METHANOL PRODUCTION USING VULCAN SYSTEMS COMBINED REFORMING TECHNOLOGY (ATR) AUTO THERMAL REFORMING...

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METHANOL PRODUCTION USING VULCAN SYSTEMS COMBINED REFORMING TECHNOLOGY

(ATR) AUTO THERMAL REFORMING AND (AGHR) ADVANCED GAS HEATED REFORING

CASE STUDY#08270414

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Contents Section 1 Introduction 2 Autothermal Reforming 2.1 Process Description 3 Gas Heated Reforming (GHR)

CASE STUDY #08270414

4 Plant Equipment List 5 Combined Reforming – ATR / AGHR PFD’s 6 Process Stream Descriptions 7 Combined Reforming Simulation Results* 8 AGHR Output Simulation Results 9 Single Column – Distillation 10 Distillation Column Profiles Hysys Output* Aspen Output 11 Scrubbers Simulation Results 12 ATR / AGHR Design Considerations

*400% PDF Magnification Required



APPENDIX FIGURES Figure 1 Conventional Small Scale Steam Methane Reformer Design

Figure 2 Compact, Tubular, Small Scale Steam Methane

Reformer Designed for Fuel Cell Applications, with Convective Heat Transfer

TABLES Table I Comparison between Different Reformer Concepts

Table 2 Advantages and Disadvantages for Different Synthesis Gas Technologies

Table 3: Small-Scale Steam Methane Reforming for Syn Gas Generation

Table 4: Small-Scale Autothermal Reformers for SynGas Generation

Table 5: Small-Scale Partial Oxidation for SynGas Generation Table 6: Small-Scale Methanol Steam Reforming for SynGas Generation Table 7: Small-Scale [Ammonia Cracking, Sorbent Enhanced

Reforming, Ion Transport Membranes, Catalytic Cracking of Methane, Plasma Reformer] for SynGas Generation



1 INTRODUCTION For heavy natural gas and oil-associated gases, the required stoichiometric number cannot be obtained by pure autothermal reforming, even if all hydrogen available is recycled. For these applications, the VULCAN SYSTEMS COMBINED REFORMING concept, proposes autothermal and advanced gas heated reforming as an economically and technically viable option, in generating synthesis gas for methanol plants. A methanol plant with natural gas feed can be divided into three main sections. In the first part of the plant natural gas is converted into synthesis gas. The synthesis gas reacts to produce methanol in the second section, and methanol is purified to the desired purity in the tail-end of the plant.

The capital cost of large scale methanol plants is substantial. The synthesis gas production including compression and oxygen production when required may account for 60% or more of the investment. In many plants today either tubular steam reforming or two-step reforming (tubular steam reforming followed by autothermal or oxygen blown secondary reforming) is used for the production of synthesis gas. Stand-alone Autothermal Reforming (ATR) at low steam to carbon (S/C) ratio is reportedly the preferred technology for large scale plants by maximizing the single line capacity and minimizing the investment. ATR combines substoichiometric combustion and catalytic steam reforming in one compact refractory lined reactor to produce synthesis gas for production of more than 10,000 MTPD of methanol. The ATR operates at low S/C ratio, thus reducing the flow through the plant and minimizing the investment. The ATR produces a synthesis gas well suited for production of both fuel grade and high purity methanol. This case study describes the benefits of using ATR and AGHR for synthesis gas production for large scale production of methanol; (ATR) Autothermal Reforming with (AGHR) Advanced Gas Heated Reforming, with emphasis on performance simulation, of a single line capacity.



2 Autothermal Reforming (ATR) 2.1. Process Description This process combines partial oxidation and steam reforming in one vessel, where the hydrocarbon conversion is driven by heat released in the POX reaction. Developed in the late1950’s by Haldor Topsøe and Société Belge de l’Azote the process is used for methanol and ammonia production. Both light and heavy hydrocarbon feed stocks can be converted. In the latter case, an adiabatic pre-reformer is required. In this process a preheated mixture of natural gas, steam and oxygen is fed through the top of the reactor. In the upper zone, partial oxidation proceeds at a temperature of around 1200°C. After that, the mixture is passed through a catalyst bed, where final reforming reaction takes place. The catalyst destroys any carbon formed at the top of the reactor. The outlet temperature of the catalyst bed is between 850 and 1050°C. In autothermal reforming, a hydrocarbon feed (methane or a liquid fuel) is reacted with both steam and air to produce a hydrogen-rich gas. Both the steam reforming and partial oxidation reactions take place. For example, with methane

CH4 + H2O ↔ CO + 3 H2 Δh = +206.16 kJ/mol CH4 (1)

CH4 + 1/2 O2 -> CO + 2 H2 Δh° = -36 MJ/kmol CH4 With the right mixture of input fuel, air and steam, the partial oxidation reaction supplies all the heat needed to drive the catalytic steam reforming reaction. Unlike the steam methane reformer, the autothermal reformer requires no external heat source and no indirect heat exchangers. This makes autothermal reformers simpler and more compact than steam reformers, and it is likely that autothermal reformers will have a lower capital cost. In an autothermal reformer all the heat generated by the partial oxidation reaction is fully utilized to drive the steam reforming reaction. Thus, autothermal reformers typically offer higher system efficiency than partial oxidation systems, where excess heat is not easily recovered. The main advantages of ATR are a favorable H2/CO ratio (1.6 to 2.6), reduction of emissions due to internal heat supply, a high methane conversion, and the possibility to adjust the syngas composition by changing the temperature of the reaction. However, it requires an oxygen source.



The capital costs for autothermal reforming are lower than those of the SMR plant by 25%, as reported by Haldor Topsøe. Operational costs, however, are the same or even higher due to the need to produce oxygen. A recent study reported a capital-cost reduction of 35%, but an 8%-increase in operational costs for the ATR technology in comparison to the SMR process. ATR technology is commercially available, but still has limited commercial experience. The main licensors are Haldor Topsøe, Lurgi, Johnson Matthey, Foster Wheeler.

The heat transfer to the catalyst bed is more favorable in an autothermal reformer than in the externally heated tubular reformers, since in the former case the heat in the gas is supplied directly to the catalyst bed.



This means that a high temperature in the catalyst bed can be achieved by burning only a small portion of the product gas. The quantity of the gas to be burned will be dependant to the inlet concentration of the methane and other “reformable” compounds (such as tars) in the gas. It is more likely that the initial temperature increase in the combustion zone will reduce the concentration of the tars and other hydrocarbons sharply. However it must be taken to account that the combustion reaction will consume a part of the hydrogen that is present in product gas. As with a steam reformer or partial oxidation system, water gas shift reactors and a hydrogen purification stage are needed. Autothermal reformers (ATRs) combine some of the best features of steam reforming and partial oxidation systems. Several companies are developing small autothermal reformers for converting liquid hydrocarbon fuels to hydrogen in fuel cell systems. (See Appendix Tables 3 – 7)



3 Gas Heated Reforming (GHR) In the gas heated reformer (GHR) concept the heat for the endothermic reaction is supplied by cooling down the reformed gas from the secondary reformer. This technology, originally developed in the 1960s by ICI, was first demonstrated during 1988 at two ammonia plants in Severnside, UK. The feed in the gas-heated reformer is passed first to the primary reformer where about 25% of reforming takes place. The partially reformed gas is then passed to a secondary oxygen-fired reformer. The effluent of the latter is used to heat up the feed in the primary reformer. For start-up, an auxiliary burner is employed. Gas Heated Reformer

The volume of a GHR is typically 15 times smaller than the volume of a fired reformer (SMR or CO2) for the same output (51). Overheating of hot metal parts and a poor temperature control can lead to problems concerning the reliable operation of heat exchange reformers. To overcome these problems, reformers usually use counter-current flows in the low-temperature part with effective heat transfer and co-current flows in the hot section for a better temperature control. Sogge et al estimated that the GHR plant would cost about 40% less to build than a comparable SMR plant, while operational costs would be about the same. According to Abbott, the GHR scheme requires 33% less oxygen than the ATR plant. The main developer of GHR technology is Johnson Matthey. (See Appendix Table 1 Comparison between different reformer concepts)



(AGHR) Advanced Gas Heated Reformer

• The original GHR was a complex device to fabricate. • Desire to simplify the design:

• eliminate the bayonet tubes • simplify the upper (triple) tubesheet

• In 1998, BHPP replaced the original GHR with the new AGHR. The objective of this case study was to examine the flowsheet performance implications of combining (ATR) Autothermal Reforming with (AGHR) Advanced Gas Heated Reforming in the production of synthesis gas for methanol plants. (See Appendix for a Comparison of Reformer Types / Configurations)

Methanol Plant Equipment List and Duty (kW)

Name Description Duty (kW)B-301A Pre-reformer Fired Heater (main coil) 43202B-301B Pre-reformer Fired Heater (HDS coil) 12752

Duty (kW)C-101 HDS interchanger 35293C-201 Saturator Blow-down Cooler 1346C-301 AGHR Interchanger 103948C-302 Distillation Bottoms Water Boiler 66865C-303 Process Boiler B/D Cooler 574C-401 Reformed Gas Saturator Water Heater 49992C-402 Desaturator Water Cooler 91696C-501 Loop Interchanger 60541C-502 Loop Saturator Water Heater 38158C-503 Loop Condenser 339670C-601 Sat Water Distillation Reboiler 215257C-602 Primary Overhead Condenser 185355C-603 Secondary Overhead Condenser 30892C-604 Methanol Product Cooler 12927C-605 Steam Heated Distillation Reboiler 12752

D-301 Distillation Bottoms Water Boiler Steam DrumD-501 Loop CatchpotD-601 Let-down Vessel / ScrubberD-602 Distillation Reflux Drum

∆P (bar) Duty (kW)J-201 Saturator Water Pumps 6.5 724J-401 Desaturator Water Pumps 5.5 842J-402 Process Condensate Pumps 18.4 312J-601 Distillation Reflux Pumps 6.0 212J-602 Bottoms Water Pumps 47.5 154

Feed [bar] Product [bar] Duty [kW]K-101 Natural Gas Compressor 20.7 52.3 12438K-501A MUG Compressor 37.6 84 43853K-501B Loop Circulator 78.6 84.7 10256KT-501 Compressor / Circulator Steam Turbine 54108

Duty (kW)R-101 HDS VesselR-102 Desulfurizer Vessls (2)R-301 Pre-reformerR-302 AGHR 328411R-303 ATRR-501 Gas Cooled Synthesis ReactorR-502 Water Cooled Synthesis Reactor 134787

Theroetical StagesT-201 Saturator 10T-401 Desaturator 10T-501 Purge Gas Scrubber 10T-601 Distiullation Column 35

X-501 H2 Recovery Membrane Package

VULCAN SYSTEMS METHANOL PLANT PFD’s

CASE STUDY#08270414

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HYDRODESULFURIZATION PFD



SATURATOR PFD



ATR & AGHR REFORMING PFD



(MUG) MAKE UP GAS COOLING PFD



SYNTHESIS PFD



DISTILLATION PFD



1- COLUMN DISTILLATION PFD



Process Streams: Base CaseStream S-101 S-102 S-103 S-104 S-105 S-106 S-201 S-202 S-203 S-204 S-205 S-206 S-207 S-301 S-302 S-303 S-304 S-306 S-307 S-308 S-309 S-310 S-311 S-312 S-401 S-402 S-403 S-404 S-405 S-406 S-407 S-408 S-501 S-502 S-503 S-504 S-505 S-506 S-507 S-508 S-509 S-510 S-511 S-512 S-513 S-601 S-602 S-603 S-604 S-605 S-606 S-607 S-608

Property UnitVapour Fraction <none> 1 1 1 1 1 1 1 0.00079 0 0.002602 0 0 0 0.997318 1 1 1 1 1 1 1 1 0 1 1 1 0.000263 0.000195 0 0 0 0.000185 1 1 1 1 1 0.997999 1 0 1 1 0 0 1 0.006611 0 0 1 1 1 0 1Temperature C 45.0 132.5 320.0 380.0 203.5 45.0 230.5 240.9 182.5 45.0 183.0 228.5 110.0 236.0 420.0 499.4 450.0 1050.0 580.0 478.5 317.3 265.8 45.0 50.0 240.0 60.0 55.0 135.0 184.2 184.2 184.9 135.0 131.9 240.1 60.0 60.0 64.6 66.5 68.7 60.0 64.6 66.5 45.0 63.7 165.7 62.2 77.2 120.2 45.0 76.4 72.4 45.0 52.8Pressure bar 20.7 52.3 51.5 51.0 50.0 20.7 49.5 51.5 50.0 49.0 56.5 52.5 50.0 49.5 48.8 48.0 47.0 41.0 40.0 39.3 38.8 49.5 48.5 45.0 38.1 37.6 39.6 39.6 38.1 38.1 56.5 41.6 84.0 81.0 78.6 78.6 78.1 37.6 84.7 78.6 78.1 77.1 80.1 78.6 84.0 6.0 1.6 2.0 1.3 1.6 1.5 7.5 5.5Molar Flow kgmole/h 14060.0 13560.0 13938.1 13938.1 13938.1 500.0 35608.3 167257.4 145587.2 460.0 167257.4 167257.4 1371.5 41369.5 41369.5 41369.5 42989.7 68410.2 68410.2 68410.2 68410.2 5761.3 117.6 6377.6 68410.2 46279.6 54293.6 145706.4 222130.6 22130.6 22130.6 54293.6 187963.8 162692.8 146001.3 7160.4 7107.7 2845.2 138838.9 16691.5 378.1 3884.4 500.0 552.7 49124.8 17499.1 12757.4 4507.4 234.3 22393.2 3174.0 500.0 243.9Mass Flow tonne/h 244.9 236.2 239.8 239.8 239.8 8.7 630.4 3012.4 2621.8 8.3 3012.4 3012.4 24.7 734.2 734.2 734.2 734.2 939.3 939.3 939.3 939.3 103.8 2.1 205.1 939.3 540.4 978.5 2625.9 4003.3 398.8 398.8 978.5 1928.2 1928.2 1444.9 70.9 68.9 13.8 1373.9 483.3 3.7 51.4 9.0 11.0 554.2 496.0 405.7 81.2 9.1 719.6 103.6 9.0 7.2Component Molar FractionHydrogen mol % 0.00% 0.00% 2.01% 2.01% 2.01% 0.00% 0.80% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.69% 0.69% 0.69% 6.41% 45.40% 45.96% 45.96% 45.96% 0.00% 0.00% 0.00% 45.96% 67.93% 0.02% 0.02% 0.02% 0.02% 0.02% 0.02% 72.35% 65.94% 73.44% 73.44% 73.99% 90.82% 73.44% 0.30% 73.99% 61.66% 0.00% 0.01% 69.25% 0.01% 0.00% 0.00% 0.39% 0.00% 0.03% 0.00% 20.14%CO 0.00% 0.00% 0.08% 0.08% 0.08% 0.00% 0.05% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.04% 0.04% 0.04% 0.03% 14.32% 13.76% 13.76% 13.76% 0.00% 0.00% 0.00% 13.76% 20.33% 0.02% 0.02% 0.02% 0.02% 0.02% 0.02% 7.31% 2.80% 3.11% 3.11% 3.13% 0.74% 3.11% 0.07% 3.13% 4.88% 0.00% 0.01% 19.19% 0.01% 0.00% 0.00% 0.56% 0.01% 0.04% 0.00% 4.56%CO2 0.00% 0.00% 0.18% 0.18% 0.18% 0.00% 0.09% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.08% 0.08% 0.08% 1.97% 5.42% 5.98% 5.98% 5.98% 0.00% 0.00% 0.00% 5.98% 8.83% 0.03% 0.03% 0.03% 0.03% 0.03% 0.03% 7.17% 6.17% 6.70% 6.70% 6.73% 3.18% 6.70% 1.51% 6.73% 9.33% 0.00% 0.24% 8.50% 0.78% 0.00% 0.00% 57.92% 0.62% 4.33% 0.00% 48.50%Methane 89.74% 89.74% 87.39% 87.39% 87.39% 89.74% 34.20% 0.31% 0.36% 0.36% 0.31% 0.31% 0.00% 29.44% 29.44% 29.44% 29.97% 0.35% 0.35% 0.35% 0.35% 0.00% 0.00% 0.00% 0.35% 0.51% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 2.51% 2.90% 3.21% 3.21% 3.23% 0.76% 3.21% 0.17% 3.23% 5.04% 0.00% 0.02% 0.53% 0.03% 0.00% 0.00% 2.57% 0.03% 0.19% 0.00% 9.27%Ethane 5.24% 5.24% 5.10% 5.10% 5.10% 5.24% 2.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 1.72% 1.72% 1.72% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%Propane 0.20% 0.20% 0.19% 0.19% 0.19% 0.20% 0.08% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.07% 0.07% 0.07% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%n-Butane 0.02% 0.02% 0.02% 0.02% 0.02% 0.02% 0.01% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.01% 0.01% 0.01% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%n-Pentane 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%n-Hexane 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%Nitrogen 4.80% 4.80% 4.95% 4.95% 4.95% 4.80% 1.94% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 1.67% 1.67% 1.67% 1.60% 1.01% 1.01% 1.01% 1.01% 0.00% 0.00% 0.00% 1.01% 1.49% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 7.95% 9.19% 10.22% 10.22% 10.29% 2.43% 10.22% 0.17% 10.29% 16.05% 0.00% 0.01% 1.55% 0.01% 0.00% 0.00% 0.88% 0.01% 0.06% 0.00% 10.66%Methanol 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.75% 8.62% 1.02% 1.02% 0.03% 0.08% 1.02% 75.13% 0.03% 0.00% 0.00% 12.72% 0.00% 72.06% 98.21% 0.00% 34.76% 99.10% 94.67% 0.00% 0.14%H2O 0.00% 0.00% 0.01% 0.01% 0.01% 0.00% 60.82% 99.68% 99.64% 99.64% 99.68% 99.68% 100.00% 66.28% 66.28% 66.28% 60.00% 33.31% 32.75% 32.75% 32.75% 100.00% 100.00% 0.00% 32.75% 0.62% 99.93% 99.93% 99.93% 99.93% 99.93% 99.93% 0.26% 2.43% 0.13% 0.13% 0.40% 0.95% 0.13% 22.52% 0.40% 0.00% 100.00% 86.98% 0.64% 27.04% 1.77% 100.00% 0.00% 0.07% 0.03% 100.00% 2.68%Ammonia 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%Oxygen 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 98.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%Argon 0.00% 0.00% 0.06% 0.06% 0.06% 0.00% 0.02% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.02% 0.02% 0.02% 0.02% 0.20% 0.20% 0.20% 0.20% 0.00% 0.00% 2.00% 0.20% 0.29% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 1.67% 1.93% 2.15% 2.15% 2.16% 1.02% 2.15% 0.06% 2.16% 3.00% 0.00% 0.00% 0.34% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 3.73%Ethanol 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.02% 0.00% 0.00% 0.00% 0.00% 0.00% 0.02% 0.02% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%1-Propanol 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%1-Butanol 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%M-Formate 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.02% 0.00% 0.00% 0.00% 0.00% 0.00% 0.02% 0.00% 0.00% 1.04% 0.08% 0.32% 0.00% 0.02%diM-Ether 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.02% 0.03% 0.02% 0.02% 0.02% 0.00% 0.02% 0.03% 0.02% 0.04% 0.00% 0.00% 0.00% 0.03% 0.00% 0.00% 1.87% 0.06% 0.30% 0.00% 0.29%Acetone 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.02% 0.01% 0.02% 0.00% 0.00%M-E-Ketone 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%M-iP-Ketone 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%Component Molar FlowHydrogen kgmole/h 0.0 0.0 279.8 279.8 279.8 0.0 284.0 5.4 1.2 0.0 5.4 5.4 0.0 284.0 284.0 284.0 2755.0 31057.5 31441.5 31441.5 31441.5 0.0 0.0 0.0 31441.5 31437.3 10.3 27.7 42.2 4.2 4.2 10.3 135991.5 107279.7 107229.7 5258.9 5258.9 2584.1 101970.2 50.0 279.8 2395.0 0.0 0.1 34021.3 0.9 0.0 0.0 0.9 0.9 0.9 0.0 49.1CO 0.0 0.0 11.8 11.8 11.8 0.0 16.2 4.5 0.2 0.0 4.5 4.5 0.0 16.2 16.2 16.2 12.3 9795.5 9411.7 9411.7 9411.7 0.0 0.0 0.0 9411.7 9407.3 10.6 28.6 43.5 4.3 4.3 10.6 13745.1 4552.0 4539.6 222.6 222.6 21.1 4316.7 12.4 11.8 189.7 0.0 0.1 9428.4 1.3 0.0 0.0 1.3 1.3 1.3 0.0 11.1CO2 0.0 0.0 25.4 25.4 25.4 0.0 32.3 8.1 1.3 0.0 8.1 8.1 0.0 32.3 32.3 32.3 846.2 3709.5 4093.3 4093.3 4093.3 0.0 0.0 0.0 4093.3 4086.5 16.8 45.0 68.6 6.8 6.8 16.8 13478.4 10034.7 9782.1 479.7 478.3 90.6 9301.3 252.7 25.4 362.3 0.0 1.4 4177.1 135.8 0.1 0.0 135.7 138.1 137.3 0.0 118.3Methane 12617.4 12168.7 12181.0 12181.0 12181.0 448.7 12179.6 517.6 518.9 1.6 517.6 517.6 0.0 12179.6 12179.6 12179.6 12883.2 236.7 236.7 236.7 236.7 0.0 0.0 0.0 236.7 236.4 0.8 2.1 3.3 0.3 0.3 0.8 4716.3 4716.3 4687.8 229.9 229.8 21.8 4458.1 28.5 12.2 195.8 0.0 0.1 258.2 6.0 0.0 0.0 6.0 6.1 6.0 0.0 22.6Ethane 736.7 710.5 710.5 710.5 710.5 26.2 710.5 0.2 0.2 0.0 0.2 0.2 0.0 710.5 710.5 710.5 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0Propane 28.1 27.1 27.1 27.1 27.1 1.0 27.1 0.0 0.0 0.0 0.0 0.0 0.0 27.1 27.1 27.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0n-Butane 2.8 2.7 2.7 2.7 2.7 0.1 2.7 0.0 0.0 0.0 0.0 0.0 0.0 2.7 2.7 2.7 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0n-Pentane 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0n-Hexane 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0Nitrogen 674.9 650.9 689.8 689.8 689.8 24.0 689.9 3.3 3.2 0.0 3.3 3.3 0.0 689.9 689.9 689.9 689.9 689.9 689.9 689.9 689.9 0.0 0.0 0.0 689.9 689.8 0.2 0.7 1.0 0.1 0.1 0.2 14944.0 14944.0 14916.0 731.6 731.5 69.3 14185.0 28.0 38.9 623.3 0.0 0.1 759.0 2.1 0.0 0.0 2.1 2.1 2.1 0.0 26.0Methanol 0.0 0.0 0.1 0.1 0.1 0.0 0.1 0.2 0.2 0.0 0.2 0.2 0.0 0.2 0.2 0.2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1411.8 14022.6 1482.3 72.7 2.4 2.3 1409.6 12540.3 0.1 0.0 0.0 70.3 2.3 12610.3 12528.8 0.0 81.4 22192.8 3004.8 0.0 0.4H2O 0.0 0.0 1.5 1.5 1.5 0.0 21657.5 166717.8 145061.9 458.3 166717.8 166717.8 1371.5 27418.7 27418.7 27418.7 25794.9 22785.2 22401.4 22401.4 22401.4 5761.2 117.6 0.0 22401.4 286.6 54254.7 145602.0 221971.4 22114.7 22114.7 54254.7 494.4 3948.3 190.0 9.3 28.6 27.1 180.7 3758.4 1.5 0.0 500.0 480.7 313.7 4732.5 225.2 4507.3 0.0 16.8 1.1 500.0 6.5Ammonia 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0Oxygen 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 6250.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0Argon 0.0 0.0 8.2 8.2 8.2 0.0 8.2 0.2 0.1 0.0 0.2 0.2 0.0 8.2 8.2 8.2 8.2 135.8 135.8 135.8 135.8 0.0 0.0 127.6 135.8 135.7 0.2 0.4 0.6 0.1 0.1 0.2 3145.9 3145.9 3135.6 153.7 153.7 29.1 2981.1 10.3 8.2 116.4 0.0 0.0 164.8 0.0 0.0 0.0 0.0 0.0 0.0 0.0 9.1Ethanol 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.3 3.1 0.3 0.0 0.0 0.0 0.3 2.8 0.0 0.0 0.0 0.0 0.0 2.8 2.8 0.0 0.0 0.7 0.1 0.0 0.01-Propanol 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.01-Butanol 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0M-Formate 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 2.0 4.8 2.1 0.1 0.1 0.0 2.0 2.7 0.0 0.1 0.0 0.0 0.0 2.7 0.2 0.0 2.4 18.5 10.2 0.0 0.0diM-Ether 0.0 0.0 0.1 0.1 0.1 0.0 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.1 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 34.0 41.0 35.7 1.8 1.7 0.0 34.0 5.3 0.1 1.7 0.0 0.0 0.0 4.6 0.2 0.0 4.4 13.1 9.5 0.0 0.7Acetone 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.2 0.1 0.0 0.0 0.0 0.1 0.1 0.0 0.0 0.0 0.0 0.0 0.1 0.1 0.0 0.1 2.9 0.8 0.0 0.0M-E-Ketone 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.0 0.0 0.0 0.0 0.0 0.1 0.0 0.0 0.0 0.0 0.0 0.1 0.1 0.0 0.0 0.2 0.0 0.0 0.0M-iP-Ketone 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0


CASE STUDY#08270414

REFORMINGName S-301 S-302 S-303 S-304 S-305 S-305A S-306 S-308

Temperature [C] 420.0 500.4 450.0 713.2 1050.0 1059.4 579.9 50.0Pressure [bar] 48.8 48.0 47.0 43.0 41.0 41.0 40.0 45.0Molar Flow [kgmole/h] 41473.5 41473.5 43122.9 49492.7 68621.6 68528.2 68528.2 6377.3Mass Flow [kg/h] 735112 735112 735112 735115 940200 940200 940200 205088

Mol % CO 0.010% 0.010% 0.028% 2.602% 14.308% 13.652% 13.652% 0.000%Mol % H2O 66.370% 66.370% 60.025% 42.007% 33.254% 32.760% 32.760% 0.000%Mol % CO2 0.020% 0.020% 1.913% 5.524% 5.398% 6.013% 6.013% 0.000%Mol % Hydrogen 0.670% 0.670% 6.458% 28.789% 45.498% 45.962% 45.962% 0.000%Mol % Methane 29.510% 29.510% 30.018% 19.719% 0.377% 0.446% 0.446% 0.000%Mol % Ethane 1.720% 1.720% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%Mol % Oxygen 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 98.000%Mol % Propane 0.070% 0.070% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%Mol % n-Butane 0.010% 0.010% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%Mol % Methanol 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%Mol % diM-Ether 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%Mol % Nitrogen 1.610% 1.610% 1.548% 1.349% 0.973% 0.974% 0.974% 0.000%Mol % Argon 0.010% 0.010% 0.010% 0.008% 0.192% 0.192% 0.192% 2.000%


CASE STUDY#08270414

(AGHR) Autothermal Gas Heated Reformer OutputStream S-301 S-302 S-303 S-304 S-305

Temperature C 450.0 50.0 709.7 1050.0 580.0Pressure bar 47.0 45.0 43.0 41.0 40.0Molar Flow kgmole/h 42989.6 6375.8 49273.0 68374.2 68374.3Mass Flow kg/h 734175 205040 734177 939214 939214

Hydrogen 6.41% 0.00% 28.57% 45.35% 45.78%CO 0.03% 0.00% 2.55% 14.30% 13.87%CO2 1.97% 0.00% 5.56% 5.43% 5.86%Methane 29.97% 0.00% 19.77% 0.37% 0.37%Nitrogen 1.60% 0.00% 1.40% 1.01% 1.01%H2O 60.00% 0.00% 42.13% 33.34% 32.91%Oxygen 0.00% 98.00% 0.00% 0.00% 0.00%Argon 0.02% 2.00% 0.02% 0.20% 0.20%

NTubes 657Tube ID m 0.14Tube OD m 0.1498Sheath ID m 0.1605Sheath OD m 0.1717Tube PD bar 3.5Heated Length m 11Bundle Area m2 24.2Bundle OD m 5.55Catalyst split 57-4Q/57-4MQ % 82:18Sheath length % 85


CASE STUDY#08270414

1-Column DistillationName S-601 S-602 S-603 S-604 S-605 S-606 S-607 S-608 S-609 S-610Temperature [C] 49.3 50.0 150.3 59.5 106.3 104.4 49.3 135.1 50.0 56.7Pressure [bar] 7.0 3.9 4.8 4.0 4.3 4.1 7.0 4.7 20.0 4.1Molar Flow [kgmole/h] 17286.6 13291.8 4176.8 315.5 25033.0 11823.7 275.5 5.0 222.0 232.5Mass Flow [kg/h] 495494 422872 75248 9745 802945 380688 8372 140 4000 4550

Comp Molar Flow (CO) [kgmole/h] 2.0 0.0 0.0 15.2 2.7 2.7 13.2 0.0 0.0 0.0Comp Molar Flow (H2O) [kgmole/h] 4203.2 234.7 4176.7 15.6 141.7 45.5 1.8 3.1 222.0 208.2Comp Molar Flow (CO2) [kgmole/h] 33.9 0.1 0.0 161.5 57.2 57.1 127.7 0.0 0.0 0.2Comp Molar Flow (Hydrogen) [kgmole/h] 1.8 0.0 0.0 37.4 2.1 2.1 35.6 0.0 0.0 0.0Comp Molar Flow (Methane) [kgmole/h] 3.8 0.0 0.0 47.1 5.0 5.0 43.4 0.0 0.0 0.0Comp Molar Flow (Methanol) [kgmole/h] 13027.6 13043.1 0.0 2.4 24692.8 11598.8 18.0 1.4 0.0 22.7Comp Molar Flow (diM-Ether) [kgmole/h] 6.2 6.0 0.0 0.3 96.2 85.1 0.1 0.0 0.0 1.1Comp Molar Flow (Ethanol) [kgmole/h] 3.1 3.1 0.0 0.0 3.0 1.1 0.0 0.0 0.0 0.0Comp Molar Flow (M-Formate) [kgmole/h] 3.0 2.9 0.0 0.0 30.8 25.5 0.0 0.0 0.0 0.2Comp Molar Flow (M-E-Ketone) [kgmole/h] 0.1 0.1 0.0 0.0 0.1 0.1 0.0 0.0 0.0 0.0Comp Molar Flow (1-Propanol) [kgmole/h] 1.2 1.2 0.0 0.0 0.3 0.1 0.0 0.0 0.0 0.0Comp Molar Flow (1-Butanol) [kgmole/h] 0.5 0.5 0.0 0.0 0.3 0.1 0.0 0.5 0.0 0.0Comp Molar Flow (Acetone) [kgmole/h] 0.2 0.2 0.0 0.0 0.6 0.4 0.0 0.0 0.0 0.0Comp Molar Flow (Nitrogen) [kgmole/h] 0.1 0.0 0.0 35.8 0.1 0.1 35.7 0.0 0.0 0.0

Comp Mole Frac (CO) 0.012% 0.000% 0.000% 4.833% 0.011% 0.023% 4.806% 0.000% 0.000% 0.006%Comp Mole Frac (H2O) 24.315% 1.766% 99.998% 4.939% 0.566% 0.385% 0.648% 61.159% 100.000% 89.586%Comp Mole Frac (CO2) 0.196% 0.001% 0.000% 51.196% 0.229% 0.483% 46.340% 0.000% 0.000% 0.074%Comp Mole Frac (Hydrogen) 0.010% 0.000% 0.000% 11.867% 0.008% 0.018% 12.934% 0.000% 0.000% 0.001%Comp Mole Frac (Methane) 0.022% 0.000% 0.000% 14.940% 0.020% 0.042% 15.740% 0.000% 0.000% 0.002%Comp Mole Frac (Methanol) 75.363% 98.129% 0.001% 0.771% 98.641% 98.098% 6.517% 27.808% 0.000% 9.765%Comp Mole Frac (diM-Ether) 0.036% 0.045% 0.000% 0.111% 0.384% 0.720% 0.042% 0.001% 0.000% 0.488%Comp Mole Frac (Ethanol) 0.018% 0.023% 0.000% 0.000% 0.012% 0.010% 0.001% 0.022% 0.000% 0.001%Comp Mole Frac (M-Formate) 0.017% 0.022% 0.001% 0.001% 0.123% 0.215% 0.008% 0.002% 0.000% 0.077%Comp Mole Frac (M-E-Ketone) 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 0.000%Comp Mole Frac (1-Propanol) 0.007% 0.009% 0.000% 0.000% 0.001% 0.001% 0.000% 0.368% 0.000% 0.000%Comp Mole Frac (1-Butanol) 0.003% 0.003% 0.000% 0.000% 0.001% 0.001% 0.000% 10.640% 0.000% 0.000%Comp Mole Frac (Acetone) 0.001% 0.001% 0.000% 0.000% 0.003% 0.003% 0.000% 0.000% 0.000% 0.000%Comp Mole Frac (Nitrogen) 0.000% 0.000% 0.000% 11.343% 0.000% 0.001% 12.964% 0.000% 0.000% 0.000%


DESIGN CASE STUDY#08270414

DistillationStage Temperature

liquid fromTemperature

vapor toPressure Heat duty Liquid flow Vapor flow Feed Draw Mass flow

liquid fromMass flow vapor to

Molecular wt liquid from

Molecular wt vapor to

Density liquid from

Density vapor to

Viscosity liquid from

Viscosity vapor to

Surface tension liquid

from C C bar MW kmol/hr kmol/hr kmol/hr kmol/hr kg/hr kg/hr gm/cc gm/cc cP cP dyne/cm1 106.3 106.7 4.30 13284.6 25041.6 423897.8 804722.2 31.91 32.05 694.3 4.69 0.209 7.76E-03 17.472 106.7 107.2 4.35 13283.4 25112.0 423229.7 804054.1 31.86 32.02 694.1 4.74 0.208 7.78E-03 17.543 107.2 107.2 4.40 25110.8 25119.2 13291.8 422872.4 803696.9 31.81 32.00 694.0 4.74 0.207 7.78E-03 17.614 107.2 107.7 4.40 125.09 14239.8 11781.9 25119.2 452347.0 877002.9 31.77 31.80 694.4 4.71 0.207 7.79E-03 17.745 107.7 108.1 4.41 117.04 14188.5 27577.1 447529.7 872185.6 31.54 31.69 695.7 4.70 0.207 7.81E-03 18.306 108.1 108.5 4.42 14132.9 27525.7 442789.1 867445.1 31.33 31.58 697.2 4.69 0.207 7.84E-03 18.877 108.5 108.8 4.44 14077.9 27470.1 438152.9 862808.8 31.12 31.47 698.8 4.68 0.207 7.86E-03 19.438 108.8 109.2 4.45 14023.8 27415.2 433617.1 858273.0 30.92 31.37 700.3 4.68 0.207 7.88E-03 19.989 109.2 109.5 4.46 13970.7 27361.1 429183.3 853839.2 30.72 31.27 701.9 4.67 0.208 7.90E-03 20.5310 109.5 109.9 4.47 13918.5 27307.9 424853.7 849509.6 30.52 31.17 703.5 4.66 0.208 7.93E-03 21.0611 109.9 110.2 4.48 13867.4 27255.8 420630.3 845286.2 30.33 31.07 705.1 4.65 0.208 7.95E-03 21.5812 110.2 110.6 4.49 13817.6 27204.7 416514.5 841170.4 30.14 30.98 706.6 4.64 0.208 7.97E-03 22.1013 110.6 110.9 4.51 13769.1 27154.9 412507.1 837163.0 29.96 30.88 708.2 4.64 0.208 7.99E-03 22.6014 110.9 111.2 4.52 13722.0 27106.3 408608.4 833264.4 29.78 30.79 709.8 4.63 0.208 8.01E-03 23.0915 111.2 111.6 4.53 13676.3 27059.2 404819.2 829475.1 29.60 30.71 711.3 4.62 0.208 8.03E-03 23.5716 111.6 111.9 4.54 13632.1 27013.6 401140.8 825796.8 29.43 30.62 712.9 4.62 0.208 8.05E-03 24.0317 111.9 112.2 4.55 13589.5 26969.4 397576.9 822232.8 29.26 30.54 714.4 4.61 0.208 8.07E-03 24.4818 112.2 112.5 4.56 13548.4 26926.8 394134.3 818790.2 29.09 30.45 716.0 4.61 0.208 8.09E-03 24.9119 112.5 112.8 4.58 13508.8 26885.6 390824.1 815480.0 28.93 30.38 717.5 4.60 0.207 8.11E-03 25.3320 112.8 113.1 4.59 13470.7 26846.0 387662.9 812318.8 28.78 30.30 719.0 4.60 0.207 8.13E-03 25.7421 113.1 113.4 4.60 13434.2 26808.0 384673.1 809329.0 28.63 30.23 720.4 4.60 0.207 8.14E-03 26.1222 113.4 113.7 4.61 13399.5 26771.5 381883.2 806539.2 28.50 30.17 721.8 4.60 0.207 8.16E-03 26.4923 113.7 114.0 4.62 13366.6 26736.7 379327.7 803983.7 28.38 30.11 723.1 4.59 0.207 8.18E-03 26.8324 114.0 114.3 4.64 13335.7 26703.8 377046.5 801702.5 28.27 30.06 724.3 4.59 0.207 8.19E-03 27.1425 114.3 114.5 4.65 13307.3 26673.0 375084.4 799740.3 28.19 30.02 725.4 4.60 0.207 8.20E-03 27.4226 114.5 114.8 4.66 13281.6 26644.6 373491.4 798147.3 28.12 29.98 726.4 4.60 0.208 8.22E-03 27.6627 114.8 115.0 4.67 13259.0 26618.9 372324.2 796980.1 28.08 29.97 727.1 4.61 0.208 8.23E-03 27.8628 115.0 116.6 4.68 32.17 28918.9 26596.3 17519.0 811764.7 736376.8 28.07 29.77 727.7 4.56 0.208 8.32E-03 28.0129 116.6 119.4 4.69 28484.7 24737.1 794548.7 719160.9 27.89 29.59 734.5 4.51 0.212 8.51E-03 29.6830 119.4 123.7 4.71 27792.3 24302.9 772571.4 697183.5 27.80 29.53 745.7 4.45 0.221 8.82E-03 32.3231 123.7 129.0 4.72 26941.2 23610.5 745999.5 670611.7 27.69 29.47 761.2 4.38 0.233 9.28E-03 35.8032 129.0 135.1 4.73 26118.9 22759.4 690683.1 615435.5 26.44 28.05 785.7 4.10 0.238 9.87E-03 40.2033 135.1 144.6 4.74 25460.7 21937.1 5.0 538740.6 463493.0 21.16 21.78 851.3 3.08 0.196 1.05E-02 46.8234 144.6 149.1 4.75 25458.5 21283.9 469201.6 393954.0 18.43 18.51 896.1 2.59 0.141 1.06E-02 48.8935 149.1 150.0 4.76 25558.6 21281.7 462111.1 386863.5 18.08 18.09 902.3 2.53 0.122 1.06E-02 48.7036 150.0 150.2 4.78 25575.1 21381.8 461061.1 385813.6 18.03 18.03 903.3 2.52 0.181 1.06E-02 48.6537 150.2 150.3 4.79 25580.4 21398.3 460909.4 385661.8 18.02 18.02 903.5 2.53 0.181 1.39E-02 48.6338 150.3 150.3 4.80 25585.5 21403.7 460952.4 385704.8 18.02 18.02 903.4 2.53 0.181 1.39E-02 48.61

228.00


Hysys Output

CASE STUDY#08270414

DistillationStage Temperature

liquid fromTemperature

vapor toPressure Density liquid

fromDensity vapor to

Viscosity liquid from

Viscosity vapor to

Surface tension liquid

from C C bar gm/cc gm/cc cP cP dyne/cm1 105.9 106.0 4.30 0.693 0.00440 0.242 0.0126 15.422 106.0 106.2 4.31 0.693 0.00441 0.242 0.0126 15.553 106.2 106.4 4.33 0.693 0.00442 0.242 0.0126 15.704 106.4 107.2 4.34 0.693 0.00438 0.242 0.0126 15.855 107.2 107.5 4.35 0.693 0.00437 0.241 0.0126 16.456 107.5 107.9 4.37 0.694 0.00437 0.240 0.0126 17.067 107.9 108.2 4.38 0.695 0.00437 0.240 0.0126 17.658 108.2 108.6 4.39 0.696 0.00436 0.240 0.0127 18.229 108.6 108.9 4.41 0.697 0.00436 0.239 0.0127 18.77

10 108.9 109.2 4.42 0.698 0.00435 0.239 0.0127 19.3011 109.2 109.5 4.43 0.698 0.00435 0.239 0.0127 19.8112 109.5 109.9 4.44 0.699 0.00435 0.238 0.0127 20.3013 109.9 110.2 4.46 0.700 0.00435 0.238 0.0127 20.7714 110.2 110.5 4.47 0.701 0.00435 0.237 0.0128 21.2215 110.5 110.8 4.48 0.702 0.00435 0.237 0.0128 21.6516 110.8 111.0 4.50 0.702 0.00435 0.237 0.0128 22.0517 111.0 111.3 4.51 0.703 0.00435 0.236 0.0128 22.4418 111.3 111.6 4.52 0.704 0.00435 0.236 0.0128 22.8019 111.6 111.8 4.54 0.705 0.00435 0.236 0.0128 23.1420 111.8 112.1 4.55 0.705 0.00435 0.235 0.0129 23.4621 112.1 112.3 4.56 0.706 0.00436 0.235 0.0129 23.7722 112.3 112.6 4.58 0.706 0.00436 0.235 0.0129 24.0523 112.6 112.8 4.59 0.707 0.00436 0.234 0.0129 24.3224 112.8 113.0 4.60 0.707 0.00437 0.234 0.0129 24.5825 113.0 113.2 4.62 0.708 0.00437 0.234 0.0129 24.8226 113.2 113.4 4.63 0.708 0.00438 0.234 0.0129 25.0427 113.4 113.6 4.64 0.709 0.00437 0.233 0.0129 25.2628 113.7 114.5 4.66 0.709 0.00436 0.233 0.0129 25.4529 114.5 115.7 4.67 0.711 0.00434 0.232 0.0130 26.2130 115.7 118.0 4.68 0.716 0.00427 0.231 0.0131 27.8131 118.0 122.4 4.69 0.726 0.00411 0.229 0.0133 31.0032 122.4 131.0 4.71 0.750 0.00368 0.223 0.0137 37.0833 131.0 142.8 4.72 0.807 0.00293 0.208 0.0142 45.3334 142.8 148.5 4.73 0.851 0.00254 0.189 0.0144 48.2935 148.5 149.8 4.75 0.860 0.00246 0.181 0.0144 48.3236 149.8 150.1 4.76 0.862 0.00245 0.180 0.0144 48.2737 150.1 150.3 4.77 0.862 0.00245 0.179 0.0144 48.2538 150.3 150.4 4.79 0.862 0.00246 0.179 0.0144 48.23

Reboiler 150.4 150.4 4.8 0.862 0.00246 0.179 0.0144 48.21

Aspen Output


CASE STUDY#08270414

Purge Gas Scrubber 2 ft diameter based on 1.5" metal Pall rings and 3 te/hr of scrubbing waterVapor to:

Tray Mass Flow [kg/h] Gas Flow [ACT_m3/h]

Mole Wt. Temperature [C] Density [kg/m3] Viscosity [cP]

1 5249.3 1000.3 26.20 66.5 5.25 1.67E-022 5299.8 985.3 26.26 66.5 5.38 1.66E-023 5350.2 958.6 26.40 63.2 5.58 1.64E-024 5488.1 914.7 26.84 52.4 6.00 1.58E-02

Liquid from:Tray Mass Flow [kg/h] Liq Flow [m3/s] Mole Wt. Temperature [C] Density [kg/m3] Viscosity [cP] Surf Ten [dyne/cm]

1 3084.9 8.80E-04 18.17 62.4 974.13 0.476 65.12 3135.3 9.01E-04 18.30 66.5 966.37 0.446 63.93 3185.7 9.22E-04 18.51 66.5 959.99 0.444 63.34 3323.6 9.77E-04 19.11 63.2 944.52 0.459 62.1

Vent & Flash Gas Scrubber 3 ft diameter based on 1.5" metal Pall rings and 4 te/hr of scrubbing waterVapor to:Tray Mass Flow [kg/h] Gas Flow [ACT_mMole Wt. Temperature [C] Density [kg/m3] Viscosity [cP]

1 9886.5 2172.7 30.91 60.4 4.55 1.59E-022 10017.8 2137.8 31.08 56.8 4.69 1.56E-023 10296.5 2099.3 31.59 47.9 4.90 1.50E-02

Liquid from:Tray Mass Flow [kg/h] Liq Flow [m3/s] Mole Wt. Temperature [C] Density [kg/m3] Viscosity [cP] Surf Ten [dyne/cm]

1 4140.9 1.18E-03 18.29 59.5 972.42 0.494 65.32 4272.2 1.24E-03 18.67 60.4 960.02 0.481 64.03 4551.0 1.35E-03 19.58 56.8 937.25 0.493 62.1


CASE STUDY#08270414

VULCAN SYSTEMS METHANOL PLANT TECHNOLOGY

(ATR) AUTO THERMAL REFORMING AND (AGHR) ADVANCED GAS HEATED REFORING CASE STUDY#08270414


Process Concept for Synthesis Gas Production by Adiabatic Prereforming and Autothermal Reforming


Presenter

Presentation Notes

A typical process concept for production of synthesis gas based on ATR is shown in Figure 1. The key steps in the process scheme are desulfurization, adiabatic prereforming, autothermal reforming, and heat recovery. The desired exit gas composition for most FT-applications is an H2/CO-ratio of about 2. This ratio is achieved by recirculating CO2. Reducing the amount of steam added to the hydrocarbon feedstock decreases the H2/CO-ratio and the required recirculation of carbon dioxide. Operation at low steam-to-carbon (H2O/C) ratio improves process economics

TYPICAL THE AUTOTHERMAL LAYOUT


Presenter

Presentation Notes

The autothermal reforming process The Topsoe ATR consists of a fixed bed reactor in which the reforming process takes place. The feedstock is mixed with oxygen and steam in a mixer/burner. In the combustion chamber, partial combustion reactions take place, followed by methane steam reforming reaction and shift conversion to equilibrium over the catalyst bed. ��The overall reaction is exothermic, resulting in high outlet temperatures, typically 950-1100°C (1750-2000ºF). The pressure may be high, up to 100 bar. Soot-free operation is achieved through optimised burner design and by catalytic conversion of soot precursors over the catalyst bed.


Autothermal Reformer

Presenter

Presentation Notes

The burner provides mixing of the feed and the oxidant. In the combustion zone, the feed and oxygen react by sub-stoichiometric combustion in a turbulent diffusion flame. The catalyst bed brings the steam reforming and shift conversion reactions to equilibrium in the synthesis gas and destroys soot precursors, so that the operation of the ATR is soot-free. The catalyst loading is optimized with respect to activity and particle shape and size to ensure low pressure drop and compact reactor design. The synthesis gas produced by autothermal reforming is rich in carbon monoxide, resulting in high reactivity of the gas. The synthesis gas has a module of 1.7 to 1.8 and is thus deficient in hydrogen. The module must be adjusted to a value of about 2 before the synthesis gas is suitable for methanol production. The adjustment can be done either by removing carbon dioxide from the synthesis gas or by recovering hydrogen from the synthesis loop purge gas and recycling the recovered hydrogen to the synthesis gas [6]. When the adjustment is done by CO2 removal, a synthesis gas with very high CO/CO2 ratio is produced. This gas resembles the synthesis gas in methanol plants based on coal gasification.


ATR Model Simulations


ATR Synthesis Gas Properties


Advanced Gas Heated Reformer

• Part of major component combined with the sheath tubeplate

• Low alloy plate P4 group materials

• Machined Fabrication • Weight 28 tonnes


Part of major component combined with catalyst tubeplate sub-assembly

Low alloy plate P4 group materials

Machined Fabrication Weight 17 tonnes


Major element of the AGHR Large Fabrication, critical

machined features Support platform for the bundle Key item with two tiers of close

tolerance tube hole arrays. Weight 45 tonnes


Fabricated tube component with laser welded fins.

High tolerance required, needs to fit precisely with corresponding components

Relatively flimsy assembly careful handling required


Fabricated tube component

High tolerance required on outside & inside diameters to achieve fit with corresponding components


Large plate fabrication.

Grillage aperture centres to be in line with tube array.

High level of accuracy required




APPENDIX METHANOL PRODUCTION USING VULCAN SYSTEMS COMBINED REFORMING TECHNOLOGY

(ATR) AUTO THERMAL REFORMING AND (AGHR) ADVANCED GAS HEATED REFORING

CASE STUDY#08270414



Figure 1



Figure 2



Table I Comparison between Different Reformer Concepts



Table 2 Advantages and Disadvantages for Different Synthesis Gas Technologies



Table 3: Small-Scale Reformers for Syn Gas Generation (Con’t)



Table 4: Small-Scale Autothermal Reformers for SynGas Generation



Table 5: Small-Scale Partial Oxidation for SynGas Generation



Table 6: Small-Scale Methanol Steam Reforming for SynGas Generation



Table 7: Small-Scale [Ammonia Cracking, Sorbent Enhanced Reforming, Ion Transport Membranes, Catalytic Cracking of Methane, Plasma Reformer] for SynGas Generation

METHANOL PRODUCTION USING VULCAN SYSTEMS COMBINED REFORMING TECHNOLOGY (ATR) AUTO THERMAL REFORMING...

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