Ammonia / Methanol Flowsheet Integration

“Reducing Risk and Increasing Profitability”

Case Study #72514GB/H

Contents

Conventional Ammonia Plant Flow Sheet

Conventional Methanol Plant Flow Sheet
Superstructure Block Diagram
Process Design Tools
Pi Algorithm Approach
Ammonia / Methanol Flow Sheet Integration: Case Study#72514GB/H
Equipment List
Integration Flowsheet 1: Feed Preparation (HDS)
Integration Flowsheet 2: Feed Preparation (Saturator Circuit)
Integration Flowsheet 3: Pre-reformer, AGHR, ATR
Integration Flowsheet 4: Isothermal Shift
Integration Flowsheet 5: CO2 Removal
Stream Component - Material Balances
Table 1
Table 2
Table 3
Conventional Ammonia Plant Flow Sheet
Conventional Methanol Plant Flow Sheet
Superstructure Block Diagram
Process Design Tools
PFD SIM - in Excel
Ammonia / Methanol Flow Sheet Integration
Case Study#72514GB/H
 Equipment List

Tag Description

B-101 HDS Fired Heater

B-301 Pre-reformer Fired Heater
E-101 HDS Interchanger
E-301 AGHR Interchanger
E-401 HT Saturator Water Heater
E-402 NH3 Syngas Saturator Water Heater
E-403 NH3 Syngas Cooler
E-404 MeOH Syngas Saturator Water Heater
E-405 MeOH Syngas Cooler
J-201 Cool Saturator Water Pump
J-202 Hot Saturator Water Pump
K-101 Natural Gas Compressor
R-101 HDS
R-102A H2S Absorber 1
R-102B H2S Absorber 2
R-301 Pre-reformer
R-302 AGHR
R-303 ATR
R-401 Isothermal Shift
T-201 Saturator
V-401 NH3 Syngas KO Pot
V-402 MeOH Syngas KO Pot
X-501 CO2 Removal
X-502 Cold Box
 Integration Flowsheet 1: Feed Preparation (HDS)

B-101

R-102B
H2 Recycle
from CO2 Removal

S-414
R-101 R-102A

S-101
Natural Gas K-101

E-101
To Saturator

S-107
 Integration Flowsheet 2: Feed Preparation (Saturator Circuit)

MP Steam

S-202
S-201 S-203
Mixed Feed
to Reformer
Water from
E-401

To FXC
To E-401
J-202

S-107
From HDS

T-201 To E-402
J-201

Process
Condensate
 Integration Flowsheet 3: Pre-reformer, AGHR, ATR
S-304
O2 from ASU
B-301

S-302
Fuel Gas
From FC
R-301
S-308
Reform Gas
to E-401

S-203
Mixed Gas
from Saturator S-203 S-301
E-301

S-307

R-302

R-303

S-305
 Integration Flowsheet 4: Isothermal Shift

S-308

Reform S-420
Gas from Water to S-410
E-301 Saturator MeOH
E-401
From Co2 Syngas
Removal
From S-401 S-415
V-402
J-202
E-404 E-405
From FCV

S-404
S-405 S-408
R-301 To CO2
From
201 Removal
V-401
E-402
E-403
 Integration Flowsheet 5: CO2 Removal

S-410 S-509
To MeOH NH3
Syngas Syngas

S-414

H2 R/C to
HDS

S-411
X-502 S-508
Fuel Gas

N2 from S-501
From
ASU
V-401

S-408
CO
X-501
S-502 Product
 Stream Component: Material Balances
Table 1
Name S-101 S-107 S-201 S-202 S-203 S-301 S-302

Temperature (C) 27 154.3 223.8 350 260.3 400 504.2

Pressure (bar) 22 52.2 51.7 55 51.7 51.1 50.3
Molar Flow (kgmole/h) 10360 10587.3 22437.5 9317.5 31755 31755 31755
Mass Flow (kg/h) 172113 172942 386425 167856 554281 554281 554281

Hydrogen 0.000% 2.005% 0.946% 0.000% 0.668% 0.668% 0.668%

CO 0.000% 0.121% 0.057% 0.000% 0.040% 0.040% 0.040%
CO2 0.640% 0.626% 0.296% 0.000% 0.209% 0.209% 0.209%
Methane 96.570% 94.514% 44.597% 0.000% 31.512% 31.512% 31.512%
Ethane 2.710% 2.652% 1.251% 0.000% 0.884% 0.884% 0.884%
Propane 0.010% 0.010% 0.005% 0.000% 0.003% 0.003% 0.003%
Nitrogen 0.070% 0.071% 0.033% 0.000% 0.024% 0.024% 0.024%
Methanol 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
H2O 0.000% 0.000% 52.815% 100.000% 66.660% 66.660% 66.660%
Oxygen 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
Argon 0.000% 0.002% 0.001% 0.000% 0.001% 0.001% 0.001%
 Stream Component: Material Balances
Table 2

Name S-303 S-304 S-305 S-307 S-308 S-401 S-402 S-404 S-405

Temperature (C) 450 40 1050 580 460.5 220 220 220 252.7
Pressure (bar) 49.3 45.8 42.8 42.3 41.9 41.3 41.3 41.3 39.8
Molar Flow 32843.6 4913.8 52509.3 52444 52444 52444 21711 4511 26222.4
(kgmole/h) 554281 157338 711619 711619 711619 711619 294600 61210 355809
Mass Flow (kg/h)
6.426% 0.000% 45.832% 45.280% 45.280% 45.280% 45.280% 45.280% 56.638%
Hydrogen 0.027% 0.000% 14.392% 14.770% 14.770% 14.770% 14.770% 14.770% 3.413%
CO 1.871% 0.000% 5.475% 5.059% 5.059% 5.059% 5.059% 5.059% 16.416%
CO2 30.529% 0.000% 0.416% 0.479% 0.479% 0.479% 0.479% 0.479% 0.479%
Methane 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
Ethane 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
Propane 0.023% 0.500% 0.061% 0.061% 0.061% 0.061% 0.061% 0.061% 0.061%
Nitrogen 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
Methanol 61.124% 0.000% 33.777% 34.304% 34.304% 34.304% 34.304% 34.304% 22.946%
H2O 0.000% 99.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
Oxygen 0.001% 0.500% 0.047% 0.047% 0.047% 0.047% 0.047% 0.047% 0.047%
Argon
 Stream Component: Material Balances
Table 3

Name S-408 S-410 S-411 S-414 S-415 S-420 S-501 S-502 S-508 S-509

Temperature (C) 45 45 45 45 220 45 0 45.3 28.8 31.7

Pressure (bar) 38.4 37.9 37.9 37.9 41.3 37.9 50 37.9 37.9 37.9
Molar Flow 20253.9 109.8 15563.5 227.2 26222 17378.6 4998.6 832 735.1 18995
(kgmole/h) 247979 400 56732 828 355809 194736 140025 23304 11709 161744
Mass Flow (kg/h)
73.328% 93.405% 93.405% 93.405% 45.280% 68.910% 0.000% 0.000% 39.549% 75.001%
Hydrogen 100.000
CO 4.418% 5.627% 5.627% 5.627% 14.770% 22.316% 0.000% % 5.956% 0.000%
CO2 21.195% 0.000% 0.000% 0.000% 5.059% 7.594% 0.000% 0.000% 0.000% 0.000%
Methane 0.620% 0.790% 0.790% 0.790% 0.479% 0.727% 0.000% 0.000% 16.717% 0.000%
Ethane 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
Propane 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
Nitrogen 100.000
Methanol 0.079% 0.101% 0.101% 0.101% 0.061% 0.093% % 0.000% 36.131% 24.999%
H2O 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
Oxygen 0.299% 0.000% 0.000% 0.000% 34.304% 0.287% 0.000% 0.000% 0.000% 0.000%
Argon 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%
0.061% 0.078% 0.078% 0.078% 0.047% 0.072% 0.000% 0.000% 1.647% 0.000%