical, and can be implemented. The results are shown in table 4.11 and chart 4.1.

Table 4.11: Comparison between scenarios

Scenario 1 Scenario 2
power consumption [kw] 2899.880 2893.980
power generation [kw] 1805.500 8247.100
Net power generation [kw] -1094.380 5353.120

Figure 4.1: Comparison between scenarios

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