Water Gas Shift Reactor Design

WATER GAS SHIFT REACTOR DESIGN

CN2116 Group 28

INTRODUCTION

EXECUTIVE SUMMARY

SIMULATION

FEATURESCONCLUSION

MA HAOTIAN

LI LAN

LIU YI FEI

LUO YUSHAN YU

INTRODUCTIONWGS Reactor Design

• Hydrogen supply for mass ammonia industrial synthesis

DESIGN OBJECTIVE

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

EXECUTIVE SUMMARYWGS Reactor Design

Heat Exchang

er I

CO2 Remova

l Tank

Heat Exchang

er II

HTS React

or

Heat Exchang

er III

LTS React

or

REACTOR SET-UP

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

• Feed Composition

Component Composition (%)

CO 7

H2O 37

CO2 4

H2 42

Inert (N2) 10

DESIGN SPECIFICATIONS

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

• Catalyst Properties

Particulars Properties

Composition (HTS) Fe3O4-Cr2O3 (90-95% Fe2O3, 5-10% Cr2O3, CuO, K2O, ZnO,

PbO, Al2O3)

Composition (LTS) Cu-Ce(La)Ox (5% Cu)

Particle Size (mm) 5

Bulk Density (kg/m3) 995

Weight (kg, HTS) 88256.5

Weight (kg, LTS) 18706

DESIGN SPECIFICATIONS (CONT)

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

• HTS Reactor Dimensions

Dimensions Values

Inner Diameter (m) 3.8

Cross-sectional Area (m2) 11.6

Height (m) 7.7

Volume (m3) 88.7

DESIGN SPECIFICATIONS (CONT)

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

• LTS Reactor Dimensions

Dimensions Values

Inner Diameter (m) 2.3

Cross-sectional Area (m2) 4.1

Height (m) 4.6

Volume (m3) 18.8

DESIGN SPECIFICATIONS (CONT)

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

• Process Specifications

Particulars HTS LTS

Inlet Temperature (OC) 300 – 500 200 - 300

Outlet Temperature (OC)

350 - 550 205 – 310

Inlet Pressure (bar) 10 9.85

Outlet Pressure (bar) 9.85 9.82

Conversion 0.81 0.99

Hydrogen Producing Rate (mol/s)

- 1467.9

DESIGN SPECIFICATIONS (CONT)

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

SIMULATIONWGS Reactor Design

GOVERNING EQUATIONS

Conversion and Temperature Correlations

H

TTC p

)(

x 0''

CO

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

GOVERNING EQUATIONS (CONT)

Rate Law

)1(20

mOH

nCO

RT

E

CO CCekr

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

GOVERNING EQUATIONS (CONT)

Design Equation

x

COCO r

dxFW

00

bulk

WV

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

ASSUMPTIONS

No deactivation of catalyst

Ideal gas condition

Mixture properties

Catalyst packing

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

METHODOLOGY

Conversion iterates from 0

Reaction rate under this conversion

Plotting 1/rate versus

conversion

Calculating area under

Volume of catalyst

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

SIMULATION RESULTS• The highest conversion for HTS inlet temperature 320.000000 Celsius is

0.810000 outlet temperature 362.849043 Celsius

• The highest conversion for LTS inlet temperature 200.000000 Celsius is 0.990500 outlet temperature 208.682034 Celsius

• HTS reactor volume is 88.687919 m^3 • LTS reactor volume is 18.837752 m^3• Total volume is 107.525670 m^3

• HTS reactor pressure drop is 14807.220752 Pa • LTS reactor pressure drop is 2505.309835 Pa• Total pressure drop is 17312.530587 Pa

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

SIMULATION RESULTS

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

FEATURESWGS Reactor Design

FEATURES

Features

Reactor volume

Operating temperature

CO2 Removal

Easy Operation

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

FEATURES (CONT)

•115.03 m3

•7% overdesign•Cost consideration•Relatively small•Height diameter ratio = 2:1

Reactor

Volume

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

FEATURES (CONT)

•HTS: 320 – 363 OC LTS: 200 – 209 OC•Relatively low temperature•Energy saving•Preventing sintering

Operating Temperatur

e

•CO conversion enhancement•Easy Operation

OthersINTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION

CONCLUSIONWGS Reactor Design

INTRO EXE. SUMMARY SIMULATION FEATURES CONCLUSION