University Name

Design of NH3
Synthesis Loop
Academic Report

Course Project

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3.2. Comparison with Feed Injection Process
Though the two processes are at different pressure levels and have different production rates, a
simple comparison shall be made by "specific values", i.e. values are normalized by division
through the mass flow of the product, i.e. 𝑚̇𝑝𝑟𝑜𝑑 = 1200 t/d for the intermittent cooling and 𝑚̇𝑝𝑟𝑜𝑑
= 900 t/d for feed injection.

Feed Injection Process

• Specific energy for compression in kWh/kg

There are four compressors C-1, C-2, C-3, C-4. After running the simulation, the following powers
(energies) are required to operate compressors with their respective flowrates as shown in Table
1.

Table 1 Parameters of compressors in feed injection process

Compressor Mass flowrate (kg/h) Energy (kW)

C-1 41002.7 3826.59
C-2 41002.7 3647.15
C-3 41002.7 3689.64
C-4 215112 1321.69

Hence, to convert kW to kWh/kg, we need to divide power with mass flowrate.

3826.59
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑜𝑓 𝐶 − 1 = = 0.0933 𝑘𝑊ℎ/𝑘𝑔
41002.7

3647.15
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑜𝑓 𝐶 − 2 = = 0.0889 𝑘𝑊ℎ/𝑘𝑔
41002.7

3689.64
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑜𝑓 𝐶 − 3 = = 0.0899 𝑘𝑊ℎ/𝑘𝑔
41002.7

1321.69
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑜𝑓 𝐶 − 4 = = 0.00614 𝑘𝑊ℎ/𝑘𝑔
215112

Therefore, total specific energy for compression of all four compressors = 0.278 kWh/kg

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• Specific reactor volume in m3/(t/d)

There are three plug flow reactors PFR-1, PFR-2, PFR-3. After running the simulation, the
following volumes are found with their respective flowrates as shown in Table 2. For converting
kg/h to t/d, we must divide the mass flowrate handled by a specific reactor by the factor of 41.67.

Table 2 Parameters of reactors in feed injection process

Mass flowrate
Reactor Mass flowrate (kg/h) Volume (m3)
(t/d)
PFR-1 151026 3624.33 7.8
PFR-2 177643 4263.09 9
PFR-3 204260 4901.84 10.9

Hence, to convert m3 to m3/(t/d), we need to divide volume with mass flowrate.

7.8
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑃𝐹𝑅 − 1 = = 0.00214 𝑚3 /(𝑡/𝑑)
3634.33

9
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑃𝐹𝑅 − 2 = = 0.00211 𝑚3 /(𝑡/𝑑)
4263.09

10.9
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑃𝐹𝑅 − 3 = = 0.00222 𝑚3 /(𝑡/𝑑)
4901.84

Therefore, total specific reactor volume of all three reactors = 0.00647 m3/(t/d)

• Specific purge amount in kgpurge/ kgprod

Mass flowrate of purge stream = 2563.64 kgpurge/h

Mass flowrate of product = 900 t/d = 37503 kgprod/h

Therefore,

2563.64
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑝𝑢𝑟𝑔𝑒 𝑎𝑚𝑜𝑢𝑛𝑡 =
37503

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 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑝𝑢𝑟𝑔𝑒 𝑎𝑚𝑜𝑢𝑛𝑡 = 0.0683 𝑘𝑔𝑝𝑢𝑟𝑔𝑒 /𝑘𝑔𝑝𝑟𝑜𝑑

• Specific condenser heat flux in kWh/kg

In this process, CL-5 acts as condenser because vapor liquid phase is found at the outlet of this
equipment.

Mass flowrate across condenser = 215112 kg/h

Heat (energy) duty of condenser = 7775.4 kW

Therefore,

7775.4
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 ℎ𝑒𝑎𝑡 𝑓𝑙𝑢𝑥 =
215112

𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 ℎ𝑒𝑎𝑡 𝑓𝑙𝑢𝑥 = 0.036 𝑘𝑊ℎ/𝑘𝑔

Intermittent Cooling Process

• Specific energy for compression in kWh/kg

There are three compressors C-1, C-2, C-3. After running the simulation, the following powers
(energies) are required to operate compressors with their respective flowrates as shown in Table
3.

Table 3 Parameters of compressors in intermittent cooling process

Compressor Mass flowrate (kg/h) Energy (kW)

C-1 57000 6413.86
C-2 57000 6413.86
C-3 365717 3502.37

Hence, to convert kW to kWh/kg, we need to divide power with mass flowrate.

6413.86
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑜𝑓 𝐶 − 1 = = 0.112 𝑘𝑊ℎ/𝑘𝑔
57000
4
 6413.86
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑜𝑓 𝐶 − 2 = = 0.112 𝑘𝑊ℎ/𝑘𝑔
57000

3502.37
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑜𝑓 𝐶 − 1 = = 0.00957 𝑘𝑊ℎ/𝑘𝑔
365717

Therefore, total specific energy for compression of all three compressors = 0.233 kWh/kg

• Specific reactor volume in m3/(t/d)

There are three plug flow reactors PFR-1, PFR-2, PFR-3. After running the simulation, the
following volumes are found with their respective flowrates as shown in Table 4. For converting
kg/h to t/d, we must divide the mass flowrate handled by a specific reactor by the factor of 41.67.

Table 4 Parameters of reactors in intermittent cooling process

Mass flowrate
Reactor Mass flowrate (kg/h) Volume (m3)
(t/d)
PFR-1 308709 7408.42 12.7
PFR-2 308709 7408.42 10.5
PFR-3 308712 7408.49 19

Hence, to convert m3 to m3/(t/d), we need to divide volume with mass flowrate.

12.7
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑃𝐹𝑅 − 1 = = 0.00171 𝑚3 /(𝑡/𝑑)
7408.42

10.5
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑃𝐹𝑅 − 2 = = 0.00141 𝑚3 /(𝑡/𝑑)
7408.42

19
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑃𝐹𝑅 − 3 = = 0.00256 𝑚3 /(𝑡/𝑑)
7408.49

Therefore, total specific reactor volume of all three reactors = 0.00568 m3/(t/d)

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• Specific purge amount in kgpurge/ kgprod

Mass flowrate of purge stream = 682.802 kgpurge/h

Mass flowrate of product = 1200 t/d = 50006.7 kgprod/h

Therefore,

682.802
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑝𝑢𝑟𝑔𝑒 𝑎𝑚𝑜𝑢𝑛𝑡 =
50006.7

𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑝𝑢𝑟𝑔𝑒 𝑎𝑚𝑜𝑢𝑛𝑡 = 0.0136 𝑘𝑔𝑝𝑢𝑟𝑔𝑒 /𝑘𝑔𝑝𝑟𝑜𝑑

• Specific condenser heat flux in kWh/kg

In this process, NH3_Cond acts as condenser because vapor liquid phase is found at the outlet of
this equipment.

Mass flowrate across condenser = 365717 kg/h

Heat (energy) duty of condenser = 32159.8 kW

Therefore,

32159.8
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 ℎ𝑒𝑎𝑡 𝑓𝑙𝑢𝑥 =
365717

𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 ℎ𝑒𝑎𝑡 𝑓𝑙𝑢𝑥 = 0.088 𝑘𝑊ℎ/𝑘𝑔

Comparison Summary

The summary of the above calculated results is shown below in Table 5. From Table 5, Specific
energy for compression in kWh/kg is slightly higher in feed injection process than intermittent
cooling process because of the fourth compressor used in the former one. Despite the number of
reactors are same in both processes, series of PFRs in feed injection process have higher specific
reactor volume in m3/(t/d) because of lower production flowrate compared to the second process.
Furthermore, a huge difference in specific purge amounts in kgpurge/ kgprod can be seen in both

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processes because of the difference in their mass flowrate of purge streams. Lastly, due to the
higher product flowrate in intermittent cooling process, specific condenser heat flux in kWh/kg is
found to be very high as compared to the feed injection process.

Table 5 Comparison of results of both processes

Feed Injection Intermittent Cooling

Parameter
Process Process
Specific energy for compression in kWh/kg 0.278 0.233
Specific reactor volume in m3/(t/d) 0.00647 0.00568
Specific purge amount in kgpurge/ kgprod 0.0683 0.0136
Specific condenser heat flux in kWh/kg 0.036 0.088