CHAPTER 3

MASS AND ENERGY BALANCE

ASPEN PLUS

3.1 ASPEN PLUS SIMULATION RESULTS

3.1.1 Aspen Plus Simulation Diagram

Figure 3.1: Aspen Plus Simulation Process Flow Diagram

3.2 MASS BALANCE
Mass balance calculation is the most basic step performed from the beginning of the
project to calculate the process flow of chemical compounds involved in this Methanol to
Olefins (MTO) process. The mass balance is calculated using two ways which are preliminary
manual calculation using Microsoft Excel 2013 and process software calculation using
software database (ASPEN Plus v10.6). The mass balance calculations are performed based on
stated objective of project to design 100,000 ton/year of olefins (ethylene and propylene)
production from Methanol to Olefins process (MTO) using ASPEN Plus simulation software.
The following product requirements are taken into consideration to perform the mass balance
calculation as shown below:

Product requirement:

 Production of olefins (ethylene and propylene) 100,000 tons/yr

 Olefins (ethylene and propylene) purity (> 98.5%)
 Energy generated will be used or sell
 Operating days (330 days/yr)

The preliminary mass balance calculations were performed by finding the appropriate
conversions and the chemical equations involved by referring to wide range of literatures. The
manual mass balance calculations serve as a basic aid to facilitate the simulation on ASPEN
Plus. The results obtained from the ASPEN Plus simulation is compared with preliminary
manual calculations to identify the deviations

For preliminary mass balance calculations, several chemicals are taken into consideration to
initiate the manual calculations. The list of chemical reactions is listed below:

Main reactions

2CH3OH (g) CH3OCH3 (g) + H2O (g) (3.1)

CH3OCH3 (g) C2H4 (g) + H2O (g) (3.2)

3CH3OCH3 (g) 2C3H6 (g) + 3H2O (g) (3.3)

Side reactions

CH3OH (g) + H2 (g) CH4 (g) + H2O (g) (3.4)

2CH3OH (g) +2/3 H2 (g) 2/3C3H8 (g) + 2H2O (g) (3.5)

CH3OH (g) 1/4C4H8 (g) + H2O (g) (3.6)

CH3OH (g) C5H10 (g) + H20 (g) (3.7)

CH3OH (g) CO (g) + 2H2O (g) (3.8)

CO (g) + H2O (g) CO2 (g) + H2 (g) (3.9)

2CH3OH(g) + H2 (g) 2/3 C2H6(g) + 2H2O(g) (3.10)

3.2.1 Preliminary Manual Mass Balance Calculations

Table 3.1: Preliminary manual mass balance calculation

Stream 1 2 3 4 5 6
Reactor to Quench QT to Methanol Methanol Recovery Methanol Recovery to
Methanol to Reactor Tower Water Removal Recovery to Reactor HPC
Components wt% kg/hr wt% kg/hr wt% kg/hr wt% kg/hr wt% kg/hr wt% kg/hr
CH30H 100.00 33213.37 90.00 29892.03 0.00 0.00 20.00 5978.41 100.00 5978.41 0.00 0.00
C2H4 0.00 0.00 0.00 0.00 0.00 0.00 28.60 8549.99 0.00 0.00 35.75 8549.99
C2H6 0.00 0.00 0.00 0.00 0.00 0.00 0.77 229.51 0.00 0.00 0.96 229.51
C3H6 0.00 0.00 0.00 0.00 0.00 0.00 13.68 4089.34 0.00 0.00 17.10 4089.34
C3H8 0.00 0.00 0.00 0.00 0.00 0.00 0.95 283.65 0.00 0.00 1.19 283.65
CH4 0.00 0.00 0.00 0.00 0.00 0.00 5.60 1673.95 0.00 0.00 7.00 1673.95
H2 0.00 0.00 0.00 0.00 0.00 0.00 5.60 1673.95 0.00 0.00 7.00 1673.95
H20 0.00 0.00 10.00 3321.34 100.00 3321.34 0.00 0.00 0.00 0.00 0.00 0.00
C4H8 0.00 0.00 0.00 0.00 0.00 0.00 20.00 5978.41 0.00 0.00 25.00 5978.41
C5 0.00 0.00 0.00 0.00 0.00 0.00 4.00 1195.68 0.00 0.00 5.00 1195.68
CO 0.00 0.00 0.00 0.00 0.00 0.00 0.80 239.14 0.00 0.00 1.00 239.14
Total 100.00 33213.37 100.00 33213.37 100.00 3321.34 100.00 29892.03 100.00 5978.41 100.00 23913.62
Stream 7 8 9 10 11 12
Removal Heavy Removal Light
HPC to LPC HPC to DEM LPC toHPC Component Component DEM to C2 stripper
Components wt% kg/hr wt% kg/hr wt% kg/hr wt% kg/hr wt% kg/hr wt% kg/hr
CH30H 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
C2H4 0.00 0.00 69.14 8549.99 0.00 0.00 0.00 0.00 0.00 0.00 64.86 8549.99
C2H6 0.00 0.00 1.86 229.51 0.00 0.00 0.00 0.00 0.00 0.00 1.74 229.51
C3H6 35.41 4089.34 0.00 0.00 93.51 4089.34 0.00 0.00 0.00 0.00 31.02 4089.34
C3H8 2.46 283.65 0.00 0.00 6.49 283.65 0.00 0.00 0.00 0.00 2.15 283.65
CH4 0.00 0.00 13.54 1673.95 0.00 0.00 0.00 0.00 46.23 1644.58 0.22 29.37
H2 0.00 0.00 13.54 1673.95 0.00 0.00 0.00 0.00 47.05 1673.95 0.00 0.00
H20 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
C4H8 51.77 5978.41 0.00 0.00 0.00 0.00 83.33 5978.41 0.00 0.00 0.00 0.00
C5 10.35 1195.68 0.00 0.00 0.00 0.00 16.67 1195.68 0.00 0.00 0.00 0.00
CO 0.00 0.00 1.93 239.14 0.00 0.00 0.00 0.00 6.72 239.14 0.00 0.00
Total 100.00 11547.07 100.00 12366.55 100.00 4372.99 100.00 7174.09 100.00 3557.67 100.00 13181.87
Stream 13 14 15 16 17 18
C2 stripper to C3
C2 stripper to Deethanizer spiltter Ethylene product Tail gas product Propylene product Tail gas product
Components wt% kg/hr wt% kg/hr wt% kg/hr wt% kg/hr wt% kg/hr wt% kg/hr
CH30H 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
C2H4 97.37 8546.60 0.08 3.39 99.53 8503.76 18.34 42.84 0.08 3.39 0.00 0.00
C2H6 2.58 226.66 0.06 2.85 0.47 39.86 79.96 186.80 0.07 2.85 0.00 0.00
C3H6 0.05 3.98 92.75 4085.35 0.00 0.00 1.71 3.98 99.01 4042.42 13.33 42.93
C3H8 0.00 0.00 6.44 283.65 0.00 0.00 0.00 0.00 0.11 4.60 86.67 279.05
CH4 0.00 0.00 0.67 29.37 0.00 0.00 0.00 0.00 0.72 29.37 0.00 0.00
H2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H20 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
C4H8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Total 100.00 8777.25 100.00 4404.62 100.00 8543.62 100.00 233.63 100.00 4082.64 100.00 321.98
 Component Total Production(kg/hr)
CH30H 0
C2H4 8507.15
C2H6 42.71
C3H6 4042.42
C3H8 4.60
CH4 29.37
H2 0
H20 0
C4H8 0
C5 0
CO 0
Total 12626.26263

Methanol In
33213.37
Methanol Out
33213.37
Propylene product
4042.42
Ethylene product
8507.15
Total production
12549.57
Purity of ethylene and propylene %
99.3926315

Table 3.2: Summary of preliminary manual mass balance calculation

3.2.2 ASPEN Plus Mass Balance Results

Name STREAM 1 STREAM 2 STREAM 3

Description P-101 HT-101 R-101
T (˚C) 25 25.143 350
P (bar) 1 3 2.85
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 1185.94 38000 1 1185.94 38000 1 1216.73 38832.7
CH4O 1.000 1185.94 38000 1 1185.94 38000 0.986254 1200 38450.7
C2H4 0.000 0 0 0 0 0 0.00170152 2.07028 58.0792
C3H6-2 0.000 0 0 0 0 0 0.00151954 1.84887 77.8016
C2H6 0.000 0 0 0 0 0 2.52E-08 3.07E-05 0.000923289
C3H8 0.000 0 0 0 0 0 7.79E-08 9.48E-05 0.00417914
CH4 0.000 0 0 0 0 0 3.75E-08 4.57E-05 0.000732363
C4H8-1 0 0 0 0 0 0 0.000383423 0.466522 26.1754
C5H10-2 0 0 0 0 0 0 2.22E-05 0.0269508 1.89018
H2 0 0 0 0 0 0 0.0002766 0.336547 0.678438
H2O 0 0 0 0 0 0 0.00970444 11.8077 212.718
CARBO-01 0 0 0 0 0 0 0.00013837 0.168359 4.7158
 Name STREAM 4 STREAM 5 STREAM 6
Description E-201 CW CWR
T (˚C) 470 25 45
P (bar) 2 1 1
Composition/Molar Flow Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Rate/Mass Flow Rate
Total 1 1691.71 38832.7 1 19428 350000 1 19428 350000
CH4O 0.00839775 14.2066 455.209 0 0 0 0 0 0
C2H4 0.123614 209.119 5866.58 0 0 0 0 0 0
C3H6-2 0.110394 186.754 7858.74 0 0 0 0 0 0
C2H6 1.83E-06 0.00310152 0.0932615 0 0 0 0 0 0
C3H8 5.66E-06 0.00957298 0.422135 0 0 0 0 0 0
CH4 2.73E-06 0.00461117 0.073976 0 0 0 0 0 0
C4H8-1 0.0278555 47.1234 2643.98 0 0 0 0 0 0
C5H10-2 0.0016092 2.7223 190.927 0 0 0 0 0 0
H2 0.0200948 33.9946 68.5291 0 0 0 0 0 0
H2O 0.697972 1180.77 21271.8 1 19428 350000 1 19428 350000
CARBO-01 0.0100525 17.0059 476.343 0 0 0 0 0 0
 Name STREAM 7 STREAM 8 STREAM 9
Description E-202 CW CWR
T (˚C) 130.315 25 45
P (bar) 2 1 1
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 1691.71 38832.7 1 19428 350000 1 19428 350000
CH4O 0.00839775 14.2066 455.209 0 0 0 0 0 0
C2H4 0.123614 209.119 5866.58 0 0 0 0 0 0
C3H6-2 0.110394 186.754 7858.74 0 0 0 0 0 0
C2H6 1.83E-06 0.00310152 0.0932615 0 0 0 0 0 0
C3H8 5.66E-06 0.00957298 0.422135 0 0 0 0 0 0
CH4 2.73E-06 0.00461117 0.073976 0 0 0 0 0 0
C4H8-1 0.0278555 47.1234 2643.98 0 0 0 0 0 0
C5H10-2 0.0016092 2.7223 190.927 0 0 0 0 0 0
H2 0.0200948 33.9946 68.5291 0 0 0 0 0 0
H2O 0.697972 1180.77 21271.8 1 19428 350000 1 19428 350000
CARBO-01 0.0100525 17.0059 476.343 0 0 0 0 0 0
 Name STREAM 10 STREAM 11 STREAM 12
Description E-203 CW CWR
T (˚C) 100.859 25 45
P (bar) 2 1 1
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 1691.71 38832.7 1 18317.8 350000 1 18317.8 350000
CH4O 0.00839775 14.2066 455.209 0 0 0 0 0 0
C2H4 0.123614 209.119 5866.58 0 0 0 0 0 0
C3H6-2 0.110394 186.754 7858.74 0 0 0 0 0 0
C2H6 1.83E-06 0.00310152 0.0932615 0 0 0 0 0 0
C3H8 5.66E-06 0.00957298 0.422135 0 0 0 0 0 0
CH4 2.73E-06 0.00461117 0.073976 0 0 0 0 0 0
C4H8-1 0.0278555 47.1234 2643.98 0 0 0 0 0 0
C5H10-2 0.0016092 2.7223 190.927 0 0 0 0 0 0
H2 0.0200948 33.9946 68.5291 0 0 0 0 0 0
H2O 0.697972 1180.77 21271.8 1 18317.8 350000 1 18317.8 350000
CARBO-01 0.0100525 17.0059 476.343 0 0 0 0 0 0
 Name STREAM 13 STREAM 14 STREAM 15
Description V-201 E-301 H20
T (˚C) 50.866 50.866 50.866
P (bar) 2 2 2
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 1691.71 38832.7 1 517.642 17598 1 1174.07 21234.7
CH4O 0.00839775 14.2066 455.209 0.0271703 14.0645 450.656 0.000121003 0.142066 4.55209
C2H4 0.123614 209.119 5866.58 0.399945 207.028 5807.92 0.00178115 2.09119 58.6658
C3H6-2 0.110394 186.754 7858.74 0.357171 184.887 7780.16 0.00159066 1.86754 78.5874
C2H6 1.83E-06 0.00310152 0.0932615 5.93E-06 0.0030705 0.0923289 2.64E-08 3.10E-05 0.000932615
C3H8 5.66E-06 0.00957298 0.422135 1.83E-05 0.00947725 0.417914 8.15E-08 9.57E-05 0.00422135
CH4 2.73E-06 0.00461117 0.073976 8.82E-06 0.00456506 0.0732362 3.93E-08 4.61E-05 0.00073976
C4H8-1 0.0278555 47.1234 2643.98 0.0901244 46.6521 2617.54 0.000401369 0.471234 26.4398
C5H10-2 0.0016092 2.7223 190.927 0.00520646 2.69508 189.018 2.32E-05 0.027223 1.90927
H2 0.0200948 33.9946 68.5291 0.0650153 33.6547 67.8438 0.000289546 0.339946 0.685291
H2O 0.697972 1180.77 21271.8 0.0228105 11.8077 212.718 0.995648 1168.96 21059.1
CARBO-01 0.0100525 17.0059 476.343 0.0325242 16.8359 471.58 0.000144846 0.170059 4.76343
 Name STREAM 16 STREAM 17 STREAM 18
Description CW CWR V-301
T(˚C) 25 45 28.1431
P( bar) 1 1 2
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 666.101 12000 1 666.101 12000 1 517.642 17598
CH4O 0 0 0 0 0 0 0.0271703 14.0645 450.656
C2H4 0 0 0 0 0 0 0.399945 207.028 5807.92
C3H6-2 0 0 0 0 0 0 0.357171 184.887 7780.16
C2H6 0 0 0 0 0 0 5.93E-06 0.0030705 0.0923289
C3H8 0 0 0 0 0 0 1.83E-05 0.00947725 0.417914
CH4 0 0 0 0 0 0 8.82E-06 0.00456506 0.0732362
C4H8-1 0 0 0 0 0 0 0.0901244 46.6521 2617.54
C5H10-2 0 0 0 0 0 0 0.00520646 2.69508 189.018
H2 0 0 0 0 0 0 0.0650153 33.6547 67.8438
H2O 1 666.101 12000 1 666.101 12000 0.0228105 11.8077 212.718
CARBO-01 0 0 0 0 0 0 0.0325242 16.8359 471.58
 Name STREAM 19 STREAM 20 STREAM 21
Description C-301 HT-101 E-302
T (˚C) 28.1431 28.1431 131.527
P (bar) 2 2 10
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 486.852 16765.3 1 30.7899 832.723 1 486.852 16765.3
CH4O 0 0 0 0.456791 14.0645 450.658 0 0 0
C2H4 0.420986 204.958 5749.84 0.067239 2.07028 58.0792 0.420986 204.958 5749.84
C3H6-2 0.375962 183.038 7702.36 0.0600479 1.84887 77.8016 0.375962 183.038 7702.36
C2H6 6.24E-06 0.0030398 0.0914056 9.97E-07 3.07E-05 0.000923289 6.24E-06 0.0030398 0.0914056
C3H8 1.93E-05 0.00938248 0.413735 3.08E-06 9.48E-05 0.00417914 1.93E-05 0.00938248 0.413735
CH4 9.28E-06 0.00451941 0.0725038 1.48E-06 4.57E-05 0.000732363 9.28E-06 0.00451941 0.0725038
C4H8-1 0.0948658 46.1856 2591.36 0.0151518 0.466522 26.1754 0.0948658 46.1856 2591.36
C5H10-2 0.00548037 2.66813 187.128 0.000875314 0.0269508 1.89018 0.00548037 2.66813 187.128
H2 0.0684358 33.3181 67.1653 0.0109304 0.336547 0.678438 0.0684358 33.3181 67.1653
H2O 0 0 0 0.383491 11.8077 212.718 0 0 0
CARBO-01 0.0342353 16.6675 466.864 0.00546799 0.168359 4.7158 0.0342353 16.6675 466.864
 Name STREAM 22 STREAM 23 STREAM 24
Description CW CWR C-302
T (˚C) 25 45 34.0153
P (bar) 1 1 10
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 1942.8 35000 1 1942.8 35000 1 486.852 16765.3
CH4O 0 0 0 0 0 0 0 0 0
C2H4 0 0 0 0 0 0 0.420986 204.958 5749.84
C3H6-2 0 0 0 0 0 0 0.375962 183.038 7702.36
C2H6 0 0 0 0 0 0 6.24E-06 0.0030398 0.0914056
C3H8 0 0 0 0 0 0 1.93E-05 0.00938248 0.413735
CH4 0 0 0 0 0 0 9.28E-06 0.00451941 0.0725038
C4H8-1 0 0 0 0 0 0 0.0948658 46.1856 2591.36
C5H10-2 0 0 0 0 0 0 0.00548037 2.66813 187.128
H2 0 0 0 0 0 0 0.0684358 33.3181 67.1653
H2O 1 1942.8 35000 1 1942.8 35000 0 0 0
CARBO-01 0 0 0 0 0 0 0.0342353 16.6675 466.864
 Name STREAM 25 STREAM 26 STREAM 27
Description E-303 CW CWR
T (˚C) 78.5915 5 25
P (bar) 20 1 1
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 486.852 16765.3 1 1.23352 80000 1 1.23352 80000
CH4O 0 0 0 0 0 0 0 0 0
C2H4 0.420986 204.958 5749.84 0 0 0 0 0 0
C3H6-2 0.375962 183.038 7702.36 0 0 0 0 0 0
C2H6 6.24E-06 0.0030398 0.0914056 0 0 0 0 0 0
C3H8 1.93E-05 0.00938248 0.413735 0 0 0 0 0 0
CH4 9.28E-06 0.00451941 0.0725038 0 0 0 0 0 0
C4H8-1 0.0948658 46.1856 2591.36 0 0 0 0 0 0
C5H10-2 0.00548037 2.66813 187.128 0 0 0 0 0 0
H2 0.0684358 33.3181 67.1653 0 0 0 0 0 0
H2O 0 0 0 1 1.23352 80000 1 1.23352 80000
CARBO-01 0.0342353 16.6675 466.864 0 0 0 0 0 0
 Name STREAM 28 STREAM 29 STREAM 30
Description D-401 D-501 D-601
T (˚C) 34.3043 -11.3826 69.6629
P (bar) 20 10 20
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 486.852 16765.3 1 389.482 11945.2 1 97.37 4820.1
CH4O 0 0 0 0 0 0 0 0 0
C2H4 0.420986 204.958 5749.84 0 204.958 5749.84 0 1.62E-06 4.54E-05
C3H6-2 0.375962 183.038 7702.36 0 134.529 5661.09 0 48.5085 2041.27
C2H6 6.24E-06 0.0030398 0.0914056 0 0.0030398 0.0914055 0 1.21E-09 3.63E-08
C3H8 1.93E-05 0.00938248 0.413735 0 0.00158897 0.0700679 0 0.00779352 0.343667
CH4 9.28E-06 0.00451941 0.0725038 0 0.00451941 0.0725038 0 0 0
C4H8-1 0.0948658 46.1856 2591.36 0 3.52E-05 0.00197365 0 46.1856 2591.36
C5H10-2 0.00548037 2.66813 187.128 0 1.07E-10 7.49E-09 0 2.66813 187.128
H2 0.0684358 33.3181 67.1653 0 33.3181 67.1653 0 0 0
H2O 0 0 0 1 0 0 1 0 0
CARBO-01 0.0342353 16.6675 466.864 0 16.6675 466.864 0 0 0
 Name STREAM 31 STREAM 32 STREAM 33
Description D-501 T-131 V-701
T (˚C) 50.0165 79.7508 -110.246
P (bar) 10 10 1
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 87.6334 4236.38 1 9.73666 583.724 1 157.744 3557
CH4O 0 0 0 0 0 0 0 0 0
C2H4 1.84E-08 1.62E-06 4.54E-05 0 0 0 0.683093 107.754 3022.9
C3H6-2 0.553539 48.5085 2041.27 4.28E-06 4.16E-05 0.00175264 5.94E-08 9.38E-06 0.000394524
C2H6 1.38E-11 1.21E-09 3.63E-08 0 0 0 1.02E-07 1.60E-05 0.000481781
C3H8 8.89E-05 0.00779349 0.343666 3.19E-09 3.11E-08 1.37E-06 1.94E-13 3.07E-11 1.35E-09
CH4 0 0 0 0 0 0 2.87E-05 0.00451941 0.0725038
C4H8-1 0.446371 39.117 2194.76 0.725945 7.06855 396.599 6.22E-20 9.81E-18 5.50E-16
C5H10-2 7.61E-07 6.67E-05 0.00467978 0.274012 2.66806 187.123 1.19E-29 1.88E-27 1.32E-25
H2 0 0 0 0 0 0 0.211217 33.3181 67.1653
H2O 0 0 0 0 0 0 0 0 0
CARBO-01 0 0 0 0 0 0 0.105662 16.6675 466.864
 Name STREAM 34 STREAM 35 STREAM 36
Description D-801 T-111
T(˚C) -82.7608 -110.246 -110.246
P( bar) 10 1 1
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 319.372 12624.6 1 49.9902 534.102 1 107.754 3022.9
CH4O 0 0 0 0 0 0 0 0 0
C2H4 0.30436 97.2041 2726.94 0 0 0 0.999999 107.754 3022.897
C3H6-2 0.573119 183.038 7702.35 1.88E-07 9.38E-06 0.000394524 0 0 0
C2H6 9.47E-06 0.00302377 0.0909238 0 0 0 1.00E-06 1.60E-05 0.0030229
C3H8 2.94E-05 0.00938245 0.413733 6.13E-13 3.07E-11 1.35E-09 0 0 0
CH4 1.47E-20 4.69E-18 7.53E-17 9.04E-05 0.00451941 0.0725038 0 0 0
C4H8-1 0.122481 39.1171 2194.76 0 0 0 0 0 0
C5H10-2 2.09E-07 6.67E-05 0.00467979 0 0 0 0 0 0
H2 1.03E-46 3.28E-44 6.61E-44 0.666493 33.3181 67.1653 0 0 0
H2O 0 0 0 0 0 0 0 0 0
CARBO-01 6.73E-25 2.15E-22 6.02E-21 0.333416 16.6675 466.864 0 0 0
 Name STREAM 37 STREAM 38 STREAM 39
Description T-111 D-901 T-131
T(˚C) -110.067 22.9296 -49.6844
P( bar) 1 10 1
Composition/Molar Flow
Rate/Mass Flow Rate Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr Fraction kmol/hr kg/hr
Total 1 95.8117 2687.88 1 223.56 9936.69 0 178.848 7506.49
CH4O 0 0 0 0 0 0 0 0 0
C2H4 0.999999 95.8116 2687 0.00622858 1.39246 39.0638 0.00778573 1.39246 39.0638
C3H6-2 1.26E-09 8.06E-08 3.39E-06 0.818742 183.038 7702.35 0.992166 177.447 7467.08
C2H6 5.35E-07 4.78E-05 0.0014385 1.33E-05 0.00297594 0.0894853 1.66E-05 0.00297594 0.0894853
C3H8 1.14E-14 6.95E-13 3.06E-11 4.20E-05 0.00938245 0.413733 3.23E-05 0.00577139 0.254498
CH4 0 0 0 0 0 0 0 0 0
C4H8-1 3.37E-17 1.62E-15 9.07E-14 0.174973 39.1171 2194.76 3.26E-08 5.83E-06 0.000327251
C5H10-2 0 0 0 2.98E-07 6.67E-05 0.00467979 0 0 0
H2 0 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0 0
CARBO-01 0 0 0 0 0 0 0 0 0
 Name STREAM 40
Description T-121
T(˚C) -16.8874
P( bar) 1
Composition/Molar
Flow Rate/Mass Flow
Rate Fraction kmol/hr kg/hr
Total 1 44.7117 2430.2
CH4O 0 0 0
C2H4 3.13E-13 1.40E-11 3.92E-10
C3H6-2 0.125043 5.59094 235.27
C2H6 1.14E-13 5.09E-12 1.53E-10
C3H8 8.08E-05 0.00361106 0.159235
CH4 0 0 0
C4H8-1 0.874867 39.1171 2194.76
C5H10-2 1.49E-06 6.67E-05 0.00467979
H2 0 0 0
H2O 0 0 0
CARBO-01 0 0 0
Table 3.4: Summary of ASPEN Plus simulation mass balance calculation

Component kg/hr
Methanol In
38000
Methanol Out
38000
Propylene product
7506.49
Ethylene product
5710.78
Total production
13217.27
Ethylene Purity(%)
99.9%
Propylene Purity(%)
99.5%
3.3 ENERGY BALANCE

Table 3.5: Energy Balance Calculations from ASPEN Simulation Results

Name PUMP (R-01)
Description INLET (STREAM 1) OUTLET (STREAM 2) Q (kW)
Stream LIQUID METHANOL-01 LIQUID METHANOL-02
Enthalpy (kJ/hr) -78535.4 -78531.1 4.3
Total Enthalpy (kJ/hr) -78535.4 -78531.1

Name HEATER (E-101)

Description INLET (STREAM 2 & 20) OUTLET (STREAM 3)
Stream LIQUID UNREACTED VAPOUR Q (kW)
METHANOL-02 METHANOL METHANOL-01
Enthalpy (kJ/hr) -78531.1 -1835.95 -61546.5
Total Enthalpy (kJ/hr) -80367.05 -61546.5

Name METHANOL TO OLEFINS REACTOR (R-101)

Description INLET (STERAM 3) OUTLET (STERAM 4) Q (kW)
Stream VAPOUR METHANOL-01 OLEFINS-01
Enthalpy (kJ/hr) -61546.5 -66392.4
Total Enthalpy (kJ/hr) -61546.5 -66392.4

Name HEAT EXCHANGER (HE-201)

Description INLET (STREAM 4 & 5) OUTLET (STREAM 6 & 7) Q (kW)
Stream OLEFINS-01 CW-01 OLEFINS-02 RCW-01
Enthalpy (kJ/hr) -66392.4 -1.54E+06 -74480.3 -1.53E+06
Total Enthalpy (kJ/hr) -1606392.4 -1604480.3

Name HEAT EXCHANGER (HE-202)

Description INLET (STREAM 7 & 8) OUTLET (STREAM 9 & 10) Q (kW)
Stream OLEFINS-02 CW-02 OLEFINS-03 RCW-02
Enthalpy (kJ/hr) -74480.3 -1.54E+06 -82568.2 -1.53E+06
Total Enthalpy (kJ/hr) -1614480.3 -1612568.2
 Name HEAT EXCHANGER (HE-203)
Description INLET (STREAM 10 &11) OUTLET (STREAM 12 & 13) Q (kW)
Stream OLEFINS-03 CW-03 OLEFINS-04 RCW-03
Enthalpy (kJ/hr) -82568.2 -1.45E+06 -90193.9 -1.45E+06
Total Enthalpy (kJ/hr) -1532568.2 -1540193.9

Name WATER SEPARATOR (V-201)

Description INLET (STREAM 13) OUTLET (STREAM 14 & 15) Q (kW)
Stream OLEFINS-04 OLEFINS-05 WATER-01
Enthalpy (kJ/hr) -90193.9 2144.9 -92151.2
Total Enthalpy (kJ/hr) -90193.9 -90006.3

Name Heat Exchanger (HE-301)

Description INLET (STREAM 14&16) OUTLET (STREAM 17 & 18) Q (kW)
Stream OLEFINS-05 CW-04 OLEFINS-06 RCW-04
Enthalpy (kJ/hr) 2144.9 -52881.1 1867.6 -52603.8
Total Enthalpy (kJ/hr) -50736.2 -50736.2

Name METHANOL SEPARATOR (V-301)

Description INLET (STREAM 18) OUTLET (STREAM 19 & 20)
Stream UNREACTED Q (kW)
OLEFINS-06 OLEFINS-07 METHANOL
Enthalpy (kJ/hr) 1867.6 3506.59 -1835.95
Total Enthalpy (kJ/hr) 1867.6 1670.64

Name COMPRESSOR(COMP-301)
Description INLET (STREAM 19) OUTLET (STREAM 21) Q (kW)
Stream OLEFINS-07 OLEFINS-08
Enthalpy (kJ/hr) 3506.59 4358.97
Total Enthalpy (kJ/hr) 3506.59 4358.97

Name HEAT EXCHANGER (HE-302)

Description INLET (STREAM 21 &22) OUTLET (STREAM 23 & 24) Q (kW)
Stream OLEFINS-08 CW-05 OLEFINS-09 RCW-05
Enthalpy (kJ/hr) 4358.97 -154236 3550.18 -153428
Total Enthalpy (kJ/hr) -149877.03 -149877.82 0.8
 Name COMPRESSOR(COMP-302)
Description INLET (STREAM 24) OUTLET (STREAM 25) Q (kW)
Stream OLEFINS-09 OLEFINS-10
Enthalpy (kJ/hr) 3550.18 3900.19
Total Enthalpy (kJ/hr) 3550.18 3900.19

Name HEAT EXCHANGER (HE-303)

Description INLET (STREAM 25 &26) OUTLET (STREAM 27 & 28) Q (kW)
Stream OLEFINS-10 REFG-01 OLEFINS-11 REFG-01
Enthalpy (kJ/hr) 3900.19 2017.81 3380.74 2537.26
Total Enthalpy (kJ/hr) 5918 5918

Name DISTILLATION (D-401)

Description INLET (STREAM 28) OUTLET (STREAM 29 & 30)
Stream C2H4, C3H6, C3H6, C4H8, Q (kW)
OLEFINS-11 CO, H2 C5H10
Enthalpy (kJ/hr) 3380.74 3049.55 -11.086
Total Enthalpy (kJ/hr) 3380.74 3038.464

Name DISTILLATION COLUMN (D-501)

Description INLET (STREAM 30) OUTLET (STREAM 31 & 32) Q (kW)
Stream C3H6, C4H8, C5H10 C3H6, C4H8 C4H8, C5H10
Enthalpy (kJ/hr) -11.086 313.525 -50.3174
Total Enthalpy (kJ/hr) -11.086 263.208

Name DISTILLATION COLUMN (D-601)

Description INLET (STREAM 29 & 31) OUTLET (STREAM 33 & 34)
Stream C2H4, C3H6, C3H6, C2H4, H2, C2H4, C3H6, Q (kW)
CO, H2 C4H8 CO C4H8
Enthalpy (kJ/hr) 3049.55 313.525 854.333 286.653
Total Enthalpy (kJ/hr) 3363.075 1140.986 -2222.089
 Name FLASH SEPARATOR (V-701)
Description INLET (STREAM 33) OUTLET (STREAM 35 & 36) Q (kW)
Stream C2H4, CH4, H2, CO C2H4 CH4 ,H2, CO
Enthalpy (kJ/hr) 854.333 1008.09 -565.459
Total Enthalpy (kJ/hr) 854.333 442.631 -411.702

Name DISTILLATION COLUMN (D-801)

Description INLET (STREAM 34) OUTLET (STREAM 37 & 38)
Stream C2H4, C3H6, C2H6, Q (kW)
C3H8, C4H8 C2H4 C3H6, C4H8
Enthalpy (kJ/hr) 286.653 908.71 80.5321
Total Enthalpy (kJ/hr) 286.653 989.2421 702.589

Name DISTILLATION COLUMN (D-901)

Description INLET (STREAM 38) OUTLET (STREAM 39 & 40) Q (kW)
Stream C3H6, C4H8 C3H6 C3H6, C4H8
Enthalpy (kJ/hr) 80.5321 -132.343 -287.595
Total Enthalpy (kJ/hr) 80.5321 -419.9380 -500.470
3.3.1 Comparison of Manual Mass Balance Calculation and ASPEN Plus Simulation
Calculation

The result from the manual calculation was used as an input for the ASPEN Plus simulation.
The feed flowrate of 33213.37 kg/hr was added into the ASPEN Plus flowsheet. Aspen Plus
was set at Metric Units and the simulation was performed. The results from mass balance and
energy balance were displayed in section 3.2 and 3.3. The results were analysed and there was
not much deviations between manual calculation and ASPEN Plus simulation calculation. The
feed flowrate was increased from 33213.37 kg/hr to 38000kg/hr which considered to be a slight
increase form the manual calculation. The total production of ethylene from manual calculation
is 8507.15 kg/hr while simulation calculation is 5710.78 kg/hr. The total production of
propylene from manual calculation is 4042.42kg/hr while simulation calculation is
7506.49kg/hr. The total production of propylene seems to be higher in simulation compared to
total production ethylene because the selectivity of propylene as final after reaction is higher
compared to ethylene. However, ethylene and propylene recorded purity of 99.5% and 99.9%
which is almost like manual calculation purity. The relative difference is due to error and due
to the accuracy of ASPEN Plus in using highly accurate molecular weight compared to manual
calculation. However, the ASPEN Plus calculation was used to perform the process design and
mechanical design due to its accurate data presentation.
3.3.2 Utility Usage

3.3.2.1 Cooling water

Cooling water is a utility used as cooling agent for heat transfer processes and reactor for our
plant. Cooling water functions to absorb heat from a hot flowing fluid to achieve requirement
of temperature for hot stream. The steam and heat generated from the heat exchanger process
is used to produce electricity. Cooling water was used at maximum rate at Methanol reactor to
absorb excess heat present due to high operating temperature and pressure to prevent any
damage to the reactor and to avoid explosion. Cooling water also has been used as intercooler
and aftercooler for compressor to avoid drastic temperature rises of air. The cooling water also
heated at times to become hot water for generation of high pressure steam at boilers.

3.3.2.2 Steam Water

Steam water is mainly used to heat up cold streams to initiate high temperature process. Steam
water was flow the region where colds streams are located to rise the temperature of reaction
at required level by transferring heat to the cold streams for an optimum reaction. Steam water
is used at maximum rate for the distillation columns especially at the reboilers to heat up light
components that mixed with heavy components and flowed downwards in the distillation
column so that separation of light components at the condenser can happen effectively. Steam
water also used to generate electricity to run the overall process of Methanol to Olefins (MTO)
process.
3.3.2.3 Refrigerant

The role of refrigerant utility is to supply refrigerant in this plant to cool down hot stream to
an optimum temperature. For our plant , we use water (R718) as refrigerant to cool down olefins
passing through the heat exchanger,HE-303 before entering the first distillation column (D-
401) for subsequent separation.Water was chose as a refrigerant for plant project based on
several factors as shown below:

 Water is environmentally friendly as it does not create any pollution to the environment
and can be recycled for subsequent process

 Water is relatively low cost and toxic free

 The thermophysical properties of water are consistent with a vapour compression chiller
system that has the potential to achieve a high coefficient of performance (COP)

 Water is widely available and can be obtained any time without limitation

 The latent heat and refrigeration effect of water is bigger than synthetic which results in
higher refrigeration capacity and cooling rate than synthetic refrigerant

 The pressure ratio water ( comparison between discharge and suction pressure of
compressor) is smaller than synthetic refrigerant pressure ratio.It will be effected small
work of compressor so it can be saving energy consumption

The refrigerant utility (R718) is used to cool down the olefins passing through the heat
exchanger HE-303 before entering the first distillation column (D-401) for subsequent
separation.
3.4 PROCESS FLOW DIAGRAM
EQUIPMENT LIST TAG NUMBER
Pump P-101
Heat exchanger E-201, E-202, E-203, E-301, E-
302, E-303, E-401, E-402, E-
501, E-502, E-601, E-602, E-
701, E-702, E-801 ,E-802, E-
901, E-902
Heater HT-101
Methanol Storage Tank T-101
Methanol Reactor R-101
Regenerator R-102
Water Separator V-201
Methanol Separator V-301
High Pressure Column D-401
DEM D-501
Low Pressure Column D-601
Ethylene Separator V-701
C2 Splitter D-801
C3 Splitter D-901
3.5 HEAT INTEGRATION AND PINCH TECHNOLOGY

Heat integration is one of the effective way to identify targets for heat exchanger network
design to assess the energy and capital cost of the design network. Heat integration significantly
helps in energy saving in heat network design. As a result, capital cost and operational cost for
the network design can be reduced. For this project, pinch analysis method was used to perform
the heat integration. The analysis of the heat exchanger network first identifies sources of heat
(hot stream) and sinks (cold streams) from the material and energy balance. The pinch analysis
method is then utilised to perform the heat integration. Pinch technology consists of seven basic
steps to identify the utilities target and hence heat integration of plant can be obtained as shown
below:

i. Data extraction is performed to identify the hot and cold stream from the material and
energy balance
ii. The ∆H, ∆T and mcp of each stream are obtained from the ASPEN Plus simulation
results
iii. Problem Table Algorithm method is used whereby the Ts shifted and Tt shifted is
calculated where for the hot streams,Ts shifted = Ts – ½ ∆Tmin and for cold streams Tt
shifted = Tt + ½ ∆Tmin.
iv. The minimum heating requirements, QHmin, minimum cooling requirement, QCmin , and
pinch temperature, Tpinch are determined from the heat cascade table.
v. The matching of streams is determined from the maximum energy recovery (MER)
method where for the above pinch region, CPH ≤ CPC and below pinch region CPH ≥
CPC.
vi. The utility consumption of every heat exchanger is calculated.
vii. Comparisons of utilities consumption before and after MER to determine the MER
efficiency.
3.5.1 Data Extraction

Table 3.6: Data Extraction from Material and Energy Balance

Stream Type Tsupply Ttarget T*supply T*target CP H

(℃ ) (℃ ) (℃ ) (KW)
2 Cold 25 350 30 355 2.82 917
4 Hot 470 130 465 125 2.47 -840
7 Hot 130 101 125 96 1.92 -56
10 Hot 101 51 96 46 2.70 -135
14 Hot 51 28 46 23 1.66 -38
21 Hot 132 34 127 29 1.95 -191
25 Hot 79 34 74 29 1.77 -80

3.5.2 Problem Table Algorithm

Table 3.7: Algorithm Table

3.5.3 Heat Cascade System

Figure 3.2: Heat Cascade Flow Diagram

From Figure 3.2,

Pinch temperature = 465

Temperature above pinch = 470

Temperature below pinch = 460

3.5.4 Network Diagram Representation

Figure 3.3: The Heat Exchanger Network Diagram

From Figure 3.2, the pinch temperature is 465 ℃. From Figure 3.3 also we found that total
number of heat exchanger units need for the current project is 2 instead of 6 after heat
integration. It proves that, heat integration reduces energy usage as well as helps to save capital
and operational cost. From the heat cascade table, the minimum hot utility, QHmin, is 0 kW and
minimum cold utility, QCmin, is 422.91kW.