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Module title: EAC_4_966

Course: BEng(Hons)Chemical and Process Engineering Year 1 (2134)

Student Name: Vivek Kanna Jayaprakash
Students Number: 3124865
Marker: Dr Fatemah Jahanzad


London South Bank University

Department of Urban Engineering
Faculty of Engineering, Science and the Built Environment
103 Borough Road, London, SE1 0AA

Description of the ammonium production process

HYSYS project - 2013-04-25
1. For the nitrogen feed
The feed flow of the nitrogen is = 1315(student no :3124865-3074024)X

= 1401.4kmol/hr
The formula for the reaction is
nitrogen + hydrogen

+ 3H2(g)



So the feed flow of hydrogen is thrice the value of the feed flow ofnitrogen
So 3 X 1401.4 = 4204 kmol/hr

Questions :
1 .Yes,There is a need for a HYSYS model to calculate the conditions and
compostions of all the process streams.

2. Mass balances can be calculated with the formula

Mass Balance= Total expected feed out total exact product out

The mass balance error % for each of the element can be calculated by dividing
the mass balance with the amount of feed in for each component
respectively.and thereby multiplying them with 100 to get the percentage

Mass balance % =

feed X 100
mass balance

Table 1 for the total feed in and the total product out

Example : To calculate the feed of nitrogen in table 1

The compositon of each of the component in mole fraction is multiplied with the
total molar flow for the input of nitrogen feed
For nitrogen
Mole fraction of nitrogen
Molar flow

= .988
= 1401.3

The feed in the in the nitrogen is therefore 1358.3

Accordingly all the values should be calculated and should be added up to get
the total feed in
The product counts i.e The ammonia out and purge out is also calculated
accordingly as shown in the table and added up

For table 2- The expected amount of product out is calculated

For the table 2

The first three rows are the same as in table 1 but the 4 row has the ammonia
received row which can be found in the reaction balance segment in the present
in the reactor
Now when the amount of ammonia received is added up with the total in
amount,the expected amount of product out is calculated
The total in in argon is 15.7 and the ammonia received is 0 therefore adding
them up gives the expected out value as 15.7

For table 3 The HYSYS calculated ammonia and purge out are added up to
comprise the total HYSYS calculated product out

For the table 3

The HYSYS calculated ammonia out is the molar flow of the ammonia product
found in the ammonia component
The HYSYS calculated purge out is the molar flow is the purge out found in the
purge component
For methane the HYSYS calculated ammonia out is 0.602 and the HYSYS
calculated purge out is 27.317 which when added gives 27.9195.This is hence
considered as the total HYSYS calculated product out

For table 4. The expected product out and the HYSYS calculated product out are
subtracted up to get the mass balance and the error percentage is found out
with the help of the formula given above.

For the table 4

The expected out can be subtracted from the total product out to get the mass
balances and the mass balances error % can be calculated bydividing it by the
feed in and multiplying it with 100 to get the percent.
For hydrogen = the expect product out form table 2 is 351.79 and the total
HYSYS calculated product out is 378.6682.By subtracting them the mass balance
is obtained which is equal to
26.882 and the error % is found out with the

Mass balance % =

feed X 100
mass balance

X 100
Mass balance % = 1385.3
= -0.0647 is identified as the mass balance error for hydrogen

3.Economic values

For the feed of the nitrogen and the hydrogen stream the mass total mass flow
of both these elements are taken respectively as the flow and is measured in
For the energies 1 and 4 the energy supplied should be used as the flow as they
are used in the feed stream and are measured in kW
For the energies 2 and 3 the power obtained should be used as the flow since
they are used in the recycle streams measured in KJ/hr
The mass flow is used as the flow stream in the case of purge and ammonia and
are measured in KJ/hr
The cost per unit given in the question is per tonne.So necessary calculations are
made such that the wright of the componts and its cost coincide.Thus the unit
cost for each of the component is typed in.Thus by The actual cost can be found
out by mu ltiplying both the flow and the unit cost

The income is calculated by adding the all the product streams togeather and
the expenses is obtained by adding all the feed streams togeather along with its
The profit is therefore Income (minus) the expenses is $ 2932


The total molar purge flow

The graph illustrates the increase in the level of purge as the decrease in the
flow ratio of the TEE-100 recycle stream.

2.The ammonia product purity

The Ammonia purity versus Purge ratio graph clearly states that when
the purity ratio increase along with the decrease in the purge.This again
proves there is a considerable decrease in profit with increase in the purge
ratio .So when the ratio of purge is neither high nor low,the profit achieved
is considerable and also the purity of ammonia is achieved.The graph
states a curvy upper line thereby when by keepin the purge ratio to be
moderate profit can be acheuived and the purge ratio is also achieved.

3.The recycle flow

The recycle flow graph indicates a decrease in the recycle flow with comprehend
decrease in the flow ratio of the purge
4. The recycle power

The recycle power graph is also similar to the recycle flow graph as the power
decreases with decrease in the purge


The profit decreases as the flow rate of the purge here as in tee-100 decrease.

HYSYS is a very impotant tool for every chemical engineer. Here in this
experiment The main descriptions of the production of ammonia is analysed.

+ 3H2(g)


Based on this equation two feed streams nitrogen and hydrogen are first
mixed,compressed,cooled splitted recycled with the help of its definite
equipments to produce ammonia and purge at a certain point during the
reaction. The final reading indicate a composition of .9994 Mole fraction of
ammonia composition has been achieved. And the active conversion % is 18.81
The profit is also calculated keeping the income and expenses in mind.
The amount of the production of ammonia increases with the increase in purge.
Thereby the decrease in purge causes less production of ammonia thereby
causing a low in the profit.