LECTURE 5-10 IIB FUEL AND INDUSTRIAL GASES.pptx

FUEL AND INDUSTRIAL GASES

1. IIB. FUEL AND INDUSTRIAL GASES 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 1

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7. 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 7 The correct ratio of steam, O2, and coal is added to reactor

8. Major Engg . Problems Designing suitable ash removal systems for various grades of coal in continuous process Optimizing cycle for regenerative process 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 8

9. 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 9 COKE OVEN GAS Liquid air fractionation plant

10. Major Engg . Problems Obtaining suitable grades of coking coal in INDIA. Choice of scrubbing liquors for CO2 & CO 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 10

11. 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 11 NATURAL GAS

12. Synthesis gas-Methods of Production Classification of Processes From petroleum hydrocarbons Reforming Partial combustion From coal or coke Water gas Coke oven gas 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 12

13. Reforming of Hydrocarbon by steam INORGANIC CHEMICAL INDUSTRIES 8/31/2023 13

14. Quantitative requirements Basis: 100 Nm3 of hydrogen of 99.+% purity Naphtha 21.9 kg Steam 560 kg Fuel 22.3 kg cooling water 6.5 tons Electricity 1.4 KWH b)Plant capacities 10-200 tons/day of H2 80,000-1680000 Nm3/day of synthesis gas 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 14

15. 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 15 Ni catalyst is packed in vertical tubes of 3-4 inches in dia and about 20-25 feet long Space velocity 500-600/ hr

16. Major Engg . Problems Sulfur contamination of reforming catalyst. Naphtha must be purified by catalytic hydrogen treatment to remove sulfur to yield a vapor feed of less than 5 ppm sulfur. Design of an efficient reformer furnace to economically supply endothermic heat of reaction. Avoid carbon formation on catalyst by use of highly specific catalyst Removal of CO2 & CO. The bulk of the CO2 is absorbed by either K2CO3 or MEA. 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 16

17. Partial Combustion process for synthesis gas 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 17

18. Raw materials Lower purity natural gas than required for steam reforming Tonnage oxygen Steam Promoted iron oxide shift converter catalyst, ethanolamines , and ammoniacal cuprous formate 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 18

19. Quantitative requirement Basis: 100 Nm3 of hydrogen of 99.+% purity Naphtha 29.2 kg or methane (35 Nm3) Steam 104 kg Oxygen 26 Nm3 cooling water 8 tons Electricity 0.7 KWH b)Plant capacities 10-200 tons/day of H2 100,000-1,600,000 Nm3/day of synthesis gas 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 19

20. 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 20 Dimethyl formamide

21. Major Engg . Problems Correct design of burner for flame stabilization in gas generator Removal of trace impurities of CO & CO2 Handling deposited carbon 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 21

22. Acetylene Pertinent Properties of Acetylene MW 26.02 Triple Point -80.6oC and 961.5 mmHg Pr B. P. -84oC Ignition point 305oC Explosive limit LFL=2.3% Vol. in air UFL=80% Vol. in air 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 22

23. Methods of Production Classification of Process From Petroleum Hydrocarbons Partial or stage-wise combustion Pyrolysis Arc Process From calcium carbide 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 23

24. Acetylene from Partial or stage-wise combustion Chemical reactions Exothermic heat supply Endothermic production reaction Undesirable side reaction 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 24

25. Raw materials Low purity natural gas or higher m.w. HC Tonnage oxygen 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 25

26. Quantitative requirement Basis: 1 ton acetylene (99% purity – 35% yield) Natural Gas 5,200 cu, m (STP) or naphtha = 4.1 tons Oxygen (95%) 4.7 tons Process steam 12 tons Electricity 350 KWH Water 1100 tons By-product yields 900 cu m (STP) of off-gas @ 3,000 Kcal/cu m – can be used for synthesis gas 20 kg carbon polymers 5 Kg acetylene polymers b)Plant capacities 10-60 tons/day 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 26

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28. Major Engg . Problems a) Thermodynamic and kinetic considerations Endothermic HC pyrolysis is favourable at high temperatures. The rate of pyrolysis is not significant until about 1,300oC. The good design is to provide rapid heat-up to induce the pyrolysis and quench to low temperature again before back reactions and side reaction to produce C+H2 become significant. 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 28

29. b) Burner design: 2-basic design are currently used One-stage burner Flame stabilization: to produce correct temperature HTR time must be uniform for all molecules Amount of oxygen must be kept low for complete combustion Two-stage burner A portion of the HC is mixed with sufficient O2 for complete combustion to supply heat requirement. Combustion fuel can be different from the reactant fuel and steam may be injected to increase equilibrium yield possibilities. c) Separation of polymers and purification of acetylene d) Design for explosion –proof plant operation 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 29

30. Pyrolysis of Hydrocarbons (Wulff Process) 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 30

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34. Acetylene from Calcium Carbide 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 34

35. Raw Materials Limestone, coke, cheap electric power and process water Limestone should be low in S & P 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 35

36. Quantitative requirement 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 36

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38. Major Engg . Problems Choice of lime Moist free CaC2 T & Pr control in generators Purification of generator gas before further use Waste disposal of lime residue from generator 31-08-2023 INORGANIC CHEMICAL INDUSTRIES 38