Material Balance

Capacity Selection
Bituminous Coal (Dry Basis)
Composition of Coal

Ultimate Analysis (wt%) Proximate Analysis (wt%)
C 81.57 Volatile
Matter
37.66
H 5.53 Fixed Carbon 53.13
O 7.61 Moisture 0.76
N 1.42 Ash 9.21
S 3.87

Considerations
Mass Balance Equation
Input output + Generation Consumption = Accumulation
Basis = second (s)
Capacity = 600 MJ/s
Low Heating Value (LHV) = 29923 KJ/Kg
Temperature of Gasifier = 1400 C
Pressure of Gasifier = 20 bar
Input
Coal Feed = 20.05 Kg/s
Steam / Coal mass = 0.05
Steam = 1 kg/s
Oxygen/ Coal mass = 0.79
Oxygen = 15.84 kg/s
Out put
1 Kg of Coal Produce 1.564 Nm3 of Syn Gas
Volume of Product Gas (Syn Gas) = 31.36 m3
Average Density of syn Gas = 0.45 kg/m3
Mass Flow rate of gas = 14.11 kg/s
Gasifier input
Components MW Coal Composition (wt
%)
Mass Flow rate
(kg/s)
C 12 81.57 16.35
H 1 5.53 1.10
O 16 7.61 1.52
N 14 1.42 0.28
S 32 3.87 0.77
Ash 9.21
20.05

Gasifier output
syn gas M.W Vol% Volume
(Nm3)
Density
(kg/m3)
mass flow
rate (kg/s)
Molar flow rate
(mole/s)
CO 28 0.5716 17.92 0.50 9.09 324.64
H2 2 0.2901 9.09 0.04 0.37 188.77
CO2 44 0.0211 0.66 1.59 1.05 23.96
COS 60 0.0007 0.02 0.60 0.01 0.22
H2S 34 0.0081 0.25 0.61 0.15 4.59
N2 14 0.0585 1.83 0.50 0.93 66.46
CH4 16 0.0135 0.42 0.58 0.24 15.36
H2O 18 0.0364 1.14 0.65 0.74 41.36
Total 1 31.36 665.39
Ashes (kg/s) 1.84674

H2S Absorber
Temperature = 300 C
Pressure = 20 bar
Solvent required to absorb H2S is Red Soil called Iron Oxide Fe2O3
Molecular Weight = 160 g/gmol

Absorption ratio
1.83 g of H2S is absorbed by 100 g of iron oxide
1 mole of H2S absorbed by 10.95 mole of Fe2O3
Acid Gas (H2S & CoS) = 4.8 mol/s
Solvent input
Iron oxide = 50.36 mole/s
Absorber input
Component M.W Mass Flow rate
(kg/s)
Mole Flow rate
(mole/s)
CO 28 9.09 324.65
H2 2 0.38 188.78
CO2 44 1.05 23.96
COS 60 0.01 0.22
H2S 34 0.16 4.60
N2 14 0.93 66.46
CH4 16 0.25 15.37
H2O 18 0.00 0.00
Total 624.04

Absorber Output
Component M.W Mass Flow rate
(kg/s)
Mole Flow rate
(mole/s)
CO 28 9.09 324.65
H2 2 0.38 188.78
CO2 44 1.05 23.96
COS 60 0.01 0.00
H2S 34 0.16 0.00
N2 14 0.93 66.46
CH4 16 0.25 15.37
H2O 18 0.00 0.00
Total 619.22

CO Shift Reactor
Temperature = 350 C
Pressure = 20 bar
Reaction Involve in the CO Shift reactor are
CO + H2O = CO2 + H2
1 mole of CO react with 1 mole of H2O to produce 1 mole of CO2 and 1 mole of H2
198 moles of CO react with 198 moles of H2O to produce 198 moles of CO2 and 198 moles of H2
So by material balance steam required is
Steam = 198 mole/s
CO2 produced = 198 mole/s
H2 produced = 198 mole/s
61 % of Cleaned Syn gas is enters into to CO Shift Reactor
Inlet of Reactor
Components MW Molar Flow rate (mole/s) 61% of SYN
Gas
CO 28 324.64 198.03
H2 2 188.77 115.15
CO2 44 23.96 14.61
COS 60 0 0
H2S 34 0 0
N2 14 66.46 40.54
CH4 16 15.36 9.37
H2O 18 0 0
Total 619.21 377.72


Outlet of Reactor
Components MW Outlet rate
(mole/s)
CO 28 0
H2 2 313.18
CO2 44 212.65
COS 60 0
H2S 34 0
N2 14 40.54
CH4 16 9.37
H2O 18 198
Total 773.79

Methanator
Temperature = 350 C
Required H2/CO ratio to carry methanator reactor is = 3
H2/CO in our process is = 3.05
Reaction carried out in the methanator are
CO + 3H2 = CH4 + H2O
1 mole of CO reacts with 3 mole of H2 to produce 1 mole of CH4 and 1 mole of H2O
Amount of CO left 0.0
Amount of H2 left 7.0
Amount of CH4
Produced
143.7
Amount of H2O
produced
324.6

Similarly for second reaction
CO2 + 4H2 = CH4 + 2H2O
Amount of H2 left 0
Amount of CH4
produced
145.4677
Amount of H2O
produced
328.1339

Input of reactor
Components 39% of SYN
Gas (mole/s)
SYN Gas as outlet of shift
reactor
total 100%
Gas (mole/s)
CO 126.61 0.00 126.61
H2 73.62 313.19 386.81
CO2 9.35 212.65 222.00
COS 0.00 0.00 0.00
H2S 0.00 0.00 0.00
N2 25.92 40.54 66.46
CH4 5.99 9.37 15.37
H2O 0.00 198.03 198.03
Total 773.79 1015.29

Outlet
Components Gas outlet
(mole/s)
CO 0
H2 0
CO2 222.00
COS 0.00
H2S 0.00
N2 66.46
CH4 145.46
H2O 328.13
Total 762.06