Feed Gas Pre-heater Efficiency

Calculation And Enhancement

Of Ammonia Plant

Supervisor : Dr Muhammad Bilal Khan Niazi

Co-supervisor : Engr Nouman Ahmed

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

Sep Oct Nov Dec Jan Feb Mar Apr 2017-2018

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

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

Additives Piperazine DEA,V2O5

Steam required t/hr Nil 44

Heat Required for 167 669

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

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 COSTING
Cost of existing unit Cost of new unit

PCE = $185,568 PCE = $155568

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

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

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

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

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How Is Cost Being Reduced?
Benfield Process Diagram

First Second Last

No heat 40 tons of About 4 times

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

generation.

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SIMULATION

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HAZOP REPORT

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Conclusions:
Replacing Benfield with MDEA

Saves about 40tons of steam per

hour

Total annual saving are $60 million

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