Group 9 Chapter 3 and 4

PRODUCTION OF 30,000 TONS/YEAR OF METHANOL FROM CARBON DIOXIDE
RECOVERED FROM THE FLARE GAS OF CRUDE OIL WELLS VIA CATALYTIC
HYDROGENATION USING Cu/Zn/Al2O3/Zr Catalyst
A FINAL YEAR DESIGN PROJECT
PRESENTED TO
THE DEPARTMENT OF CHEMICAL ENGINEERING
BY
GROUP 9
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE

BACHELOR OF ENGINEERING (B.Eng.) IN CHEMICAL ENGINEERING, COVENANT
UNIVERSITY, OTA
OCTOBER 2022
DESIGN TEAM
1. CHARLES DANIEL CHRIS 18CF023951
2. FADIORA AYOBAMI DANIEL 18CF023957
3. SHOWUNMI MOFEYIFOLUWA 18CF023999
4. OJOMO PETER 17CF022368
5. OKEGBENRO OLAMIDE 17CF022370
6. OKPARA UCHENNA 18CF023983
7. SHOROYE MODESOLA ESTHER 18CF023998
8. SHOWUNMI MOFEYIFOLUWA 18CF023999

TABLE OF CONTENTS
DESIGN TEAM ii
LIST OF TABLES v
LIST OF FIGURES vii
CHAPTER 3 1
3.1 Introduction 1
3.2 Aspen Simulation 1
3.3 Overall Material Balance for the Production Process 4
3.4 Reforming Process 6
3.4.1 Material balance around P.S.A (A) 7
3.4.2 Material balance around Heater (B) 10
3.4.3 Material balance around Mixer 1 12
3.4.4 Material balance around Heat Exchanger (C) 13
3.4.5 Material balance around Compressor (D) 16
3.4.6 Material balance around Heater (E) 18
3.4.7 Material balance around Steam Reformer (F) 20
3.4.8 Material balance around Cooler (G) 22
3.4.9 Material balance around Water Gas Shift Reactor (H) 24
3.5 Methanol Synthesis Process 27
3.5.1 Material balance around mixer 2 28
3.5.2 Material balance around compressor (I) 30
3.5.3 Material balance around cooler (J) 32
3.5.4 Material balance around methanol synthesis reactor (K) 34
3.5.5 Material balance around cooler (L) 36
3.5.6 Material balance around flash separator (M) 38
3.5.7 Material balance around splitter 41
3.5.8 Material balance around Mixer 3 42
3.5.9 Material balance around P.S.A (N) 44
3.5.10 Material balance around Cooler (O) 46
3.5.11 Material balance around Expansion valve (P) 48
3.5.12 Material balance around Flash separator (Q) 50
3.6 Methanol Purification Process 53
3.6.1 Material balance around Heater (R) 54
3.6.2 Material balance around Distillation column (S) 56
3.6.3 Material balance around Cooler (T) 58
CHAPTER 4 60
4.1 Introduction 60
4.2 Overall Energy Balance 61
4.2.1 Energy balance around P.S.A (A) 63
4.2.2 Energy balance around Heater, B 65
4.2.3 Energy balance around Mixer 1 66
4.2.4 Energy Balance around Heat Exchanger (C) 68
4.2.5 Energy Balance around Compressor (D) 70
4.2.6 Energy Balance around Heater (E) 71
4.2.7 Energy Balance around Steam Reformer (F) 73
4.2.8 Energy Balance around Cooler (G) 75
4.2.9 Energy Balance around W.G.S Reactor (H) 77
4.2.10 Energy Balance around Mixer 2 79
4.2.11 Energy Balance around Compressor (I) 80
4.2.12 Energy Balance around Cooler (J) 81
4.2.13 Energy Balance around Synthesis Reactor (K) 82
4.2.14 Energy Balance around Cooler (L) 84
4.2.15 Energy Balance around Flash Separator (M) 86
4.2.16 Energy Balance around Splitter 87
4.2.17 Energy Balance around Mixer 3 88
4.2.18 Energy Balance around P.S.A (N) 89
4.2.19 Energy Balance around Cooler (O) 91
4.2.20 Energy Balance around Expansion valve (P) 92
4.2.21 Energy Balance around Flash Separator (Q) 94
4.2.23 Energy balance around Heater (R) 95
4.2.24 Energy balance around Distillation Column (S) 97
4.2.25 Energy balance around Cooler (T) 98
LIST OF TABLES
Table 2.1: Greenhouse Gases and their Major Sources.................Error! Bookmark not defined.
Table 2.2: Notable milestones in the history of hydrogen.............Error! Bookmark not defined.
Table 2.3: Properties of Methanol.................................................................................................34
Table 2.4: Reaction units and respective reactions........................Error! Bookmark not defined.
Table 2.5: Mass balance inputs, outputs and conversion ratios for different process steps. .Error!
Bookmark not defined.
Table 3.1: Components Specifications Table 4

Table 3.2: Overall material balance for the production process 5
Table 3.3: Overall material balance for the reforming process 7
Table 3.4: Material balance around P.S.A (A) 9
Table 3.5: Material balance around Heater (B) 11
Table 3.6: Material balance around Mixer 1 12
Table 3.7: Material balance around Heat exchanger (C) 15
Table 3.8: Material balance around Compressor (D) 17
Table 3.9: Material balance around Heater (E) 19
Table 3.10: Material balance around Steam reformer (F) 21
Table 3.11: Material balance around Cooler (G) 23
Table 3.12: Material balance around Water Gas Shift Reactor (H) 26
Table 3.13: Overall material balance for the synthesis process 27
Table 3.14: Material balance around mixer 2 29
Table 3.16: Material balance around cooler (J) 33
Table 3.17: Material balance around methanol synthesis reactor (K) 35
Table 3.18: Material balance around compressor (L) 37
Table 3.19: Material balance around flash separator (M) 40
Table 3.20: Material balance around splitter 41
Table 3.21: Material balance around Mixer 3 43
Table 3.22: Material balance around P.S.A (N) 45
Table 3.23: Material balance around Cooler (O) 47
Table 3.24: Material balance around Expansion valve (P) 49
Table 3.25: Material balance around Flash separator (Q) 52
Table 3.26: Overall material balance for purification process 53
Table 3.27: Material balance around Heater (R) 55
Table 3.28: Material balance around Distillation column (S) 57
Table 3.29: Material balance around Cooler (T) 59
Table 4.1: Overall Energy balance for the production process 62
Table 4.2: Energy Balance around P.S.A (A) 64
Table 4.3: Energy balance around Heater (B) 65
Table 4.4: Energy balance around Mixer 1 67
Table 4.5: Energy balance around Heat exchanger (C) 69
Table 4.6: Energy balance around Compressor (D) 71
Table 4.7: Energy balance around Heater (E) 72
Table 4.8: Energy balance around Steam reformer (F) 74
Table 4.9: Energy balance around Cooler (G) 76
Table 4.10: Energy balance around Water Gas Shift Reactor (H) 78
Table 4.11: Energy balance around mixer 2 79
Table 4.12: Energy balance around compressor (I) 80
Table 4.13: Energy balance around cooler (J) 82
Table 4.14: Energy balance around methanol synthesis reactor (K) 83
Table 4.15: Energy balance around cooler (L) 85
Table 4.16: Energy balance around compressor (M) 87
Table 4.17: Energy balance around splitter 88
Table 4.18: Energy balance around Mixer 3 89
Table 4.19: Energy balance around P.S.A (N) 90
Table 4.20: Energy balance around Cooler (O) 91
Table 4.21: Energy balance around Expansion valve (P) 93
Table 4.22: Energy balance around Flash separator (Q) 95
Table 4.23: Energy balance around Heater (R) 96
Table 4.24: Energy balance around Distillation column (S) 97
Table 4.25: Overall material balance for Cooler (T) 98
LIST OF FIGURES
Figure 3.1: Aspen Plus simulation flowsheet for the overall process. 2
Figure 3.2: Overall process flow diagram for the process 3
Figure 3.3: Process Flow Diagram for Reforming Process 6
Figure 3.4: Aspen simulation Diagram for P.S.A (A) 8
Figure 3.5: Process Flow Diagram for P.S.A (A) 8
Figure 3.6: Process flow Diagram for Heater (B) 10
Figure 3.7: Aspen simulation Diagram for Heater (B) 10
Figure 3.8: Aspen simulation Diagram for Mixer 1 12
Figure 3.10: Aspen simulation Diagram for Heater Exchanger (C) 14
Figure 3.12: Process flow Diagram for compressor (D) 16
Figure 3.13: Process flow Diagram for Heater (E) 18
Figure 3.14: Aspen simulation Diagram for Heater (E) 18
Figure 3.15: Process flow Diagram for steam reformer (F) 20
Figure 3.16: Aspen simulation Diagram for steam reformer (F) 20
Figure 3.17: Process flow Diagram for Cooler (G) 22
Figure 3.18: Aspen simulation Diagram for Cooler (G) 23
Figure 3.19: Process flow Diagram for W.G.S Reactor (H) 25
Figure 3.20: Aspen simulation Diagram for W.G.S Reactor (H) 25
Figure 3.21: Block Flow Diagram for Methanol Synthesis Process 27
Figure 3.22: Aspen simulation Diagram for mixer 2 29
Figure 3.23: Process flow Diagram for compressor (I) 31
Figure 3.24: Aspen simulation Diagram for compressor (I) 31
Figure 3.25: Process flow Diagram for compressor (J) 33
Figure 3.26: Aspen simulation Diagram for cooler (J) 33
Figure 3.27: Process flow Diagram for methanol synthesis reactor (K) 35
Figure 3.28: Aspen simulation Diagram for methanol synthesis reactor (K) 35
Figure 3.29: Process flow Diagram for cooler (L) 37
Figure 3.30: Aspen simulation Diagram for cooler (L) 37
Figure 3.31: Process flow Diagram for flash separator (M) 39
Figure 3.32: Aspen simulation Diagram for flash separator (M) 39
Figure 3.33: Aspen simulation Diagram for splitter 41
Figure 3.35: Process flow Diagram for PSA (N) 45
Figure 3.36: Aspen simulation Diagram for P.S.A (N) 45
Figure 3.37: Process flow Diagram for Cooler (O) 47
Figure 3.38: Aspen simulation Diagram for COOLER (O) 47
Figure 3.39: Process flow Diagram for Expansion valve (P) 49
Figure 3.40: Aspen simulation Diagram for Expansion valve (P) 49
Figure 3.41: Process flow Diagram for Flash separator (Q) 51
Figure 3.42: Aspen simulation Diagram for Flash separator (Q) 51
Figure 3.43: Process Flow Diagram for Methanol Purification Process 53
Figure 3.44: Process flow Diagram for Heater (R) 54
Figure 3.45: Aspen simulation Diagram for Heater (R) 55
Figure 3.46: Process flow Diagram for Distillation column (S) 56
Figure 3.47: Aspen Diagram for Distillation column (S) 57
Figure 3.48: Process flow Diagram for Cooler (T) 58
Figure 3.49: Aspen simulation Diagram for Cooler (T) 58
Figure 4.1: Aspen simulation Diagram for P.S.A (A) 63
Figure 4.2: Process Flow Diagram for P.S.A (A) 64
Figure 4.3: Process flow Diagram for Heater (B) 65
Figure 4.4: Aspen simulation Diagram for Heater (B) 65
Figure 4.5: Aspen simulation Diagram for Mixer 1 66
Figure 4.6: Process flow Diagram for Heater Exchanger (C) 68
Figure 4.7: Aspen simulation Diagram for Heater Exchanger (C) 68
Figure 4.8: Process flow Diagram for compressor (D) 70
Figure 4.9: Aspen simulation Diagram for compressor (D) 70
Figure 4.10: Process flow Diagram for Heater (E) 71
Figure 4.11: Aspen simulation Diagram for Heater (E) 72
Figure 4.12: Process flow Diagram for steam reformer (F) 73
Figure 4.13: Aspen simulation Diagram for steam reformer (F) 73
Figure 4.14: Process flow Diagram for Cooler (G) 75
Figure 4.15: Aspen simulation Diagram for Cooler (G) 75
Figure 4.16: Process flow Diagram for W.G.S Reactor (H) 77
Figure 4.17: Aspen simulation Diagram for W.G.S Reactor (H) 77
Figure 4.19: Process flow Diagram for compressor (I) 80
Figure 4.20: Aspen simulation Diagram for compressor (I) 80
Figure 4.21: Process flow Diagram for cooler (J) 81
Figure 4.22: Aspen simulation Diagram for cooler (J) 81
Figure 4.23: Process flow Diagram for methanol synthesis reactor (K) 83
Figure 4.24: Aspen simulation Diagram for methanol synthesis reactor (K) 83
Figure 4.25: Process flow Diagram for cooler (L) 84
Figure 4.26: Aspen simulation Diagram for cooler (L) 84
Figure 4.27: Process flow Diagram for flash separator (M) 86
Figure 4.28: Aspen simulation Diagram for compressor (M) 86
Figure 4.29: Aspen simulation Diagram for splitter 87
Figure 4.31: Process flow Diagram for P.S.A (N) 89
Figure 4.32: Aspen simulation Diagram for P.S.A (N) 90
Figure 4.33: Process flow Diagram for Cooler (O) 91
Figure 4.34: Aspen simulation Diagram for Cooler (O) 91
Figure 4.35: Process flow Diagram for Expansion valve (P) 92
Figure 4.36: Aspen simulation Diagram for Expansion valve (P) 92
Figure 4.37: Process flow Diagram for Flash separator (Q) 94
Figure 4.38: Aspen simulation Diagram for Flash separator (Q) 94
Figure 4.39: Process flow Diagram for Heater (R) 95
Figure 4.40: Aspen simulation Diagram for Heater (R) 96
Figure 4.41: Process flow Diagram for Distillation column (S) 97
Figure 4.42: Aspen Diagram for Distillation column (S) 97
Figure 4.43: Process flow Diagram for Cooler (T) 98
Figure 4.44: Aspen simulation Diagram for Cooler (T) 98
CHAPTER 3
MATERIAL BALANCE
3.1 Introduction
For the study of physical systems, mass or material balance is based on the law of conservation
of matter. This The law asserts that mass cannot be created or destroyed by physical or chemical
methods in an ideal system, and that mass remains constant. Theis equation for material balance
equation calculates determines the number of reactants and products needed required for a
process, and, as well as their quantities that can be obtained in the appropriate amounts. Hence,
Mmaterial balances are is fundamental to the control of processingprocess control, particularly in
the control of yields of the products.
The general material balance equation for a system is given below;
Mass Input + Mass Generation – Mass Output -Mass Consumption = Mass Accumulation (3.1)
Where:
i. Mass Input: Enters Matter entering through the system boundaries
ii. Mass Generation: Matter pProduced within the system
iii. Mass Output: Matter lLeavinges through system boundaries
iv. Mass Consumption: Matter cConsumed within the system
v. Mass Accumulation: MatterMass built dup within the system
3.2 Aspen PlusAspen Simulation
The simulation of this process was carried out using the process simulation software, Aspen Plus
(V11). The process was simulated to achieve the design intent of producing 30,000 tons of pure
methanol per year using flare gas from crude oil wells as a feedstock. The Aspen Plus simulation
flowsheet and overall block diagram for the process is shown in Figures 3.1 and 3.2
Figure 1: Aspen Plus simulation flowsheet for the overall process.Figure 3.1: Aspen Plus
simulation flowsheet for the overall process.
BFD
Figure 3.2: Overall flow diagram for the process

Figure 2: Overall process flow diagram for the process
Table 1.1: Components Specifications TableTable 3.4: Material balance around P.S.A (A)
COMPONENT TYPE COMPONENT NAME CHEMICAL
ID FORMULA
CO2 Conventional CARBON DIOXIDE CO2
H2O Conventional WATER H2O
CO Conventional CARBON MONOXIDE CO
H2 Conventional HYDROGEN H2
CH3OH Conventional METHANOL METHANOL
CH4 Conventional METHANE CH4
C3H8 Conventional PROPANNE C3H8
C2H6 Conventional ETHANE C2H6
N-BUTANE Conventional N-BUTANE C4H10
N-PENTANE Conventional N-PENTANE C5H12
ISO-BUTANE Conventional ISO-BUTANE HC(CH3)3
ISO-PENTANE ISO-PENTANE CH3CH2CH(CH3)
Conventional 2
N-HEXANE Conventional N-HEXANE C6H14
N-HEPTANE Conventional N-HEPTANE C7H16
H2S HYDROGEN
Conventional SULPHIDE H2S
Component
Table 3.1
3.3 Overall Material Balance for the Production Process
The material balance calculations performed around the various unit operations and equipment in
the green hydrogen productionmethanol production process can be grouped into the following:
i. Material balance around the reforming process

ii. Material balance around the synthesis process
iii. Material balance around the purification process
The overall material balance of the production process is shown in Table 3.2.Figure 3.3
Table 2.2: Overall material balance for the production process
FEED PRODUCT
24 25 29
4 30
1 (CO2 32
(WATE 3 (COMBUST 33
(FLARE FOR (PURE
R) (H2S) (PURE
Component GAS) IBLE STORA WATER
Mass Mass METHAN
s Mass GE) )
flow flow rate GASES) OL)
flow rate Mass Mass
rate (kg/s) Mass flow Mass flow
(kg/s) flow rate flow rate
(kg/s) rate (kg/s) rate (kg/s)
(kg/s) (kg/s)
CO2 0.040141 0.402285 1.03464 0.0011592
0 0
779 0.004063488 339 E-84 29
H2O 0.008341 1.65740 0.812074 2.73379E-
0
075 576 0.007616634 0 74 12
CO 1.4099E- 4.61193E-
0 0 0
0.036834994 0 134 08
H2 5.4233E- 7.42419E-
0 0 0
0.133548234 0 143 08
CH3OH 0.024592 0.8618265
0 0 0
0.041506292 0 334 81
CH4 0.652160 3.5563E- 1.72267E-
0 0
654 0.032606128 0 111 06
C3H8 0.052511 8.51192 2.14632E-
0 0
723 0.052489259 0 E-87 05
C2H6 0.059865 3.3655E- 2.36696E-
0 0
646 0.059841073 0 94 05
N- 0.022686 8.4122E- 6.21747E-
0 0
BUTANE 086 0.022679454 0 83 06
N- 0.006347 2.93123 5.20651E-
0 0
PENTANE 06 0.00634646 0 E-83 07
ISO- 0.014801 3.74871 1.02639E-
0 0
BUTANE 124 0.014799949 0 E-91 06
ISO- 0.008852 3.02883 6.04069E-
0 0
PENTANE 479 0.008851774 0 E-85 07
N- 0.006783 2.69158 1.05196E-
0 0
HEXANE 004 0.006782847 0 E-85 07
N- 0.007887 1.50921 2.22132E-
0 0
HEPTANE 06 0.007887007 0 E-87 08
H2S 0.002682 0.002682
0
585 585 0 0 0 0
Total (kg/s) 0.883060 1.65740 0.002682 0.402285 0.836667 0.8630412
0.435789756
275 576 585 339 074 82
From Table 3.2 above,

Total feed mass flowrate = 0.883060275 + 1.65740576 = 2.540466035 kg/s
Total product mass flowrate = 0.002682585 + 0.435789756 + 0.402285339 + 0.836667074 +
0.863041282 = 2.540466035 kg/s
Since the total feed mass flowrate and product mass flowrate are equal, this implies that there is
no accumulation in the system. Hence, it is balanced.
3.4 Reforming Process
Figure 3: Process Flow Diagram for Reforming Process3.3Process
title
Table 3.3: Overall material balance for the reforming process
FEED PRODUCT
1
4 3 13
(FLARE
(WATER) (H2S) (CO, CO2, H2)
Components GAS)
Mass flow Mass flow Mass flow rate
Mass flow
rate (kg/s) rate (kg/s) (kg/s)
rate (kg/s)
CO2 0.040141779 0 0 1.654768414
H2O 0.008341075 1.6574058 0 0.309075215
CO 0 0 0 0.054086444
H2 0 0 0 0.307511162
CH3OH 0 0 0 0
CH4 0.652160654 0 0 0.032608033
C3H8 0.052511723 0 0 0.052511723
C2H6 0.059865646 0 0 0.059865646
N-BUTANE 0.022686086 0 0 0.022686086
N-PENTANE 0.00634706 0 0 0.00634706
ISO-BUTANE 0.014801124 0 0 0.014801124
ISO-PENTANE 0.008852479 0 0 0.008852479
N-HEXANE 0.006783004 0 0 0.006783004
N-HEPTANE 0.00788706 0 0 0.00788706
H2S 0.002682585 0 0.002682585 0
Total (kg/s) 0.883060275 1.6574056 0.002682585 2.53778345

Total product mass flowrate = 0.002682585 + 2.53778345 = 2.540466035 kg/s
Since the total feed mass flowrate and product mass flowrate are equal, this implies that there is
no accumulation in the system. Hence, it is balanced.
3.4.1 Materiaal balance around P.S.A (A)
The feed (flare gas) contains hydrogen sulphide which can cause fouling and corrosion in
equipment downstream. Hence, the P.S.A (A) is installed to selectively adsorb H2S from the feed
gas (stream 1).
Assumptions:
1. High H2S selectivity.
CLEAN
FLARE GAS
GAS
S1
S2
A
S3
P.S.A
(REMOVES H2S)
H2S
Figure 4: Aspen simulation Diagram for P.S.A (A)

Figure 53.4: Aspen simulation Diagram for P.S.A (A)
Figure 6: Process Flow Diagram for P.S.A (A) Figure 73.5: Block Process Flow Diagram
for P.S.A (A)
Table 4.4: Material balance around P.S.A (A)Table 3.4: Material balance around P.S.A (A)
FEED PRODUCT
1
3 2
(FLARE
Mass (H2S) Mass (CLEAN GAS) Mass
Components GAS)
fraction Mass flow rate fraction Mass flow rate fraction
Mass flow
(kg/s) (kg/s)
rate (kg/s)
CO2 0.04014177 0.04545757
0 0 0.040141779 0.045596088
9 5
H2O 0.00834107 0.00944564
0 0 8.34E-03 0.009474428
5 6
CO 0.00E+00 0 0 0 0 0
H2 0.00E+00 0 0 0 0 0
CH3OH 0 0 0 0 0 0
CH4 0.73852337
6.52E-01 0 0 6.52E-01 0.740773717
4
C3H8 0.05946561
5.25E-02 0 0 5.25E-02 0.059646813
6
C2H6 0.06779338
5.99E-02 0 0 5.99E-02 0.067999958
6
N-BUTANE 0.02569030
2.27E-02 0 0 2.27E-02 0.025768584
3
N-PENTANE 0.00718757
6.35E-03 0 0 6.35E-03 0.007209474
3
ISO-BUTANE 1.48E-02 0.01676117 0 0 1.48E-02 0.016812243
ISO-PENTANE 0.01002477
8.85E-03 0 0 8.85E-03 0.010055319
3
N-HEXANE 0.00768124
6.78E-03 0 0 6.78E-03 0.007704653
7
N-HEPTANE 0.00893150
7.89E-03 0 0 7.89E-03 0.008958723
8
H2S 0.00268258 0.00303782
0.002682585 1 0 0
5 7
Total (kg/s) 0.88306027
0.002682585 0.88037769
5
Total feed mass flowrate = 0.883060275 kg/s

Since the total feed mass flowrate and product mass flowrate are equal, this implies that there
is no accumulation of mass in the system. Hence, the system is balanced.
3.4.2 Material balance around Heater (B)
Steam is required in the steam methane reforming process carried out in the S.M.R Reactor (F).
Hence, a heater is used to generate steam from water at ambient temperature.
Assumptions
1. Operates isothermally at 105℃

2.
3.
4.
Figure 8Figure 93.6: Block Process flow Diagram for Heater (B)
HEATER
WATER S4
STEAM
S5
Figure 10Figure 113.7: Aspen simulation Diagram for Heater (B)

Assumptions
Table 5.5: Material balance around Heater (B)TABLE
FEED PRODUCT
Components 4 Mass 5 Mass
(WATER) Fraction (STEAM) Fraction
Mass flow Mass flow
rate (kg/s) rate (kg/s)
CO2 0 0 0 0
H2O 1.65740576 1 1.65740576 1
CO 0 0 0 0
H2 0 0 0 0
CH3OH 0 0 0 0
CH4 0 0 0 0
C3H8 0 0 0 0
C2H6 0 0 0 0
N-BUTANE 0 0 0 0
N-PENTANE 0 0 0 0
ISO- 0 0
BUTANE 0 0
ISO- 0 0
PENTANE 0 0
N-HEXANE 0 0 0 0
N-HEPTANE 0 0 0 0
H2S 0 0 0 0
Total (kg/s) 1.65740576 1.65740576
From Table 3.5x above,

Total product mass flowrate = 1.65740576 kg/s
3.4.3 Material balance around Mixer 1

The mixer is used to combine steam and H2S-free gas streams and supply a uniform mixture as
feed to the S.M.R reactor (F).
Assumptions
1. 100% mixing efficiency.
2.
Figure 12: Block flow Diagram for Heater (B)Mixer
3.
STEAM
S5
MIXER-01
CLEAN
GAS
S2
COLD
STREAM
INLET
S6
Figure 13Figure 3.814: Aspen simulation Diagram for Heater (B)Mixer 1

Table 6.67.5: Material balance around Mixer 1
FEED PRODUCT
Components 33 Mass 5 Mass 6 Mass
(H2S) Fraction (STEAM) Fraction (COLD Fraction
Mass flow Mass flow STREAM
rate (kg/s) rate (kg/s) INLET)
Mass flow
rate (kg/s)
CO2 0.040141779 0 0 0 0.040141779 0.015817653
H2O 0.008341075 0 1.65740576 1 1.665746835 0.656378634
CO 0 0 0 0 0 0
H2 0 0 0 0 0 0
CH3OH 0 0 0 0 0 0
CH4 0.652160654 0 0 0 0.652160654 0.256980419
C3H8 0.052511723 0 0 0 0.052511723 0.020691964
C2H6 0.059865646 0 0 0 0.059865646 0.023589738
N-BUTANE 0.022686086 0 0 0 0.022686086 0.008939331
N-PENTANE 0.00634706 0 0 0 0.00634706 0.002501025
ISO- 0.014801124 0 0 0.014801124
BUTANE 0 0.005832304
ISO- 0.008852479 0 0 0.008852479
PENTANE 0 0.003488272
N-HEXANE 0.006783004 0 0 0 0.006783004 0.002672807
N-HEPTANE 0.00788706 0 0 0 0.00788706 0.003107854
H2S 0 1 0 0 0 0
Total (kg/s) 0.88037769 1.65740576 2.53778345

Total product mass flowrate = 0.88037769 + 1.65740576= 2.53778345 kg/s
3.4.4 Material balance around Heat Exchanger (C)(C)

In order to reduce heat duty (thereby making the process more cost-effective), a heat exchanger
is installed to utilize the high temperature of the S.M.R reactor outlet to pre-heat the feed to the
reactor. This simultaneously reduces the workload of the heater (E) placed before the reactor and
the cooler (G) used to cool down the feed to the W.G.S reactor.
Assumptions
1. Operates adiabatically.
2. Hot stream temperature decrease of 100℃
Figure 3.915: Block Process flow Diagram for Heater Exchanger (C)
COLD S11
STREAM HOT S10
INLET STREAM S7
S6 OUTLET
COLD
STREAM
OUTLET
HOT
STREAM
C INLET
HEAT
EXCHANGER
Figure 16Figure 173.10: Aspen simulation en Diagram for Heater Exchanger (C)
Assumptions
Ubs
Table 8.79.6: Material balance around Heat exchanger (C)
FEED PRODUCT
Components 6 10 7 11
(COLD (HOT (COLD (HOT
STREAM STREAM STREAM STREAM
INLET) INLET) OUTLET) OUTLET)
Mass flow Mass flow Mass flow Mass flow
rate (kg/s) rate (kg/s) rate (kg/s) rate (kg/s)
CO2 0.040141779 0.040141779 0.040141779 0.040141779
H2O 1.665746835 0.970017799 1.665746835 0.970017799
CO 0 1.081728876 0 1.081728876
H2 0 0.233552781 0 0.233552781
CH3OH 0 0 0 0
CH4 0.652160654 0.032608033 0.652160654 0.032608033
C3H8 0.052511723 0.052511723 0.052511723 0.052511723
C2H6 0.059865646 0.059865646 0.059865646 0.059865646
N-BUTANE 0.022686086 0.022686086 0.022686086 0.022686086
N-PENTANE 0.00634706 0.00634706 0.00634706 0.00634706
ISO- 0.014801124 0.014801124 0.014801124 0.014801124
BUTANE
ISO- 0.008852479 0.008852479 0.008852479 0.008852479
PENTANE
N-HEXANE 0.006783004 0.006783004 0.006783004 0.006783004
N-HEPTANE 0.00788706 0.00788706 0.00788706 0.00788706
H2S 0 0 0 0
Total (kg/s) 2.53778345 2.53778345 2.53778345 2.53778345

3.4.5 Material balance around Compressor (D)

This compressor raises the feed to the S.M.R reactor to the required pressure of 25 bars. This
also serves to reduce the work done by compressor (I) which raises the feed to the methanol
synthesis to the specified pressure of 58 bars. An additional benefit of the increase in pressure is
a simultaneous increase in temperature, thus reducing the heat duty of heater (E).
Assumptions
1. Operates isentropically with an at efficiency of 75%

Figure 18Figure 193.11: Aspen Process flow Diagram for Heater Exchanger (C)compressor (D)
S8
STEAM
CLEAN GAS
D
COMPRESSOR
COLD
STREAM
OUTLET
S7
Figure 3.1220: Aspen simulation Diagram for compressor (D)Heater Exchanger (C)
Table 10.811.7: Material balance around Compressor (D)
FEED PRODUCT

(COLD Fraction (COLD Fraction
STREAM STREAM
INLET) OUTLET)
Mass flow Mass flow
CO2 0.040141779 0.015817653 0.040141779 0.015817653
H2O 1.665746835 0.656378634 1.665746835 0.656378634
CO 0 0 0 0
H2 0 0 0 0
CH3OH 0 0 0 0
CH4 0.652160654 0.256980419 0.652160654 0.256980419
C3H8 0.052511723 0.020691964 0.052511723 0.020691964
C2H6 0.059865646 0.023589738 0.059865646 0.023589738
N-BUTANE 0.022686086 0.008939331 0.022686086 0.008939331
N-PENTANE 0.00634706 0.002501025 0.00634706 0.002501025
ISO-
0.014801124 0.005832304 0.014801124 0.005832304
BUTANE
ISO-
0.008852479 0.003488272 0.008852479 0.003488272
PENTANE
N-HEXANE 0.006783004 0.002672807 0.006783004 0.002672807
N-HEPTANE 0.00788706 0.003107854 0.00788706 0.003107854
H2S 0 0 0 0
Total (kg/s) 2.53778345 2.53778345

The total feed mass flowrate = 2.53778345 + 2.53778345 = 5.0755669 kg/s
And the total product mass flowrate = 2.53778345 + 2.53778345 = 5.0755669 kg/s
3.4.6 Material balance around Heater (E)

This raises the temperature of the S.M.R reactor feed to the required temperature of 800℃.
Assumptions
Figure 21Figure 223.13: Block Process flow Diagram for Heater (E)
E
SMR REACTOR
HEATER
FEED
S8 S9
STEAM
CLEAN GAS
Figure 23Figure 243.14: Aspen simulation Diagram for Heater (E)

Table 12.9.8: Material balance around Heater (E)
FEED PRODUCT

(STEAM + Fraction (S.M.R Fraction
CLEAN REACTOR
GAS) FEED)
Mass flow Mass flow
CO2 0.040141779 0.015817653 0.040141779 0.015817653
H2O 1.665746835 0.656378634 1.665746835 0.656378634
CO 0 0 0 0
H2 0 0 0 0
CH3OH 0 0 0 0
CH4 0.652160654 0.256980419 0.652160654 0.256980419
C3H8 0.052511723 0.020691964 0.052511723 0.020691964
C2H6 0.059865646 0.023589738 0.059865646 0.023589738
N-BUTANE 0.022686086 0.008939331 0.022686086 0.008939331
N-PENTANE 0.00634706 0.002501025 0.00634706 0.002501025
ISO-
0.014801124 0.005832304 0.014801124 0.005832304
BUTANE
ISO-
0.008852479 0.003488272 0.008852479 0.003488272
PENTANE
N-HEXANE 0.006783004 0.002672807 0.006783004 0.002672807
N-HEPTANE 0.00788706 0.003107854 0.00788706 0.003107854
H2S 0 0 0 0
Total (kg/s) 2.53778345 2.53778345
The tTotal feed mass flowrate = 2.53778345 kg/s

And the tTotal product mass flowrate = 2.53778345 kg/s
3.4.7 Material balance around Steam Reformer (F)

In this reactor, methane reacts with steam to yield carbon monoxide and hydrogen at a pressure
of 800ºC and 25 bars.
Assumptions
1. Operates isothermally at 800ºC and 25 bars.
2. 95% conversion of methane [add BFD]

Figure 25Figure 263.15: BlockProcess flow Diagram for steam reformer (F)
SMR REACTOR
FEED F
S9
STEAM METHA NE
REFORMER
HOT
STREAM
INLET
S10
Figure 27Figure 283.16: Aspen simulation Diagram for steam reformer (F)
Table 13.10.8: Material balance around Steam reformer (F)
FEED PRODUCT
Components 99 Mass 10 10 Mass

(S.M.R (HOT
REACTOR STREAM
FEED) Fraction INLET) Fraction
Mass flow Mass flow
CO2 0.040141779 0.015817653 0.040141779 0.015817653
H2O 1.665746835 0.656378634 0.970017799 0.382230327
CO 0 0 1.081728876 0.42624948
H2 0 0 0.233552781 0.092030225
CH3OH 0 0 0 0
CH4 0.652160654 0.256980419 0.032608033 0.012849021
C3H8 0.052511723 0.020691964 0.052511723 0.020691964
C2H6 0.059865646 0.023589738 0.059865646 0.023589738
N-BUTANE 0.022686086 0.008939331 0.022686086 0.008939331
N-PENTANE 0.00634706 0.002501025 0.00634706 0.002501025
ISO-
0.014801124 0.005832304 0.014801124 0.005832304
BUTANE
ISO-
0.008852479 0.003488272 0.008852479 0.003488272
PENTANE
N-HEXANE 0.006783004 0.002672807 0.006783004 0.002672807
N-HEPTANE 0.00788706 0.003107854 0.00788706 0.003107854
H2S 0 0 0 0
Total (kg/s) 2.53778345 2.53778345
The total feed mass flowrate = 2.53778345 kg/s

3.4.8 Material balance around Cooler (G)
This equipment is responsible for reducing the temperature of the hot stream outlet of the heat
exchanger (C) to the required temperature for the W.G.S reaction which is 430℃.
Assumptions
[add BFD]
Figure 29Figure 303.17: BlockProcess flow Diagram for Cooler (G)
HOT G
STREAM
COOLER
OUTLET
W.G.S
S11
REACTOR
FEED
S12
Figure 31Figure 323.18: Aspen simulation Diagram for Cooler (G)

Table 14.11.9: Material balance around Cooler (G)
FEED PRODUCT
11 122
(HOT (W.G.S
STREAM Mass REACTOR Mass
Components
OUTLET) Fraction FEED) Fraction
Mass flow Mass flow
CO2 0.040141779 0.015817653 0.040141779 0.015817653
H2O 0.970017799 0.382230327 0.970017799 0.382230327
CO 1.081728876 0.42624948 1.081728876 0.42624948
H2 0.233552781 0.092030225 0.233552781 0.092030225
CH3OH 0 0 0 0
CH4 0.032608033 0.012849021 0.032608033 0.012849021
C3H8 0.052511723 0.020691964 0.052511723 0.020691964
C2H6 0.059865646 0.023589738 0.059865646 0.023589738
N-BUTANE 0.022686086 0.008939331 0.022686086 0.008939331
N-PENTANE 0.00634706 0.002501025 0.00634706 0.002501025
ISO-
0.014801124 0.005832304 0.014801124 0.005832304
BUTANE
ISO-
0.008852479 0.003488272 0.008852479 0.003488272
PENTANE
N-HEXANE 0.006783004 0.002672807 0.006783004 0.002672807
N-HEPTANE 0.00788706 0.003107854 0.00788706 0.003107854
H2S 0 0 0 0
Total (kg/s) 2.53778345 2.53778345

3.4.9 Material balance around Water Gas Shift Reactor (H)

In this reactor, carbon monoxide reacts with steam and is converted into carbon dioxide and
more hydrogen. The reactor operates adiabatically. Ideally, a stream of steam should be
introduced into the reactor. However, this was not done due to the fact that excess steam was
supplied into the S.M.R reactor (F). Thus, sufficient amount of steam was still present for the
reaction to take place.
Assumptions
1. 1. Adiabatic operation.
2. 2. 95% conversion of carbon monoxide.
Figure 33Figure 3.1934: BlockProcess flow Diagram for W.G.S Reactor (H)
S12 S13
W.G.S
REACTOR
FEED
CO2, CO, H2
WATER GAS
SHIFT REACTOR
Figure 35Figure 363.20: Aspen simulation Diagram for W.G.S Reactor (H)
Assumptions
1. Adiabatic operatio2. 95% conversion of carbon monoxide.
Table 15.12: Material balance around Water Gas Shift Reactor (H)
FEED PRODUCT
(W.G.S Fraction (CO2, H2, Fraction
REACTOR CO)
FEED) Mass flow
Mass flow rate (kg/s)
rate (kg/s)
CO2 0.040141779 0.015817653 1.654768414 0.652052646
H2O 0.970017799 0.382230327 0.309075215 0.121789436
CO 1.081728876 0.42624948 0.054086444 0.021312474
H2 0.233552781 0.092030225 0.307511162 0.121173129
CH3OH 0 0 0 0
CH4 0.032608033 0.012849021 0.032608033 0.012849021
C3H8 0.052511723 0.020691964 0.052511723 0.020691964
C2H6 0.059865646 0.023589738 0.059865646 0.023589738
N-BUTANE 0.022686086 0.008939331 0.022686086 0.008939331
N-PENTANE 0.00634706 0.002501025 0.00634706 0.002501025
ISO-
0.014801124 0.005832304 0.014801124 0.005832304
BUTANE
ISO-
0.008852479 0.003488272 0.008852479 0.003488272
PENTANE
N-HEXANE 0.006783004 0.002672807 0.006783004 0.002672807
N-HEPTANE 0.00788706 0.003107854 0.00788706 0.003107854
H2S 0 0 0 0
Total (kg/s) 2.53778345 2.53778345

3.5 Methanol Synthesis Process
Figure 373.21: Block Flow Diagram for Methanol Synthesis Process
Table: Overall material balance for the synthesis process (update)
Table 16.1317.11: Overall material balance for the synthesis process (update)
FEED PRODUCT
Components 133 25 24 29
(CO2, H2, CO) (CO2 FOR (COMBUSTIBL (MeOH + H2O
Mass flow rate STORAGE) E GASES) – FL2)
(kg/s) Mass flow rate Mass flow rate Mass flow rate
(kg/s) (kg/s) (kg/s)
CO2 1.654768414 0.402285339 0.004063488 0.001159229
H2O 0.309075215 0 0.007616634 0.81207474
CO 0.054086444 0 0.036834994 4.61193E-08
H2 0.307511162 0 0.133548234 7.42419E-08
CH3OH 0 0 0.041506292 0.886418915
CH4 0.032608033 0 0.032606128 1.72267E-06
C3H8 0.052511723 0 0.052489259 2.14632E-05
C2H6 0.059865646 0 0.059841073 2.36696E-05
N-BUTANE 0.022686086 0 0.022679454 6.21747E-06
N-PENTANE 0.00634706 0 0.00634646 5.20651E-07
ISO-BUTANE 0.014801124 0 0.014799949 1.02639E-06
ISO- 0
0.008852479
PENTANE 0.008851774 6.04069E-07
N-HEXANE 0.006783004 0 0.006782847 1.05196E-07
N-HEPTANE 0.00788706 0 0.007887007 2.22132E-08
H2S 0 0 0 0
Total (kg/s) 2.53778345 0.402285339 0.435789755 1.699708356
From Table 3.13 x above,

The total feed mass flowrate = 0.402285339+ 0.435789755 + 1.699708356 = 2.53778345 kg/s
And the tTotal feed product mass flowrate = 2.53778345 kg/s
Since the total feed mass flowrate and product mass flowrate are equal, this implies that
there
3.54.10 Material balance around mixer 2

This combines the outlet from the W.G.S reactor (H) and the recycle stream and supplies them as
a single stream to the methanol synthesis reactor (K).
Assumptions
1. 100% mixing efficiency.
2. [add BFD]
Figure 38: Block flow Diagram for mixer

RECYCLE
S20
MIX-02
RECYCLE
S14
+
FEED
S13
CO2, CO, H2
Figure 39: Aspen simulation Diagram for mixer 2
Table 18.1419.12: Material balance around mixer 2
FEED PRODUCT
(CO2, H2, Fraction (RECYCLE) Fraction (RECYCLE + Fraction
CO) Mass flow FEED)
Mass flow rate (kg/s) Mass flow
CO2 0.65205264 6.585884427
1.654768414
6 4.930942189 0.482319842 0.516085013
H2O 0.12178943 0.400717386
0.309075215
6 0.091654662 0.008965196 0.031401134
CO 0.02131247 0.508144588
0.054086444
4 0.454066642 0.044414504 0.039819376
H2 0.12117312 1.953897641
0.307511162
9 1.646457395 0.161048141 0.153111902
CH3OH 0 0 0.49740009 0.048653163 0.497390683 0.038976675
CH4 0.01284902 0.43356146
0.032608033
1 0.40095362 0.039219257 0.033974871
C3H8 0.02069196 0.694809213
0.052511723
4 0.64229855 0.062826398 0.054446844
C2H6 0.02358973 0.792383032
0.059865646
8 0.732518343 0.071651242 0.062092952
N-BUTANE 0.00893933 0.300525038
0.022686086
1 0.277839391 0.027176845 0.023549831
N- 0.00250102
0.00634706 0.07795504 0.007625168 0.084302016 0.006606099
PENTANE 5
ISO- 0.00583230
0.014801124 0.181864514 0.017789068 0.19666548 0.015411158
BUTANE 4
ISO- 0.00348827
0.008852479 0.108761355 0.010638486 0.117613727 0.009216482
PENTANE 2
N-HEXANE 0.00267280
0.006783004 0.083491078 0.008166675 0.090274027 0.00707408
7
N- 0.00310785
0.00788706 0.097183691 0.009506017 0.105070719 0.008233583
HEPTANE 4
H2S 0 0 0 0 0 0
Total (kg/s) 2.53778345 10.22338656 12.76123944
The total feed mass flowrate = 2.53778345 + 10.22338656 = 12.76123944 kg/s

3.4.115.2 Material balance around compressor (I)
This raises the pressure of the methanol synthesis reactor (K) feed to the required pressure of 58
bars.
Assumptions
1. Operates isentropically with a discharge pressure of 58 bar.

2. Isentropic efficiency is 75%
[add BFD]
Figure 40: Process Block flow Diagram for compressor (I)
RECYCLE
S14
+
FEED
COMPRESSOR
COMPRESSED
CO2,
CO, H2
S15
Figure 41: Aspen simulation Diagram for compressor (I)

Table 3.1520.13: Material balance around compressor (I)
FEED PRODUCT
(RECYCLE Fraction (COMPRESSED Fraction
+ FEED) CO2, H2)
Mass flow Mass flow rate
rate (kg/s) (kg/s)
CO2 6.585884427 0.516085013 6.585884427 0.516085013
H2O 0.400717386 0.031401134 0.400717386 0.031401134
CO 0.508144588 0.039819376 0.508144588 0.039819376
H2 1.953897641 0.153111902 1.953897641 0.153111902
CH3OH 0.497390683 0.038976675 0.497390683 0.038976675
CH4 0.43356146 0.033974871 0.43356146 0.033974871
C3H8 0.694809213 0.054446844 0.694809213 0.054446844
C2H6 0.792383032 0.062092952 0.792383032 0.062092952
N-BUTANE 0.300525038 0.023549831 0.300525038 0.023549831
N-PENTANE 0.084302016 0.006606099 0.084302016 0.006606099
ISO- 0.19666548 0.015411158 0.19666548 0.015411158
BUTANE
ISO- 0.117613727
PENTANE 0.009216482 0.117613727 0.009216482
N-HEXANE 0.090274027 0.00707408 0.090274027 0.00707408
N-HEPTANE 0.105070719 0.008233583 0.105070719 0.008233583
H2S 0 0 0 0
Total (kg/s) 12.76123944 12.76123944

3.5.34.12 Material balance around compressorcooler (J)

This reduces the temperature of the methanol synthesis reactor (K) feed to the required inlet
temperature of 200ºC. This is done as higher temperatures (≥250℃) reduces the conversion of
reactants.
Assumptions
1. 1. Operates isothermally at 200ºC
[add BFD]
Figure 42: BlockProcess flow Diagram for compressor (J)

S15
COMPRESSED
CO2,
CO, H2
J
COOLER
S16
MeOH
SYNTHESIS
REACTOR FEED
Figure 43: Aspen simulation Diagram for compressorcooler (J)
Table 21.1622.14: Material balance around compressorcooler (J)
FEED PRODUCT
(COMPRESSED Fraction (MeOH Fraction
CO2, H2) Synthesis
Mass flow rate Reactor Feed)
(kg/s) Mass flow rate
(kg/s)
CO2 6.585884427 0.516085013 6.585884427 0.516085013
H2O 0.400717386 0.031401134 0.400717386 0.031401134
CO 0.508144588 0.039819376 0.508144588 0.039819376
H2 1.953897641 0.153111902 1.953897641 0.153111902
CH3OH 0.497390683 0.038976675 0.497390683 0.038976675
CH4 0.43356146 0.033974871 0.43356146 0.033974871
C3H8 0.694809213 0.054446844 0.694809213 0.054446844
C2H6 0.792383032 0.062092952 0.792383032 0.062092952
N-BUTANE 0.300525038 0.023549831 0.300525038 0.023549831
N-PENTANE 0.084302016 0.006606099 0.084302016 0.006606099
ISO-
BUTANE 0.19666548 0.015411158 0.19666548 0.015411158
ISO-
PENTANE 0.117613727 0.009216482 0.117613727 0.009216482
N-HEXANE 0.090274027 0.00707408 0.090274027 0.00707408
N-HEPTANE 0.105070719 0.008233583 0.105070719 0.008233583
H2S 0 0 0 0
Total (kg/s) 12.76123944 12.76123944

3.5.4.13 Material balance around methanol synthesis reactor (K)

Here, carbon dioxide is reacted with hydrogen to produce methanol and water in the presence of
a catalyst. The relatively smaller amounts of carbon monoxide present are also converted into
methanol in the reactor. Temperature varies across the reactor as this has been shown to help
maximize conversion.
Assumptions
1. Temperature varies across packed bed reactor from 200ºC at the inlet to 240ºC at the
outlet
2. >20% conversion of carbon dioxide.
3. [add BFD]
Figure 44: BlockProcess flow Diagram for methanol synthesis reactor (K)
S17
MeOH SYNTHESIS
REACTOR OUTLET
K
METHANOL SYNTHESIS
REACTOR
S16
MeOH
SYNTHESIS
REACTOR FEED
Figure 45: Aspen simulation Diagram for methanol synthesis reactor (K)
Table 23.1724.14: Material balance around methanol synthesis reactor (K)
FEED PRODUCT
(MeOH Fraction (MeOH Fraction
Synthesis Synthesis
Reactor Feed) Reactor Outlet)
Mass flow rate Mass flow rate
(kg/s) (kg/s)
CO2 6.585884427 0.516085013 5.338462449 0.418334165
H2O 0.400717386 0.031401134 0.911345842 0.071415151
CO 0.508144588 0.039819376 0.490901616 0.038468177
H2 1.953897641 0.153111902 1.780000287 0.139484906
CH3OH 0.497390683 0.038976675 1.425324531 0.1116917
CH4 0.43356146 0.033974871 0.43356146 0.033974871
C3H8 0.694809213 0.054446844 0.694809213 0.054446844
C2H6 0.792383032 0.062092952 0.792383032 0.062092952
N-BUTANE 0.300525038 0.023549831 0.300525038 0.023549831
N-PENTANE 0.084302016 0.006606099 0.084302016 0.006606099
ISO-
BUTANE 0.19666548 0.015411158 0.19666548 0.015411158
ISO-
PENTANE 0.117613727 0.009216482 0.117613727 0.009216482
N-HEXANE 0.090274027 0.00707408 0.090274027 0.00707408
N-HEPTANE 0.105070719 0.008233583 0.105070719 0.008233583
H2S 0 0 0 0
Total (kg/s) 12.76123944 12.76123944
From Table 3.x 17 above,

L3.5.54.14 Material balance around compressorcooler (L)

This is used to reduce temperature in order to condense water vapour present. This helps to
facilitate separation of water in the flash separator (L) downstream.
Assumptions
2. [add BFD]
Figure 4647: BlockProcess flow Diagram for compressorcooler (L)

S18
MeOH, CO2,
CO, H2, H2O
L
COOLER
S17
MeOH SYNTHESIS
REACTOR OUTLET
Figure 48: Aspen simulation Diagram for compressorcooler (L)
Table 25.1826.15: Material balance around compressor (L)

FEED PRODUCT
(MeOH Fraction (MeOH, CO2, Fraction
Synthesis CO, H2, H2O)
Reactor Outlet) Mass flow rate
(kg/s)
CO2 5.338462449 0.418334165 5.338462449 0.418334165
H2O 0.911345842 0.071415151 0.911345842 0.071415151
CO 0.490901616 0.038468177 0.490901616 0.038468177
H2 1.780000287 0.139484906 1.780000287 0.139484906
CH3OH 1.425324531 0.1116917 1.425324531 0.1116917
CH4 0.43356146 0.033974871 0.43356146 0.033974871
C3H8 0.694809213 0.054446844 0.694809213 0.054446844
C2H6 0.792383032 0.062092952 0.792383032 0.062092952
N-BUTANE 0.300525038 0.023549831 0.300525038 0.023549831
N-PENTANE 0.084302016 0.006606099 0.084302016 0.006606099
ISO-
BUTANE 0.19666548 0.015411158 0.19666548 0.015411158
ISO-
PENTANE 0.117613727 0.009216482 0.117613727 0.009216482
N-HEXANE 0.090274027 0.00707408 0.090274027 0.00707408
N-HEPTANE 0.105070719 0.008233583 0.105070719 0.008233583
H2S 0 0 0 0
Total (kg/s) 12.76123944 12.76123944

3.4.15.6 Material balance around flash separator (M)

This separates unreacted gases from the liquid phase methanol and water.
Assumptions
1. High vapour-liquid separation efficiency.

[add
BFD]
Figure 49: BlockProcess flow Diagram for flash separator (M)
S19
UNREACTED
GASES (FL1)
FLASH DRUM 1
MeOH
S18 H2O (FL1)
MeOH, CO2,
CO, H2, H2O
S26
Figure 50: Aspen simulation Diagram for flash separator (M)
Table 27.19: Material balance around flash separator (M)

FEED PRODUCT
Component 18 Mass 19 Mass 26 Mass
s (MeOH, Fraction (UNREACTED Fraction (MeOH + Fraction
CO2, CO, GASES – FL1) H2O – FL1)
H2, H2O) Mass flow rate Mass flow rate
Mass flow (kg/s) (kg/s)
rate (kg/s)
CO2 5.338462449 0.418334165 5.330748312 0.482319842 0.007714137 0.004514017
H2O 0.911345842 0.071415151 0.099086121 0.008965196 0.812259721 0.475303196
CO 0.490901616 0.038468177 0.490882856 0.044414504 1.87603E-05 1.09778E-05
H2 1.780000287 0.139484906 1.779953941 0.161048141 4.63461E-05 2.712E-05
CH3OH 1.425324531 0.1116917 0.537729828 0.048653163 0.887594703 0.519386335
CH4 0.43356146 0.033974871 0.433463373 0.039219257 9.80868E-05 5.73966E-05
C3H8 0.694809213 0.054446844 0.694376811 0.062826398 0.000432402 0.000253025
C2H6 0.792383032 0.062092952 0.791911722 0.071651242 0.000471311 0.000275793
N-
BUTANE 0.300525038 0.023549831 0.300366909 0.027176845 0.000158129 9.25308E-05
N-
PENTANE 0.084302016 0.006606099 0.084275719 0.007625168 2.62974E-05 1.53882E-05
ISO-
BUTANE 0.19666548 0.015411158 0.196610285 0.017789068 5.51946E-05 3.22977E-05
ISO-
PENTANE 0.117613727 0.009216482 0.117579843 0.010638486 3.38839E-05 1.98276E-05
N-
HEXANE 0.090274027 0.00707408 0.090260625 0.008166675 1.34025E-05 7.84261E-06
N-
HEPTANE 0.105070719 0.008233583 0.10506345 0.009506017 7.26868E-06 4.25335E-06
H2S 0 0 0 0 0 0
Total (kg/s) 12.76123944 11.05230979 1.708929642

And the tTotal product mass flowrate = 11.05230979 + 1.708929642 = 12.76123944 kg/s
SPLITTER
3.5.74.16 Material balance around splitter
The unreacted gases separated by the flash separator (M) is split into two streams: a recycle
stream which is sent back to the synthesis reactor for further conversion and a purge stream
which is used as a fuel (source of energy). The mass ratio of the recycle stream to the purge
stream is 1:13.
Assumptions
1. Purge to recycle ratio of 1:13Assumptions
2.
Figure 51: Block flow Diagram for splitter

PURGE
S21
S20
RECYCLE
SPLIT
S19
UNREACTED
GASES (FL1)
Figure 52: Aspen simulation Diagram for splitter
Assumptions
1. 1. Purge to recycle ratio of 1:13

Table 28.20: Material balance around splitter
FEED PRODUCT
(UNREACTED Fraction (PURGE) Fraction (RECYCLE) Fraction
GASES – FL1) Mass flow Mass flow
Mass flow rate rate (kg/s) rate (kg/s)
(kg/s)
CO2 0.39980612
5.330748312 0.482319842 3 0.482319842 4.930942189 0.482319842
H2O 0.00743145
0.099086121 0.008965196 9 0.008965196 0.091654662 0.008965196
CO 0.03681621
0.490882856 0.044414504 4 0.044414504 0.454066642 0.044414504
H2 0.13349654
1.779953941 0.161048141 6 0.161048141 1.646457395 0.161048141
CH3OH 0.04032973
0.537729828 0.048653163 7 0.048653163 0.49740009 0.048653163
CH4 0.03250975
0.433463373 0.039219257 3 0.039219257 0.40095362 0.039219257
C3H8 0.05207826
0.694376811 0.062826398 1 0.062826398 0.64229855 0.062826398
C2H6 0.05939337
0.791911722 0.071651242 9 0.071651242 0.732518343 0.071651242
N-BUTANE 0.02252751
0.300366909 0.027176845 8 0.027176845 0.277839391 0.027176845
N-PENTANE 0.00632067
0.084275719 0.007625168 9 0.007625168 0.07795504 0.007625168
ISO-BUTANE 0.01474577
0.196610285 0.017789068 1 0.017789068 0.181864514 0.017789068
ISO- 0.00881848
PENTANE 0.117579843 0.010638486 8 0.010638486 0.108761355 0.010638486
N-HEXANE 0.00676954
0.090260625 0.008166675 7 0.008166675 0.083491078 0.008166675
N-HEPTANE 0.00787975
0.10506345 0.009506017 9 0.009506017 0.097183691 0.009506017
H2S 0 0 0 0 0 0
Total (kg/s) 11.05230979 0.82892323 10.22338656
5

And the tTotal product mass flowrate = 0.828923235 + 10.22338656= 11.05230979 kg/s
(Mixer)3.5.84.17 Material balance around Mmixer 3

This combines the unreacted/combustible gases released overhead from the flash separators (M
and Q) and supplies as a single stream to the P.S.A (N) for easy separation.
Assumptions
1. High mixing efficiency
Figure 53: Block flow Diagram for mixer
PURGE
S21
TOTAL
MIX-03 PURGE S22
UNREACTED
GASES (FL2)
S28

Table 29.21: Material balance around Mixer 3
FEED PRODUCT
(PURGE) Fraction (UNREACTED Fraction (TOTAL Fraction
Mass flow GASES – FL2) PURGE)
rate (kg/s) Mass flow rate Mass flow
(kg/s) rate (kg/s)
CO2 0.399806123 0.482319842 0.006554908 0.710845236 0.406361031 0.484834084
H2O 0.007431459 0.008965196 0.000184981 0.020060225 0.00761644 0.009087264
CO 0.036816214 0.044414504 1.87142E-05 0.002029459 0.036834928 0.043948183
H2 0.133496546 0.161048141 4.62719E-05 0.005017944 0.133542817 0.159331492
CH3OH 0.040329737 0.048653163 0.001175788 0.127508057 0.041505525 0.049520726
CH4 0.032509753 0.039219257 9.63641E-05 0.010450183 0.032606117 0.038902738
C3H8 0.052078261 0.062826398 0.000410938 0.044564112 0.052489199 0.062625476
C2H6 0.059393379 0.071651242 0.000447641 0.048544327 0.05984102 0.071397019
N-BUTANE 0.022527518 0.027176845 0.000151911 0.01647397 0.022679429 0.027059092
N-
PENTANE 0.006320679 0.007625168 2.57767E-05 0.002795349 0.006346456 0.00757203
ISO-
BUTANE 0.014745771 0.017789068 5.41682E-05 0.005874253 0.01479994 0.01765798
ISO-
PENTANE 0.008818488 0.010638486 3.32799E-05 0.003609025 0.008851768 0.010561148
N-HEXANE 0.006769547 0.008166675 1.32973E-05 0.00144202 0.006782844 0.00809269
N-
HEPTANE 0.007879759 0.009506017 7.24647E-06 0.000785842 0.007887005 0.009410078
H2S 0 0 0 0 0 0
Total (kg/s) 0.828923235 0.00915186 0.838075095
The total product mass flowrate = 0.838075095 kg/s

And the total feed mass flowrate = 0.828923235 + 0.00915186 = 0.838075095 kg/s
PSA – N3.5.94.18 Material balance around P.S.A (-N)

This selectively adsorbs CO2 from the total stream of combustible gases for both environmental
and economic purposes (as it is then cooled and stored for sales to generate extra revenue).
Assumptions
1. High CO2 selectivity
Figure 5556: BlockProcess flow Diagram for PSA (N)

CO2
S23
TOTAL
PURGE S22
P.S.A (REMOVES CO2)

COMBUSTIBLE
GASES
S24
Figure 57: Aspen simulation Diagram for P.S.A (-N)
Table 30.22: Material balance around P.S.A (N)

FEED PRODUCT
(TOTAL Fraction (CO2) Fraction (COMBUSTIBL Fraction
PURGE) Mass flow E
Mass flow rate rate (kg/s) GASES)
(kg/s)
CO2 0.48483408 0.009323058
0.402285339
0.406361031 4 1 0.004063488
H2O 0.00908726 0.017475212
0.00761644 4 0 0 0.007616634
CO 0.04394818 0.084512311
0.036834928 3 0 0 0.036834994
H2 0.15933149 0.306406178
0.133542817 2 0 0 0.133548234
CH3OH 0.04952072 0.095229894
0.041505525 0 0 0.041506292
6
CH4 0.03890273 0.074809817
0.032606117 8 0 0 0.032606128
C3H8 0.06262547 0.120428648
0.052489199 6 0 0 0.052489259
C2H6 0.07139701 0.13729627
0.05984102 9 0 0 0.059841073
N-BUTANE 0.02705909 0.05203457
0.022679429 2 0 0 0.022679454
N- 0.014560991
PENTANE 0.006346456 0.00757203 0 0 0.00634646
ISO- 0.033956238
BUTANE 0.01479994 0.01765798 0 0 0.014799949
ISO- 0.01056114 0.020309054
PENTANE 0.008851768 8 0 0 0.008851774
N-HEXANE 0.006782844 0.00809269 0 0 0.006782847 0.015562215
N- 0.00941007 0.018095542
HEPTANE 0.007887005 8 0 0 0.007887007
H2S 0 0 0 0 0 0
Total (kg/s) 0.838075095 0.402285339 0.435789756

COOLER – O3.54.109 Material balance around Cooler (-O)

This reduces the temperature of the carbon dioxide recovered from the total purge stream to a
suitable temperature for storage.
Assumptions
Figure 5859: BlockProcess flow Diagram for Cooler (O)-G
O
COOLER
S25
CO2 CO2
FOR STORAGE
S23
Figure 6061: Aspen simulation Diagram for COOLER (O)-G

Table 31.23: Material balance around Cooler (O)
FEED PRODUCT
(CO2) Fraction (CO2 FOR Fraction
Mass flow rate STORAGE)
(kg/s)
CO2 0.402285339 1 0.402285339 1
H2O 0 0 0 0
CO 0 0 0 0
H2 0 0 0 0
CH3OH 0 0 0 0
CH4 0 0 0 0
C3H8 0 0 0 0
C2H6 0 0 0 0
N-BUTANE 0 0 0 0
N-PENTANE 0 0 0 0
ISO-
BUTANE 0 0 0 0
ISO-
PENTANE 0 0 0 0
N-HEXANE 0 0 0 0
N-HEPTANE 0 0 0 0
H2S 0 0 0 0
Total (kg/s) 0.402285339 0.402285339
The total feed mass flowrate = 1.708932361 0.402285339 kg/s
And the tTotal product mass flowrate = 0.4022853391.708932361 kg/s

P3.54.1120 Material balance around Expansion valve (P)

Assumptions
1. Operates at a discharge pressure of 1.4 bars
Figure 6263: BlockProcess flow Diagram for Expansion valve (P)

MeOH
P
H2O (FL1)
EXPANSION VALVE
S26 S27
MeOH
H2O
Figure 64: Aspen simulation Diagram for Expansion valve (P)

Table 32.2433.21: Material balance around Expansion valve (P)
Operates at a discharge pressure of 1.4 bars
FEED PRODUCT
(MeOH + Fraction (MeOH, H2O) Fraction
H2O – FL1) Mass flow rate
(kg/s)
CO2 0.00451401
0.007714137 7 0.007714137 0.004514017
H2O 0.47530319
0.812259721 6 0.812259721 0.475303196
CO 1.87603E-05 1.09778E-05 1.87603E-05 1.09778E-05
H2 4.63461E-05 2.712E-05 4.63461E-05 2.712E-05
CH3OH 0.51938633
0.887594703 5 0.887594703 0.519386335
CH4 9.80868E-05 5.73966E-05 9.80868E-05 5.73966E-05
C3H8 0.00025302
0.000432402 5 0.000432402 0.000253025
C2H6 0.00027579
0.000471311 3 0.000471311 0.000275793
N-BUTANE 0.000158129 9.25308E-05 0.000158129 9.25308E-05
N-PENTANE 2.62974E-05 1.53882E-05 2.62974E-05 1.53882E-05
ISO-BUTANE 5.51946E-05 3.22977E-05 5.51946E-05 3.22977E-05
ISO-PENTANE 3.38839E-05 1.98276E-05 3.38839E-05 1.98276E-05
N-HEXANE 1.34025E-05 7.84261E-06 1.34025E-05 7.84261E-06
N-HEPTANE 7.26868E-06 4.25335E-06 7.26868E-06 4.25335E-06
H2S 0 0 0 0
Total (kg/s) 1.708929642 1.708929642

3.5.12 Material balance around Flash separator (Q)

This equipment further separates unreacted gases from methanol and water and sends the stream
of gases to the mixer supplying feed to CO2 recovery unit, P.S.A (N).
Q (update)
Assumptions
1. High vapour-liquid separation efficiency.

Figure 65: BlockProcess flow Diagram for Flash separator (Q)
UNREACTED
GASES (FL2)
S28
Q
S27
FLA SH DRUM 2
MeOH
H2O
MeOH
H2O (FL2)
S29
Figure 66: Aspen simulation Diagram for Flash separator (Q)
Operates adiabatically at 37ºC and 1 barHigh vapour-liquid separation efficiency.
Table 34.2535.22: Material balance around Flash separator (Q)
PRODUCT
FEED

(MeOH, H2O Fraction (UNREACTED Fraction (MeOH, H2O Fraction
Mass flow rate GASES – FL2) – FL2)
(kg/s) Mass flow rate Mass flow rate
(kg/s) (kg/s)
CO2 0.71084523
0.007714137 0.004514017 0.006554908 6 0.001159229 0.000682016
H2O 0.02006022
0.812259721 0.475303196 0.000184981 5 0.81207474 0.477772988
CO 0.00202945
1.87603E-05 1.09778E-05 1.87142E-05 9 4.61193E-08 2.71336E-08
H2 0.00501794
4.63461E-05 2.712E-05 4.62719E-05 4 7.42419E-08 4.36792E-08
CH3OH 0.12750805
0.887594703 0.519386335 0.001175788 7 0.886418915 0.521512359
CH4 0.01045018
9.80868E-05 5.73966E-05 9.63641E-05 3 1.72267E-06 1.01351E-06
C3H8 0.04456411
0.000432402 0.000253025 0.000410938 2 2.14632E-05 1.26276E-05
C2H6 0.04854432
0.000471311 0.000275793 0.000447641 7 2.36696E-05 1.39257E-05
N-BUTANE 0.000158129 9.25308E-05 0.000151911 0.01647397 6.21747E-06 3.65797E-06
N- 0.00279534
PENTANE 2.62974E-05 1.53882E-05 2.57767E-05 9 5.20651E-07 3.06318E-07
ISO- 0.00587425
BUTANE 5.51946E-05 3.22977E-05 5.41682E-05 3 1.02639E-06 6.03864E-07
ISO- 0.00360902
PENTANE 3.38839E-05 1.98276E-05 3.32799E-05 5 6.04069E-07 3.55396E-07
N-HEXANE 1.34025E-05 7.84261E-06 1.32973E-05 0.00144202 1.05196E-07 6.18904E-08
N- 0.00078584
HEPTANE 7.26868E-06 4.25335E-06 7.24647E-06 2 2.22132E-08 1.30688E-08
H2S 0 0 0 0 0 0
Total (kg/s) 1.708929642 0.00915186 1.699708356

3.6 Methanol Purification Process
Figure 67: BlockProcess Flow Diagram for Methanol Purification Process
Overall material balance for purification processTable 36.2637.23: Overall material balance for
purification process
FEED PRODUCT
(MeOH, H2O Fraction (PURE Fraction (PURE Fraction
– FL2) WATER) METHANOL)
CO2 0.001159229 0.000682016 1.03464E-84 1.23663E-84 0.001159229 0.001343191
H2O 0.81207474 0.477772988 0.81207474 0.970606787 2.73379E-12 3.16762E-12
CO 4.61193E-08 2.71336E-08 1.4099E-134 1.6852E-134 4.61193E-08 5.34381E-08
H2 7.42419E-08 4.36792E-08 5.4233E-143 6.4821E-143 7.42419E-08 8.60235E-08
CH3OH 0.02459233
0.886418915 0.521512359 4 0.029393213 0.861826581 0.998592534
CH4 1.72267E-06 1.01351E-06 3.5563E-111 4.2506E-111 1.72267E-06 1.99605E-06
C3H8 2.14632E-05 1.26276E-05 8.51192E-87 1.01736E-86 2.14632E-05 2.48693E-05
C2H6 2.36696E-05 1.39257E-05 3.3655E-94 4.02251E-94 2.36696E-05 2.74258E-05
N-BUTANE 6.21747E-06 3.65797E-06 8.4122E-83 1.00544E-82 6.21747E-06 7.20414E-06
N-PENTANE 5.20651E-07 3.06318E-07 2.93123E-83 3.50346E-83 5.20651E-07 6.03274E-07
ISO-
BUTANE 1.02639E-06 6.03864E-07 3.74871E-91 4.48053E-91 1.02639E-06 1.18927E-06
ISO-
PENTANE 6.04069E-07 3.55396E-07 3.02883E-85 3.62011E-85 6.04069E-07 6.99931E-07
N-HEXANE 1.05196E-07 6.18904E-08 2.69158E-85 3.21703E-85 1.05196E-07 1.21889E-07
N-HEPTANE 2.22132E-08 1.30688E-08 1.50921E-87 1.80384E-87 2.22132E-08 2.57383E-08
H2S 0 0 0 0 0 0
Total (kg/s) 1.699708356 0.83666707 0.863041282
4
From Table 3.x26 above,
The tTotal feed mass flowrate = 1.699708356 kg/s

And the tTotal product mass flowrate = 0.836667074+ 0.863041282 = 1.699708356 kg/s
3.64.122 Material balance around Heater (R)
This raises the temperature of the distillation feed to a suitable separation for separation.
Assumptions
Figure 68: BlockProcess flow Diagram for Heater (R)

MeOH
H2O (FL2)
S29
S30
R DISTILLATION
HEATER
COLUMN
FEED
Figure 69: Aspen simulation Diagram for Heater (R)
Table 38.27: Overall materialMaterial balance foraround Heater (R)1. Operates isothermally at
67℃
FEED PRODUCT
(MeOH, H2O Fraction (DISTILLATIO Fraction
– FL2) N COLUMN
Mass flow FEED)
rate (kg/s) Mass flow rate
(kg/s)
CO2 0.001159229 0.000682016 0.001159229 0.000682016
H2O 0.81207474 0.477772988 0.81207474 0.477772988
CO 4.61193E-08 2.71336E-08 4.61193E-08 2.71336E-08
H2 7.42419E-08 4.36792E-08 7.42419E-08 4.36792E-08
CH3OH 0.886418915 0.521512359 0.886418915 0.521512359
CH4 1.72267E-06 1.01351E-06 1.72267E-06 1.01351E-06
C3H8 2.14632E-05 1.26276E-05 2.14632E-05 1.26276E-05
C2H6 2.36696E-05 1.39257E-05 2.36696E-05 1.39257E-05
N-BUTANE 6.21747E-06 3.65797E-06 6.21747E-06 3.65797E-06
N-PENTANE 5.20651E-07 3.06318E-07 5.20651E-07 3.06318E-07
ISO-
BUTANE 1.02639E-06 6.03864E-07 1.02639E-06 6.03864E-07
ISO-
PENTANE 6.04069E-07 3.55396E-07 6.04069E-07 3.55396E-07
N-HEXANE 1.05196E-07 6.18904E-08 1.05196E-07 6.18904E-08
N-HEPTANE 2.22132E-08 1.30688E-08 2.22132E-08 1.30688E-08
H2S 0 0 0 0
Total (kg/s) 1.699708356 1.699708356

is no accumulation of mass in the system. Hence, the system is balanced.is no accumulation of
mass in the system. Hence, the system is balanced.
3.6.24.22 Material balance around Distillation column (S)

Here, water is separated to a very high degree from methanol to produce a methanol stream of
99% purity.
Assumptions
1. Operates with 58 stages at reflux of 5.

2. Partial condenser is used.
3.
Figure 70: BlockProcess flow Diagram for Distillation column (S)

DISTILLATE
S31
S
S30 DISTILLATION COLUMN
DISTILLATION S32 PURE WATER
COLUMN
FEED
Figure 71: Aspen Diagram for Distillation column (S)
Table 39.2840.25: Overall Mmaterial balance foraround Distillation column (S)
Operates with 58 stages at reflux of 5.
Partial condenser is used.
FEED PRODUCT
(DISTILLATIO Fraction (DISTILLATE) Fraction (PURE Fraction
N COLUMN Mass flow rate WATER)
FEED) (kg/s) Mass flow
Mass flow rate rate (kg/s)
(kg/s)
CO2 0.001159229 0.000682016 0.001159229 0.001343191 1.03464E-84 1.23663E-84
H2O 0.81207474 0.477772988 2.73379E-12 3.16762E-12 0.81207474 0.970606787
CO 4.61193E-08 2.71336E-08 4.61193E-08 5.34381E-08 1.4099E-134 1.6852E-134
H2 7.42419E-08 4.36792E-08 7.42419E-08 8.60235E-08 5.4233E-143 6.4821E-143
CH3OH 0.886418915 0.521512359 0.861826581 0.998592534 0.024592334 0.029393213
CH4 1.72267E-06 1.01351E-06 1.72267E-06 1.99605E-06 3.5563E-111 4.2506E-111
C3H8 2.14632E-05 1.26276E-05 2.14632E-05 2.48693E-05 8.51192E-87 1.01736E-86
C2H6 2.36696E-05 1.39257E-05 2.36696E-05 2.74258E-05 3.3655E-94 4.02251E-94
N-BUTANE 6.21747E-06 3.65797E-06 6.21747E-06 7.20414E-06 8.4122E-83 1.00544E-82
N-PENTANE 5.20651E-07 3.06318E-07 5.20651E-07 6.03274E-07 2.93123E-83 3.50346E-83
ISO-BUTANE 1.02639E-06 6.03864E-07 1.02639E-06 1.18927E-06 3.74871E-91 4.48053E-91
ISO-
PENTANE 6.04069E-07 3.55396E-07 6.04069E-07 6.99931E-07 3.02883E-85 3.62011E-85
N-HEXANE 1.05196E-07 6.18904E-08 1.05196E-07 1.21889E-07 2.69158E-85 3.21703E-85
N-HEPTANE 2.22132E-08 1.30688E-08 2.22132E-08 2.57383E-08 1.50921E-87 1.80384E-87
H2S 0 0 0 0 0 0
Total (kg/s) 1.699708356 0.863041282 0.836667074
0.000682016

And the tTotal product mass flowrate = 0.863041282 + 0.836667074= 1.699708356 kg/s
3.6.3 Material balance around Cooler (T)

This reduces the temperature of the distillate from the distillation column (pure methanol) to a
suitable temperature for storage.
T
Assumptions
1. Operates isothermally at 25ºC

2.
Figure 72: BlockProcess flow Diagram for Cooler (T)
T
DISTILLATE HEATER PURE
S31 S33
METHANOL
Figure 7374: Aspen simulation Diagram for Cooler (T)
Table 41.2942.26: Overall Mmaterial balance foraround Cooler (T)Operates isothermally at 25ºC
FEED PRODUCT
Components / 31 Mass 33 Mass
Flow (kg/s) (DISTILLATE Fraction (PURE Fraction
) METHANOL
Mass flow rate )
(kg/s) Mass flow
rate (kg/s)
CO2 0.001159229 0.001343191 0.001159229 0.001343191
H2O 0.81207474 3.16762E-12 2.73379E-12 3.16762E-12
CO 4.61193E-08 5.34381E-08 4.61193E-08 5.34381E-08
H2 7.42419E-08 8.60235E-08 7.42419E-08 8.60235E-08
CH3OH 0.886418915 0.998592534 0.861826581 0.998592534
CH4 1.72267E-06 1.99605E-06 1.72267E-06 1.99605E-06
C3H8 2.14632E-05 2.48693E-05 2.14632E-05 2.48693E-05
C2H6 2.36696E-05 2.74258E-05 2.36696E-05 2.74258E-05
N-BUTANE 6.21747E-06 7.20414E-06 6.21747E-06 7.20414E-06
N-PENTANE 5.20651E-07 6.03274E-07 5.20651E-07 6.03274E-07
ISO-
BUTANE 1.02639E-06 1.18927E-06 1.02639E-06 1.18927E-06
ISO-
PENTANE 6.04069E-07 6.99931E-07 6.04069E-07 6.99931E-07
N-HEXANE 1.05196E-07 1.21889E-07 1.05196E-07 1.21889E-07
N-HEPTANE 2.22132E-08 2.57383E-08 2.22132E-08 2.57383E-08
H2S 0 0 0 0
Total (kg/s) 0.863041282 0.863041282

3.7 Conclusion to Material Balance
From the material balance, it is deduced that 0.883060275 kg/s of feedstock (flare gas) and
1.65740576 of water are required to produce 30,000 tons/year of pure methanol at the storage
conditions of 25ºC, 1 atm. In absolute comparative terms, the methanol production rate of
0.863041282 kg/s at storage conditions of 25ºC, 1 atm is equivalent to 30,000 tons of pure
methanol per year. The purity of the final liquid product (methanol) is 99.86%. Furthermore,
with the mass flow rates of flare gas and water used in the project, 0.402285339 kg/s of CO2 was
obtained as a byproduct.
CHAPTER 4
ENERGY BALANCE
4.1 Introduction
The application of theThe rule of conservation of energy is applied to the study of physical
systems in a processis known as energy balancing. All processes, excluding nuclear operations,
can conserve energy individually. Except for nuclear operations, all processes can conserve
energy individually. Energy can be created or expended in a chemical reaction, which and this
distinguishes energy conservation from mass conservation.
Energy may be created or consumed in a chemical reaction, which distinguishes it from mass
conservation. When the mass of a system is in mass balanced, the amount of material that goes in
must equal the amount of material that comes out. Furthermore, this is true for energy but not for
stream enthalpy. If energy is created or utilisedutilized during the a process;, for example, as a
result of the heat of reaction, the total enthalpy of the exit streams will be less than the enthalpy
of the entrance stream. Energy is expensive, and as such, a chemical engineer must learn how to
effectively utilize the resource the effective use of energy is an important task for a chemical
engineer (Harding, 2018).
Similar to the mass balance equation, the eEnergy balance equation is s are similar to mass
balance equations and are given below:
Energy in – Energy out = generation – consumption + accumulation
At steady state, this equation can be written as follows:
(Internal energy + Kinetic Energy + Potential energy + Work + Heat) into the system =
(Internal energy + Kinetic Energy + Potential energy + Work + Heat) out of the system. (4.1)
It can also be written as:
𝛥𝐻 ̇ + 𝛥𝐸𝑘 + 𝛥𝐸𝑝̇ = ̇- ̇ (4.2)
Where,
𝛥𝐻̇ = is Enthalpy,
𝛥𝐸𝑘̇ is = Kinetic Energy,
𝛥𝐸̇𝑝 is = Potential Energy,
𝑄 is = Heat and,
𝑊 is = Work.
Due to the following assumptionsAssuming the following, equation 4.2 is reduced into another
form as shown in equation 4.3:
i. No change in the velocity of the process fluids.
ii. Negligible elevation difference between the streams of the unit equipment.
Equation 4.2 is reduced into another form as shown in equation 4.3 below:The reduced form
is shown below:
(4.3)
4.2 Overall Energy Balance
The difference between the enthalpy of streams into (feed) and out of (product) of the system
boundary is considered and compared with the energy in transit (heat and work) in the system to
account for the energy balance across the system.
Table 4.1 below shows the streams and equipment considered in the energy balance of the entire
system.
Table 43: Overall Energy balance for the production process
Enthalpy Change Enthalpy in Transit
Feed Enthalpy, Product Enthalpy, Heat Duty Work Done

Equipment Equipment
Stream H1 (J/s) Stream H2 (J/s) (J/s) W
D
1 3 A
-3.96E+06 -2.84E+03 -1.11E+03 (COMPRESSO 3.47E+06
FLARE GAS H2S (P.S.A)
R)
24 I
4 B
-2.65E+07 PURGE -1.04E+06 4.47E+06 (COMPRESSO 5.92E+06
WATER (HEATER)
GAS R)
25 E
-3.61E+06 4.33E+05
CO2 (HEATER)
32 F
PURE -1.29E+07 (STEAM 8.74E+06
WATER REFORMER)
33
PURE G
-6.50E+06 -2.07E+06
METHAN (COOLER)
OL
J
-4.14E+06
(COOLER)
K
(SYNTHETIC 3.75E+04
REACTOR)
L
-1.06E+07
(COOLER)
M
(FLASH 2.40E+05
SEPARATOR)
N
-1.55E+02
(P.S.A)
O
-3.11E+04
(COOLER)
Q
(FLASH -2.00E+05
SEPARATOR)
R
2.10E+05
(HEATER)
S
(DISTILLATI
1.08E+06
ON
COLUMN)
T
-1.13E+06
(COOLER)
TOTAL (J/s) -3.04E+07 -2.40E+07 -2.99E+06 9.39E+06
ENTHALPY
CHANGE = H2 6.40E+06 6.40E+06
– H1
From Table 4.1, the following deduction is made:
Change in enthalpy, ΔH = H2 – H1 = 6.40E+06 J/s
Energy in transit, Q + W = 6.40E+06 J/s
Since the overall enthalpy change of the streams is equal to the energy in transit across the
process boundary, this implies that there is no energy accumulation in the process.
4.2.1 Energy balance around P.S.A (A)
CLEAN
FLARE GAS
GAS
S1
S2
A
S3
P.S.A
(REMOVES H2S)
H2S
Figure 75: Aspen simulation Diagram for P.S.A (A)
Figure 76: Process Flow Diagram for P.S.A (A)

Table 44: Energy Balance around P.S.A (A)
Input Output
Stream 1 2 3
(FLARE GAS) (CLEAN (H2S)
GAS)
Parameter Unit
Temperature o
C 26.7 26.7 25
Pressure bar 27.46 27.46 1.01325
Enthalpy J/sec -3964321.867 -3962595.366 -2836.631273
Flow
Heat duty J/sec -1110.13086
The enthalpy flow is calculated thus:
Enthalpy change across equipment = Enthalpy out – Enthalpy in
ΔH = ΔHout – ΔHin
= (-3962595.366 + -2836.631273)) – 3964321.867 = -1110.13086 J/sec
Heat Duty (Q) = -1110.13086 J/sec
Since heat duty equals enthalpy change, therefore the energy of the system is balanced.
4.2.2 Energy balance around Heater, B

Figure 77: Process flow Diagram for Heater (B)
HEATER
WATER S4
STEAM
S5
Figure 78: Aspen simulation Diagram for Heater (B)
Table 45: Energy balance around Heater (B)
INPUT OUTPUT
/STREAMS 4 5
(WATER) (STEAM)
PARAMETERS UNITS
Temperature o
C 25 105
Pressure bar 1.01325 1

Enthalpy flow J/sec -26472207.57 -22004900.81
Heat duty J/sec 4467306.76
= -22004900.81– (-26472207.57) = 4467306.76 J/sec
Heat Duty (Q) = 4467306.76 J/sec
4.2.3 Energy balance around Mixer 1
STEAM
S5
MIXER-01
CLEAN
GAS
S2
COLD
STREAM
INLET
S6
Figure 79: Aspen simulation Diagram for Mixer 1

Table 46: Energy balance around Mixer 1
Input Output
Streams 2 5 6
(CLEAN GAS) STEAM (HOT-STEAM+
CLEAN GAS)
PARAMETERS Units
Temperature ˚C 26.7 105 90.56811706
Pressure Bar 27.46 1 1
Enthalpy flow J/sec -3962595.366 -22004900.81 -25967496.17
Heat Duty J/sec 0
The enthalpy flow is calculated as,
Enthalpy change across equipment = Enthalpy out – enthalpy in
= -25967496.17 – (-3962595.366 + (-25967496.17)) = 0 J/sec
Heat Duty (Q) = 0 J/sec

4.2.4 Energy Balance around Heat Exchanger (C)
Figure 80: Process flow Diagram for Heater Exchanger (C)

COLD S11
STREAM HOT S10
INLET STREAM S7
S6 OUTLET
COLD
STREAM
OUTLET
HOT
STREAM
C INLET
HEAT
EXCHANGER
Figure 81: Aspen simulation Diagram for Heater Exchanger (C)

Table 47: Energy balance around Heat exchanger (C)
INPUT OUTPUT
STREAMS 6 10 7 11
(HOT (COLD (HOT
(COLD HOT-
STEAM STEAM STEAM
STEAM
INLET) OUTLET) OUTLET)
INLET)
PARAMETERS UNITS
Temperature o
C 90.56811706 800 219.2522852 700
Pressure bar 1 25 1 25
Enthalpy flow J/sec -25967496.17 -12526516.26 -25169836.23 -13324176.2
Heat duty J/sec 0

Enthalpy change across equipment =
Enthalpy out – Enthalpy in ΔH in=
ΔHout – ΔHin = (-25169836.23+ -13324176.2) - (-25967496.17+ -12526516.26) J/sec= 0 J/sec.
Heat duty (Q) = 0 J/sec.
4.2.5 Energy Balance around Compressor (D)
Figure 82: Process flow Diagram for compressor (D)

S8
STEAM
CLEAN GAS
D
COMPRESSOR
COLD
STREAM
OUTLET
S7
Figure 83: Aspen simulation Diagram for compressor (D)
Table 48: Energy balance around Compressor (D)
BFD
INPUT OUTPUT
STREAMS 7 8
(COLD-STEAM (STEAM +
OUTLET) CLEAN GAS)
PARAMETERS UNITS
Temperature o
C 219.2522852 744.088816
Pressure bar 1 25
Heat duty J/sec 0
Work J/sec 3467602.99
Enthalpy out – Enthalpy in ΔH =
ΔHout – ΔHin = (-21702233.25) - ( -25169836.23) J/sec= 3467602.99 J/sec.
Heat duty (Q) = 3467602.99 J/sec.
4.2.6 Energy Balance around Heater (E)
Figure 84: Process flow Diagram for Heater (E)

E
SMR REACTOR
HEATER
FEED
S8 S9
STEAM
CLEAN GAS
Figure 85: Aspen simulation Diagram for Heater (E)
Table 49: Energy balance around Heater (E)
INPUT OUTPUT
STREAMS 8 9
(SMR
(STEAM +
REACTOR
CLEAN GAS)
FEED)
PARAMETER UNITS
S
Temperature o
C 744.088816 800
Pressure bar 25 25
Enthalpy out – Enthalpy in ΔH =
ΔHout – ΔHin = (-21269130.64) - ( -21702233.25) J/sec= 433102.603 J/sec

Heat duty (Q) = 433102.603 J/sec.
4.2.7 Energy Balance around Steam Reformer (F)
Figure 86: Process flow Diagram for steam reformer (F)
SMR REACTOR
FEED F
S9
STEAM METHA NE
REFORMER
HOT
STREAM
INLET
S10
Figure 87: Aspen simulation Diagram for steam reformer (F)
Table 50: Energy balance around Steam reformer (F)
Bfd
INPUT OUTPUT
STREAMS 9 10
(HOT
(SMR
STEAM
REACTOR
INLET)
FEED)
PARAMETER UNITS
S
Temperature o
C 800 800
Pressure bar 25 25

Enthalpy flow is
calculated thus:
Enthalpy change across equipment = Enthalpy out – Enthalpy in= in ΔH
= ΔHout – ΔHin = (-12523847.61) - ( -21269130.64) J/sec = 8742614.39 J/sec.
Heat duty (Q) = 8742614.39 J/sec
Since heat duty equals enthalpy change, therefore the energy of the system is balanced
4.2.8 Energy Balance around Cooler (G)
Figure 88: Process flow Diagram for Cooler (G)
HOT G
STREAM
COOLER
OUTLET
W.G.S
S11
REACTOR
FEED
S12
Figure 89: Aspen simulation Diagram for Cooler (G)

Table 51: Energy balance around Cooler (G)
INPUT OUTPUT
STREAMS 11 12
(HOT STREAM (W.G.S

OUTLET) REACTOR
FEED)
PARAMETERS UNITS
Temperature o
C 700 430
Pressure bar 25 25
Enthalpy change across equipment = Enthalpy out – Enthalpy in ΔH =
ΔHout – ΔHin = (-15391406.04) - ( -13324176.2) J/sec= -2067229.84 J/sec
Heat duty (Q) = -2067229.84 J/sec.
4.2.9 Energy Balance around W.G.S Reactor (H)
Figure 90: Process flow Diagram for W.G.S Reactor (H)
S12 S13
W.G.S
REACTOR
FEED
CO2, CO, H2
WATER GAS
SHIFT REACTOR
Figure 91: Aspen simulation Diagram for W.G.S Reactor (H)

Table 52: Energy balance around Water Gas Shift Reactor (H)
Input Output
Streams (12) (13)
W.G.S REACTOR CO2, H2 , CO
FEED
PARAMETERS Units
Temperature ˚C 430 603.8531522
Pressure bar 25 25
Heat duty J/sec 0
= -15391406.04- (-15391406.04) = 0 J/sec
Heat Duty (Q) = 0 J/sec.
Since heat duty equals enthalpy change, the energy of the system is balanced.
4.2.10 Energy Balance around Mixer 2
RECYCLE
S20
MIX-02
RECYCLE
S14
+
FEED
S13
CO2, CO, H2
Table 53: Energy balance around mixer 2
Input Output
Streams (13) (20) (14)
CO2, H2, CO Recycle Recycle + feed
PARAMETERS Units
Temperature ˚C 603.8531522 65 159.3079251
Pressure Bar 25 40 25
Heat duty J/sec 0
= -71549213.4- (-15391406.04 + (-56155253.85)) = 0 J/sec
4.2.11 Energy Balance around Compressor (I)
Figure 93: Process flow Diagram for compressor (I)
RECYCLE
S14
+
FEED
COMPRESSOR
COMPRESSED
CO2,
CO, H2
S15
Figure 94: Aspen simulation Diagram for compressor (I)
Table 54: Energy balance around compressor (I)
Input Output
Streams (14) (15)
Recycle + feed Compressed CO2, H2,
CO
PARAMETERS Units
Temperature ˚C 159.3079251 290.6536912
Pressure bar 25 58
Work Done J/sec 5922153.13
ΔH = ΔHout – Δhin
= --65627060.26 - (-71549213.4) =-5922153.13 J/sec
Net work done = 5922153.13W = 5922153.13 J/sec
4.2.12 Energy Balance around Cooler (J)
Figure 95: Process flow Diagram for cooler (J)

S15
COMPRESSED
CO2,
CO, H2
J
COOLER
S16
MeOH
SYNTHESIS
REACTOR FEED
Figure 96: Aspen simulation Diagram for cooler (J)
Table 55: Energy balance around cooler (J)
Input Output
Streams (15) (16)
Compressed CO2, MeOH SYNTHESIS
H2, CO REACTOR FEED
PARAMETERS Units
Temperature ˚C 290.6536912 200
Pressure bar 58 58
Heat Duty J/sec -4139657.58

= -69766717.84– (-65627060.26) = -4139657.58 J/sec.
Heat Duty (Q) = -4139657.58 J/sec
Since heat duty equals enthalpy change, the energy of the system is balanced.
4.2.13 Energy Balance around Synthesis Reactor (K)
Figure 97: Process flow Diagram for methanol synthesis reactor (K)
S17
MeOH SYNTHESIS
REACTOR OUTLET
K
METHANOL SYNTHESIS
REACTOR
S16
MeOH
SYNTHESIS
REACTOR FEED
Figure 98: Aspen simulation Diagram for methanol synthesis reactor (K)
Table 56: Energy balance around methanol synthesis reactor (K)
Input Output
Stream 16 17
(MeOH SYNTHESIS (MeOH SYNTHESIS
REACTOR FEED) REACTOR)
Parameter Unit
Temperature o
C 200 240
Pressure Bar 58 58
Enthalpy J/sec -69766717.84 -69729257.39
Flow
Heat Duty J/sec 37460.4564
= (-69729257.39) – (-69766717.84) = 37460.4564 J/sec
Heat duty (Q) = 37460.4564 J/sec
4.2.14 Energy Balance around Cooler (L)
Figure 99: Process flow Diagram for cooler (L)
S18
MeOH, CO2,
CO, H2, H2O
L
COOLER
S17
MeOH SYNTHESIS
REACTOR OUTLET
Figure 100: Aspen simulation Diagram for cooler (L)

Table 57: Energy balance around cooler (L)
Input Output
Stream 17 18
(MeOH SYNTHESIS (MeOH, CO2, CO, H2, H20)
REACTOR OUTLET)
Parameter
Temperature Unit 240 65
Pressure o
C 58 58
Enthalpy Bar -69766717.84 -80362644.89
Flow
Heat Duty J/sec -10633387.5
= (-80362644.89) – (-69766717.84) = -10633387.5 J/sec
Heat duty (Q) = -10633387.5 J/sec
4.2.15 Energy Balance around Flash Separator (M)
Figure 101: Process flow Diagram for flash separator (M)
S19
UNREACTED
GASES (FL1)
FLASH DRUM 1
MeOH
S18 H2O (FL1)
MeOH, CO2,
CO, H2, H2O
S26
Figure 102: Aspen simulation Diagram for flash separator (M)

Table 58: Energy balance around flash separator (M)
Input Output
Stream 18 19 26
(MeOH, CO2, CO, H2, (UNREACTED (MeOH + H20
H20) GAS[FL1]) [FL1])
Parameter Unit
Temperature o
C 65 65 65
Pressure bar 58 40 40
Enthalpy J/sec -80362644.89 -60708382.54 -19414476.53
Flow
= (-60708382.54 + -19414476.53)) – 80362644.89 = 239785.819 J/sec
Heat Duty (Q) = 239785.819 J/sec
4.2.16 Energy Balance around Splitter
PURGE
S21
S20
RECYCLE
SPLIT
S19
UNREACTED
GASES (FL1)
Figure 103: Aspen simulation Diagram for splitter
Table 59: Energy balance around splitter

Input Output
Stream 19 21 20
(UNREACTED GAS[FL1]) (Purge) (Recycle)
Parameter Unit
Temperature o
C 65 65 65
Enthalpy J/sec -60708382.54 -4553128.691 -56155253.85
Flow
Heat duty J/sec 0

= (-4553128.691 + -56155253.85)) – -60708382.54) = 0 J/sec
Heat Duty (Q) = 0 J/sec
4.2.17 Energy Balance around Mixer 3
PURGE
S21
TOTAL
MIX-03 PURGE S22
UNREACTED
GASES (FL2)
S28
Table 60: Energy balance around Mixer 3
Input Output
Streams 21 28 22
(Purge) (Unreacted gases) (TOTAL
PURGETotal
purge)
PARAMETERS Units
Temperature ˚C 65 37 61.90110098
Pressure Bar 40 1 1
Heat Duty J/sec 0
= -4624830.689 – (-4553128.691+ (-71701.99784)) = 0 J/sec
4.2.18 Energy Balance around P.S.A (N)
Figure 105: Process flow Diagram for P.S.A (N)

CO2
S23
TOTAL
PURGE S22
P.S.A (REMOVES CO2)

COMBUSTIBLE
GASES
S24
Figure 106: Aspen simulation Diagram for P.S.A (N)
Table 61: Energy balance around P.S.A (N)

Input Output
Stream 22 23 24
(Total purge) (PurgeCO2) (RecycleCombustibl
e gases)
Parameter Unit
Temperature o
C 65 65 65
Enthalpy J/sec
-4624830.689 -3582565.534 -1042419.99
Flow
= (-4553128.691 + -56155253.85)) – -60708382.54) = -154.830202 J/sec
Heat Duty (Q) = -154.830202 J/sec

4.2.19 Energy Balance around Cooler (O)
Figure 107: Process flow Diagram for Cooler (O)
O
COOLER
S25
CO2 CO2
FOR STORAGE
S23
Figure 108: Aspen simulation Diagram for Cooler (O)
Table 62: Energy balance around Cooler (O)
Input Output
Stream 23 25
(CO2) (CO2 FOR STORAGE)
Parameter Unit
Temperature o
C 65 25
Pressure Bar 40 40
Enthalpy J/sec -3613714.042
-3582565.534
Flow
Heat Duty J/sec -3.11E+040
= (-3613714.04219414476.53) – (-3582565.534-19414476.53) = -3.11E+040 J/sec
Heat duty (Q) = -3.11E+040 J/sec
4.2.20 Energy Balance around Expansion valve (P)
Figure 109: Process flow Diagram for Expansion valve (P)

MeOH
P
H2O (FL1)
EXPANSION VALVE
S26 S27
MeOH
H2O
Figure 110: Aspen simulation Diagram for Expansion valve (P)
Table 63: Energy balance around Expansion valve (P)
Input Output
Stream 26 27
(water + methanol) (water + methanol)
Parameter Unit
Temperature o
C 65 64.94910856
Pressure Bar 40 1.4
Enthalpy J/sec -19414476.53 -19414476.53
Flow
Heat Duty J/sec 0
= (-19414476.53) – (-19414476.53) = 0 J/sec
Heat duty (Q) = 0 J/sec
4.2.21 Energy Balance around Flash Separator (Q)
Figure 111: Process flow Diagram for Flash separator (Q)

UNREACTED
GASES (FL2)
S28
Q
S27
FLA SH DRUM 2
MeOH
H2O
MeOH
H2O (FL2)
S29
Figure 112: Aspen simulation Diagram for Flash separator (Q)
Table 64: Energy balance around Flash separator (Q)
Input Output
Stream 27 28 29
(water + methanol) (unreacted (water +
gas) methanol)
Parameter Unit
Temperature o
C 64.94910856 37 37
Pressure Bar 1.4 1 1
Enthalpy J/sec -19414476.53 -71701.99784 -19542808.8
Flow
= (-19414476.53) – (-71701.99784 + -19542808.8)) = -200034.272 J/sec
Heat duty (Q) = -200034.272 J/sec
4.2.232 Energy balance around Heater (R)
Figure 113: Process flow Diagram for Heater (R)
MeOH
H2O (FL2)
S29
S30
R DISTILLATION
HEATER
COLUMN
FEED
Figure 114: Aspen simulation Diagram for Heater (R)
Table 65: Energy balance around Heater (R)

Input Output
Stream 29 30
(water + methanol) (distillation column feed)
Parameter Unit
Temperature o
C 37 67
Pressure Bar 1 1
Enthalpy J/sec -19542808.8 -19333308.46
flow
= (-19542808.8) – -19333308.46) J/sec = 209500.344 J/sec
Heat duty = 209500.344 J/sec
Since heat duty equals enthalpy change, therefore the energy of the system is balanced
4.2.242 Energy balance around Distillation Column (S)
Figure 115: Process flow Diagram for Distillation column (S)
DISTILLATE
S31
S
S30 DISTILLATION COLUMN
DISTILLATION S32 PURE WATER
COLUMN
FEED
Figure 116: Aspen Diagram for Distillation column (S)
Table 66: Energy balance around Distillation column (S)

Input Output
Stream 30 31 32
(DISTILLATION (PURE
COLUMN FEED) (DISTILLATE) WATER)
Parameter Unit
Temperature o
C 67 63.69770609 37
Pressure Bar 1 1 1
Enthalpy J/sec -19333308.46 -5371693.647 -12879463.52
Flow
= ((-5371693.647) + (-12879463.52))- (-19333308.46) = 1082151.293 J/sec
Heat Duty (Q) = 1082151.293 J/sec
4.2.253 Energy balance around Cooler (T)
Figure 117: Process flow Diagram for Cooler (T)
T
DISTILLATE HEATER PURE
S31 S33
METHANOL
Figure 118: Aspen simulation Diagram for Cooler (T)

Table 67: Overall material balance for Cooler (T)
INPUT OUTPUT
STREAMS (33)
(31) PURE
DISTILLATE METHANOL
PARAMETERS Units
Temperature ˚C 63.69770609 25
Pressure Atmbar 1 1
HEAT DUTY J/sec -1128867.84
= (-6500561.488)- (-5371693.647) = -1128867.84 J/sec
Heat Duty (Q) = -1128867.84 J/sec2

Group 9 Chapter 3 and 4

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PRODUCTION OF 30,000 TONS/YEAR OF METHANOL FROM CARBON DIOXIDE

A FINAL YEAR DESIGN PROJECT

THE DEPARTMENT OF CHEMICAL ENGINEERING

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE

1. CHARLES DANIEL CHRIS 18CF023951

2. FADIORA AYOBAMI DANIEL 18CF023957

3. SHOWUNMI MOFEYIFOLUWA 18CF023999

4. OJOMO PETER 17CF022368

5. OKEGBENRO OLAMIDE 17CF022370

6. OKPARA UCHENNA 18CF023983

7. SHOROYE MODESOLA ESTHER 18CF023998

8. SHOWUNMI MOFEYIFOLUWA 18CF023999

Table 3.1: Components Specifications Table 4

The general material balance equation for a system is given below;

i. Mass Input: Enters Matter entering through the system boundaries

ii. Mass Generation: Matter pProduced within the system

iii. Mass Output: Matter lLeavinges through system boundaries

iv. Mass Consumption: Matter cConsumed within the system

v. Mass Accumulation: MatterMass built dup within the system

3.2 Aspen PlusAspen Simulation

Figure 3.2: Overall flow diagram for the process

i. Material balance around the reforming process

From Table 3.2 above,

From Table 3.3 above,

Total feed mass flowrate = 0.883060275 + 1.65740576 = 2.540466035 kg/s

1. High H2S selectivity.

Figure 4: Aspen simulation Diagram for P.S.A (A)

From Table 3.4 above,

Total feed mass flowrate = 0.883060275 kg/s

Total product mass flowrate = 0.002682585 + 0.88037769 = 0.883060275 kg/s

3.4.2 Material balance around Heater (B)

1. Operates isothermally at 105℃

Figure 10Figure 113.7: Aspen simulation Diagram for Heater (B)

1. Operates isothermally at 105℃

Table 5.5: Material balance around Heater (B)TABLE

From Table 3.5x above,

Total feed mass flowrate = 1.65740576 kg/s

3.4.3 Material balance around Mixer 1

1. 100% mixing efficiency.

Figure 13Figure 3.814: Aspen simulation Diagram for Heater (B)Mixer 1

From Table 3.6x above,

Total feed mass flowrate = 2.53778345 kg/s

3.4.4 Material balance around Heat Exchanger (C)(C)

From Table 3.7x above,

3.4.5 Material balance around Compressor (D)

1. Operates isentropically with an at efficiency of 75%

Components 6 Mass 7 Mass

From Table 3.8 above,

3.4.6 Material balance around Heater (E)

1. Operates isothermally at 800℃

Figure 23Figure 243.14: Aspen simulation Diagram for Heater (E)

Components 88 Mass 99 Mass

The tTotal feed mass flowrate = 2.53778345 kg/s

3.4.7 Material balance around Steam Reformer (F)

1. Operates isothermally at 800ºC and 25 bars.

2. 95% conversion of methane [add BFD]

Table 13.10.8: Material balance around Steam reformer (F)

Components 99 Mass 10 10 Mass

From Table 3.10x above,

The total feed mass flowrate = 2.53778345 kg/s

1. Operates isothermally at 430℃

Figure 29Figure 303.17: BlockProcess flow Diagram for Cooler (G)

Figure 31Figure 323.18: Aspen simulation Diagram for Cooler (G)