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Matrial Balance Report

The document summarizes the material and energy balance for producing 5480 metric tons per year of methanol from synthesis gas. It describes the inputs and outputs from the gasifier that produces the synthesis gas from coal, as well as the cyclone separator and absorber used to purify the gas. Tables are provided showing the material flow rates and balances for the gasifier, cyclone separator, and absorber. The absorber uses Selexol solvent to remove acid gases like H2S and CO2 from the syngas so they do not deactivate the catalyst in the downstream Fischer-Tropsch reactor that will produce the methanol.

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Shah Ali Naqvi
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251 views14 pages

Matrial Balance Report

The document summarizes the material and energy balance for producing 5480 metric tons per year of methanol from synthesis gas. It describes the inputs and outputs from the gasifier that produces the synthesis gas from coal, as well as the cyclone separator and absorber used to purify the gas. Tables are provided showing the material flow rates and balances for the gasifier, cyclone separator, and absorber. The absorber uses Selexol solvent to remove acid gases like H2S and CO2 from the syngas so they do not deactivate the catalyst in the downstream Fischer-Tropsch reactor that will produce the methanol.

Uploaded by

Shah Ali Naqvi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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CHAPTER-3 MATERIAL & ENERGY BALANCE

PRODUCTION OF 5480 MTY METHANOL FROM


SYNTHESIS GAS

Wah Engineering College


Group#04
Session 2015 – 2019
Supervised by
Mr. Usman Asghar
Mr.Nazar Mehmood
Group Members

Sohail Farooq UW-15-Ch.E-BSc-018


Ahsan Khan UW-15-Ch.E-BSc-003
Aqib Javed UW-15-Ch.E-BSc-006
Ahsan Nawaz UW-15-Ch.E-BSc-038

DEPARTMENT OF CHEMICAL ENGINEERING


WAH ENGINEERING COLLEGE,
UNIVERSITY OF WAH, WAH CANTT
CHAPTER-3 MATERIAL & ENERGY BALANCE

Chapter No.3
3 Material and Energy Balance
CHAPTER-3 MATERIAL & ENERGY BALANCE

3.1 Material Balance


Plant capacity =5480 MTY= 20MTD
Operating Time:
Operating Days=300days/year
Production Rate:
20MT 1000Kg 1 Day
DAY MT 24 Hour

= 833kg/hr
Reactant Rate:
Yield=product/reactant
Reactant=product/yield
From literature, yield is 80%
Reactant=833/0.8=1041Kg/hr
Table 1: Proximate and Ultimate Analysis of Coal

Coal %
Moisture 25
Ash 3
Sulphur 2
Hydrogen 4.94
Nitrogen 1.37
Oxygen 7.53
Carbon 56.16
Total 100

3.2.1 Gasifier
Gasifier is used to produce syngas, Steam and oxygen are the gasification agents, and high
conversions are achieved in the gasifier using steam and oxygen as gasification agents. Under the
specified conditions of temperature and pressure in the gasifier, 90% of carbon is converted into
syngas. The principal components of the syngas are H2, CO, CO2 and CH4, with the key materials
being H2 and CO.
CHAPTER-3 MATERIAL & ENERGY BALANCE

Reaction 1
C + ½ O2 → CO Conversion=12%
C in feed =(1041*0.5616)/12
= 48.71 kgmol/hr
C consumed = 5.84 kgmol/hr
O2 Consumed = 5.84/2
=2.92 kgmol/hr
CO produced = 5.84 kgmol/hr
Reaction 2
C + O2 → CO2 , Conversion=6%

C in feed = 48.71 kgmol/hr


C consumed = 2.92 kgmol/hr
O2 consumed = 2.92 kgmol/hr
CO2 Produced = 2.92 kgmol/hr
Reaction 3
C + H2O → CO + H2 Conversion=52%
C in feed = 48.71 kgmol/hr
C consumed = 25.32 kgmol/hr
H2O consumed = 25.32 kgmol/hr
CO produced = 25.32 kgmol/hr
H2 produced = 25.32 kgmol/hr
Reaction 4
4. H2 + S → H2S Conversion=2%
S in feed = (1041*0.02)/32
=0.65 kgmol/hr
S consumed = 0.013 kgmol/hr
H2S produced = 0.013 kgmol/hr
Reaction 5
C + 2H2 → CH4 Conversion=20%
C in feed = 48.71 kgmol/hr
C consumed = 9.74 kgmol/hr
CHAPTER-3 MATERIAL & ENERGY BALANCE

CH4 produced = 9.74 kgmol/hr


Unreacted Carbon = 58.68 kg/hr
Steam Required= For reaction 3 - Already present moisture
=25.32-14.45
=10.87 kgmol/hr
Total oxygen required for reaction = 5.84 kgmol/hr
1 kgmol of oxygen contains 2 atoms of “O”=11.68 kgmol/hr
Oxygen Already present =2.44 kgmol/hr
Oxygen required =9.24 kgmol/hr
=295 kg/hr

Ash Unreacted=31.23kg/hr
Carbon=58.68kg/hr
3 Carbon Monoxide=872.48kg/hr
Carbon Dioxide=128.48kg/hr
Hydrogen=129kg/hr
Hydrogen Sulphide=0.442kg/hr
Methane=155kg/hr

Coal 1041kg/hr 1
Coal

Oxygen 295kg/hr
Oxygen/steam 2
Steam195.66kg/hr

R-101
CHAPTER-3 MATERIAL & ENERGY BALANCE

Table 2: Summary of Material Balance on Gasifier

Input (kg/hr) Output (kg/hr)


Components S1 S2 S3
Moisture 260.25
Ash 31.23
Sulphur 20.82
Hydrogen 51.42
Nitrogen 14.26
Oxygen 78.38 295
Carbon 584.62
Ash Unreacted 195.66 31.23
Steam
Carbon 58.68
Carbon dioxide 128.48
Carbon Monoxide 872.48
Hydrogen 129
Hydrogen Sulphide 0.442
Methane 155
Total=1531.66 Total=1531.66

3.2.2 Cyclone Separator


Cyclone separator is used to separate the gases from solid particles on the basis of density
difference. The gaseous stream goes upward and solid stream goes downward. The solid particles
consist of coal residue and unreacted coal.
CHAPTER-3 MATERIAL & ENERGY BALANCE

5
3

Gases
Gases and Solids 1271.742 Kg/hr
1530.03 kg/hr

CS-201

258.294
Kg/hr

Material balance on cyclone separator


It is mixture of Solids and gases
Total In = 1530.03 kg/hr
Out Solids = 258.294 kg/hr
Out Gases = 1271.742
Total Out = 1530.03 kg/hr
Table 3:Material Balance on Cyclone Separator

Material In(Kg/hr) Material Out(kg/hr)


S3 S4 S5
Gases & Solids Flow rate (kg/hr) Solids Flow rate(kg/hr)
Solids and Gases 1530.03 Solvent 258.294
Gases 1271.742
Total in= 1530.03 Total=1530.03

3.2.3 Absorber
Absorption column is used to remove acid gases (H2S, CO2) and methane (CH4) from syngas
because these gases permanently deactivates the catalyst of FT reactor.
CHAPTER-3 MATERIAL & ENERGY BALANCE

Selexol is used as solvent in absorption column because it work very effectively for absorption of
acid gases.
Solvent Gases
4 6 994.68 kg/hr
2481.98 kg/hr

A-301

Solvent
Gases 5 7
2758.98 kg/hr
1271 kg/hr

Material balance on absorber

Solvent is Selexol and its concentration is 100%.


Solubility of gases in solvent [4]
H2S = 8.82 kg/L
CO2 = 1 kg/L
CH4 = 0.066 kg/L
Solvent requires for H2S:
L/hr of solvent req. to absorbed = 0.05kg/hr
Solvent requires for CO2:
CO2 IN =128.42 kg/hr
CO2 Out =6/100*128.2
=7.70kg/hr
CO2 to remove=128.42-7.70
CHAPTER-3 MATERIAL & ENERGY BALANCE

=120.70 kg/hr
Solvent requires for CH4:
9 Solvent required=2361.21 kg/hr

Acid Gases Total Solvent


7
994.68 Kg/hr
required=0.05+120.72+2361.21
Lean Solvent
3753.662 Kg/hr =2481.98kg/hr
S-501 Total In = 2722992 kg/hr
Solvent out = 1746910.61 kg/hr
8
Gases out = 976081.38 kg/hr
Rich Solvent
2758.662 Kg/hr Total Out = 2722992 kg/ hr
Table 4:Material Balance on Absorber

Components Total In (Kg/hr) Total Out (Kg/hr)


Streams S4 S5 S6 S7
Solvent 2481.98
Carbon 872.48
monoxide
Hydrogen 114.50
Nitrogen 1263
Hydrogen 0.442
Sulphide
Methane 155.84
Carbon dioxide 7.70 120.72
Solvent 2758.98
Gases 1271.742 994.68
Total=3753.722 Total=3753.722
3.2.4 Stripper
Table 5: Material Balance on Stripper

Components Material In (Kg/Hr) Material Out (Kg/hr)


Streams S7 S8 S9
Lean Solvent 3753.662
Acid Gases 994.68
Rich Solvent 2758.98
Total=3753.662 Total=3753.662
CHAPTER-3 MATERIAL & ENERGY BALANCE

3.2.5 Isothermal Reactor


Gases carbon monoxide (CO) and hydrogen (H2) is entered in FT reactor as a reactants. Heat is
released during process.

Steam

CO=872.48 Kg/hr
H2=129 Kg/hr
CO2=7.70 Kg/hr
Total=1006.18Kg/hr
Condensate

CH3OH=1002.49 kg/hr
H2O=5.823 Kg/hr
Unreacted H2=0.376Kg/hr
Total=1006.07 Kg/hr

Material balance on Isothermal reactor


Reaction 1
CO+2H2→CH3OH
Conversion =100%.
Reactant
CO in Feed=31.16 Kgmol/hr
CO Consumed=63.68 Kgmol/hr
H2 Consumed=52 Kgmol/hr
Product
CH3OH=31.16kgmol/hr
CHAPTER-3 MATERIAL & ENERGY BALANCE

Reaction 2
CO2+3H2→CH3OH+H2O
Conversion=96%
Reactant
CO2 in feed=0.175 Kgmol/hr
CO2 Consumed=0.148 Kgmol/hr
H2 Consumed=0.444 Kgmol/hr
H2O Produced=0.148 Kgmol/hr
Product
CH3OH Produced=0.148 Kgmol/hr
Total In = 1006.18 kg/hr
Total Out = 1006.07 kg/hr
Summary of material balance on Isothermal reactor

Table 6: Material Balance on Isothermal Reactor

Components Inlet (Kg/hr) Outlet (kg/hr)


Streams S13 S14
CO 872.48
H2 129
CO2 7.70
CH3OH 1002.49
H2O 5.823
Unreacted H2 0.376

Total=1006.18 Total=1006.07
CHAPTER-3 MATERIAL & ENERGY BALANCE

3.2.6 Flash Drum


15 Gases=1.564 Kg/hr

Crude Methanol and


gases =1006.078 14 C-101
Kg/hr

16

Crude Methanol=1004.514 Kg/hr

Table 7:Material Balance on Flash Drum

Components Input (Kg/hr) Output(Kg/hr)

Streams S14 S15 S16

Crude Methanol and Gases 1006.078


Gases =1.564
Crude Methanol= 1004.514
Total=1006.07 Total=1006.07

3.2.7 Mixer
From Literature the solubility of Potassium Per magnate (KMnO4) in Water =63.8g/L
Impurities water =4.662Kg/hr
CHAPTER-3 MATERIAL & ENERGY BALANCE

KMnO4 required =197.289Kg/hr

A Crude Methanol=1004.514
KMnO4=197.289 Kg/hr
M-101 17 kg/hr
Total 1201.803 Kg/hr

KMnO4 and
Impurities=297Kg/hr
18 Un Purified
Methanol=900Kg/hr
Total=1201 Kg/hr

Table 8:Material Balance on Mixer

Components Input(Kg/hr) Output(Kg/hr)


Streams S(A) S17 S18
KMnO4 197.289
Crude Methanol 1004.514
KMnO4 and Impurities 297
Un Purified Methanol 900
Total 1200.03 Total=1200

3.2.8 Distillation Column


Distillation column is used to separate the gasoline from diesel on the basis on their boiling point
or relative volatility. The gasoline is separated as top product and diesel is separated as a bottom
product.
Material balance on distillation column
Distillation Collumn
Overall Material Balance
F=D+W
Distillate=D=833 Kg/hr
Bottom=71.2Kg/hr
CHAPTER-3 MATERIAL & ENERGY BALANCE

Table 9:Material Balance on Flash Drum

Components Input (Kg/hr) Output (Kg/hr)

Streams S18 S23 S24


Unpurified Methanol 900
Distillate 833
Bottom 71
Total=900 Total=900

CW in CW out
21

C-101
22

23

Distillate=833Kg/hr

Methanol
D-101

D-101

20

Unpurified Steam
Methanol=900 Kg/hr 18 19
RB-602
Total=900 Kg/hr
Condensate Bottom=71 Kg/hr

24

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