CHAPTER III

TECHNICAL DESIGN AND REQUIREMENTS

This chapter presents the data and information as well as the

assumptions related to the technical aspects and requirements needed for the

design of the steam methane reforming plant. Standards were used to come

up with a technically viable design. Technical catalogues were used to

carefully identify the design specifications of each equipment.

DESIGN OPTION 1

A. Process Flow Diagram

Figure 3.1 Process Flow Diagram for Design Option 1

Design option 1 is a traditional steam reforming (SMR) with carbon

capture from the syngas stream. The heat required in the reactor is delivered

by a furnace burning the process tail gas as well as additional natural gas if

needed.
 B. Design Specification of each Equipment

Gas Heated Reformer (GHR) (Pre-Reformer)

The principle of the pre-reformer is to convert heavier hydrocarbons to

methane prior to the main reforming reactor. The pre-reforming reactor usually

contains a nickel catalyst bed and is basically a low temperature adiabatic

steam reforming unit. The temperature is normally in the range from 350– 550

°C. There are several benefits to pre-reforming, but most important is the

enabling of process optimization of methane reforming. This results in lower

feed consumption and hence a smaller reactor size. A sophisticated pre-

reformer is the gas heated reformer (GHR), also referred to as a convective

reformer. What differentiate it from the traditional steam methane reforming

(SMR) are the temperature range and the method of heat transfer. Where the

SMR reactors are heated by external combustion of natural gas in a system of

reactor tubes and burners, the GHR works as a heat exchanger, absorbing

energy by convective heat transfer with another gas.

Figure 3.2 Gas Heated reformer

Table 3.1 Design Specification of GHR

 Type Gibbs Reactor

Operating Temperature 700ºC

Operating Pressure 25 bar

Efficiency 100%

S/C Ratio: 0.25 Mole-H2O/Mole-C

Steam Methane Reformer (SMR)

A widely used method to produce hydrogen from natural gas (NG) is by

the use of steam methane reforming (SMR). The reaction is endothermic and

converts steam and methane into H2 and CO. The reaction is a catalytic

reaction supported by nickel- based catalysts. Nickel-based catalysts are cost

efficient and have sufficient activity. When more activity is needed, a more

noble catalyst can be used. Nobel catalysts provide higher activities and faster

reactions but are very expensive. The reactor consists of several reactor

tubes filled with reforming catalysts and kept in a furnace that provides the

necessary heat for the reaction to happen.

 Figure 3.3 Steam Methane Reformer

Table 3.2 Design Specification of GHR

Type Gibbs Reactor

Operating Temperature 950ºC

Operating Pressure 24 bar

Efficiency 100%

S/C Ratio: 3 Mole-H2O/Mole-C

Water Gas Shift (WGS)

After the reforming process, the syngas undergoes a water gas shift,

where the CO is reacted with water, over a catalyst, to produce additional

hydrogen as well as CO2. The process is slightly exothermic and is

controlled by equilibrium.

The equilibrium constant is a function of temperature, meaning the

reaction is favourable at low temperatures. On the other hand, the reaction

rates diminish at low temperatures. Because of this the process is usually

done in two steps, a high temperature shift (HTS) and a low temperature shift

(LTS). In the HTS, the mole fraction of CO is reduced from typically 10-13% to

2-3%, with an inlet temperature between 350-550°C. In the LTS, the CO

concentration is further reduced to 0.2-0.4% at temperatures of 190-250. The

lower limit is set due to the water dew point of the gas. Condensation

could damage the catalysts in the WGS chamber.

Table 3.3 Design Specification of WGS

 Type Equilibrium Reactor

High Temperature WGS

Operating Temperature 320

Operating Pressure 23 bar

Efficiency 100%

Low Temperature WGS

Operating Temperature 190

Operating Pressure 22.5 bar

Efficiency 100%

CO2 ABSORPER

After the WGS, hydrogen and CO2 are produced and have to be

separated and purified. Concepts for CO2 separation are presented in this

section. CO2 absorption is a commercially mature technology and is

commonly used to remove CO2 from NG [8]. The liquid solvent can be

divided into two groups, chemical and physical solvents. Chemical

solvents react with CO2 and require heat to activate the reaction. Chemical

solvents offer fast reaction rates which results in smaller plant size. Physical

solvents do not react but dissolve CO2 and require less heat than chemical

solvents. Chemical solvents have relatively high capacity at low pressure

compared to physical solvents and are therefore preferred at low CO2 partial

pressures. The chemical solvents will begin to saturate with increasing CO2

partial pressures and physical solvents are therefore preferred at high CO2
partial pressures. The CO2 recovery and purity will depend on the syngas

composition and various solvents may be optimal for CO2 separation. Studies

have shown that MDEA can capture as much as 95% of the CO2 with a purity

of above 99%.

Figure 3.4 CO2 Absorper

Table 3.4 Design Specification of CO2 Absorper

Type Component Splitter

Operating Temperature 25ºC

Operating Pressure 22 bar

CO2 Purity 99.999%

CO2 Recovery Rate 95% mole-basis

Pressure Swing Absorber (PSA)

Over 85% of current global hydrogen production units use PSA

technology for hydrogen purification and is the most used hydrogen

purification technology today. When PSA is used to purify hydrogen, the

syngas is sent through an adsorption column at high pressures letting through

hydrogen while adsorbing CO2 and other impurities. The pressure inside the

column is then lowered near atmospheric pressure desorbing impurities

from the adsorption material. There are usually several columns

operating simultaneous making the hydrogen purification process semi-

continuous. Columns with multiple adsorbents are normally used when

purifying hydrogen. Typical adsorbents are silica gel, alumina, activated

carbon and zeolite. Operating temperature in PSA units is typically ambient

temperature receiving the feed syngas at a pressure between 20-60 bar.

Hydrogen is purified with a pressure drop between 1-2 bar. The off-gas exits

the unit with pressures between 1-2 bar. The PSA

unit produces hydrogen with a purity up to 99.9999% and with a hydrogen

recovery between 60-95%.

Figure 3.5 Pressure Swing Absorber

Table 3.5 Design Specification of Pressure Swing Absorber

Type Component Splitter

Operating Temperature 25ºC

Operating Pressure 20 bar

Pressure Tail Gas 2 bar

 H2 Purity 99.999%

H2 Recovery Rate 90% mole-basis

COMPRESSOR

Air is drawn in and compressed when passing through rows of rotating

blades and stationary vanes. At the end of the compressor, before reaching

the combustion chamber, the air is compressed to a certain pressure and

temperature by compression.

The H-Series serves the requirements of many industries, from air

separation, chemical, petrochemical, process air etc. It is widely known and

accepted as an efficient, dependable and cost-effective compressor solution

that comes as a standard package but also fully engineered to API

specifications.

Figure 3.6 Compressor

Table 3.6 Design Specification of Compressor

Type Centrifugal

Inlet pressure 1 bar

Outlet Pressure 1.2 bar

 Inlet Temperature 25ºC

WATER PUMP

The pumps are installed for the circulation of water for steam

generation.

Figure 3.7 Water Pump

Table 3.7 Design Specification of Water Pump

Type Water Pump

Inlet Pressure 1 bar

Outlet Pressure 25 bar

Capacity 20000 kg/h

Fluid temperature 25ºC

Motor 60 Hz
GAS EXPANDER

It is a centrifugal or axial-flow turbine, through which a high-

pressure gas is expanded to produce work that is often used to drive

a compressor or generator. Natural Gas is expanded to decrease it feed

pressure going to the pre-reformer.

Figure 3.8 Gas Expander

Table 3.8 Design Specification of Expander

Type Gas Expander

Inlet Pressure 50 bar

Outlet Pressure 25 bar

Capacity 15000 m3/h

Fluid temperature 50ºC

FURNACE

The furnace is as mentioned supplying the SMR with the

required heat by burning NG and the tail gas with air. The required air is

heated and supplied at a temperature of 335°C and a pressure of 1.2 bar

while the NG and tail gas is heated to a temperature of 500°C before entering

the furnace. Post combustion, the flue gas leaves the furnace at a

temperature of 1000°C and at atmospheric pressure. The flue gas is cooled

down to 100°C supplying heat to the reforming system.

Figure 3.9 Furnace

Table 3.9 Furnace

Type Gibbs Reactor

Operating Pressure 20 bar

Operating Temperature 1000ºC

 C. Mass Balance and Energy Balance Computations

Table 3.10 Mass Balance Calculations for Design Option 1

MASS BALANCE CALCULATIONS

Equipment Diagram Efficiency Computation

S + NG = M1
Steam= 2,722 kg/hr
Steam
GHR M1 100%
NG NG= 9,903 kg/hr

M1= 12,625 kg/hr

M1 + Steam = M2
M1 M1=12,625 kg/hr
SMR M2 100% Steam= 26,818 kg/hr
Steam M2=39,443 kg/hr

M2 = M3 + H20
M2=39,443 kg/hr
M2 M3
WGS 100% M3=29,908 kg/hr
H20= 9,535 kg/hr
H20

M3 M4 M3 + CO2 = M4
CO2 M3=29,908 kg/hr
100%
Absorber CO2=23,450 kg/hr
CO2 M4= 6,458 kg/hr
 M4 = H2 + M5
M4 M5 M4=6,458 kg/hr
PSA 100% H2=3,848 kg/hr
M5= 2,610 kg/hr
H2

M5 + A + NG = FG + W
M5 M5= 2,610 kg/hr
Air
Flue Gas Air=60,957 kg/hr
NG
Furnace 100% NG=2,199 kg/hr
Waste
Flue Gas= 65,766 kg/hr
Waste = 0 kg/hr

Table 3.11 Energy Balance Calculations for Design Option 1

ENERGY BALANCE PREHEATING WATER TO GHR AND SMR

OPERATING CONDITIONS CALCULATIONS
Mwater=2,722kg/hr &26,818 kg/hr Q = mwaterCp water(t2-t1)
Cp water = 4.184 KJ/Kg K Q =( 2,722 + 26,818 Kg/hr )x 4.19 KJ/Kg K

T1 = 298.15 K
 (623.15K – 298.15K)

Q = 40,226,095 KJ/hr
T2 = 623.15 K


1ST WATER PUMP POWER OUTPUT GOING TO GHR

OPERATING CONDITIONS CALCULATIONS
Mwater=2,722kg/hr Q = MD deltaP
Dwater = 1 kg/m3 Q =2,722 kg/hr x1 kg/m3 x (23.287x 100)KPa
Pump effciency = 100 % Q = 6338721.4 KJ/hr
DeltaP= 23.897 bar
2nd WATER PUMP POWER OUTPUT GOING TO GHR
OPERATING CONDITIONS CALCULATIONS
Mwater=26,818 kg/hr Q = MD deltaP
Dwater = 1 kg/m3 Q =26,818 kg/hr x1 kg/m3 x (23.287x 100)KPa
Pump effciency = 100 % Q = 43442319.94 KJ/hr
DeltaP= 23.897 bar
ENERGY BALANCE PREHEATING STREAM TO GHR
OPERATING CONDITIONS CALCULATIONS
Mwater=2,722kg/hr Q1 = mwaterCp water(t2-t1)
MNg=9,903kg/hr Q2 = mNGCp NG(t2-t1)
Cp water = 4.184 KJ/Kg K Q1 =( 2,722 Kg/hr)x 2.489 KJ/Kg K
Cp NG = 2.365 KJ/Kg K (673.15K – 623.15K) =338752.9 KJ/hr

T1w = 623.15 K
 Q2 =( 9,903 Kg/hr)x 2.365KJ/Kg K

(673.15K –323.15K) = 8197208.25
T1NG = 323.15 K

Qtotal= Q1 + Q2

T2 = 673.15 K
 Qtotal = 8535961.15 KJ/hr

ENERGY BALANCE PREHEATING STREAM TO SMR

OPERATING CONDITIONS
Mwater=26,818kg/hr
Mstream=12,625kg/hr
Cp water = 4.184 KJ/Kg K
Cp stream = 2.365 KJ/Kg K
CALCULATIONS
Q1 = mwaterCp water(t2-t1)
Q2 = mstreamCstream(t2-t1)
Q1 =( 26,818 Kg/hr)x 2.489 KJ/Kg K
(973.15K – 623.15K) =23362730.51 KJ/hr

T1w = 623.15 K
 Q2 =( 9,903 Kg/hr)x 2.365KJ/Kg K

(973.15K –973.15K) = 0 KJ/hr
T1stream = 973.15 K

Qtotal= Q1 + Q2

T2 = 973.15 K
 Qtotal = 23362730.51 KJ/hr

ENERGY BALANCE AT GHR

OPERATING CONDITIONS CALCULATIONS
Mstream=12,625kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 6.354 KJ/Kg K Q =( 12,625 Kg/hr)x 6.354 KJ/Kg K

T1stream = 623.15 K
 (923.15K – 623.15K)

Q= 24067165.74 KJ/hr
T2 = 923.15 K


ENERGY BALANCE AT SMR

OPERATING CONDITIONS CALCULATIONS
Mstream=39,443 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 39443 Kg/hr)x 13.391 KJ/Kg K

T1stream = 923.15 K
 (1223.15K – 923.15K)

Q= 132046176.4KJ/hr
T2 = 1223.15 K


ENERGY BALANCE COOLING OF SMR PRODUCT

OPERATING CONDITIONS CALCULATIONS
Mstream=39,443 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 39443 Kg/hr)x 2.896 KJ/Kg K

T1stream = 1223.15 K
 (593.15K – 1223.15K)

Q= - 71961379.68KJ/hr
T2 = 593.15 K


ENERGY BALANCE AT WATER GAS SHIFTER

OPERATING CONDITIONS CALCULATIONS
Mstream=39,443 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 39443 Kg/hr)x 6.043 KJ/Kg K

T1stream = 593.15 K
 (298.15K – 593.15K)

Q= - 70317498.06KJ/hr
T2 = 298.15 K


ENERGY BALANCE AT CO2 ABSORPTION

OPERATING CONDITIONS CALCULATIONS
Mstream=29,908 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 29,908 Kg/hr)x 13.927 KJ/Kg K

T1stream = 298.15 K
 (388.15K – 298.15K)

Q= 46896802.62 KJ/hr
T2 = 388.15 K


ENERGY BALANCE PREHEATING FURNACE INPUTS

OPERATING CONDITIONS CALCULATIONS
Mtailgas=2,610kg/hr Q1 = mtailgasCp tailgas(t2-t1)
Mair=60,957kg/hr Q2 = mairCair(t2-t1)
MNG=2,199kg/hr Q3 = mNGCNG(t2-t1)

Cp tail gas = 3.41 KJ/Kg K Q1 =( 2,610 Kg/hr) x3.41 KJ/Kg K

Cp air = 1.0 KJ/Kg K (773.15K – 298.15K) =4233974.82 KJ/hr
Cp NG = 2.365 KJ/Kg K Q2 =( 60,957 Kg/hr)x 1.0 KJ/Kg K

T1tailgas = 298.15 K
 (608.15K –298.15K) = 18896670 KJ/hr

Q3 =( 2,199 Kg/hr)x 2.365KJ/Kg K
T1air = 298.15 K

(773.15K –323.15K) = 2340285 KJ/hr

T1NG = 323.15 K
 Qtotal= Q1 + Q2 + Q3

Qtotal = 25470929.82KJ/hr
T2tailgas = 298.15 K
T2air = 608.15 K

T2NG = 773.15 K
 
 


ENERGY BALANCE AT FURNACE

OPERATING CONDITIONS CALCULATIONS
Mtailgas=2,610kg/hr Q= 132046176.4 KJ/hr
Mair=60,957kg/hr
MNG=2,199kg/hr

Tcombustion = 1273.15 K


ENERGY BALANCE AT COOLING THE FLUE GAS

OPERATING CONDITIONS CALCULATIONS
Mstream=29,908 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 65,766 Kg/hr)x 1.2869 KJ/Kg K

T1stream = 1273.15 K
 (1273.15.15K – 373.15K)

Q= 76172671.92 KJ/hr
T2 = 373.15 K

 Figure 3.10 Plant Layout for Design Option 1

DESIGN OPTION 2

A. Process Flow Diagram

Figure 3.10 Process Flow Diagram for Design Option 2

In order to further reduce the carbon emissions, the natural gas feed to

the furnace is replaced by produced hydrogen. Thus, the CO2 emissions per

produced hydrogen is further reduced by 60 percent. The carbon captured

accounts for 90 percent of the produced CO2, making SMR+ an interesting

carbon-lean solution.

As mentioned earlier, the concept of SMR+ is to replace the furnace

NG feed with produced hydrogen in order to reduce CO2 emissions. Thus,

the optimal SMR conditions are used in SMR+ as well. It is possible to

achieve higher energy efficiencies with SMR+, but that would result in

increased emissions and the concept would be pointless.

 B. Design Specification of each Equipment

Gas Heated Reformer (GHR) (Pre-Reformer)

The principle of the pre-reformer is to convert heavier hydrocarbons to

methane prior to the main reforming reactor. The pre-reforming reactor usually

contains a nickel catalyst bed and is basically a low temperature adiabatic

steam reforming unit. The temperature is normally in the range from 350– 550

°C. There are several benefits to pre-reforming, but most important is the

enabling of process optimization of methane reforming. This results in lower

feed consumption and hence a smaller reactor size. A sophisticated pre-

reformer is the gas heated reformer (GHR), also referred to as a convective

reformer. What differentiate it from the traditional steam methane reforming

(SMR) are the temperature range and the method of heat transfer. Where the

SMR reactors are heated by external combustion of natural gas in a system of

reactor tubes and burners, the GHR works as a heat exchanger, absorbing

energy by convective heat transfer with another gas.

Figure 3.2 Gas Heated reformer

Table 3.1 Design Specification of GHR

 Type Gibbs Reactor

Operating Temperature 700ºC

Operating Pressure 25 bar

Efficiency 100%

S/C Ratio: 0.25 Mole-H2O/Mole-C

Steam Methane Reformer (SMR)

A widely used method to produce hydrogen from natural gas (NG) is by

the use of steam methane reforming (SMR). The reaction is endothermic and

converts steam and methane into H2 and CO. The reaction is a catalytic

reaction supported by nickel- based catalysts. Nickel-based catalysts are cost

efficient and have sufficient activity. When more activity is needed, a more

noble catalyst can be used. Nobel catalysts provide higher activities and faster

reactions but are very expensive. The reactor consists of several reactor

tubes filled with reforming catalysts and kept in a furnace that provides the

necessary heat for the reaction to happen.

 Figure 3.3 Steam Methane Reformer

Table 3.2 Design Specification of GHR

Type Gibbs Reactor

Operating Temperature 950ºC

Operating Pressure 24 bar

Efficiency 100%

S/C Ratio: 3 Mole-H2O/Mole-C

Water Gas Shift (WGS)

After the reforming process, the syngas undergoes a water gas shift,

where the CO is reacted with water, over a catalyst, to produce additional

hydrogen as well as CO2. The process is slightly exothermic and is

controlled by equilibrium.

The equilibrium constant is a function of temperature, meaning the

reaction is favourable at low temperatures. On the other hand, the reaction

rates diminish at low temperatures. Because of this the process is usually

done in two steps, a high temperature shift (HTS) and a low temperature shift

(LTS). In the HTS, the mole fraction of CO is reduced from typically 10-13% to

2-3%, with an inlet temperature between 350-550°C. In the LTS, the CO

concentration is further reduced to 0.2-0.4% at temperatures of 190-250. The

lower limit is set due to the water dew point of the gas. Condensation

could damage the catalysts in the WGS chamber.

Table 3.3 Design Specification of WGS

 Type Equilibrium Reactor

High Temperature WGS

Operating Temperature 320

Operating Pressure 23 bar

Efficiency 100%

Low Temperature WGS

Operating Temperature 190

Operating Pressure 22.5 bar

Efficiency 100%

CO2 ABSORPER

After the WGS, hydrogen and CO2 are produced and have to be

separated and purified. Concepts for CO2 separation are presented in this

section. CO2 absorption is a commercially mature technology and is

commonly used to remove CO2 from NG [8]. The liquid solvent can be

divided into two groups, chemical and physical solvents. Chemical

solvents react with CO2 and require heat to activate the reaction. Chemical

solvents offer fast reaction rates which results in smaller plant size. Physical

solvents do not react but dissolve CO2 and require less heat than chemical

solvents. Chemical solvents have relatively high capacity at low pressure

compared to physical solvents and are therefore preferred at low CO2 partial

pressures. The chemical solvents will begin to saturate with increasing CO2

partial pressures and physical solvents are therefore preferred at high CO2
partial pressures. The CO2 recovery and purity will depend on the syngas

composition and various solvents may be optimal for CO2 separation. Studies

have shown that MDEA can capture as much as 95% of the CO2 with a purity

of above 99%.

Figure 3.4 CO2 Absorper

Table 3.4 Design Specification of CO2 Absorper

Type Component Splitter

Operating Temperature 25ºC

Operating Pressure 22 bar

CO2 Purity 99.999%

CO2 Recovery Rate 95% mole-basis

Pressure Swing Absorber (PSA)

Over 85% of current global hydrogen production units use PSA

technology for hydrogen purification and is the most used hydrogen

purification technology today. When PSA is used to purify hydrogen, the

syngas is sent through an adsorption column at high pressures letting through

hydrogen while adsorbing CO2 and other impurities. The pressure inside the

column is then lowered near atmospheric pressure desorbing impurities

from the adsorption material. There are usually several columns

operating simultaneous making the hydrogen purification process semi-

continuous. Columns with multiple adsorbents are normally used when

purifying hydrogen. Typical adsorbents are silica gel, alumina, activated

carbon and zeolite. Operating temperature in PSA units is typically ambient

temperature receiving the feed syngas at a pressure between 20-60 bar.

Hydrogen is purified with a pressure drop between 1-2 bar. The off-gas exits

the unit with pressures between 1-2 bar. The PSA

unit produces hydrogen with a purity up to 99.9999% and with a hydrogen

recovery between 60-95%.

Figure 3.5 Pressure Swing Absorber

Table 3.5 Design Specification of Pressure Swing Absorber

Type Component Splitter

Operating Temperature 25ºC

Operating Pressure 20 bar

Pressure Tail Gas 2 bar

 H2 Purity 99.999%

H2 Recovery Rate 90% mole-basis

COMPRESSOR

Air is drawn in and compressed when passing through rows of rotating

blades and stationary vanes. At the end of the compressor, before reaching

the combustion chamber, the air is compressed to a certain pressure and

temperature by compression.

The H-Series serves the requirements of many industries, from air

separation, chemical, petrochemical, process air etc. It is widely known and

accepted as an efficient, dependable and cost-effective compressor solution

that comes as a standard package but also fully engineered to API

specifications.

Figure 3.6 Compressor

Table 3.6 Design Specification of Compressor

Type Centrifugal

Inlet pressure 1 bar

Outlet Pressure 1.2 bar

 Inlet Temperature 25ºC

WATER PUMP

The pumps are installed for the circulation of water for steam

generation.

Figure 3.7 Water Pump

Table 3.7 Design Specification of Water Pump

Type Water Pump

Inlet Pressure 1 bar

Outlet Pressure 25 bar

Capacity 20000 kg/h

Fluid temperature 25ºC

Motor 60 Hz
GAS EXPANDER

It is a centrifugal or axial-flow turbine, through which a high-

pressure gas is expanded to produce work that is often used to drive

a compressor or generator. Natural Gas is expanded to decrease it feed

pressure going to the pre-reformer.

Figure 3.8 Gas Expander

Table 3.8 Design Specification of Expander

Type Gas Expander

Inlet Pressure 50 bar

Outlet Pressure 25 bar

Capacity 15000 m3/h

Fluid temperature 50ºC

FURNACE
 The furnace is as mentioned supplying the SMR with the

required heat by burning NG and the tail gas with air. The required air is

heated and supplied at a temperature of 335°C and a pressure of 1.2 bar

while the NG and tail gas is heated to a temperature of 500°C before entering

the furnace. Post combustion, the flue gas leaves the furnace at a

temperature of 1000°C and at atmospheric pressure. The flue gas is cooled

down to 100°C supplying heat to the reforming system.

Figure 3.9 Furnace

Table 3.9 Furnace

Type Gibbs Reactor

Operating Pressure 20 bar

Operating Temperature 1000ºC

C. Mass Balance and Energy Balance Computations

Table 3.10 Mass Balance Calculations for Design Option 1

MASS BALANCE CALCULATIONS

Equipment Diagram Efficiency Computation
 S + NG = M1
Steam
Steam= 3,498 kg/hr
GHR M1 100%
NG NG= 12,719 kg/hr
M1= 16,217 kg/hr

M1 + Steam = M2
M1 M1=16,217 kg/hr
SMR M2 100% Steam= 34,444 kg/hr
Steam M2=50,661 kg/hr

M2 = M3 + H20
M2=50,661 kg/hr
M2 M3
WGS 100% M3=37,316 kg/hr
H20= 13,345 kg/hr
H20

M3 M4 M3 + CO2 = M4
CO2 M3=37,316 kg/hr
100%
Absorber CO2=30,115 kg/hr
CO2 M4= 7,201 kg/hr

M4 = H2 + M5
M4 M5 M4=7,201kg/hr
PSA 100% H2=3,848 kg/hr
M5= 3,353 kg/hr
H2

M5 + A + NG = FG + W
M5 M5= 3,353kg/hr
Air
Flue Gas Air=71,231kg/hr
H2
Furnace 100% H2=1,094 kg/hr
Waste
Flue Gas= 75678 kg/hr
Waste = 0 kg/hr
 Table 3.11 Energy Balance Calculations for Design Option 2

ENERGY BALANCE PREHEATING WATER TO GHR AND SMR

OPERATING CONDITIONS CALCULATIONS
Mwater=2,722kg/hr &26,818 kg/hr Q = mwaterCp water(t2-t1)
Cp water = 4.184 KJ/Kg K Q =( 2,722 + 26,818 Kg/hr )x 4.19 KJ/Kg K

T1 = 298.15 K
 (623.15K – 298.15K)

Q = 40,226,095 KJ/hr
T2 = 623.15 K


1ST WATER PUMP POWER OUTPUT GOING TO GHR

OPERATING CONDITIONS CALCULATIONS
Mwater=2,722kg/hr Q = MD deltaP
Dwater = 1 kg/m3 Q =2,722 kg/hr x1 kg/m3 x (23.287x 100)KPa
Pump effciency = 100 % Q = 6338721.4 KJ/hr
DeltaP= 23.897 bar
2nd WATER PUMP POWER OUTPUT GOING TO GHR
OPERATING CONDITIONS CALCULATIONS
Mwater=26,818 kg/hr Q = MD deltaP
Dwater = 1 kg/m3 Q =26,818 kg/hr x1 kg/m3 x (23.287x 100)KPa
Pump effciency = 100 % Q = 43442319.94 KJ/hr
DeltaP= 23.897 bar
ENERGY BALANCE PREHEATING STREAM TO GHR
OPERATING CONDITIONS CALCULATIONS
Mwater=2,722kg/hr Q1 = mwaterCp water(t2-t1)
MNg=9,903kg/hr Q2 = mNGCp NG(t2-t1)
Cp water = 4.184 KJ/Kg K Q1 =( 2,722 Kg/hr)x 2.489 KJ/Kg K
Cp NG = 2.365 KJ/Kg K (673.15K – 623.15K) =338752.9 KJ/hr

T1w = 623.15 K
 Q2 =( 9,903 Kg/hr)x 2.365KJ/Kg K

(673.15K –323.15K) = 8197208.25
T1NG = 323.15 K

Qtotal= Q1 + Q2

T2 = 673.15 K
 Qtotal = 8535961.15 KJ/hr

ENERGY BALANCE PREHEATING STREAM TO SMR

OPERATING CONDITIONS
Mwater=26,818kg/hr
Mstream=12,625kg/hr
Cp water = 4.184 KJ/Kg K
Cp stream = 2.365 KJ/Kg K
CALCULATIONS
Q1 = mwaterCp water(t2-t1)
Q2 = mstreamCstream(t2-t1)
Q1 =( 26,818 Kg/hr)x 2.489 KJ/Kg K
(973.15K – 623.15K) =23362730.51 KJ/hr

T1w = 623.15 K
 Q2 =( 9,903 Kg/hr)x 2.365KJ/Kg K

(973.15K –973.15K) = 0 KJ/hr
T1stream = 973.15 K

Qtotal= Q1 + Q2

T2 = 973.15 K
 Qtotal = 23362730.51 KJ/hr

ENERGY BALANCE AT GHR

OPERATING CONDITIONS CALCULATIONS
Mstream=12,625kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 6.354 KJ/Kg K Q =( 12,625 Kg/hr)x 6.354 KJ/Kg K

T1stream = 623.15 K
 (923.15K – 623.15K)

Q= 24067165.74 KJ/hr
T2 = 923.15 K


ENERGY BALANCE AT SMR

OPERATING CONDITIONS CALCULATIONS
Mstream=39,443 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 39443 Kg/hr)x 13.391 KJ/Kg K

T1stream = 923.15 K
 (1223.15K – 923.15K)

Q= 132046176.4KJ/hr
T2 = 1223.15 K


ENERGY BALANCE COOLING OF SMR PRODUCT

OPERATING CONDITIONS CALCULATIONS
Mstream=39,443 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 39443 Kg/hr)x 2.896 KJ/Kg K

T1stream = 1223.15 K
 (593.15K – 1223.15K)

Q= - 71961379.68KJ/hr
T2 = 593.15 K


ENERGY BALANCE AT WATER GAS SHIFTER

OPERATING CONDITIONS CALCULATIONS
Mstream=39,443 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 39443 Kg/hr)x 6.043 KJ/Kg K

T1stream = 593.15 K
 (298.15K – 593.15K)

Q= - 70317498.06KJ/hr
T2 = 298.15 K


ENERGY BALANCE AT CO2 ABSORPTION

OPERATING CONDITIONS CALCULATIONS
Mstream=29,908 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 29,908 Kg/hr)x 13.927 KJ/Kg K

T1stream = 298.15 K
 (388.15K – 298.15K)

Q= 46896802.62 KJ/hr
T2 = 388.15 K


ENERGY BALANCE PREHEATING FURNACE INPUTS

OPERATING CONDITIONS CALCULATIONS
Mtailgas=2,610kg/hr Q1 = mtailgasCp tailgas(t2-t1)
Mair=60,957kg/hr Q2 = mairCair(t2-t1)
MNG=2,199kg/hr Q3 = mNGCNG(t2-t1)

Cp tail gas = 3.41 KJ/Kg K Q1 =( 2,610 Kg/hr) x3.41 KJ/Kg K

Cp air = 1.0 KJ/Kg K (773.15K – 298.15K) =4233974.82 KJ/hr
Cp NG = 2.365 KJ/Kg K Q2 =( 60,957 Kg/hr)x 1.0 KJ/Kg K

T1tailgas = 298.15 K
 (608.15K –298.15K) = 18896670 KJ/hr

Q3 =( 2,199 Kg/hr)x 2.365KJ/Kg K
T1air = 298.15 K

(773.15K –323.15K) = 2340285 KJ/hr

T1NG = 323.15 K
 Qtotal= Q1 + Q2 + Q3

Qtotal = 25470929.82KJ/hr
T2tailgas = 298.15 K
T2air = 608.15 K

T2NG = 773.15 K
 
 


ENERGY BALANCE AT FURNACE

OPERATING CONDITIONS CALCULATIONS
Mtailgas=2,610kg/hr Q= 132046176.4 KJ/hr
Mair=60,957kg/hr
MNG=2,199kg/hr

Tcombustion = 1273.15 K


ENERGY BALANCE AT COOLING THE FLUE GAS

OPERATING CONDITIONS CALCULATIONS
Mstream=29,908 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 65,766 Kg/hr)x 1.2869 KJ/Kg K

T1stream = 1273.15 K
 (1273.15.15K – 373.15K)

Q= 76172671.92 KJ/hr
T2 = 373.15 K

Figure 3.10 Plant Layout for Design Option 2
DESIGN OPTION 3

A. Process Flow Diagram

Figure 3.X Process Flow Diagram for Design Option 3

ATR is a combination of non-catalytic POX and SMR. NG is partially

oxidised in a combustion zone, while steam is injected in a SMR zone. Hence,

both the POX and the SMR reactions are active simultaneously. This concept

also need pure oxygen input as well as a catalyst bed in the steam reforming

section of the reactor. The core benefits of this system is that the heat

generated by the POX reaction is consumed by the endothermic SMR

reaction.

B. Design Specification of each Equipment

Gas Heated Reformer (GHR) (Pre-Reformer)

The principle of the pre-reformer is to convert heavier hydrocarbons to

methane prior to the main reforming reactor. The pre-reforming reactor usually

contains a nickel catalyst bed and is basically a low temperature adiabatic

steam reforming unit. The temperature is normally in the range from 350– 550
°C. There are several benefits to pre-reforming, but most important is the

enabling of process optimization of methane reforming. This results in lower

feed consumption and hence a smaller reactor size. A sophisticated pre-

reformer is the gas heated reformer (GHR), also referred to as a convective

reformer. What differentiate it from the traditional steam methane reforming

(SMR) are the temperature range and the method of heat transfer. Where the

SMR reactors are heated by external combustion of natural gas in a system of

reactor tubes and burners, the GHR works as a heat exchanger, absorbing

energy by convective heat transfer with another gas.

Figure 3.2 Gas Heated reformer

Table 3.1 Design Specification of GHR

Type Gibbs Reactor

Operating Temperature 700ºC

Operating Pressure 25 bar

Efficiency 100%

S/C Ratio: 0.25 Mole-H2O/Mole-C

AUTOTHERMAL REFORMER (ATR)

A widely used method to produce hydrogen from natural gas (NG) is by

The ATR reactors usually operate at temperatures between 900-1150 °C, with

pressure levels in the range 1 to 80 bar existing today. Figure below shows

the principles of the ATR reactor, with the different inputs and reaction zones.

No specific range was found for the typical energy efficiency of ATR, but it

should operate with lower energy efficiency than SMR.

Figure 3.3 ATR Reactor

Table 3.2 Design Specification of ATR Reactor

Type Gibbs Reactor

Operating Temperature 1020ºC

Operating Pressure 24 bar

Efficiency 100%

S/C Ratio: 1.5 Mole-H2O/Mole-C

Water Gas Shift (WGS)

 After the reforming process, the syngas undergoes a water gas shift,

where the CO is reacted with water, over a catalyst, to produce additional

hydrogen as well as CO2. The process is slightly exothermic and is

controlled by equilibrium.

The equilibrium constant is a function of temperature, meaning the

reaction is favourable at low temperatures. On the other hand, the reaction

rates diminish at low temperatures. Because of this the process is usually

done in two steps, a high temperature shift (HTS) and a low temperature shift

(LTS). In the HTS, the mole fraction of CO is reduced from typically 10-13% to

2-3%, with an inlet temperature between 350-550°C. In the LTS, the CO

concentration is further reduced to 0.2-0.4% at temperatures of 190-250. The

lower limit is set due to the water dew point of the gas. Condensation

could damage the catalysts in the WGS chamber.

Table 3.3 Design Specification of WGS

Type Equilibrium Reactor

High Temperature WGS

Operating Temperature 320

Operating Pressure 23 bar

Efficiency 100%

Low Temperature WGS

Operating Temperature 190

Operating Pressure 22.5 bar

Efficiency 100%
CO2 ABSORPER

After the WGS, hydrogen and CO2 are produced and have to be

separated and purified. Concepts for CO2 separation are presented in this

section. CO2 absorption is a commercially mature technology and is

commonly used to remove CO2 from NG [8]. The liquid solvent can be

divided into two groups, chemical and physical solvents. Chemical

solvents react with CO2 and require heat to activate the reaction. Chemical

solvents offer fast reaction rates which results in smaller plant size. Physical

solvents do not react but dissolve CO2 and require less heat than chemical

solvents. Chemical solvents have relatively high capacity at low pressure

compared to physical solvents and are therefore preferred at low CO2 partial

pressures. The chemical solvents will begin to saturate with increasing CO2

partial pressures and physical solvents are therefore preferred at high CO2

partial pressures. The CO2 recovery and purity will depend on the syngas

composition and various solvents may be optimal for CO2 separation. Studies

have shown that MDEA can capture as much as 95% of the CO2 with a purity

of above 99%.

Figure 3.4 CO2 Absorper

Table 3.4 Design Specification of CO2 Absorper

 Type Component Splitter

Operating Temperature 25ºC

Operating Pressure 22 bar

CO2 Purity 99.999%

CO2 Recovery Rate 95% mole-basis

2 Pressure Swing Absorber (PSA)

Over 85% of current global hydrogen production units use PSA

technology for hydrogen purification and is the most used hydrogen

purification technology today. When PSA is used to purify hydrogen, the

syngas is sent through an adsorption column at high pressures letting through

hydrogen while adsorbing CO2 and other impurities. The pressure inside the

column is then lowered near atmospheric pressure desorbing impurities

from the adsorption material. There are usually several columns

operating simultaneous making the hydrogen purification process semi-

continuous. Columns with multiple adsorbents are normally used when

purifying hydrogen. Typical adsorbents are silica gel, alumina, activated

carbon and zeolite. Operating temperature in PSA units is typically ambient

temperature receiving the feed syngas at a pressure between 20-60 bar.

Hydrogen is purified with a pressure drop between 1-2 bar. The off-gas exits

the unit with pressures between 1-2 bar. The PSA

unit produces hydrogen with a purity up to 99.9999% and with a hydrogen

recovery between 60-95%.

 Figure 3.5 2 Pressure Swing Absorber

Table 3.5 Design Specification of 2 Pressure Swing Absorber

Type Component Splitter

Operating Temperature 25ºC

Operating Pressure 20 bar

Pressure Tail Gas 2 bar

H2 Purity 99.999%

H2 Recovery Rate 90% mole-basis

COMPRESSOR

Air is drawn in and compressed when passing through rows of rotating

blades and stationary vanes. At the end of the compressor, before reaching

the combustion chamber, the air is compressed to a certain pressure and

temperature by compression.
 The H-Series serves the requirements of many industries, from air

separation, chemical, petrochemical, process air etc. It is widely known and

accepted as an efficient, dependable and cost-effective compressor solution

that comes as a standard package but also fully engineered to API

specifications.

Figure 3.6 Compressor

Table 3.6 Design Specification of Compressor

Type Centrifugal

Inlet pressure 1 bar

Outlet Pressure 1.2 bar

Inlet Temperature 25ºC

WATER PUMP

The pumps are installed for the circulation of water for steam

generation.
 Figure 3.7 Water Pump

Table 3.7 Design Specification of Water Pump

Type Water Pump

Inlet Pressure 1 bar

Outlet Pressure 25 bar

Capacity 20000 kg/h

Fluid temperature 25ºC

Motor 60 Hz
GAS EXPANDER

It is a centrifugal or axial-flow turbine, through which a high-

pressure gas is expanded to produce work that is often used to drive

a compressor or generator. Natural Gas is expanded to decrease it feed

pressure going to the pre-reformer.

Figure 3.8 Gas Expander

Table 3.8 Design Specification of Expander

Type Gas Expander

Inlet Pressure 50 bar

Outlet Pressure 25 bar

Capacity 15000 m3/h

Fluid temperature 50ºC

FURNACE

The furnace is as mentioned supplying the SMR with the required

heat by burning NG and the tail gas with air. The required air is heated and

supplied at a temperature of 335°C and a pressure of 1.2 bar while the NG and

tail gas is heated to a temperature of 500°C before entering the furnace. Post

combustion, the flue gas leaves the furnace at a temperature of 1000°C and at

atmospheric pressure. The flue gas is cooled down to 100°C supplying heat to

the reforming system.

Figure 3.9 Furnace

Table 3.9 Furnace

Type Gibbs Reactor

Operating Pressure 20 bar

Operating Temperature 1000ºC

C. Mass Balance and Energy Balance Computations

Table 3.10 Mass Balance Calculations for Design Option 1

 MASS BALANCE CALCULATIONS
Equipment Diagram Efficiency Computation

S + NG = M1
Steam
Steam= 3,241 kg/hr
GHR M1 100%
NG NG= 11,787 kg/hr
M1= 15,028 kg/hr

M1 + Steam + O2 = M2
M1=15,028 kg/hr
M1 O2=11,822 kg/hr
ATR O2 M2 100%
Steam Steam= 15,449 kg/hr
M2= 42,299 kg/hr

M2 + Steam = M3 + H20
Steam
Steam=1,159 kg/hr
M2 M3 M2=42,299 kg/hr
WGS 100%
M3=37,768 kg/hr
H20 H20= 5,690 kg/hr

M3 M4 M3 = M4 + CO2
CO2 M3=37,768 kg/hr
100%
Absorber CO2=31,816 kg/hr
CO2 M4=5,952 kg/hr

M4 = H2 + M5
M4 M5 M4=5,952 kg/hr
PSA1 100% H2=3,498 kg/hr
M5= 2,454 kg/hr
H2
 M5 = H2 + M6
M5 M6 M5=2,454 kg/hr
PSA2 100% H2=350 kg/hr
M6= 2,104 kg/hr
H2

M6 + A = FG + W
M6
M6= 2,104kg/hr
Flue Gas
Air Air=4830/hr
Furnace 100%
Flue Gas= 6934 kg/hr
Waste Waste = 0 kg/hr

Table 3.11 Energy Balance Calculations for Design Option 3

ENERGY BALANCE PREHEATING WATER TO GHR AND SMR

OPERATING CONDITIONS CALCULATIONS
Mwater=2,722kg/hr &26,818 kg/hr Q = mwaterCp water(t2-t1)
Cp water = 4.184 KJ/Kg K Q =( 2,722 + 26,818 Kg/hr )x 4.19 KJ/Kg K

T1 = 298.15 K
 (623.15K – 298.15K)

Q = 40,226,095 KJ/hr
T2 = 623.15 K


1ST WATER PUMP POWER OUTPUT GOING TO GHR

OPERATING CONDITIONS CALCULATIONS
Mwater=2,722kg/hr Q = MD deltaP
Dwater = 1 kg/m3 Q =2,722 kg/hr x1 kg/m3 x (23.287x 100)KPa
Pump effciency = 100 % Q = 6338721.4 KJ/hr
DeltaP= 23.897 bar
2nd WATER PUMP POWER OUTPUT GOING TO GHR
OPERATING CONDITIONS CALCULATIONS
Mwater=26,818 kg/hr Q = MD deltaP
Dwater = 1 kg/m3 Q =26,818 kg/hr x1 kg/m3 x (23.287x 100)KPa
Pump effciency = 100 % Q = 43442319.94 KJ/hr
DeltaP= 23.897 bar
ENERGY BALANCE PREHEATING STREAM TO GHR
OPERATING CONDITIONS CALCULATIONS
Mwater=2,722kg/hr Q1 = mwaterCp water(t2-t1)
MNg=9,903kg/hr Q2 = mNGCp NG(t2-t1)
Cp water = 4.184 KJ/Kg K Q1 =( 2,722 Kg/hr)x 2.489 KJ/Kg K
Cp NG = 2.365 KJ/Kg K (673.15K – 623.15K) =338752.9 KJ/hr

T1w = 623.15 K
 Q2 =( 9,903 Kg/hr)x 2.365KJ/Kg K

(673.15K –323.15K) = 8197208.25
T1NG = 323.15 K

Qtotal= Q1 + Q2

T2 = 673.15 K
 Qtotal = 8535961.15 KJ/hr

ENERGY BALANCE PREHEATING STREAM TO SMR

OPERATING CONDITIONS
Mwater=26,818kg/hr
Mstream=12,625kg/hr
Cp water = 4.184 KJ/Kg K
Cp stream = 2.365 KJ/Kg K
CALCULATIONS
Q1 = mwaterCp water(t2-t1)
Q2 = mstreamCstream(t2-t1)
Q1 =( 26,818 Kg/hr)x 2.489 KJ/Kg K
(973.15K – 623.15K) =23362730.51 KJ/hr

T1w = 623.15 K
 Q2 =( 9,903 Kg/hr)x 2.365KJ/Kg K

(973.15K –973.15K) = 0 KJ/hr
T1stream = 973.15 K

Qtotal= Q1 + Q2

T2 = 973.15 K
 Qtotal = 23362730.51 KJ/hr

ENERGY BALANCE AT GHR

OPERATING CONDITIONS CALCULATIONS
Mstream=12,625kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 6.354 KJ/Kg K Q =( 12,625 Kg/hr)x 6.354 KJ/Kg K

T1stream = 623.15 K
 (923.15K – 623.15K)

Q= 24067165.74 KJ/hr
T2 = 923.15 K


ENERGY BALANCE AT SMR

OPERATING CONDITIONS CALCULATIONS
Mstream=39,443 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 39443 Kg/hr)x 13.391 KJ/Kg K

T1stream = 923.15 K
 (1223.15K – 923.15K)

Q= 132046176.4KJ/hr
T2 = 1223.15 K


ENERGY BALANCE COOLING OF SMR PRODUCT

OPERATING CONDITIONS CALCULATIONS
Mstream=39,443 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 39443 Kg/hr)x 2.896 KJ/Kg K

T1stream = 1223.15 K
 (593.15K – 1223.15K)

Q= - 71961379.68KJ/hr
T2 = 593.15 K


ENERGY BALANCE AT WATER GAS SHIFTER

OPERATING CONDITIONS CALCULATIONS
Mstream=39,443 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 39443 Kg/hr)x 6.043 KJ/Kg K

T1stream = 593.15 K
 (298.15K – 593.15K)

Q= - 70317498.06KJ/hr
T2 = 298.15 K


ENERGY BALANCE AT CO2 ABSORPTION

OPERATING CONDITIONS CALCULATIONS
Mstream=29,908 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 29,908 Kg/hr)x 13.927 KJ/Kg K

T1stream = 298.15 K
 (388.15K – 298.15K)

Q= 46896802.62 KJ/hr
T2 = 388.15 K


ENERGY BALANCE PREHEATING FURNACE INPUTS

OPERATING CONDITIONS CALCULATIONS
Mtailgas=2,610kg/hr Q1 = mtailgasCp tailgas(t2-t1)
Mair=60,957kg/hr Q2 = mairCair(t2-t1)
MNG=2,199kg/hr Q3 = mNGCNG(t2-t1)

Cp tail gas = 3.41 KJ/Kg K Q1 =( 2,610 Kg/hr) x3.41 KJ/Kg K

Cp air = 1.0 KJ/Kg K (773.15K – 298.15K) =4233974.82 KJ/hr
Cp NG = 2.365 KJ/Kg K Q2 =( 60,957 Kg/hr)x 1.0 KJ/Kg K

T1tailgas = 298.15 K
 (608.15K –298.15K) = 18896670 KJ/hr

Q3 =( 2,199 Kg/hr)x 2.365KJ/Kg K
T1air = 298.15 K

(773.15K –323.15K) = 2340285 KJ/hr

T1NG = 323.15 K
 Qtotal= Q1 + Q2 + Q3

Qtotal = 25470929.82KJ/hr
T2tailgas = 298.15 K
T2air = 608.15 K

T2NG = 773.15 K
 
 


ENERGY BALANCE AT FURNACE

OPERATING CONDITIONS CALCULATIONS
Mtailgas=2,610kg/hr Q= 132046176.4 KJ/hr
Mair=60,957kg/hr
MNG=2,199kg/hr

Tcombustion = 1273.15 K


ENERGY BALANCE AT COOLING THE FLUE GAS

OPERATING CONDITIONS CALCULATIONS
Mstream=29,908 kg/hr Q = mstreamCstream(t2-t1)
Cp stream = 13.391 KJ/Kg K Q =( 65,766 Kg/hr)x 1.2869 KJ/Kg K

T1stream = 1273.15 K
 (1273.15.15K – 373.15K)

Q= 76172671.92 KJ/hr
T2 = 373.15 K

Figure 3.10 Plant Layout for Design Option 1