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CHEMICAL PROCESS DESIGN MODULE B: PLANT DESIGN CPDB411, JULY 2013

DEPARTMENT OF CHEMICAL ENGINEERING TECHNOLOGY

S4, NATIONAL DIPLOMA


CHEMICAL PROCESS DESIGN PRINCIPLES
CPD3111

MAIN DESIGN PROJECT:


AMMONIA SYNTHESIS: PRODUCTION COST ESTIMATES

Submission date: 01 November 2013


This project will make 80% of the final mark

October 2013
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CHEMICAL PROCESS DESIGN MODULE B: PLANT DESIGN CPDB411, JULY 2013

Project statement
As S4 students in Chemical Engineering Technology at the University of Johannesburg,
you are tasked to design a chemical plant that will produce ammonia from hydrogen and
nitrogen as feedstock. The available amount of the feedstock is specified and you will
determine the achievable plant capacity.
Project objectives:
-

Design an industrial facility that will produce ammonia from hydrogen and nitrogen
as feedstock;
Evaluate plant capital cost;
Evaluate plant operating costs;
Evaluate ammonia production cost.

Process description and design assumptions


The feed to the process (at 27oC, 1 bar) consists of nitrogen (50 kmol/h) and hydrogen
(150 kmol/h). It is supplied from an adjacent plant at 0.13 $/kg and does not require any
purification. It is first compressed to 276 bar (with an isentropic efficiency of 0.65),
mixed with the recycle stream and heated to 482oC, the reactor temperature. The
pressure drop in the reactor is about 2 bar. The reactor outlet is cooled to 27oC and the
liquid and vapor phases are separated in an isothermal flash drum operating at the
pressure and temperature of its inlet stream. The vapor phase goes to recycle (95% of
the unreacted H2 and N2 and 2% of the produced ammonia) where a compressor (with
isentropic efficiency of 0.65) brings the pressure up to 276 bar. The liquid ammonia is
sent to storage tanks with on-site storing capacities of 24h production.
The conversion in the reactor is 25%.
Tasks
1. Produce a Process Flow Diagram (PFD) with streams table showing the materials
balance (a PFD template is attached).
2. Process equipment design
2.1 Produce the process equipment list
2.2 Design and size all equipment
2.2.1 Compressors
Use centrifugal compressors and the discharge temperature must
not exceed 200oC and the use of multistage compressors can be
considered.

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CHEMICAL PROCESS DESIGN MODULE B: PLANT DESIGN CPDB411, JULY 2013

Report the following for each compressor:


i)
Number of compression stages in case of a multistage
compressor;
ii)
The required power in kW.
2.2.2 Heat exchangers
i)
Determine the heat duty in kJ/s;
ii)
Specify the type of exchanger used;
iii)
Specify streams allocation;
iv)
Calculate the required transfer area in m2;
v)
Select the material of construction.
2.2.3 Flash drum
i)
Determine the internal diameter in m;
ii)
Determine the total height/length in m;
iii)
Select the material of construction.
Assume a liquid holdup time of 15 minutes and 10 mm thickness for
the flash drum wall.
2.2.4 Reactor
The reactor design and sizing is out of scope. However, for costing
purposes, assume the purchase cost of the reactor to be 20% of
the total purchase cost of the plant equipment.
2.2.5 Storage tanks
Storage tank of 8m diameter and 5m high (with 75% filling capacity)
will be used.
i)
Determine the number of required tanks;
ii)
Select the material of construction;
Assume wall thickness of 40 mm.

3. Plant Utilities
Determine and list the utilities required for the plant.
4. Cost estimation
- Determine the capital cost (in ZAR) for the plant using the detailed factorial
method;
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CHEMICAL PROCESS DESIGN MODULE B: PLANT DESIGN CPDB411, JULY 2013

Determine the plant operating costs in ZAR per year;


Determine the production cost for ammonia in ZAR/kg.

5. Final design report including an executive summary, recommendations and


conclusions. A paragraph on the environmental impact for this process must be
included in the report.

Additional information
Typical costs of utilities and process equipment cost estimates can be found in your
prescribed textbook and in Chemical Engineering Design by Ray Sinnott, Gavin
Towler, Fifth edition available in our library under reserved books.
To update the equipment purchase cost, use the latest CE index as calculated on
September 5th, 2013 and is 541.2.
Use the class notes and the prescribed book for chemical engineering thermodynamics
(CIT3111) covered last semester. Especially module 3 will be very useful.

Submission details
One submission for each group of four students will be required and will consist of:
1. A cover page containing the title of the project, the name of the group and the
details (initials, surname and student number) for each group member;
2. An executive summary;
3. A table of content;
4. A page containing the project statement and list of the tasks to be performed;
5. A report addressing each task;
6. A paragraph on the environmental impact of the process;
7. Conclusion and recommendations;
8. A CD containing an excel spreadsheet that was used for design calculations (the
group name must be written on the CD);
9. All submission must be handed in by 16h00 on 01/11/2013 and no late
submission will be accepted.

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