SYNGAS Process Integration

Ammonia / Methanol Flowsheet Integration “Reducing Risk and Increasing Profitability”

Case Study #72514GB/H

Contents Conventional Ammonia Plant Flow Sheet Conventional Methanol Plant Flow Sheet Superstructure Block Diagram Process Design Tools Pi Algorithm Approach Ammonia / Methanol Flow Sheet Integration: Case Study#72514GB/H Equipment List Integration Flowsheet 1: Feed Preparation (HDS) Integration Flowsheet 2: Feed Preparation (Saturator Circuit) Integration Flowsheet 3: Pre-reformer, AGHR, ATR Integration Flowsheet 4: Isothermal Shift Integration Flowsheet 5: CO2 Removal Stream Component - Material Balances Table 1 Table 2 Table 3

Conventional Ammonia Plant Flow Sheet

Conventional Methanol Plant Flow Sheet

Superstructure Block Diagram

Process Design Tools

PFD SIM - in Excel

Ammonia / Methanol Flow Sheet Integration Case Study#72514GB/H

Equipment List

Tag Description

B-101 HDS Fired Heater B-301 Pre-reformer Fired Heater E-101 HDS Interchanger E-301 AGHR Interchanger E-401 HT Saturator Water Heater E-402 NH3 Syngas Saturator Water Heater E-403 NH3 Syngas Cooler E-404 MeOH Syngas Saturator Water Heater E-405 MeOH Syngas Cooler J-201 Cool Saturator Water Pump J-202 Hot Saturator Water Pump K-101 Natural Gas Compressor R-101 HDS R-102A H2S Absorber 1 R-102B H2S Absorber 2 R-301 Pre-reformer R-302 AGHR R-303 ATR R-401 Isothermal Shift T-201 Saturator V-401 NH3 Syngas KO Pot V-402 MeOH Syngas KO Pot X-501 CO2 Removal X-502 Cold Box

To Saturator

Natural Gas

H2 Recycle from CO2 Removal

S-414

S-101 K-101

B-101

E-101

S-107

R-101 R-102A

R-102B

Integration Flowsheet 1: Feed Preparation (HDS)

S-107

S-203 S-201

MP Steam

To FXC

Water from E-401

To E-401

Mixed Feed to Reformer

Process Condensate

To E-402 J-201

J-202

From HDS

S-20

2

T-201

Integration Flowsheet 2: Feed Preparation (Saturator Circuit)

Fuel Gas

O2 from ASU

R-301

R-302

R-303

E-301 S-203 Mixed Gas from Saturator S-301

Reform Gas to E-401

S-307

S-308

S-30

2

B-301

S-20

3

From FC

S-304

S-305

Integration Flowsheet 3: Pre-reformer, AGHR, ATR

From FCV

Water to Saturator

E-403

To CO2 Removal

S-401

S-308

E-402

S-408

V-401

From 201

S-415

E-401

S-40

4

S-405

Reform Gas from E-301

From J-202

R-301

From Co2 Removal

E-405 E-404

MeOH Syngas

S-420

V-402

S-410

Integration Flowsheet 4: Isothermal Shift

S-414

S-410

S-411

S-501

S-408

N2 from ASU

Fuel Gas S-508

S-502

X-502

X-501

From V-401

CO Product

NH3 Syngas

S-509

H2 R/C to HDS

To MeOH Syngas

Integration Flowsheet 5: CO2 Removal

Name S-101 S-107 S-201 S-202 S-203 S-301 S-302

Temperature (C) 27 154.3 223.8 350 260.3 400 504.2 Pressure (bar) 22 52.2 51.7 55 51.7 51.1 50.3 Molar Flow (kgmole/h) 10360 10587.3 22437.5 9317.5 31755 31755 31755 Mass Flow (kg/h) 172113 172942 386425 167856 554281 554281 554281

Hydrogen 0.000% 2.005% 0.946% 0.000% 0.668% 0.668% 0.668% CO 0.000% 0.121% 0.057% 0.000% 0.040% 0.040% 0.040% CO2 0.640% 0.626% 0.296% 0.000% 0.209% 0.209% 0.209% Methane 96.570% 94.514% 44.597% 0.000% 31.512% 31.512% 31.512% Ethane 2.710% 2.652% 1.251% 0.000% 0.884% 0.884% 0.884% Propane 0.010% 0.010% 0.005% 0.000% 0.003% 0.003% 0.003% Nitrogen 0.070% 0.071% 0.033% 0.000% 0.024% 0.024% 0.024% Methanol 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% H2O 0.000% 0.000% 52.815% 100.000% 66.660% 66.660% 66.660% Oxygen 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% Argon 0.000% 0.002% 0.001% 0.000% 0.001% 0.001% 0.001%

Stream Component: Material Balances Table 1

S-303 S-304 S-305 S-307 S-308 S-401 S-402 S-404 S-405

450 40 1050 580 460.5 220 220 220 252.7 49.3 45.8 42.8 42.3 41.9 41.3 41.3 41.3 39.8

32843.6 4913.8 52509.3 52444 52444 52444 21711 4511 26222.4 554281 157338 711619 711619 711619 711619 294600 61210 355809

6.426% 0.000% 45.832% 45.280% 45.280% 45.280% 45.280% 45.280% 56.638% 0.027% 0.000% 14.392% 14.770% 14.770% 14.770% 14.770% 14.770% 3.413% 1.871% 0.000% 5.475% 5.059% 5.059% 5.059% 5.059% 5.059% 16.416% 30.529% 0.000% 0.416% 0.479% 0.479% 0.479% 0.479% 0.479% 0.479% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.023% 0.500% 0.061% 0.061% 0.061% 0.061% 0.061% 0.061% 0.061% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 61.124% 0.000% 33.777% 34.304% 34.304% 34.304% 34.304% 34.304% 22.946% 0.000% 99.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.001% 0.500% 0.047% 0.047% 0.047% 0.047% 0.047% 0.047% 0.047%

Name

Temperature (C) Pressure (bar) Molar Flow (kgmole/h) Mass Flow (kg/h)

Hydrogen CO CO2 Methane Ethane Propane Nitrogen Methanol H2O Oxygen Argon

Stream Component: Material Balances Table 2

S-408 S-410 S-411 S-414 S-415 S-420 S-501 S-502 S-508 S-509

45 45 45 45 220 45 0 45.3 28.8 31.7 38.4 37.9 37.9 37.9 41.3 37.9 50 37.9 37.9 37.9

20253.9 109.8 15563.5 227.2 26222 17378.6 4998.6 832 735.1 18995 247979 400 56732 828 355809 194736 140025 23304 11709 161744

73.328% 93.405% 93.405% 93.405% 45.280% 68.910% 0.000% 0.000% 39.549% 75.001%

4.418% 5.627% 5.627% 5.627% 14.770% 22.316% 0.000% 100.000

% 5.956% 0.000% 21.195% 0.000% 0.000% 0.000% 5.059% 7.594% 0.000% 0.000% 0.000% 0.000% 0.620% 0.790% 0.790% 0.790% 0.479% 0.727% 0.000% 0.000% 16.717% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%

0.079% 0.101% 0.101% 0.101% 0.061% 0.093% 100.000

% 0.000% 36.131% 24.999% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.299% 0.000% 0.000% 0.000% 34.304% 0.287% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.061% 0.078% 0.078% 0.078% 0.047% 0.072% 0.000% 0.000% 1.647% 0.000%

Name

Temperature (C) Pressure (bar) Molar Flow (kgmole/h) Mass Flow (kg/h)

Hydrogen CO CO2 Methane Ethane Propane Nitrogen Methanol H2O Oxygen Argon

Stream Component: Material Balances Table 3