![Page 1: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/1.jpg)
SUPERPRO-BASED AMMONIA PLANT RETROFIT
REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE
NORTH CAROLINA STATE UNIVERSITYDEPARTMENT OF CHEMICAL ENGINEERING
SPRING 2004
R. BARNHILLE. FABRICIUSA. HERRMANND. JONES
![Page 2: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/2.jpg)
PROJECT OVERVIEW Objective: make 3000 metric tons of liquid
ammonia per day Two options for SuperPro simulation
Single-pressure process Dual-pressure process
Compare and contrast Economics (capital and operational) Environmental (emissions and solid/liquid)
Determine the most profitable process
![Page 3: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/3.jpg)
KINETICS SUPPLIED
Equation:
Constants: K1 = k01exp(-E1/RT)
K2 = k02exp(-E2/RT)
K01 = 1.78954*104 kgmol/m3-hr-atm1.5
K02 = 2.5714*1016 kgmol-atm0.5/m3-hr
E1 = 20,800 kcal/kgmol
E2 = 47,400 kcal/kgmol
)1(
/
3
2
3
5.12
232
5.121
3
N
HNHHN
PK
PPKPPKfK
![Page 4: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/4.jpg)
CHALLENGES WITH SUPERPRO
Rate equation proves to be incompatible with given data SuperPro only accepts
simplified kinetics However, SuperPro
offers extent of reaction option
![Page 5: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/5.jpg)
ASPEN THEORY
Supply SuperPro with extent of reaction Optimize through analysis of critical parameters that affect
the rate of reaction
Advantages Basic Aspen simulation with one piece of equipment Aspen supports supplied kinetics
Disadvantages Basic knowledge of Aspen required Iterative process between two simulation systems
![Page 6: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/6.jpg)
ASPEN SIMULATION: STEP 1
Setup Aspen to run ammonia reaction with supplied kinetics
![Page 7: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/7.jpg)
ASPEN SIMULATION: STEP 2
Run simulations varying critical parameters Temperature Pressure Reactor Size Composition of inlet stream
Study the relationship between the different parameters of the reaction Plotting the information and studying trends
works well
![Page 8: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/8.jpg)
ASPEN SIMULATION: STEP 3
Simulate the reactor at an “initial composition” obtained
Record SuperPro required Data Temperature Pressure Reactor Size Extent of Reaction
![Page 9: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/9.jpg)
SUPERPRO SIMULATION: STEP 1
Plug the results from Aspen reactor simulation into SuperPro simulation (shown on next two slides) Conduct mass and energy balances
![Page 10: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/10.jpg)
SUPERPRO SIMULATION: STEP 1a
Set Aspen operating temperature of the reactor
![Page 11: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/11.jpg)
SUPERPRO SIMULATION: STEP 1b
Set the extent of reaction that agrees with the Aspen data
![Page 12: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/12.jpg)
SUPERPRO SIMULATION: STEP 2
Study the effects that the new outlet stream (from the reactor) has on the inlet stream
Take new inlet stream data and plug back into Aspen and re-run the simulations This step is the final step in the cycle between
Aspen and SuperPro – this cycle is to be repeated several times until optimal results are obtained
![Page 13: SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE](https://reader036.vdocuments.us/reader036/viewer/2022082612/56813e03550346895da7e04f/html5/thumbnails/13.jpg)
SUMMARY AND KEY POINTS
Iterations between Aspen and SuperPro require the use of multiple sets of data Keep accurate records
Optimize the system based on costs Cost of pressurizing the feed stream
Cost of compressors Energy cost of the compressors
Cost of cooling the reactor to the optimal temperature Cost of the reactor (size dependent)