CHE 397CHE 397Group CharlieGroup Charlie

Priya Chetty, Scott Morgan, Brian Mottel, Priya Chetty, Scott Morgan, Brian Mottel, Daniyal Qamar, Sukhjinder SinghDaniyal Qamar, Sukhjinder Singh

Mentor: Dennis O’ BrienMentor: Dennis O’ Brien Dr. Jeffery PerlDr. Jeffery Perl

BLOCK FLOW DIAGRAM

MS Compressor HX

Water

Splitter Reactor Condenser Flash

Distillation I Distillation II

Higher Alcohols

Hot Feed

Cold Syngas

Grade AA Methanol

Crude Methanol

Recycle Stream

Low Key impurities

SCHEMATIC FLOW DIAGRAM

MATERIAL AND ENERGY BALANCESREACTOR

MATERIAL AND ENERGY BALANCE

Material Balance Reactor

ComponentMole Flow

Composition In

Feed to Reactor

(lbmol/hr)

Purge (lbmol/hr)

Recycle (lbmol/hr)

Product Out (lbmol/hr)

M Tons per day

CO lbmol/hr .32 7675.84 187.434 7300.97116 0 0

H2 lbmol/hr .66 15831.42 253.426 75641.534 0 0

CO2 lbmol/hr .02 479.74 462.976 4546.87986 0 0

CH3OH lbmol/hr 0 0 0 0 7488.406 2608.653

H2O lbmol/hr 0 0 0 0 181.2046 35.50739

MATERIAL AND ENERGY BALANCE

Energy Balance Reactor

ComponentTemperature (F)

inPressure (psi) in

Enthalpy (Btu/lbmol) in

Temp(F) out

Enthalpy (Btu/lbmol) out

CO 482 1200 2.57190E+08 489.23 2.616E+08

H2 482 1200 1.5378E+09 489.23 1.56E+09

CO2 482 1200 1.19E+08 489.23 1.215E+08

CH3OH 0 0 0 489.23 2.34806E+08

H2O 0 0 0 489.23 5.78894E+06

Reaction 1 482 288745426.9

Reaction 2 482 1113130.387

Total 2.2E+09 2.18E+09

HAND CALCULATIONS AND DATA REACTOR

Reactor Material Balance

Assumptions: 100% separation of all feed gases (CO, H2, CO2)

and products (CH3OH, H2O) Purge Concentrations are controllable for now No Nitrogen or Water in feed syngas Other side reactions ignored Pressure effects on Cp

Hand Calculations Reactor

Reaction 1: CO +H2 ↔ CH3OH ΔHrxn = -38559 Btu/lbmol

Reaction 2: CO2 +3H2 ↔ CH3OH + H20 ΔHrxn = -21324.1 Btu/lbmol

Reaction 1 Conv = 0.5 Reaction 2 Conv = .04 Material Balance:

COout = COfeed + COrec– .5(COfeed + COrec) – COpurge

CO2out = (CO2 feed + CO2rec) – 0.04 (CO2 feed + CO2rec) – CO2 purge

CH3OHout = .5(COout + COfeed) + .04(CO2out + CO2 feed)

Energy Balance Enthalpy in (BTU) : H = Δ Href + ∫Cpdt for each component Where Cp was used for gases: Cp = A + BT + CT2 +DT3

Enthalpy of reaction = .5(ΔHrxn1)COin + .04(ΔHrxn2)CO2in

Data Reactor

Component IN (lbmol/hr) Reaction 1 2 3 4 5 6 7

100+

CO 7675.84 3837.92 5569.4455826435.20837

36868.08976

97084.5304

77192.75

17246.8609

9 7300.971

H2 15831.42 8098.0112 12049.4102214271.7853

815626.3860

616546.093

717247.3

517838.372

11 75641.53

CO2 479.74 460.5504 439.7027721456.466760

2473.230748

4489.99473

6506.758

7523.52271

27 4546.88

CH3OH 0 3857.1096 5794.4916166659.42050

27055.52418

77271.9648

87380.18

57434.2954

08 7488.406

H2O 0 19.1896 18.42201617.5881108

818.2586704

118.929229

919.5997

920.270348

98 181.2046

Purge (lbmol/hr)

CO 187.4344

H2 253.4261

CO2 462.976

Enthalpies In Btu/lbmol Flows In (lbmol/hr) Total In (Btu)

CO 1.72E+04 14976.81116 2.57190E+08

H2 1.68E+04 91472.95398 1.53777E+09

CO2 2.37E+04 5026.619862 1.19327E+08

CH3OH 3.08E+04 0 0.00000E+00

H20 3.13E+04 0 0.00000E+00

1.20E+05 1.11E+05 1.91428E+09

MATERIAL AND ENERGY BALANCESDISTILLATION COLUMN

Material Balance

Material Balance Distillation Column

ComponentFeed

Composition

Amount in feed

(LB-MOL/Hr)

Distillate Composition

Amount in Distillate

(LB-Mol/Hr)

Bottoms Composition

Amount in Bottoms

(LB-Mol/Hr)

Methanol 0.9764 7488.405 0.995 7450.963 0.172 37.442

Water 0.0236 181.205 0.005 0.906 0.828 180.299

Total 1.00 7669.61 1.00 7451.87 1.00 217.74

Energy Balance

HAND CALCULATIONS AND DATA DISTILLATION COLUMN

Distillation Column Material Balance

Assumptions 7669.62 lb-Moles/Hr of Methanol/H20 in feed

Feed composition 97.6% Methanol, 2.4% H20 Feed Pressure is 14.7psia 99.5% Methanol in Distillate

Hand Calculations Distillation Column

Material Balance F = B + D Fz = BxB + DxD

Energy Balance Fhf + QC + QR = DhD +BhB

Q = mCPΔT

MATERIAL AND ENERGY BALANCEHEAT EXCHANGER

MATERIAL BALANCE AND DATA for HEAT EXCHANGER

Crude In Temperature (F)Flow-Ratelbmol/hr (in/out)

Temperature Out (F)

MeOH 515 31.22 482

Water 515 .7554 482

Syngas In Temperature (F)Flow-Ratelbmol/hr(in/out)

Temperature Out (F)

H2 482 6.6 505

CO 482 3.2 505

CO2 482 2 505

Hand Calculations HX

Q = Σ miCpiΔT T(Syngas in) = 482 ˚F T(Crude MeOH in) = 515 ˚F Crude MeOH in = 31.22 lbmol/hr Water in = .7554 lbmol/hr Syngas Compositions ( H2 = 6.6, CO = 3.2, CO2 = 2)

Q = 31.22lbmol/hr(267)(482-515) +.7554lbmol/hr(271)(482-515) Q = -281834.9622 Btu/hr

= 6.6(122)(T-482) + 3.2(126)(T-482) + 2(188)(T-482) = 8052T - 388106.4 + 403.2T – 194342.4 + 37.6T – 18123.2

281834.96 Btu/hr = 100 (125) (T-482) T(Syngas out) = 505 ˚F

Methanol 267

H2O 271

Cp Values (Btu/lbmol°F

ECONOMIC ANALYSIS

Fixed Capital Cost

Table 1.1: Estimate costs of specific units in the process flow diagram

Unit Type Description Base Cost/unit No. of units Total Cost $

Pumps

P-100 Pump 17,237,109 3 51,711,327

Compressors

CMP-200 Compressor 46,311,255 1 46,311,255

Reactors

R-300 MSR 16,392,569 1 16,392,569

HEX

C-200 Heat Exchanger 8,948,014 1 8,948,014

C-300 Heat Exchanger 182,177 1 182,177

Separators

U-200 Flash unit 698,198 2 1,396,396

D-100 Distillation tower 581,086 2 1,162,172

Storage Tanks

Floating roof Storage Tank 430,558 7 3,013,906

Total$169,507,011

Amirkhas, Elton , and Raj Bedi. "METHANOL PRODUCTION IN TRINIDAD & TOBAGO." Phase II Design Report 07062006. n. pag. Web. 15 Feb 2011.

Cost Factor Annual Cost

Feed stocks (raw materials) Syngas Feed water make-up Total

$ 6,102 $ 364,001 $ 370,103

Utilities Electricity Cooling water, 90F, 65psig (CW) Chilled cooling water, 60F Total

$7,634,000 $7,769,894 $90,009,785 $105,413,679

Operations (labor-related) Direct wages and benefits Direct salaries and benefits Operating supplies and services Control laboratory Total

$1,048,320 $209,664 $4,504,177 $78,624 $5,840,785

Maintenance Wages and benefits Materials and services Total

$15,260,000 $18,767,405 $34,027,405

Depreciation $665,018,119 (entire plant life)

Cost of Manufacture $183,764,004

Total General Expenses $10,764,720

Total Production Cost $155,622,979

Sales Methanol Product Total Sales

$215,294,400

Operating CostTable 1.2: Estimate plant costs and operations

Harkins, John. "WHAT IS UNDERGROUND COAL GASIFICATION (UCG)? ." Clean Global Energy (2010): n. pag. Web. 15 Feb 2011

Capital InvestmentTable 1.3: Annual costs

Cost Factor Typical factor in American engineering units

Utilities

Steam, 300psig $2.40/ 1000lbs

Electricity $0.04/KWh

Cooling water $0.05/ 1000gal

Waste treatment $3.00/ 1000gal

MSR catalyst price $6.00/ lb

feed water make-up $1.50/ 1000gal

Bell, David, and Brian Towler. Coal Gasification and Its Applications. William Andrew, 2010. Print.

Future Goals Include side reactions Account for by products Refine calculations using more accurate

conditions Reaction kinetics Economics consistent with our project Distillation column specifics Sizing of equipment Heat exchangers and pumps Compressor

QUESTIONS?