Natural gas feedstock is supplied at 25 ℃ and 10 barg with a volumetric flowrate of

50.3205 m3/s. It is to be compressed to a pressure of 39 barg and pre-heated to a

temperature of XXX ℃ for the hydrodesulphurization process and subsequent reforming
steps.

Compression selection process is first conducted with the aid of figure 3.2.1.1 to
determine the most ideal compressor type for best performance.

Converting natural gas flow rate from m3/s to actual cubic feet per minute (ACFM):
𝑚3
1 = 2118.88 𝐴𝐶𝐹𝑀
𝑠
3
𝑚
50.3205 = 106623.1012 𝐴𝐶𝐹𝑀
𝑠
Interpolating figure 3.2.1.1 with natural gas flow rate determined in ACFM:

Figure A3.1.2: Discharge pressure (psig) vs inlet volume flow (ACFM) compressor selection chart ( Society of Petroleum Engineers, 2015)

Based on the interpolation done in the figure above, a multi-stage compressor operating
polytropically is selected.

Calculate Total Duty of Compressor

The maximum duty of each compressor is limited to 2 MW thus the total work required
to compress natural gas from 10 barg to 37.9868 barg is determined using the equation
shown below:

𝑛−1
𝑅𝑇1 𝑛 𝑃2 𝑛
−𝑊 = 𝑍 [ − 1 ] ⋯ 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 3.2.1.1
𝑀 𝑛 − 1 𝑃1
Where Z = Compressibility factor
R = universal gas constant, 8.314 JK-1mol-1
T1 = inlet temperature, K
M = molecular mass of gas, kg/kmol
W = Work done, J/kg

The polytropic temperature exponent, m is calculated using Equation 3.2.1.2.

𝛾−1
𝑚= ⋯ 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 3.2.1.2
𝛾𝐸𝑝

𝐶𝑃
𝛾 𝑐𝑎𝑛 𝑏𝑒 𝑒𝑠𝑡𝑖𝑚𝑎𝑡𝑒𝑑 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝
𝐶𝑉

The polytropic exponent n is determined using Equation 3.2.1.3.

1
𝑛= ⋯ 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 3.2.1.2
1−𝑚

The efficiency of the compressor is first determined using figure 3.2.1.2. by interpolating
the volumetric flow rate of natural gas at 50.3205 m3/s.

Figure A3.1.3 Efficiency of compressor (%) vs volumetric flowrate at suction conditions (m3/s)

Table A3.1.2 Tabulation of parameters for compressor duty calculations

Parameters Unit Values

Compressibility factor, Z 0.9748
Inlet temperature T1 K 298.15
Molar mass of natural gas, M Kg/kmol 16.8837
 Outlet pressure, P2 Pa 3751325
Inlet pressure, P1 Pa 1101325
Specific heat capacity J/kmol.K
(constant pressure), Cp 37187.3749
Specific heat capacity J/kmol.K
(constant volume), Cv 27843.4426
𝛾 1.3356
Compressor efficiency, Ep 0.7577
m 0.3316
n 1.4961
𝐽 1.4961−1
8.314 × 298.15𝐾 1.4961 3751325𝑃𝑎 1.4961
−𝑊𝑇𝑜𝑡𝑎𝑙 = 0.9784 𝐾. 𝑚𝑜𝑙 [ − 1]
𝐾𝑔 1.4961 − 1 1101325𝑃𝑎
16.8837
𝐾𝑚𝑜𝑙
𝑘𝑚𝑜𝑙 𝐽
× 1000 = 217207.2472
𝑚𝑜𝑙 𝑘𝑔

Given the mass flow rate of natural gas required for methanol synthesis is 38.5005 kg/s.

𝑘𝑔 𝐽
−𝑊𝑇𝑜𝑡𝑎𝑙 = 217207.2472 × 38.5005 = 8362587.6210 = 8.3626𝑀𝑊
𝑠 𝑠

The total work required to compress natural gas from 10 barg to 36.5 barg (37.5133bar)
is 8.3626 MW.

To reduce the temperature of the outlet stream when one compressor is used, the
compression work is done in two stages with an intercooler in between. This serves to
limit the discharge temperature of compressor to below 225℉ (approximately 107.2℃)
because system breakdown can potentially occur due to worn rings, formation of acids
and vaporization of oil in the lubrication system at temperature above 225℉ thereby
resulting in overheating of compressors. This can be explained by the actual discharge
valve’s temperature potentially reaching up to 75 ℉ hence increasing the actual
compressor’s discharge valve temperature to 300℉ (150℃) (theNEWS, 2002).

Calculate the work done by each compression stage:

𝑃2 𝑃3
=
𝑃1 𝑃2

𝑃2 3751325
=
1101325 𝑃4
 𝑃2 3751325
=
1101325 𝑃4

𝑃2 𝑃2 = 3751325 𝑃𝑎 × 1101325 𝑃𝑎 = 4.1314 × 1012 𝑃𝑎2 ⋯ 1

𝑃2 2 = 4.1314 × 1012 𝑃𝑎2

𝑷𝟐 = 𝟐𝟎𝟑𝟐𝟓𝟗𝟏. 𝟒𝟓𝟏𝟎 𝑷𝒂

Cooling water will be used to extract heat from the natural gas stream to reduce the
stream temperature entering the subsequent compressor down to approximately 40℃.
Intercooling between compressors are vital to generate energy and ultimately cost
savings as they serve to decrease the discharge temperature of the exiting stream thereby
reducing the amount of work done in compressing the natural gas stream ( Society of
Petroleum Engineers, 2015). The pressure drop across each heat exchanger is predicted
to be 0.5 bar.

Compressor 1

Table A3.1.3 Tabulation of parameters for compressor duty calculations

Parameters Unit Values

Compressibility factor, Z 0.9748
Inlet temperature T1 K 298.15
Molar mass of natural gas, M Kg/kmol 16.8837
Outlet pressure, P2 Pa 2032591.4510
Inlet pressure, P1 Pa 1101325
Specific heat capacity J/kmol.K
(constant pressure), Cp 37187.3749
Specific heat capacity J/kmol.K
(constant volume), Cv 27843.4426
𝛾 1.3356
Compressor efficiency, Ep 0.7577
m 0.3316
n 1.4961

𝑊𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟,1
𝐽 1.4961−1
8.314 × 298.15𝐾 1.4961 2032591.4510 𝑃𝑎 1.4961
= 0.9784 𝐾. 𝑚𝑜𝑙 [ − 1]
𝐾𝑔 1.4961 − 1 1101325𝑃𝑎
16.8837
𝐾𝑚𝑜𝑙
𝑘𝑚𝑜𝑙 𝐽
× 1000 = 97607.2578
𝑚𝑜𝑙 𝑘𝑔
Given the mass flow rate of natural gas required for methanol synthesis is 38.5005 kg/s.

𝐽 𝑘𝑔 𝐽
−𝑊𝑇𝑜𝑡𝑎𝑙 = 97607.2578 × 38.5005 = 3757928.2290 = 3.7579 𝑀𝑊
𝑘𝑔 𝑠 𝑠
= 3.76𝑀𝑊

The total work required to compress natural gas from 10 barg to 19.3127 barg (20.3260
bar) is 3.76MW.

Compressor 2
Taking into account a pressure drop of 0.5 bar across the intercooler, 𝑃2,𝑛𝑒𝑤 =
18.8127 𝑏𝑎𝑟.

Table A3.1.4 Tabulation of parameters for compressor duty calculations

Parameters Unit Values

Compressibility factor, Z 0.9627
Inlet temperature T1 K 313.15
Molar mass of natural gas, M Kg/kmol 16.8837
Outlet pressure, P3 Pa 3751325
Inlet pressure, P2,New Pa 1982591.4510
Specific heat capacity J/kmol.K 38773.875
(constant pressure), Cp
Specific heat capacity J/kmol.K 28796.6547
(constant volume), Cv
𝛾 1.34647151
Compressor efficiency, Ep 0.7577
m 0.33960421
n 1.51424346
Work done, -W MW 4.0697
Following the same calculation steps as compressor 1, the amount of work done to
compress natural gas from 18.8127 barg (19.8260 bar) to 36.5 barg (37.5133 bar) for
compressor 2 is found to be 4.07 MW.

Calculate Intercooler Duty between Compressors

Table A3.1.5 Tabulation of parameters for intercooler duty calculations

Parameters for Natural Gas Unit

Mass flow rate, m Kg/s 38.5005
Mole flow rate, n Kmol/s 2.2803
Specific heat capacity, Cp J/kmol-K 40988.09
Inlet temperature, T1 K 359.9394
 Outlet temperature, T2 K 313.15

𝑄𝑁𝑎𝑡𝑢𝑟𝑎𝑙 𝐺𝑎𝑠 = 𝑛𝑁𝑎𝑡𝑢𝑟𝑎𝑙 𝐺𝑎𝑠 × 𝐶𝑝, 𝑁𝑎𝑡𝑢𝑟𝑎𝑙 𝐺𝑎𝑠 × (𝑇2 − 𝑇1 )

𝑘𝑚𝑜𝑙 𝐽
= 2.2803 × 40988.09 × (313.15 − 359.9394)𝐾
𝑠 𝑘𝑚𝑜𝑙. 𝐾
𝐽
= −4373177.898 = −4373.1779 𝑘𝑊
𝑠

The total duty of the intercooler is found to be -4373.1779 kW.

Calculate Amount of Cooling Water Required

Cooling water is supplied at ambient temperature of 25℃ and the outlet of cooling water
is capped at a maximum of 10℃ temperature difference thus the outlet temperature of
cooling water would be 35℃.

Table A3.1.6 Tabulation of parameters for cooling water quantity calculations

Parameters for Cooling Water Unit

Specific heat capacity, Cp J/kg.K 4181.6
Inlet temperature, T1 K 298.15
Outlet temperature, T2 K 308.15
Assuming the heat released by the cooling of natural gas is completely absorbed by
cooling water,

𝑄𝑁𝑎𝑡𝑢𝑟𝑎𝑙 𝐺𝑎𝑠 = −𝑄𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟

𝑄𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟 = 4373177.898

𝑄𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟 = 𝑚𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟 × 𝐶𝑝, 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟 × (𝑇2 − 𝑇1 )

Rearranging the equation above and making mass flow rate of cooling water the subject:

𝑄𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟
𝑚𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟 =
𝐶𝑝, 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟 × (𝑇2 − 𝑇1 )
𝐽
4373177.898 𝑠
=
𝐽
4181.6 × (308.15 − 298.15)𝐾
𝑘𝑔. 𝐾
𝑘𝑔
= 104.5814
𝑠