Beruflich Dokumente
Kultur Dokumente
performing the heat integration, total hot and cold utilities needed are 726 MW and 9536 MW
respectively. After the targeting, the hot and cold utilities usage are reduced to 180 MW and 3657
MW respectively, showing savings of 76% and 62% of utilities respectively. The utility targeting is
done based on the Grand Composite Curve, and the results of utility selection are shown in
Appendix D. The specification of electrical power requirement is also made based on the total power
needed for the operation of pump, compressor, expander and the mixers agitator from simulation.
Preliminary Equipment Schedule for Major Equipment
Preliminary equipment schedule is prepared in Appendix E for the major equipment, highlighting its
details such as objectives, material of construction, size and operating conditions.
Preliminary Pipe Sizing and Specifications
The size of pipes for major equipment piping is calculated in accordance of standard pipe schedule
size used in United States and is available in Appendix F, to enable easy purchase. For the pipes that
exceeds standard nominal pipe sizing, the flow rate is divided into a few smaller pipes, which will
then be combined by using pipe fittings before entering the required equipment. Piping material is
chosen based on the suitability to the operating conditions. (Peters, Timmerhaus and West 2004).
Preliminary Environmental Impact Assessment (EIA) and Effluent Disposal Strategies
EIA is carried out to study the potential adverse impacts that the proposed project will have to its
surrounding environment, which is around 10 km radius of the proposed plant site. The impact of
the plant to the surrounding receptors such as land, water and people is investigated in Appendix G.
Other than that, mitigation measures have also been outlined as a way to reduce the impact to the
receptors so as to achieve sustainability. The results from EIA can help in integrating the mitigation
measures in the detailed design of the plant so to reduce impacts to the environment. Appendix H
shows the waste disposal methods for three types of waste produced within the plant.
Initial Safety and Hazards Review
A Hazard and Operability (HAZOP) studies is outlined in Appendix I, which is aimed to identify major
hazards involved in selected high risk equipment due to certain process variations. The HAZOP
results gave the necessary information on the elements of the plant that should be controlled in
order to achieve a better process safety. Other than that, key issues regarding start up, shutdown,
cleaning and maintenance of the plant are outlined in Appendix J, which state the necessary steps
that should be taken during the operations of the plant. A hazard analysis on general process
material which is ammonia, carbon dioxide and refrigerants are also provided in Appendix K, which
will give a brief introduction to the level of risk involved in handling the process material. Besides
that, a contingency plan is prepared in Appendix L to address the low possibility high risk scenarios.
Process Control
A plant wide process control configurations is drafted to ensure that the plant operates at its optimal
conditions. Generally, the objectives of process control are as following; (a) To keep the purity of
carbon dioxide and ammonia product above the market purity of 99.5% and 99.3% respectively so
that it could be marketed. (b) Safe operations (c) To ensures the temperature fluctuation is lower
than 10% for reactors to maintain product quality. (d) To achieve complete combustion in the
primary reformer to reduce pollutants release. P&ID containing the final result of the plant wide
control is available in Appendix M. The process control configurations for selected equipment are
available in Appendix N (Luyben et. al. 1999).
Equipment Sizing and Costing
All the equipment is sized for the cost estimation on the later section. The calculated sizes and also
methods are provided in Appendix D and Appendix M.
Economic Analysis and Profitability Analysis
The total capital investment (TCI) (capital investment) is calculated using two methods in Appendix N,
which are Percentage of Delivered Equipment Cost and Lang Factors Approximation of TCI. The total
product cost (TPC) (operating cost) is calculated based on the first method only. To improve the first
method, the costs of equipment items, instrumentation items and land are calculated in detail. The
difference of results of TCI calculations is $22 mil., around 6.7%. By comparison, the calculated TCI
are roughly accurate. It is shown in Appendix O that the net profit of this project is roughly $76 mil.
per year with payback period of 4.04 years which proved the feasibility of the plant to be built. The
following economic assumptions are made in the profitability analysis (a) The salvage value is
estimated to be 9% of the original value of the plant properties (Ngu 2012). (b) An income tax rate of
35% is subjected as the gross profit ($78,683,069.27) for this ammonia plant exceeded $18K. (c) The
mar is estimated to be 8%/year for an ammonia plant with a new capacity due to the fact that it is
established process (Peters, Timmerhaus and West 2004).
Economic Sensitivity Analyses
In the best case scenario, ammonia price has been estimated to have increase of 30% to $0.85/kg
due to the current global price trend of Ammonia which have an increment every year. Ammonia
usage will estimated to increase due to the fertilizer demand based on world population growth rate.
Therefore, our government might take the profitable opportunity through encourage more
investment in Ammonia production by further reducing the local taxes. On the other hand, worst
case scenario has assumed ammonia market price will drop 20% to price of $0.52/kg due the
possibility of more ammonia production plant will be constructed especially in China which creates a
situation of supply higher than demand. Besides that, raw materials, utilities and tax rate might
increase by 20% and 10% each due to the high demand in raw materials and higher energy cost.
Based on the calculation in Appendix O, the plant still exhibits profit in both conditions, at $128 mil.
and $67 mil. respectively as shown in Appendix P.
Conclusions
In conclusion, the second stage of design has been carried out. The heat integration has assisted in
reducing utilities usage. Based on the results of the EIA, it is found out that the plant has only
manageable impacts on the surrounding. From the safety review, necessary mitigation measures
and key issues pertaining to managing process risks has been outlined as well. Process control
configurations suggested based on objectives has found to improve the process operability by
reducing fluctuations in pressure and temperature, while maintaining safety as the top priority.
Economic analysis has shown that the plant is profitable with low payback period, even in worst case
scenario. In the next stage, detailed equipment design will be conducted for major and minor
equipment as highlighted in Appendix Q.
References
Argus Media LTD. 2012. Argus FMB Ammonia Report. Accessed September 1, http://www.a
rgusmedia.com/Fertilizer/~/media/ Files/PDFs/Samples/Argus-FMB-Ammonia.ashx.
Ngu, Ling Ngee.2012. Analysis of Cost Estimation PowerPoint lecture note. http://moodle.curtin.edu.my/mod/
resource/view.php?id=16724.
Peters, Max S., Klaus D. Timmerhaus and Ronald E.West.2004. Plant Design and Economics for Chemical Engineers: Fifth
Edition. New York. Mc-Graw Hill.
James R.Couper, W.Roy Penney, James R.Fair and Stanley M.Walas. 2005. Chemical Process Equipment: Selection and
Design, Second Edition. USA: Elsevier Inc
th
R.K.Sinnot. 2005. Coulson & Richardsons Chemical Engineering: Chemical Engineering Design, Volume 6. 4 ed. India:
Elsevier Inc.
Safe Drinking Water Foundation. Wastewater Treatment. Accessed August 26,
http://www.safewater.org/PDFS/resourcesknowthefacts/WastewaterTreatment.pdf
Waste to Energy Research and Technology Council. 2010. Flue Gas Cleaning. Accessed August 26,
http://www.wtert.eu/default.asp?Menue=12&ShowDok=23
National Water Services Commission. 2012. Water Rates 2012. http://www.span.gov.my/index.php?option=com_content&
view=article&id=529&Itemid=424&lang=en.
P&M Invest. 2011. 1,2-Dichlorohexafluoropropane. Accessed August 30, http://fluorine1.ru/search/detail.php?query=0299.
th
Peters, Max S., Klaus D. Timmerhaus and Ronald E. West. 2004. Plant Design and Economics for Chemical Engineers. 5 ed.
New York: Mc-Graw Hill.
Cooling Water Treatment. n.d. IEC Fabchem Limited. Accessed September 1, http://iecfabchem.in/cwt.htm.
Quzhou DFS Chem Co. n.d. Refrigerant R407C Price. Accessed September 2, http://www.alibaba.com/productgs/582734983/refrigerant_r407c_price_good.html.
Johnston, Lucy, Ezra Hausman, Bruce Biewald, Rachel Wilson and David White. 2011. 2011 Carbon Dioxide Price Forecast.
Synapse Energy Economy Inc. http://www.synapse-energy.com/Downloads/SynapsePaper.2011-02.0.2011Carbon-Paper.A0029.pdf
Luyben, William L., Bjorn D. Tyreus and Michael L. Luyben. Plantwide Process Control. New York: Mc Graw Hill.
21
11
10
K-100
12
13
14
R-103
15
16
17
18
20
19
AIR
V-100
E-100
NG
FEED
E-104
FLUE
E-101
E-105
E-106
R-102
K-101
E-107
CONDE
-NSATE
R-105
R-104
E-103
CO2
30
E-110
8
H2O
32
28
Purge2
K-102
E-102
R-100
22
MEAREC
25
K103
M100
24
FUEL
R-101
E-108
36
FH_AIR
E-113
E-119
E-109
V-101
23
33
E-118
43
44
R-107
E-116
42
41
27
K-105
40
REC
39
K-104
37
MEA
Purge1
35
E-117
R-108
45
46
P-100
E-112
E-115
26
T-101
T-101
E-111
38
49
V-103
R-106
M101
47
REBOUT
52
E-114
P-101
V-102
53
34
48
Amm
50
GREC
Project A001
51
T-102
Drawing by
Checked by
Client
AKZ
MYY
CURTIN (M) SDN. BHD.
Date
Document Ref.
No.
Revision No.
Revisions
03/09/2012
A001/CURTIN/PFD/002
2
Added a product separator after first
ammonia reactor
Added a water boiler
Condensate flash replaces condensate stripper
Stream Tables
Vap. Frac.
Temp. (Celcius)
Pressure (kPa)
Mass Flow (kg/h)
Mol frac. (MEA)
Mol frac. (Methane)
Mol frac. (Ethane)
Mol frac. (CO2)
Mol frac. (Nitrogen)
Mol frac. (Propane)
Mol frac. (H2O)
Mol frac. (CO)
Mol frac. (Hydrogen)
Mol frac. (Oxygen)
Mol frac. (Ammonia)
NG
FEED
1
20
150
26660
0
0.92869
3
0.04076
1
0.01832
7
0.00450
7
0.00771
2
0
0
0
0
0
Vap. Frac.
Temp. (Celcius)
Pressure (kPa)
Mass Flow (kg/h)
Mol frac. (MEA)
Mol frac. (Methane)
Mol frac. (Ethane)
Mol frac. (CO2)
Mol frac. (Nitrogen)
Mol frac. (Propane)
Mol frac. (H2O)
Mol frac. (CO)
Mol frac. (Hydrogen)
Mol frac. (Oxygen)
Mol frac. (Ammonia)
15
1
821.45815
485
176335.21
0
0.003976
0
0.063454
0.12776
0
0.341436
0.073632
0.389741
0
0
Vap. Frac.
Temp. (Celcius)
Pressure (kPa)
Mass Flow (kg/h)
Mol frac. (MEA)
Mol frac. (Methane)
Mol frac. (Ethane)
Mol frac. (CO2)
Mol frac. (Nitrogen)
Mol frac. (Propane)
Mol frac. (H2O)
Mol frac. (CO)
Mol frac. (Hydrogen)
Mol frac. (Oxygen)
Mol frac. (Ammonia)
PURGE1
0
20
200
3889.25
53
0.99405
4
0
0
0.00539
3
0
0
0.00055
2
0
0
0
0
AIR
1
25
101.325
53052.3
1
0
0
0
0
0.79
0
0
0
0
0.21
0
H20
0
25
98.06652
96622.41
7
0
0
0
0
0
0
1
0
0
0
0
16
1
400
480
176335.21
0
0.003976
0
0.063454
0.12776
0
0.341436
0.073632
0.389741
0
0
REBOUT
0
193.4
202
3.664E+7
0.9999
0
0
0
0
0
0.0001
0
0
0
0
1
1
100
98.06652
96622.41
7
0
0
0
0
0
0
1
0
0
0
0
17
1
456.17571
480
176335.03
0
0.003976
0
0.113748
0.12776
0
0.291142
0.023338
0.440036
0
0
REC
0
26
110
3664421
0.78
0.9999
0
0
0
0
0
0.0001
0
0
0
0
2
1
133.7970
8
500
26660
0
0.928693
0.040761
0.018327
0.004507
0.007712
0
0
0
0
0
18
1
210
470
176335.03
0
0.003976
0
0.113748
0.12776
0
0.291142
0.023338
0.440036
0
0
MEAREC
0
26
110
18322105.
39
0.9999
0
0
0
0
0
0.0001
0
0
0
0
3
1
403.1546
5
500
123282.4
2
0
0.206376
0.009058
0.004073
0.001002
0.001714
0.777778
0
0
0
0
4
1
700
500
123282.4
2
0
0.206376
0.009058
0.004073
0.001002
0.001714
0.777778
0
0
0
0
19
1
235.47831
470
176334.96
0
0.003976
0
0.134754
0.12776
0
0.270136
0.002332
0.461041
0
0
20
0.733515
20
465
176334.96
0
0.003976
0
0.134754
0.12776
0
0.270136
0.002332
0.461041
0
0
PURGE2
0
26
110
18322105.3
9
0.9999
0
0
0
0
0
0.0001
0
0
0
0
33
1
280
110
53094.652
0
0.006672
0
0.000558
0.214599
0
0
0.003915
0.774256
0
0
5
1
609.1270
4
500
123282.5
5
0
0.197203
0
0.003892
0.000957
0
0.720985
0.022223
0.05474
0
0
21
1
20
465
121451.47
0
0.005421
0
0.183545
0.174172
0
0.005147
0.003179
0.628536
0
0
34
1
308.70849
105
53094.628
0
0.010671
0
0.000563
0.216292
0
0.003946
0
0.768528
0
0
FH-AIR
1
25
101.3
322136.0
4
0
0
0
0
0.79
0
0
0
0
0.21
0
CONDENSATE
0
20
465
54883.48414
0
0
0
0.000455
0.000011
0
0.999531
0
0.000003
0
0
35
1
308.20221
105
57865.103
0
0.01436
0.000161
0.000505
0.206897
0.000002
0.003543
0.001058
0.773449
0
0.000026
FLUE
1
1290
101.3
338810.2
5
0
0
0
0.082985
0.726193
0
0.158648
0
0
0.032173
0
FUEL
1
25
140
16674.21
6
0
0.9287
0.0408
0.0183
0.0045
0.0077
0
0
0
0
0
22
0.994946
-44.101411
115
121451.47
0
0.005421
0
0.183545
0.174172
0
0.005147
0.003179
0.628536
0
0
36
1
1848.699
6
7424
57865.10
3
0
0.01436
0.000161
0.000505
0.206897
0.000002
0.003543
0.001058
0.773449
0
0.000026
6
1
510.0316
4
1310
96622.41
7
0
0
0
0
0
0
1
0
0
0
0
23
1
40
110
121451.47
0
0.005421
0
0.183545
0.174172
0
0.005147
0.003179
0.628536
0
0
37
1
550
7419
57865.103
0
0.01436
0.000161
0.000505
0.206897
0.000002
0.003543
0.001058
0.773449
0
0.000026
8
1
693.5160
6
500
123283.3
1
0
0.036801
0
0.077105
0.000737
0
0.36597
0.058035
0.461352
0
0
24
0
26
110
3.665E+7
1
0
0
0
0
0
0
0
0
0
0
38
1
608.0754
15000
479.2375
5
0
0
0
0
0
0
1
0
0
0
0
9
1
1000
490
123283.3
1
0
0.036801
0
0.077105
0.000737
0
0.36597
0.058035
0.461352
0
0
25
1
25.98795
110
53094.652
0
0.006672
0
0.000558
0.214599
0
0
0.003915
0.774256
0
0
39
1
550
7419
57385.865
0
0.014411
0.000161
0.000507
0.207632
0.000002
0
0.001062
0.776199
0
0.000026
10
1
450
91.32499
7
53052.31
0
0
0
0
0.79
0
0
0
0
0.21
0
11
1
968.9726
5
500
53052.31
0
0
0
0
0.79
0
0
0
0
0.21
0
12
1
995.5589
490
176335.6
2
0
0.030765
0
0.064458
0.130186
0
0.305947
0.048516
0.385684
0.034443
0
26
0
27.332041
110
36715576
0.997365
0
0
0.002551
0.000002
0
0.000072
0
0.00001
0
0
27
0
27.372826
200
36715576
0.997365
0
0
0.002551
0.000002
0
0.000072
0
0.00001
0
0
28
0
104.5
200
36715576
0.997365
0
0
0.002551
0.000002
0
0.000072
0
0.00001
0
0
40
1
776.98876
15000
57385.865
0
0.014411
0.000161
0.000507
0.207632
0.000002
0
0.001062
0.776199
0
0.000026
41
1
250
15000
57385.865
0
0.014411
0.000161
0.000507
0.207632
0.000002
0
0.001062
0.776199
0
0.000026
42
1
764.3366
14995
2
57384.80
0
6
0.020106
0.000225
0.000708
0.092078
0.000003
0
0.001482
0.490125
0
0.395274
13
1
1420.619
9
490
176334.9
3
0
0.031863
0
0.066758
0.13483
0
0.388203
0.050247
0.3281
0
0
30
1
104.5
200
7.087E+4
0.0401
0
0
0.9552
0.0009
0
0
0
0.0039
0
0
43
0.602872
-100
14990
57384.806
0
0.020106
0.000225
0.000708
0.092078
0.000003
0
0.001482
0.490125
0
0.395274
14
1
980
485
176334.9
3
0
0.031863
0
0.066758
0.13483
0
0.388203
0.050247
0.3281
0
0
CO2
1
20
200
66981.234
0.000235
0
0
0.99481
0.000905
0
0.000003
0.000025
0.004023
0
0
44
1
-100
14990
21038.869
0
0.031934
0.000167
0.000048
0.152697
0.000001
0
0.002451
0.812459
0
0.000243
Unit
Vap. Frac.
Temp. (Celcius)
Pressure (kPa)
Mass Flow (kg/h)
Mol frac. (MEA)
Mol frac. (Methane)
Mol frac. (Ethane)
Mol frac. (CO2)
Mol frac. (Nitrogen)
Mol frac. (Propane)
Mol frac. (H2O)
Mol frac. (CO)
Mol frac. (Hydrogen)
Mol frac. (Oxygen)
Mol frac. (Ammonia)
C
kPa
kg/h
45
1
250
14985
21038.869
0
0.031934
0.000167
0.000048
0.152697
0.000001
0
0.002451
0.812459
0
0.000243
46
1
719.9385
14980
21038.44
0
0.04332
0.000226
0.000065
0.028875
0.000001
0
0.003325
0.567333
0
0.356854
47
0.641128
-100
14975
21038.445
0
0.04332
0.000226
0.000065
0.028875
0.000001
0
0.003325
0.567333
0
0.356854
48
1
-100
14975
6479.9664
0
0.064977
0.000162
0.000004
0.045029
0
0
0.005174
0.884411
0
0.000242
49
1
-100
14975
3239.9832
0
0.064977
0.000162
0.000004
0.045029
0
0
0.005174
0.884411
0
0.000242
PURGE
1
-100
14975
3239.9832
0
0.064977
0.000162
0.000004
0.045029
0
0
0.005174
0.884411
0
0.000242
51
0
-100
14975
14558.479
0
0.004629
0.000341
0.000174
0.000016
0.000003
0
0.000021
0.000872
0
0.993944
Note: The Energy Streams can be found in Appendix B (Energy Balances Part under HYSYS simulation results)
52
0
-99.99756
14995
14558.479
0
0.004629
0.000341
0.000174
0.000016
0.000003
0
0.000021
0.000872
0
0.993944
53
0
-100
14990
36345.937
0
0.00215
0.000314
0.001709
0.000052
0.000006
0
0.00001
0.000795
0
0.994965
GREC
1
300
14970
3239.9832
0
0.064977
0.000162
0.000004
0.045029
0
0
0.005174
0.884411
0
0.000242
AMM
0
99.998986
14990
50904.415
0
0.002861
0.000322
0.001269
0.000041
0.000005
0
0.000013
0.000817
0
0.994672
The A, B, C and D are the equation constants while is the ratio between target temperature and reference temperature
o
(25 C). Heat duty for E-100 is obtained by subtracting the outlet enthalpy with the inlet enthalpy.
Energy Balances Result for Heaters, Coolers and Compressors (kJ/hour)
Equipment E-100
E-101
E-102
E-103
E-104
E-105
E-106
E-107
E-108
E-109
E-110
HYSYS
2.38E7 9.31E7 2.51E8 1.11E8 1.99E8 1.71E8 9.45E7 2.15E8 2.33E7 8.45E9 2.1E10
Manual
2.37E8 2.05E7 1.36E8 1.12E8 1.99E8 1.70E8 9.51E7 7.96E7 2.97E7 6.56E9 2.1E10
Equipment E-112
E-113
E-114
E-115
E-116
E-117
E-118
E-119
K-100
K-101
K-102
HYSYS
9.76E6 5.02E7 9.32E6 9.23E7 1.22E8 3.45E7 2.24E8 3.29E8 3.15E7 6.83E6 7.86E7
Manual
9.76E6 5.03E7 9.09E6 6.93E7 1.21E8 3.32E7 1.66E8 3.27E8 3.11E7 6.90e6 7.97e7
Equipment K-104
K-105
P-100
P-101
HYSYS
3.85E8 5.41E7 4.29E6 5.19E2
Manual
3.82E8 5.31E7 3.47E6 6.04E1
E-111
1.2E10
K-103
1.81E7
1.60e7
H3
H4
H5
H6
H7
H8
H9
H10
1421
57.33 MW
980
821.5
400
456.2
447.38
210
235.5
193.4
116.13
77.95
6.37 MW
104.5
20
20
193.4
193.4
1849
1465.88
176.6
176.37
118.26
3575.85 MW
1169.13
26
550
777
738.86
250
764.3
193.4
719.9
421.07
260.07
62.23
193.4
140.73
100
9.73 MW
-100
7.22 MW
-100
25
9
700
403.2
23.74
450
183.4
25
2.67
1.58
1000
693.5
30.65
40
-19.96
4.2
1.69
280
183.4
-44.1
25.99
4.83
7.87
104.5
27.33
2252.59
193.4
179.51 MW
188.32
186.92
49.53
185.49
50.58
184.52
34.22
183.78
26.11
183.53
183.4
8.97
4.63
166.6
651.5
C1
C2
C3
C4
C5
C6
C7
C8
34.25
250
183.4
-100
2
279.9
8.5
183.4
0.97
-100
2.83
C9
C10
Work,
For compression,
Pumps
1191 kW
Mixers
21.7 kW
Head pump,
Total Power
E-121
7.22
H10
R-407C
-110, -90.89
240.67
(Sinnot 2005,212)
For viscosity lower than 5000cp, three-bladed Marine Propeller will be used in agitated
vessels. For calculation of power consumption of baffled vessel,
(Peters, Timmerhaus and West 2004, 544)
140598.7 kW
Appendix E Preliminary Equipment Schedule for Major Equipment and Equipment Costing
Methodologies
Equipment
Pre Reformer
R-100
Primary Reformer
R-101
nd
2 Reformer
R-102
HTS Reactor
R-103
LTS Reactor
R-104
CO2 Absorber
T-100
CO2 Stripper
T-101
Methanator
R-105
Ammonia Converter
R-106 & R-107
No.
1
Objective
Convert the higher hydrocarbons to H2 and CO to reduce
the load on the primary reformer.
Convert 65% of the methane to H2 and CO. CO2 is
produced from side reaction.
Convert 99% of the remaining methane to hydrogen.
1
1
Costing Methodologies for Equipment (Douglas 1998) and (Couper et. al. 2005)
Reactor
(Douglas 1998)
Reformer (Couper et.
(
)
al. 2005)
Flash drum
Heat exchanger
,
Packed tower
Op. Cond.
0
700 C
500 kPa
0
693.5 C
500 kPa
o
980 C
480 kPa
o
400 C
480 kPa
o
210 C
470 kPa
0
26 C
110 kPa
0
104.5 C
200 kPa
0
280 C
110 kPa
0
250 C
15000 kPa
Material
Stainless steel
Stainless steel
Stainless steel
Carbon steel
Carbon steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Compressor
Vessels
Note: All symbols have their usual engineering meanings. The costing of the rest of the equipment is based on the costing
graphs obtained from Peters, Timmerhaus and West (2004)
4
700
500
SS430
5
609
500
SS430
7
1290
500
Titanium
9
1000
490
SS309
12
995
490
SS309
15
821
485
SS430
16
400
480
CS
17
456
480
CS
18
210
470
CS
19
235
470
CS
20
20
465
CS
23
20
110
CS
24
25.99
110
CS
25
25.99
210
CS
26
27
110
CS
26.0569
29.25
40s
3
26.0569
29.25
40s
3
29.20
29.25
40
4
35.13
35.25
40
3
33.217
35.25
40
3
28
28.75
30
5
34.88
35.25
40
2
22.96
23.25
40
5
21.096
22.624
40
4
21.65
22.062
60
4
28.32
28.75
30
1
34.75
35
40
1
34.97
35
40
1
26.45
28.75
30
4
32.98
35.25
40
6
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
28
105
200
CS
29
104.5
200
CS
30
20
200
CS
31
193.4
202
CS
CO2
20
200
CS
32
20
200
CS
33
280
110
CS
34
309
105
CS
37
550
7419
SS502
39
550
7419
SS502
41
250
15000
CS
42
764
14995
SS430
43
-100
14900
A353
45
250
15000
CS
46
720
14980
SS430
33.37
35.25
40
6
21.37
21.56
80
1
18.44
19
30
1
32.57
35.25
40
8
18.44
19
30
1
0.8380
0.884
10
1
29.23
29.25
40
6
33.69
35.25
40
5
11.34
11.37
80
1
0.468
0.493
40
1
6.44
6.875
xx
1
7.61
7.63
80
1
2.58
2.635
10
1
4.24
4.313
160
1
4.96
5.047
40
1
Aspects
Flora &
Fauna
Wetland,
Water
(Surface /
Ground,
Land
Pollution
Air, Soil,
Water and
Noise
Social
Heritage
and Visual
Potential Impacts
Clearing of land will some impact to local flora, however the dominant species is Imperata
Cylindrica (Lalang), is not a rare species. Some reptiles and birds such as mynah, sparrow and crows
are spotted on site which might be affected from the release of gas from the plant. (Perdana
Environmental Technology & Services SDN. BHD 2010). Pollutants from industries might affect the
quality of wetland which is the Sungai Mamam located approximately 2.25km from the plant site.
Surface and ground water can be polluted by unmanaged solid waste (primarily catalysts) and also
by accidental spillage of chemical toxics and oil. Clearing of land will expose the land to the sun,
which if prolonged will cause land degradation.
Decreasing air quality due to the pollutants from emissions from industry vehicles and machines.
Heat pollution exists from cooling water tower and other unit operations. Water quality will be
affected from accidental discharge of waste and oil. Soil will be contaminated by solid waste and
the nutrients will diminish due to prolonged exposure. Other than that, mechanical movements of
vehicles and equipment might produce noise.
There is no of indigenous population near plant site. There will be a visual change in the existing
landscape due to the proposed development.
Others
Decommis
sioning
A large amount of noise pollution will be produced during decommissioning and also solid wastes
will be produced from plant debris.
Mitigation Measures
Re-vegetate the surrounding unused area to provide a buffer
region for flora and fauna. A proper waste management system
is also to be designed to reduced impacts to flora and fauna.
Practice a zero spillage to the ground policy and ensure solid
wastes are properly managed. Only clear the required area for
factory complex. Use catalytic converter on vehicles. Purify the
gas emission before release to the atmosphere. Other than that,
efficient process control for reducing emissions will be
favorable. Besides that, silencer should be installed for
equipment that produces noise which exceeds the permitted
level, 70 dBa at day and 60 dBa at night (Jabatan Alam Sekitar
Malaysia 2004).
The visual impact of the plant can be minimized by selecting
colors for the plant buildings that suits the surrounding
landscape. Appropriate landscaping can also be done to screen
the plant and associated infrastructure from public visibility.
Ensure decommissioning will be done after careful planning. The
old equipment can be sold or recycled. Plant site could be
vegetated or used as a new project site.
Gas (Flue Gas) from the Primary Reformer and purge gas from the
ammonia synthesis loop. The amount is 340000 kg/hr and 3240 kg/hr.
The flue gas contains nitrogen, hydrogen, carbon dioxide and oxygen
for complete combustion and may contains carbon monoxide during
incomplete combustion while the purge gas contains ammonia,
nitrogen, carbon monoxide, hydrogen and hydrocarbons. The standards
limit for carbon monoxide release is 30 ppm.
Note: Standards limit are based on Environmental Quality Act 1974 by Malaysian government.
R-103
HTS Reactor
T-100
CO2 Absorber
R-107
Ammonia
Converter
Deviation
LESS
Temperature
Possible Causes
- Airborne solids interfering with the
operation
- Not enough fuel feed
MORE
temperature
MORE
pressure
MORE
pressure
MORE
temperature
MORE flow
MORE
pressure
MORE
temperature
MORE
pressure
Consequences
- Decreased conversion
- Potential disposal concerns for liquid hydrocarbon and
plant upset
- Potential incomplete combustion in reformer which can
cause release of pollutants such as carbon monoxide.
- Potential of explosion with flames coming out of the top
and bottom of the reactor
- Major injuries / fatality from the major explosion accident
- Pressure will rise to maximum allowable pressure or
exceed the design pressure which cause system breakdown
Action Required
- Review the need for installing weather protection
over the natural gas feed.
- Install temperature control.
Major hazards
Potential of toxic and fire/explosion
Carbon Dioxide
Hydrogen
Liquid ammonia
Monoethanolamine
Fire/explosion hazard
R-407C
- Individuals would face breathing problem due to oxygendeficient environment at high concentrations of H2
- Inhalation will cause burn eyes and any mucus membrane it
touches, poisoning and dizziness
- Inhalation will cause irritating, chemical burns and organs
damage
- May cause dizziness and loss concentration during
overexposure
Possibility of Occurrence
Likely
Very unlikely
Plans
- Backup power generator onsite using natural gas generator to supply power to critical units.
- Tight security
Unlikely
- Regular maintenance, ensure that proper procedures are followed, ensure the refrigeration system of ammonia is working.
Possible
- Firefighting devices should be ready all the time, ensure constant maintenance of the supply pipelines to prevent leakage.
- Emergency valve to close the supply line once leakage occurs.
CV-2
FT
Flue
Gas
K-102
TC
TT
E-100
E-101
CV-1
Cooling
Water
PC
PC
TT
CV-6
PC
FC
E-103
FC
CV-10
CV-7
K-101
LS
CV-3
E-128
CV-12
CV-14
Cooling
Water Out
TC
Project A001
TT
CV-13
TT
R-101
Ratio
PT
E-105
E-106
TT
FT
FT
Water
PT
TT
TT
CV-5
CV-4
TC
TC
O2
C
PT
Natural
Gas
CV-11
O2
T
TC
TC
CV-15
E-102
HS
CV-8
FC
CV-26
FT
Air
CV-23
CV-24
CV-9
TC
E-108
PC
E-109
PT
V-100
TT
LC
TT
Condensate Water
CV-19
LT
CV-25
CV-18
PT
TT
K-103
CV-16
E-115
TC
TT
E-116
Water
PC
Date
Doc No.
Version
TT
TC
E-110
TC
TC
CV-17
TC
CV-21
TC
TT
E-107
TT
CV-20
TT
K-100
Drawing by
Checked by
Client
NG Fuel
TC
Cooling
Water
CV-22
Air
CT
E-112
CV-33
PC
TC
E-113
TC
CT
CV-50
TC
V-106
CO2
To MOX
CV-34
TT
Pure
MEA
PC
CV-60
Cooling
Water
Out
CV-40
CV-30
Legends:
PT
TC
TT
CC
CT
LC
LT
PC
PT
O2C
O2T
PT
TT
TC
CV-42
PC
CV-35
PC
PC
TC
TT
PT
CV-51
LC
TT
CV-52
TT
CV-49
E-114
CC
CV-41
CC
LT
MEA
Recycle
CV-27
V-103
PT
CV-43
E-119
PT
CV-59
TT
PC
Steam
In
PT
CV-32
TC
CV-39
M-100
T-100
TT
E-126
CV-37
K-105
TC
TT
TT
CV-48
E-125
FC
Purge
MEA
Cooling
Water
CV-57
Purge
CV-56
FT
PC
CV-55
PT
CV-53
TT
Steam
Out
E-124
V-102
PG
LT
LC
TT
TC
E-117
TT
Refrid
gerant
In
E-121
CV-47
Refrid
gerant
Out
CC
CT
CV-54
M101
FT
PG
CV-36
temperature controller
temperature transmitter
composition controller
composition transmitter
level controller
level transmitter
pressure controller
pressure transmitter
oxygen composition analyser
oxygen composition
transmitter
high selector
low selector
pressure gauge
ratio controller
FC
TC
E-122
Cooling
Water
Out
HS
LS
PG
Ratio
FC
TC
T-101
PG
CV-28
CV-58
Refrid
gerant
Out
CV-45
TT
CV-31
LC
E-120
LT
CV-29
V-101
TT
LC
FT
PC
PT
TT
E-118
LC
PG
CV-61
LT
TC
CV-38
FT
LT
Refrid
gerant
In
CV-44
K-104
FC
E-123
TC
AKZ
MYY
CURTIN (M) SDN.
BHD.
03/09/2012
A001/CURTIN/PID
1
P-101
CV-46
V-105
V-104
Process Control
Equipment
R-107
Second
Ammonia
Reactor
T-100
Absorber
E-100 Heat
Exchanger
R-101
Primary
Reformer
Details
Objectives: To produce a high purity ammonia product while maintaining the pressure and temperature
conditions of the ammonia reactor for safety and high conversion.
Strategies: A higher temperature will produce higher conversion. Hence, to be able to manipulate the
conversion value, temperature control is installed at the heat exchanger before the reactor. Pressure is
regulated within the reactor by measuring the reactor pressure and controlling the outlet gas flow.
Composition analyzer is installed only for second ammonia reactor to save cost,
Objectives: To produce a high purity ammonia product while maintaining the pressure and level conditions of
the ammonia reactor.
Strategies: The pressure within the absorber is regulated by measuring the absorber pressure and controlling
the outlet gas flow. The level of liquid is controlled by controlling the outlet liquid flow. To control the
composition of CO2 in outlet gas, the solvent MEA flow rate is manipulated.
Objectives: To produce the desired temperature in the outlet streams of heat exchanger and maintain
temperature fluctuation below 5% so as to not affect the conversion in the reactor R-100.
Strategies: A bypass stream is created at the cold stream. Controller and valve are placed at the cold stream
because it will be cheaper to control the stream with lower temperature. Any changes to the outlet
temperature of the cold stream will be regulated by manipulating the bypass flow rate. As the cold stream is
inlet stream for R-100, maintaining a constant temperature will ensure less fluctuation of conversion of the
reactions, hence reducing the load on separation equipment and maintaining constant production rate.
Objectives: To ensure that the combustion is complete and maintaining the temperature fluctuation of the
outlet stream to be less than 5%.
Strategies: Ratio control is employed to ratio the air flow with fuel flow by the information signal from the
excess oxygen controller which measures the composition of O 2 in flue gas. When the demand changes (outlet
temperature), it is preferable to change the air flow rate than the fuel flow rate because surplus of fuel will
cause rapid combustion. Hence, high selector and low selector are respectively placed for this objective.
Equipment Sizing
Equipment
R-100
R-101
R-102
R-103
R-104
R-105
R- 106
R-107
Size (D in m, V in
cubic m)
D = 3, L = 25, V = 178
D = 1.3, L = 10, V = 12
D = 5, L = 10, V = 550
D = 3, L = 23, V = 140
D = 3, L = 42, V = 120
D = 2.6, L = 21, V =
100
D = 0.4, L = 1.8, V =
0.16
D = 0.4, L = 1.7, V =
0.15
Equipment
V-100 (Flash)
V-101 (Flash)
V-102 (Flash)
V-103 (Flash)
V-106 (Dryer)
V-104
( Storage
Tank)
V-105(Storage
Tank)
MIX-101
MIX-102
Equipment
Equipment
E-100
Area
2
(m )
293
E-101
E-102
E-103
E-104
E-105
E-106
E-107
E-108
E-109
E-110
164
340
71
173
264
65
36
996
811
153
Size (D and H in
m, V in cubic m)
D = 9, H = 17
D = 1.8, H = 6.5
D = 1.2, H = 5.5
D = 7, L = 12
D = 1.4, H = 2
V = 13590
V = 13590
Methodologies:
Reactor
The sizing is based on trial and error and is done
together with the material balance for reactor
(Refer to Appendix B). An assumed volume is
inserted to solve the differential equations. The
iterations stopped when the desired conversion
value is reached.
Flash
L
V = 12
V=2
Equipment
E-111
Area
2
(m )
173
E-122
Area
2
(m )
119
E-112
E-113
E-114
E-115
E-116
E-117
E-118
E-119
E-120
E-121
106
3413
334
77
633
139
221
206
68
145
E-123
E-124
E-125
E-126
E-127
E-128
336
3650
64
6973
198
66
v v
Item
Direct cost
Purchased Equipment
Land
Process Instrumentation and
control
Purchase Equipment Installation
Manufacturing expenses
Variable Production Cost
Raw material
Operating labor
Direct supervisory and
clerical
labor
Utilities
Maintenance and repairs
Operating supplies
Laboratory charges
Patents and Royalties
Catalyst and solvents
Fixed charges
Plant overhead charges
General expenses
Administrative
Distribution & marketing
Research & Development
Total Production Cost (TPC)
24,319,817
18,239,863
22,661,648
2,210,892
12,159,909
260,000,000
49,192,357
309,400,000
$(US Dollar)
TCI ($)
331, 600, 000
29,501,831
1,115,100
111,510
48,280,000
5,203,891
520,389
111,510
111,510
62,148,783
3,952,111
3,215,251
223,020
223,020
223,020
154, 900, 000
Amount (kg/year)
403163006
530491372
Price ($/kg)
0.65 (Argus 2012)
0.01 (Johnson et al. 2012)
Total Annual Revenue
Base case
Sales
262055954
5464061
267,520,000
Best case
112,579,000
16,254,000
9,758,000
66,834,000
76,591,560
21.60
4.04
7.456
827,451,529
518,064,625
24.68%
193,212,000
16,254,000
9,758,000
128,418,000
138,175,000
41.51
2.24
7.456
1,484,845,811
1,175,458,907
44.66%
Worst Case
49,991,487
16,254,218
9,758,000
24,140,000
33,898,000
7.80
9.13
7.456
371,706,666
62,319,762
10.18%
3500
3000
Land,salvage &
working capital
recovery
Cost, Million
2500
2000
1500
1000
500
Construction period
0
-5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10111213141516171819202122232425
-500
Fixed capital
Land
Zero Time
investment
Working capital line
investment
Base case
Best case
Worst
case
Major Design
R-101 Primary Reformer
T-100 CO2 Absorber
R-103 High Temperature Shift
T-101 CO2 Stripper
R-106 First Ammonia Converter
Minor Design
E-100 Heat Exchanger
E-111 Condensate Preflash Cooler
V-100 Condensate Flash
M-101Product Mixer
V-106 Ammonia Refrigerated Storage Tank