simulation Ammonia plant on PRO II

PRO/II CASEBOOK Ammonia Synthesis

ABSTRACT Over 100 million tons of ammonia are produced each year. The rewards for reducing costs, increasing efficiency and improving the profitability of ammonia plants are enormous. Computer simulation of the plant is the first step towards identifying which parameters control the conversion rate, the product purity, the energy usage and the production rate. This casebook demonstrates the use of PRO/II ® in the simulation of ammonia process. The entire plant plant is modeled, from the reforming of the hydrocarbon feedstream to synthesis gas through its purification to its conversion to ammonia in a synthesis reactor. The ammonia synthesis loop involves a large recycle compared to the feed and and product rates. In addition there are several thermal recycles and two control loops. Special thermodynamics are used to ensure that the separation of ammonia from the other components is predicted accurately. The casebook outlines the use of the model for parametric studies in the evolution of a control strategy.

Casebook #3. Ammonia Synthesis Rev. 0 January 1992 ®

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INTRODUCTION Chemically combined nitrogen is essential for the growth of all living organisms. Neither animals nor (with one or two exceptions) plants can assimilate free nitrogen from the air; they depend upon nitrates, ammonium salts or other nitrogen compounds found in the soil. The natural supplies of fixed nitrogen were adequate for many centuries to satisfy the normal processes of nature. However, by the beginning of the nineteenth century, the increase in world population and the growth of big cities created a demand from the more industrialized countries for other supplemental sources of fixed nitrogen. This supplement was first found in imported guano and sodium nitrate and later in ammoniacal solutions and ammonium sulphate by-products from the carbonization of coal in gas-works and coke ovens. By the start of this century, with the demand for fertilizer nitrogen again having outstripped supply, necessity had once again become the mother of invention and three different processes for the fixation of nitrogen were in commercial operation and adequate supplies of fertilizer nitrogen were assured. One of those three was the direct synthesis of ammonia from nitrogen and hydrogen by the Haber-Bosch process. This was developed in Germany between 1905 and 1913 and virtually all fixed nitrogen is now produced by this process. The total world production in 1990 was over 100 million tons of fixed nitrogen and is increasing at the rate of over 4% per annum. More than 90% of this is produced as ammonia and about about 80% of the total fixed nitrogen production is used in fertilizers.

Alternative Routes to Ammonia There are three principal licensors of ammonia synthesis processes 1: Braun, ICI and Kellogg. All produce ammonia from hydrocarbon feedstocks and air. The hydrocarbon feedstock is usually a natural gas although others, such as naphtha, are used where natural gas is not locally available. The processes are fundamentally similar: the feed hydrocarbon gas is desulfurized then converted to synthesis gas in a reforming process process followed by a CO shift and methanation. The resulting syngas, after purification, is a mixture of hydrogen and nitrogen in stoichiometric quantities (3:1). This is converted to ammonia in a synthesis reactor which, because of a low conversion per pass, is in a recycle loop. Braun Process The key features of the Braun Purifier process are mild primary reforming, secondary reforming with excess air, cryogenic purification of Syngas and synthesis of ammonia in Braun converters. Twenty five single-train plants of Braun design have been contracted worldwide including the w orld’s largest at 2,000 tons/day. 1 ICI Process There are two ICI processes. The AMV process is a large, world-scale process for ammonia production and has a tightly integrated energy energy recovery system. The LCA process produces ammonia efficiently in small scale plants of the order of 500 tons/day and uses pressure swing adsorption to remove nitrogen, carbon monoxide and inerts from the syngas. 1 ICI licenses its ammonia processes to Chiyoda and Mannesman/KTI. The Kellogg Process At almost 150 units worldwide, the Kellogg process has been installed in more ammonia plants than any other process.

1 Hydrocarbon Processing, March 1991

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Although the Kellogg process is a licensed process, operational benefits can be gained from changing a number of the variable parameters: temperatures, recycle rates, air and steam quantities and so on. Recently there has been some work on lowering the steam to carbon ratio to the primary reformer and modifying the catalysts used in the shift converters. The emphasis in ammonia plants today is for lower energy energy usage. New Kellogg plants claim 6.3Gcal/short ton for all energy requirements. This compares with 6.5 Gcal/ton claimed for the ICI AMV process and 7.0 Gcal/ton for the ICI LCA process. 1

PROCESS OVERVIEW The ammonia process is a single train process and divides into four stages, which operate sequentially. In stage 1 the natural gas gas undergoes catalytic reforming to produce hydrogen from methane and steam. The nitrogen required for the the ammonia is introduced at this stage. In stage 2, the resulting syngas is purified by the removal of carbon monoxide and carbon dioxide. Stage 3 consists of compression of the syngas up to the pressure required in stage 4, the ammonia loop.

Feedstocks and Products Main Feeds The main feedstock for this ammonia process is 6 million SCFD of natural gas at a temperature of 60 oF and a pressure of 340 340 psig. Its composition is shown in Table 1. Table 1 Natural Gas Feed Component

Mole %

Carbon dioxide

2.95

Nitrogen

3.05

Methane

80.75

Ethane

7.45

Propane

3.25

Butane

2.31

Pentane

0.24

Before entering the primary reformer, the natural gas is mixed with superheated steam at 334 psig and 950F. Nitrogen is supplied from the air which is fed to the secondary reformer at 289 psig and 330 F. The composition of air is displayed in Table 2. Table 2 Air Feed Component

Mole %

Oxygen

21.00

Nitrogen

78.05

Argon

0.95

There is also a water feed which is used to saturate the syngas in the MEA plant.

4

Products The main product of an ammonia plant plant is, of course, ammonia. The ammonia product stream must have a purity greater than 99.5%. The major impurities are hydrogen, nitrogen, argon and methane. methane. The other product streams are: -- letdown gas from the final separator consisting of of 45% ammonia, 30% hydrogen with the rest being nitrogen, argon and methane -- purge gas from the ammonia loop consisting of of 10% ammonia, 50% hydrogen plus nitrogen, argon and methane Ammonia is recovered from the letdown and purge gases in an absorber. Detailed descriptions of the product streams may be found at the end of the Simulation section in Table 3.

Stage 1: Catalytic Reforming

AIR

PRIMARY REFORMER

SECONDARY REFORMER

AIR COMPRESSOR STEAM

DESULFURIZER

AIR

GAS WASTE HEAT BOILER

GAS HEATER

TO SHIFT REACTORS INTERCHANGER

NATURAL GAS

Following sulfur removal, the primary steam reformer converts about 70% of the hydrocarbon feed into raw synthesis gas in the presence of steam using a nickel catalyst. The main reforming reactions are: CH 4 + H 2O CO + H 2O

→ ← → ←

CO + 3H 2 CO 2 + H 2

In the secondary reformer, air is introduced to supply supply the nitrogen. The heat of combustion of the partially reformed gas raises the temperature and supplies the energy to reform most of the remaining hydrocarbon feed. The reformer product stream is used to generate steam and to preheat the natural gas feed.

5

Stage 2: Shift and Methanation

The shift conversion is carried out in two stages. The first uses a high temperature catalyst and the second uses a low temperature one. The shift convertors remove the carbon monoxide produced in the reforming stage by converting it to carbon dioxide by the reaction: CO + H 2O

→ ←

CO 2 + H 2

This reaction also creates additional hydrogen for the ammonia synthesis. Shift reactor effluent is cooled and the condensed water is separated. The gas is then passed to the purification section where carbon dioxide is removed from the synthesis gas in any one of a number of systems such as hot carbonate, MEA, Selexol etc. After the purification stage, the last traces of carbon monoxide and carbon dioxide are removed in the methanation reactions: CO + 3H 2O CO 2 + 4H 2

6

→ ← → ←

CH 4 + H 2 CH 4 + 2H 2O

Stage 3: Compression

The purified synthesis gas is cooled and the condensed water is removed. The gas is then compressed in a three stage unit. The centrifugal compressors are driven by steam turbines using steam generated in the plant itself, reducing overall power consumption.

Stage 4: Conversion

The compressed synthesis gas is dried, mixed with a recycle stream and introduced into the synthesis loop after the recycle compressor. The gas mixture is chilled and liquid ammonia is removed from the secondary separator. The vapor is heated and passed to the ammonia converter. The feed is preheated inside the convertor before entering the catalyst bed.

7

The ammonia synthesis reaction is: N 2 + 3H 2

→ ←

2NH 3

Very high pressures (typically in excess of 300 atmospheres) are required in order to obtain a reasonable conversion. The conversion of hydrogen per pass is still less than 30% and so a large recycle of unreacted gases is necessary. The convertor vapor product is cooled by ammonia refrigeration in the primary separator to condense the ammonia product. A purge is removed from the remaining gases to prevent the build up of inerts in the loop. The molar concentration of inerts (argon and methane) in the convertor feed is maintained at 12%.

ENERGY INTEGRATION The process features a high level of energy integration. Nearly all the power and heating requirements of the process are met by the heat available elsewhere in the process.

In the Reformer The primary reformer passes the natural gas and steam mixture through catalyst-packed tubes in a furnace. The furnace exhaust gases are used to generate steam in a series of boilers. This steam is then used to drive the compressors. The effluent from the secondary reformer is used in a waste heat boiler and then to preheat the feed to the desulfurizer.

In the Shift and Methanators The methanator feed is preheated by exchanging with the methanator product and then further heated by exchange with the high temperature shift reactor effluent. Energy from this effluent is further recovered in a waste heat boiler. The effluent from the low temperature shift reaction is used in another reboiler.

In the Conversion The products from the ammonia converter are mixed with the synthesis gas from the compressors and cooled for ammonia separation by exchange with the converter feed. The convertor feed is preheated by the products inside the convertor vessel.

MATERIAL RECYCLE The final stage, the Synthesis Loop, is a recycle operation. The conversion of nitrogen and hydrogen to ammonia in the converter is very low - less than 30% of the hydrogen is converted per pass. Therefore there has to be a large recycle in order to convert all the feed and ensure that the final ammonia product reaches the required purity. The ratio of recycle to ammonia product is of the order of 3:1.

8

PROCESS SIMULATION The full input for the simulation may be found in Appendix B. Fragments of the input are shown here to illustrate points of interest. For detailed explanations of all the input data, please refer to the PRO/II Keyword Input Manual, which may be obtained from SimSci. The ‘‘Simulation Flowsheets’’ shown below differ from the previous process flowsheets in that they include stream identifiers and show the way the simulation is solved. This is especially important for recycle solutions, both for thermal recycles and material recycles. A full flowsheet may be found in Appendix A.

General Data Because stage 4 of this process involves a loop which has a large recycle rate in comparison to the product rates, it is essential that the flowsheet balances. The normal stream recycle convergence tolerances must therefore be tightened - in this case to 0.05%. The threshold mole fraction limit for trace components in the recycle is also reduced in order to ensure that all components are checked for the loop convergence. The maximum allowed number of recycle trials is increased to 100 and, to check the overall balance, PRO/II is asked to carry out an overall material balance (MBAL) PRINT CALC TOLER

INPUT=SEQUENCE, STREAM=PART, RATE=M, MBAL TRIAL=100 STREAM=5e-4,-1.0,0.001,0.01

Component Data All the components in the simulation are in the PRO/II data bank.

Thermodynamic Data For most of the units in the flowsheet the Soave-Redlich-Kwong (SRK) equation of state is an excellent predictor of phase equilibrium and thermal properties. However, in stage 4 where the ammonia is being separated from the recycle gas in flash units, a more accurate prediction is needed to represent the interaction between ammonia and the other components in the streams. For this, a second method is defined with SRK interaction parameters: THERMO DATA METHOD SYSTEM=SRK, DENS(L)=RACKETT, SET=1, DEFAULT METHOD SYSTEM=SRK, DENS(L)=RACKETT, SET=2 $ TEMPERATURE DEPENDENT KIJ’S FOR THE NH3 SEPARATORS

KVALUE SRK(R) 5, 5, 5, 7, 5, 6, 7, 8,

6, 0.0850 7, 0.0004 8, -0.2079 8, 0.0204 13, 0.2760 13, 0.3100 13, 0.3383 13, 0.1800

/ / / / / / /

& & & & & & &

$ $ $ $ $ $ $ $

H2 H2 H2 A H2 N2 A C1

-

N2 A C1 C1 NH3 NH3 NH3 NH3

9

The alternative data set is invoked in the ammonia separators by the instruction: METHODS SET=2

Stream Data Feed Streams The main feed streams - natural gas, steam and air - are defined in the normal way by rate, composition, temperature and pressure. In addition there is a water feed to the MEA plant which ensures that the syngas leaves the plant saturated. Recycle Streams There is a recycle stream in stage 4. Because of the large flowrate of this stream relative to the flowsheet feeds and products and because the ammonia species is created in the recycle, an initial estimate of the rate and composition of the recycle stream is supplied. $ RECYCLE GUESS PROP STRM=31R, TEMP=85, PRES=4660, * COMP=5,6000 / 6,2000 / 7,300 / 8,1000 / 13,700

Other Streams There are several thermal recycles in this flowsheet. These may be simulated in several ways -- they can be input as they are and allowed to converge naturally -- they may be replaced by simpler units and solved rigorously after the flowsheet has solved -- they may be circumvented by using the REFERENCE STREAM facility. PROP STRM=13, REFS=11, TEMP=400, PRES=274 PROP STRM=21, REFS=19, TEMP=675, PRES=254

$ LTS SHIFT FEED $ METHANATOR FEED

In stage 2, the feed to the low temperature shift reactor (stream 13) is referenced to the high temperature shift product (stream 11). This defines all the properties of stream 13 except temperature and pressure, which are always as defined on this instruction. Similarly, stream 21 is referenced to stream 19. These reference streams allow the heat exchangers to be solved separately after converging the air flowrate controller loop. Stream 13 is not defined as a product from a unit operation. However, in stage 4, stream 38B is a unit operation product. Nevertheless, in order to eliminate a thermal recycle around the Ammonia Converter, it is referenced to stream 38. PROP

STRM=38B, REFS=38, PRESS=4780, TEMP=575

This means that stream 38B takes its composition and rate at all times from stream 38 but its temperature and pressure are calculated by the heat exchanger from which it is a product.

10

Unit Operations for Stage 1 - Catalytic Reforming

Input Since there is no sulfur in the input, the Desulfurizer RX1 can be modeled as an isothermal flash to set the temperature and pressure of the reformer feed. Both the reformers, RX2 and RX3, are modeled as Gibbs Free Energy reactors with typical temperature approaches specified. The rate of air feed to the secondary reformer must be such that the syngas product from stage 2 has the correct nitrogen:hydrogen ratio. This is achieved by putting a controller on the stage 2 Methanator product and varying the air feed rate to the secondary reformer. This means that stages 1 and 2 are in a controller loop. To satisfy the primary reformer, the molar ratio of steam (stream 5) to natural gas (stream 1) should be 6:1. The flow rate of the steam could be set to the correct value in the Stream Data Section. However, that would involve calculating the molar rate of natural gas (the stream is known only in volume units) before the simulation begins. It is much easier to let the program do the calculation. Furthermore, now the natural gas stream can be changed at any time (for a turndown case or a different design case) and the steam rate is automatically recalculated. CALC

UID=S1, NAME=STM-GAS FLOW SEQU STREAM=1,5 PROCEDURE R(1) = 6.0 * SMR(1) $ SET R(1) TO 6 * GAS RATE CALL SRXSTR(SMR,R(1),5) $ SET RATE OF STREAM 5 TO R(1) RETURN

11

The secondary reformer product (stream 8) is used to preheat the desulfurizer feed (stream 2). This thermal recycle is not a simple one in that the process demands a fixed temperature for both the products from exchanger X-1. This is achieved by dividing the exchanger into two halves: the cold side is X-1A and is solved before the desulfurizer; the secondary reformed product is cooled in H-1, a combination of waste heat boiler WHB1 and the hot side of X-1. HX

UID=X-1A COLD FEED=2, V=3, DP=2 SPEC COLD, TEMP=750 .............. Solve Desulfurizer Solve Primary Reformer Solve Secondary Reformer ..............

HX

UID=H-1, NAME=COOL REFGAS HOT FEED=8, M=10, DP=4 SPEC HOT, TEMP=675

After stages 1 and 2 have solved, H-1 is divided into WHB1 and the hot side of X-1 (X-1B). This can be achieved because PRO/II allows streams to be feeds to more than one unit although care must be taken not to duplicate product stream names (hence stream 10X). This procedure also uses the facility to reference duties from one exchanger to another. HX

UID=WHB1 HOT FEED=8, V=9, DP=2 DEFI DUTY, AS, HX=H-1, DUTY, MINUS, HX=X-1A, DUTY

HX

UID=X1-B HOT FEED=9, V=10X, DP=1 DEFI DUTY, AS, HX=X-1A, DUTY, MULTIPLY, -1.0

WHB1’s duty is calculated as the difference between the duties of H-1 and X-1A. X1-B’s duty is simply the same as that for X1-A but with the opposite sign. Results The stream calculator determines the steam flowrate as 3953 lb mole/hr which is six times the natural gas flowrate. Virtually all of the C2 and higher hydrocarbons are broken down in the primary reformer and converted to hydrogen, carbon monoxide and carbon dioxide. 58% of the methane in the feed is also converted. 95% of the residual methane is converted in the secondary reformer along with the remaining traces of ethane and propane. All of the oxygen is consumed in the secondary reformer. The duties of WHB1 and X-1 are 53.7 and 4.2 MM Btu/hr respectively.

12

Unit Operations for Stage 2 - Catalytic Shift and Methanation

Input Both the High Temperature Shift Reactor (RX4) and the Low Temperature Shift Reactor (RX5) are modeled by the general reactor unit operation using built-in shift reaction equilibrium data. They operate adiabatically and the products are assumed to be at equilibrium. The MEA plant removes the bulk (99.92%) of the carbon dioxide from the shift reactor product and is modeled as a stream calculator (T-1). The treated gas is saturated with water in flash unit SAT and excess water discharged. The final part of stage 2 is the Methanator (RX6), modeled by the general reactor unit using built-in methanator and shift reaction equilibrium data. The reactor operates adiabatically and equilibrium is assumed to be achieved. The syngas must have a hydrogen:nitrogen molar ratio of 3:1 to satisfy the stoichiometry of the ammonia reaction. This is accomplished by inserting a controller to measure that ratio in the Methanator product and vary the air feed to the Secondary Reformer until the required ratio is achieved. Thus there is a significant loop involving most of the units of stages 1 and 2. This makes it all the more important for any thermal recycles within that loop to be eliminated if at all possible. The thermal recycle in stage 2 of the plant is a complex one, involving preheating the Methanator feed first with its own product and then with the RX4 product. This recycle is eliminated by referencing streams 13 and 21 to bypass these exchangers completely.

13

Stream 13 is the same as stream 11 except for its temperature and pressure, both of which are known. Therefore stream 13 is set in the Stream Data Section and referenced to stream 11. It gets its rate and composition from stream 11 and its conditions from the Stream Data Section. In the same way, stream 21 is referenced to stream 19. After the control loop has solved, exchangers X-2, WHB2 and X-3 are solved in the normal way, except that product stream names must not be duplicated. Results The controller solves after 3 trials with an air flowrate of 1009 lb mole/hr. This produces the required hydrogen:nitrogen ratio in the product from the methanator. 85% of the carbon monoxide is converted in RX-4 and 93% of the remainder is converted in RX-5. This gives a concentration of 0.055% carbon monoxide and 11.1% carbon dioxide in the exit gas from RX-5. The concentration of carbon dioxide is reduced to 0.02% in the MEA Plant. The final removal of all the carbon monoxide and carbon dioxide is carried out in the methanator reactor.

Unit Operations for Stage 3- Compression

Input The Condensate Separator (D-2) is modeled as a flash unit, decanting water in a declared water stream and using the PRO/II built-in water solubility data. The compressors are modeled as single stage isentropic compressions with a specified adiabatic efficiency of 95%. Each one has an aftercooler reducing the product temperature to 95 F. The first and second compressors also have water decantation streams to knock out any liquid water that may have condensed out in the aftercoolers. Finally, all the remaining water is removed in a drying unit (SEP1), modeled as a stream calculator. Results The compressor work for the three stages is 1752, 1831 and 1778 HP respectively. The corresponding aftercooler duties are 4.73, 4.70 and 4.35 MM Btu/hr. Most of the water is removed after the first compressor with smaller amounts after the other two. The final separator removes all remaining water from the synthesis loop feed.

14

Unit Operations for Stage 4 - Conversion

Input The fourth compressor (CP-4) is in the ammonia recycle loop. The loop starts at that unit, stream 31R being the main recycle stream. An initial estimate for this stream is needed, as discussed in the Stream Data Section above. The Ammonia Converter feed is preheated by exchanging inside the converter with its product stream. This exchanger is modeled separately in the flowsheet as FDEF. The exchangers before the separators do not appear on the simulation flowsheet as they are combined with the separators. There are two thermal recycles in the loop. The loop involving the convertor and feed preheater is split by referencing the convertor feed (stream 38B) to the product from exchanger X-4 (stream 38) in the Stream Data Section. FDEF is then solved after the convertor when both feed streams have been calculated. The loop involving exchanger X-4 is solved explicitly as it appears in the flowsheet. This involves introducing an inner loop within the ammonia recycle loop. This loop could also be eliminated by using the devices mentioned above. The Ammonia Converter (RX-7) is modeled using a general reactor model with supplied equilibrium data. REAC

UID=RX-7, NAME=CONVERTER FEED 38B PROD V=29A OPER PHASE=V, ADIA, DP=30, TEMP=900 $ TEMP ESTIMATE RXCA EQUIL, REFTEMP=800 STOI 5,-3 / 6,-1 / 13,2 $ 3H2 + N2 = 2NH3 BASE COMP=6, HEAT=-45.108 EQUI -32.975, 22930.4 $ LN(K) = A + B / DEG R APPR DT=20

The reference condition for heat of reaction data is given as vapor at 800 F and the stoichiometry represents the well-known ammonia synthesis reaction. The heat of reaction is given as -45.18 thousand energy units per mole of base component reacted, in this case nitrogen. The equilibrium constant is a function of temperature according to the Arrhenius equation: Ln(K eq ) = A + B/T

15

The equilibrium constant is computed at a temperature equal to the reaction temperature minus the approach temperature difference given. The feed to the reactor has to contain 12 mole% of inerts (argon and methane). This is achieved by varying the rate of the recycle stream 31R using a controller (CTL1). Because this stream is also the recycle stream for the main loop, the action of the controller could conflict with the recycle convergence. This is avoided by solving the recycle before the controller is invoked. In order to maintain the inerts material balance, a purge stream is taken off the recycle stream. The rate of this stream is calculated in a calculator (BD-1). CALCULATOR

UID=BD1, NAME=PURGE RATE DEFINE P(1) AS STREAM=28,COMP=7,RATE DEFINE P(2) AS STREAM=32A,COMP=7,RATE DEFINE P(3) AS STREAM=37A,COMP=7,RATE SEQUENCE STREAM=31X PROCEDURE V(1) = P(1) - P(2) - P(3) IF (V(1) .LE. 0.001) V(1) = 0.001 CALL SRXSTR(SMR, V(1), 31X) RETURN

SPLIT

UID=SP1, NAME=PURGE FEED 31 PROD V=31P, V=31R SPEC STRE=31P, COMP=7, RATE, RATIO, STRE=31X, VALUE=1

The calculator builds a dummy stream 31X consisting of stream 28, the dry syngas feed to the loop, minus the products from the loop, streams 32 and 37. The splitter SP1 operates such that the argon rate in the purge stream 31P is equal to the argon rate in the dummy stream 31X - in other words equal to the net argon coming in to the loop. Thus there is an exact argon balance in the loop and there will be no build up of inerts as the flowsheet recycle solves. Results The synthesis loop solves with a production of 1546 lb mole/hr of 99.66% purity ammonia. The product compositions are shown in Table 3. The overall conversion to ammonia is 99% with a reactor conversion per pass of 27%. The recycle stream rate is 10618 lb mole/hr giving a recycle:feed ratio of 3.2:1. The purge stream is 73 lb mol/hr which is 0.69% of the recycle flowrate.

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Table 3 Ammonia Plant Product Streams NH3 Product

Let Down Gas

Purge

H2

1.46

21.25

41.7089

N2

0.43

6.07

14.3781

A

1.36

3.26

4.9649

C1

1.95

7.52

5.9786

NH3

1540.35

31.98

6.2537

Rate (Lb mole/hr)

1545.55

70.08

73.3

Temperature (o F)

78.9

78.9

85.0

Pressure (psig)

350.0

350.0

4660.0

USE OF THE MODEL IN PROCESS CONTROL Very clear benefits of using a computer model of a Kellogg Ammonia plant were demonstrated in a paper published in Hydrocarbon Processing, November 1980. The paper focuses on the design of control strategies and uses a simulation model to derive the responses of the plant to different settings of various parameters. The parameters that were examined were: The ratio of synthesis loop recycle rate to fresh syngas In many plants the fresh syngas feed to the synthesis loop is limited by front-end restrictions such as insufficient synthesis compressor power or absorber capacity. The ratio of nitrogen to hydrogen in the syngas At constant syngas make-up rates, ammonia production increased as H/N decreased, but synthesis compressor loadings increased. Synthesis loop pressure Production of ammonia increases with increased loop pressure. The design pressure, constrained by mechanical considerations, is the limiting factor and the purge system should be operated the keep the operating pressure just below the design pressure. The temperature of the synthesizer feed Production is extremely sensitive to this parameter and an optimum temperature can be found. The control of this parameter is critical to the profitability of the plant. Methane content in syngas Ammonia production decreases with increasing methane. Improved primary reformer temperature control can alleviate this problem. The results of these simulations have been put into practice in a number of installations and these have consistently led to improved productivity and higher conversion efficiency.

17

APPENDIX A - Complete Ammonia Plant Flowsheet

18

AIR

PRIMARY REFORMER AIR COMPRESSOR

CO2

SECONDARY REFORMER

SHIFT REACTORS MEA PLANT

HIGH TEMP SHIFT

STEAM

LOW TEMP SHIFT

CONDENSATE SEPARATOR METHANATOR

DESULFURIZER

AIR WATER

WASTE HEAT BOILER

GAS

COOLER

WASTE HEAT BOILER GAS HEATER

INTERCHANGER

REBOILER INTERCHANGER

NATURAL GAS

COOLER

SYN GAS COMPRESSORS

INTERCHANGER

AMMONIA CONVERTER

REACTOR FEED

PURGE SPLITTER RECYCLE SECONDARY SEPARATOR

RECYCLE COMPRESSOR CONDENSATE SEPARATOR

DRIER

LETDOWN GAS

PRIMARY SEPARATOR

WATER WATER

WATER

WATER NH3 DRY SYNGAS

PRODUCT

19

APPENDIX B - PRO/II Input File TITLE

PROJ=NH3 PLANT,PROB=AMMONIA,USER=SIMSCI,DATE=JAN 1992 PRINT INPUT=SEQUENCE, STREAM=PART, RATE=M, MBAL DIMEN ENGLISH, PRES=PSIG CALCU TRIAL=100, RECYCLE=TEAR TOLER STREAM=5.0e-4,-1.0,0.0001,0.01 SEQUENCE & HTR , X-1A , RX-1 , S1 , RX-2 , RX-3 , & H-1 , RX-4 , RX-5 , REB1 , CW-1 , D-1 , & T-1 , SAT , RX-6 , CT1 , X-3 , X-2 , & WHB2 , WHB1 , X1-B , CW2 , D-2 , CP-1 , & CP-2 , CP-3 , SEP1 , & REFC , CP-4 , X-4 , D-7 , DM2, , DM1, & RX-7 , FDEF , D-6 , DM3, DM4, BD1 , SP1 DUM1 , CAL1 , DUM2 , CTL1 , D-8

,&

COMPONENT DATA LIBID 1,H2O / 2,O2 / 3,CO / 4,CO2 / 5,H2 / 6,N2 / 7,A / & 8,C1 / 9,C2 / 10,C3 / 11,NC4 / 12,NC5 / 13,NH3 THERMO DATA METHOD SYSTEM=SRK, DENS(L)=RACKETT, SET=1, DEFAULT METHOD SYSTEM=SRK, DENS(L)=RACKETT, SET=2 $ TEMPERATURE DEPENDENT KIJ’S FOR THE NH3 SEPARATORS KVALUE SRK(R) 5, 6, 0.0850 / & $ H2 - N2 5, 7, 0.0004 / & $ H2 - A 5, 8, -0.2079 / & $ H2 - C1 7, 8, 0.0204 / & $ A - C1 5, 13, 0.2760 / & $ H2 - NH3 6, 13, 0.3100 / & $ N2 - NH3 7, 13, 0.3383 / & $ A - NH3 8, 13, 0.1800 $ C1 - NH3 STREAM DATA OUTPUT FORMAT=1, NSTREAM=4 FORMAT IDNO=1, NAME, PHASE, CRATE, LINE, RATE(M), MW, RATE(W), LINE, & TEMP, PRES, ENTH, LINE, VAPOR, RATE (G,FT3/D), & DENS (LB/FT3), LINE, LIQUID, ARATE(V,GAL/M), DENS(LB/GAL) PROP STRM=1, TEMP=60, PRES=340, & COMP=4,2.95 / 6,3.05 / 8,80.75 / 7.45 / 3.25 / 2.31 / 0.24, & RATE(G)=250000 $ 6.0 MMSCFD PROP STRM=5, TEMP=950, PRES=334, COMP=1,1000 PROP STRM=7, TEMP=330, PRES=289, & COMP=2,21.0 / 6,78.05 / 7,0.95 / & RATE(G)=375000 $ GUESS OF RATE - ACTUAL RATE IS CALCULATED PROP STRM=WAT, TEMP=100, PRES=271, COMP=1,1000 $ WATER STREAM $ REFERENCE STREAMS FOR LOOP CALCULATIONS PROP STRM=13, REFS=11, TEMP=400, PRES=274 $ LTS SHIFT FEED PROP STRM=21, REFS=19, TEMP=675, PRES=254 $ METHANATOR FEED $ RECYCLE GUESS PROP STRM=31R, TEMP=85, PRES=4660, & COMP=5,6000 / 6,2000 / 7,300 / 8,1000 / 13,700 PROP STRM=31X, TEMP=85, PRES=4660, & COMP= 7,7

20

$ REFERENCE STREAM TO ELIMINATE THERMAL RECYCLE PROP STRM=38B, REFS=38, TEMP=575, PRESS=4780 NAME 1, NAT GAS / 5, STEAM / 6, PR 8, SEC REF OUT / 11, HTS OUT / 14, LTS 19, TRTD GAS / 22, METH PROD / 25, SYN 31P, PURGE / 31, PRI SEP / 36, SEC 39, LET DWN GAS / 40, NH3 PROD

$$ FEED-EFFLUENT XCHG REF OUT / 7, AIR OUT / 17, MEA FEED GAS / 31R, RECYCLE SEP / 38, RX FEED

/ / / /

& & & &

UNIT OPS DATA $ ---------------------------------------------------------------$ REFORMING SECTION $ ---------------------------------------------------------------FLASH UID=HTR, NAME=GAS HEATER FEED 1 PROD V=2 ADIA DP=2, DUTY=1.6, TEST=200 HX UID=X-1A COLD FEED=2, V=3, DP=2 SPEC COLD, TEMP=750 FLASH UID=RX-1, NAME=DESULFURIZER FEED 3 PROD V=4 ISOTHERMAL DP=2, TEMP=740 CALC UID=S1, NAME=STM-GAS FLOW SEQU STREAM=1,5 PROCEDURE R(1) = 6.0 * SMR(1) $ SET STEAM RATE CALL SRXSTR(SMR,R(1),5) $ STEAM/GAS RATIO = 6:1 RETURN GIBBS UID=RX-2, NAME=PRI REFORMER FEED 4,5 PROD V=6 OPER TEMP=1360, DP=45 CONV APPROACH=-35 ELEM REACTANTS=1/3/4/5/8/9/10/11/12 GIBBS UID=RX-3, NAME=SEC REFORMER FEED 6,7 PROD V=8 OPER ADIA, DP=5 CONV APPROACH=-35 ELEM REACTANTS=1/2/3/4/5/8/9/10/11/12 HX UID=H-1, NAME=COOL REFGAS HOT FEED=8, M=10, DP=4 SPEC HOT, TEMP=675 $ ---------------------------------------------------------------$ SHIFT AND METHANATION SECTION $ ---------------------------------------------------------------REACT UID=RX-4, NAME=H T SHIFT FEED 10 PROD V=11 RXCA MODEL=SHIFT, EQUILIBRIUM OPER ADIA, DP=2 REACT UID=RX-5, NAME=L T SHIFT FEED 13 PROD V=14

21

$

$ $ $

22

RXCA MODEL=SHIFT, EQUILIBRIUM OPER ADIA, DP=2 FLASH UID=REB1, NAME=REBOILER FEED 14 PROD V=15 ADIA DUTY=-45, DP=4 HX UID=CW-1 HOT FEED=15, V=16, DP=2 SPEC HOT, TEMP=100 FLASH UID=D-1, NAME=COND SEP FEED 16 PROD W=18, V=17 ADIA STCALC UID=T-1, NAME=MEA COLUMN FEED 17 OVHD V=CO2, DEWT BTMS L=19A, TEMP=100, DP=12 FOVHD 1,3,0 / 4,4,0.9992 / 5,13,0 FLASH UID=SAT, NAME=H2O SAT FEED 19A, WAT PROD V=19, W=XS ISOTHERMAL TEMP=100 REACT UID=RX-6, NAME=METHANATOR FEED 21 PROD V=22 RXCA MODEL=METHAN, EQUILIBRIUM OPER ADIA, DP=2 CONTROL AIR TO HAVE STOICHIOMETRIC H2 TO N2 RATIO (3:1) CONTROL UID=CT1 SPEC STRM=22, COMP=5, RATE(M), RATIO, COMP=6, RATE(M), VALUE=3.0 VARY STRM=7, RATE ---------------------------------------------------------------NOW COMPLETE HEAT EXCHANGER CALCULATIONS ---------------------------------------------------------------HX UID=X-3 HOT FEED=22, M=23, DP=2 COLD FEED=19, V=20, DP=2 CONFIG U=90, AREA=1025 HX UID=X-2 HOT FEED=11, V=12, DP=2 COLD FEED=20, V=21X, DP=2 SPEC COLD, TEMP=675 HX UID=WHB2 HOT FEED=12, V=13X, DP=2 SPEC HOT, TEMP=400 HX UID=WHB1 HOT FEED=8, V=9, DP=2 DEFI DUTY, AS, HX=H-1, DUTY, MINUS, HX=X-1A, DUTY HX UID=X1-B HOT FEED=9, V=10X, DP=1 DEFI DUTY, AS, HX=X-1A, DUTY, MULTIPLY, -1.0 FLASH UID=CW2 FEED 23 PROD M=24 ISO TEMP=100

FLASH

UID=D-2, NAME=COND SEP FEED 24 PROD W=24W, V=25 ADIA

$ ---------------------------------------------------------------$ SYNTHESIS LOOP COMPRESSORS $ ---------------------------------------------------------------COMP UID=CP-1, NAME=1ST STAGE FEED 25 PROD V=26, W=WA1 OPER POUT=700, EFF=95 COOL TOUT=95, DP=5 COMP UID=CP-2, NAME=2ND STAGE FEED 26 PROD V=27, W=WA2 OPER POUT=1950, EFF=95 COOL TOUT=95, DP=5 COMP UID=CP-3, NAME=3RD STAGE FEED 27 PROD V=28A OPER POUT=4960, EFF=95 COOL TOUT=95, DP=5 STCA

UID=SEP1, NAME=WATER REMOVL FEED 28A,1.0 OVHD TEMP=95 L=WA3 BTMS TEMP=95 V=28 FOVHD 1,1,1/2,13,0

$ ---------------------------------------------------------------$ START OF SYNTHESIS LOOP $ ---------------------------------------------------------------CALC UID=REFC NAME=REF_RATE SEQUENCE STREAM=31R DEFINE P(1) AS STREAM=31R, RATE(M) PROCEDURE IF (R(1) .GT. 0) GOTO 100 R(1) = P(1) 100 CALL SRXSTR(SMR,R(1),31R) RETURN COMP

HX

FLASH

UID=CP-4, NAME=RECYCLE COMP FEED 31R PROD V=33 OPER POUT=4950, EFF=95 , WTOL=0.00001 UID=X-4 COLD FEED=36A, V=38, DP=50 HOT FEED=28,33, M=34, DP=50 OPER CTEM=85 UID=D-7, NAME=SEC SEP FEED 34 PROD L=37, V=36 ISOTHERMAL TEMP=40, PRES=4840 METH SET=2

23

FLASH

UID=DM1 FEED 37 PROD L=37A ISOT TEMP=40 FLASH UID=DM2 FEED 36 PROD V=36A ISOT TEMP=40 $ SIMULATE THE REACTOR WITH AN EQUILIBRIUM MODEL REAC UID=RX-7, NAME=CONVERTER FEED 38B PROD V=29A OPER PHASE=V, ADIA, DP=30, TEMP=900 $ TEMP ESTIMATE RXCA EQUIL, REFTEMP=800 STOI 5,-3 / 6,-1 / 13,2 $ 3H2 + N2 = 2NH3 BASE COMP=6, HEAT=-45.108 EQUI -32.975, 22930.4 $ LN(K) = A + B / DEG R APPR DT=20 HX UID=FDEF, NAME=RX EFFL EXCH HOT FEED=29A, V=29, DP=30 COLD FEED=38, V=38B, DP=30 OPER HTEM=430 FLASH UID=D-6, NAME=PRI SEP FEED 29 PROD V=31, L=32 ISOTHERMAL TEMP=85, PRES=4660 METH SET=2 FLASH UID=DM3 FEED 31 PROD V=31A ISOT TEMP=85 FLASH UID=DM4 FEED 32 PROD L=32A ISOT TEMP=85 CALCULATOR UID=BD1, NAME=PURGE RATE DEFINE P(1) AS STREAM=28,COMP=7,RATE DEFINE P(2) AS STREAM=32A,COMP=7,RATE DEFINE P(3) AS STREAM=37A,COMP=7,RATE SEQUENCE STREAM=31X PROCEDURE V(1) = P(1) - P(2) - P(3) IF (V(1) .LE. 0.001) V(1) = 0.001 CALL SRXSTR(SMR, V(1), 31X) RETURN SPLIT UID=SP1, NAME=PURGE FEED 31A PROD V=31P, V=31RA SPEC STRE=31P, COMP=7, RATE, RATIO, STRE=31X, VALUE=1 , RTOL=0.00001 $ PURGE FLASH UID=DUM1 FEED 31RA PROD M=31RB ADIA CALC UID=CAL1 NAME=SET_RATE

24

SEQUENCE STREAM=31RB DEFINE P(1) AS CALC=REFC, R(1) PROCEDURE CALL SRXSTR(SMR,P(1),31RB) RETURN FLASH UID=DUM2 FEED 31RB PROD M=31R ADIA $ END RECYCLE LOOP CONTR

UID=CTL1 SPEC STRE=38, COMP=7,8, FRAC, VALUE=0.12,ATOL=1.0E-3 $ 12% INERTS IN RX FEED VARY CALC=REFC, R(1), EST2=10500,STEPSIZE=3.0E-4 $ ADJUST RECYCLE CPARA ITER=200, IPRINT FLASH

UID=D-8, NAME=LETDOWN FEED 32A,37A PROD L=40, V=39 ADIA PRES=350 RECYCLE DATA LOOP NO=1, START=X-4, END=DM2,TOLE=0.000002 LOOP NO=2, START=CP-4, END=DUM2 , TOLE=0.0015 ACCEL TYPE=WEGS, STREAM=36A,31R $ CASE STUDY TO CHANGE INERT MOLE % IN RECYCLE TO 14% CASESTUDY OLDCASE=BASECASE,NEWCASE=14PT CHANGE CONTROLLER=CTL1,SPEC,VALUE=0.14

25

APPENDIX C - PRO/II ® Output The following pages show selected parts of the output file from the ammonia plant simulation. A complete copy of the output can be obtained from SimSci. The order of the output is shown below: Plant material balance Compressor CP-3 Reactors RX-4 RX-5 RX-6 RX-7 RX-2 RX-3 Heat exchanger X-3 Stream calculator T-1 (MEA Column) User defined output for all streams in the simulation

26

SIMULATION SCIENCES INC. R PAGE P-1 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE PLANT MATERIAL BALANCE MAR 1992 ============================================================================== FEED STREAMS:

1 WAT 8

5 13 19A

7 21 28

PRODUCT STREAMS:

17 40 21X 24W 28A

31P 18 13X WA1

39 XS 10X WA2

OVERALL PLANT MOLAR BALANCE -------------------------------- LB-MOL/HR ----------------------------- PERCENT COMPONENT FEED +REACTION -PRODUCT =DEVIATION DEV -------------------------------------------- -------------------- ----------------- ----------------- ----------------- ---------------1 H2O 11121.489 -1072.243 10049.246 0.000 0.00 2 O2 211.874 -211.874 0.000 0.000 0.00 3 CO 408.041 0.000 408.041 0.000 0.00 4 CO2 1164.029 747.995 1912.024 0.000 0.00 5 H2 11784.837 57.594 11849.259 -6.828 -0.06 6 N2 4845.337 -788.920 4058.665 -2.248 -0.06 7 A 57.509 0.000 57.509 0.000 0.00 8 C1 589.934 -516.825 73.404 -0.295 -0.40 9 C2 49.080 -49.080 0.000 0.000 0.00 10 C3 21.411 -21.411 0.000 0.000 0.00 11 NC4 15.218 -15.218 0.000 0.000 0.00 12 NC5 1.581 -1.581 0.000 0.000 0.00 13 NH3 0.000 1577.793 1578.581 -0.788 -0.05 TOTAL

30270.340

-293.769

29986.727

-10.156

-0.03

OVERALL PLANT MASS BALANCE -------------------------------- LB-MOL/HR ----------------------------- PERCENT COMPONENT FEED +REACTION -PRODUCT =DEVIATION DEV -------------------------------------------- -------------------- ----------------- ----------------- ----------------- ---------------1 H2O 200353.63 -19316.46 181037.16 0.00 0.00 2 O2 6779.74 -6779.74 0.00 0.00 0.00 3 CO 11429.63 0.00 11429.63 0.00 0.00 4 CO2 51228.94 32919.26 84148.20 0.00 0.00 5 H2 23758.23 116.11 23888.11 -13.76 -0.06 6 N2 135732.44 -22100.02 113695.38 -62.96 -0.06 7 A 2297.35 0.00 2297.35 0.00 0.00 8 C1 9464.32 -8291.43 1177.63 -4.74 -0.40 9 C2 1475.83 -1475.83 0.00 0.00 0.00 10 C3 944.15 -944.15 0.00 0.00 0.00 11 NC4 884.53 -884.53 0.00 0.00 0.00 12 NC5 114.08 -114.08 0.00 0.00 0.00 13 NH3 0.00 26871.40 26884.81 -13.42 -0.05 TOTAL

444462.84

0.53

444558.22

-94.85

-0.02

27

SIMULATION SCIENCES INC. R PAGE P-5 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE COMPRESSOR SUMMARY MAR 1992 ============================================================================== UNIT 24, ’CP-1’, ’1ST STAGE’ FEEDS PRODUCTS VAPOR WATER

25 26 WA1

OPERATING CONDITIONS

TEMPERATURE, F PRESSURE, PSIG ENTHALPY, MM BTU/HR ENTROPY, BTU/LB-MOL-F CP, BTU/LB-MOL-F CV, BTU/LB-MOL-F CP/(CP-R) CP/CV MOLE PERCENT VAPOR MOLE PERCENT LIQUID MOLE PERCENT H/C LIQUID MOLE PERCENT WATER ACT VAP RATE, M FT3/MIN ADIABATIC EFF, PERCENT POLYTROPIC EFF, PERCENT ISENTROPIC COEFFICIENT, K POLYTROPIC COEFFICIENT, N HEAD, FT ADIABATIC POLYTROPIC ACTUAL WORK, HP THEORETICAL POLYTROPIC ACTUAL AFTERCOOLER DUTY, MM BTU/HR TEMPERATURE, F PRESSURE, PSIG

INLET ---------------100.00 250.00 -5.9524 31.0928 6.9731 4.9419 1.3982 1.4110 100.0000 0.0000 0.0000 0.0000 1.2463

ISENTROPIC -------------------283.71 700.00 -1.7168 31.0928

NOTE: POLYTROPIC AND ISENTROPIC COEFFICIENTS CALCULATED FROM HEAD EQUATION

28

100.0000 0.0000 0.0000 0.0000

OUTLET -------------------293.34 700.00 -1.4938 31.1840 7.0889 5.0481 1.3892 1.4043 100.0000 0.0000 0.0000 0.0000 95.0000 95.6409 1.3993 1.4253 116241.85 117026.06 122359.84 1664.67 1675.90 1752.28 -4.73 95.00 695.00

SIMULATION SCIENCES INC. R PAGE P-9 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 8, ’RX-4’, ’H T SHIFT’ OPERATING CONDITIONS REACTOR TYPE DUTY, MM BTU/HR TOTAL HEAT OF REACTION AT 77.00 F, MM BTU/HR

FEED VAPOR PRODUCT TEMPERATURE, F PRESSURE, PSIG

ADIABATIC SHIFT CONVERTER -1.49948E-04 -5.2517

INLET -------------------10

OUTLET -------------------11 758.58 278.0000

675.00 280.0000

REACTION DATA

COMPONENT ----------------------------------------1 H2O 2 O2 3 CO 4 CO2 5 H2 6 N2 7 A 8 C1 9 C2 10 C3 11 NC4 12 NC5 TOTAL

BASE COMPONENT -------------------------------------------3 CO

-------------------- RATES, LB-MOL/HR -------------------FRACTION FEED CHANGE PRODUCT CONVERTED ---------------------------------------- --------------------- -------------------3220.2144 -296.8296 2923.3848 0.0922 1.77822E-08 0.0000 1.77822E-08 348.6051 -296.8295 51.7756 0.8515 423.2684 296.8296 720.0980 2093.5256 296.8296 2390.3552 807.5563 0.0000 807.5563 9.5848 0.0000 9.5848 10.7034 0.0000 10.7034 6.41714E-07 0.0000 6.41714E-07 1.29036E-08 0.0000 1.29036E-08 9.78961E-09 0.0000 9.78961E-09 7.88639E-09 0.0000 7.88639E-09 6913.4580

REACTION ---------------SHIFT

0.0000 LB-MOL/HR CONVERTED -------------------296.8295

6913.4580 FRACTION CONVERTED(1) ------------------------0.8515

(1) FRACTION CONVERTED BASED ON AMOUNT IN FEED

29

SIMULATION SCIENCES INC. R PAGE P-10 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 8, ’RX-4’, ’H T SHIFT’

(CONT)

REACTOR MASS BALANCE

COMPONENT ----------------------------------------1 H2O 2 O2 3 CO 4 CO2 5 H2 6 N2 7 A 8 C1 9 C2 10 C3 11 NC4 12 NC5 TOTAL

30

------------------------ RATES, LB/HR FEED CHANGE --------------------- --------------------58012.1563 -5347.3789 5.69011E-07 0.0000 9764.7783 -8314.4922 18628.0430 13063.4707 4220.5479 598.4082 22622.0742 0.0000 382.8918 0.0000 171.7144 0.0000 1.92963E-05 0.0000 5.69011E-07 0.0000 5.69011E-07 0.0000 5.69011E-07 0.0000

--------------------PRODUCT --------------------52664.7773 5.69011E-07 1450.2860 31691.5137 4818.9561 22622.0742 382.8918 171.7144 1.92963E-05 5.69011E-07 5.69011E-07 5.69011E-07

113802.2110

113802.2110

0.0000

FRACTION CONVERTED ----------------0.0922 0.8515

SIMULATION SCIENCES INC. R PAGE P-11 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 9, ’RX-5’, ’L T SHIFT’ OPERATING CONDITIONS REACTOR TYPE DUTY, MM BTU/HR TOTAL HEAT OF REACTION AT 77.00 F, MM BTU/HR


ADIABATIC SHIFT CONVERTER 6.16452E-05 -0.8483

INLET -------------------13

OUTLET -------------------14 413.61 272.0000

400.00 274.0000

REACTION DATA

COMPONENT ---------------------------------------1 H2O 2 O2 3 CO 4 CO2 5 H2 6 N2 7 A 8 C1 9 C2 10 C3 11 NC4 12 NC5 TOTAL

BASE COMPONENT ------------------------------------3 CO

--------------------- RATES, LB-MOL/HR ----------------FEED CHANGE PRODUCT ---------------------------------------- -----------------------2923.3848 -47.9456 2875.4392 1.77822E-08 0.0000 1.77822E-08 51.7756 -47.9456 3.8300 720.0980 47.9456 768.0436 2390.3552 47.9456 2438.3008 807.5563 0.0000 807.5563 9.5848 0.0000 9.5848 10.7034 0.0000 10.7034 6.41714E-07 0.0000 6.41714E-07 1.29036E-08 0.0000 1.29036E-08 9.78961E-09 0.0000 9.78961E-09 7.88639E-09 0.0000 7.88639E-09 6913.4580

REACTION -------------------SHIFT

0.0000 LB-MOL/HR CONVERTED --------------------47.9456

FRACTION CONVERTED --------------------0.0164 0.9260

6913.4580 FRACTION CONVERTED(1) -----------------------0.9260


31

SIMULATION SCIENCES INC. R PAGE P-12 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 9, ’RX-5’, ’L T SHIFT’

(CONT)



32

--------------------- RATES, LB-MOL/HR ----------------FEED CHANGE PRODUCT ---------------------------------------- -----------------------52664.7773 -863.7422 51801.0352 5.69011E-07 0.0000 5.69011E-07 1450.2860 -1343.0044 107.2816 31691.5137 2110.0879 33801.6016 4818.9561 96.6582 4915.6143 22622.0742 0.0000 22622.0742 382.8918 0.0000 382.8918 171.7144 0.0000 171.7144 1.92963E-05 0.0000 1.92963E-05 5.69011E-07 0.0000 5.69011E-07 5.69011E-07 0.0000 5.69011E-07 5.69011E-07 0.0000 5.69011E-07 113802.2110

0.0000

113802.2110

FRACTION CONVERTED --------------------0.0164 0.9260

SIMULATION SCIENCES INC. R PAGE P-13 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 15, ’RX-6’, ’METHANATOR’ OPERATING CONDITIONS REACTOR TYPE DUTY, MM BTU/HR TOTAL HEAT OF REACTION AT 77.00 F, MM BTU/HR


ADIABATIC METHANATOR -4.16521E-06 -0.3832

INLET -------------------21

OUTLET -------------------22 692.54 252.0000

675.00 254.0000

REACTION DATA


BASE COMPONENT ------------------------------------3 CO 3 CO

--------------------- RATES, LB-MOL/HR ----------------FRACTION FEED CHANGE PRODUCT CONVERTED ---------------------------------------- -------------------------------------------11.5273 5.0588 16.5861 1.77822E-08 0.0000 1.77822E-08 3.8300 -3.8300 4.61974E-07 1.0000 0.6144 -0.6144 0.0000 1.0000 2438.3010 -13.9478 2424.3533 5.72028E-03 807.5562 0.0000 807.5562 9.5848 0.0000 9.5848 10.7034 4.4444 15.1478 6.41714E-07 0.0000 6.41714E-07 1.29036E-08 0.0000 1.29036E-08 9.78961E-09 0.0000 9.78961E-09 7.88639E-09 0.0000 7.88639E-09 3282.1172

-8.8889

REACTION --------------------METHANATION SHIFT

LB-MOL/HR CONVERTED -------------------4.4444 1.5903

3273.2283 FRACTION CONVERTED(1) -----------------------1.1604 0.4152


33

SIMULATION SCIENCES INC. R PAGE P-14 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 15, ’RX-6’, ’METHANATOR’

(CONT)



34

--------------------- RATES, LB-MOL/HR ----------------FRACTION FEED CHANGE PRODUCT CONVERTED ---------------------------------------- -------------------------------------------207.6640 91.1342 298.7982 5.69011E-07 0.0000 5.69011E-07 107.2816 -107.2816 1.29403E-05 1.0000 27.0402 -27.0402 0.0000 1.0000 4915.6152 -28.1187 4887.4966 5.72027E-03 22622.0723 0.0000 22622.0723 382.8918 0.0000 382.8918 171.7144 71.3013 243.0157 1.92963E-05 0.0000 1.92963E-05 5.69011E-07 0.0000 5.69011E-07 5.69011E-07 0.0000 5.69011E-07 5.69011E-07 0.0000 5.69011E-07 28434.2813 0.0000 28434.2754

SIMULATION SCIENCES INC. R PAGE P-15 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 34, ’RX-7’, ’CONVERTER’ OPERATING CONDITIONS REACTOR TYPE DUTY, MM BTU/HR TOTAL HEAT OF REACTION AT 800.00 F, MM BTU/HR


INLET ---------------------------38B

ADIABATIC REACTOR -2.29920E-04 -35.5866 OUTLET ----------------------------29A 924.35 4729.9995

568.10 4759.9995

REACTION DATA

COMPONENT ------------------------------------------------------------------2 O2 3 CO 5 H2 6 N2 7 A 8 C1 9 C2 10 C3 11 NC4 12 NC5 13 NH3 TOTAL

BASE COMPONENT ----------------------------------------------------------6 N2

------------------------ RATES, LB-MOL/HR -----------------------FRACTION FEED CHANGE PRODUCT CONVERTED ------------------------ ---------------------------- ---------------------------- -------6.29842E-07 3.25999E-05 8465.1299 2890.1084 727.6616 879.5477 2.47163E-05 4.81262E-07 3.61721E-07 3.25164E-07 528.3845

0.0000 0.0000 -2366.7593 -788.9202 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 1577.7932

6.29842E-07 3.25999E-05 6098.3706 2101.1882 727.6615 879.5477 2.47163E-05 4.81262E-07 3.61721E-07 3.25164E-07 2106.1777

13490.8320

-1577.8857

11912.9463

LB-MOL/HR REACTION CONVERTED ------------------------ -----------------------1

0.2796 0.2730

FRACTION CONVERTED(1) --------------------

788.9198

0.2730



COMPONENT ------------------------------------------------------------------2 O2 3 CO 5 H2 6 N2 7 A SIMULATION SCIENCES INC. PROJECT NH3 PLANT PROBLEM AMMONIA BASE CASE

--------------------- RATES, LB/HR -----------------------FRACTION FEED CHANGE PRODUCT CONVERTED ------------------------ ---------------------------- ---------------------------- -------2.01543E-05 0.0000 9.13156E-04 0.0000 17065.7012 -4771.3857 80960.6094 -22100.0195 29068.6211 0.0000 R PRO/II VERSION 3.13 OUTPUT REACTOR SUMMARY

2.01543E-05 9.13156E-04 12294.3154 58860.5898 29068.6211

0.2796 0.2730 PAGE P-16 386/EM SIMSCI MAR 1992

35

============================================================================== UNIT 34, ’RX-7’, ’CONVERTER’

COMPONENT --------------------------------------------------------------8 C1 9 C2 10 C3 11 NC4 12 NC5 13 NH3 TOTAL

36

(CONT)

---------------------------- RATES, LB/HR ---------------------------FRACTION FEED CHANGE PRODUCT CONVERTED ------------------------ ---------------------------- ---------------------------- -------14110.5830 7.43220E-04 2.12222E-05 2.10247E-05 2.34609E-05 8998.9170

0.0000 0.0000 0.0000 0.0000 0.0000 26871.3984

14110.5820 7.43220E-04 2.12222E-05 2.10247E-05 2.34609E-05 35870.3164

150204.4380

0.0000

150204.4220

SIMULATION SCIENCES INC. R PAGE P-17 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE GIBBS REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 5, ’RX-2’, ’PRI REFORMER’ OPERATING CONDITIONS REACTOR TYPE DUTY, MM BTU/HR TOTAL HEAT OF REACTION AT 77.00 F, MM BTU/HR MINIMUM DIMENSIONLESS GIBBS FREE ENERGY (G/RT) INLET ---------------------------4 5


ISOTHERMAL 65.7106 37.5384 -12.1943 OUTLET ----------------------------

6 1360.00 289.0000

901.01 334.0000

REACTION DATA

COMPONENT --------------------------------------------------------------1 H2O 3 CO 4 CO2 5 H2 6 N2 8 C1 9 C2 10 C3 11 NC4 12 NC5 TOTAL

------------------------ RATES, LB-MOL/HR -----------------------FRACTION FEED CHANGE PRODUCT CONVERTED ------------------------ ---------------------------- ---------------------------- -------3952.7412 0.0000 19.4343 0.0000 20.0931 531.9731 49.0799 21.4107 15.2181 1.5811

-907.2722 171.4357 367.9181 1842.1045 0.0000 -308.1938 -49.0751 -21.4107 -15.2181 -1.5811

3045.4690 171.4357 387.3524 1842.1045 20.0931 223.7794 4.735E-03 3.199E-07 7.276E-09 5.861E-09

4611.5313

1078.7075

5690.2388

0.2295

0.5793 0.9999 1.0000 1.0000 1.0000


COMPONENT --------------------------------------------------------------1 H2O 3 CO 4 CO2 5 H2 6 N2 8 C1 9 C2

---------------------------- RATES, LB/HR ---------------------------FRACTION FEED CHANGE PRODUCT CONVERTED ------------------------ ---------------------------- ---------------------------- -------71208.6250 0.0000 855.3041 0.0000 562.8681 8534.4453 1475.8319

-16344.5039 4802.0845 16192.0771 3713.6829 0.0000 -4944.3535 -1475.6895

54864.1211 4802.0845 17047.3809 3713.6829 562.8680 3590.0920 0.1424

0.2295

0.5793 0.9999

37

SIMULATION SCIENCES INC. R PAGE P-18 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE GIBBS REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 5, ’RX-2’, ’PRI REFORMER’

COMPONENT --------------------------------------------------------------10 C3 11 NC4 12 NC5 TOTAL

38

(CONT)

---------------------------- RATES, LB/HR ---------------------------FRACTION FEED CHANGE PRODUCT CONVERTED ------------------------ ---------------------------- ------------------------ -----------944.1470 884.5342 114.0777

-944.1470 -884.5342 -114.0777

1.41070E-05 4.22899E-07 4.22899E-07

84579.8281

0.5391

84580.3672

1.0000 1.0000 1.0000

SIMULATION SCIENCES INC. R PAGE P-19 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE GIBBS REACTOR SUMMARY MAR 1992 ============================================================================== UNIT 6, ’RX-3’, ’SEC REFORMER’ OPERATING CONDITIONS REACTOR TYPE DUTY, MM BTU/HR TOTAL HEAT OF REACTION AT 77.00 F, MM BTU/HR MINIMUM DIMENSIONLESS GIBBS FREE ENERGY (G/RT) INLET ---------------------------6 7


ADIABATIC 4.678E-03 -25.8425 -12.0010 OUTLET ------------------------

8 1634.44 284.0000

1232.12 289.0000

REACTION DATA

COMPONENT ------------------------------------------------------------------1 H2O 2 O2 3 CO 4 CO2 5 H2 6 N2 7 A 8 C1 9 C2 10 C3 11 NC4 12 NC5 TOTAL

------------------------ RATES, LB-MOL/HR -----------------------FRACTION FEED CHANGE PRODUCT CONVERTED ------------------------ ---------------------------- ---------------------------- -------3045.4690 211.8735 171.4357 387.3524 1842.1046 807.5563 9.5848 223.7793 4.735E-03 3.199E-07 7.276E-09 5.861E-09

174.7454 -211.8735 177.1695 35.9160 251.4210 0.0000 0.0000 -213.0760 -4.735E-03 -3.070E-07 2.514E-09 2.025E-09

3220.2144 1.778E-08 348.6051 423.2684 2093.5256 807.5563 9.5848 10.7034 6.417E-07 1.290E-08 9.790E-09 7.886E-09

6699.1602

214.2979

6913.4580

1.0000

0.9522 0.9999 0.9597

REACTOR MASS BALANCE ---------------------------- RATES, LB/HR ---------------------------FRACTION COMPONENT FEED CHANGE PRODUCT CONVERTED ----------------------------------------------------------------------- ---------------------------- ---------------------------- ----------------------1 H2O 54864.1211 3148.0352 58012.1563 2 O2 6779.7397 -6779.7397 5.69011E-07 1.0000 3 CO 4802.0840 4962.6943 9764.7783 4 CO2 17047.3809 1580.6621 18628.0430 5 H2 3713.6829 506.8650 4220.5479 6 N2 22622.0742 0.0000 22622.0742 7 A 382.8917 0.0000 382.8918 8 C1 3590.0918 -3418.3774 171.7144 0.9522 9 C2 0.1424 -0.1424 1.92963E-05 0.9999 SIMULATION SCIENCES INC. R PAGE P-20 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE GIBBS REACTOR SUMMARY MAR 1992 ==============================================================================

39

UNIT 6, ’RX-3’, ’SEC REFORMER’

COMPONENT --------------------------------------------------------------10 C3 11 NC4 12 NC5 TOTAL

40

(CONT)

---------------------------- RATES, LB/HR ---------------------------FRACTION FEED CHANGE PRODUCT CONVERTED ------------------------ ---------------------------- ---------------------------- -------1.41070E-05 -1.35380E-05 4.22899E-07 1.46112E-07 4.22899E-07 1.46112E-07

5.69011E-07 5.69011E-07 5.69011E-07

113802.2030

113802.2110

0.0000

0.9597

SIMULATION SCIENCES INC. R PAGE P-23 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE HEAT EXCHANGER SUMMARY MAR 1992 ============================================================================== UNIT 17, ’X-3’ OPERATING CONDITIONS DUTY, MM BTU/HR LMTD, F F FACTOR (FT) MTD, F U*A, BTU/HR-F U, BTU/HR-FT2-F AREA, FT2

HOT SIDE CONDITIONS FEED VAPOR PRODUCT VAPOR, LB-MOL/HR M LB/HR CP, BTU/LB-F TOTAL, LB-MOL/HR M LB/HR CONDENSATION, LB-MOL/HR TEMPERATURE, F PRESSURE, PSIG

COLD SIDE CONDITIONS FEED VAPOR PRODUCT VAPOR, LB-MOL/HR M LB/HR CP, BTU/LB-F TOTAL, LB-MOL/HR M LB/HR CONDENSATION, LB-MOL/HR TEMPERATURE, F PRESSURE, PSIG

10.961 118.819 1.000 118.819 92250.070 90.000 1025.000

INLET OUTLET ---------------------------- ---------------------------22 23 3273.228 3273.228 28.434 28.434 0.820 0.809 3273.228 3273.228 28.434 28.434 0.000 692.535 219.255 252.000 250.000

INLET OUTLET ---------------------------- ---------------------------19 20 3282.117 3282.117 28.434 28.434 0.805 0.818 3282.117 3282.117 28.434 28.434 0.000 100.000 574.152 254.000 252.000

41

SIMULATION SCIENCES INC. R PAGE P-29 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE STREAM CALCULATOR SUMMARY MAR 1992 ============================================================================== UNIT 13, ’T-1’, ’MEA COLUMN’ NET DUTY, MM BTU/HR FEEDS

TOTAL RATE, LB-MOL/HR TEMPERATURE, F PRESSURE, PSIG MOLECULAR WEIGHT MOL FRAC VAPOR MOL FRAC TOTAL LIQUID MOL FRAC H/C LIQUID MOL FRAC WATER ENTHALPY, MM BTU/HR PRODUCTS

MIXED VAPOR TOTAL RATE, LB-MOL/HR TEMPERATURE, F PRESSURE, PSIG PRESSURE DROP, PSI ENTHALPY, MM BTU/HR

42

-0.99927 STREAM ID

FACTOR

17

1.000

4051.640 100.000 266.000 15.3633 1.00000 0.00000 0.00000 0.00000 -1.49300 OVERHEAD

BOTTOMS

ALTERNATE PRODUCT

19A CO2 767.429 -4.876 266.000 0.000 3.49010

3284.211 100.000 254.000 12.000 -5.98237

N/A N/A N/A N/A N/A

SIMULATION SCIENCES INC. R PAGE P-32 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE USER DEFINED PROPERTIES SET JAN 1992 ============================================================================== STREAM ID NAME PHASE

CO2

WAT

WA1

WA2

DRY VAPOR

WATER

WATER

WATER

DRY VAPOR

WATER

WATER

WATER

0.0000 0.0000 0.0000 767.4293 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

999.9999 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

7.9296 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

2.3755 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

767.4293 44.0100 33774.5625

999.9999 18.0150 18014.9980

7.9296 18.0150 142.8509

2.3755 18.0150 42.7943

-4.88 266.000 4.5478

100.00 271.000 1.2387

95.00 695.000 1.1699

95.00 1945.000 1.2290

*** VAPOR PHASE *** RATE, M FT3/DAY DENSITY, LB/M FT3

6989.4463 3118.8838

N/A N/A

N/A N/A

N/A N/A

*** LIQUID PHASE *** ACT.RATE, GAL/MIN DENSITY, LB/GAL

N/A N/A

36.2343 8.2864

0.2870 8.2944

0.0860 8.2944

NAME PHASE COMP. MOLE RATES, LB-MOL/HR 1 H2O 2 O2 3 CO 4 CO2 5 H2 6 N2 7 A 8 C1 9 C2 10 C3 11 NC4 12 NC5 13 NH3 RATE, LB-MOL/HR MOLECULAR WEIGHT RATE, LB/HR TEMPERATURE, F PRESSURE, PSIG ENTHALPY, M BTU/LB-MOL

43

SIMULATION SCIENCES INC. R PAGE P-33 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE USER DEFINED PROPERTIES SET JAN 1992 ============================================================================== STREAM ID NAME PHASE

WATER

1 NAT GAS DRY VAPOR

DRY VAPOR

WATER

WATER

NAT GAS DRY VAPOR

DRY VAPOR

1.3472 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

1002.0942 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

0.0000 0.0000 0.0000 19.4343 0.0000 20.0931 0.0000 531.9731 49.0799 21.4107 15.2181 1.5811 0.0000

0.0000 0.0000 0.0000 19.4343 0.0000 20.0931 0.0000 531.9731 49.0799 21.4107 15.2181 1.5811 0.0000

1.3472 18.0150 24.2690

1002.0942 18.0150 18052.7266

658.7902 20.2966 13371.2080

658.7902 20.2966 13371.2080

95.00 4955.000 1.3705

100.00 254.000 1.2378

60.00 340.000 0.9590

282.86 338.000 3.3877


N/A N/A

N/A N/A

6000.0039 1388.8752

6000.0039 910.5820


0.0488 8.2944

36.3102 8.2864

N/A N/A

N/A N/A


44

WA3

XS

WATER

2

SIMULATION SCIENCES INC. R PAGE P-34 PROJECT NH3 PLANT PRO/II VERSION 3.13 386/EM PROBLEM AMMONIA OUTPUT SIMSCI BASE CASE USER DEFINED PROPERTIES SET MAR 1992 ============================================================================== STREAM ID NAME PHASE

DRY VAPOR

5 STEAM WATER VAPOR

6 PR REF OUT WET VAPOR

DRY VAPOR

DRY VAPOR

STEAM WATER VAPOR

PR REF OUT WET VAPOR

0.0000 0.0000 0.0000 19.4343 0.0000 20.0931 0.0000 531.9731 49.0799 21.4107 15.2181 1.5811 0.0000

0.0000 0.0000 0.0000 19.4343 0.0000 20.0931 0.0000 531.9731 49.0799 21.4107 15.2181 1.5811 0.0000

3952.7412 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

3045.4690 0.0000 171.4357 387.3524 1842.1046 20.0931 0.0000 223.7794 4.7355E-03 3.1991E-07 7.2758E-09 5.8613E-09 0.0000

658.7902 20.2966 13371.2080

658.7902 20.2966 13371.2080

3952.7412 18.0150 71208.6328

5690.2388 14.8641 84580.3750

750.00 336.000 9.7143

740.00 334.000 9.5598

950.00 334.000 26.9699

1360.00 289.000 21.2011


6000.0039 544.6247

6000.0039 546.1139

36000.0234 422.8545

51824.4727 231.2722


N/A N/A

N/A N/A

N/A N/A

N/A N/A


3

4

DRY VAPOR

45


7 AIR DRY VAPOR

8 SEC REF OUT WET VAPOR

9

10

WET VAPOR

WET VAPOR

AIR DRY VAPOR

SEC REF OUT WET VAPOR

WET VAPOR

WET VAPOR

0.0000 211.8735 0.0000 0.0000 0.0000 787.4632 9.5848 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

3220.2144 1.7782E-08 348.6051 423.2684 2093.5256 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

3220.2144 1.7782E-08 348.6051 423.2684 2093.5256 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

3220.2144 1.7782E-08 348.6051 423.2684 2093.5256 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

1008.9215 28.9634 29221.8379

6913.4580 16.4610 113802.2030

6913.4580 16.4610 113802.2030

6913.4580 16.4610 113802.2030

330.00 289.000 -0.2170

1634.44 284.000 21.5924

747.58 282.000 13.8234

675.00 280.000 13.2206


9188.8633 1029.2030

62965.0781 218.6197

62965.0781 378.4246

62965.0781 400.5077


N/A N/A

N/A N/A

N/A N/A

N/A N/A


46


12

13

WET VAPOR

11 HTS OUT WET VAPOR

WET VAPOR

WET VAPOR

WET VAPOR

HTS OUT WET VAPOR

WET VAPOR

WET VAPOR

3220.2144 1.7782E-08 348.6051 423.2684 2093.5256 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

2923.3848 1.7782E-08 51.7756 720.0980 2390.3552 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

2923.3848 1.7782E-08 51.7756 720.0980 2390.3552 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

2923.3848 1.7782E-08 51.7756 720.0980 2390.3552 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

6913.4580 16.4610 113802.2030

6913.4580 16.4610 113802.2030

6913.4580 16.4610 113802.2030

6913.4580 16.4610 113802.2030

675.02 281.000 13.2206

758.58 278.000 13.3591

718.17 276.000 13.0193

400.00 274.000 10.3592


62965.0781 401.8654

62965.0781 369.4207

62965.0781 379.7067

62965.0781 523.8746


N/A N/A

N/A N/A

N/A N/A

N/A N/A


10X

47


15

16

WET VAPOR

14 LTS OUT WET VAPOR

MIXED

MIXED

WET VAPOR

LTS OUT WET VAPOR

MIXED

MIXED

2923.3848 1.7782E-08 51.7756 720.0980 2390.3552 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

2875.4390 1.7782E-08 3.8300 768.0436 2438.3008 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

2875.4390 1.7782E-08 3.8300 768.0436 2438.3008 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

2875.4390 1.7782E-08 3.8300 768.0436 2438.3008 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

6913.4580 16.4610 113802.2030

6913.4580 16.4610 113802.2030

6913.4580 16.4610 113802.2030

6913.4580 16.4610 113802.2030

400.00 274.000 10.3592

413.61 272.000 10.3815

267.51 268.000 3.8725

100.00 266.000 0.2967


62965.0781 523.8745

62965.0781 511.0703

42818.0508 570.2701

36900.7617 718.6578


N/A N/A

N/A N/A

85.2055 7.7951

103.6961 8.2864


48

13X


WATER

19 TRTD GAS WET VAPOR

MIXED

MEA FEED WET VAPOR

WATER

TRTD GAS WET VAPOR

MIXED

13.6215 1.7782E-08 3.8300 768.0436 2438.3010 807.5563 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

2861.8179 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

11.5273 1.7782E-08 3.8300 0.6144 2438.3010 807.5562 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

13.6215 1.7782E-08 3.8300 0.6144 2438.3010 807.5562 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

4051.6404 15.3633 62246.5703

2861.8179 18.0150 51555.6445

3282.1172 8.6634 28434.2793

3284.2114 8.6694 28472.0078

100.00 266.000 -0.3685

100.00 266.000 1.2384

100.00 254.000 -1.8235

100.00 254.000 -1.8216


36900.7617 718.6578

N/A N/A

29892.2422 384.3220

29892.2422 384.3220


N/A N/A

103.6961 8.2864

N/A N/A

0.0759 8.2864


17 MEA FEED WET VAPOR

18

19A

49


20

21

21X

WET VAPOR

WET VAPOR

WET VAPOR

22 METH PROD WET VAPOR

WET VAPOR

WET VAPOR

WET VAPOR

METH PROD WET VAPOR

11.5273 1.7782E-08 3.8300 0.6144 2438.3010 807.5562 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

11.5273 1.7782E-08 3.8300 0.6144 2438.3010 807.5562 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

11.5273 1.7782E-08 3.8300 0.6144 2438.3010 807.5562 9.5848 10.7034 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

16.5861 1.7782E-08 4.6197E-07 0.0000 2424.3533 807.5562 9.5848 15.1478 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

3282.1172 8.6634 28434.2793

3282.1172 8.6634 28434.2793

3282.1172 8.6634 28434.2793

3273.2283 8.6869 28434.2773

574.15 252.000 1.5161

675.00 254.000 2.2320

675.00 250.000 2.2319

692.54 252.000 2.3955


29892.2422 206.8127

29892.2422 189.9177

29892.2422 187.1087

29811.2871 186.1654


N/A N/A

N/A N/A

N/A N/A

N/A N/A


50


23

24

24W

WET VAPOR

MIXED

WATER

25 SYN GAS WET VAPOR

WET VAPOR

MIXED

WATER

SYN GAS WET VAPOR

16.5861 1.7782E-08 4.6197E-07 0.0000 2424.3533 807.5562 9.5848 15.1478 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

16.5861 1.7782E-08 4.6197E-07 0.0000 2424.3533 807.5562 9.5848 15.1478 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

4.9339 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

11.6522 1.7782E-08 4.6197E-07 0.0000 2424.3535 807.5562 9.5848 15.1478 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

3273.2283 8.6869 28434.2773

3273.2283 8.6869 28434.2773

4.9339 18.0150 88.8840

3268.2944 8.6728 28345.3926

219.26 250.000 -0.9532

100.00 250.000 -1.8166

100.00 250.000 1.2376

100.00 250.000 -1.8213


29811.2871 312.9745

29766.3516 379.0680

N/A N/A

29766.3516 379.0680


N/A N/A

0.1788 8.2864

0.1788 8.2864

N/A N/A


51


26

27

28

28A

WET VAPOR

WET VAPOR

DRY VAPOR

MIXED

WET VAPOR

WET VAPOR

DRY VAPOR

MIXED

3.7226 1.7782E-08 4.6197E-07 0.0000 2424.3535 807.5562 9.5848 15.1478 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

1.3472 1.7782E-08 4.6197E-07 0.0000 2424.3535 807.5563 9.5848 15.1478 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

0.0000 1.7782E-08 4.6197E-07 0.0000 2424.3535 807.5562 9.5848 15.1478 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

1.3472 1.7782E-08 4.6197E-07 0.0000 2424.3535 807.5563 9.5848 15.1478 6.4171E-07 1.2904E-08 9.7896E-09 7.8864E-09 0.0000

3260.3650 8.6501 28202.5430

3257.9895 8.6433 28159.7480

3256.6423 8.6394 28135.4785

3257.9895 8.6433 28159.7480

95.00 695.000 -1.9132

95.00 1945.000 -1.9287

95.00 4955.000 -1.8808

95.00 4955.000 -1.8764


29694.1328 1007.7769

29672.4961 2655.5073

29660.2266 5954.0464

29665.0645 5955.4702


N/A N/A

N/A N/A

N/A N/A

0.0295 8.2944


52


DRY VAPOR

31 PRI SEP DRY VAPOR

DRY VAPOR

DRY VAPOR

DRY VAPOR

PRI SEP DRY VAPOR

DRY VAPOR

0.0000 6.2984E-07 3.2600E-05 0.0000 6098.3706 2101.1882 727.6615 879.5476 2.4716E-05 4.8126E-07 3.6172E-07 3.2516E-07 2106.1777

0.0000 6.2984E-07 3.2600E-05 0.0000 6098.3706 2101.1882 727.6615 879.5476 2.4716E-05 4.8126E-07 3.6172E-07 3.2516E-07 2106.1777

0.0000 6.1825E-07 3.2391E-05 0.0000 6079.1968 2095.6528 723.6483 871.4004 2.4296E-05 4.7263E-07 3.5508E-07 3.1995E-07 911.4990

0.0000 6.1825E-07 3.2391E-05 0.0000 6079.1968 2095.6528 723.6483 871.4004 2.4296E-05 4.7263E-07 3.5508E-07 3.1995E-07 911.4990

11912.9453 12.6085 150204.4220

11912.9453 12.6085 150204.4220

10681.3975 12.1120 129373.1090

10681.3975 12.1120 129373.1090

430.00 4700.000 2.8194

924.35 4730.000 7.0395

85.00 4660.000 -0.9457

85.00 4660.000 -0.9726


108498.4690 5574.7974

108498.4690 3661.2556

97281.9922 8445.1504

97281.9922 8494.1504


N/A N/A

N/A N/A

N/A N/A

N/A N/A


29

29A

DRY VAPOR

31A

53


31P PURGE DRY VAPOR

31R RECYCLE DRY VAPOR

31RA

31RB

DRY VAPOR

DRY VAPOR

PURGE DRY VAPOR

RECYCLE DRY VAPOR

DRY VAPOR

DRY VAPOR

0.0000 4.2418E-09 2.2224E-07 0.0000 41.7089 14.3781 4.9649 5.9786 1.6670E-07 3.2427E-09 2.4362E-09 2.1952E-09 6.2537

0.0000 6.1460E-07 3.2200E-05 0.0000 6043.2681 2083.2673 719.3715 866.2504 2.4153E-05 4.6984E-07 3.5298E-07 3.1806E-07 906.1120

0.0000 6.1401E-07 3.2169E-05 0.0000 6037.4878 2081.2749 718.6834 865.4218 2.4130E-05 4.6939E-07 3.5264E-07 3.1775E-07 905.2454

0.0000 6.1460E-07 3.2200E-05 0.0000 6043.2681 2083.2673 719.3715 866.2504 2.4153E-05 4.6984E-07 3.5298E-07 3.1806E-07 906.1120

RATE, LB-MOL/HR MOLECULAR WEIGHT RATE, LB/HR

73.2843 12.1120 887.6198

10618.2695 12.1120 128608.4920

10608.1133 12.1120 128485.4920

10618.2695 12.1120 128608.4920

TEMPERATURE, F PRESSURE, PSIG ENTHALPY, M BTU/LB-MOL

85.00 4660.000 -0.9726

85.00 4660.000 -0.9726

85.00 4660.000 -0.9726

85.00 4660.000 -0.9726


667.4450 8494.1113

96707.0547 8494.1113

96614.5625 8494.1113

96707.0547 8494.1113


N/A N/A

N/A N/A

N/A N/A

N/A N/A

NAME PHASE COMP. MOLE RATES, LB-MOL/HR 1 H2O 2 O2 3 CO 4 CO2 5 H2 6 N2 7 A 8 C1 9 C2 10 C3 11 NC4 12 NC5 13 NH3

54


31X

32

32A

33

DRY VAPOR

DRY LIQUID

DRY LIQUID

DRY VAPOR

DRY VAPOR

DRY LIQUID

DRY LIQUID

DRY VAPOR

0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 4.9649 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

0.0000 1.1588E-08 2.0848E-07 0.0000 19.1734 5.5356 4.0131 8.1472 4.1987E-07 8.6308E-09 6.6437E-09 5.2145E-09 1194.6786

0.0000 1.1588E-08 2.0848E-07 0.0000 19.1734 5.5356 4.0131 8.1472 4.1987E-07 8.6308E-09 6.6437E-09 5.2145E-09 1194.6786

0.0000 6.1450E-07 3.2173E-05 0.0000 6044.3154 2083.5227 718.6836 865.7172 2.4145E-05 4.6967E-07 3.5283E-07 3.1788E-07 906.0308

RATE, LB-MOL/HR MOLECULAR WEIGHT RATE, LB/HR

4.9649 39.9480 198.3378

1231.5481 16.9147 20831.3164

1231.5481 16.9147 20831.3164

10618.2705 12.1094 128580.3440

TEMPERATURE, F PRESSURE, PSIG ENTHALPY, M BTU/LB-MOL

85.00 4660.000 -1.7133

85.00 4660.000 1.0303

85.00 4660.000 1.0093

94.07 4950.000 -0.8987


45.2184 30750.1934

N/A N/A

N/A N/A

96707.0625 8759.1260


N/A N/A

71.0096 4.8893

71.0096 4.8893

N/A N/A

NAME PHASE COMP. MOLE RATES, LB-MOL/HR 1 H2O 2 O2 3 CO 4 CO2 5 H2 6 N2 7 A 8 C1 9 C2 10 C3 11 NC4 12 NC5 13 NH3

55


36A

37

MIXED

36 SEC SEP DRY VAPOR

DRY VAPOR

DRY LIQUID

MIXED

SEC SEP DRY VAPOR

DRY VAPOR

DRY LIQUID

0.0000 6.3229E-07 3.2635E-05 0.0000 8468.6689 2891.0789 728.2684 880.8651 2.4787E-05 4.8257E-07 3.6262E-07 3.2577E-07 906.0308

0.0000 6.2984E-07 3.2600E-05 0.0000 8465.1289 2890.1082 727.6615 879.5476 2.4716E-05 4.8126E-07 3.6172E-07 3.2516E-07 528.3845

0.0000 6.2984E-07 3.2600E-05 0.0000 8465.1289 2890.1082 727.6615 879.5476 2.4716E-05 4.8126E-07 3.6172E-07 3.2516E-07 528.3845

0.0000 2.4445E-09 3.4768E-08 0.0000 3.5391 0.9700 0.6067 1.3171 7.0651E-08 1.3116E-09 9.0112E-10 6.0634E-10 377.6484

13874.9131 11.2949 156715.8280

13490.8311 11.1338 150204.4380

13490.8311 11.1338 150204.4380

384.0815 16.9532 6511.4072

54.90 4900.000 -1.4778

40.00 4840.000 -1.7863

40.00 4840.000 -1.7998

40.00 4840.000 0.1345


125550.4450 8538.7656

122869.2340 8499.6279

122869.2340 8525.0176

N/A N/A


4.9682 5.1201

N/A N/A

N/A N/A

20.7735 5.2241


56

34


DRY LIQUID

38 RX FEED DRY VAPOR

DRY VAPOR

39 LET DWN GAS DRY VAPOR

DRY LIQUID

RX FEED DRY VAPOR

DRY VAPOR

LET DWN GAS DRY VAPOR

0.0000 2.4445E-09 3.4768E-08 0.0000 3.5391 0.9700 0.6067 1.3171 7.0651E-08 1.3116E-09 9.0112E-10 6.0634E-10 377.6484

0.0000 6.2984E-07 3.2600E-05 0.0000 8465.1289 2890.1082 727.6615 879.5476 2.4716E-05 4.8126E-07 3.6172E-07 3.2516E-07 528.3845

0.0000 6.2984E-07 3.2600E-05 0.0000 8465.1289 2890.1082 727.6615 879.5476 2.4716E-05 4.8126E-07 3.6172E-07 3.2516E-07 528.3845

0.0000 9.7714E-09 2.1355E-07 0.0000 21.2506 6.0712 3.2630 7.5173 2.8712E-07 4.9529E-09 3.1406E-09 2.2444E-09 31.9782

384.0815 16.9532 6511.4072

13490.8311 11.1338 150204.4380

13490.8311 11.1338 150204.4380

70.0804 14.3904 1008.4857

40.00 4840.000 0.1229

85.00 4790.000 -1.4413

567.41 4760.000 2.2853

78.89 350.000 3.4674


N/A N/A

122869.2340 7779.4751

122869.2340 4269.7148

638.2646 960.9985


20.7735 5.2241

N/A N/A

N/A N/A

N/A N/A


37A

38B

57

simulation Ammonia plant on PRO II

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