Group 3 FYP 2nd Presentations final.pptx

Lorapai presentation on hard dzk

1. Page 01 Group members 2020-CH-255 ( Hassnain Faisal) 2020-CH-275 ( Zeeshan Abid ) 2020-CH-229 ( Arslan Sheraz ) 2020-Ch-238 (Burhan Bashir) Enhancing Green Ammonia Synthesis Process By Adsorber Based Separation Group Supervisor Dr. Ing Izzat Iqbal Cheema

2. Page 02 Overview Methodology Material Balance Heat Exchanger Reactor Equipment design Economic analysis Sustainability Adsorber Compressor References Socio Economic consideration Problem statement

3. Page 05 Problem Statements Fossil fuels, central to the world's energy needs, drive economic development but their extraction, processing, and combustion contribute to environmental harm, leading to global warming and adverse economic impacts. Transitioning to sustainable energy sources is crucial for mitigating these effects . High pressure used in separator. Low pressure in adsorber is maintained to favor the Separation of ammonia. Past Data Analysis

4. Page 05 Capacity We have Selected the Capacity of 150MTD Quaid-e- Azam Solar Park has 400MWh of capacity. Each ton of Ammonia Production Required 9-10 MW of Electricity Past Data Analysis Quaid-e- Azam Solar Park, Bahawlpur Site Selection

5. Page 10 Objectives Design an innovative ammonia synthesis loop incorporating adsorber instead of separator, aiming for enhances efficiency 01 Optimal Design of multiple stage Reactor , adsorber and heat exchangers for maximum conversion 02 We are capturing ammonia using metal halides because it will be economical and efficient compared to the separator. 03 Perform Economic and Energy Analysis to visualize the efficiency of the system 03

6. Page 03 Methodology We use it because we get: Cost efficiency . Use less pressure Overall efficient. More production. Less energy consumption. : Absorber instead of Separator:

7. Page 04 Process Flow Diagram M1,2,3,4 : Mixer V1,2,3,4 : Valves MCOMP : Multistage compressor S1 : Splitter HX : Heat exchanger REC 1,2,3 : Reactors S2: Splitter ADS: Adsorber STRIP: Stripper COND : Condenser

8. Page 05 Material Balance

9. Page 17 Energy Balance Results

10. Heat Exchanger Detail Design of Equipments

11. Page 07 Heat Exchanger Selection Feature Plate Heat Exchanger Double Pipe Heat Exchanger Shell and Tube Heat Exchanger Construction Plates with flow channels Two concentric pipes Shell with multiple tubes Heat Transfer Area High per unit volume Moderate Moderate to high Pressure Drop Low Moderate Moderate to high (depends on design) Maintenance Easier cleaning due to accessible plates Moderate difficulty More complex cleaning due to tubes Fouling Sensitivity Less prone to fouling Moderately prone to fouling Can be prone to fouling depending on fluids Cost Lower for smaller capacities Lower for low flow rates and pressures Moderate to high Versatility Limited to moderate pressures and temperatures Limited flow rates and pressures Wide range of pressures, temperatures, and flow rates Suitability for: - Clean fluids - Low pressure applications - Sanitary applications - Low flow rates - Low pressures - Viscous fluids - High pressures - High temperatures - Dirty or viscous fluids - Wide range of applications

12. Page 08 Design Procedure Cold In Temp= 100°C Pressure= 30 bar Flow rates in kg/ hr N2=16241.69889 H2= 3458.201002 AR=1546.753516 NH3=219.9477668 Total =21466.60118 Cold out Temp= 400°C Pressure= 30 bar Flow rates in kg/ hr N2=16241.69889 H2= 3458.201002 AR=1546.753516 NH3=219.9477668 Total =21466.60118 Hot In Temp= 479.13°C Pressure= 30bar Flow rates in kg/ hr N2=15767.98538 H2=3343.84587 AR=1933.441895 NH3=5788.075438 Total=26833.34858 Hot out Temp= 223.72 °C Pressure= 30bar Flow rates in Kg/ hr N2=15767.98538 H2=3343.84587 AR=1933.441895 NH3=5788.075438 Total=26833.34858 Design Specs Heat Exchanger Shell and tube Type BEM Material Carbon Steel Shell passes 1 Tube Passes 1 Pitch Type Triangular Baffle Single Segmental

13. Page 09 Background Data for calculations

14. Page 10 Design Steps and Results Design Sketch

15. Page 11 Setting Plan and Tube sheet layout on Aspen EDR Specs a nd Results

16. Page 12 Hazop Analysis of HX Guide Word Deviation Parameter Cause Consequence Safeguard More Overheating Temperature Cooling system failure Equipment damage, fire Temperature sensors, emergency cooling system, regular maintenance of cooling system Less Freezing Temperature Heating system failure Equipment damage, process shutdown Temperature sensors, emergency heating system, regular maintenance of heating system Part of Corrosion Material Corrosive process fluid Equipment damage, loss of containment Material selection, corrosion monitoring, regular inspection of equipment for signs of corrosion Abnormal Fouling Flow rate Process fluid contamination Reduced heat transfer, process upset Strainers, regular maintenance and cleaning of equipment Reverse Flow reversal Flow direction Piping configuration or operator error Reduced heat transfer, equipment damage Check valves, operator training on correct handling of equipment Other than Improper installation Equipment installation Errors in equipment installation Equipment damage, safety hazard Quality control of equipment installation, operator training on correct installation procedures

17. Page 13 Cost Estimation For HX Cost Estimation Equipment weight 1100 lbs Installed weight 11988 lbs Surface area 1030 ft2 Purchased cost 15848 $ Operation pressure 3000 kpa Correction factor 1.16 Tube and shell Final cost 18384 $

18. Reactor Design

19. Page 15 Reactor Design and Procedure

20. Page 16 Reactor 1 0.8m 2.07m 1.25m

21. Page 17 Reactor 2 2m 3.25m 1.25m

22. Page 18 Reactor 3 4m 5.28m 1.25m

23. Page 19 Conversion vs Temp

24. Page 20 Results Reactor Parametrs Bed 1 Bed 2 Bed 3 Vbed (m3) 0.412948 0.989513 2.075206 mcat (kg) 1156.255 2770.637 5810.578 Ltube (m) 0.8 2 4 dtube (m) 0.15 0.15 0.15 N tube 30 30 30 Lreactor (m) 2.076937 3.250151 5.280169 Dreactor (m) 1.276937 1.250151 1.280169 Vreactor (m3) 2.732044 4.091604 6.864727 Space velocity (h-1) 10867.19 14863.3 17483.42 Pressure Drop ( atm ) 0.249216 0.657704 0.814598

25. Page 21 Cost estimation Cost estimation Total weight of Shell 6118.629 kg Total weight of heads 3507.98 kg Cost of Reactor 1 27435.71 $ Cost of Reactor 2 31346.87 $ Cost of Reactor 3 40250.8 $ Cost of Catalyst 125613.4 $ Total cost 224646.7 $

26. Page 22 Hazop Analysis Node Parameter Guide Word Deviation Consequence Safeguard Reactor Temperature More High temperature Thermal runaway, equipment failure High-temperature alarm, cooling system Reactor Pressure More High pressure Equipment failure, safety valve failure High-pressure alarm, safety valve Reactor Catalyst flow No No catalyst flow Reduced ammonia production Low-flow alarm

27. Compressor Design

28. Page 24 Design and Selection of Compressor Selection R eciprocating Centrifuge Rotary R eciprocating Compression ratio 1.75 Stages Single Multiple Multiple stage Ideal for 1 stage is 1.2-1.4 Compression ratio 1.75 Flow rate 26833.25kg/hr Volume 1.32m2/kg Work 1876 kJ/kg Mass flow rate 5.64kg/sec Power 10 kW Conditions P1=17.07 bar , P2=30 bar T=100°C Detail design link https:// eu.docworkspace.com/d/sIJzp-rFb-8ausQY

29. Page 25 Hazop Analysis Guide word Deviation Parameter Cause Consequences Safeguards Less Low Pressure Pressure Compressor failure Impact to reactor Pressure indicator is provided More High Pressure Pressure Failure of pressure relief valve Pipe vibration Pressure indicator is provided No No Flow Flow Line leakage No process gas into the reactor Flow indicator is provided

30. Adsorber Design

31. Page 26 Adsorber Design

32. Adsorbent Selection Choose adsorbent type based on Langmuir Adsorption Isotherm: q= a*m*b*P/1+b*P Calculate mass of adsorbent (𝑚) and volume (V). Column Dimensions Determine L/D ratio (2-5). Calculate bed diameter (D) and length (𝐿). S aturation Time Find initial (𝐶) and final (𝐶o) concentrations. Calculate equilibrium loading ( Wsat ) and superficial velocity (𝑈o). B reakthrough Loading Determine used bed length (Lb) and breakthrough loading ( Wb ). Overall Mass Transfer Coefficient Calculate internal (Kc internal) and external (Kc external) mass transfer coefficients. Determine overall mass transfer coefficient (Kc) and surface area per unit volume (a). Saturated Bed Length Calculate saturated bed length (L last ) Page 27 Design Procedure

33. Page 28 Design Calculations T (K) 298 K P (Bar) 28 bar R 8.31E-02 m3.bar.K-1.mol-1 M.M 10.28183951 kmol /kg den 1.16E+01 kg/m3 visc 1.13E-05 N-s/m2 q 0.0586 kg of NH3 / kg of Mgcl2 M of Ads 118527.1421 kg den of ads 2320 kg/m3 V 51.08928537 m3 Q 2.31E+03 m3/h D 2.533533503 m L 10.13413401 m Hv 11.13413401 m Co 2.51E+00 kg/m3 C 1.25E-01 kg/m3 Wsat 0.27 kg of NH3 / kg of Mgcl2 W 0.0135 kg of NH3 / kg of Mgcl2 V 51.08928537 m3 uo 1.27E-01 m/s t 5.25E+00 h tb 5 h Lb 9.65E+00 m Lub 4.87E-01 m Wb 2.58E-01 kg of NH3 / kg of Mgcl2 kint 8.91E-03 m/s Part Dia 2.00E-07 m porasity 0.005568 - tourasity 2.5 - Diffusivity 1.78E-10 m2/s ke . Int 8.91E-03 m/s Re 5.20E+00 - Sc 2.74E+01 - Sh 9.262672942 - ke . ext 8.25E-03 m/s Kc 4.28E-03 m/s a 2.98E+07 1/m aKc 1.28E+05 1/s vz 5.36E-04 m/s t1 1.86E-03 Lsat 2.68E-03

34. Page 29 Hazop Analysis Node Guide word Parameter Deviation Consequence Safeguard Action Adsorber inlet No Flow Low Incomplete adsorption Flow meter Check flowrate, calibrate flowmeter High Overloading Pressure relief valve Adjust flowrate, install pressure relief valve Adsorber outlet No Pressure Low Decreased efficiency Pressure gauge Monitor pressure, check for leaks High Pressurization Pressure relief valve Adjust pressure, install relief valve Burst disc Install burst disc Emergency shutdown Implement emergency shutdown procedure Adsorbent bed No Temperature Low Reduced adsorption capacity Temperature sensor Monitor temperature, adjust heating High Thermal decomposition Temperature controller Monitor temperature, adjust heating Fire suppression system Install fire suppression system Emergency shutdown Implement emergency shutdown procedure

35. Page 30 Cost Estimation of Adsorber Total weight of shell 2800 lb Purchased cost of carbon steel shell 2 8000lb 11,100 $ Cost of 19 installed 18 inch manholes 39,672 $ Cost of 1 installed 1 6 inch nozzle inlet 690 $ Cost of 1 installed 16 inch nozzle outlet 828 $ 6 installed 1 inch couple 114 $ Cost of packing material ( Activated carbon) 45 $ Cost of Adsorbent MgCl2 Cost od rashing rings 535 4518 $ $ Total purchased cost of tower 56,950 $ For Packed bed column following are the conditions , 18 inch man holes, shell ⅝ inch, six 1 inch coupling, flanged nozzles attached each 10 inch, 2 nozzles of 16 inch

36. Page 31 Economic Analysis

37. Page 32 Socio Economic Considerations Sustainability considerations

38. Page 33 FAUGET UNIVERSITY References Improving Absorbent-Enhanced Ammonia Separation For Efficient Small Scale Ammonia Synthesis Emmanuel Onuoha1 Matthew Kale1 Mahdi Malmali2 Paul Dauenhauer Alon McCormick1 ,* Department of Chemical Engineering & Materials Science, 421 Washington Ave. SE, University of Minnesota , Minneapolis, MN, USA 55455 . Department of Chemical Engineering, 807 Canton Ave, Texas Tech University, Lubbock, TX 794 Achieving +95% Ammonia Purity by Optimizing the Absorption and Desorption Conditions of Supported Metal Halides Daniel J. Hrtus , Fouzia Hasan Nowrin , Austin Lomas, Yanick Fotsa , and Mahdi Malmali * Optimizing the Conditions for Ammonia Production Using Absorption Collin Smith, Alon V. McCormick, and E. L. Cussler * Green ammonia project set for launch in UK today Article by Adam Duckett Modeling and Optimal Design of Absorbent Enhanced Ammonia Synthesis by Matthew J. Palys,Alon McCormickORCID,E . L. Cussler andProdromos Daoutidis * ORCID Department of Chemical Engineering and Materials Science, University of Minnesota, Minneapolis, MN 5405, USA Ammonia Synthesis at Low Pressure Edward Cussler , 1 Alon McCormick, 1 Michael Reese, 2 and Mahdi Malmali 1

39. Page 34 FOR YOUR ATTENTION Any Questions? THANK YOU