MATERIAL BALANCE

A. COAL GASIFICATION

Mass Flow
(MT/day)
Coal

Wet
Coal
1280.00

H2O

0.00

N2
O2
S
H2
C
ASH

Water

P-1

Oxygen

P-2

Slag

Syngas

0.00

0.00

0.00

0.00

0.00

683.40

0.00

34.56

0.00

34.56

0.00
0.00
0.00
0.00
0.00
0.00

0.00
549.0
0
0.00
0.00
0.00
0.00
0.00
0.00

17.02
149.38
14.08
56.06
765.70
143.36

0.00
900.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
143.36

24.38
0.00
0.00
96.42
0.00
0.00

CO

0.00

0.00

0.00

0.00

0.00

2135.81

CO2
H2S

0.00
0.00

0.00
0.00

45.79
21.25

1280.00

0.00
0.00
1829.0
0

0.00
0.00

Total (MT/Day)

0.00
0.00
549.0
0

24.38
0.00
0.00
96.42
0.00
143.36
2135.8
1
45.79
21.25
2501.5
8

143.36

2358.22

900.00

Pressure (Mpa)
Temperature

0.101
25

0.101
25

4.17
25

0.101
25

5.17
1315

5.16
711

B. ACID GAS REMOVAL

CO + 2 H 2 CH3 OH
CO2 + H 2 CO + H 2 O
CO2 + 3H 2 CH 3OH + H2 O

(Eqn. 1)
(Eqn. 2)
(Eqn. 3)

5.16
711

Mass Flow
(MT/hr)

P1

P2

P3

P4

P5

P6

P7

P8

P9

H2O

1.44

1.44

0.15

0.15

0.15

N2

1.016

1.016

SO2
H2

0
4.018
88.99
2
1.908

0
0

0
0

0
0

0
0

0
0

0.37
0

CO2

0
4.018
88.99
2
1.908

0
0.55
4
0
0

0.886

0
0.60
4
0.75
4

0
0.60
4
1.12
4

98.26

0
0.60
4
0.75
4

98.26

0
0.88
6
0.88
6

0.886

0
0.88
6
0.88
6

H2S

0
0.88
6
0.88
6

0.55
4

0.21
4

6.27

6.27

6.27

2.41

2.41

2.41

2.41

2.41

2.41

2.41

467

39.8

46

26.8
5

1000

1000

350

350

300

300

CO

Total
(MT/Day)
Pressure
(Mpa)
Temperature

P10
0.21
4
0
0
0
0

C. WATER GAS SHIFT PROCESS

Mass F
low (M
T/hr)

P1

P2

P3

P4

P5

P6

P7

P8

P9

H2O
N2
H2
CO
CO2
Total
(MT/D
ay)
Pressur
e
(Mpa)
Temper
ature

1.44
1.016
4.018
89
1.908

1.44
1.016
4.018
89
1.908

1.44
1.016
4.018
72.72
1.908

0.000346 0.000346
1.014
1.014
5.124
4.924
76.406
76.406
21.7
21.7

0.166
1.014
6.956
48.16
66.082

0.166
1.014
6.956
48.16
66.082

0.166
0
0
0
0

0
1.014
48.16
66.0822
66.0822

97.38
2

97.38
2

97.38
2

104.044

104.044

122.37
8

122.37
8

0.166

122.212

6.27

5.17

5.17

5.17

5.17

5.17

5.17

5.17

5.17

46

38.15

371

354

200

184

150

150

150

D. METHANOL SYNTHESIS

PFR
1
IN

PFR
2
OU
T

IN

PFR
3
OU
T

IN

PFR
4
OU
T

IN

PFR
5
OUT

IN

OUT

Flow
(MT/day)
Trac
e
156.
2
1.4
Trac
e

2.2

101.
8
437.
8
16.6

33.4

10

CO

115.6

231.2

CO2

158.6

H2O

0.4

H2

16.8

CH4O

227

227

Temp (K)

663

1744

798

473.4

405.
4
945

217.4

Trac
e

596.6

576

17

25.4
Trac
e

26.6

462.
4
120
9.6
27

340.4

360

12.2

432.4

750

228.4

345.4

346.2

559.4

66.8

Trace

33.4

Trace

405.4

740

740

987.8

987.8

762

815

500

556

522

1063.
2
571

E. METHANOL REFINING

Distillatio
n1
Flow
(Ton/day
)
Methano

Distillati
on2

Distillati
on3

Distillati
on4

In

Distilla
te

In

Distill
ate

In

Distill
ate

In

Distill
ate

1063

1060.2

1060.2

1059.

1059.8

1059

1059

1058.

l
Ethanol
Water

15.2
558

3.868
Trace

3.868
Trace

8
0.708
Trace

0.708
Trace

0.156
Trace

0.156
Trace

4
0
Trace

ENERGY BALANCE
Gasifier
As coal, or any other carbonaceous feedstock enters a gasifier, its
temperature increases and
any moisture present in the material quickly escapes to the gas phase.
Pyrolysis (also known as devolatilization) occurs as the feedstock
temperature continues to increase. During pyrolysis, the feedstock
undergoes heat-induced decomposition, which results in the liberation of
volatile constituents to the gas phase. Volatile matter can include: H2,
CO2, CO, CH4, H2S, NH3, various short-chain hydrocarbons, and a small
amount of aromatic hydrocarbons and tars [5]. In general, the gas phase
has greater hydrogen, oxygen, and sulfur content than the original feed
material, while the remaining solid material (char) is a mixture of carbonrich organics and any minerals that were present in the feedstock.

According to the reactions net enthalpy of reaction at 298K is 319.1 kJ/mol

. The temperature inside the gasifier is 1310K.So the enthalpy of reaction
at 1310 K can be calculated by following :

H1310 =H298 + Mp Cp T
So

Mp Cp T=3162.539*10^6 KJ

Hrxn=8268.1392*10^6 KJ

Low grade coal used as fuel souce.

HHV=3700 Kcal/Kg
HHV=3700*4.186 =15466 KJ/Kg
Hrxn=m*HHV
m= 534.601 Ton/day
Mass of low grade coal

HEAT EXCHANGER (E4)

Mi Cpi T=MCpTc
(34.56*4.186+24.38*1.029+96.42*14.42+2134.81*1.043+0.671*45.79+
21.25*29.09) *1000*604 = M* 2.2*1000* (700-30)

M=1.818 Ton/hr
Cooling Fluid Used: DOWTHERM-A (Mass used=M)