PAN Reactor Data Case-1 Case-2 Case-3 Case-4

co2/co ratio 2.56 2.56 2.56 2.56

No.of tubes Nos 7000 7000 7000 7000
Air flow per tube NM3/hr.tube 3.7 3.7 3.7 3.7
Grammage gm of OX/Nm3 of air 79.5 82 85 90
Crude pa yield reactor exit % 114 114 114 114
Ma yield % 3.83 3.83 3.83 3.83
Ba yield % 0.73 0.73 0.73 0.73
Ca yield % 0.19 0.19 0.19 0.19
Pd yield % 0.123 0.123 0.123 0.123
Heavies % 0.01 0.01 0.01 0.01
Reactor inlet temp Deg.C 165 165 165 165
Reactor outlet temp Deg.C 359 359 359 359
Steam wetness % 3 3 3 3
Heat content lose % 0 0 0 0
BFW Water inlet SBC enthalpy K.cal/kg 181 181 181 181
Sat. steam enthalpy K.cal/kg 669.12 669.12 669.12 669.12
Sup.steam enthalpy K.cal/kg 741 741 741 741

Gas Temperature
SH Bundle O/L Deg.C 308 308 308 308
PBR O/L Deg.C 315 315 315 315
TS Bundle O/L Deg.C 295 295 295 295
GC O/L Deg.C 171 171 171 171
Eco. Bundle O/L BFW Temp Deg.C 181 181 181 181
Air Pre-Heater Data
APH inlet temperature Deg.C 75 75 75 75
Stage- I O/L temperature Deg.C 140 140 140 140
Stage- II O/L temperature Deg.C 206 206 206 206

O-X Pre-Heater Data

O-X inlet temperature Deg.C 32 32 32 32
O-X outlet temperature Deg.C 145 145 145 145

BFW system Data

BFW tank inlet temperature Deg.C 85 85 85 85
BFW tank temperature Deg.C 145 145 145 145
Water Sp.Heat K.Cal/kg 1 1 1 1

SWC system Data

Cold oil I/L temperature Deg.C 60 60 60 60
Cold oil O/L temperature Deg.C 70 70 70 70
Hot oil I/L temperature Deg.C 195 195 195 195
SWC weight Kg 25000 25000 25000 25000

Steam Enthalpy Properties

4 bar steam - Enthalpy
Vapor K.Cal/kg 655.403 655.403 655.403 655.403
Liquid K.Cal/kg 149 149 149 149
latent heat K.Cal/kg 506.403 506.403 506.403 506.403
 6 bar steam - Enthalpy
Vapor K.Cal/kg 660 660 660 660
Liquid K.Cal/kg 166 166 166 166
latent heat K.Cal/kg 494 494 494 494
15 bar steam - Enthalpy
Vapor K.Cal/kg 667 667 667 667
Liquid K.Cal/kg 205 205 205 205
latent heat K.Cal/kg 462 462 462 462
22 bar steam - Enthalpy
Vapor K.Cal/kg 669 669 669 669
Liquid K.Cal/kg 225 225 225 225
latent heat K.Cal/kg 444 444 444 444
Case-5 Case-6 Case-7 Case-8 Case-9

2.56 2.56 2.56 2.62 2.62

7000 7000 7000 7000 7000
3.7 3.7 3.7 3.8 3.82
95 97 100 93 98
114 114 114 110 110
3.83 3.83 3.83 4.18 4.18
0.73 0.73 0.73 0.73 0.73
0.19 0.19 0.19 0.22 0.22
0.123 0.123 0.123 0.271 0.271
0.01 0.01 0.01 0.02 0.02
165 165 165 164.1 162.2
359 359 359 359.9 361
3 3 3 3 3
0 0 0 0 0
181 181 181 177 177
669.12 669.12 669.12 669 669
741 741 741 742 742

308 308 308 310.9 310.2

315 315 315 316.1 316
295 295 295 296.9 297
171 171 171 168.6 169
181 181 181 176.2 176.8

75 75 75 70 70
140 140 140
206 206 206 199.89 199.3

32 32 32 32 32
145 145 145 149 150

85 85 85 85 85
145 145 145 141 141
1 1 1 1 1

60 60 60 60 60
70 70 70 76 76
195 195 195 185 185
25000 25000 25000 50000 50000

655.403 655.403 655.403 655.403 655.403

149 149 149 149 149
506.403 506.403 506.403 506.403 506.403
660 660 660 660 660
166 166 166 166 166
494 494 494 494 494

667 667 667 667 667

205 205 205 205 205
462 462 462 462 462

669 669 669 669 669

225 225 225 225 225
444 444 444 444 444
 1.30 M.K.Cal/hr

SALT
BATH
SUPER REACTOR COOLER
HEATER

5.23 M.K.Cal/hr

3.09 M.K.Cal/hr
2.59 2.66
M.K.Cal/hr M.K.Cal/hr

SH BUNDLE PBR BUNDLE TS BUNDLE

SALT
BATH
OOLER

2.47 1.30
M.K.Cal/hr M.K.Cal/hr

TS BUNDLE ECONOMISER
BUNDLE
 22 bar Steam Network

Generation Sources Case-1 Case-2 Case-3 Case-4 Case-5 Case-6

SBC & Super Heater MT/hr 9.35 9.74 10.21 10.99 11.77 12.08

Steam Drum MT/hr 0.39 0.39 0.40 0.40 0.40 0.40

De-super heater MT/hr 0.40 0.40 0.40 0.40 0.40 0.40

Total Generation MT/hr 10.14 10.53 11.00 11.79 12.57 12.89

Consumption Sources

APH Bundles MT/hr 1.19 1.19 1.19 1.19 1.19 1.19

Oil Heater MT/hr 1.38 1.39 1.41 1.44 1.47 1.48

TG Ejectors MT/hr 0.2 0.2 0.2 0.2 0.2 0.2

Turbo Generator MT/hr 7.2 7.2 7.2 7.2 7.2 7.2

Steam Vent MT/hr 0.15 0.15 0.15 0.15 0.15 0.15

Total Consumption MT/hr 10.12 10.13 10.15 10.18 10.21 10.22

Net Difference MT/hr 0.02 0.40 0.85 1.61 2.36 2.67

6 bar Steam Network

Generation Sources

Boiler MT/hr 3.2 3.2 3.2 3.2 3.2 3.2

MP Flash Drum MT/hr 0.25 0.31 0.31 0.31 0.32 0.32

GC Flashing MT/hr 0.69 0.68 0.67 0.65 0.63 0.63

Letdown PCV MT/hr 0 0 0 0 0 0

Thermo Compressor MT/hr 0 0 0 0 0 0

Total Generation MT/hr 4.14 4.19 4.18 4.16 4.15 4.14

Consumption Sources

O-X Heater MT/hr 0.22 0.22 0.23 0.24 0.26 0.26

Plant Heating MT/hr 4 4 4 4 4 4

Total Consumption MT/hr 4.22 4.22 4.23 4.24 4.26 4.26

Net Difference MT/hr -0.08 -0.04 -0.05 -0.08 -0.11 -0.12

4 bar Steam Network

 Generation Sources

Distillation Plant MT/hr 1.78 1.78 1.78 1.78 1.78 1.78

LP FD MT/hr 0.09 0.09 0.09 0.09 0.09 0.09

Total Generation MT/hr 1.87 1.87 1.87 1.87 1.87 1.87

Consumption Sources

APH Bundle MT/hr 1.03 1.03 1.03 1.03 1.03 1.03

BFW Tank MT/hr 1.11 1.15 1.21 1.30 1.39 1.43

Steam Vent MT/hr 0.00 0.00 0.00 0.00 0.00 0.00

Total Consumption MT/hr 2.14 2.18 2.24 2.33 2.42 2.46

Net Difference MT/hr -0.27 -0.31 -0.37 -0.46 -0.55 -0.59

Case-7 Case-8 Case-9

12.55 15.76 16.50

0.40 0.39 0.39

0.40 0.40 0.40

13.36 16.55 17.29

1.19 2.41 2.41

1.49 2.19 2.22

0.2 0.2 0.2

7.2 7.8 7.8

0.15 0.4 0.8

10.24 13.00 13.43

3.12 3.55 3.86

3.2 1.08 0.46

0.32 0.55 0.55

0.61 0.41 0.40

0 0.00 0.00

0 0 0

4.14 2.04 1.41

0.27 0.27 0.29

4 5 6

4.27 5.27 6.29

-0.14 -3.23 -4.88

1.78 1.78 1.78

0.09 0.15 0.16

1.87 1.94 1.94

1.03 0.00 0.00

1.49 1.74 1.82

0.00 1.00 2.00

2.52 2.74 3.82

-0.64 -0.81 -1.89

 Steam Production Analysis
Description Unit Case-1 Case-2
Expected 22 bar steam production MT/hr 9.35 9.74
Heat generation ratio KJ/Kg of OX 10642.47 10750.44
co2/co ratio 2.56 2.56
No.of tubes Nos 7000.00 7000.00
Air flow per tube NM3/hr.tube 3.70 3.70
Grammage gm of OX/Nm3 of air 79.50 82.00
Ox flow rate Kg/hr 2059 2124
Air flow rate NM3/hr 25900 25900
Crude pa yield reactor exit % 114.00 114.00
Ma yield % 3.83 3.83
Ba yield % 0.73 0.73
Ca yield % 0.19 0.19
Pd yield % 0.12 0.12
Heavies % 0.01 0.01
Reactor inlet temp % 165.00 165.00
G.C outlet temp % 359.00 359.00
Steam wetness 3.00 3.00
Heat content lose % 0.00 0.00
Water inlet enthalpy K.cal/kg 181.00 181.00
Sat. steam enthalpy K.cal/kg 669.12 669.12
Super heater O/L enthalpy K.cal/kg 741.00 741.00
Solving Constrain steam production 0.00 0.00
mol wt
Ox 106 106
PAN 148 148
MAN 98 98
BAC 122 122
CA 130 130
PD 134 134
Uknowns 148 148
O2 32 32
N2 28 28
CO2 44 44
CO 28 28
HEAT OF FORMATION AT 25 C
OX(g) K.cal/mol 4540 4540
AIR K.cal/mol 0 0
PAN(g) K.cal/mol -88800 -88800
MAN(g) K.cal/mol -96000 -96000
BA(g) ASSUMED K.cal/mol -88800 -88800
CA(g) ASSUMED K.cal/mol -96000 -96000
PD(g) ASSUMED K.cal/mol -88800 -88800
HY(g) ASSUMED K.cal/mol -88800 -88800
CO2 K.cal/mol -94050 -94050
CO K.cal/mol -26416 -26416
H2O(g) K.cal/mol -57800 -57800

Mean inlet temp K 368 368

Mean outlet temp K 465 465
INLET GAS SP. HEAT
OX K.cal/mol.K 37.17 38.17
O2 K.cal/mol.K 6.98 6.98
N2 K.cal/mol.K 6.87 6.87
CO2 K.cal/mol.K 9.90 9.90
H2O K.cal/mol.K 8.46 8.46

EXIT GAS SP. HEAT

PAN K.cal/mol.K 46.2 46.2
MAN K.cal/mol.K 25.9 25.9
BA K.cal/mol.K 46.2 46.2
CA K.cal/mol.K 25.9 25.9
PD K.cal/mol.K 46.2 46.2
HY K.cal/mol.K 46.2 46.2
O2 K.cal/mol.K 7.5 7.5
CO2 K.cal/mol.K 10.7 10.7
CO K.cal/mol.K 7.2 7.2
N2 K.cal/mol.K 7.0 7.0
H2O K.cal/mol.K 8.6 8.6
OUTLET QUANTITIES

PAN Kg/hr 2347.3 2421.1

MAN Kg/hr 78.9 81.3
BA Kg/hr 15.0 15.5
CA Kg/hr 3.9 4.0
PD Kg/hr 2.5 2.6
HY Kg/hr 0.2 0.2
OX Converted to PA 1681.2 1734.1
MA quantity of OX 85.3 88.0
BA used to produce 13.1 13.5
CA individual product 3.2 3.3
PD kg/hr 2.0 2.1
HY 0.1 0.2
OX not converted to PA,MA,BA,CA kg/hr 274.2 282.8
Carbon not converted to PA etc 248.3 256.1
C converted to CO2/CO
When MA is produced 38.6 39.8
BA 1.5 1.5
CA 1.1 1.1
Total 289.5 298.6
CO2 763.3 787.3
CO 189.7 195.7
H2O 1153.9 1190.2
O2 Consumed 2495.7 2574.2
INLET QUANTITIES in kg
O2 kg/hr 7502.4 7502.4
N2 kg/hr 24890.2 24890.2
CO2 kg/hr 16.1 16.1
H2O kg/hr 671.4 671.4
HEAT OF FORMATION OF REACTANTS
OX K.cal/hr 88189.5 90962.8
HEAT CARRIED BY REACTANTS
O2 K.cal/hr 229070.3 229070.3
N2 K.cal/hr 854731.1 854731.1
CO2 K.cal/hr 507.8 507.8
H2O K.cal/hr 28388.1 28388.1
OX K.cal/hr 101083.8 107067.6
Total heat inlet K.cal/hr 1301970.6 1310727.7

HEAT OF FORMATION OF PRODUCTS

PAN(g) K.cal/hr -1408390.2 -1452679.2
MAN K.cal/hr -77252.2 -79681.5
BA K.cal/hr -10940.6 -11284.7
CA K.cal/hr -2889.0 -2979.9
PD K.cal/hr -1678.3 -1731.1
HY K.cal/hr -123.5 -127.4
CO2 K.cal/hr -1631535.9 -1682842.1
CO K.cal/hr -179004.9 -184634.0
H2O K.cal/hr -3705413.0 -3821935.4

Total K.cal/hr -7017227.8 -7237895.3

HEAT CARRIED BY PRODUCT
PAN(g) K.cal/hr 244662.2 252356.0
MAN K.cal/hr 6969.8 7189.0
BA K.cal/hr 1900.6 1960.3
CA K.cal/hr 260.7 268.8
PD K.cal/hr 291.6 300.7
HY K.cal/hr 21.5 22.1
O2 K.cal/hr 393075.7 386914.1
N2 K.cal/hr 2067943.9 2067943.9
CO2 K.cal/hr 63364.2 65315.6
CO K.cal/hr 16200.8 16710.2
H2O K.cal/hr 290584.9 296361.7
Total K.cal/hr 3085275.8 3095342.6
Heat available for steam production M.K.cal/hr 5.2 5.5
with out heat lose M.K.cal/hr 5.2 5.5
With-out Super heater
22 Bar steam production (satu) MT/hr 11.1 11.5
HEAT FOR SUPERHEATER
Inlet Enthalpy K.cal/Kg 181.000 181.000
Outlet Enthalpy K.cal/Kg 741.000 741.000
Steam Quantity Kg/hr 9346.3 9738.0
Heat Quantity M.K.cal/hr 5.2 5.5
 Case-3 Case-4 Case-5 Case-6 Case-7 Case-8 Case-9
10.21 10.99 11.77 12.08 12.55 15.76 16.50
10870.95 11051.07 11212.81 11276.32 11364.46 11790.04 11896.39
2.56 2.56 2.56 2.56 2.56 2.62 2.62
7000.00 7000.00 7000.00 7000.00 7000.00 7000.00 7000.00
3.70 3.70 3.70 3.70 3.70 3.80 3.82
85.00 90.00 95.00 97.00 100.00 93.00 98.00
2202 2331 2461 2512 2590 2474 2621
25900 25900 25900 25900 25900 26600 26740
114.00 114.00 114.00 114.00 114.00 110.00 110.00
3.83 3.83 3.83 3.83 3.83 4.18 4.18
0.73 0.73 0.73 0.73 0.73 0.73 0.73
0.19 0.19 0.19 0.19 0.19 0.22 0.22
0.12 0.12 0.12 0.12 0.12 0.27 0.27
0.01 0.01 0.01 0.01 0.01 0.02 0.02
165.00 165.00 165.00 165.00 165.00 164.10 162.20
359.00 359.00 359.00 359.00 359.00 359.90 361.00
3.00 3.00 3.00 3.00 3.00 3.00 3.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00
181.00 181.00 181.00 181.00 181.00 177.00 177.00
669.12 669.12 669.12 669.12 669.12 669.00 669.00
741.00 741.00 741.00 741.00 741.00 742.00 742.00
0.00 0.00 0.00 0.00 0.00 -1.94 -1.88

106 106 106 106 106 106 106

148 148 148 148 148 148 148
98 98 98 98 98 98 98
122 122 122 122 122 122 122
130 130 130 130 130 130 130
134 134 134 134 134 134 134
148 148 148 148 148 148 148
32 32 32 32 32 32 32
28 28 28 28 28 28 28
44 44 44 44 44 44 44
28 28 28 28 28 28 28

4540 4540 4540 4540 4540 4540 4540

0 0 0 0 0 0 0
-88800 -88800 -88800 -88800 -88800 -88800 -88800
-96000 -96000 -96000 -96000 -96000 -96000 -96000
-88800 -88800 -88800 -88800 -88800 -88800 -88800
-96000 -96000 -96000 -96000 -96000 -96000 -96000
-88800 -88800 -88800 -88800 -88800 -88800 -88800
-88800 -88800 -88800 -88800 -88800 -88800 -88800
-94050 -94050 -94050 -94050 -94050 -94050 -94050
-26416 -26416 -26416 -26416 -26416 -26416 -26416
-57800 -57800 -57800 -57800 -57800 -57800 -57800

368 368 368 368 368 368 367

465 465 465 465 465 465 466

39.17 40.17 41.17 42.17 43.17 44.17 45.17

6.98 6.98 6.98 6.98 6.98 6.98 6.97
6.87 6.87 6.87 6.87 6.87 6.87 6.87
9.90 9.90 9.90 9.90 9.90 9.90 9.89
8.46 8.46 8.46 8.46 8.46 8.46 8.46

46.2 46.2 46.2 46.2 46.2 46.2 46.3

25.9 25.9 25.9 25.9 25.9 26.0 26.0
46.2 46.2 46.2 46.2 46.2 46.2 46.3
25.9 25.9 25.9 25.9 25.9 26.0 26.0
46.2 46.2 46.2 46.2 46.2 46.2 46.3
46.2 46.2 46.2 46.2 46.2 46.2 46.3
7.5 7.5 7.5 7.5 7.5 7.5 7.5
10.7 10.7 10.7 10.7 10.7 10.7 10.7
7.2 7.2 7.2 7.2 7.2 7.2 7.2
7.0 7.0 7.0 7.0 7.0 7.0 7.0
8.6 8.6 8.6 8.6 8.6 8.6 8.6

2509.7 2657.3 2805.0 2864.0 2952.6 2721.2 2882.6

84.3 89.3 94.2 96.2 99.2 103.4 109.5
16.1 17.0 18.0 18.3 18.9 18.1 19.1
4.2 4.4 4.7 4.8 4.9 5.4 5.8
2.7 2.9 3.0 3.1 3.2 6.7 7.1
0.2 0.2 0.2 0.3 0.3 0.5 0.5
1797.5 1903.2 2009.0 2051.3 2114.7 1949.0 2064.5
91.2 96.6 101.9 104.1 107.3 111.8 118.5
14.0 14.8 15.6 15.9 16.4 15.7 16.6
3.4 3.6 3.8 3.9 4.0 4.4 4.7
2.1 2.3 2.4 2.4 2.5 5.3 5.6
0.2 0.2 0.2 0.2 0.2 0.4 0.4
293.1 310.4 327.6 334.5 344.9 387.2 410.2
 265.5 281.1 296.7 303.0 312.3 350.7 371.5

41.3 43.7 46.2 47.1 48.6 50.6 53.7

1.6 1.7 1.8 1.8 1.9 1.8 1.9
1.2 1.2 1.3 1.3 1.4 1.5 1.6
309.5 327.7 345.9 353.2 364.1 404.6 428.6
816.1 864.1 912.1 931.3 960.1 1073.8 1137.4
202.9 214.8 226.7 231.5 238.7 260.8 276.3
1233.8 1306.3 1378.9 1407.9 1451.5 1407.0 1490.5
2668.4 2825.3 2982.3 3045.1 3139.3 3123.0 3308.3

7502.4 7502.4 7502.4 7502.4 7502.4 7705.2 7745.8

24890.2 24890.2 24890.2 24890.2 24890.2 25563.0 25697.5
16.1 16.1 16.1 16.1 16.1 16.5 16.6
671.4 671.4 671.4 671.4 671.4 689.5 693.2

94290.7 99837.2 105383.7 107602.3 110930.2 105953.3 112237.4

229070.3 229070.3 229070.3 229070.3 229070.3 233631.4 231405.4

854731.1 854731.1 854731.1 854731.1 854731.1 872131.5 864626.7
507.8 507.8 507.8 507.8 507.8 517.9 513.0
28388.1 28388.1 28388.1 28388.1 28388.1 28966.2 28717.3
113892.3 123670.5 133790.8 139925.6 147674.0 143388.1 153209.5
1320880.3 1336205.0 1351871.9 1360225.2 1371301.5 1384588.5 1390709.3

-1505826.0 -1594404.0 -1682982.0 -1718413.2 -1771560.0 -1632708.0 -1729543.2

-82596.7 -87455.3 -92313.9 -94257.4 -97172.6 -101294.5 -107302.3
-11697.5 -12385.6 -13073.7 -13349.0 -13761.8 -13144.4 -13924.0
-3088.9 -3270.6 -3452.3 -3525.0 -3634.0 -4019.0 -4257.3
-1794.5 -1900.0 -2005.6 -2047.8 -2111.1 -4442.6 -4706.1
-132.1 -139.9 -147.6 -150.7 -155.4 -296.9 -314.5
-1744409.5 -1847021.8 -1949634.1 -1990679.0 -2052246.4 -2295162.5 -2431287.6
-191388.9 -202647.1 -213905.2 -218408.5 -225163.4 -246048.3 -260641.3
-3961762.4 -4194807.2 -4427852.0 -4521070.0 -4660896.9 -4518185.7 -4786157.4

-7502696.4 -7944031.4 -8385366.5 -8561900.6 -8826701.6 -8815302.0 -9338133.7

261588.5 276976.1 292363.6 298518.6 307751.2 284589.8 302712.6

7452.0 7890.4 8328.7 8504.1 8767.1 9172.1 9759.1
2032.1 2151.6 2271.1 2318.9 2390.7 2291.1 2437.0
278.7 295.1 311.5 318.0 327.9 363.9 387.2
 311.7 330.1 348.4 355.7 366.7 774.4 823.7
22.9 24.3 25.6 26.2 27.0 51.7 55.0
379520.2 367197.1 354873.9 349944.6 342550.7 360801.0 350659.0
2067943.9 2067943.9 2067943.9 2067943.9 2067943.9 2129694.8 2148105.2
67657.3 71560.1 75462.9 77024.0 79365.7 88903.8 94444.8
17321.6 18340.5 19359.4 19767.0 20378.3 22330.2 23734.5
303293.9 314847.6 326401.2 331022.7 337954.9 334692.3 349769.9
3107422.9 3127556.6 3147690.3 3155743.8 3167824.0 3233665.1 3282888.2
5.7 6.2 6.6 6.8 7.0 7.0 7.4
5.7 6.2 6.6 6.8 7.0 7.0 7.4

12.1 13.0 13.9 14.3 14.8 15.7 16.8

181.000 181.000 181.000 181.000 181.000 177.000 177.000

741.000 741.000 741.000 741.000 741.000 742.000 742.000
10207.4 10986.9 11767.1 12082.8 12553.9 15760.0 16500.0
5.7 6.2 6.6 6.8 7.0 8.9 9.3

15.7
 EXIT GAS SP. HEAT at RCT O/L temp
PAN K.cal/mol.K 46.2 46.2
MAN K.cal/mol.K 25.9 25.9
BA K.cal/mol.K 46.2 46.2
CA K.cal/mol.K 25.9 25.9
PD K.cal/mol.K 46.2 46.2
HY K.cal/mol.K 46.2 46.2
O2 K.cal/mol.K 7.5 7.5
CO2 K.cal/mol.K 10.7 10.7
CO K.cal/mol.K 7.2 7.2
N2 K.cal/mol.K 7.0 7.0
H2O K.cal/mol.K 8.6 8.6

EXIT GAS SP. HEAT at SH Bundle O/L temp

PAN K.cal/mol.K 44.4 44.4
MAN K.cal/mol.K 24.6 24.6
BA K.cal/mol.K 44.4 44.4
CA K.cal/mol.K 24.6 24.6
PD K.cal/mol.K 44.4 44.4
HY K.cal/mol.K 44.4 44.4
O2 K.cal/mol.K 7.4 7.4
CO2 K.cal/mol.K 10.5 10.5
CO K.cal/mol.K 7.1 7.1
N2 K.cal/mol.K 6.9 6.9
H2O K.cal/mol.K 8.5 8.5

EXIT GAS SP. HEAT at PBR O/L Temp

PAN K.cal/mol.K 44.6 44.6
MAN K.cal/mol.K 24.8 24.8
BA K.cal/mol.K 44.6 44.6
CA K.cal/mol.K 24.8 24.8
PD K.cal/mol.K 44.6 44.6
HY K.cal/mol.K 44.6 44.6
O2 K.cal/mol.K 7.4 7.4
CO2 K.cal/mol.K 10.6 10.6
CO K.cal/mol.K 7.1 7.1
N2 K.cal/mol.K 6.9 6.9
H2O K.cal/mol.K 8.5 8.5

EXIT GAS SP. HEAT at TS Bundle O/L temp

PAN K.cal/mol.K 43.9 43.9
MAN K.cal/mol.K 24.2 24.2
BA K.cal/mol.K 43.9 43.9
CA K.cal/mol.K 24.2 24.2
PD K.cal/mol.K 43.9 43.9
HY K.cal/mol.K 43.9 43.9
O2 K.cal/mol.K 7.4 7.4
CO2 K.cal/mol.K 10.5 10.5
CO K.cal/mol.K 7.1 7.1
N2 K.cal/mol.K 6.9 6.9
H2O K.cal/mol.K 8.5 8.5

EXIT GAS SP. HEAT at Eco. Bundle O/L temp

 PAN K.cal/mol.K 39.6 39.6
MAN K.cal/mol.K 20.9 20.9
BA K.cal/mol.K 39.6 39.6
CA K.cal/mol.K 20.9 20.9
PD K.cal/mol.K 39.6 39.6
HY K.cal/mol.K 39.6 39.6
O2 K.cal/mol.K 7.0 7.0
CO2 K.cal/mol.K 9.9 9.9
CO K.cal/mol.K 7.0 7.0
N2 K.cal/mol.K 6.9 6.9
H2O K.cal/mol.K 8.5 8.5

Gas Temperature
RCT O/L Deg.C 359 359
SH Bundle O/L Deg.C 308 308
PBR O/L Deg.C 315 315
TS Bundle O/L Deg.C 295 295
GC O/L Deg.C 171 171

Mean Temperature
RCT O/L K 465 465
SH Bundle O/L K 439.5 439.5
PBR O/L K 443 443
TS Bundle O/L K 433 433
GC O/L K 371 371

Outlet Quanties
PAN Kg/hr 2347.3 2421.1
MAN Kg/hr 78.9 81.3
BA Kg/hr 15.0 15.5
CA Kg/hr 3.9 4.0
PD Kg/hr 2.5 2.6
HY Kg/hr 0.2 0.2
OX Converted to PA 1681.2 1734.1
MA 85.3 88.0
BA 13.1 13.5
CA 3.2 3.3
PD 2.0 2.1
HY 0.1 0.2
OX not converted to PA,MA,BA,CA 274.2 282.8
0 0.0 0.0
Carbon not converted to PA etc 248.3 256.1
C converted to CO2/CO 0.0 0.0
When MA is produced 38.6 39.8
BA 1.5 1.5
CA 1.1 1.1
Total 289.5 298.6
CO2 763.3 787.3
CO 189.7 195.7
H2O 1153.9 1190.2
O2 Consumed 2495.7 2574.2
 mol wt
Ox 106.0 106.0
PAN 148.0 148.0
MAN 98.0 98.0
BAC 122.0 122.0
CA 130.0 130.0
PD 134.0 134.0
Uknowns 148.0 148.0
O2 32.0 32.0
N2 28.0 28.0
CO2 44.0 44.0
CO 28.0 28.0

Heat Carried by Product at RCT O/L

PAN(g) K.Cal/hr 244662 252356
MAN K.Cal/hr 6970 7189
BA K.Cal/hr 1901 1960
CA K.Cal/hr 261 269
PD K.Cal/hr 292 301
HY K.Cal/hr 21 22
O2 K.Cal/hr 393076 386914
N2 K.Cal/hr 2067944 2067944
CO2 K.Cal/hr 63364 65316
CO K.Cal/hr 16201 16710
H2O K.Cal/hr 290585 296362
Total K,Cal/hr 3085276 3095343

Heat Carried by Product at SH Bunble O/L

PAN(g) K.Cal/hr 199234 205500
MAN K.Cal/hr 5595 5771
BA K.Cal/hr 1548 1596
CA K.Cal/hr 209 216
PD K.Cal/hr 237 245
HY K.Cal/hr 17 18
O2 K.Cal/hr 328174 323030
N2 K.Cal/hr 1745765 1745765
CO2 K.Cal/hr 52797 54423
CO K.Cal/hr 13668 14098
H2O K.Cal/hr 245217 250092
Total K,Cal/hr 2592464 2600754

Heat Carried by Product at PBR O/L

PAN(g) K.Cal/hr 205297 211753
MAN K.Cal/hr 5777 5959
BA K.Cal/hr 1595 1645
CA K.Cal/hr 216 223
PD K.Cal/hr 245 252
HY K.Cal/hr 18 19
O2 K.Cal/hr 337027 331744
N2 K.Cal/hr 1789849 1789849
CO2 K.Cal/hr 54234 55905
CO K.Cal/hr 14015 14455
H2O K.Cal/hr 251420 256418
 Total K,Cal/hr 2659692 2668221

Heat Carried by Product at TS Bundle O/L

PAN(g) K.Cal/hr 188120 194036
MAN K.Cal/hr 5262 5428
BA K.Cal/hr 1461 1507
CA K.Cal/hr 197 203
PD K.Cal/hr 224 231
HY K.Cal/hr 17 17
O2 K.Cal/hr 311787 306899
N2 K.Cal/hr 1664011 1664011
CO2 K.Cal/hr 50140 51685
CO K.Cal/hr 13026 13436
H2O K.Cal/hr 233718 238365
Total K,Cal/hr 2467963 2475817

Heat Carried by Product at Eco. Bundle O/L

PAN(g) K.Cal/hr 91603 94483
MAN K.Cal/hr 2456 2533
BA K.Cal/hr 712 734
CA K.Cal/hr 92 95
PD K.Cal/hr 109 113
HY K.Cal/hr 8 8
O2 K.Cal/hr 159948 157441
N2 K.Cal/hr 891752 891752
CO2 K.Cal/hr 25697 26488
CO K.Cal/hr 6970 7189
H2O K.Cal/hr 125254 127744
Total K,Cal/hr 1304601 1308581

Total Heat Inlet by Reactant K,Cal/hr 1301970.64216 1310727.652065

Heat of Formation of Reactant K.Cal/hr 88189.5 90962.75471698

Heat of Formation of Product K.Cal/hr -7017227.77093 -7237895.3109
Total Heat Of Reaction K.Cal/hr -7017227.77093 -7237895.3109

Heat Content at RCT O/L K.Cal/hr 3085276 3095343

RCT Heat Load M.K.Cal/hr 5.23 5.45

Heat Content at SH Bundle O/L K,Cal/hr 2592464 2600754

SH Bundle Heat Load M,K,Cal/hr 0.49 0.49

Heat Content at PBR O/L K.Cal/hr 2659692 2668221

PBR O/L Heat Load M,K.Cal/hr -0.07 -0.07

Heat content at TS Bunble O/L K.Cal/hr 2467963 2475817

TS Bundle Heat Load M,K.Cal/hr 0.19 0.19

Heat Content at Eco. Bundle O/L K.Cal/hr 1304601 1308581

Eco. Bundle Heat Load M,K.Cal/hr 1.16 1.17

BFW Flow Rate (Calculated) kg/hr 32316 32423

 Steam Drum Water Make-up kg/hr 393 394
SBC Water Make-up kg/hr 9346 9738
22 bar network Total Water Make-up kg/hr 9739 10132

Gas Cooler Flashing Water kg/hr 22576 22291

MP steam by GC Flashing kg/hr 686 677

46.2 46.2 46.2 46.2 46.2 46.2
25.9 25.9 25.9 25.9 25.9 26.0
46.2 46.2 46.2 46.2 46.2 46.2
25.9 25.9 25.9 25.9 25.9 26.0
46.2 46.2 46.2 46.2 46.2 46.2
46.2 46.2 46.2 46.2 46.2 46.2
7.5 7.5 7.5 7.5 7.5 7.5
10.7 10.7 10.7 10.7 10.7 10.7
7.2 7.2 7.2 7.2 7.2 7.2
7.0 7.0 7.0 7.0 7.0 7.0
8.6 8.6 8.6 8.6 8.6 8.6

44.4 44.4 44.4 44.4 44.4 44.5

24.6 24.6 24.6 24.6 24.6 24.6
44.4 44.4 44.4 44.4 44.4 44.5
24.6 24.6 24.6 24.6 24.6 24.6
44.4 44.4 44.4 44.4 44.4 44.5
44.4 44.4 44.4 44.4 44.4 44.5
7.4 7.4 7.4 7.4 7.4 7.4
10.5 10.5 10.5 10.5 10.5 10.5
7.1 7.1 7.1 7.1 7.1 7.1
6.9 6.9 6.9 6.9 6.9 6.9
8.5 8.5 8.5 8.5 8.5 8.5

44.6 44.6 44.6 44.6 44.6 44.7

24.8 24.8 24.8 24.8 24.8 24.8
44.6 44.6 44.6 44.6 44.6 44.7
24.8 24.8 24.8 24.8 24.8 24.8
44.6 44.6 44.6 44.6 44.6 44.7
44.6 44.6 44.6 44.6 44.6 44.7
7.4 7.4 7.4 7.4 7.4 7.4
10.6 10.6 10.6 10.6 10.6 10.6
7.1 7.1 7.1 7.1 7.1 7.1
6.9 6.9 6.9 6.9 6.9 6.9
8.5 8.5 8.5 8.5 8.5 8.6

43.9 43.9 43.9 43.9 43.9 44.0

24.2 24.2 24.2 24.2 24.2 24.3
43.9 43.9 43.9 43.9 43.9 44.0
24.2 24.2 24.2 24.2 24.2 24.3
43.9 43.9 43.9 43.9 43.9 44.0
43.9 43.9 43.9 43.9 43.9 44.0
7.4 7.4 7.4 7.4 7.4 7.4
10.5 10.5 10.5 10.5 10.5 10.5
7.1 7.1 7.1 7.1 7.1 7.1
6.9 6.9 6.9 6.9 6.9 6.9
8.5 8.5 8.5 8.5 8.5 8.5
 39.6 39.6 39.6 39.6 39.6 39.5
20.9 20.9 20.9 20.9 20.9 20.8
39.6 39.6 39.6 39.6 39.6 39.5
20.9 20.9 20.9 20.9 20.9 20.8
39.6 39.6 39.6 39.6 39.6 39.5
39.6 39.6 39.6 39.6 39.6 39.5
7.0 7.0 7.0 7.0 7.0 7.0
9.9 9.9 9.9 9.9 9.9 9.9
7.0 7.0 7.0 7.0 7.0 7.0
6.9 6.9 6.9 6.9 6.9 6.9
8.5 8.5 8.5 8.5 8.5 8.5

359 359 359 359 359 359.9

308 308 308 308 308 310.9
315 315 315 315 315 316.1
295 295 295 295 295 296.9
171 171 171 171 171 168.6

465 465 465 465 465 465.45

439.5 439.5 439.5 439.5 439.5 440.95
443 443 443 443 443 443.55
433 433 433 433 433 433.95
371 371 371 371 371 369.8

2509.7 2657.3 2805.0 2864.0 2952.6 2721.2

84.3 89.3 94.2 96.2 99.2 103.4
16.1 17.0 18.0 18.3 18.9 18.1
4.2 4.4 4.7 4.8 4.9 5.4
2.7 2.9 3.0 3.1 3.2 6.7
0.2 0.2 0.2 0.3 0.3 0.5
1797.5 1903.2 2009.0 2051.3 2114.7 1949.0
91.2 96.6 101.9 104.1 107.3 111.8
14.0 14.8 15.6 15.9 16.4 15.7
3.4 3.6 3.8 3.9 4.0 4.4
2.1 2.3 2.4 2.4 2.5 5.3
0.2 0.2 0.2 0.2 0.2 0.4
293.1 310.4 327.6 334.5 344.9 387.2
0.0 0.0 0.0 0.0 0.0 0.0
265.5 281.1 296.7 303.0 312.3 350.7
0.0 0.0 0.0 0.0 0.0 0.0
41.3 43.7 46.2 47.1 48.6 50.6
1.6 1.7 1.8 1.8 1.9 1.8
1.2 1.2 1.3 1.3 1.4 1.5
309.5 327.7 345.9 353.2 364.1 404.6
816.1 864.1 912.1 931.3 960.1 1073.8
202.9 214.8 226.7 231.5 238.7 260.8
1233.8 1306.3 1378.9 1407.9 1451.5 1407.0
2668.4 2825.3 2982.3 3045.1 3139.3 3123.0
 106.0 106.0 106.0 106.0 106.0 106.0
148.0 148.0 148.0 148.0 148.0 148.0
98.0 98.0 98.0 98.0 98.0 98.0
122.0 122.0 122.0 122.0 122.0 122.0
130.0 130.0 130.0 130.0 130.0 130.0
134.0 134.0 134.0 134.0 134.0 134.0
148.0 148.0 148.0 148.0 148.0 148.0
32.0 32.0 32.0 32.0 32.0 32.0
28.0 28.0 28.0 28.0 28.0 28.0
44.0 44.0 44.0 44.0 44.0 44.0
28.0 28.0 28.0 28.0 28.0 28.0

261588 276976 292364 298519 307751 284590

7452 7890 8329 8504 8767 9172
2032 2152 2271 2319 2391 2291
279 295 311 318 328 364
312 330 348 356 367 774
23 24 26 26 27 52
379520 367197 354874 349945 342551 360801
2067944 2067944 2067944 2067944 2067944 2129695
67657 71560 75463 77024 79366 88904
17322 18341 19359 19767 20378 22330
303294 314848 326401 331023 337955 334692
3107423 3127557 3147690 3155744 3167824 3233665

213018 225548 238079 243091 250609 233871

5982 6334 6686 6826 7038 7435
1655 1752 1849 1888 1947 1883
224 237 250 255 263 295
254 269 284 290 299 636
19 20 21 21 22 43
316857 306568 296280 292165 285991 303702
1745765 1745765 1745765 1745765 1745765 1811699
56375 59626 62878 64179 66130 74690
14614 15474 16333 16677 17193 18985
255942 265692 275442 279342 285192 284609
2610704 2627285 2643867 2650500 2660449 2737848

219500 232412 245324 250489 258236 239106

6177 6540 6903 7049 7267 7613
1705 1805 1906 1946 2006 1925
231 245 258 264 272 302
262 277 292 299 308 651
19 20 22 22 23 43
325404 314838 304272 300046 293706 309724
1789849 1789849 1789849 1789849 1789849 1845342
57909 61249 64590 65926 67930 76185
14984 15866 16747 17100 17629 19338
262416 272413 282409 286408 292406 289904
 2678456 2695514 2712572 2719395 2729630 2790132

201135 212966 224797 229530 236629 219952

5626 5957 6288 6421 6619 6963
1562 1654 1746 1783 1838 1771
210 223 235 240 248 276
240 254 268 274 282 598
18 19 20 20 21 40
301034 291260 281485 277575 271710 287537
1664011 1664011 1664011 1664011 1664011 1721246
53538 56626 59714 60950 62802 70683
13927 14747 15566 15894 16385 18034
243940 253233 262525 266242 271818 270379
2485241 2500949 2516656 2522939 2532363 2597480

97940 103701 109462 111767 115223 104223

2626 2780 2935 2996 3089 3157
761 806 850 868 895 839
98 104 110 112 116 125
117 124 130 133 137 284
9 9 10 10 10 19
154432 149418 144403 142397 139389 143791
891752 891752 891752 891752 891752 900641
27438 29021 30604 31237 32186 35312
7452 7891 8329 8504 8768 9421
130732 135713 140693 142685 145673 141480
1313357 1321317 1329277 1332462 1337238 1339293

1320880.305462 1336205.042254 1351871.854518 1360225.239801 1371301.50 1384588.54

94290.66037736 99837.16981132 105383.6792453 107602.2830189 110930.19 105953.32

-7502696.35886 -7944031.43879 -8385366.51872 -8561900.5507 -8826701.599 -8815302.00
-7502696.35886 -7944031.43879 -8385366.51872 -8561900.5507 -8826701.59866 -8815302.00

3107423 3127557 3147690 3155744 3167824 3233665

5.72 6.15 6.59 6.77 7.03 6.97

2610704 2627285 2643867 2650500 2660449 2737848

0.50 0.50 0.50 0.51 0.51 0.50

2678456 2695514 2712572 2719395 2729630 2790132

-0.07 -0.07 -0.07 -0.07 -0.07 -0.05

2485241 2500949 2516656 2522939 2532363 2597480

0.19 0.19 0.20 0.20 0.20 0.19

1313357 1321317 1329277 1332462 1337238 1339293

1.17 1.18 1.19 1.19 1.20 1.26

32552 32768 32983 33069 33198 35744

 396 399 401 403 404 391
10207 10987 11767 12083 12554 15690
10603 11386 12169 12485 12958 16081

21949 21382 20814 20583 20240 19663

666 649 632 625 615 406

15689.697001
46.3
26.0
46.3
26.0
46.3
46.3
7.5
10.7
7.2
7.0
8.6

44.5
24.6
44.5
24.6
44.5
44.5
7.4
10.5
7.1
6.9
8.5

44.7
24.8
44.7
24.8
44.7
44.7
7.4
10.6
7.1
6.9
8.6

44.0
24.3
44.0
24.3
44.0
44.0
7.4
10.5
7.1
6.9
8.5
 39.5
20.8
39.5
20.8
39.5
39.5
7.0
9.9
7.0
6.9
8.5

361
310.2
316
297
169

466
440.6
443.5
434
370

2882.6
109.5
19.1
5.8
7.1
0.5
2064.5
118.5
16.6
4.7
5.6
0.4
410.2
0.0
371.5
0.0
53.7
1.9
1.6
428.6
1137.4
276.3
1490.5
3308.3
 106.0
148.0
98.0
122.0
130.0
134.0
148.0
32.0
28.0
44.0
28.0

302713
9759
2437
387
824
55
350659
2148105
94445
23734
349770
3282888

246998
7850
1989
311
672
45
293329
1816684
78846
20060
295689
2762473

253180
8061
2038
320
689
46
299833
1854403
80611
20478
301839
 2821497

233101
7380
1877
293
634
42
278570
1730954
74848
19111
281715
2628525

110752
3356
892
133
301
20
139669
907929
37489
10008
147771
1358322

1390709.34

112237.37
-9338133.72
-9338133.72

3282888
7.45

2762473
0.52

2821497 4 Numbers of ports are present

-0.06

2628525
530 mm
0.19

1358322
370 mm
1.27
200 mm
35481
20 mm
 200 mm

20 mm

510 mm

110 mm

480 mm
392
16770
17162

18318

400

16770.168693
 Air Pre-Heater System

Nm3/hr 25900 25900 25900

Airflow rate
kg/hr 33411 33411 33411
Air Sp.Heat Kcal/kg.Deg.c 0.24 0.24 0.24
Stage-1
Inlet temperature Deg.C 75 75 75
outlet temperature Deg.C 140 140 140
air heat load K.Cal/hr 521212 521212 521212
4 bar steam latent heat k.Cal/kg 506 506 506
4 bar steam required MT/hr 1.03 1.03 1.03
Stage-2
Inlet temperature Deg.C 140 140 140
outlet temperature Deg.C 206 206 206
air heat load K.Cal/hr 529230 529230 529230
22 bar steam latent heat k.Cal/kg 444 444 444
22 bar steam required MT/hr 1.19 1.19 1.19

APH Total steam consumptiuon MT/hr 2.22 2.22 2.22

O-X Pre-Heater System

O-X flow kg/hr 2059 2124 2202
inlet temperature Deg.C 32 32 32
oulet temperature Deg.C 145 145 145
Sp.Heat K.Cal/kg.Deg.C 0.4584 0.4584 0.4584
heat load K.Cal/hr 106657 110011 114036
6 bar steam latent heat K.Cal/kg 494 494 494
6 bar steam required MT/hr 0.22 0.22 0.23

OX Total steam consumptiuon MT/hr 0.22 0.22 0.23

m

25900 25900 25900 25900 26600 26740

33411 33411 33411 33411 34314 34494.6
0.24 0.24 0.24 0.24 0.24 0.24

75 75 75 75 70 70
140 140 140 140
521212 521212 521212 521212
506 506 506 506
1.03 1.03 1.03 1.03

140 140 140 140 0 0

206 206 206 206 199.89 199.3
529230 529230 529230 529230 1069691 1070436
444 444 444 444 444 444
1.19 1.19 1.19 1.19 2.41 2.41

2.22 2.22 2.22 2.22 2.41 2.41

em
2331 2461 2512 2590 2474 2621
32 32 32 32 32 32
145 145 145 145 149 150
0.4584 0.4584 0.4584 0.4584 0.4584 0.4584
120744 127452 130135 134160 132677 141747
494 494 494 494 494 494
0.24 0.26 0.26 0.27 0.27 0.29

0.24 0.26 0.26 0.27 0.27 0.29

 BFW Tank system

water rate kg/hr 9346 9738 10207 10987 11767

inlet temperature Deg.C 85 85 85 85 85
outlet temperature Deg.C 145 145 145 145 145
Sp.heat K.Cal/kg.Deg.C 1 1 1 1 1
heat load K.Cal/hr 560777.426 584280 612445.05 659215.7 706023
4 bar steam latent heat K.Cal/kg 506.403 506.403 506.403 506.403 506.403
BFW Tank steam required MT/hr 1.11 1.15 1.21 1.30 1.39
 12083 12554 15760 16500
85 85 85 85
145 145 141 141
1 1 1 1
724969.5 753233.47 882560 924000
506.403 506.403 506.403 506.403
1.43 1.49 1.74 1.82
 Oil Heater System
PA production rate kg/hr 2347.317 2421.132 2509.71
Specific Heat of PA K.Cal/kg.Deg.C 0.397 0.397 0.397
Latent heat of fusion K.Cal/kg 38 38 38
Latent heat of vaporisation K.Cal/kg 105.5 105.5 105.5
Cold oil temperature inlet Deg.c 60 60 60
Cold oil temperature outlet Deg.c 70 70 70
Cold oil Specific Heat at 60 dec.C K.Cal/kg.Deg.C 0.4036 1.4036 2.4036
Hot oil temperatur inlet Deg.c 195 195 195
Freezing point of PA Deg.c 130.8 130.8 130.8
Specific Heat capacity of metal K.Cal/kg.Deg.C 0.12 0.12 0.12
SWC Weight kg 25000 25000 25000
Sensible heat required K.Cal/hr 56658.599 58440.316 60578.376
Energy required to raise to180 deg.C K.Cal/hr 59827.007 61708.36 63965.983
Heat gained by SWC K.Cal/hr 405000 405000 405000
Heat required to melt PA K.Cal/hr 89198.046 92003.016 95368.98
Total heat load K.Cal/hr 610684 617152 624913
22 bar steam latent heat K.Cal/kg 444 444 444
Quantity of steam required MT/hr 1.3754136 1.3899813 1.4074625

Total Steam required MT/hr 1.38 1.39 1.41

Melting time min

No of cycle per day No
Total steam consumption hr
Steam required MT/day
 Current
condition
2657.34 2804.97 2864.022 2952.6 2721.18 2882.572
0.397 0.397 0.397 0.397 0.397 0.397
38 38 38 38 38 38
105.5 105.5 105.5 105.5 105.5 105.5
60 60 60 60 60 60
70 70 70 70 76 76
3.4036 4.4036 5.4036 6.4036 7.4036 8.4036
195 195 195 195 185 185
130.8 130.8 130.8 130.8 130.8 130.8
0.12 0.12 0.12 0.12 0.12 0.12
25000 25000 25000 25000 50000 50000
64141.81 67705.244 69130.617 71268.678 59200.904 62712.083
67728.688 71491.392 72996.474 75254.097 58552.719 62025.455
405000 405000 405000 405000 750000 750000
100978.92 106588.86 108832.84 112198.8 103404.84 109537.74
637849 650785 655960 663722 971158 984275
444 444 444 444 444 444
1.4365978 1.4657331 1.4773872 1.4948684 2.1872938 2.2168362

1.44 1.47 1.48 1.49 2.19 2.22

45 45
16 16
12 12
26.2 26.6
 Steam Enthalpy Properties
vapor K.Cal/kg 655.403 655.403 655.403
4 bar steam
Liquid K.Cal/kg 149 149 149
vapor K.Cal/kg 660 660 660
6 bar steam
Liquid K.Cal/kg 166 166 166
vapor K.Cal/kg 667 667 667
15 bar steam
Liquid K.Cal/kg 205 205 205
vapor K.Cal/kg 669 669 669
22 bar steam
Liquid K.Cal/kg 225 225 225

HP Flash Drum - Steam Recovery

APH Budle MT/hr 0.14 0.14 0.14 0.14
Oil heater MT/hr 0.11 0.17 0.17 0.17

Total HP Flash steam Recovery MT/hr 0.25 0.31 0.31 0.31

LP Flash Drum - Steam Recovery

Condensate from HP FD MT/hr 0.09 0.09 0.09 0.09

Total LP Flash steam Recovery MT/hr 0.09 0.09 0.09 0.09

655.403 655.403 655.403 655.403 655.403
149 149 149 149 149
660 660 660 660 660
166 166 166 166 166
667 667 667 667 667
205 205 205 205 205
669 669 669 669 669
225 225 225 225 225

0.14 0.14 0.14 0.29 0.29

0.18 0.18 0.18 0.26 0.26

0.32 0.32 0.32 0.55 0.55

0.09 0.09 0.09 0.15 0.16

0.09 0.09 0.09 0.15 0.16

 Steam Production Analysis
Description Unit Case-1 Case-2
Expected 22 bar steam production MT/hr 9.35 9.74
Heat generation ratio KJ/Kg of OX 10642.47 10750.44
co2/co ratio 2.56 2.56
No.of tubes Nos 7000.00 7000.00
Air flow per tube NM3/hr.tube 3.70 3.70
Grammage gm of OX/Nm3 of air 79.50 82.00
Ox flow rate Kg/hr 2059.05 2123.80
Air flow rate NM3/hr 25900.00 25900.00
Crude pa yield reactor exit % 114.00 114.00
Ma yield % 3.83 3.83
Ba yield % 0.73 0.73
Ca yield % 0.19 0.19
Pd yield % 0.12 0.12
Heavies % 0.01 0.01
Reactor inlet temp % 165.00 165.00
G.C outlet temp % 359.00 359.00
Steam wetness 3.00 3.00
Heat content lose % 0.00 0.00
Water inlet enthalpy K.cal/kg 181.00 181.00
Sat. steam enthalpy K.cal/kg 669.12 669.12
Super heater O/L enthalpy K.cal/kg 741.00 741.00
Solving Constrain steam production 0.00 0.00
mol wt 0 0
Ox 106 106
PAN 148 148
MAN 98 98
BAC 122 122
CA 130 130
PD 134 134
Uknowns 148 148
O2 32 32
N2 28 28
CO2 44 44
CO 28 28
HEAT OF FORMATION AT 25 C
OX(g) K.cal/mol 4540 4540
AIR K.cal/mol 0 0
PAN(g) K.cal/mol -88800 -88800
MAN(g) K.cal/mol -96000 -96000
BA(g) ASSUMED K.cal/mol -88800 -88800
CA(g) ASSUMED K.cal/mol -96000 -96000
PD(g) ASSUMED K.cal/mol -88800 -88800
HY(g) ASSUMED K.cal/mol -88800 -88800
CO2 K.cal/mol -94050 -94050
CO K.cal/mol -26416 -26416
H2O(g) K.cal/mol -57800 -57800

Mean inlet temp K 368 368

Mean outlet temp K 465 465
INLET GAS SP. HEAT
OX K.cal/mol.K 37.17 38.17
O2 K.cal/mol.K 6.98 6.98
N2 K.cal/mol.K 6.87 6.87
CO2 K.cal/mol.K 9.90 9.90
H2O K.cal/mol.K 8.46 8.46

EXIT GAS SP. HEAT

PAN K.cal/mol.K 46.19 46.19
MAN K.cal/mol.K 25.93 25.93
BA K.cal/mol.K 46.19 46.19
CA K.cal/mol.K 25.93 25.93
PD K.cal/mol.K 46.19 46.19
HY K.cal/mol.K 46.19 46.19
O2 K.cal/mol.K 7.52 7.52
CO2 K.cal/mol.K 10.71 10.71
CO K.cal/mol.K 7.16 7.16
N2 K.cal/mol.K 6.97 6.97
H2O K.cal/mol.K 8.58 8.58
OUTLET QUANTITIES

PAN Kg/hr 2347.32 2421.13

MAN Kg/hr 78.86 81.34
BA Kg/hr 15.03 15.50
CA Kg/hr 3.91 4.04
PD Kg/hr 2.53 2.61
HY Kg/hr 0.21 0.21
OX Converted to PA 1681.19 1734.05
MA quantity of OX used 85.30 87.98
BA to produce 13.06 13.47
CA individual product 3.19 3.29
PD kg/hr 2.00 2.07
HY 0.15 0.15
OX not converted to PA,MA,BA,CA kg/hr 274.16 282.79
Carbon not converted to PA etc 248.30 256.11
C converted to CO2/CO
When MA is produced 38.63 39.84
BA 1.48 1.52
CA 1.08 1.12
Total 289.49 298.59
CO2 763.29 787.29
CO 189.74 195.71
H2O 1153.93 1190.22
O2 Consumed 2495.72 2574.20
INLET QUANTITIES in kg
O2 kg/hr 7502.43 7502.43
N2 kg/hr 24890.25 24890.25
CO2 kg/hr 16.11 16.11
H2O kg/hr 671.38 671.38
HEAT OF FORMATION OF REACTANTS
OX K.cal/hr 88189.50 90962.75
HEAT CARRIED BY REACTANTS
O2 K.cal/hr 229070.33 229070.33
N2 K.cal/hr 854731.06 854731.06
CO2 K.cal/hr 507.80 507.80
H2O K.cal/hr 28388.13 28388.13
OX K.cal/hr 101083.82 107067.57
Total heat inlet K.cal/hr 1301970.64 1310727.65

HEAT OF FORMATION OF PRODUCTS

PAN(g) K.cal/hr -1408390.20 -1452679.20
MAN K.cal/hr -77252.19 -79681.51
BA K.cal/hr -10940.64 -11284.69
CA K.cal/hr -2889.01 -2979.85
PD K.cal/hr -1678.34 -1731.12
HY K.cal/hr -123.54 -127.43
CO2 K.cal/hr -1631535.91 -1682842.07
CO K.cal/hr -179004.90 -184633.99
H2O K.cal/hr -3705413.03 -3821935.45

Total K.cal/hr -7017227.77 -7237895.31

HEAT CARRIED BY PRODUCT
PAN(g) K.cal/hr 244662.18 252355.96
MAN K.cal/hr 6969.83 7189.01
BA K.cal/hr 1900.58 1960.35
CA K.cal/hr 260.65 268.85
PD K.cal/hr 291.56 300.73
HY K.cal/hr 21.46 22.14
O2 K.cal/hr 393075.72 386914.13
N2 K.cal/hr 2067943.90 2067943.90
CO2 K.cal/hr 63364.24 65315.63
CO K.cal/hr 16200.78 16710.24
H2O K.cal/hr 290584.86 296361.70
Total K.cal/hr 3085275.77 3095342.63
Heat available for steam production M.K.cal/hr 5.23 5.45
After heat lose M.K.cal/hr 5.23 5.45
With-out Super heater
22 Bar steam production (satu) MT/hr 11.05 11.52
HEAT FOR SUPERHEATER
Inlet Enthalpy K.cal/Kg 181.00 181.00
Outlet Enthalpy K.cal/Kg 741.00 741.00
Steam Quantity Kg/hr 9346.29 9738.00
Heat Quantity M.K.cal/hr 5.23 5.45
 Case-3 Case-4 Case-5 Case-6 Case-7 Case-8
10.21 10.99 11.77 12.08 12.55 15.76
10870.95 11051.07 11212.81 11276.32 11364.46 11790.04
2.56 2.56 2.56 2.56 2.56 2.62
7000.00 7000.00 7000.00 7000.00 7000.00 7000.00
3.70 3.70 3.70 3.70 3.70 3.80
85.00 90.00 95.00 97.00 100.00 93.00
2201.50 2331.00 2460.50 2512.30 2590.00 2473.80
25900.00 25900.00 25900.00 25900.00 25900.00 26600.00
114.00 114.00 114.00 114.00 114.00 110.00
3.83 3.83 3.83 3.83 3.83 4.18
0.73 0.73 0.73 0.73 0.73 0.73
0.19 0.19 0.19 0.19 0.19 0.22
0.12 0.12 0.12 0.12 0.12 0.27
0.01 0.01 0.01 0.01 0.01 0.02
165.00 165.00 165.00 165.00 165.00 164.10
359.00 359.00 359.00 359.00 359.00 359.90
3.00 3.00 3.00 3.00 3.00 3.00
0.00 0.00 0.00 0.00 0.00 0.00
181.00 181.00 181.00 181.00 181.00 177.00
669.12 669.12 669.12 669.12 669.12 669.00
741.00 741.00 741.00 741.00 741.00 742.00
0.00 0.00 0.00 0.00 0.00 -1.94
0 0 0 0 0 0
106 106 106 106 106 106
148 148 148 148 148 148
98 98 98 98 98 98
122 122 122 122 122 122
130 130 130 130 130 130
134 134 134 134 134 134
148 148 148 148 148 148
32 32 32 32 32 32
28 28 28 28 28 28
44 44 44 44 44 44
28 28 28 28 28 28

4540 4540 4540 4540 4540 4540

0 0 0 0 0 0
-88800 -88800 -88800 -88800 -88800 -88800
-96000 -96000 -96000 -96000 -96000 -96000
-88800 -88800 -88800 -88800 -88800 -88800
-96000 -96000 -96000 -96000 -96000 -96000
-88800 -88800 -88800 -88800 -88800 -88800
-88800 -88800 -88800 -88800 -88800 -88800
-94050 -94050 -94050 -94050 -94050 -94050
-26416 -26416 -26416 -26416 -26416 -26416
-57800 -57800 -57800 -57800 -57800 -57800

368 368 368 368 368 367.55

465 465 465 465 465 465.45

39.17 40.17 41.17 42.17 43.17 44.17

6.98 6.98 6.98 6.98 6.98 6.98
6.87 6.87 6.87 6.87 6.87 6.87
9.90 9.90 9.90 9.90 9.90 9.90
8.46 8.46 8.46 8.46 8.46 8.46

46.19 46.19 46.19 46.19 46.19 46.22

25.93 25.93 25.93 25.93 25.93 25.96
46.19 46.19 46.19 46.19 46.19 46.22
25.93 25.93 25.93 25.93 25.93 25.96
46.19 46.19 46.19 46.19 46.19 46.22
46.19 46.19 46.19 46.19 46.19 46.22
7.52 7.52 7.52 7.52 7.52 7.52
10.71 10.71 10.71 10.71 10.71 10.71
7.16 7.16 7.16 7.16 7.16 7.16
6.97 6.97 6.97 6.97 6.97 6.97
8.58 8.58 8.58 8.58 8.58 8.58

2509.71 2657.34 2804.97 2864.02 2952.60 2721.18

84.32 89.28 94.24 96.22 99.20 103.40
16.07 17.02 17.96 18.34 18.91 18.06
4.18 4.43 4.67 4.77 4.92 5.44
2.71 2.87 3.03 3.09 3.19 6.70
0.22 0.23 0.25 0.25 0.26 0.49
1797.50 1903.23 2008.97 2051.26 2114.70 1948.95
91.20 96.57 101.93 104.08 107.29 111.85
13.96 14.78 15.61 15.93 16.43 15.69
3.41 3.61 3.81 3.89 4.01 4.44
2.14 2.27 2.39 2.44 2.52 5.30
0.16 0.17 0.18 0.18 0.19 0.35
293.13 310.37 327.62 334.51 344.86 387.22
 265.48 281.09 296.71 302.96 312.33 350.69

41.30 43.73 46.16 47.13 48.59 50.65

1.58 1.67 1.77 1.80 1.86 1.78
1.16 1.23 1.29 1.32 1.36 1.51
309.51 327.72 345.93 353.21 364.13 404.62
816.10 864.10 912.11 931.31 960.12 1073.76
202.87 214.80 226.73 231.51 238.67 260.80
1233.77 1306.34 1378.92 1407.95 1451.49 1407.05
2668.38 2825.35 2982.31 3045.09 3139.27 3123.02

7502.43 7502.43 7502.43 7502.43 7502.43 7705.20

24890.25 24890.25 24890.25 24890.25 24890.25 25562.96
16.11 16.11 16.11 16.11 16.11 16.55
671.38 671.38 671.38 671.38 671.38 689.52

94290.66 99837.17 105383.68 107602.28 110930.19 105953.32

229070.33 229070.33 229070.33 229070.33 229070.33 233631.39

854731.06 854731.06 854731.06 854731.06 854731.06 872131.55
507.80 507.80 507.80 507.80 507.80 517.93
28388.13 28388.13 28388.13 28388.13 28388.13 28966.20
113892.32 123670.55 133790.85 139925.63 147673.98 143388.15
1320880.31 1336205.04 1351871.85 1360225.24 1371301.50 1384588.54

-1505826.00 -1594404.00 -1682982.00 -1718413.20 -1771560.00 -1632708.00

-82596.69 -87455.31 -92313.94 -94257.39 -97172.57 -101294.54
-11697.54 -12385.63 -13073.73 -13348.96 -13761.82 -13144.39
-3088.87 -3270.57 -3452.27 -3524.95 -3633.97 -4018.97
-1794.45 -1900.01 -2005.56 -2047.79 -2111.12 -4442.65
-132.09 -139.86 -147.63 -150.74 -155.40 -296.86
-1744409.47 -1847021.79 -1949634.11 -1990679.04 -2052246.43 -2295162.52
-191388.89 -202647.06 -213905.23 -218408.50 -225163.40 -246048.32
-3961762.36 -4194807.20 -4427852.04 -4521069.98 -4660896.89 -4518185.74

-7502696.36 -7944031.44 -8385366.52 -8561900.55 -8826701.60 -8815302.00

261588.50 276976.06 292363.62 298518.64 307751.17 284589.76

7452.02 7890.37 8328.73 8504.07 8767.08 9172.10
2032.07 2151.60 2271.14 2318.95 2390.67 2291.14
278.68 295.08 311.47 318.03 327.86 363.91
 311.73 330.06 348.40 355.74 366.74 774.38
22.95 24.30 25.65 26.19 27.00 51.74
379520.23 367197.05 354873.88 349944.61 342550.70 360800.98
2067943.90 2067943.90 2067943.90 2067943.90 2067943.90 2129694.77
67657.31 71560.09 75462.88 77023.99 79365.66 88903.78
17321.59 18340.51 19359.43 19766.99 20378.34 22330.22
303293.89 314847.56 326401.22 331022.68 337954.88 334692.28
3107422.86 3127556.57 3147690.29 3155743.78 3167824.00 3233665.07
5.72 6.15 6.59 6.77 7.03 6.97
5.72 6.15 6.59 6.77 7.03 6.97

12.07 12.99 13.92 14.29 14.85 15.69

181.00 181.00 181.00 181.00 181.00 177.00

741.00 741.00 741.00 741.00 741.00 742.00
10207.42 10986.93 11767.05 12082.83 12553.89 15760.00
5.72 6.15 6.59 6.77 7.03 8.90
 Case-9
16.50
11896.39
2.62
7000.00
3.82
98.00
2620.52
26740.00
110.00
4.18
0.73
0.22
0.27
0.02
162.20
361.00
3.00
0.00
177.00
669.00
742.00
-1.88
0
106
148
98
122
130
134
148
32
28
44
28

4540
0
-88800
-96000
-88800
-96000
-88800
-88800
-94050
-26416
-57800

366.6
466

45.17
6.97
6.87
9.89
8.46

46.26
25.99
46.26
25.99
46.26
46.26
7.53
10.72
7.16
6.97
8.58

2882.57
109.54
19.13
5.77
7.10
0.52
2064.54
118.48
16.62
4.70
5.62
0.38
410.18
 371.48

53.65
1.88
1.60
428.61
1137.44
276.27
1490.50
3308.25

7745.76
25697.50
16.64
693.15

112237.37

231405.41
864626.74
513.02
28717.26
153209.54
1390709.34

-1729543.20
-107302.27
-13923.98
-4257.34
-4706.14
-314.46
-2431287.61
-260641.34
-4786157.37

-9338133.72

302712.60
9759.06
2437.04
387.20
 823.69
55.04
350659.03
2148105.22
94444.83
23734.50
349769.94
3282888.16
7.45
7.45

16.77

177.00
742.00
16500.00
9.32