THE HIGHER TECHNOLOGICAL INSTITUTE

TENTH OF RAMADAN CITY

CHEMICAL ENGINEERING DEPARTMENT

PRODUCTION OF HYDROGEN
''Steam Reforming''

Amr Hisham Mohamed Ramadan

20110625

Dr.Maher Gamal
Dr.Noura Yehia

B.S.C
May – Aug 2018
 Acknowledgment
There are a number of people without their help this project might not have been
accomplished, and to whom I am greatly indebted.

I would like to thank my supervisor, Dr. Maher Gamal and Dr.Noura Yehia
who taught me that even the largest task can be accomplished if it is done one step
at a time and whose advice and patience encouragement aided the writing of this
project in innumerable ways.

Also I would like to thank Dr. Mustafa Azab and for their valuable suggestions,
helping me in support of this project as it was greatly needed deeply appreciated.

To my advisors, Dr.Soad and Dr.Maha special thanks for helping me. Their
encouragement and guidance through this research project and their support did not
go unnoticed.

I would like also to thank Dr.Noha for helping me in all thing in the technical
part of the project (special thanks for Dr.Noha).

I am also very grateful to Eng.Mohamed Yehia for his help and his patience
during this project, Particularly ,his huge help in devising the control system
of the project (learning from you a lot , really you are best big brother ).

Most of all thanks to GOD, who continues to make this project.

I
 Abstract
The objective of this project is to develop Steam reforming of methane is the
main industrial route to produce hydrogen and synthesis gas (a mixture of
hydrogen and carbon monoxide) Syngas, or synthesis gas, is a fuel gas mixture
consisting primarily of hydrogen, carbon monoxide, and very often some carbon
dioxide.

The name comes from its use as intermediates in creating synthetic natural gas
and for producing ammonia or methanol.

Syngas is combustible and often used as a fuel of internal combustion engines.

Steam methane reforming is used to produce synthesis gas .

Material balance was made for the complete process starting from the raw
materials ( methane and H2O ) and ending with the products (CH4 , CO ,
CO2 and H2 ) .

Material balance was made on reactor (reformer), separator (Knockout),

absorber, and stripper.

Methane will mix with steam at 400 ℃ and then reacted in reformer at 800 ℃ to
produce ( CH4 , CO2 , CO , H2 and H2O ) The products will enter to knockout
to separate water from the gases.

In absorber column, CO2 amount will decrease approximately 95% of the feed
to the absorber by react with Mono ethanol amine with water coming from
stripper ''In continuous process''.

II
3
 List of Contents
Chapter one Introduction..............................................................................................................1
1.1 History.............................................................................................................................................. 2
1.2 Physical Properties ......................................................................................................................... 3
1.3 Chemical Properties ....................................................................................................................... 5
1.4 Methods Of Production.................................................................................................................. 6
1.5 Handling And storage .................................................................................................................. 10
1.6 Safety.............................................................................................................................................. 11
Chapter Two Process Description ..............................................................................................13
2.1 Process Description “Steam Reforming’’.................................................................................. 14
Chapter Three Mass Balance ......................................................................................................20
3.1 Pressure swing adsorption (PSA) ........................................................................................22
3.2 Cold process condensate drum (flash drum) ......................................................................23
3.3 Hot process condensate drum (flash drum) .........................................................................24
3.4 Co conversion reactor..........................................................................................................24
3.5 Steam reformer ....................................................................................................................25
3.6 Pre-reformer ........................................................................................................................26
3.7 Desulfurization ....................................................................................................................28
3.8 Hydrogenation.....................................................................................................................28
Chapter Four Heat Balance .......................................................................................................30
4.1 Heat balance around reactors .............................................................................................34
4.2 Heat balance around heat exchangers .................................................................................50
Chapter Five Special Design .......................................................................................................54
Chapter Six Cost Estimation.......................................................................................................62
6.1 Calculation cost of the equipment .......................................................................................63
6.2 Cost of labor .......................................................................................................................70
6.3 Cost of utilities ....................................................................................................................70
6.4 Cost of raw material ............................................................................................................71
Chapter Seven Layout .................................................................................................................72
Chapter Eight Control .................................................................................................................81
Conclusion ....................................................................................................................................83
References .....................................................................................................................................84

III
 List of Figures
(1.1) Hydrogen structure .............................................................................................................2
(1.2) Methods of production........................................................................................................6
(1.3) Auto thermal reforming ......................................................................................................7
(1.4) Production from coal ..........................................................................................................8
(1.5) Biomass to hydrogen ..........................................................................................................9
(1.6) Handling and storage ........................................................................................................10
(5.1) Reactor type ......................................................................................................................60
(5.2) Catalyst type .....................................................................................................................61

List of Tables
(1.1) Physical properties ..............................................................................................................4
(3.1) Mass balance on (PSA)unit ..............................................................................................22
(3.2) Mass balance on cold process condensate ........................................................................23
(3.3) Mass balance on hot process condensate ..........................................................................24
(3.4) Mass balance on CO conversion .....................................................................................25
(3.5) Mass balance on steam reformer ......................................................................................26
(3.6) Mass balance on prereformer............................................................................................27
(3.7) Mass balance on desulfurization.......................................................................................28
(3.8) Mass balance on hydrogenation .......................................................................................29
(4.1) Vapor constant & delHF ...................................................................................................32
(4.2) Antoine’s constant ............................................................................................................33

IV
Chapter One

Introduction

1
1.1 Introduction
Hydrogen (H), a colorless, odorless, tasteless, flammable gaseous substance that is the simplest
member of the family of chemical elements. The hydrogen atom has a nucleus consisting of a
proton bearing one unit of positive electrical charge; an electron, bearing one unit of negative
electrical charge, is also associated with this nucleus. Under ordinary conditions, hydrogen gas is
a loose aggregation of hydrogen molecules, each consisting of a pair of atoms, a diatomic
molecule, H2. The earliest known important chemical property of hydrogen is that it burns with
oxygen to form water, H2O; indeed, the name hydrogen is derived from Greek words meaning
―maker of water.‖

Figure (1.1)

Although hydrogen is the most abundant element in the universe (three times as abundant
as helium, the next most widely occurring element), it makes up only about 0.14 percent
of Earth’s crust by weight. It occurs, however, in vast quantities as part of the water in
oceans, ice packs, rivers, lakes, and the atmosphere. As part of innumerable carbon compounds,
hydrogen is present in all animal and vegetable tissue and in petroleum. Even though it is often
said that there are more known compounds of carbon than of any other element, the fact is that,
since hydrogen is contained in almost all carbon compounds and also forms a multitude of
compounds with all other elements (except some of the noble gases), it is possible that hydrogen
compounds are more numerous.

2
Elementary hydrogen finds its principal industrial application in the manufacture of ammonia
(a compound of hydrogen and nitrogen, NH3) and in the hydrogenation of carbon monoxide and
organic compounds.

Hydrogen has three known isotopes. The mass numbers of hydrogen’s isotopes are 1, 2, and 3,
the most abundant being the mass 1 isotope generally called hydrogen (symbol H, or 1H) but also
known as protium. The mass 2 isotope, which has a nucleus of one proton and one neutronand
has been named deuterium, or heavy hydrogen (symbol D, or 2H), constitutes 0.0156 percent of
the ordinary mixture of hydrogen. Tritium (symbol T, or 3H), with one proton and two neutrons
in each nucleus, is the mass 3 isotope and constitutes about 10−15 to 10−16 percent of hydrogen.

1.2 Physical Properties

The Table lists the important properties of molecular hydrogen, H2. The extremely low melting
and boiling points result from weak forces of attraction between the molecules. The existence of
these weak intermolecular forces is also revealed by the fact that, when hydrogen gas expands
from high to low pressure at room temperature, its temperature rises, whereas the temperature of
most other gases falls. According to thermodynamic principles, this implies that repulsive forces
exceed attractive forces between hydrogen molecules at room temperature—otherwise, the
expansion would cool the hydrogen. In fact, at −68.6° C attractive forces predominate, and
hydrogen, therefore, cools upon being allowed to expand below that temperature. The cooling
effect becomes so pronounced at temperatures below that of liquid nitrogen (−196° C) that the
effect is utilized to achieve the liquefaction temperature of hydrogen gas itself.

Hydrogen is transparent to visible light, to infrared light, and to ultraviolet light to wavelengths
below 1800 Å. Because its molecular weight is lower than that of any other gas, its molecules
have a velocity higher than those of any other gas at a given temperature and it diffuses faster
than any other gas. Consequently, kinetic energy is distributed faster through hydrogen than
through any other gas; it has, for example, the greatest heat conductivity.

A molecule of hydrogen is the simplest possible molecule. It consists of two protons and two
electrons held together by electrostatic forces. Like atomic hydrogen, the assemblage can exist in
a number of energy levels.

3
Some properties of normal hydrogen and deuterium

Table (1.1)

4
1.3 Chemical properties:

1.3.1 Action with indicators:

It does not show any reaction with litmus and hence is neutral towards litmus paper and other
indicators.
1.3.2 Combustibility:
Hydrogen is a inflammable and combustible gas. It is non-supporter of combustion.
It gives pale blue flame in air or oxygen to form water. So, hydrogen is also called water gas.

2H2+O2⟶H2O
1.3.3 Reaction with halogen:
Hydrogen does not react with halogens at ordinary temperature. But at high temperature in the
presence of catalyst, hydrogen react to give their respective halides.

H2+F2⟶2HF
H2+Cl2⟶2HCl
H2+Br2⟶2HBr
H2+I2⟶2Hl
Note: The reactivity order of hydrogen with other halides is: F2 > Cl2 > Br2 > I2.
1.3.4 Reaction with metals:
It reduces metal oxides to metals, when heated.

CuO+H2⟶ΔCu+H2O
PbO+H2⟶ΔPb+H2O
ZnO+H2⟶ΔZn+H2O
Fe2O3+4H2⟶Δ3Fe+4H2O

5
1.4 Method of Production

Figure (1.2)

Hydrogen can be produced from a variety of feed stocks. These include fossil resources, such as
natural gas and coal, as well as renewable resources, such as biomass and water with input from
renewable energy sources (e.g. sunlight, wind, wave or hydro-power). A variety of process
technologies can be used, including chemical, biological, electrolytic, photolytic and thermo-
chemical. Each technology is in a different stage of development, and each offers unique
opportunities, benefits and challenges.

Steam reforming this method accounts for about 95% of the hydrogen produced in the United
States.

1.4.1 Production from natural gas

Hydrogen can currently be produced from natural gas by means of three different chemical
processes:

1.4.1.1 Steam reforming (steam methane reforming – SMR).

Steam reforming involves the endothermic conversion of methane and water vapor into hydrogen
and carbon monoxide (1.1). The heat is often supplied from the combustion of some of the
methane feed-gas. The process typically occurs at temperatures of 700 to 900 °C and pressures of
20 to 40 bars. The product gas contains approximately 12 % CO, which can be further converted
to CO2 and H2 through the water-gas shift reaction (1.2).

CH4 + H2O + heat ➞ CO + 3H2 (1.1)

CO + H2O ➞ CO2 + H2 + heat (1.2)

6
1.4.1.2 Partial oxidation (POX):
Partial oxidation of natural gas is the process whereby hydrogen is produced through the partial
combustion of methane with oxygen gas to yield carbon monoxide and hydrogen (1.3). In this
process, heat is produced in an exothermic reaction, and hence a more compact design is possible
as there is no need for any external heating of the reactor. The CO produced is further converted
to H2 as described in equation (1.2).

CH4 + 1/2O2 ➞ CO + 2H2 + heat (1.3)

1.4.1.3 Auto thermal reforming (ATR).

Auto thermal reforming is a combination of both steam reforming (1.1) and partial oxidation
(1.3). The total reaction is exothermic, and so it releases heat. The outlet temperature from the
reactor is in the range of 950 to 1100 °C, and the gas pressure can be as high as 100 bar. Again,
the CO produced is converted to H2 through the water-gas shift reaction (1.2). The need to purify
the output gases adds significantly to plant costs and reduces the total efficiency.

Figure (1.3)

7
1.4.2 Production from coal
Another process is charcoal gasification1. Charcoal consists mainly of carbon and water. Burned
in a reactor at a very high temperature of between 1,200 and 1,500 °C, the charcoal releases gas
that separates and reforms to produce hydrogen (H2) and carbon monoxide (CO).

Hydrogen can be produced from coal through a variety of gasification processes (e.g. fixed bed,
fluidized bed or entrained flow). In practice, high-temperature entrained flow processes are
favored to maximize carbon conversion to gas, thus avoiding the formation of significant
amounts of char, tars and phenols. A typical reaction for the process is given in equation (1.4), in
which carbon is converted to carbon monoxide and hydrogen.

C(s) + H2O + heat ➞ CO + H2 (1.4)

Figure (1.4)

8
1.4.3 BIOMASS TO HYDROGEN
Many types of organic matter can be burned to produce bio gas. Although wood (in the form of
charcoal) is the main feedstock used, plant waste such as straw is also suitable. Because biomass
sources can be replanted, the carbon footprint is low.

The simulation predicted 95 % hydrogen in the product gas. Steam gasification with CO2
adsorption using CaO as sorbent. The Empty Fruit Bunch (EFB) is pretreated prior to
gasification, the moisture is removed through drying and the EFB is subsequently grinded. The
EFB and sorbent are fed into the gasifier at atmospheric temperature. The steam produced in a
steam generator is superheated to 523 K and forward to the system. The gasification process is
integrated with CO2 adsorption step and six major reactions listed in Table 1 are assumed to take
place in the gasifier. As the steam gasification process is endothermic, external energy, Q r , is
supplied. Fly ash and other solid particulates are removed from the product gas using a filter.
Next the product gas is cooled down by passing it through a scrubber. Finally a pressure swing
adsorption unit is used to purify the product gas to achieve 99.99 % pure hydrogen.

Figure (1.5)

1.4.4 Hydrogen from electricity

Hydrogen can also be produced using electricity, through electrolysis of water. An electric
current is used to split water (H2O) into oxygen (O2) and hydrogen (H2). This method is not as
cost-effective as using fossil fuels. Hydrogen produced by steam methane reforming costs
around €1.5 per kilogram at the plant gate (excluding distribution costs), triple the cost of natural
gas. Hydrogen produced using electrolysis is currently around four times more expensive, even
before the cost of the electricity required is factored in.

9
1.5 Handling and Storage:
1.5.1 Transportation:
When hydrogen is being transported, it is compressed and kept in high-pressure composite and
metal storage tanks. It can also be transported in vehicles once it has been cooled into a liquid
and kept in some super-insulated tanks.

1.5.2 Storage:
Hydrogen can be stored physically as either a gas or a liquid. Storage of hydrogen as a gas
typically requires high-pressure tanks (350–700 bar [5,000–10,000 psi] tank pressure). Storage of
hydrogen as a liquid requires cryogenic temperatures because the boiling point of hydrogen at
one atmosphere pressure is −252.8°C. Hydrogen can also be stored on the surfaces of solids (by
adsorption) or within solids (by absorption).

Hydrogen cylinders must be stored with valve’s protective cap in place. If the cap has been
removed, the cylinder must be stored upright and secured with noncombustible straps or chains.

Hydrogen cylinders must be stored more than 20 feet away from cylinders of oxygen or other
oxidizers, e.g., bromine, chlorine, fluorine (which we do not have) or be separated by a
noncombustible wall extending not less than 18‖ above and to the sides of the stored material.

Never open the cylinder valve before making sure all your connections are secure as the static
discharge from flowing gas may cause hydrogen to be ignited.

Figure (1.6)

10
1.6 Hydrogen Safety

Hydrogen (H2) is an extremely flammable, colorless odorless compressed gas that is used in
many research laboratories. It has virtually no toxic effects on the human body, but it can
displace air causing asphyxiation if enough is released in an enclosed room. The biggest danger
when dealing with hydrogen is that is has a wide explosive/flammability range (4%-74% in air).
This means that even a small leak can cause a hazardous fire.

1.6.1 Fire Hazards

When hydrogen is in air it can ignite with extremely low energy input. For instance, hydrogen
only needs 10% of the energy (0.02 millijoules) required to ignite a gasolineair mixture. Even a
static spark from a person or clothing can ignite hydrogen gas. Hydrogen needs only a minimum
of 10% oxygen or a maximum of 41% of oxygen in air to ignite. Also, because the flame is
almost invisible in daylight, finding and fighting a hydrogen fire can be difficult.

1.6.2 Protective Measures

There should be no open flames or smoking in areas where hydrogen is used.

Work in an area with plenty of ventilation. If possible, work in a fume hood or use a canopy
hood as fugitive vapors, if not captured, may collect near the ceiling.

Ground all equipment and piping used with hydrogen, and make sure that you are properly
grounded before working with hydrogen. Rubber soled shoes prevent you from being grounded,
so you should touch a grounded object to discharge built up static electricity before beginning
work.

Wear appropriate lab safety gear for the work being performed: safety glasses/ goggles, lab coat,
gloves and preferably a face shield.

If working with liquid hydrogen you must have appropriate insulated gloves and protective
shoes in addition to the appropriate safety gear. (Cryogenic liquid hydrogen can cause severe
burns to the skin due to the extremely low.

Use metal piping with hydrogen. Do not use non-conductive or plastic tubing. Be sure to
dissipate static charge when flowing hydrogen gas by electrically bonding and grounding the
cylinder, metal piping and apparatus being used.

11
1.7 Uses for Hydrogen :

Hydrogen has a variety of important uses, including:

1. Refining and treating metals.

2. Processing foods, such as hydrogenating oils or fats (like what you might find in the
margarine in your fridge).

3. Refining crude oil in the petroleum industry.

4. Providing electricity through fuel cells

The main use for hydrogen, though, is as rocket fuel. Liquid hydrogen fuel is used by NASA to
get space shuttles into orbit, and hydrogen batteries power the shuttles’ electrical equipment. The
hydrogen’s only byproduct is pure water, which the shuttle crew can use as drinking water!

Figure (1.7)

12
 Chapter Two

Process Description

13
2.1 Process Description “ Steam Reforming ”
NG feed from B.L. at a pressure of 8.0 kg/cm²g is received in D-101 and then compressed up to
37.0 bar by using the two stages reciprocating compressors K-101. After compression the NG is
mixed with H2 recycle in the ratio of 0.05 on molar basis. H2 recycle is compressed at the proper
pressure by the using K-02A/B.

The plant feedstock (NG plus H2 recycle or off-gas) is then preheated up to 380°C in the heat
exchanger E-102 and in the CC-02.

The preheated feedstock from CC-02 enters the R-01. The effluent from R-101 then sent to R-
102A/B. the preheating of the R-101 feed is required to operate the feed of R-102A/B at the
optimum temperature for the absorption of H2S on the zinc oxide catalyst according to the
reaction:

H2S + ZnO  H2O + ZnS

R-102A/B are operated in series. When the ZnO of the first is exhausted, it can bypassed for the
replacement of the zinc oxide, while the second remains in operation. Once the replacement is
completed it is putted in operation downstream. The gas exiting the first is tested for H2S by
Dräger tube and by laboratory analysis on daily basis.

Pre-reforming
The desulfurized feedstock is mixed under flow control with a controlled quantity of steam
super-heated at 350°C and it is further preheated to 482°C in CC-02.

The preheated feedstock is then sent to R-103 where all HCS are converted to an equilibrium
mixture of CH4, CO2 and H2. In R-103 the feed moving downwards is reformed over a high
content nickel oxide catalyst into a mixture of H2, CO, CO2 and CH4 according to the reaction:

CnHm + nH2O  nCO + (n+ ½ m) H2 (Endothermic)

CO + 3 H2  CH4 + H2O (Exothermic)

CO + H2O  CO2 + H2 (Exothermic)

The steam / carbon molar ratio of R-103 feed is generally determined by the feedstock
characteristics, catalyst type and purification system type; and must be enough high to prevent
the carbon formation, for the present case this ratio is 2.7 at pre-reformer inlet . The steam rate is
under flow control and the set point of the flow controller is reset by steam/carbon ratio

14
controller from the capacity control system. R-103 inlet temperature controlled by bypassing the
preheating coil CC-02.

Steam Reforming
The pre-reformer effluent is mixed with an additional amount of superheated process steam and
then super-heated in CC-03 up to 600°C

In the primary reformer (H-101) the following reactions take place:

CH4 + H2O  CO2 + 3 H2 (1)

CO + H2O  CO2 + H2 (2)

These reactions take place simultaneously and the product is a mixture of H2, CO, CO2, CH4 and
excess H2O, the composition of the mixture being defined by the equilibrium for reactions (1)
and (2) at the operating exits T & P.

The reforming reaction (1) is endothermic while the reaction (2) is exothermic and the volume of
the reaction products is larger than the volume of the reagents.

Since the heat required by the reaction (1) is larger than the heat developed by reaction (2), the
reaction yield increases by increasing the reformer T and by decreasing the reformer P. The
operating conditions of the reformer are then determined by the required pressure of the H2
product and by the maximum operating temperature allowed by the mechanical stress of the
catalyst tubes immersed in the radiant chamber of the reformer.

The most important aspect for the operation of a steam reformer is the prevention of carbon
formation.

The outlet reformer conditions are 870°C and 29.4 bar. The reformer effluent is cooled down to
220°C in E-103 by generating high pressure steam and then in E-104 by preheating the BFW.

The outlet temperature of the process gas from E-104 is controlled by a temperature controller
which actuated the by-pass of the process gas around E-104. the cooled reformer effluent is sent
to the CO shift section.

The flue gas from the radiant section of the reformer enters the convection section where is used
as heat source to:

generate high pressure steam (CC-04A/B)

preheat the reformer feed (CC-03)

preheat the pre-reformer feed (CC-02)

15
Super heat the generated steam (CC-01)

Preheat the feed to hydrogenator reactor (CC-02)

Preheat the combustion air (CC-05).

H-101 is equipped with a balanced draft by using the combustion air fan F-101 and the flue gas
fan
F-102. The draft in the radiant section of the reformer is controlled by a pressure controller
which controls the flue gas rate to the flue gas fan.

CO Shift:

The effluent from the reformer contains a considerable amount of CO due the high reforming
temperature. The CO reacts with the steam according to the exothermic reaction:

CO + H2O  CO2 + H2 to increase the H2 yield.

The reaction is performed adiabatically in R-104 over catalyst bed. R-104 catalyst is Cu
promoted catalyst.

Cu promoter gives increased activity and flexibility to operate at low ratio without concern or
unwanted side reactions. In the R-201the temperature of the process gas is increased from 220°C
to 313°C. The effluent of R-104 is cooled by:

Pre-heating the feedstock to the R-01 in E-102

Pre-heating the BFW in E-105

Pre-heating the process steam condensate and demi-water make-up in the E-106.

The cooled effluent then enters D-104 where the condensate formed during the cooling is
separated and sent to D-105 under level control after being pre-heated in E-106. the saturated
process gas is first cooled to 55°C in E-107 and then to 37°C in E-108. The condensate formed is
separated in D-104 and sent to D-105 after being pre-heated in the E-106. The cooled gas is sent
to the PSA Unit.

PSA Unit

H2 rich gas from the D-05 is sent to the PSA unit where pure H2 is recovered at a P of 26.0 bar
by pressure sewing adsorption. 86% of H2 present in the PSA feed is recovered as pure H2. The
hydrogen balanced is collected together with impurities which is delivered by the PSA unit at a P
of 0.35 bar from absorbers into the process gas stream

16
Combustion System

Purpose of the combustion system is to provide the heat required by the steam reforming
reaction taken place in the catalyst tubes of the reformer. FG is burnt in 108 burners place on
the sides of the furnace (54 on each side). The burners are designed to fire PG discharged by
PSA with NG .

The major part of the eat required is provide by combustion of PG; the purge gas provides in
every operating condition of the plant an approximate contribution of 70% to the total fired
duty. NG or va The quantity of NG to be burnt is determined by a temperature controller at the
reformer bridge wall which is connected in cascade with either the NG fuel flow controller.

It is to be noted that the average composition of the purge gas changes with the operating
conditions of the process system, S/C ratio, reformer and shift outlet temperature.

The process gas flow rate from the process gas drum is controlled by pressure to the burners.

Combustion air: The burners are designed forced draft.

Flue gas: The generated flue gas leaves the firebox and is cooled down in the convection
section before being sent to stack through the induced draft fan F-02A/B. F-02A/B provides the
necessary draft in the furnace by pressure control PIC-046 that gives action on a damper at the
suction of F-02A/B at the base of the stack.

17
Flow Sheet

18
Block Diagram

19
Chapter Three

Mass balance

20
Calculate to produce 105Nm3/day of H2 gas :

Density at temperature (20oc) 273 k and pressure (1 atm)

ρ = 0.0832 kg/m3

to be m3/hr = = 4166.67 m3/hr

to be Kg/hr = density * volume

= 0.0832 * 4166.67 = 346.67 Kg/hr

to be Kmole/hr =

= = 171.62 Kmol/hr
This hydrogen produced by purity 99.99% as a final product
and the rest 0.01% Methane.

So :
Kmol/hr Percent%

H2 171.62 99.99%

CH4 ? 0.01%

Total = = 171.64 Kmol/hr

21
3.1 Mass balance pressure swing adsorption (PSA)
For H2 :
M14 = M15 + M16

73.67 % M14 = 30.12 % M15 + 171.62

M15 = (73.67 % M14 - 171.62) / (30.12 %) (1

For CH4 :
M14 = M15 + M16

5.54% M14 = 14.69 % M15 + 0.02

M15 = (5.54% M14 - 0.02) / (14.69 %) (2

From 1 , 2 :
(73.67 % M14 - 171.62) / (30.12 %)
=
(5.54% M14 - 0.02) / (14.69 %)

So :
M14 = 275.37 Kmol/hr

M15 = 275.37 - 171.64 = 103.73 Kmol/hr

22
3.2 Mass balance drum (Cold Process Separation):
For H2O :
M14 + M13 = M12

0.67 + 99.7 % M13 = 13.64 % M12

M12 = (0.67 + 99.7 % M13) / (13.64 %) (1

For CO2 :
M14 + M13 = M12

51.36 + 0.31 % M13 = 16.18 % M12

M12 = (51.36 + 0.31 % M13) / (16.18 %) (2

From 1 , 2 :
(0.67 + 99.7 % M13) / (13.64 %)
=
(51.36 + 0.31 % M13) / (16.18 %)
So :
M13 = 42.86 Kmol/hr
M12 = 275.37 +42.86 = 318.23 Kmol/hr

23
3.3 Mass balance drum (Hot Process Separator):

H2O Separation by 52.65 % :

H2O in M10 = H2O in M12 / (1 - Separation %)

= 43.4 / (1 - 0.5265)
= 91.65 Kmol/hr

H2O in M11 = H2O in M10 * Separation %

= 91.65 * 0.5265
= 48.25 Kmol/hr

3.4 Mass balance CO shift converter :

CO + H2O CO2 + H2

Input: 35.66 122.42

Reacted: 30.79 30.79 30.79 30.79

Output: 4.87 91.65 30.79 30.79

Conversion for CO = 86.35 %

Conversion = Reacted / Feed

0.8635 = (Feed - Output) / Feed

0.8635 = (Feed - 4.87) / Feed

Feed of CO = 35.66 Kmol/hr

24
3.5 Mass balance steam reforming:
CH4 + H2 O CO + 3H2

Input: 62.75 181.87

Reacted: 47.5 47.5 47.5 142.5

Output: 15.25 134.37 47.5 142.5

Conversion for CO = 75.7 %

Conversion = Reacted / Feed

0.757 = (Feed - Output) / Feed

0.757 = (Feed - 15.25) / Feed

Feed of CO = 62.75 Kmol/hr

CO + H2O CO2 + H2
Input: 47.62 134.37

Reacted: 11.95 11.95 11.95 11.95

Output: 35.67 122.42 11.95 11.95

Conversion for CO = 25.1 %

0.251 = (Feed - 35.67) / Feed

Feed of CO = 47.62 Kmol/hr

25
3.6 Mass balance Pre-reformer (Methanation) :
C5H12 + 5H2O 5CO + 11H2

Input: 0.02

Reacted: 0.02 0.1 0.1 0.22

Output: 0.00 0.1 0.22

C4H10 + 4H2O 4CO + 9H2

Input: 0.34

Reacted: 0.34 1.36 1.36 3.06

Output: 0.00 1.36 3.06

C3H8 + 3H2O 3CO + 7H2

Input: 3.28

Reacted: 3.28 9.84 9.84 22.96

Output: 0.00 9.84 22.96

26
 C2H6 + 2H2O 2CO + 5H2

Input: 7.54

Reacted: 7.54 15.08 15.08 37.7

Output: 0.00 15.08 37.7

CO + 3H2 CH4 + H2O

Input:

Reacted: 18.74 56.22 18.74 18.74

Output: 18.74 18.74

Conversion for CO = 71.21 %

CO + H2O CO2 + H2

Input:

Reacted: 7.51 7.51 7.51 7.51

Output: 7.51 7.51

Conversion for CO = 28.31 %

27
3.7 Mass balance Desulfurization:
H2S + ZnO ZnS + H2O

Input: 5ppm

Reacted: 5ppm 5ppm 5ppm 5ppm

Output: 0.00 5ppm 5ppm

3.8 Mass balance Hydrogenation:

C4H4S + 4H2 H2S + C4H10

Input: 2.9*10-4 2.84116

Reacted: 2.9*10-4 1.16*10-3 2.9*10-4 2.9*10-4

Output: 0.00 2.84 2.9*10-4 2.9*10-4

28
29
Chapter Four

Heat Balanc

30
31
 Stnd. heat of
(Cp)vapor constants formation
Components (ΔoHr)
A B C D (KJ/mol)
C5 H12 -2.58*10-4 5.3*10-8
-3.626 4.87*10-1 -146.54
n-Pentane
C4 H4S 4.48*10-1 -3.77*10-4 1.25*10-7 115.81
Thiophene -30.606
C4 H10 9.487 3.31*10-1 -1.11*10-4 -2.82*10-9 -126.23
n-Butane
C3 H8 -4.224 3.06*10-1 -1.59*10-4 3.21*10-8 -103.92
Propane
C2H6 5.409 1.78*10-1 -6.94*10-5 8.71*10-9 -84.74
Ethane
CH4 5.21*10-2 1.2*10-5 -1.13*10-8 -74.8
Methane 19.251
CO2 19.251 7.34*10-2 -5.6*10-5 1.72*10-8 -393.77
Carbon dioxide
CO 30.869 -1.29*10-2 2.78*10-5 -1.27*10-8 -110.62
Carbon monoxide
H2 27.143 9.27*10-3 -1.38*10-5 7.65*10-9 ───
Hydrogen
H2O 32.243 1.92*10-3 1.06*10-5 3.6*10-9 -242
Water
H2S 31.941 1.44*10-3 2.43*10-5 -1.18*10-8 -20.18
Hydrgen sulfide
N2
31.15 -1.36*10-2 2.68*10-5 -1.17*10-8 ───
Nitrogen
Table (4.1) : Vapor constant & delHF

32
 Tables of Data: some values were out of range (corresponding to
temperature and pressure), so it was obtained by Hysys:

(a) Boiling points:

Antoine's constants
component
A B C
C5 H12
15.834 2477.07 -39.94
n-Pentane
C4 H4S 16.0243 2869.07 -51.80
Thiophene
C4 H10 15.6782 2154.9 -34.42
n-Butane
C3 H8 15.726 1872.46 -25.16
Propane
C2H6 15.6637 1511.42 -17.16
Ethane
CH4 15.2243 597.84 -7.16
Methane
CO2 22.5898 3103.39 -0.16
Carbon dioxide
CO 14.3686 530.22 -13.15
Carbon monoxide
H2 13.633 164.9 3.19
Hydrogen
H2O 18.3036 3816.44 -46.13
Water
N2 14.954 588.72 -6.60
Nitrogen
H2S 16.1040 1768.69 -26.06
Hydrgen sulfide
Table (4.2) : Antoine’s constants

Ln (vapour pressure) = ANTA - ( ANTB/ (T + ANTC))

Vap. press. mmHg, T deg K.
33
4.1. Reactors heat balance calculation :
4.1.1. Heat balance calculation around hydrogenationReactor :

4.1.1.1. Qin from hydrogenation reactor

TIN = 653 K Pressure at 35.7 bar

Tref = 298 K

Components N2 C5H12 C4H10 C3H8

C1 31.2 -3.6 9.5 -4.2
C2 -1.4E-02 4.9E-01 3.3E-01 3.1E-01
C3 2.7E-05 -2.6E-04 -1.1E-04 -1.6E-04
C4 -1.2E-08 5.3E-08 -2.8E-09 3.2E-08
Moles = 357.7 23.7 335.7 3275.5
Heat of vap = (j/mole) 3373.5 4452.3 6175.7
∫Cp×∆T = (j/mole) 10510.4 33874.8 35841.6 33304.2
Cp liquid (j/mole.K) 2343.1 846.7 343.9
∫CPL×∆T liq = (j/mole) 433473.5 104147.0 21247.1
Q(comp) = (joule) 3.8E+06 1.1E+07 4.8E+07 2.0E+08

Components C2H6 CH4 CO2 H2 C4H4S

C1 5.4 19.3 19.8 27.1 -30.6
C2 1.8*10-1 5.2*10-2 7.3*10-2 9.3*10-3 4.5*10-1
C3 -6.9*10-5 1.2*10-5 -5.6*10-5 -1.4*10-5 -3.8*10-4
C4 8.7*10-9 -1.1*10-8 1.7*10-8 7.6*10-9 1.3*10-7
Moles = 7.54*103 4.40*104 1.30*103 2.84*103 0.3
Heat of vap = (j/mole) 1.56*104
∫Cp×∆T = (j/mole) 2.65*104 1.61*104 1.55*104 1.04*104 1.44*104
Cp liquid (j/mole.K) 2.45*102
∫CPL×∆T liq = (j/mole) 5.95*104
Q(comp) = (joule) 2.0*108 7.1*108 2.0*107 2.9*107 2.7*104

Qin (total) = 1.22*109 joule

Qin (total) = 1.22*106 Kjoule

34
 4.1.1.2. Qout from hydrogenation reactor

TOut = 603 K Pressure at 35.7 bar

Tref = 298 K

Components N2 C5H12 C4H10 C3H8

C1 31.2 -3.6 9.5 -4.2
C2 -1.36*10-2 4.87*10-1 3.31*10-1 3.06*10-1
C3 2.68*10-5 -2.58*10-4 -1.11*10-4 -1.59*10-4
C4 -1.17*10-8 5.30*10-8 -2.82*10-9 3.21*10-8
Moles = 3.58*102 2.37*10 3.36*102 3.28*103
∫Cp×∆T = (j/mole) 9.00*103 2.32*104 2.72*104 2.66*104
Heat of vap = (j/mole) ---- 3.37*103 4.45*103 6.18*103
Cp liquid (j/mole.K) ---- 2.34*103 8.46*102 3.44*102
∫CPL×∆T liq = (j/mole) ---- 4.33*105 1.04*105 2.12*104
Q(comp) = (joule) 3.2*106 1.1*107 4.6*107 1.8*108

Components C2H6 CH4 CO2 H2 H2S

C1 5.4 19.3 19.8 27.1 31.9
C2 1.78*10-1 5.2*10-2 7.34*10-2 9.27*10-3 1.44*10-3
C3 -6.94*10-5 1.2*10-5 -5.60*10-5 -1.38*10-5 2.43*10-5
C4 8.71*10-9 -1.1*10-8 1.72*10-8 7.65*10-9 -1.18*10-8
Moles = 7.54*103 4.4*104 1.30*103 2.84*103 2.96*10-1
∫Cp×∆T = (j/mole) 2.19*104 1.35*104 1.31*104 8.90*103 1.03*104
Heat of vap = (j/mole) ---- ---- ---- ---- 1.19*104
Cp liquid (j/mole.K) ---- ---- ---- ---- 9.34*10
∫CPL×∆T liq = (j/mole) ---- ---- ---- ---- 2.31*103
Q(comp) = (joule) 1.7*108 5.9*108 1.7*107 2.5*107 7.3*103

QOut(total) = 1.04*109 joule

QOut(total) = 1.04*106 Kjoule
35
4.1.1.3. Heat of reaction calculation on hydrogenation Reactor :

Comp C4H4S 4H2 H2S C4H10

-1 -1
Reacted (mole) 2.90*10 1.16 2.90*10 2.90*10-1
HF (Kj/mole) 115.81 0 -20.18 -126.23
Total ( Kj) 33.5849 0 -5.8522 -36.6067
Total ∆Hr = -76.0438 KJ

Q Removed Q Added
6
1.22*10 1.04*106
7.60*10
1.22*106 1.04*106
Q removed = 1.86*105

36
4.1.2. Heat balance calculation around desulfurization Reactor :
4.1.2.1. Qin from desulfurization reactor
TIN = 603 K Pressure at 35.7 bar

Tref = 298 K

Components N2 C5H12 C4H10 C3H8

C1 31.2 -3.6 9.5 -4.2
C2 -1.36*10-2 4.87*10-1 3.31*10-1 3.06*10-1
C3 2.68E-05 -2.58E-04 -1.11E-04 -1.59*10-4
C4 -1.17E-08 5.30E-08 -2.82E-09 3.21*10-8
Moles = 3.58*102 2.37*10 3.36*102 3.28*103
∫Cp×∆T = (j/mole) 8995.2 23185.9 27185.4 26629.2
Heat of vap = (j/mole) ---- 3373.5 4452.3 6175.7
Cp liquid (j/mole.K) ---- 2343.1 846.2 343.9
∫CPL×∆T liq = (j/mole) ---- 433473.5 104083.3 21247.1
Q(comp) = (joule) 3.2*106 1.1*107 4.6*107 1.8*108

Components C2H6 CH4 CO2 H2 H2S

C1 5.4 19.3 19.8 27.1 31.9
-1 -2 -2 -3
C2 1.78*10 5.2*10 7.34*10 9.27*10 1.44*10-3
C3 -6.94*10-5 1.2*10-5 -5.60*10-5 -1.38*10-5 2.43*10-5
C4 8.71*10-9 -1.1*10-8 1.72*10-8 7.65*10-9 -1.18*10-8
Moles = 7.54*103 4.4*104 1.30*103 2.84*103 2.96*10-1
∫Cp×∆T = (j/mole) 21934.7 13451.5 13060.8 8903.0 10286.0
Heat of vap = (j/mole) ---- ---- ---- ---- 11946.3
Cp liquid (j/mole.K) ---- ---- ---- ---- 93.4
∫CPL×∆T liq = (j/mole) ---- ---- ---- ---- 2310.7
Q(comp) = (joule) 1.7*108 5.9*108 1.7*107 2.5*107 7.3*103

Qin(total) = 1.04*109 joule

Qin(total) = 1.04*106 Kjoule

37
4.1.2.2. Qout from desulfurization reactor
TOut = 623 K Pressure at 35.7 bar

Tref = 298 K

Components N2 C5H12 C4H10 C3H8

C1 31.2 -3.6 9.5 -4.2
C2 -1.36E-02 4.87E-01 3.31E-01 3.06E-01
C3 2.68E-05 -2.58E-04 -1.11E-04 -1.59E-04
C4 -1.17E-08 5.30E-08 -2.82E-09 3.21E-08
Moles = 357.7 23.7 336.0 3275.5
∫Cp×∆T = (j/mole) 9599.4 27393.5 30591.1 29255.6
Heat of vap = (j/mole) ---- 3373.5 4452.3 6175.7
Cp liquid (j/mole.K) ---- 2343.1 846.2 343.9
∫CPL×∆T liq = (j/mole) ---- 433473.5 104083.3 21247.1
Q(comp) = (joule) 3.43E+06 1.10E+07 4.67E+07 1.86E+08

Components C2H6 CH4 CO2 H2

C1 5.4 19.3 19.8 27.1
C2 1.78E-01 5.21E-02 7.34E-02 9.27E-03
C3 -6.94E-05 1.20E-05 -5.60E-05 -1.38E-05
C4 8.71E-09 -1.13E-08 1.72E-08 7.65E-09
Moles = 7540.0 44012.8 1302.5 2836.6
∫Cp×∆T = (j/mole) 23745.2 14513.4 14015.0 9491.0
Q(comp) = (joule) 1.79E+08 6.39E+08 1.83E+07 2.69E+07

QOut(total) = 1.11E+09 joule

QOut(total) = 1.11E+06 Kjoule

38
4.1.2.3. Heat of reaction calculation on desulfurization Reactor :
Comp H2S ZNO ZNS H2 O
Reacted mole 2.90E-01 2.90E-01 2.90E-01 2.90E-01
HF Kj/mole -20.18 -348 -202.9 -242
Total Kj -5.8522 -100.92 -58.841 -70.18
Total ∆Hr = -22.2488 KJ

Q Removed Q Added
1.04E+06 1.11E+06
-22.2488
1036503.039 1109836.438
73333.3987

39
4.1.3. Heat balance calculation around prereformer Reactor :
4.1.3.1. Qin from prereformer reactor
TIN = 755 K Pressure at 32 bar

Tref = 298 K

Components N2 C5H12 C4H10 C3H8

C1 31.2 -3.6 9.5 -4.2
C2 -1.4E-02 4.9E-01 3.3E-01 3.1E-01
C3 2.7E-05 -2.6E-04 -1.1E-04 -1.6E-04
C4 -1.2E-08 5.3E-08 -2.8E-09 3.2E-08
Moles = 357.7 23.7 336.0 3275.5
∫Cp×∆T = (j/mole) 13652.4 60310.4 55785.2 48568.3
Heat of vap = (j/mole) ---- 4772.2 7290.8 7728.6
Cp liquid (j/mole.K) ---- 1055.8 413.3 255.2
∫CPL×∆T liq = (j/mole) ---- 177380.6 47947.3 14035.5
Q(comp) = (joule) 4.9E+06 5.8E+06 3.7E+07 2.3E+08

Components C2H6 CH4 CO2 H2 H2O

C1 5.4 19.3 19.8 27.1 32.2
C2 1.8E-01 5.2E-02 7.3E-02 9.3E-03 1.9E-03
C3 -6.9E-05 1.2E-05 -5.6E-05 -1.4E-05 1.1E-05
C4 8.7E-09 -1.1E-08 1.7E-08 7.6E-09 -3.6E-09
Moles = 7540.0 44012.8 1302.5 2836.6 189673.3
∫Cp×∆T = (j/mole) 33579.1 22054.7 20533.1 13382.4 8978.3
Heat of vap = (j/mole) ---- ---- ---- ---- 31980.0
Cp liquid (j/mole.K) ---- ---- ---- ---- 97.4
∫CPL×∆T liq = (j/mole) ---- ---- ---- ---- 20744.1
Q(comp) = (joule) 2.5E+08 9.7E+08 2.7E+07 3.8E+07 1.2E+10

Qin(total) = 1.33E+10 joule

Qin(total) = 1.33E+07 Kjoule

40
4.1.3.2. Qout from prereformer reactor
TOut = 723 K Pressure at 32 bar

Tref = 298 K

Components N2 CH4 CO2

C1 31.2 19.3 19.8
C2 -1.4E-02 5.2E-02 7.3E-02
C3 2.7E-05 1.2E-05 -5.6E-05
C4 -1.2E-08 -1.1E-08 1.7E-08
Moles = 357.7 62784.2 8769.6
∫Cp×∆T = (j/mole) 12659.0 20142.9 18920.6
Q(comp) = (joule) 4.5E+06 1.3E+09 1.7E+08

Components CO H2 H2 O
C1 30.9 27.1 32.2
C2 -1.3E-02 9.3E-03 1.9E-03
C3 2.8E-05 -1.4E-05 1.1E-05
C4 -1.3E-08 7.6E-09 -3.6E-09
Moles = 122.5 17864.0 174891.7
∫Cp×∆T = (j/mole) 12748.2 12437.1 7763.0
Heat of vap = (j/mole) ---- ---- 31980.0
Cp liquid (j/mole.K) ---- ---- 97.4
∫CPL×∆T liq = (j/mole) ---- ---- 20744.1
Q(comp) = (joule) 1.6E+06 2.2E+08 1.1E+10

QOut(total) = 1.22E+10 joule

QOut(total) = 1.22E+07 Kjoule

41
4.1.3.3. Heat of reaction calculation on Prereformer Reactor :
Comp C5H12 5H2O 5CO 11H2
Reacted mole 20 100 100 220
HF Kj/mole -146.54 -242 -110.62 0
Total Kj -2930.8 -24200 -11062 0
∆Hr = 16068.8 KJ

Comp C4H10 4H2O 4CO 9H2

Reacted mole 340 1360 1360 3060
HF Kj/mole -126.23 -242 -110.62 0
Total Kj -42918.2 -329120 -150443.2 0
∆Hr = 221595 KJ

Comp C3H8 3H2O 3CO 7H2

Reacted mole 3280 9840 9840 22960
HF Kj/mole -103.92 -242 -110.62 0
Total Kj -340857.6 -2381280 -1088500.8 0
∆Hr = 1633637 KJ

Comp C2H6 2H2O 2CO 5H2

Reacted mole 7540 15080 15080 37700
HF Kj/mole -84.74 -242 -110.62 0
Total Kj -638939.6 -3649360 -1668149.6 0
∆Hr = 2620150 KJ

Comp CO 3H2 CH4 H2O

Reacted mole 18740 56220 18740 18740
HF Kj/mole -110.62 0 -74.8 -242
Total Kj -2073018.8 0 -1401752 -4535080
∆Hr = -3863813 KJ
42
Comp CO H2O CO2 H2
Reacted mole 7510 7510 7510 7510
HF Kj/mole -110.62 -242 -393.77 0
Total Kj -830756.2 -1817420 -2957212.7 0
∆Hr = -309037 KJ

Total ∆Hr = 318601 KJ

Q Removed Q Added
1.33E+07 1.22E+07
318600.9
13270192.74 12556145.15
714047.5927

43
4.1.4. Heat balance calculation around reformer Reactor :
4.1.4.1 Qin from reformer reactor
TIN = 723 K Pressure at 32 bar

Tref = 298 K

Components N2 CH4 CO2

C1 31.2 19.3 19.8
C2 -1.4E-02 5.2E-02 7.3E-02
C3 2.7E-05 1.2E-05 -5.6E-05
C4 -1.2E-08 -1.1E-08 1.7E-08
Moles = 357.7 62784.2 8769.6
∫Cp×∆T = (j/mole) 12659.0 20142.9 18920.6
Q(comp) = (joule) 4.5E+06 1.3E+09 1.7E+08

Components CO H2 H2O
C1 30.9 27.1 32.2
C2 -1.3E-02 9.3E-03 1.9E-03
C3 2.8E-05 -1.4E-05 1.1E-05
C4 -1.3E-08 7.6E-09 -3.6E-09
Moles = 122.5 17864.0 181936.1
∫Cp×∆T = (j/mole) 12748.2 12437.1 7763.0
Heat of vap = (j/mole) ---- ---- 31980.0
Cp liquid (j/mole.K) ---- ---- 97.4
∫CPL×∆T liq = (j/mole) ---- ---- 20744.1
Q(comp) = (joule) 1.6E+06 2.2E+08 1.1E+10

Qin(total) = 1.27E+10 joule

Qin(total) = 1.27E+07 Kjoule

44
4.1.4.3. Qout from reformer reactor
TOut = 1143 K Pressure at 30 bar

Tref = 298 K

Components N2 CH4 CO2

C1 31.2 19.3 19.8
C2 -1.4E-02 5.2E-02 7.3E-02
C3 2.7E-05 1.2E-05 -5.6E-05
C4 -1.2E-08 -1.1E-08 1.7E-08
Moles = 357.7 15252.8 20764.9
∫Cp×∆T = (j/mole) 26200.7 49049.1 41331.5
Q(comp) = (joule) 9.4E+06 7.5E+08 8.6E+08

Components CO H2 H2 O
C1 30.9 27.1 32.2
C2 -1.3E-02 9.3E-03 1.9E-03
C3 2.8E-05 -1.4E-05 1.1E-05
C4 -1.3E-08 7.6E-09 -3.6E-09
Moles = 35670.0 172070.0 122423.6
∫Cp×∆T = (j/mole) 26466.4 25076.8 24815.0
Heat of vap = (j/mole) ---- ---- 32840.0
Cp liquid (j/mole.K) ---- ---- 94.8
∫CPL×∆T liq = (j/mole) ---- ---- 19870.1
Q(comp) = (joule) 9.4E+08 4.3E+09 9.5E+09

QOut(total) = 1.64E+10 joule

QOut(total) = 1.64E+07 Kjoule

45
4.1.4.3. Heat of reaction calculation on reformer Reactor :

Comp CH4 H2 O CO 3H2

Reacted mole 47500 47500 47500 142500
HF Kj/mole -74.8 -242 -110.62 0
Total Kj -3553000 -11495000 -5254450 0

∆Hr = 9793550 KJ

Comp CO H2O CO2 H2

Reacted mole 11950 11950 11950 11950
HF Kj/mole -110.62 -242 -393.77 0
Total Kj -1321909 -2891900 -4705551.5 0
∆Hr = - 491742.5 KJ

Total ∆Hr = 9301807.5 KJ

Q Removed Q Added
1.22E+07 1.64E+07
9301807.5
1.22E+07 2.57E+07
1.34E+07

46
4.1.5. Heat balance calculation around CO converter Reactor :
4.1.5.1. Qin from CO converter reactor
TIN = 513 K Pressure at 28 bar

Tref = 298 K

Components N2 CH4 CO2

C1 31.2 19.3 19.8
C2 -1.4E-02 5.2E-02 7.3E-02
C3 2.7E-05 1.2E-05 -5.6E-05
C4 -1.2E-08 -1.1E-08 1.7E-08
Moles = 357.7 15252.8 20764.9
∫Cp×∆T = (j/mole) 6304.5 8943.0 8894.6
Q(comp) = (joule) 2.3E+06 1.4E+08 1.8E+08

Components CO H2 H2O
C1 30.9 27.1 32.2
C2 -1.3E-02 9.3E-03 1.9E-03
C3 2.8E-05 -1.4E-05 1.1E-05
C4 -1.3E-08 7.6E-09 -3.6E-09
Moles = 35670.0 172070.0 122423.6
∫Cp×∆T = (j/mole) 6328.4 6261.9 329.9
Heat of vap = (j/mole) ---- ---- 33152.0
Cp liquid (j/mole.K) ---- ---- 93.9
∫CPL×∆T liq = (j/mole) ---- ---- 19313.4
Q(comp) = (joule) 2.3E+08 1.1E+09 6.5E+09

Qin(total) = 8.09E+09 joule

Qin(total) = 8.09E+06 Kjoule

47
4.2.1.1. Qout from CO converter reactor
TOut = 586 K Pressure at 28 bar

Tref = 298 K

Components N2 CH4 CO2

C1 31.2 19.3 19.8
C2 -1.4E-02 5.2E-02 7.3E-02
C3 2.7E-05 1.2E-05 -5.6E-05
C4 -1.2E-08 -1.1E-08 1.7E-08
Moles = 357.7 15252.8 51552.5
∫Cp×∆T = (j/mole) 8483.5 12565.9 12257.5
Q(comp) = (joule) 3.0E+06 1.9E+08 6.3E+08

Components CO H2 H2 O
C1 30.9 27.1 32.2
C2 -1.3E-02 9.3E-03 1.9E-03
C3 2.8E-05 -1.4E-05 1.1E-05
C4 -1.3E-08 7.6E-09 -3.6E-09
Moles = 4866.2 202863.3 91645.8
∫Cp×∆T = (j/mole) 8526.0 8403.5 2950.1
Heat of vap = (j/mole) ---- ---- 33152.0
Cp liquid (j/mole.K) ---- ---- 93.9
∫CPL×∆T liq = (j/mole) ---- ---- 19313.4
Q(comp) = (joule) 9.4E+08 4.3E+09 9.5E+09

QOut(total) = 7.65E+09 joule

QOut(total) = 7.65E+06 Kjoule

48
4.1.5.3. Heat of reaction calculation on CO converter Reactor :

Comp CO H2O CO2 H2

Reacted mole 30790 30790 30790 30790
HF Kj/mole -110.62 -242 -393.77 0
Total Kj -3405989.8 -7451180 -12124178.3 0
∆Hr = -1267008.5 KJ

Q Removed Q Added
8.09E+06 7.65E+06
1.27E+06
9.36E+06 7.65E+06
1.71E+06

49
4.2. Heat exchangers heat balance calculation :

4.2.2. Heat balance calculation around E-2 :

4.2.1.1. Gas stream from BL to E-2

TOut = 473 K Pressure at 37 bar

TIn = 388 K

Components N2 C5H12 C4H10 C3H8

C1 31.2 -3.6 9.5 -4.2
C2 -1.4E-02 4.9E-01 3.3E-01 3.1E-01
C3 2.7E-05 -2.6E-04 -1.1E-04 -1.6E-04
C4 -1.2E-08 5.3E-08 -2.8E-09 3.2E-08
Moles = 357.7 23.7 335.7 3275.5
∫Cp×∆T = (j/mole) 2494.7 13810.5 11159.1 8561.4
Q(comp) = (joule) 8.92E+05 3.28E+05 3.75E+06 2.80E+07

Components C2H6 CH4 CO2 C4H4S

C1 5.4 19.3 19.8 -30.6
C2 1.8E-01 5.2E-02 7.3E-02 4.5E-01
C3 -6.9E-05 1.2E-05 -5.6E-05 -3.8E-04
C4 8.7E-09 -1.1E-08 1.7E-08 1.3E-07
Moles = 7540.0 44012.8 1302.5 0.3
∫Cp×∆T = (j/mole) 5940.42 3655.48 3601.89 8688.02
Q(comp) = (joule) 4.48E+07 1.61E+08 4.69E+06 2.58E+03

Qin (total) = 2.4E+08 joule

Qin (total) = 2.4E+05 Kjoule

50
4.2.1.2. Out gas stream from CO converter reactor to E -2 :

TOut = 586 K Pressure at 28 bar

Tref = 566.7 K

Components N2 CH4 CO2

C1 31.2 19.3 19.8
C2 -1.4E-02 5.2E-02 7.3E-02
C3 2.7E-05 1.2E-05 -5.6E-05
C4 -1.2E-08 -1.1E-08 1.7E-08
Moles = 357.7 15252.8 51552.5
∫Cp×∆T = (j/mole) 578.88 986.30 903.13
Q(comp) = (joule) 2.07E+05 1.50E+07 4.66E+07

Components CO H2 H2 O
C1 30.9 27.1 32.2
C2 -1.3E-02 9.3E-03 1.9E-03
C3 2.8E-05 -1.4E-05 1.1E-05
C4 -1.3E-08 7.6E-09 -3.6E-09
Moles = 4866.2 202863.3 91645.8
∫Cp×∆T = (j/mole) 584.27 566.73 698.07
Q(comp) = (joule) 2.84E+06 1.15E+08 6.40E+07

QOut(total) = 2.4E+08 joule

QOut(total) = 2.4E+05 Kjoule

51
4.2.3. Heat balance calculation around E-3 :

Out gas stream from reformer reactor to E -3

TIn = 1143 K Pressure at 30 bar

TOut = 613 K

Components N2 CH4 CO2

C1 31.2 19.3 19.8
C2 -1.4E-02 5.2E-02 7.3E-02
C3 2.7E-05 1.2E-05 -5.6E-05
C4 -1.2E-08 -1.1E-08 1.7E-08
Moles = 357.7 15252.8 20764.9
∫Cp×∆T = (j/mole) 16903.71 35069.43 27794.75
Q(comp) = (joule) 6.05E+06 5.35E+08 5.77E+08

Components CO H2 H2 O
C1 30.9 27.1 32.2
C2 -1.3E-02 9.3E-03 1.9E-03
C3 2.8E-05 -1.4E-05 1.1E-05
C4 -1.3E-08 7.6E-09 -3.6E-09
Moles = 35670.0 172070.0 122423.6
∫Cp×∆T = (j/mole) 17118.89 15879.90 21019.92
Q(comp) = (joule) 6.11E+08 2.73E+09 2.57E+09

QOut(total) = 1.64E+10 joule

QOut(total) = 1.64E+07 Kjoule

H2O CALCULATION FOR E -2

over heated steam
T2 523
Tav 508
T1 493
Latent heat J/mole 31507.5
Cp (liq) J/mole.k 94.6055
Cpliq del T + latent heat 34345.7
Q by Kg 3.69E+03
Q by Mole 2.05E+05
Q by Kmole 2.05E+02

52
4.2.3. Heat balance calculation around E-4 :
Out gas stream from E -3 to E -4

TIn = 613 K Pressure at 30 bar

TOut = 513 K

Components N2 CH4 CO2

C1 31.2 19.3 19.8
C2 -1.4E-02 5.2E-02 7.3E-02
C3 2.7E-05 1.2E-05 -5.6E-05
C4 -1.2E-08 -1.1E-08 1.7E-08
Moles = 357.7 15252.8 20764.9
∫Cp×∆T = (j/mole) 2992.51 5036.72 4642.13
Q(comp) = (joule) 1.07E+06 7.68E+07 9.64E+07

Components CO H2 H2 O
C1 30.9 27.1 32.2
C2 -1.3E-02 9.3E-03 1.9E-03
C3 2.8E-05 -1.4E-05 1.1E-05
C4 -1.3E-08 7.6E-09 -3.6E-09
Moles = 35670.0 172070.0 122423.6
∫Cp×∆T = (j/mole) 3019.17 2935.03 3603.37
Q(comp) = (joule) 1.08E+08 5.05E+08 4.41E+08

QOut(total) = 1.23E+09 joule

QOut(total) = 1.23E+06 Kjoule

H2O CALCULATION FOR E -2

over heated steam
Tout 488
Tav 475.5
Tin 463
Cp (vap) J/mole.k 38.35
Cp(vap) del T 18234.55
Q by Kg 1.21E+03
Q by Mole 6.74E+04
Q by Kmole 6.74E+01

53
Chapter Five

Special design

54
The water gas shift reaction (reaction 2) is a heterogeneous reaction (gas/solid).
According to (Smith et al., 2010) in this kind of application, in the WGSR step.
LTS reactors are copper based catalyst. Typical compositions include Cu, Zn, Cr and Al
oxides.
Recent catalysts can be operated at medium temperatures around 300ºC.
Copper is more sensitive to catalyst thermal sintering and should not be operated at higher
temperatures.
Sulfur is also a poison to LTS reactors. Typical exit concentration is of 0,1% of CO.
The reaction is operated adiabatically in industrial scale, where the temperature increases
along the length of the reactor.
According to Arrhenius law of kinetics, increasing temperature increases the reaction rate.
By the other side, the thermodynamic of equilibrium or Le Châtelier principle states that
increasing the temperature of an exothermic reaction shifts the reaction to reactants side
decreasing its equilibrium conversion.
Therefore the water gas shift reaction is a balance between these effects and the reactor
optimal operational point takes into account the tradeoff between kinetics and equilibrium
driving forces.
An empirical rate expression succesfully used to describe the WGSR in ferrochrome catalysts
is a power law type: (Newsome, 1980), [1].

Where:
r – reaction rate.
Ea – activation energy.
Ko – pre exponential factor.
Keq – reaction equilibrium constant.
l, m, n, q – estimated parameters by experimental data.
Py – partial pressure of component y.
R – universal gases constant.
T – absolute temperature.

55
The reaction equilibrium constant derived from thermodynamics as function of temperature
is given by (Smith et al., 2010):

Author Catalyst information Ko Ea (kJ/mol) l m N q

Ovesen et al. (1992) Cu/ZnO/Al2O3 7.25*102 7.08E+04 1 1.5 -0.7 -0.7

Mathematical modeling
In this section, mathematical expressions for the fixed bed adiabatic catalytic WGSR
Fundamental principles (conservation equations) are developed.
A basic ideal flow steady state one-dimensional model is presented.
The differential molar balance simplified to a fixed bed reactor can be expressed as equation

where
Xa – component “a” conversion.
W – catalyst weight.
ra – rate of reaction of component “a”.
Fa0 – molar feed rate of reactant “a”.
Fa – molar flow of component “a” leaving the reactor.
ρB – catalyst bulk density.
The ideal model assumes that concentration and temperature gradients only occur in the
Axial direction.
The only transport mechanism operating in this direction is the overall flow
it self, and is considered to be of the plug flow type.

X = 0.85 Pt = 2.79*106 Pa T = 539.5 k

CO H2O CO2 H2 N2 CH4

IN 2.14*105 7.35*105 1.25*105 1.03*106

R 1.82*105 1.82*105 1.82*105 1.82*105

OUT 3.21*104 5.53*105 3.07*105 1.21*106 2.16*103 9.15*104

56
Total number of moles :

Nt = 2.20*106 Mole/hr
Nt = 2.20*103 kmol/hr

Parameters :

L M n Q
1 1.5 -0.7 -0.7

Pi partial pressure :

Pi = * Pt

KP equilibrium constant by using pressure :

( ) ( )
( ) ( )

PA = 4.08*104 Pa
PB = 7.02*105 Pa Kp = 2.10*10 Pa
PC = 3.90*105 Pa
PD = 1.54*106 Pa

PA^l = 4.08*104 Pa
PB^m = 5.89*108 Pa
PC^n = 1.20*10-4 Pa
PD^q = 4.657*10-5 Pa

57
ln keq = 4.27
Keq = 7.17*10
(1/keq) = 1.40*10-2
Ea = 70800 J/mol
KO= 7.25*102
R = 8.314 J/mol.k
e^-(Ea/RT) = 1.40*10-7
( )
(KO) *( ) = 1.01*10-4

ra = 9.7711 Mol/gcatalyst.hr

X y (ra)
0 2.9*102
0.05 2.6*102
0.1 2.2*102
0.15 1.9*102
0.2 1.7*102
0.25 1.5*102
0.3 1.3*102
0.35 1.1*102
0.4 9.3*10
0.45 7.9*10
0.5 6.7*10
0.55 5.6*10
0.6 4.6*10
0.65 3.7*10
0.7 2.9*10
0.75 2.2*10
0.8 1.6*10
0.85 9.8

58
By trapezoidal equation :

Where :
∆X = 0.05

integration 90.8
Fa0 2.1*105 mol/hr

∫ ∫

Integration =

Weight of catalyst = integration * Fao

Catalyst weight 1.9*107 gm/hr

4
Catalyst weight 1.9*10 kg/hr
Bulk density 1250 Kg/m3
Where :
ρB ─ is the bulk density
59
Catalyst volume =
Catalyst volume 15.5 m3
Diameter of reactor 2.6 m2
Length of reactor 3.8 M

Total volume reactor 20.2 m3

Figure (5.1) : Reactor type

60
 Figure (5.2) : Catalyst type

This calculation by scale up the mass balance six times

61
 Chapter Six

Cost Estimation

62
6.1 Cost of equipment :

Vertical vessel drum cost (D - 4) :

The vertical vessel drum dimensions

D -4
L 2.8
D 1.5
V= (π/4) * (D)2 * L 4.9

Equipment cost = 7.8 * 1000 = 7.80*103$ at diameter =1m

Material factor for carbon steel = 1

Pressure factor from (20 to 30) = 1.4

Purchased cost = 7800 * 1 * 1.4 = 1.09*104$ at diameter =1m

For scale up to diameter = 1.5m

C2 = C1 * ( )n = 0.6
Purchased cost = 1.09*104 * (1.5/1)0.6 = 1.39*104$

Vertical vessel drum cost (D - 5) :

The vertical vessel drum dimensions
D -5
L 2.5 m
D 1.3 m
V= (π/4) * (D)2 * L 3.3 m3
Equipment cost = 7.1 * 1000 = 7100$ at diameter =1m

Material factor for carbon steel = 1

Pressure factor from (20 to 30) = 1.4

Purchased cost = 7100 * 1 * 1.4 = 9.94*103$ at diameter =1m

For scale up to diameter = 1.3m

63
C2 = C1 * ( )n = 0.6
Purchased cost = 9.94*103 * (1.3/1)0.6 = 1.16*104$

Reactors cost :
Vertical vessel reactor cost (R -4) :
The vertical vessel reactor dimensions
D -5
L 3.8 m
D 2.6 m
V= (π/4) * (D)2 * L 20 m3
Equipment cost = 15 * 1000 = 1.50*104$ at diameter =2m

Material factor for carbon steel = 1

Pressure factor from (20 to 30) = 1.4

Purchased cost = 15000 * 1 * 1.4 = 2.10*104$ at diameter =2m

For scale up to diameter = 2.6m

C2 = C1 * ( )n = 0.6
Purchased cost = 21000 * (2.6/2)0.6 = 2.46*104$

Total cost for 4 Vertical vessels reactors (R -1) , (R - 2) , (R – 3) and (R – 4)

Purchased cost for 4 = 24580.2 * 4 = 9.83*104$

Cost of trays for reactors :

Type of tray sieve tray
Material factor for carbon steel = 1
Cost per tray = 1300 * 1 = 1300$
Cost per 8 trays = 1300 * 8 = 1.04*104$

64
Catalyst cost for reactors
Catalyst cost for hydrogenation reactor (R - 2) = 19.5 ton * 4250 $/ton = 8.29*104 $

Catalyst cost for hydrogenation reactor (R - 3) =19500 kg * 12.5 $/kg = 2.44*105$

Catalyst cost for hydrogenation reactor (R - 4) = 19500 kg * 12.5 $/kg = 2.44*105$

Catalyst cost for hydrogenation reactor (R - 5) = 19500 kg * 14.6$/kg =2.85*105 $

Heat exchanger cost :

Shell and tube heat exchanger cost for (E -1)
Shell and tube heat exchanger dimensions
E -1
L 2.44 m
D 0.0254m
No of tubes 66 tube
A = (π)*(D)* L*no of 13m2
tubes

Exchanger cost = 9 * 1000 = 9.00*103$

Shell type = carbon steel
Tubes types = carbon steel
Pressure factor = 1.3
Type factor U tube = 0.85
Purchased cost = 9000 * 1.3 * 0.85 = 9.95*103$

65
Shell and tube heat exchanger cost for (E -2)
Shell and tube heat exchanger dimensions
E -2
L 3m
D 0.0254m
No of tubes 83 tube
A = (π)*(D)* L*no of 20 m2
tubes

Exchanger cost = 13 * 1000 = 1.30*104$

Shell type = carbon steel
Tubes types = carbon steel
Pressure factor = 1.25
Type factor U tube = 0.85
Purchased cost = 13000 * 1.25 * 0.85 = 1.38*104$

Shell and tube heat exchanger cost for (E -3)

Shell and tube heat exchanger dimensions
E -3
L 3.66 m
D 0.0254 m
No of tubes 139 tube
A = (π)*(D)* L*no of 41 m2
tubes

Exchanger cost = 20 * 1000 = 2.00*104$

Shell type = carbon steel
Tubes types = carbon steel

Pressure factor = 1.25

Type factor U tube = 0.85
Purchased cost = 20000 * 1.25 * 0.85 = 2.13*104$

66
Shell and tube heat exchanger cost for (E -4 (A/B))
Shell and tube heat exchanger dimensions
E -4 (A/B)
L 3.05 m
D 0.0254m
No of tubes 154 tube
A = (π)*(D)* L*no of 37m2
tubes

Exchanger cost = 18 * 1000 = 1.80*104$

Shell type = carbon steel
Tubes types = carbon steel
Pressure factor = 1.25
Type factor U tube = 0.85
Purchased cost = 18000 * 1.25 * 0.85 = 1.91*104$
For 2 exchanger = 19125 * 2 = 3.83*104$

Shell and tube heat exchanger cost for (E -5)

Shell and tube heat exchanger dimensions
E -5
L 1.86 m
D 0.0254 m
No of tube 93 tube
A = (π)*(D)* L*no of 14 m2
tubes

Exchanger cost = 9.8 * 1000 = 9.80*103$

Shell type = carbon steel
Tubes types = carbon steel
Pressure factor = 1.25
Type factor U tube = 0.85
Purchased cost = 9800 * 1.25 * 0.85 = 1.04*104$

67
Shell and tube heat exchanger cost for (E -6)
Shell and tube heat exchanger dimensions
E -6
L 3.66 m
D 0.0254m
No of tube 312 tube
A = (π)*(D)* L*no of 91m2
tubes

Exchanger cost = 34 * 1000 = 3.40*104$

Shell type = carbon steel

Tubes types = carbon steel

Pressure factor = 1.25

Type factor U tube = 0.85

Purchased cost = 34000 * 1.25 * 0.85 = 3.61*104$

Cost for reformer heater :

Purchased cost = 2.00*107 $

Cost for compressors :

Type of compressor = Reciprocating
Size range = 500 KW
Constant cost = 2700 $
Index = 0.8
Purchased cost = 2700 * (500 )0.8 = 3.90*105 $
At size = 10000 KW
C2 = C1 * ( )n = 0.6
Purchased cost = 389529 * (10000/500)0.6 = 2.35*106 $

68
Cost for PSA (pressure swing adsorbtion) :

The vertical vessel PSA dimensions

L 5m
D 1.2 m
V= (π/4) * (D)2 * L 5.7 m3

Equipment cost = 18 * 1000 = 18000$ at diameter =2m

Material factor for carbon steel = 1

Pressure factor from (20 to 30) = 1.4

Purchased cost = 18000 * 1 * 1.4 = 2.52*104$ at diameter =2m

For scale up to diameter = 1.2m

C2 = C1 * ( )n = 0.6
Purchased cost = 25200 * (1.2/2)0.6 = 1.85*104$

Total cost for 6 Vertical vessels for PSA

Purchased cost for 6 = 18548 * 6 = 1.11*105$

Carbon molecular sieve

Cost = 16900 kg * 9 $/kg =1.52*105 $

Total equipment cost = 2.37*107$

Fixed cost = 2.37*107* 4.74 (lang factor) = 1.12*108$

Total cost = fixed cost + working cost (0.2*fixed cost )

= 1.12*108+ ( 0.2 * 1.12*108) = 1.35*108$

69
6.2 Estimation of Operating Labor Requirements :
+

the amount shift per operators per year

= (49 week/year) * (5 shift/week) = 245
The number of operators needed to provide this number of shifts
= (365*3) / 245 = 4.5 operators

Equipment type Number of equipment Nnp

Reactors 5 5
Heat exchangers 7 7
Compressors 1 1
Towers 8 8
Total 15 21

Nop = (6.29+(0.23*21))0.5 = (11.12)0.5 = 3.34

The number of operators required per shift = 3.34

Operating Labor = (4.5)(3.34) = 15

Labor Costs = (15)*(170*12) = 3.06*104 $/y

6.3 Cost of utilities :

Cost of air = 104.1*(0.49/100) = 0.51009 $/hr
Cost of air per year = 0.51009 * 8000 = 4.08*103 $/year

Cost of water = (0.067/1000) * 26748 = 1.79 $/hr

Cost of water per year = 1.79 * 8000 =1.43*104$/year

Cost of natural gas = (208.2 / 0.7 ) * 0.42 = 124.92 $/hr

Cost of natural gas per year = 124.92 * 8000 = 9.99*105$/year

Total cost of utilities = 6*(9.99*105+ 1.43*104+4.08*103)

= 1.02*106 $/year

70
6.4 Cost of raw material :

Natural gas feed cost = (1.18*103 / 0.7) * 0.42 = 7.08*102 $/hr

Natural gas feed cost Per year = 7.08*102 * 8000 = 5.66*106$/year

Total cost for raw material = 6*5.66*106 = 3.40*107 $/year

COM = 0.180 FCI + 2.73COL + 1.23(Cutilities + CRW)

= 6.74*107$

Production rate = 348kg/hr * 8000 = 2.78*106kg/year

= 6* 2.78*106 = 1.67*107 kg/year

Production cost = 4 $/kg in 2004

In 2018 = 4*1.8 = 7.20 $/ kg

71
Chapter seven

Plant Layout

72
Plant Layout

73
Site Location:
The weighted score method is used to locate more than roughly the site of the plant to locate the
final site is hard work needing vast knowledge’s and experience however arty is made in this
report.

Market is assumed to been Suez , North Sinai and Borg El Arab , these cities are
proposed as aside of this plant the final site in the one that having the highest score .

Factors Suez North Sinai Borg El Arab

Raw material (100) 90 90 70
Marketing (100) 90 80 80
Labor supply (60) 50 50 50
Energy availability (20) 20 20 20
Transportation facilities (50) 50 40 45
Climate (20) 20 18 15
Water supply (20) 20 20 20
Water disposal (20) 20 20 15
Community factor (10) 10 8 7
Total (400) 370 346 322

The proposed n al plant site was found to be in the Suez as it achieves the highest score .

General Site Considerations Introduction:

A suitable site must be found for a new project, and the site and equipment layout planned.
Provision must be made for the ancillary buildings and services needed for plant operation; and
for the environmentally acceptable disposal of effluent. These subjects are discussed briefly in
this chapter.

Plant location and site selection:

The location of the plant can have a crucial effect on the profitability of a project, and the scope
for future expansion. Many factors must be considered when selecting a suitable site, and only a
brief review of the principal factors will be given in this section.

74
The principal factors to consider are:
1. Location, with respect to the marketing area.
2. Raw material supply.
3. Transport facilities.
4. Availability of labor.
5. Availability of utilities: water, fuel, power.
6. Availability of suitable land.
7. Environmental impact, and effluent disposal.
8. Local community considerations.
9. Climate.
10. Political and strategic considerations.

Marketing area:
For materials that are produced in bulk quantities; such as, pharmaceuticals, where the cost of
the product per ton is relatively low and the cost of transport a significant fraction of the sales
price, the plant should be located close to the primary market. This consideration will be less
important for low volume production, high-priced products; such as pharmaceuticals. In an
international market, there may be an advantage to be gained by locating the plant within an area
with preferential tariff agreements; such as the European Community (EC).

Raw materials:
The availability and price of suitable raw materials will often determine the site location. Plants
producing bulk chemicals are best located close to the source of the major raw material; where
this is also close to the marketing area.

Transport:
The transport of materials and products to and from the plant will be an overriding consideration
in site selection. If practicable, a site should be selected that is close to at least two major forms
of transport: road, rail, waterway (canal or river), or a sea port. Road transport is being
increasingly used, and is suitable for local distribution from a central warehouse. Rail transport
will be cheaper for the long-distance transport of bulk chemicals. Air transport is convenient and
efficient for the movement of personnel and essential equipment and supplies, and the proximity
of the site to a major airport should be considered.

75
Availability of labor:
Labor will be needed for construction of the plant and its operation. Skilled construction
workers will usually be brought in from outside the site area, but there should be an adequate
pool of unskilled labour available locally; and labour suitable for training to operate the plant.
Skilled tradesmen will be needed for plant maintenance. Local trade union customs and
restrictive practices will have to be considered when assessing the availability and suitability of
the local labour for recruitment and training.

Utilities (services):
Chemical processes invariably require large quantities of water for cooling and general process
use, and the plant must be located near a source of water of suitable quality. Process water may
be drawn from a river, from wells, or purchased from a local authority. At some sites, the cooling
water required can be taken from a river or lake, or from the sea; at other locations cooling
towers will be needed. Electrical power will be needed at all sites. Electrochemical processes that
require large quantities of power; for example, aluminium smelters, need to be located close to a
cheap source of power. A competitively priced fuel must be available on site for steam and
power generation.

Environmental impact and effluent disposal:

All industrial processes produce waste products, and full consideration must be given to the
difficulties and cost of their disposal. The disposal of toxic and harmful effluents will be covered
by local regulations, and the appropriate authorities must be consulted during the initial site
survey to determine the standards that must be met.

An environmental impact assessment should be made for each new project, or major
modification or addition to an existing process.

Local community considerations:

The proposed plant must fit in with and be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not impose a
significant additional risk to the community. On a new site, the local community must be able to
provide adequate facilities for the plant personnel: schools, banks, housing, and recreational and
cultural facilities.

Land (site considerations):

Sufficient suitable land must be available for the proposed plant and for future expansion. The
land should ideally be flat, well drained and have suitable load-bearing characteristics. A full site
evaluation should be made to determine the need for piling or other special foundations.

76
Climate:
Adverse climatic conditions at a site will increase costs. Abnormally low temperatures will
require the provision of additional insulation and special heating for equipment and pipe runs.
Stronger structures will be needed at locations subject to high winds (cyclone/hurricane areas) or
earthquakes.

Political and strategic considerations:

Capital grants, tax concessions, and other inducements are often given by governments to
direct new investment to preferred locations; such as areas of high unemployment. The
availability of such grants can be the overriding consideration in site selection.

Site Layout:
The process units and ancillary buildings should be laid out to give the most economical flow of
materials and personnel around the site. Hazardous processes must be located at a safe distance
from other buildings. Consideration must also be given to the future expansion of the site. The
ancillary buildings and services required on a site, in addition to the main processing units
(buildings), will include:

1. Storages for raw materials and products: tank farms and warehouses.

2. Maintenance workshops.

3. Stores, for maintenance and operating supplies.

4. Laboratories for process control.

5. Fire stations and other emergency services.

6. Utilities: steam boilers, compressed air, power generation, refrigeration, transformer stations.

7. Effluent disposal plant.

8. Offices for general.

9. Canteens and other amenity buildings, such as medical centres.

10. Car parks.

77
Plant Layout:
The economic construction and efficient operation of a process unit will depend on how well the
plant and equipment specified on the process flow-sheet is laid out.

The principal factors to be considered are:

1. Economic considerations: construction and operating costs.

2. The process requirements.

3. Convenience of operation.

4. Convenience of maintenance.

5. Safety.

6. Future expansion.

Costs:
The cost of construction can be minimized by adopting a layout that gives the shortest run of
connecting pipe between equipment, and the least amount of structural steel work. However, this
will not necessarily be the best arrangement for operation and maintenance.

Process requirements:
An example of the need to take into account process considerations is the need to elevate the
base of columns to provide the necessary net positive suction head to a pump or the operating
head for a thermosyphon reboiler.

Operation:
Equipment that needs to have frequent operator attention should be located convenient to the
control room. Valves, sample points, and instruments should be located at convenient positions
and heights. Sufficient working space and headroom must be provided to allow easy access to
equipment.

Maintenance:
Heat exchangers need to be sited so that the tube bundles can be easily withdrawn for cleaning
and tube replacement. Vessels that require frequent replacement of catalyst or packing should be
located on the outside of buildings. Equipment that requires dismantling for maintenance, such
as compressors and large pumps, should be placed under cover.

78
Safety:
Blast walls may be needed to isolate potentially hazardous equipment, and confine the effects of
an explosion. At least two escape routes for operators must be provided from each level in
process buildings.

Plant expansion:
Equipment should be located so that it can be conveniently tied in with any future expansion of
the process. Space should be left on pipe alleys for future needs, and service pipes over-sized to
allow for future requirements.

Utilities:
The word “Utilities” is now generally used for the ancillary services needed in the operation of
any production process. These services will normally be supplied from a central site facility; and
will include:

1. Electricity.

2. Steam, for process heating.

3. Cooling water.

4. Water for general use.

5. Demineralised water.

6. Compressed air.

7. Inert-gas supplies.

8. Refrigeration.

9. Effluent disposal facilities.

Environmental Considerations:
All individuals and companies have a duty of care to their neighbours, and to the environment in
general. In the United Kingdom this is embodied in the Common Law. In addition to this moral
duty, stringent controls over the environment are being introduced in the United Kingdom, the
European Union, the United States, and in other industrialized countries and developing
countries. Vigilance is required in both the design and operation of process plant to ensure that
legal standards are met and that no harm is done to the environment. Consideration must be

79
Given to:

1. All emissions to land, air, water.

2. Waste management.

3. Smells.

4. Noise.

Waste management Gaseous wastes:

Gaseous effluents which contain toxic or noxious substances will need treatment before
discharge into the atmosphere. The practice of relying on dispersion from tall stacks is seldom
entirely satisfactory. Witness the problems with acid rain in Scandinavian countries attributed to
discharges from power stations in the United Kingdom. Gaseous pollutants can be removed by
absorption or adsorption. Finely dispersed solids can be removed by scrubbing, or using
electrostatic precipitators. Flammable gases can be burnt.

Liquid wastes:
The waste liquids from a chemical process, other than aqueous effluent, will usually be
flammable and can be disposed of by burning in suitably designed incinerators. Care must be
taken to ensure that the temperatures attained in the incinerator are high enough to completely
destroy any harmful compounds that may be formed; such as the possible formation of dioxins
when burning chlorinated compounds. The gases leaving an incinerator may be scrubbed, and
acid gases neutralized. In the past, small quantities of liquid waste, in drums, have been disposed
of by dumping at sea or in land-fill sites. This is not an environmentally acceptable method and
is now subject to stringent controls.

Solid wastes:
Solid waste can be burnt in suitable incinerators or disposed by burial at licensed land-fill sites.
As for liquid wastes, the dumping of toxic solid waste at sea is now not acceptable.

Noise:
Noise can cause a serious nuisance in the neighborhood of a process plant. Care needs to be
taken when selecting and specifying equipment such as compressors, air-cooler fans, induced
and forced draught fans for furnaces, and other noisy plant. Excessive noise can also be
generated when venting through steam and other relief valves, and from flare stacks. Such
equipment should be fitted with silencers. Vendors’ specifications should be checked to ensure
that equipment complies with statutory noise levels; both for the protection of employees as well
as for noise pollution considerations. Noisy equipment should, as far as practicable, be sited well
away from the site boundary.
Earth banks and screens of trees can be used to reduce the noise level perceived outside the site.

80
Chapter Eight

Control

81
Flow sheet

Controlled

82
Conclusion
The plant has been designed to produce H2 through steam reforming of NG.

The process involves the main following steps:

1. Hydrodesulphurization of the feed in order to protect the reformer catalyst.
2. Performing of the feed to convert the HCS to CH4 and a small amount of H2, CO, and CO2.
3. Steam reforming performing effluent to produce a mixture of H2, CO, CO2 and unconverted CH4.
4. Medium temperature shift conversion to reduce the CO by converted it to CO2 and H2.
5. Purification of the raw hydrogen by absorption of impurities on molecular sieves.
Steam Methane Reforming is the most widely used process for bulk gas production, accounting
for 95% of the hydrogen produced in the United States. The Steam Methane Reforming process
can be broken down into five distinct steps:
Water enters the furnace, producing steam at a very high temperature.
Steam reacts with natural gas, producing hydrogen and carbon monoxide.
In the water shift reactor, carbon monoxide and steam react to form carbon dioxide and more
hydrogen gas.
The hydrogen gas is purified to the customer’s specifications, removing contaminants.
Pure hydrogen is delivered to the customer.
Remaining gases are recycled back into the process or recovered for other uses.
These individual steps function together as a continuous process; a large plant can operate at all
hours of the day to produce a constant stream of hydrogen.
Hydrogen gas is consumed across the globe for many different uses, including electrical power
production.
Hydrogen fuel cells can be used to power anything from cars to individual homes, with the only
exhaust being clean water.
This green technology may reduce our dependence on fossil fuels in the future. However, the
SMR process is dependent on an input of methane, most easily obtained from natural gas,With
limited natural gas reservoirs available, a different means of producing hydrogen is needed for a
truly renewable process.
Until that technology becomes available, Steam Methane Reforming remains the most cost
efficient way to produce hydrogen in an industrial setting.

83
Reference :
Ullman’s Enc. of Industrial Chemistry

Coulson_&_Richardson_s_Chemical_Engineering._Vol._6_(www.chemicalebooks.c
om)

[1] Douglas Falleiros Barbosa Lima1, Fernando Ademar Zanella1,Marcelo Kaminski

Lenzi2 and Papa Matar Ndiaye2. Modeling and Simulation of Water
Gas Shift Reactor: An Industrial Case. http://cdn.intechopen.com/pdfs/34193/InTech-
Modeling_and_simulation_of_water_gas_shift_reactor_an_industrial_case.pdf

Analysis, Synthesis and Design of Chemical Processes, Fourth Edition

http://www.wikihow.com/Calculate-Vapor-Pressure

http://citeseerx.ist.psu.edu/viewdoc/download?doi=10.1.1.463.6890&rep=rep1&type=
pdf

https://www.energy.gov/eere/fuelcells/hydrogen-storage

http://cleangreenenergyzone.com/hydrogen-storage/

https://www.eolss.net/Sample-Chapters/C08/E3-13-05-03.pdf

https://www.rsmeansonline.com/references/unit/refpdf/hci.pdf

http://inside.mines.edu/~jjechura/EnergyTech/07_Hydrogen_from_SMR.pdf

http://www.chemengonline.com/psa-technology-beyond-hydrogen-
purification/?printmode=1

https://docs.google.com/file/d/0B6mmcxyrKnEhdEY0ZTMzeHNVSHM/edit

http://www.peacesoftware.de/einigewerte/wasser_dampf_e.html

https://www.engineering-4e.com/physical-properties-calculator

84