Design Project

Design Report
Air Separation Unit and

Ammonia Production Process
Nuttawat Suwattanapongtada 5630194021

Prakitr Srisuma 5630355721
Poom Sittisomwong 5630488521
1. Introduction
Ammonia is a compound consisting of nitrogen and hydrogen atoms. Nowadays,
ammonia is commonly and widely used in various aspects; for instance, fertilizer,
cleaner and refrigerant. Normally, ammonia is produced from hydrogen and nitrogen.
In this work, we perform a plant design for producing ammonia. Nitrogen is obtained
from the air separation unit, while hydrogen is bought. Therefore, raw materials of this
work are air and hydrogen. Our primary product is high-purity liquid ammonia.
Air is normally brought from an atmosphere without any cost. The properties
and compositions of typical air are shown in Table 1.1 and 1.2, respectively.
Table 1.1. Properties of air [1]
Properties Data
Melting point -215.0oC
Boiling point -194.3oC
Density 870 kg/m3
Molecular Weight 29 g/mol
Table 1.2. Typical compositions of air [1]
Components vol% Boiling point (oC)

N2 78.08 -195.8
O2 20.993081 -183.0
Ar 0.93 -185.9
CO2 0.05 -78.5
He 0.005 -268.9
Ne 0.0018 -246.1
Kr 0.00011 -153.2
Xe 0.000009 -108.0
2
In the air separation process, we obtain three products which are oxygen, argon
and nitrogen. Nitrogen is used as a raw material in an ammonia production process.
Oxygen and argon are sold as by-products. Specifications of all components are shown
in Table 1.3 to 1.5.
Table 1.3. Liquid nitrogen specifications [1, 2]
Properties Data
Chemical formula N2
Purity 99.995 mol%
Production Rate 673,000 tpy
Molecular weight 28 g/mol
Density 0.81 g/cm3
Phase Liquid
Table 1.4. Argon specifications [1, 3]
Properties Data
Chemical formula Ar
Purity 99.998 mol%
Density 1.4 g/cm3
Phase Liquid
3
Table 1.5. Oxygen specifications [1, 4]
Properties Data
Chemical formula O2
Purity 99.95 mol%
Density 1.43 g/cm3
Phase Liquid
In the ammonia production process, two raw materials are used as mentioned
above. The first one is nitrogen from the air separation unit. Another one is high-purity
hydrogen of which specifications are shown in Table 1.6.
Table 1.6. Specifications of hydrogen [5]
Properties Data
Chemical formula H2
Purity 99.999 mol% hydrogen
from existing hydrogen
production plant
Density 0.07 g/cm3
4
A primary product from the ammonia production process is ammonia. Its
properties are shown in Table 1.7.
Table 1.7. Ammonia specifications [6]
Properties Data
Chemical formula NH3
Purity 99.98 mol%
Density 0.68 g/cm3
Phase Liquid
5
2. Reaction Information
2.1. Operating Conditions
In this process, high purity nitrogen and hydrogen are compressed and heated to
reach operating conditions shown in Table 2.1. After that, they are fed into the reactor
with magnetic ferro-oxide as a catalyst. Nitrogen reacts with hydrogen which results in
ammonia as a product.
N 2 (g) 3H 2 (g) 2NH 3 (g)
Table 2.1. Operating conditions [7]
Parameter Data
Pressure 130-140 bar
Temperature 370-500 C
Catalyst Magnetic ferro-oxide
2.2. Kinetics and Equilibrium Data

The rate of reaction in the process is calculated by using modified Temkin Eq. (1)
to (7) [7].
a 3H2

a 2NH3
1-

R NH3 =2k K a a N2 2
2
- 3 (1)
a NH aH
3 2
where is a constant and k is a rate constant.
-E
k=k0 eRT (2)
2001.6
log Ka =-2.691122 log T -505192510-5 T+1.84886310-7 T2 + +2.689 (3)
T
where k0 is the Arrhenius coefficient, 8.849 1014 , E is activation energy,
approximate 40765 kcal/kmol, R is a gas constant, Ka is an equilibrium constant and ai
is an activity coefficient of component i.
fi fi
ai = = =f =y P (4)
f0 1 i i i
-P
(-3.8402T0.125 +0.541) (-0.1263T0.5 -15.98) 2
(e P-e P +300[e(-0.011901T-5.941) ](e300 )) (5)
H2 =e
6
N2 =0.93431737+0.202853810-3 T+0.29589610-3 P-0.27072710-6 T2 +
(6)
0.477520710-6 P2
NH3 =0.1438996+0.202853810-2 T-0.448767210-3 P-0.114294510-5 T2 +

(7)
0.276121610-6 P2
T is in term of Kelvin and P is in term of atmosphere.
2.3. Heat of Reaction

The heat of reaction (kJ/mol) can be calculated by using Eq. (8) [10].
846.609 459.734106

- 0.54526+ + P - 5.34685T
H r =4.184 T T3 (8)
-3 2 -5 3
- 0.252510 T + 106919710 T - 9157.09
2.4. Stream Information

In this process, there are two feed streams which are hydrogen and air. Product
streams consist of one vent stream, two valuable by-products, one primary product, one
waste stream, and one purge stream. Valuable by-product 1 and 2 mainly consist of
oxygen and argon, respectively. Waste stream and purge stream are sent out of the
system. The primary product stream is ammonia.
Table 2.2. Overall material balance for each stream
Stream Input (tpy) Output (tpy)

Hydrogen 161,000 -
Air 992,000 -
Vent - 19.1
VBP 1 - 12,700
VBP 2 - 230,000
Waste - 756
Primary Product - 910,000
Overall 1,150,000 1,150,000
7
3. Process Description
The process flow diagram with a heat exchanger network for this work is shown in Fig. 3.1. This diagram is shortened due to the limitation of paper size. However, it can be zoomed in order to see details of the process flow diagram obviously. Process flow diagrams for each
part of the process can be seen in appendices.
C-101 E-101 E-102 E-103 V-101 V-102 V-103 V-104 C-102 E-104 E-105 C-103 E-106 E-107 C-104 T-101 E-108 E-109 V-105 E-110 C-105 E-111 E-112 C-106 E-113 E-114 E-115 E-116 T-102 E-117 E-118 V-106 T-103 E-119 V-107 E-120 E-121 C-107 E-122 E-123 C-108 E-124 E-125 E-126 E-127 C-109 E-128 E-129 C-110 E-130 R-101 E-131 E-132 V-108 C-111 V-109
Air Air Air Air Molecular Molecular Molecular Molecular Booster Cryogenic Cryogenic Booster Cryogenic Cryogenic Expansion Air Nitrogen Oxygen Nitrogen Oxygen Oxygen Oxygen Oxygen Oxygen Oxygen Oxygen Oxygen Vent Crude Argon Crude Argon Crude Argon Crude Argon Pure Argon Distillates Distillates Pure Argon Pure Argon Argon Argon Argon Argon Argon Argon Argon Nitrogen Nitrogen Nitrogen Nitrogen Nitrogen Feed Ammonia Reactor Ammonia Primary Recycle Secondary
Compressor Cooler 1 Cooler 2 Cooler 3 Sieve Sieve Sieve Sieve Compressor 1 Cooler 1 Cooler 2 Compressor 2 Cooler 3 Cooler 4 Turbine Cryogenic Condenser Reboiler Reflux Heater Compressor 1 Cooler 1 Cooler 2 Compressor 2 Cooler 3 Cooler 4 Cooler 5 Heater Column Condenser Reboiler Reflux Column Condenser Reflux Reboiler Heater Compressor 1 Cooler 1 Cooler 2 Compressor 2 Cooler 2 Cooler 4 Cooler 5 Feed Feed Feed Feed Feed Heater Reactor Effluent Cooler Phase Stream Phase
Adsorber A Adsorber B Adsorber C Adsorber D Column Drum Drum Drum Heater Compressor 1 Cooler 1 Cooler 2 Compressor 2 Cooler Separator Compressor Separator
62
Hydrogen 55
81 82
Vent
E-116
71 72 73
20 E-131
Air 1 2 C-111
68 69
E-108 Purge
E-101 E-102 Propane 77
E-103 16 17 E-119
Liq. N2 V-105 37 38
3 4 5 6 E-117
C-101 V-107 70
Liq. N2
32 33
LPS CW CHW 59
Liq. N2 V-106
T-101
18 19
39 40
R-101
34 36 T-103 56 57 58
15 50 E-130
31 C-109 C-110 V-108 76
V-101 V-102 V-103 V-104
E-127 74
T-102
C-104 75
53
54
E-128 E-129 63
E-120
E-109 51 52
41 LPS CW V-109
8 C-102 C-103 78
22 65
67 Ammonia
14
E-118 E-132
11 35
E-104 E-105 12 E-106 E-107
9 C-108
66 42 C-107
7 10 13 E-122 E-123 E-124 E-125 E-126
E-121 C-105 C-106
60 43 44 45
LPS CHW LPS CHW 46 47 48 49 Argon
E-111 E-112 E-113 E-114 E-115
LPS CW LPS CW CHW
23 27 28 29 30
24 25 26 Oxygen
E-110
61
LPS CW LPS CW CHW
Waste
Fig. 3.1. Process flow diagram for the air separation and ammonia production process
8
The process shown in Fig. 3.1 produces 816,000 metric tons per year of 99.98% by
mole ammonia. Two valuable by-products are 99.95% by mole oxygen and 99.998%
by mole argon. The number of operating hours is taken to be 8000 per year. Two raw
materials used are air and hydrogen. Air is brought freely from an atmosphere at the
temperature of 40oC and the pressure of 1 bar in a gas phase. Hydrogen is stored at the
temperature of 35oC and the pressure of 150 bar in a gas phase as well. Firstly, air is fed
into the process, passing through a filter to remove solid impurities. Then, it enters a
compressor to increase its pressure to 10 bars. After that, air is cooled to 25C and fed
into PSA (Pressure Swing Adsorption) unit. The PSA unit is included to separate carbon
dioxide by using CMS (Carbon Molecular Sieve) as an adsorbent and purges high-
concentration carbon dioxide out of the system to prevent solid formation during
cryogenic distillation. After carbon dioxide has been removed, air is cooled to an
extremely low temperature by using a two-stage compressor with intercooling and
turbine before entering the first distillation column. This column separates nitrogen as
a distillate and oxygen as a bottoms. At the top of this column, a partial condenser is
selected in order to remove light ends further and vent them out of the process. The
bottoms stream is oxygen which is sent out of the process as a valuable by-product. It
is adjusted conditions before sending to a storage. At the middle of this column, liquid
stream which consists of the highest purity of argon is brought to the second column.
The second column separates nitrogen and argon as a distillate which is sent to the third
column, while high-purity oxygen is removed as a bottoms stream and recycled back to
the first column. The third column separates nitrogen as a distillate which is vent out of
the process. High-purity argon is a bottoms product and sent to a storage after adjusting
conditions. After the air-separation process is completed, nitrogen is compressed to
136.5 bars which is the reactor operating pressure. Another raw material, hydrogen, is
passed through a reducing valve to decrease a pressure from 150 to 136.5 bars. After
that, nitrogen and hydrogen are mixed and combined with recycle stream. The mixed
stream is heated to 350oC which is the reactor operating temperature. Next, raw
materials are fed to a packed bed reactor with a catalyst of ferro-oxide. The reactor R-
101 consist of two identical packed bed reactor with one heat exchanger located
between them. After the reaction completes, the product stream from a reactor is cooled
by passing through other heat exchangers as a heating fluid. Then, it is fed to a high-
pressure flash drum. Gas stream from this drum is compressed and recycled back, while
some of them are purged out of the process. Liquid stream is passed through a reducing
valve and sent to a low-pressure flash drum. Gas stream from this drum is vent out of
the process. Liquid stream which is a high-purity ammonia is adjusted conditions until
it becomes saturated liquid. Finally, saturated liquid ammonia is stored in storage tank.
Stream table and equipment summary of this process are shown in Table 3.1 and 3.2,
respectively.
9
Table 3.1. Flow summary table for the air separation and ammonia production process
Stream 1 2 3 4 5 6 7 8 9 10
Temperature (oC) 40 40 394 120 50 25 25 25 205.15 120
Pressure (bar) 1 1 10 10 10 10 10 10 40 40
Vapor Fraction 1 1 1 1 1 1 1 1 1 1
Mass Flow (kg/h) 103568 103568 103568 103568 103568 103568 79 103489 103489 103489
Mole Flow (kmol/h) 3575.34 3575.34 3575.34 3575.34 3575.34 3575.34 1.79 3573.55 3573.55 3573.55
Component Flow Rates (kmol/h)
Helium 0.18 0.18 0.18 0.18 0.18 0.18 0 0.18 0.18 0.18
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0.064 0.064 0.064 0.064 0.064 0.064 0 0.064 0.064 0.064
Nitrogen 2789.95 2789.95 2789.95 2789.95 2789.95 2789.95 0 2789.95 2789.95 2789.95
Argon 33.23 33.23 33.23 33.23 33.23 33.23 0 33.23 33.23 33.23
Oxygen 750.12 750.12 750.12 750.12 750.12 750.12 0 750.12 750.12 750.12
Krypton 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039 0 0.0039 0.0039 0.0039
Xenon 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032 0 0.00032 0.00032 0.00032
Carbon Dioxide 1.79 1.79 1.79 1.79 1.79 1.79 1.79 3.04x10-9 3.04x10-9 3.04x10-9
Ammonia 0 0 0 0 0 0 0 0 0 0
10
Table 3.1. Flow summary table for the air separation and ammonia production process (cont)
Stream 11 12 13 14 15 16 17 18 19 20
Temperature (oC) 25 170.54 120 25 -149 -192.05 -192.05 -192.05 -192.05 -192.05
Pressure (bar) 40 127 127 127 2.28 1.52 1.52 1.52 1.52 1.52
Vapor Fraction 1 1 1 1 1 1 0.04 0 0 1
Mass Flow (kg/h) 103489 103489 103489 103489 103489 495254 495254 417875 69645.83 7733.7
Mole Flow (kmol/h) 3573.55 3573.55 3573.55 3573.55 3573.55 17679.36 17679.36 14916.96 2486.16 276.24
Helium 0.18 0.18 0.18 0.18 0.18 0.1877 0.1877 0.0066 0.0011 0.18
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0.064 0.064 0.064 0.064 0.064 0.0901 0.0901 0.0258 0.0043 0.06
Nitrogen 2789.95 2789.95 2789.95 2789.95 2789.95 17679.05 17679.05 14916.9 2486.15 276
Argon 33.23 33.23 33.23 33.23 33.23 0 0 0 0 0
Oxygen 750.12 750.12 750.12 750.12 750.12 0 0 0 0 0
Krypton 0.0039 0.0039 0.0039 0.0039 0.0039 0 0 0 0 0
Xenon 0.00032 0.00032 0.00032 0.00032 0.00032 0 0 0 0 0
Carbon Dioxide 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 0 0 0 0 0
Ammonia 0 0 0 0 0 0 0 0 0 0
11
Stream 21 22 23 24 25 26 27 28 29 30
Temperature (oC) -192.87 -174.96 25 333 120 50 401 120 50 25
Pressure (bar) 1.38 2.21 2.21 20 20 20 200 200 200 200
Vapor Fraction 1 0 1 1 1 1 1 1 1 1
Mass Flow (kg/h) 8600.44 24016.37 24016.37 24016.37 24016.37 24016.37 24016.37 24016.37 24016.37 24016.37
Mole Flow (kmol/h) 306.24 750.45 750.45 750.45 750.45 750.45 750.45 750.45 750.45 750.45
Helium 0.18 0 0 0 0 0 0 0 0 0
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0.06 0 0 0 0 0 0 0 0 0
Nitrogen 303.8 0 0 0 0 0 0 0 0 0
Argon 2.21 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33
Oxygen 0 750.12 750.12 750.12 750.12 750.12 750.12 750.12 750.12 750.12
Krypton 0 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039
Xenon 0 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032
Carbon Dioxide 0 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9
Ammonia 0 0 0 0 0 0 0 0 0 0
12
Stream 31 32 33 34 35 36 37 38 39 40
Temperature (oC) -182.46 -185.72 -188.22 -188.22 -174.98 -188.22 -191.95 -192.52 -192.52 -192.52
Pressure (bar) 2.04 1.52 1.52 1.52 2.21 1.52 1.38 1.38 1.38 1.38
Vapor Fraction 0 0 0 0 0 0 1 0 0 0
Mass Flow (kg/h) 3350.72 43955.54 43955.54 41862.82 1257.58 2093.14 13867.82 13867.82 13001.1 866.74
Mole Flow (kmol/h) 100 1274.7 1274.7 1214 39.3 60.7 480 480 450 30
Helium 0 0 0 0 0 0 0 0 0 0
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0 0 0 0 0 0 0 0 0 0
Nitrogen 27.79 583.59 583.59 555.87 0 27.79 444.64 444.64 416.85 27.79
Argon 32.91 691.11 691.11 658.13 0.0031 32.91 35.36 35.36 33.15 2.21
Oxygen 39.30 0.0019 0.0019 0.0018 39.3 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 0 0 0 0 0 0 0 0 0 0
13
Stream 41 42 43 44 45 46 47 48 49 50
Temperature (oC) -178.52 25 575.18 120 50 583.05 120 50 25 -100
Pressure (bar) 2.07 2.07 20 20 20 200 200 200 200 1.52
Vapor Fraction 0 1 1 1 1 1 1 1 1 1
Mass Flow (kg/h) 1226.4 1226.4 1226.4 1226.4 1226.4 1226.4 1226.4 1226.4 1226.4 69645.83
Mole Flow (kmol/h) 30.70 30.70 30.70 30.70 30.70 30.70 30.70 30.70 30.70 2486.16
Helium 0 0 0 0 0 0 0 0 0 0.0011
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0 0 0 0 0 0 0 0 0 0.0043
Nitrogen 0 0 0 0 0 0 0 0 0 2486.15
Argon 30.7 30.7 30.7 30.7 30.7 30.7 30.7 30.7 30.7 0
Oxygen 0 0 0 0 0 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 0 0 0 0 0 0 0 0 0 0
14
Stream 51 52 53 54 55 56 57 58 59 60
Temperature (oC) 270.06 120 100 253.93 35 35.38 -15.70 350 400 399.79
Pressure (bar) 50 50 50 136.5 150 136.5 136.5 136.5 136.44 136.44
Vapor Fraction 1 1 1 1 1 1 1 1 1 1
Mass Flow (kg/h) 69645.83 69645.83 69645.83 69645.83 15132.4 15132.4 271258 271258 271258 271258
Mole Flow (kmol/h) 2486.16 2486.16 2486.16 2486.16 7500 7500 53485.6 53485.6 48523.1 48523.1
Helium 0.0011 0.0011 0.0011 0.0011 0 0 0.9141 0.9141 0.9141 0.9141
Hydrogen 0 0 0 0 7500 7500 47039.7 47039.7 39595.9 39595.9
Neon 0.0043 0.0043 0.0043 0.0043 0 0 2.27 2.27 2.27 2.27
Nitrogen 2486.15 2486.15 2486.15 2486.15 0 0 6069.35 6069.35 3588.09 3588.09
Argon 0 0 0 0 0 0 0 0 0 0
Oxygen 0 0 0 0 0 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 0 0 0 0 0 0 373.38 373.38 5335.9 5335.9
15
Stream 61 62 63 64 65 66 67 68 69 70
Temperature (oC) 393.74 392.36 21.96 21.47 20.93 19.12 -3.96 -11.10 -40 -40
Pressure (bar) 136.44 136.44 136.44 136.44 136.44 136.44 136.44 136.44 136.44 136.44
Vapor Fraction 1 1 0.980 0.979 0.977 0.972 0.926 0.917 0.897 1
Mass Flow (kg/h) 271258 271258 271258 271258 271258 271258 271258 271258 271258 186671
Mole Flow (kmol/h) 48523.1 48523.1 48523.1 48523.1 48523.1 48523.1 48523.1 48523.1 48523.1 43545.1
Helium 0.9141 0.9141 0.9141 0.9141 0.9141 0.9141 0.9141 0.9141 0.9141 0.91
Hydrogen 39595.9 39595.9 39595.9 39595.9 39595.9 39595.9 39595.9 39595.9 39595.9 39582.3
Neon 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.26
Nitrogen 3588.09 3588.09 3588.09 3588.09 3588.09 3588.09 3588.09 3588.09 3588.09 3586.77
Argon 0 0 0 0 0 0 0 0 0 0
Oxygen 0 0 0 0 0 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 5335.9 5335.9 5335.9 5335.9 5335.9 5335.9 5335.9 5335.9 5335.9 372.88
16
Stream 71 72 73 74 75 76 77 78 79 80
Temperature (oC) -40 -40 -41.28 -40 -36.59 -36.59 -37.36 -36.59 -36.66 -33.33
Pressure (bar) 136.5 136.5 1.01 136.5 6 6 1.01 6 1.01 1.01
Vapor Fraction 1 1 1 0 0 1 1 0 0 0
Mass Flow (kg/h) 186480 186.67 186.67 84587.6 84587.6 102.42 102.42 84485.2 84485.2 84485.2
Mole Flow (kmol/h) 43499.5 43.55 43.55 4977.95 4977.95 16.7 16.7 4961.28 4961.28 4961.28
Helium 0.91 0.00091 0.00091 0.0002 0.0002 0.0002 0.0002 0 0 0
Hydrogen 39540.6 39.58 39.58 13.60 13.60 13 13 0.5983 0.5983 0.5983
Neon 2.26 0.0023 0.0023 0.0020 0.0020 0.0018 0.0018 0.0002 0.0002 0.0002
Nitrogen 3583.2 3.59 3.59 1.32 1.32 1.25 1.25 0.0718 0.0718 0.0718
Argon 0 0 0 0 0 0 0 0 0 0
Oxygen 0 0 0 0 0 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 372.49 0.37 0.37 4963.03 4963.03 2.42 2.42 4960.61 4960.61 4960.61
17
Stream 81 82
Temperature (oC) 25 21.64
Pressure (bar) 1.38 1.01
Vapor Fraction 1 1
Mass Flow (kg/h) 8600.44 8702.86
Mole Flow (kmol/h) 306.24 322.94
Helium 0.18 0.18
Hydrogen 0 13
Neon 0.06 0.0618
Nitrogen 303.8 305.5
Argon 2.21 2.21
Oxygen 0 0
Krypton 0 0
Xenon 0 0
Carbon Dioxide 0 0
Ammonia 0 2.42
18
Table 3.2. Equipment summary for the air separation and ammonia production process
Heat exchangers E-101 E-102 E-103 E-104

Type Floating Floating Floating Floating
Area (m2) 3,345 279 153 226
Duty (MJ/h) 8,218 2,057 735 2,567
Shell
Temperature (oC) 110 60 25 11
Pressure (bar) 1.42 1 1 1.42
Phase Vap. Liq. Liq. Vap.
MOC CS CS CS CS
Tube
Pressure (bar) 10 10 10 40
Phase Vap. Vap. Vap. Vap.
MOC SS-304 CS CS CS
19
Type Floating U-tube U-tube Floating
Area (m2) 259 191 282 2,202
Duty (MJ/h) 2,898 1,608 3,156 28,938
Shell
Temperature (oC) 25 110 25 -192.05
Pressure (bar) 1 1.42 1 1.52
Phase Liq. Vap. Liq. Vap.
MOC CS CS CS SS-304
Tube
Temperature (oC) 25 120 25 -203
Pressure (bar) 40 127 127 0.3
MOC CS CS CS SS-304
Type U-tube U-tube Floating Floating
Area (m2) 1,237 111 68 60
Duty (MJ/h) 22,541 2,590 1,396 445
Shell
Temperature (oC) -174.96 25 110 60
Pressure (bar) 2.21 2.21 1.42 1
Phase Liq. Liq. Vap. Liq.
MOC SS-304 SS-304 CS CS
Tube
Temperature (oC) -3.96 393.74 120 50
Pressure (bar) 136.5 136.5 20 20
MOC SS-304 SS-304H CS CS
20
Type U-tube U-tube U-tube U-tube
Area (m2) 80 199 42 20
Duty (MJ/h) 1,995 526 201 590
Shell
Pressure (bar) 1.42 1.00 1.00 1.38
MOC CS CS CS SS-304
Tube
Temperature (oC) 120 50 25 392.36
Pressure (bar) 200 200 200 136.5
MOC SS-304H CS CS SS-304
Type Floating U-tube Floating U-tube
Area (m2) 138 108 58 32
Duty (MJ/h) 2,117 2,116 743 642
Shell
Temperature (oC) -188.22 -174.98 -192.52 -178.52
Pressure (bar) 1.52 2.21 1.38 2.07
Phase Liq. Vap. Vap. Vap.
MOC SS-304 SS-304 SS-304 SS-304
Tube
Temperature (oC) -203 19.12 -203 20.93
Pressure (bar) 0.3 136.5 0.3 136.5
MOC SS-304 CS SS-304 CS
21
Type Fixed Fixed Fixed Fixed
Area (m2) 3.8 2.3 1.6 3
Duty (MJ/h) 89.6 81.6 123 103
Shell
Pressure (bar) 2.07 1.42 1.00 1.42
MOC SS-304 CS CS CS
Tube
Temperature (oC) 399.79 120 50 120
Pressure (bar) 136.50 20 20 200
MOC SS-304H SS-304H CS SS-304H
Type Fixed Fixed U-tube U-tube
Area (m2) 2 1.3 834 194
Duty (MJ/h) 16 6 5667 3148
Shell
Temperature (oC) 60 25 -100 110
Pressure (bar) 1 1 1.52 1.42
Phase Liq. Liq Liq. Vap.
MOC CS CS SS-304 CS
Tube
Temperature (oC) 50 25 -11.1 120
Pressure (bar) 200 200 136.5 50
MOC CS CS SS-304 CS
22
Area (m2) 24 101,359 180 207
Duty (MJ/h) 423 162,028 18,987 586
Shell
Temperature (oC) 60 21.96 -40 -33.33
Pressure (bar) 1 136.5 136.5 1.01
MOC CS SS-304 SS-304 SS-304
Tube
Temperature (oC) 100 350 -50 21.47
Pressure (bar) 50 136.5 0.7 136.5
Phase Vap. Vap. Liq. Vap.
MOC CS SS-304 SS-304 CS
Heat exchangers Internal Heat Exchanger in Reactor
Type U-tube
Area (m2) 5,021
Duty (MJ/h) 86,913
Shell
Temperature (oC) 250
Pressure (bar) 40
Phase Vap.
MOC CS
Tube
Pressure (bar) 136.5
Phase Vap.
MOC SS
23
Vessels/Tower/
V-101 V-102 V-103 V-104
Reactors
Orientation Vertical Vertical Vertical Vertical
MOC CS CS CS CS
Size
Height/Length (m) 5 5 5 5
Diameter (m) 1 1 1 1
Internals CMS CMS CMS CMS
Vessels/Tower/
V-105 V-106 V-107 V-108
Reactors
Temperature (oC) -192.05 -188.22 -192.52 -40
Pressure (bar) 1.52 1.52 1.38 136.5
Orientation Vertical Horizontal Horizontal Vertical
MOC SS-304 SS-304 SS-304 SS-304
Size
Height/Length (m) 9 4.5 3.75 9
Diameter (m) 2 1.5 1.25 3
Internals - - - Demister
24
Vessels/Tower/
V-109 T-101 T-102 T-103
Reactors
Temperature (oC) -36.59 -192.05 -188.22 -192.52
Pressure (bar) 6 2.28 2.21 2.07
Orientation Horizontal Vertical Vertical Vertical
MOC SS-304 TP304 TP304 TP304
Size
Height/Length (m) 10 46.5 57.65 36.75
Diameter (m) 2.5 6.6 2.5 1.5
Internals - 120 trays 160 trays 100 trays
Feed on tray 80 Feed on tray 110 Feed on tray 60
Vessels/Tower/
R-101
Reactors
Temperature (oC) 350 - 500
Orientation Vertical
MOC SS-304H
Size
Height/Length (m) 2.439
Diameter (m) 2.914
Internals Two identical reactors in series with one heat exchanger between
25
Pumps/
Compressors/ C-101 C-102 C-103 C-104
Turbine
Flow (kg/h) 103,489 103,489 103,489 103,489
Fluid density
11.74 11.74 47.51 151.15
(kg/m3)
Type/Drive Reciprocating/ Reciprocating/ Reciprocating/ Reciprocating/
Electric Electric Electric Electric
Power (shaft) (kW) 5,241 5,241 4,245 4,258
Efficiency 80 80 80 80
MOC SS-304H CS CS TP-304
Temp. (in) (oC) 25 25 25 25
Pres. (in) (bar) 10 10 40 127
Pres. (out) (bar) 40 40 127 2.28
Pumps/
Turbine
Flow (kg/h) 24,016 24,016 1,226 1,226
Fluid density
2.86 24.12 3.34 30.1
(kg/m3)
Power (shaft) (kW) 1,964 2,284 98 109
MOC CS SS-304H TP-304 SS-304L
Temp. (in) (oC) 25 50 25 50
Pres. (in) (bar) 2.21 20 2.07 20
Pres. (out) (bar) 20 200 20 200
26
Pumps/
C-109 C-110 C-111
Compressors
Flow (kg/h) 69,646 69,646 186,480
Fluid density
2.98 44.83 28.16
(kg/m3)
Type/Drive Screw Reciprocating/ Reciprocating/
Electric Electric
Power (shaft) (kW) 7,475 3,201 29
Efficiency 80 80 80
MOC TP-304 CS 31/2 Ni
Temp. (in) (oC) -100 100 -40
Pres. (in) (bar) 1.52 50 136.35
Pres. (out) (bar) 50 136.5 136.5
27
References
[1] The Linde Group. Cryogenic air separation. History and technological progress.
[2] Nitrogen. (n.d.). Retrieved May 12, 2017, from http://webbook.nist.gov/cgi/cbook.
cgi?ID=7727-37-9
[3] Argon. (n.d.). Retrieved May 12, 2017, from http://webbook.nist.gov/cgi/inchi?ID
=C7440371&Mask=200
[4] Oxygen. (n.d.). Retrieved May 12, 2017, from http://webbook.nist.gov/cgi/cbook.
cgi?ID=7782-44-7
[5] Hydrogen. (n.d.). Retrieved May 12, 2017, from http://webbook.nist.gov/cgi/cbook.
cgi?ID=C1333740
[6] Ammonia. (n.d.). Retrieved May 12, 2017, from http://webbook.nist.gov/cgi/cbook.
cgi?ID=C7664417
[7] Dashti, A., Khorsand, K., Marvast, M. A., & Kakavand, M. (2006). MODELING
AND SIMULATION OF AMMONIA SYNTHESIS REACTOR. Petroleum &
Coal, 48(2), 15-23
28
Appendix A.
Design Data
29
In this process, raw materials are air and hydrogen (H2). Air will be passed through the
air separation unit producing pure nitrogen. Nitrogen and hydrogen are fed to the
ammonia production process. Our primary product is high purity liquid ammonia.
A.1. Feed Specifications

A.1.1. Air Separation Process
In this process, air is used as a raw material in the air separation process.
Properties and compositions of air used in this process are shown in Table A.1 and A.2,
respectively.
Table A.1. Properties of air [1]
Properties Data
Density 870 kg/m3
Table A.2. Typical compositions of air [1]
Components vol% Boiling point (oC)

N2 78.08 -195.8
O2 20.993081 -183.0
Ar 0.93 -185.9
CO2 0.05 -78.5
He 0.005 -268.9
Ne 0.0018 -246.1
Kr 0.00011 -153.2
Xe 0.000009 -108.0
30
A.1.2. Hydrogen
Hydrogen and nitrogen are used as raw materials for the ammonia production
process. Specifications for hydrogen are also shown in Table A.3. Since nitrogen is a
product from the air separation process, its properties are shown in the next section.
Table A.3. Specifications of hydrogen [2]
Properties Data
Chemical formula H2
Purity 99.999 mol% hydrogen
from existing hydrogen
production plant
Density 0.07 g/cm3
31
A.2. Product Specifications
A.2.1. Air Separation Process
A primary product from the air separation process is liquid nitrogen. Its
specifications are shown in Table A.4. However, argon and oxygen are produced as
valuable by-products. The specifications are shown in Table A.5 and A.6, respectively.
Table A.4. Liquid nitrogen specifications [1, 3]
Properties Data
Chemical formula N2
Purity 99.995 mol%
Density 0.81 g/cm3
Phase Liquid
Table A.5. Argon specifications [1, 4]
Properties Data
Chemical formula Ar
Purity 99.998 mol%
Density 1.4 g/cm3
Phase Liquid
32
Table A.6. Oxygen specifications [1, 5]
Properties Data
Chemical formula O2
Purity 99.95 mol%
Density 1.43 g/cm3
Phase Liquid
A.2.2. Ammonia Production Process

A primary product from the ammonia production process is ammonia. Its
properties are shown in Table A.7.
Table A.7. Ammonia specifications [6]
Properties Data
Chemical formula NH3
Purity 99.98 mol%
Density 0.68 g/cm3
Phase Liquid
33
A.2.3. Production Rates
Production rates of nitrogen and oxygen based on Linde air separation plant are
shown in Table A.8.
Table A.8. Production rates [1]
Component Production Rate (tpy)

Nitrogen 202,000
Oxygen 230,000
An amount of air required will be calculated based on the limiting product which
is oxygen. Then, nitrogen production rate will be recalculated. The production rate of
ammonia will be calculated based on nitrogen rate by using stoichiometry in the later
part.
A.3. Storage Conditions

Air is normally brought from atmosphere, so a storage is not required. Today
gaseous hydrogen is stored in steel cylinders at a pressure of 150-200 bars and at an
ambient temperature of approximately 25oC. However, an ambient temperature for
Thailand is approximately 35oC. Oxygen and argon could be stored in both gas and
liquid phases. In this work, we store oxygen and argon at 200 bars and 25oC [7, 8]. Also,
liquid ammonia is stored below its boiling point at ambient pressure [9].
34
References for Appendix A
[1] The Linde Group. Cryogenic air separation. History and technological progress.
[2] Hydrogen. (n.d.). Retrieved May 12, 2017, from
http://webbook.nist.gov/cgi/cbook.
cgi?ID=C1333740
[3] Nitrogen. (n.d.). Retrieved May 12, 2017, from http://webbook.nist.gov/cgi/cbook.
cgi?ID=7727-37-9
[4] Argon. (n.d.). Retrieved May 12, 2017, from http://webbook.nist.gov/cgi/inchi?ID
=C7440371&Mask=200
[5] Oxygen. (n.d.). Retrieved May 12, 2017, from http://webbook.nist.gov/cgi/cbook.
cgi?ID=7782-44-7
[6] Ammonia. (n.d.). Retrieved May 12, 2017, from http://webbook.nist.gov/cgi/
cbook.cgi?ID=C7664417
[7] Oxygen storage. (2017, April 04). Retrieved May 12, 2017, from https://en.
wikipedia.org/wiki/Oxygen_storage
[8] Liquid Argon Storage Tank Losses Recovery - Industrial Professionals. (1969,
December 31). Retrieved May 12, 2017, from https://www.cheresources.com/
invision/topic/23442-liquid-argon-storage-tank-losses-recovery/
[9] Liquid Argon Storage Tank Losses Recovery - Industrial Professionals. (1969,
December 31). Retrieved May 12, 2017, from https://www.cheresources.com/
invision/topic/23442-liquid-argon-storage-tank-losses-recovery/
35
Appendix B.
Batch and Continuous
Considerations
36
Guidelines [1] used in considering types of the operation (batch and continuous) are
shown in Table B.1.
Table B.1. Batch and continuous consideration
Guidelines Process Consideration

Production rate 910,000 tpy Continuous
Multiple products No Continuous
High product quality No Continuous
Scale up problems No Continuous
Market forces No Continuous
It can be seen from Table B.1 that a continuous process is obviously suitable for
this process. The production rate is specified at 910,000 tpy which is higher than a
criterion of 5,000 tpy. This high production rate is recommended to operate with a
continuous process. Multiple products do not exist because we use hydrogen and
nitrogen in order to synthesize ammonia so that a batch process is not required. The
product purity of ammonia is not high, so it is not necessary to verify frequently. The
reaction time may not a problem because this type of reaction is used widely in many
industries. There is no slurry because hydrogen and nitrogen is normally gas. No fouling
material is severely concerned. Also, there are no scale-up problems.
Reference for Appendix B

[1] Douglas, J. M. (2000). Conceptual design of chemical processes. New York, NY:
McGraw-Hill.
37
Appendix C.
Input-Output
Structure Design
38
C.1. Input Structure
The input structure of this process is shown in Table C.1.
Table C.1. Input structure of the process
Feed Stream Component Classification

Air Helium Inert Impurity
Neon Inert Impurity
Nitrogen Reactant
Argon Inert Impurity
Oxygen Inert Impurity
Krypton Inert Impurity
Xenon Inert Impurity
Carbon Dioxide Inert Impurity
Hydrogen Hydrogen Reactant
High purity nitrogen is required for the ammonia production unit; however, air
consists of many impurities in a significant amount. Thus, feed purification or air
separation is required.
C.2. Output Structure

All components in this process are sequenced by using normal boiling points.
The output structure of this process is shown in Table C.2. A schematic diagram for
input-output structure is shown in Fig. C.1.
Table C.2. Output Structure
Normal Boiling
Components Classification Destination Code
Point (oC)
Helium Gas Impurity Vent -268.9
Hydrogen Gas Reactant Recycle and Purge -252.9
Neon Gas Impurity Vent -246.1
Nitrogen Gas Reactant Recycle and Purge -195.8
39
Argon Gas By-Product VBP 1 -185.9
Oxygen Gas By-Product VBP 2 -183.0
Krypton Gas Impurity Waste -153.2
Xenon Gas Impurity Waste -108.0
Carbon Dioxide Gas Impurity Waste -78.5
Ammonia Liquid Primary Product Primary Product -33.3
Vent
Recycle
Purge
VBP 1
Hydrogen Chemical
VBP 2
Air
Process
Waste
Primary Product
Fig. C.1. Input-Output Diagram

In this process, there are two feed streams which are hydrogen and air. Product
streams consist of one vent stream, two valuable by-products, one primary product, one
waste stream, and one purge stream. Valuable by-product 1 and 2 mainly consist of
oxygen and argon, respectively. Waste stream and purge stream are sent out of the
system. The primary product stream is ammonia.
40
Appendix D.
Overall Material
Balance
41
D.1. Overall Material Balance
To obtain 230,000 tpy oxygen, 992,000 tpy air is required. Table D.1. shows the
overall material balance in this process for every component. Table D.2 shows the
overall material balance in this process for each stream. It should be noted that this
calculation is preliminary estimation; thus, the result is not exactly same as Aspen.
Table D.1. Overall material balance for each component
Components Input (tpy) Output (tpy)

Helium 6.84 6.84
Hydrogen 161,000 -
Neon 12.3 12.3
Nitrogen 749,000
Argon 12,700 12,700
Oxygen 230,000 230,000
Krypton 3.16 3.16
Xenon 0.403 0.403
Carbon Dioxide 753 753
Ammonia - 910,000
Overall 1,150,000 1,150,000
Table D.2. Overall material balance for each stream
Stream Input (tpy) Output (tpy)

Hydrogen 161,000 -
Air 992,000 -
Vent - 19.1
VBP 1 - 12,700
VBP 2 - 230,000
Waste - 756
Primary Product - 910,000
Overall 1,150,000 1,150,000
42
D.2. Reaction & Recycle Material Balance
The equilibrium constant of ammonia synthesis reaction [1] could be determined
from Eq. (1).
2001.6
log Ka =-2.691122 log T -5.05192510-5 T+1.84886310-7 T2 + +2.689 (1)
T
The equilibrium constant at the product temperature calculated from Eq. (1),
which equals to 730 K, is 6.12410-3 M-2. The equilibrium conversion is reported to be
0.24 of nitrogen [1]. This process
Since the capacity of nitrogen production is 749,000 tpy, the produced ammonia
and hydrogen can be determined by using a concept of stoichiometry shown below.
1. If we need to convert all produced nitrogen, an amount of hydrogen is feed is
749000 6
161,000 tpy.
28
2. The input nitrogen can be calculated by divided used nitrogen with conversion
749000
3,120,000 tpy. So, recycle nitrogen flow rate is 3,120,000 749,000 =
0.24
2,371,000 tpy. As a result, an amount of hydrogen required is
3120000 6
669,000 tpy.
28
3. Generally, nitrogen is fed excessively 1.4 times of hydrogen, so an amount of
nitrogen required (feed + recycle) is 669,000/1.4 = 478,000 tpy. Also, recycle
hydrogen flow rate is 478,000 161,000 = 317,000 tpy
N2 + 3H2 2NH3
Stoichiometric 28 6 34
Input (Feed
3,120,000 478,000 0
+Recycle)
Change -749,000 -161,000 +910,000
Output 2,371,000 317,000 910,000
References for Appendix D

Coal, 48(2), 15-23.
43
Appendix E.
General Process
Design
44
The general process design of this process is shown in Fig. E.1. Also, considerations for general process design are shown below.
Vent (19.1 tpy)
Recycle System Purge
161,000 tpy Hydrogen

Feed Preparation Phase Separation Primary Product
Reactor System
System System (910,000 tpy)
992,000 tpy Air
VBP 1 (12,700 tpy)
VBP 2 (230,000 tpy)
Waste (753 tpy)
Fig. E.1. Block flow diagram of general process design
45
1. Reactor Feed Preparation System
In this process, one reactor feed preparation system is required because of one
reactor system. Feed preparation system mainly consists of the air separation unit.
The air separation unit also consists of adsorbers and distillation columns. Valuable
by-products, vent stream (Helium + Neon) and waste stream are sent out of the
process from this system. This is the biggest and most important system.
2. Reactor System
In this process, one reactor system is required because we have only one main
reaction. The reactor operates at 130-140 bars and 350-500oC [1] by using two
identical packed bed reactors in series with one heat exchanger.
3. Phase Separation System

Phase separation system is required because our products consist of both gas
and liquid phase. It is used to separate nitrogen and hydrogen from ammonia.
4. Separation System
Since there is only one liquid stream in our system, separation system is not
required. However, we can imply that separation system is one part of the feed
preparation system which is a distillation column.
5. Recycle System
Recycle system is required in the ammonia production unit because the
reaction is limited by chemical equilibrium, nitrogen and hydrogen should be
recycled. Note that the purge stream flow rate is very small, so it is not shown in Fig.
E.1. The recycle stream consists of only one compressor in order to increase streams
pressure before sending back to the reactor.
Reference for Appendix G

Coal, 48(2), 15-23.
46
Appendix F.
Feed Preparation
System
47
Fig. F.1 and F.2 shows a consideration for feed preparation system for air and
hydrogen, respectively.
Air To the Reactor
Remove Solid Increase

Particles Temperature
Decrease
Increase Pressure
Temeprature
Remove Carbon
Increase Pressure Distillation
Dioxide
Fig. F.1. Consideration for air
Increase
Hydrogen Decrease Pressure To the Reactor
Temperature
Fig. F.2. Consideration for hydrogen
48
F.1. Filter: Particle Removal
As shown in Fig. F.3, the air is fed and filtered to separate any dust that will
accumulate in any part of the process. Then, the air is compressed to 10 bars and cooled
to 25C.
Air 1 2
E-101 E-102 E-103
3 4 5 6
C-101
LPS CW CHW
Fig. F.3. Filter process flow diagram
F.2. Adsorber: CO2 Removal

Since carbon dioxide can be frozen and become solid in cryogenic condition, it
must be separated before entering the system by using carbon molecular sieve (CMS)
to adsorb carbon dioxide. In the operation period, it is found that the required time to
regenerate the adsorber is much longer than operating time so there must be four
adsorbers in the process. The operating condition is at the temperature 25C and
pressure 10 bars.
V-101 V-102 V-103 V-104
Fig. F.4. Adsorber process flow diagram
49
F.3. Refrigeration Cycle
Fig. F.5 shows a refrigeration production in our process. Since air fed to a
distillation column requires very low temperature, we should produce it by our own. In
Fig. F.5, air is compressed by two-stage compressor with intercooling heat exchangers.
Then, it is expanded by using a turbine. As a result, we get superheated vapor with very
low temperature so that it could be fed to a cryogenic distillation unit.
C-102 C-103
14
C-104
11 E-106 E-107
9 E-104 E-105 12
10 13
LPS CHW LPS CHW
Fig. F.5. Low temperature production
F.5. Cryogenic Distillation

In the distillation process, three distillation columns are used. The operating
pressures are approximately 1.5 2.5 bars for all columns because boiling points of all
components are very low. The column sequence is based on Linde Air Separation
Process. The first column is used to separate nitrogen and oxygen which has a side
stream sent to the second column. The second column is used to purify oxygen and
recycle to the first column. The last column is used to separate nitrogen and argon. The
process flow diagram is shown in Fig. F.6. High purity nitrogen from distillation is
adjusted its temperature and pressure and then mixed with hydrogen.
F.6. Hydrogen
Hydrogen is fed through valve to reduce its pressure before mixing with nitrogen.
Finally, hydrogen and nitrogen are heated to meet reactor operating conditions.
50
20
E-108
16 17 E-119
Liq. N2 E-106 37 38
E-117
Liq. N2
32 33
T-101 Liq. N2
18 19
39 40
34 36 T-103
21
T-102
41
22
E-120
E-109
E-118
35
Fig. F.6. Cryogenic distillation
51
Appendix G.
Reactor System
52
G.1. General Information
The information about ammonia synthesis is brought from Dashti [1]. In the
reactor, there are two main reactants which are hydrogen and nitrogen gas. According
to the experimental data, we decide to excess nitrogen 1.4 times of hydrogen at the
reactor inlet. The reaction is carried out at 350C and 136.5 bar. The catalyst used for
this reaction is magnetic ferro-oxide. The chemical reaction is shown below.
N 2 (g) 3H 2 (g) 2NH 3 (g)
According to the experimental data, the ammonia synthesis reaction has

conversion of 0.24.
G.2. Heat of Reaction

The reaction between nitrogen and hydrogen gas to produce ammonia gas is
an exothermic equilibrium reaction, releasing 92.4 kJ/mol of energy. Thus, overall
heat of reaction for 84,515 kmol/h is 1.3 x 108 kJ/h. It should be noted that this value
is brought from Aspen.
G.3. Heat Effect of Reactor

Flow rates of all components at the exit of the reactor and heat capacities at
reactor operating conditions (350 C, 136.5 bars) are determined from a simulation
program (Aspen Plus 8.8). The components which have small amount in the reactor
is negligible, all data are shown in Table G.1.
Table G.1. Reactor heat effect calculation
Flow rate, F Heat Capacity, Cp FCp

Component
(kg/h) (kJ/kgK) (kJ/hK)
Helium 3.65881 4.97136 18.18926
Hydrogen 79820.6 7.03174 561277.7
Neon 45.7296 4.98463 227.9451
Nitrogen 100515 7.51277 755146.1
Ammonia 90873.4 12.8728 1169795
FCp 2486465
53
Temperature change in the reactor can be calculated using the equation below.
QR = FCp (T)
1.3 x 108 = 2486465(Tout-Tin)
Tout-Tin = 52
Tout = 402 C
Because the outlet temperature changes dramatically compared with the inlet
stream, an adiabatic is not suitable. It can be seen that these reactions are highly
exothermic, so a reactor is recommended to operate in series with one heat exchanger
to make the temperature change in reactor acceptable. Considerations of a reactor is
shown in Fig. G.1 and the process flow diagram of a reactor system is also shown in
Fig G.2. Internal of R-101 is shown in Fig. G.3.
From Feed To Phase

Reactor
Preparation System Separation System
Fig G.1. Reactor system considerations
R-101
Ammonia
Reactor
34 35
From feed To phase

preparation system Separation system
R-101
Fig. G.2. Reactor process flow diagram
54
Reactor with Heat Reactor with
bed 1 exchanger bed 2
R-101
Fig. G.3. Internal of R-101
Reference for Appendix G

Coal, 48(2), 15-23.
55
Appendix H.
Phase Separation
System
56
Since the reactor effluent, stream 59, is mainly vapor phase, we firstly reduce its
temperature to -40 C by transferring its heat or energy to other streams. With this
method, we can optimize our utility requirement using heat exchangers, E-121, E-110,
E-116, E-130, E-132, E-120, E-118, E-109, E-127 and E-131, respectively. After that,
stream 69 is sent to a flash drum or phase separator where gas and liquid phase are
separated. Liquid flows downward and gas moves upward to the top of the flash drum.
The gas stream, stream 70, still consists of unwanted components so it is partially purge
out of the process with 0.001 fraction. Another fraction flows through a compressor in
order to recycle to the feed preparation system. Then, the liquid stream, stream 74, pass
through a pressure reducing valve to reduce its pressure to 6 bar before flows to another
flash drum to separate liquid ammonia and light ends. The light ends passed through a
reducing valve to decrease its pressure before purged out of the process. Another stream
is liquid ammonia; its conditions are adjusted to meet the appropriate storage at 1 bar
and -33 C or ammonia boiling point. Considerations of a phase separation system are
shown in Fig. H.1. The process flow diagram of a phase separation system is also shown
in Fig. H.2.
57
Recycle
Increase Decrease Vent
Pressure Pressure Purge
Gas Decrease
Pressure
From
Reactor
Decrease Gas-Liquid
Temperature Separation Gas
Liquid Decrease Gas-Liquid

Pressure Separation
To
Liquid Storage
Decrease Increase
Pressure Temperature
Fig. H.1. Phase separation considerations
58
E-109 E-110 E-116 E-127 E-118 E-120 E-121 E-130 E-131 E-132 V-108 C-111 V-109
Oxygen Oxygen Vent Nitrogen Crude Argon Pure Argon Pure Argon Feed Reactor Ammonia Primary Recycle Secondary
Reboiler Heater Heater Feed Reboiler Reboiler Heater Heater Effluent Cooler Phase Stream Phase
Heater Cooler Separator Compressor Separator
To Recycle
71 72 73 Purge
C-111
70
Vent
77
69 V-108
74
76
75
68 67 66 65
E-131 E-127 E-109 E-118 E-120
64
V-109
59 60 61 62 63
78
E-121 E-110 E-116 E-130 E-132
Ammonia
E-132
Fig. H.2. Process flow diagram of a phase separation system
59
Appendix I.
Heat Exchanger
Network
60
I.1. Process Flow Diagram
C-101 E-101 E-102 E-103 V-101 V-102 V-103 V-104 C-102 E-104 E-105 C-103 E-106 E-107 C-104 T-101 E-108 E-109 V-105 E-110 C-105 E-111 E-112 C-106 E-113 E-114 E-115 E-116 T-102 E-117 E-118 V-106 T-103 E-119 V-107 E-120 E-121 C-107 E-122 E-123 C-108 E-124 E-125 E-126 E-127 C-109 E-128 E-129 C-110 E-130 R-101 E-131 E-132 V-108 C-111 V-109
Air Air Air Air Molecular Molecular Molecular Molecular Booster Cryogenic Cryogenic Booster Cryogenic Cryogenic Expansion Air Nitrogen Oxygen Nitrogen Oxygen Oxygen Oxygen Oxygen Oxygen Oxygen Oxygen Oxygen Vent Crude Argon Crude Argon Crude Argon Crude Argon Pure Argon Distillates Distillates Pure Argon Pure Argon Argon Argon Argon Argon Argon Argon Argon Nitrogen Nitrogen Nitrogen Nitrogen Nitrogen Feed Ammonia Reactor Ammonia Primary Recycle Secondary
Compressor Cooler 1 Cooler 2 Cooler 3 Sieve Sieve Sieve Sieve Compressor 1 Cooler 1 Cooler 2 Compressor 2 Cooler 3 Cooler 4 Turbine Cryogenic Condenser Reboiler Reflux Heater Compressor 1 Cooler 1 Cooler 2 Compressor 2 Cooler 3 Cooler 4 Cooler 5 Heater Column Condenser Reboiler Reflux Column Condenser Reflux Reboiler Heater Compressor 1 Cooler 1 Cooler 2 Compressor 2 Cooler 2 Cooler 4 Cooler 5 Feed Feed Feed Feed Feed Heater Reactor Effluent Cooler Phase Stream Phase
Adsorber A Adsorber B Adsorber C Adsorber D Column Drum Drum Drum Heater Compressor 1 Cooler 1 Cooler 2 Compressor 2 Cooler Separator Compressor Separator
62
Hydrogen 55
81 82
Vent
E-116
71 72 73
20 E-131
Air 1 2 C-111
68 69
E-108 Purge
E-101 E-102 Propane 77
E-103 16 17 E-119
Liq. N2 V-105 37 38
3 4 5 6 E-117
C-101 V-107 70
Liq. N2
32 33
LPS CW CHW 59
Liq. N2 V-106
T-101
18 19
39 40
R-101
34 36 T-103 56 57 58
15 50 E-130
31 C-109 C-110 V-108 76
V-101 V-102 V-103 V-104
E-127 74
T-102
C-104 75
53
54
E-128 E-129 63
E-120
E-109 51 52
41 LPS CW V-109
8 C-102 C-103 78
22 65
67 Ammonia
14
E-118 E-132
11 35
E-104 E-105 12 E-106 E-107
9 C-108
66 42 C-107
7 10 13 E-122 E-123 E-124 E-125 E-126
E-121 C-105 C-106
60 43 44 45
LPS CHW LPS CHW 46 47 48 49 Argon
E-111 E-112 E-113 E-114 E-115
LPS CW LPS CW CHW
23 27 28 29 30
24 25 26 Oxygen
E-110
61
LPS CW LPS CW CHW
Waste
Fig. I.1 Process Flow Diagram of the ammonia production process

61
Table I.1. Flow summary table for the ammonia production process
Stream 1 2 3 4 5 6 7 8 9 10
Temperature (oC) 40 40 394 120 50 25 25 25 205.15 120
Pressure (bar) 1 1 10 10 10 10 10 10 40 40
Vapor Fraction 1 1 1 1 1 1 1 1 1 1
Mass Flow (kg/h) 103568 103568 103568 103568 103568 103568 79 103489 103489 103489
Mole Flow (kmol/h) 3575.34 3575.34 3575.34 3575.34 3575.34 3575.34 1.79 3573.55 3573.55 3573.55
Helium 0.18 0.18 0.18 0.18 0.18 0.18 0 0.18 0.18 0.18
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0.064 0.064 0.064 0.064 0.064 0.064 0 0.064 0.064 0.064
Nitrogen 2789.95 2789.95 2789.95 2789.95 2789.95 2789.95 0 2789.95 2789.95 2789.95
Argon 33.23 33.23 33.23 33.23 33.23 33.23 0 33.23 33.23 33.23
Oxygen 750.12 750.12 750.12 750.12 750.12 750.12 0 750.12 750.12 750.12
Krypton 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039 0 0.0039 0.0039 0.0039
Xenon 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032 0 0.00032 0.00032 0.00032
Carbon Dioxide 1.79 1.79 1.79 1.79 1.79 1.79 1.79 3.04x10-9 3.04x10-9 3.04x10-9
Ammonia 0 0 0 0 0 0 0 0 0 0
62
Table I.1. Flow summary table for the air separation and ammonia production process (cont)
Stream 11 12 13 14 15 16 17 18 19 20
Temperature (oC) 25 170.54 120 25 -149 -192.05 -192.05 -192.05 -192.05 -192.05
Pressure (bar) 40 127 127 127 2.28 1.52 1.52 1.52 1.52 1.52
Vapor Fraction 1 1 1 1 1 1 0.04 0 0 1
Mass Flow (kg/h) 103489 103489 103489 103489 103489 495254 495254 417875 69645.83 7733.7
Mole Flow (kmol/h) 3573.55 3573.55 3573.55 3573.55 3573.55 17679.36 17679.36 14916.96 2486.16 276.24
Helium 0.18 0.18 0.18 0.18 0.18 0.1877 0.1877 0.0066 0.0011 0.18
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0.064 0.064 0.064 0.064 0.064 0.0901 0.0901 0.0258 0.0043 0.06
Nitrogen 2789.95 2789.95 2789.95 2789.95 2789.95 17679.05 17679.05 14916.9 2486.15 276
Argon 33.23 33.23 33.23 33.23 33.23 0 0 0 0 0
Oxygen 750.12 750.12 750.12 750.12 750.12 0 0 0 0 0
Krypton 0.0039 0.0039 0.0039 0.0039 0.0039 0 0 0 0 0
Xenon 0.00032 0.00032 0.00032 0.00032 0.00032 0 0 0 0 0
Carbon Dioxide 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 0 0 0 0 0
Ammonia 0 0 0 0 0 0 0 0 0 0
63
Stream 21 22 23 24 25 26 27 28 29 30
Temperature (oC) -192.87 -174.96 25 333 120 50 401 120 50 25
Pressure (bar) 1.38 2.21 2.21 20 20 20 200 200 200 200
Vapor Fraction 1 0 1 1 1 1 1 1 1 1
Mass Flow (kg/h) 8600.44 24016.37 24016.37 24016.37 24016.37 24016.37 24016.37 24016.37 24016.37 24016.37
Mole Flow (kmol/h) 306.24 750.45 750.45 750.45 750.45 750.45 750.45 750.45 750.45 750.45
Helium 0.18 0 0 0 0 0 0 0 0 0
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0.06 0 0 0 0 0 0 0 0 0
Nitrogen 303.8 0 0 0 0 0 0 0 0 0
Argon 2.21 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33
Oxygen 0 750.12 750.12 750.12 750.12 750.12 750.12 750.12 750.12 750.12
Krypton 0 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039 0.0039
Xenon 0 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032 0.00032
Carbon Dioxide 0 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9 3.04x10-9
Ammonia 0 0 0 0 0 0 0 0 0 0
64
Stream 31 32 33 34 35 36 37 38 39 40
Temperature (oC) -182.46 -185.72 -188.22 -188.22 -174.98 -188.22 -191.95 -192.52 -192.52 -192.52
Pressure (bar) 2.04 1.52 1.52 1.52 2.21 1.52 1.38 1.38 1.38 1.38
Vapor Fraction 0 0 0 0 0 0 1 0 0 0
Mass Flow (kg/h) 3350.72 43955.54 43955.54 41862.82 1257.58 2093.14 13867.82 13867.82 13001.1 866.74
Mole Flow (kmol/h) 100 1274.7 1274.7 1214 39.3 60.7 480 480 450 30
Helium 0 0 0 0 0 0 0 0 0 0
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0 0 0 0 0 0 0 0 0 0
Nitrogen 27.79 583.59 583.59 555.87 0 27.79 444.64 444.64 416.85 27.79
Argon 32.91 691.11 691.11 658.13 0.0031 32.91 35.36 35.36 33.15 2.21
Oxygen 39.30 0.0019 0.0019 0.0018 39.3 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 0 0 0 0 0 0 0 0 0 0
65
Stream 41 42 43 44 45 46 47 48 49 50
Temperature (oC) -178.52 25 575.18 120 50 583.05 120 50 25 -100
Pressure (bar) 2.07 2.07 20 20 20 200 200 200 200 1.52
Vapor Fraction 0 1 1 1 1 1 1 1 1 1
Mass Flow (kg/h) 1226.4 1226.4 1226.4 1226.4 1226.4 1226.4 1226.4 1226.4 1226.4 69645.83
Mole Flow (kmol/h) 30.70 30.70 30.70 30.70 30.70 30.70 30.70 30.70 30.70 2486.16
Helium 0 0 0 0 0 0 0 0 0 0.0011
Hydrogen 0 0 0 0 0 0 0 0 0 0
Neon 0 0 0 0 0 0 0 0 0 0.0043
Nitrogen 0 0 0 0 0 0 0 0 0 2486.15
Argon 30.7 30.7 30.7 30.7 30.7 30.7 30.7 30.7 30.7 0
Oxygen 0 0 0 0 0 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 0 0 0 0 0 0 0 0 0 0
66
Stream 51 52 53 54 55 56 57 58 59 60
Temperature (oC) 270.06 120 100 253.93 35 35.38 -15.70 350 400 399.79
Pressure (bar) 50 50 50 136.5 150 136.5 136.5 136.5 136.44 136.44
Vapor Fraction 1 1 1 1 1 1 1 1 1 1
Mass Flow (kg/h) 69645.83 69645.83 69645.83 69645.83 15132.4 15132.4 271258 271258 271258 271258
Mole Flow (kmol/h) 2486.16 2486.16 2486.16 2486.16 7500 7500 53485.6 53485.6 48523.1 48523.1
Helium 0.0011 0.0011 0.0011 0.0011 0 0 0.9141 0.9141 0.9141 0.9141
Hydrogen 0 0 0 0 7500 7500 47039.7 47039.7 39595.9 39595.9
Neon 0.0043 0.0043 0.0043 0.0043 0 0 2.27 2.27 2.27 2.27
Nitrogen 2486.15 2486.15 2486.15 2486.15 0 0 6069.35 6069.35 3588.09 3588.09
Argon 0 0 0 0 0 0 0 0 0 0
Oxygen 0 0 0 0 0 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 0 0 0 0 0 0 373.38 373.38 5335.9 5335.9
67
Stream 61 62 63 64 65 66 67 68 69 70
Temperature (oC) 393.74 392.36 21.96 21.47 20.93 19.12 -3.96 -11.10 -40 -40
Pressure (bar) 136.44 136.44 136.44 136.44 136.44 136.44 136.44 136.44 136.44 136.44
Vapor Fraction 1 1 0.980 0.979 0.977 0.972 0.926 0.917 0.897 1
Mass Flow (kg/h) 271258 271258 271258 271258 271258 271258 271258 271258 271258 186671
Mole Flow (kmol/h) 48523.1 48523.1 48523.1 48523.1 48523.1 48523.1 48523.1 48523.1 48523.1 43545.1
Helium 0.9141 0.9141 0.9141 0.9141 0.9141 0.9141 0.9141 0.9141 0.9141 0.91
Hydrogen 39595.9 39595.9 39595.9 39595.9 39595.9 39595.9 39595.9 39595.9 39595.9 39582.3
Neon 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.26
Nitrogen 3588.09 3588.09 3588.09 3588.09 3588.09 3588.09 3588.09 3588.09 3588.09 3586.77
Argon 0 0 0 0 0 0 0 0 0 0
Oxygen 0 0 0 0 0 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 5335.9 5335.9 5335.9 5335.9 5335.9 5335.9 5335.9 5335.9 5335.9 372.88
68
Stream 71 72 73 74 75 76 77 78 79 80
Temperature (oC) -40 -40 -41.28 -40 -36.59 -36.59 -37.36 -36.59 -36.66 -33.33
Pressure (bar) 136.5 136.5 1.01 136.5 6 6 1.01 6 1.01 1.01
Vapor Fraction 1 1 1 0 0 1 1 0 0 0
Mass Flow (kg/h) 186480 186.67 186.67 84587.6 84587.6 102.42 102.42 84485.2 84485.2 84485.2
Mole Flow (kmol/h) 43499.5 43.55 43.55 4977.95 4977.95 16.7 16.7 4961.28 4961.28 4961.28
Helium 0.91 0.00091 0.00091 0.0002 0.0002 0.0002 0.0002 0 0 0
Hydrogen 39540.6 39.58 39.58 13.60 13.60 13 13 0.5983 0.5983 0.5983
Neon 2.26 0.0023 0.0023 0.0020 0.0020 0.0018 0.0018 0.0002 0.0002 0.0002
Nitrogen 3583.2 3.59 3.59 1.32 1.32 1.25 1.25 0.0718 0.0718 0.0718
Argon 0 0 0 0 0 0 0 0 0 0
Oxygen 0 0 0 0 0 0 0 0 0 0
Krypton 0 0 0 0 0 0 0 0 0 0
Xenon 0 0 0 0 0 0 0 0 0 0
Carbon Dioxide 0 0 0 0 0 0 0 0 0 0
Ammonia 372.49 0.37 0.37 4963.03 4963.03 2.42 2.42 4960.61 4960.61 4960.61
69
Table I.1. Flow summary table for the ammonia production process (cont)
Stream 81 82
Temperature (oC) 25 21.64
Pressure (bar) 1.38 1.01
Vapor Fraction 1 1
Mass Flow (kg/h) 8600.44 8702.86
Mole Flow (kmol/h) 306.24 322.94
Helium 0.18 0.18
Hydrogen 0 13
Neon 0.06 0.0618
Nitrogen 303.8 305.5
Argon 2.21 2.21
Oxygen 0 0
Krypton 0 0
Xenon 0 0
Carbon Dioxide 0 0
Ammonia 0 2.42
70
I.2. Heat Exchanger Network Design
I.2.1. Stream Information
Table I.2 shows information of all streams considered in HEN design.
Table I.2. Stream Information
Stream Heat Inlet Outlet

FCp Q (kW)
Number Exchanger Temperature (oC) Temperature (oC)
3 E-101 394 120 29.99 -8217.92
4 E-102 120 50 29.38 -2056.74
5 E-103 50 25 29.41 -735.29
9 E-104 205.15 120 30.14 -2566.75
10 E-105 120 25 30.50 -2897.56
12 E-106 170.54 120 31.82 -1608.39
13 E-107 120 25 33.22 -3155.73
16 E-108 -192.05 -192.05 - -28937.7
Bottom
E-109 -174.96 -174.96 - +22541.28
T-101
22 E-110 -174.96 25 12.95 +2589.88
24 E-111 333 120 6.55 -1395.81
25 E-112 120 50 6.35 -444.65
27 E-113 401 120 7.10 -1994.82
28 E-114 120 50 7.51 -525.89
29 E-115 50 25 8.03 -200.73
21 E-116 -192.87 25 2.71 +589.55
32 E-117 -185.72 -188.22 - -2116.68
Bottom
E-118 -174.98 -174.98 - +2115.59
T-102
37 E-119 -191.95 -192.52 - -742.99
Bottom
E-120 -178.52 -178.52 - +642.48
T-103
41 E-121 -178.52 25 0.44 +89.63
43 E-122 575.18 120 0.18 -81.62
44 E-123 120 50 0.18 -12.84
46 E-124 583.05 120 0.22 -103.17
71
47 E-125 120 50 0.23 -16
48 E-126 50 25 0.25 -6.27
19 E-127 -192.05 -100 61.56 +5666.90
51 E-128 270.06 120 20.98 -3147.8
52 E-129 120 100 21.15 -422.98
57 E-130 -15.70 350 443.06 +162028.2
59 E-121 400 399.79 426.76 -89.62
60 E-110 399.79 393.74 428.08 -2589.88
61 E-116 393.74 392.36 427.21 -589.55
62 E-130 392.36 21.96 437.44 -162029
63 E-132 21.96 21.47 1196.84 -586.45
64 E-120 21.47 20.93 1189.78 -642.48
65 E-118 20.93 19.12 1168.83 -2115.59
66 E-109 19.12 -3.96 976.66 -22541.28
67 E-127 -3.96 -11.10 793.68 -5666.90
68 E-131 -11.10 -40 657.00 -18,987.4
79 E-132 -36.657 -33.33 176.27 +586.45
Reactor internal
500.00 300.00 434.56 -86912.83
heat exchanger
Sum -167,289
72
I.2.2. Utilities Information
Referring to Table I.1, the minimum heat that we need to remove from the
process is 167,294 kW. Available utilities are shown in Table I.2.
Table I.2. Utility Information
Inlet Outlet Duty based Duty HEN

Utility
Temperature (oC) Temperature (oC) case (kW) (kW)
Hot
Low Pressure
110 110 34,821.8 -
Steam
Fired Heater >230 162,028.2 -
Cold
Produce High
Pressure 250 250 86,912.8 86,912.8
Steam
Produce Low
Pressure 110 110 - 19,116.3
Steam
Cooling water 40 60 - 3,479.1
Chilled water 10 25 29,590.9 7,008.41
Refrigerant
-50 -50 215,834 18,980
propane
Liquid
-203 -203 31,797.4 31,797.4
Nitrogen
In conclusion, if we do not use heat exchanger network, we have to use 196,850 kW

hot utilities and 364,135 kW cold utilities. If heat exchanger network is applied, we
use only 167,294 kW cold utilities and no hot utilities are required.
73
Appendix J.
Separator and Reflux
Drum Design
74
J.1. Flash Drum Design Method
J.1.1. Velocity Determination
This design method is based on Towler Chemical Engineering Design [1]. It
should be noted that the design is based on vertical drums. If H/D is more than 5, a
horizontal drum will be considered. First of all, the velocity of vapor phase is
determined from Eq. (J.1).
u t = 0.07[( L - v )/ v ]1/2 (J.1)

where L and v are density of liquid and vapor phases, respectively. The value
of ut obtained from Eq. (J.1) should be multiplied by a factor of 0.15 to provide a
margin of safety and to allow for flow surges. The result is denoted by u s .
J.1.2. Diameter Determination

The volumetric flow rate of vapor (Qv) is used to determine a diameter (D) of
a flash drum by using Eq. (J.2).
4Q v
Dv = (J.2)
u s
The result diameter is round to nearest standard vessel size.
J.1.3. Liquid Height Determination

Using the volumetric flow rate of liquid (QL) to determine a volume (V) of a
vessel by using Eq. (J.3). The retention time (t) of liquid is allowed at 10 minutes.
The liquid height (hL) in a vessel is also calculated from Eq. (J.4).
V = QL t (J.3)
4V
hL = (J.4)
D 2
J.1.4. Vessel Height Determination

The height of vessel can be determined from Eq. (J.5). It should be noted that
this equation is based on the geometric structure in Fig J.1.
H = h L + 0.4 + DV + DV /2 (J.5)
75
Fig. J.1. Geometric Structure of a Pressure vessel [1]
J.1.5. Horizontal Drum Design

If H/D is higher than 5, this topic should be considered. Firstly, we take the
liquid height to be half of the horizontal flash drum. The preliminary design
recommends to define L/D or H/D to be 4. Using vapor residence time to determine
the diameter. Also, using liquid residence time to determine the height. After all, the
liquid residence time has to be higher than 10 minutes. If not, a new diameter should
be selected.
76
J.2. Reflux Drum Design Method
J.2.1. Orientation
This design method is based on Towler Chemical Engineering Design [1].
Reflux drums are usually horizontal because the liquid load is important.
J.2.2. L/D Selection

The optimal L/D should be selected based on operating pressure which is
shown in Table J.1.
Table J.1. Optimal L/D ratio [1]
Operating Pressure (bar) L/D

0-20 3
20-35 4
>35 5
J.2.3. Volume Determination

The volume of a reflux drum is calculated from Eq. (J.6). The retention time
of liquid are 5 minutes half-filled.
V = QL t (J.6)
J.2.4. Height and Diameter Calculation

The length and diameter of a reflux drum can be calculated from its volume
and L/D ratio.
77
J.3. Input Parameters of all separators and reflux drums
Table J.2 shows all input parameters obtained from Aspen in order to design
the pressure vessel.
Table J.2. Input parameters of all separators and reflux drums
V-105 (Flash) V-106 (Reflux)

Parameter Value Parameter Value
Qv (m3/s) 0.3214155 Qv (m3/s) No vapor
QL (m3/s) 0.024563 QL (m3/s) 0.011323274
v (kg/m3) 6.68372 v (kg/m3) No vapor
L (kg/m3) 787.6101 L (kg/m3) 1078.309
V-107 (Reflux) V-108 (Flash)
Qv (m3/s) No vapor Qv (m3/s) 1.841516667
QL (m3/s) 0.004652141 QL (m3/s) 0.034157983
v (kg/m3) No vapor v (kg/m3) 28.1577
L (kg/m3) 828.0421 L (kg/m3) 687.879
V-109 (Flash)
Parameter Value
Qv (m3/s) 0.015159813
QL (m3/s) 0.034180283
v (kg/m3) 1.87671
L (kg/m3) 686.5978
78
J.4. Design Results
Table J.3 shows the results calculated from the design method mentioned in
part J.1 and J.2 for each pressure vessel.
Table J.3. Design results of all separators and reflux drums

Diameter (m) 2 Diameter (m) 1.5
Height (m) 9 Length (m) 4.5
H/D 4.5 L/D 3
Orientation Vertical Orientation Horizontal
Closure Torispherical Closure Torispherical
Diameter (m) 1.25 Diameter (m) 3
Length (m) 3.75 Height (m) 9
L/D 3 H/D 3
Orientation Horizontal Orientation Vertical
Closure Torispherical Closure Hemispherical
with Demister
V-109 (Flash)
Parameter Value
Diameter (m) 2.5
Length (m) 10
L/D 4
Orientation Horizontal
Closure Hemispherical
79
J.5. Material of Construction and Thickness Design
J.5.1. Material of Construction (MOC) Considerations
As the air separation and ammonia synthesis system are cryogenic processes, the material which is normally used in air-
separation-system construction is Aluminum alloy and stainless steel. MOC is designed based on design temperature which is could
be calculated using Eq. (J.7) and (J.8). MOC of flash drums and reflux drums are shown in Table J.4.
Maximum Temperature = Operating Temperature + 50oF (J.7)
Minimum Temperature = Operating Temperature - 25oF (J.8)
Table J.4. Material of Construction for separators and reflux drums
Operating Maximum Minimum

Vessels MOC
Temperature (C) Temperature (C) Temperature (C)
V-105 -192.05 -164.27 -205.94 SS-304
V-106 -188.22 -160.44 -202.11 SS-304
V-107 -192.52 -164.74 -206.41 SS-304
V-108 -40.00 -12.22 -53.89 SS-304
V-109 -36.59 -8.81 -50.48 SS-304
80
J.5.2. Pressure Vessel Wall Thickness Considerations
Thickness mainly depends on design pressures. First of all, the design pressure should be determined. It could be estimated
from the value of normal operating pressure and max operating pressure using simple correlations, Eq. (J.9) and (J.10).
Maximum Operating Pressure = 1.2 x Operating Pressure (J.9)
Design Pressure = 1.1 x Maximum Operating Pressure (J.10)
Under ASME BVP Code Sec. VIII D.1, minimum wall thickness is 1/16 (1.5 mm) with no corrosion allowance. However,
most pressure vessels require much thicker walls in order to withstand the governing load. The value of wall thickness for hoop stress
and longitudinal stress could be expressed as Eq. (J.11) and (J.12), respectively.
Pi Di
t (J.11)
2SE 1.2Pi
Pi Di
t (J.12)
4SE 0.8Pi
where t is thickness [m]

P is design gauge pressure [N/m2]
D is vessel diameter [m]
S is the maximum allowable stress [N/m2] (obtained from ASME BVP Code Sec. II for different materials as function of
temperature)
E is the welded joint efficiency (assume 0.9)
After calculating the thickness for hoop stress and longitudinal stress, we must choose the value of thickness which is higher
for the safety reason. Then, we add an extra thickness for a corrosion allowance which is 1.5 to 5 mm. We usually prefer the smallest
thickness we can use because wall thickness can affect heat transfer. The vessel thickness added with corrosion allowance is shown
81
in Table J.5. However, a thickness of each vessel should follow the minimum thickness guideline [1] shown in Table J.6. The detail
of each material is shown in Table J.7.
Table J.5. Thickness of separator and reflux drum thickness
Vessel
Design P S S Thickness for Thickness for Selected
Vessel Diameter (m) thickness with
(N/m2) (ksi) (N/m2) Hoop Stress (m) Longitudinal (m) thickness (m)
C.A. (m)
V-105 2.00 1.01105 20 1.38108 0.0008 0.0004 0.0023 0.007
V-106 1.50 1.01105 20 1.38108 0.0006 0.0003 0.0021 0.007
V-107 1.25 8.22104 20 1.38108 0.0004 0.0002 0.0019 0.007
V-108 3.00 1.79107 20 1.38108 0.2166 0.1052 0.2181 0.2181
V-109 2.50 6.92105 20 1.38108 0.0070 0.0035 0.0085 0.0090
Table J.6. Minimum thickness guideline [1]
Vessel Diameter (m) Minimum thickness (mm)

1 5
1 to 2 7
2 to 2.5 9
2.5 to 3 10
3.0 to 3.5 12
82
Table J.7. Detail of each material [1]
Material Type Composition Design Temperature
-101oC or Lower /
SS-304 Stainless Steel 0.08% C, 2% Mn, 17.5% Cr, 8% Ni
425oC Maximum
0.1% C, 2% Mn, 0.75% Si, 0.045% P,
SS-304H Stainless Steel 648oC Maximum
20% Cr, 10.5% Ni
CS Carbon Steel 0.05 0.25% Carbon -10oC to 380oC
31/2 Ni Nickel Steel 3-4% Nickel -45oC to -100oC
83
J.6. Economic Costing Method
To determine cost of vessels, bare module factor method is used according to
analysis, synthesis and design of chemical processes, Turton [2]. The bare module
cost of the vessel can be estimated as shown in Eq. (J.13).
CBM = Cp FBM (J.13)
where CBM is bare module cost (USD), Cp is cost for ambient pressure and
carbon steel (USD) and FBM is bare module factor.
The factor Cp for horizontal and vertical vessels could be obtained from Eq.
(J.14).
logCP = K1 +K2 log(V) +K3 (log(V))2 (J.14)
D2 H
V= (J.15)
4

where V is the volume of the vessel (m3) and Cp is the cost for ambient
pressure and carbon steel (USD). K parameters used for horizontal and vertical
vessels are shown in Table J.8.
Table J.8. K parameters for pressure vessels
Parameters Horizontal Vertical

K1 3.5565 3.4974
K2 0.3776 0.44851
K3 0.0905 0.1074
The bare module factor can be determined from Eq. (J.16).

FBM = B1 +B2 FM FP (J.16)
where FBM is bare module cost factor, FM is material factor and FP is pressure
factor. B parameters used for horizontal and vertical vessels are shown in Table J.9.
Table J.9. B parameters for pressure vessels

B1 1.49 2.25
B2 1.52 1.82
84
The pressure factor of the vessel, which is thicker than 6.3 mm. is determined
by using Eq. (J.17).
P+1 D +0.00315
2 SE-0.6 P+1
FP,vessel = (J.17)
0.0063
where FP,vessel is pressure factor, P is the operating pressure (barg), S is the

maximum allowable stress [N/m2] (obtained from ASME BVP Code Sec. II for
different materials as function of temperature), E is weld efficiency and D is vessel
diameter (m). If a thickness is lower than 6.3 mm, a pressure factor of 1 is used. If the
operating pressure is lower than -0.5 barg, then, a pressure factor of 1.25 is used.
The material factor (FM) of each vessel is determined according to material
factors for equipment in analysis, synthesis and design of chemical processes (fourth
edition), the material factor of stainless steel is 3.1 and the factor of nickel is 7.1.
The estimated cost of each vessel is calculated on the basis of price in 2001
(CEPCI = 397). In 2014, the CEPCI is estimated to be 576.1, the equation which is
used to convert the price is shown in Eq. (J.18).
CBM,2014 576.1
= (J.18)
CBM,2001 397
85
J.7. Costing Parameters
Table J.10 shows all input parameter used to estimate capital cost by using
bare module method.
Table J.10. Input parameters of separator costing

D (m) 2 D (m) 1.5
H (m) 9 H (m) 4.5
FM 3.1 FM 3.1
P (barg) 0.52 P (barg) 0.52
Orientation Vertical Orientation Horizontal
B1 2.25 B1 1.49
B2 1.82 B2 1.52
K1 3.4974 K1 3.5565
K2 0.44851 K2 0.3776
K3 0.01074 K3 0.0905
D (m) 1.25 D (m) 3
H (m) 3.75 H (m) 9
FM 3.1 FM 3.1
P (barg) 0.38 P (barg) 135.5
Orientation Horizontal Orientation Vertical
B1 1.49 B1 2.25
B2 1.52 B2 1.82
K1 3.5565 K1 3.4974
K2 0.3776 K2 0.44851
K3 0.0905 K3 0.01074
86
Table J.10. Input parameters of separator costing (cont)
V-109 (Flash)
Parameter Value
D (m) 2.5
H (m) 10
FM 3.1
P (barg) 5
B1 1.49
B2 1.52
K1 3.5565
K2 0.3776
K3 0.0905
87
J.8. Costing Results
Table J.11 shows the results calculated from the design method mentioned in
part 6 for each pressure vessel.
Table J.11. Separator costing results

Cp (USD) 19,700 Cp (USD) 9,730
CBM,2001 (USD) 155,700 CBM,2001 (USD) 60,400
CBM,2014 (USD) 226,000 CBM,2014 (USD) 87,600
Cp (USD) 7,020 Cp (USD) 45,300
CBM,2001 (USD) 43,600 CBM,2001 (USD) 11,000,000
CBM,2014 (USD) 63,200 CBM,2014 (USD) 16,000,000
V-109 (Flash)
Parameter Value
Cp (USD) 28,400
CBM,2001 (USD) 298,000
CBM,2014 (USD) 432,000
88
J.9. New Equipment Summary
The new equipment summary after performing vessel design is shown in Table
J.12.
Table J.12. Equipment Summary
Vessels/Tower/
V-105 V-106 V-107 V-108
Reactors
Temperature (oC) -192.05 -188.22 -192.52 -40
Pressure (bar) 1.52 1.52 1.38 136.5
Orientation Vertical Horizontal Horizontal Vertical
MOC SS-304 SS-304 SS-304 SS-304
Size
Height/Length (m) 9 4.5 3.75 9
Diameter (m) 2 1.5 1.25 3
Internals - - - Demister
Vessels/Tower/
V-109
Reactors
Temperature (oC) -36.59
Pressure (bar) 6
MOC SS-304
Size
Height/Length (m) 10
Diameter (m) 2.5
Internals -
89
References for Appendix J
[1] Towler, G. P., & Sinnott, R. K. (2013). Chemical engineering design principles,
practice, and economics of plant and process design. Oxford: Butterworth-
Heinemann.
[2] Turton, R., Bailie, R. C., Whiting, W. B., Shaeiwitz, J. A., & Bhattacharyya, D.
(2012). Analysis, synthesis, and design of chemical processes. Pearson Education.
90
Appendix K.
Adsorber Design
91
K.1 Adsorber Design
The amount of carbon dioxide feed in air separation system is 753 tpy or
94.125 kg/hr (consider that there are 8,000 hours for operating time in a year). The
calculation of solid formation starts with estimating the fugacity of pure solid carbon
dioxide and as vapor under the coldest part of distillation column. The equation used
in calculation is shown in Eq. (K.1).
fsCO2 =fvCO2 = yP (K.1)
In this report, the value of fugacity in solid is calculated by Aspen which is
6.4910-12 bar. By assuming that air is an ideal solution, the fugacity of carbon
dioxide in mixture is yP. Thus, the allowable mole fraction of carbon dioxide is
calculated and the result shows it must be less than 4.3310-12 .
Adsorption equilibrium and thermodynamics of CO2 and CH4 on carbon
molecular sieves, Langmuir isotherm, is used in this calculation for CMS-1 adsorber
[1]. Langmuir isotherm equation is shown in Eq. (K.2) and (K.3)
qm byp
q= (K.2)
1+byp
qm : maximum adsorption capacity (mol/kg)
q: adsorbed amount (mol/kg)
b: adsorption equilibrium which is 2.97 (Pa-1)
P: Pressure (Pa)
y: mole fraction of carbon dioxide
8.472.97yP
q= (K.3)
1+2.97yP
The density of CMS is 2267 kg/m3 and the bulk density of the bulk density of
the packed bed is 650 kg/m3 [2]. The molar flux of air can be calculated by Eq. (K.4).
4F
N= (K.4)
D2 Mw
92
The mass transfer coefficient (k m ) is calculated by using empirical solution
shown in Eq. (K.5) to (K.9).
1 2 -0.25 0.625 0.8
1 Re D
Sh=0.3+ [0.62Re2D Sc3 (1+(0.4Sc)3 ) ] [1+ ( ) ] (K.5)
282000
4F
G= (K.6)
D2
GD
ReD = (K.7)

Sc= (K.8)
Dx
km L
Sh= (K.9)
Dx
In order to calculate and design the adsorber shell balance of the cylindrical
system and mass balance of adsorption process are used assuming the surface
diffusion of carbon dioxide limits the adsorption process as shown in Eq. (K.10) to
(K.12)
dq
(yCO N-y*CO N) A=b Ax (K.10)
2 2 dt
dq
km (yCO -y*CO ) = (K.11)
2 2 dt
-N dyCO2 dq qmax bP dy*CO (K.12)

km (yCO -y*CO ) = = = 2
2
2 2 dx dt dt
(1+bPy*CO )
2
In this design, numerical method is used to calculate these differential

equations, in addition, they are calculated several times to approximate the suitable
differential range (x) with small error compared to other calculations. The numerical
estimation is shown in Eq. (K.13).
km
y2 =y1 - (y1 -y*1 )x (K.13)
N
93
However, it is found that the result from Eq. (K.13) is inaccurate, for the values
of mole fraction change with specified ranges. Thus, the trapezoidal rule is used
instead.
km y1 +y*1 +y2 +y*2
y2 =y1 - ( ) x (K.14)
N 2
The mole fraction of carbon dioxide on the CMS as a function of time is

calculated from the equation below.
2
km (yCO -y*CO ) (1+bPy*CO ) t
y*CO (t+t)=y*CO (t)+ 2 2 2 (K.15)
2 2 qmax bP
The smallest diameter of column is trialed to be 1 m and the height to diameter

ratio is assume to be 5, as the solid column design guideline, the height is 5 m. The
result shows the adsorber column operating period is approximately 15 minutes or
900 seconds, same as the industrial operating period of the equipment.
Carbon dioxide mole fraction from numerical method is 8.5310-13 . In Aspen
simulation, the oxygen product line mole fraction is 4.0510-12 which is acceptable.
According to the previous sizing, the volume of packed CMS is 0.763 m3,
therefore the weight of CMS can be determined by multiply bulk density with the
volume 0.763650 = 496 kg CMS.
94
K.2. Input Parameters of adsorbers
Table K.1 shows all input parameters obtained from the previous calculation
in order to design the adsorber.
Table K.1. Input designing parameter of the adsorber
V-101 (Adsorber) V-102 (Adsorber)

Diameter (m) 1 Diameter (m) 1
Pressure (bar) 10 Pressure (bar) 10
H/D 5 H/D 5
Operating Operating
15 15
period (min) period (min)
Orientation Vertical Orientation Vertical
Air mass flow Air mass flow
1,000,000 1,000,000
rate (tpy) rate (tpy)
Initial Initial
carbon dioxide carbon dioxide
0.05 0.05
concentration concentration
(vol%) (vol%)
Bulk Density of Bulk Density of
650 650
CMS (kg/m3) CMS (kg/m3)
Air molecular Air molecular
28.955 28.955
weight (g/mol) weight (g/mol)
95
Table K.1. Input designing parameter of the adsorber (cont)

Diameter (m) 1 Diameter (m) 1
Pressure (bar) 10 Pressure (bar) 10
H/D 5 H/D 5
Operating Operating
15 15
period (min) period (min)
Air mass flow Air mass flow
1,000,000 1,000,000
rate (tpy) rate (tpy)
Initial Initial
carbon dioxide carbon dioxide
0.05 0.05
(vol%) (vol%)
Bulk Density of Bulk Density of
650 650
CMS (kg/m3) CMS (kg/m3)
Air molecular Air molecular
28.955 28.955
weight (g/mol) weight (g/mol)
96
K.3. Design Results
Table K.2 shows the results calculated from the design method mentioned in
part 1 for each adsorber.
Table K.2. Design results of the adsorber

Height (m) 5 Height (m) 5
Mole fraction Mole fraction
-13
carbon dioxide 8.5310 carbon dioxide 8.5310-13
Adsorbent Adsorbent
496 496
Weight (kg) Weight (kg)
Height (m) 5 Height (m) 5
Mole fraction Mole fraction
carbon dioxide 8.5310-13 carbon dioxide 8.5310-13
Adsorbent Adsorbent
496 496
Weight (kg) Weight (kg)
97
K.4. Material of Construction and Thickness Design
K.4.1. Material of Construction (MOC) Considerations
As the temperature of the vessel is 25C carbon steel is used. MOC is designed based on design temperature which is could
be calculated using Eq. (K.16) and (K.17). MOC of flash drums and reflux drums are shown in Table K.3.
Maximum Temperature = Operating Temperature + 50oF (K.16)
Minimum Temperature = Operating Temperature - 25oF (K.17)
Table K.3. Material of Construction for separators and reflux drums

Vessels MOC
V-101 25 52.78 11.11 Carbon Steel
V-102 25 52.78 11.11 Carbon Steel
V-103 25 52.78 11.11 Carbon Steel
V-104 25 52.78 11.11 Carbon Steel
98
K.4.2. Pressure Vessel Wall Thickness Considerations
from the value of normal operating pressure and max operating pressure using simple correlations, Eq. (K.18) and (K.19).
Maximum Operating Pressure = 1.2 x Operating Pressure (K.18)
Design Pressure = 1.1 x Maximum Operating Pressure (K.19)
and longitudinal stress could be expressed as Eq. (K.20) and (K.21), respectively.
Pi Di
t (K.20)
2SE 1.2Pi
Pi Di
t (K.21)
4SE 0.8Pi
temperature)
in Table K.4. The minimum thickness guideline is shown in Table K.5. The detail of each material is shown in Table K.6.
99
Table K.4. Calculation of separator and reflux drum thickness
Vessel
C.A. (m)
V-101 1.00 106 12.9 8.89107 0.0076 0.0038 0.0091 0.0091
V-102 1.00 106 12.9 8.89107 0.0076 0.0038 0.0091 0.0091
V-103 1.00 106 12.9 8.89107 0.0076 0.0038 0.0091 0.0091
V-104 1.00 106 12.9 8.89107 0.0076 0.0038 0.0091 0.0091
Table K.5. Minimum thickness guideline

1 5
1 to 2 7
2 to 2.5 9
2.5 to 3 10
3.0 to 3.5 12
100
Table K.6. Detail of each material
SS-304 Stainless Steel 0.07% C, 2% Mn, 0.75% Si, 0.045% P, -101oC or Lower /
19.5% Cr, 10.5% Ni, 0.1% N 425oC Maximum
0.1% C, 2% Mn, 0.75% Si, 0.045% P,
20% Cr, 10.5% Ni
101
K.5. Economic Costing Method
To determine cost of vessels, bare module factor method is used according to
analysis, synthesis and design of chemical processes. The bare module cost of the
vessel can be estimated as shown in Eq. (K.22).
CBM = Cp FBM (K.22)
The factor Cp for horizontal and vertical vessels could be obtained from Eq.
(K.23).
logCP = K1 +K2 log(V) +K3 (log(V))2 (K.23)
D2 H
V= (K.24)
4
vessels are shown in Table K.7.
Table K.7. K parameters for pressure vessels
Parameters Vertical
K1 3.4974
K2 0.44851
K3 0.1074
The bare module factor can be determined from Eq. (K.25).

FBM = B1 +B2 FM FP (K.25)
factor. B parameters used for horizontal and vertical vessels are shown in Table K.8.
Table K.8. B parameters for pressure vessels
Parameters Vertical
B1 2.25
B2 1.82
102
The pressure factor of the vessel, which is thicker than 6.3 mm. is determined
by using Eq. (K.26).
P+1 D +0.00315
2 SE-0.6 P+1 (K.26)
FP,vessel =
0.0063
maximum allowable stress [N/m 2] (obtained from ASME BVP Code Sec. II for
diameter (m). If a thickness is lower than 6.3 mm, a pressure factor of 1 is used. If
the operating pressure is lower than -0.5 barg, then, a pressure factor of 1.25 is used.
In addition, the price of carbon molecular sieve is also take into account. The
price of CMS is approximately 1,000 USD/ton [3].
used to convert the price is shown in Eq. (K.27).
CBM,2014 576.1
= (K.27)
CBM,2001 397
103
K.6. Costing Parameters
Table K.9 shows all input parameter used to estimate capital cost by using bare
module method.
Table K.9. Input parameters of all adsorbers
V-101 V-102
(Adsorber) (Adsorber)
D (m) 1 D (m) 1
H (m) 5 H (m) 5
FM 1 FM 1
P (barg) 9 P (barg) 9
B1 2.25 B1 2.25
B2 1.82 B2 1.82
K1 3.4974 K1 3.4974
K2 0.44851 K2 0.44851
K3 0.01074 K3 0.01074
V-103 V-104
D (m) 1 D (m) 1
H (m) 5 H (m) 5
FM 1 FM 1
P (barg) 9 P (barg) 9
B1 2.25 B1 2.25
B2 1.82 B2 1.82
K1 3.4974 K1 3.4974
K2 0.44851 K2 0.44851
K3 0.01074 K3 0.01074
104
K.7. Costing Results
Table K.10 shows the results calculated from the design method mentioned in
part K.3 for each adsorber.
Table K.10. Input parameters of all adsorbers
V-101 V-102
Cp (USD) 2,800 Cp (USD) 2,800
CBM,2001 (USD) 11,700 CBM,2001 (USD) 11,700
CBM,2014 (USD) 17,000 CBM,2014 (USD) 17,000
V-103 V-104
Cp (USD) 2,800 Cp (USD) 2,800
CBM,2001 (USD) 11,700 CBM,2001 (USD) 11,700
CBM,2014 (USD) 17,000 CBM,2014 (USD) 17,000
Since the market price of CMS which is the adsorber is $ 1,000 per ton, total cost of
the reactor is 68,000 + 4(0.496)(1000) = $ 70,000.
105
K.8. New Equipment Summary
The new equipment summary after performing adsrober or vessel design is
shown in Table K.11.
Table K.11. Equipment Summary
Vessels/Tower/
V-101 V-102 V-103 V-104
Reactors
Orientation Vertical Vertical Vertical Vertical
MOC CS CS CS CS
Size
Height/Length (m) 5 5 5 5
Diameter (m) 1 1 1 1
Internals CMS CMS CMS CMS
106
References for Appendix K
[1] Song, X., Wang, L., Ma, X., & Zeng, Y. (2017). Adsorption equilibrium and
thermodynamics of CO2 and CH4 on carbon molecular sieves. Applied Surface
Science, 396, 870-878. doi:10.1016/j.apsusc.2016.11.050
[2] Carbon Molecular Sieves (CMS) and Nitrogen gas genelator KURASEP | Our
Products. (n.d.). Retrieved May 12, 2017, from http://www.kuraray-
c.co.jp/en/products/device.html [2] Turton, R., Bailie, R. C., Whiting, W. B.,
Shaeiwitz, J. A., & Bhattacharyya, D.
[3] Alibaba Manufacturer Directory - Suppliers, Manufacturers, Exporters &
Importers . (n.d.). Retrieved May 13, 2017, from
https://www.alibaba.com/product-detail/high-quality-cheap-price-carbon-
molecular_60497753630.html?s=p
107
Appendix L.
Fractionation Tower
Design
108
L.1. Tray Distillation Column Design Method
The design method for distillation columns is based on Seader [1].
L.1.1. Velocity Determination

The entrainment velocity of each tray is calculated by using Eq. (L.1).
u t = C[( L - v )/ v ]1/2 (L.1)

where L and v are density of liquid and vapor phases, respectively, C is the
constant in (ft/s) which can be obtained by Eq. (L.2).
C=FST FF FHA CF (L.2)
Other factor such as surface-tension factor (FST), foaming factor (FF) and FHA
are determined as in Eq. (L.3), Eq. (L.4) and Eq. (L.5).

0.2
FST (L.3)
20
where is surface-tension force in (dyne/cm).
FF = 1 (L.4)
For non-foaming system, the value of FF is 1.
Ah
1; 0.1
Aa
FHA = (L.5)
5 A h +0.5;0.06 A h 0.1
A a Aa
where Aa is active area and Ah is hole area of each tray.
P
CF =f ,FLV (L.6)
L
P
where is pressure drop per height.
L
LM L V
FLV = (L.7)
VM V L
where L is molar liquid flow rate on each tray, V is molar vapor flow rate
passing each tray, ML is liquid phase molecular weight and MV is vapor phase
molecular weight.
109
0.1 ;FLV 0.1
Ad F -0.1
= 0.1+ LV ;0.1 FLV 1.0 (L.8)
Aa 9
0.2 ;FLV 0.1
where Ad is liquid downcomer area.
L.1.2. Tray Diameter Determination

The minimum required diameter of each tray is determined by Eq. (L.9).
4VM V
DT =
A (L.9)
fU f 1- d v
A
The calculated diameter of the biggest tray is chosen and rounded up to nearest
standard column size. The operating flow velocity (Uf) is 80% of entrainment
velocity.
Uf = 0.8ut (L.10)
L.1.3. Liquid Volumetric Flux Determination

After the previous calculation, the liquid volumetric flux is determined by
using Eq. (L.11) to validate the use of tray. If the flux is less than 30 m/h, the packed
column will be used instead. When L is molar liquid flow rate on each tray, ML is
liquid phase molecular weight, v is the density of vapor phase and DT is the diameter
of the tray.
4LM L
G= (L.11)
v DT2
110
L.2. Input Parameters of all Columns
Table L.1 shows all input parameters obtained from Aspen plus in order to
design the column. Since the calculation is done on every tray the whole information
is too much to be informed in this report, only the calculation example of the biggest
diameter is shown.
Table L.1. Input parameters of all columns
T-101 T-102
L (kg/m3 ) 787.41 L (kg/m3 ) 1353.43
V (kg/m3 ) 6.735 V (kg/m3 ) 8.41
LML (kg/h) 464444.30 LML (kg/h) 45897.26
VMV (kg/h) 541685.08 VMV (kg/h) 47914.52
Internal Sieve tray Internal Sieve tray
Ah/Aa 0.1 Ah/Aa 0.1
Ad/Aa 0.1 Ad/Aa 0.1
(dyne/cm) 26.27788 (dyne/cm) 24.03881
T-103
Parameter Value
L (kg/m3 ) 874.96
V (kg/m3 ) 6.40
LML (kg/h) 13282.72
VMV (kg/h) 13867.81
Internal Sieve tray
Ah/Aa 0.1
Ad/Aa 0.1
(dyne/cm) 26.1075
111
L.3. Tray Column Design Results
Table L.2 shows the results calculated from the design method mentioned in
L.1 for each column.
Table L.2. Design diameters of each column
Calculated Selected
Column
Diameter (m) Diameter (m)
T-101 6.59 6.6
T-102 1.46 1.5
T-103 0.93 0.95
Determination of the volume flux in the columns is done in order to decide

whether the internals should be tray or packing.
Table L.3. Liquid flux of each column
Column Liquid flux (m3/m2h)

T-101 17.29
T-102 20.24
T-103 22.31
The results show that the liquid flux of the columns are less than 30 m3/m2h,
which is the minimum liquid flux in tray column. Thus, structured packing columns
are used instead.
112
L.4. Packed Distillation Column Design Method
The design of the column in some part is the same as tray column design such
as the calculation method of FLV, however, FLV, liquid density and liquid viscosity
are used in other correlation as shown in Fig L.1, L.2 and L.3 [1].
Fig L.1. Generalized pressure-drop correlation of Leva for packed columns.
Fig L.2. Correction factor for liquid density.
Fig L.3. Correction factor for liquid viscosity.
113
a
FP = (L.12)
3
when Fp is packing factor, a is surface area per volume (m2/m3) and is void fraction.
In this calculation, ISP packing type by Koch (vendor) has packing factor 99.51
m2/m3 with void fraction 0.98 is used.
4VM V
DT = (L.13)
fU f v
The diameter of packed columns are determined by Eq. (L.13) and rounded up
to standard size of column.
Htotal = H+Hmin (L.14)
The total height of the columns are calculated based on packed height (H) and
required height (Hmin).
H=Nequilibrium(HETP) (L.15)
The packed height of each column is calculated based on HETP = 0.3 m. The
number of equilibrium stages of each structured packing column and equilibrium
stage is obtained from Aspen plus. Hsump is also considered to be half of column
diameter. Hfeed and Hreflux of which height are 1.2 m are added to install liquid
distributor. Hdis is the height of the distributors, which are installed every 6 to 8 m, in
the columns equals 1.2 m are also taken into account.
114
L.5. Input Parameters of Packed Columns
Table L.4 shows all input parameters obtained from Aspen in order to design
the column.
Table L.4. Input parameters of all columns
T-101 T-102
L (kg/m3 ) 787.41 L (kg/m3 ) 1218.24
V (kg/m3 ) 6.735 V (kg/m3 ) 7.97
LML (kg/h) 464444.30 LML (kg/h) 43863.96
VMV (kg/h) 541685.08 VMV (kg/h) 43955.96
Internal Structured Internal Structured
Packing Packing
(kg/ms) 0.1368 (kg/ms) 0.214383
T-103
Parameter Value
L (kg/m3 ) 1342.70
V (kg/m3 ) 7.794
LML (kg/h) 15704.09
VMV (kg/h) 16543.13
Internal Structured
Packing
(kg/ms) 0.234638
115
Table L.5. Input parameter of the first column
Liquid Vapor
Liquid flow Vapor flow density Viscosity Diameter
Stage density
(kg/h) (kg/h) of Liquid (m)
(g/cm3) (g/cm3)
1 464306 7734 0.7876 0.0067 0.1370 0.77
2 464444 541685 0.7874 0.0067 0.1368 6.48
3 464543 541824 0.7872 0.0068 0.1366 6.47
4 464642 541923 0.7871 0.0068 0.1365 6.46
5 464741 542022 0.7869 0.0068 0.1363 6.46
6 464840 542121 0.7868 0.0068 0.1361 6.45
7 464939 542220 0.7866 0.0069 0.1359 6.45
8 465037 542318 0.7864 0.0069 0.1358 6.44
9 465135 542417 0.7863 0.0069 0.1356 6.44
10 465234 542515 0.7861 0.0069 0.1354 6.43
11 465332 542613 0.7859 0.0069 0.1353 6.42
12 465430 542711 0.7858 0.007 0.1351 6.42
13 465528 542809 0.7856 0.007 0.1349 6.41
14 465626 542907 0.7855 0.007 0.1347 6.41
15 465723 543005 0.7853 0.007 0.1346 6.40
16 465821 543103 0.7851 0.0071 0.1344 6.40
17 465918 543200 0.785 0.0071 0.1343 6.39
18 466016 543298 0.7848 0.0071 0.1341 6.39
19 466113 543395 0.7847 0.0071 0.1339 6.38
20 466210 543492 0.7845 0.0072 0.1338 6.38
21 466307 543590 0.7844 0.0072 0.1336 6.37
22 466404 543687 0.7842 0.0072 0.1334 6.36
23 466501 543783 0.784 0.0072 0.1333 6.36
24 466597 543880 0.7839 0.0073 0.1331 6.35
25 466694 543977 0.7837 0.0073 0.1330 6.35
26 466791 544074 0.7836 0.0073 0.1328 6.34
27 466887 544170 0.7834 0.0073 0.1326 6.34
28 466983 544266 0.7833 0.0073 0.1325 6.33
116
29 467079 544363 0.7831 0.0074 0.1323 6.33
30 467175 544459 0.783 0.0074 0.1322 6.32
31 467271 544555 0.7828 0.0074 0.1320 6.32
32 467367 544651 0.7827 0.0074 0.1319 6.31
33 467463 544747 0.7825 0.0075 0.1317 6.31
34 467559 544843 0.7824 0.0075 0.1315 6.30
35 467654 544938 0.7822 0.0075 0.1314 6.30
36 467750 545034 0.782 0.0075 0.1312 6.29
37 467845 545129 0.7819 0.0076 0.1311 6.29
38 467941 545225 0.7817 0.0076 0.1309 6.28
39 468036 545320 0.7816 0.0076 0.1308 6.28
40 468131 545415 0.7814 0.0076 0.1306 6.27
41 468226 545510 0.7813 0.0077 0.1305 6.27
42 468321 545605 0.7811 0.0077 0.1303 6.26
43 468416 545700 0.781 0.0077 0.1302 6.26
44 468510 545795 0.7808 0.0077 0.1300 6.25
45 468605 545890 0.7807 0.0077 0.1299 6.25
46 468699 545984 0.7805 0.0078 0.1297 6.24
47 468794 546079 0.7804 0.0078 0.1296 6.24
48 468888 546173 0.7803 0.0078 0.1294 6.23
49 468983 546268 0.7801 0.0078 0.1293 6.23
50 469077 546362 0.78 0.0079 0.1292 6.22
51 469171 546456 0.7798 0.0079 0.1290 6.22
52 469265 546550 0.7797 0.0079 0.1289 6.21
53 469359 546644 0.7795 0.0079 0.1287 6.21
54 469453 546738 0.7794 0.008 0.1286 6.21
55 469546 546832 0.7792 0.008 0.1284 6.20
56 469640 546926 0.7791 0.008 0.1283 6.20
57 469734 547019 0.7789 0.008 0.1281 6.19
58 469827 547113 0.7788 0.0081 0.1280 6.19
59 469920 547207 0.7786 0.0081 0.1279 6.18
60 470014 547300 0.7785 0.0081 0.1277 6.18
117
61 470107 547393 0.7784 0.0081 0.1276 6.17
62 470200 547487 0.7782 0.0081 0.1274 6.17
63 470293 547580 0.7781 0.0082 0.1273 6.16
64 470386 547673 0.7779 0.0082 0.1272 6.16
65 470479 547766 0.7778 0.0082 0.1270 6.15
66 470572 547859 0.7776 0.0082 0.1269 6.15
67 470665 547952 0.7775 0.0083 0.1268 6.15
68 470758 548044 0.7774 0.0083 0.1266 6.14
69 470850 548137 0.7772 0.0083 0.1265 6.14
70 470943 548230 0.7771 0.0083 0.1264 6.13
71 471035 548322 0.777 0.0084 0.1262 6.13
72 471125 548414 0.7768 0.0084 0.1261 6.12
73 471211 548505 0.7767 0.0084 0.1260 6.12
74 471284 548591 0.7767 0.0084 0.1258 6.12
75 471317 548663 0.7769 0.0084 0.1258 6.11
76 471241 548696 0.7776 0.0085 0.1258 6.11
77 470869 548620 0.7795 0.0085 0.1260 6.12
78 469733 548249 0.7846 0.0085 0.1267 6.13
79 446787 547113 0.7976 0.0077 0.1286 6.32
80 446887 420677 0.7975 0.0085 0.1285 5.40
81 446993 420777 0.7974 0.0086 0.1284 5.40
82 447112 420883 0.7974 0.0086 0.1283 5.40
83 447262 421002 0.7977 0.0086 0.1282 5.40
84 447479 421152 0.7984 0.0086 0.1282 5.40
85 447839 421369 0.8004 0.0087 0.1284 5.40
86 448496 421729 0.8051 0.0087 0.1291 5.41
87 449744 422387 0.8162 0.0087 0.1308 5.44
88 452093 423634 0.8413 0.0088 0.1348 5.51
89 456271 425983 0.8935 0.009 0.1431 5.65
90 462583 430162 0.9814 0.0092 0.1568 5.88
91 465808 436474 1.0814 0.0094 0.1710 6.11
92 469287 443050 1.1496 0.0095 0.1790 6.28
118
93 468564 446528 1.1777 0.0095 0.1812 6.36
94 464967 445805 1.1826 0.0095 0.1806 6.37
95 460040 442208 1.1776 0.0094 0.1790 6.35
96 454703 437281 1.1689 0.0093 0.1771 6.31
97 449438 431944 1.1594 0.0093 0.1752 6.27
98 444515 426679 1.1501 0.0092 0.1733 6.22
99 440094 421756 1.1416 0.0091 0.1716 6.18
100 436255 417335 1.134 0.0091 0.1701 6.14
101 433018 413496 1.1276 0.009 0.1688 6.11
102 430359 410260 1.1222 0.009 0.1678 6.08
103 428220 407600 1.1178 0.009 0.1669 6.05
104 426532 405461 1.1142 0.009 0.1661 6.03
105 425221 403773 1.1114 0.0089 0.1655 6.01
106 424218 402462 1.1091 0.0089 0.1650 6.00
107 423460 401459 1.1073 0.009 0.1646 5.98
108 422895 400701 1.1059 0.009 0.1643 5.97
109 422481 400137 1.1048 0.009 0.1640 5.97
110 422183 399722 1.104 0.009 0.1638 5.96
111 421973 399424 1.1033 0.009 0.1636 5.95
112 421832 399215 1.1027 0.009 0.1634 5.95
113 421741 399073 1.1022 0.009 0.1632 5.94
114 421690 398982 1.1018 0.0091 0.1630 5.94
115 421668 398931 1.1015 0.0091 0.1629 5.93
116 421668 398909 1.1012 0.0091 0.1628 5.93
117 421684 398909 1.1009 0.0091 0.1626 5.92
118 421714 398926 1.1007 0.0091 0.1625 5.92
119 421753 398955 1.1005 0.0092 0.1624 5.92
120 24016.3712 398993.852 1.1003 0 0
119
Table L.6. Input parameter of the second column
Liquid Vapor Liquid Vapor

density Viscosity Diameter
Stage flow flow density
of Liquid (m)
(kg/h) (kg/h) (g/cm3) (g/cm3)
1 41863 1.0783 0.0076 0.1910
2 43864 43956 1.2182 0.008 0.2144 2.44
3 45075 45957 1.3015 0.0082 0.2259 2.35
4 45615 47168 1.3366 0.0083 0.2298 2.40
5 45821 47708 1.3492 0.0084 0.2309 2.42
6 45897 47915 1.3534 0.0084 0.2311 2.42
7 45927 47990 1.3547 0.0084 0.2311 2.42
8 45941 48020 1.355 0.0085 0.2309 2.42
9 45950 48034 1.355 0.0085 0.2307 2.42
10 45957 48043 1.3549 0.0085 0.2305 2.42
11 45963 48050 1.3547 0.0085 0.2303 2.42
12 45969 48056 1.3546 0.0085 0.2301 2.42
13 45975 48062 1.3544 0.0086 0.2299 2.42
14 45981 48068 1.3542 0.0086 0.2297 2.41
15 45987 48074 1.354 0.0086 0.2295 2.41
16 45993 48080 1.3538 0.0086 0.2293 2.41
17 45999 48086 1.3536 0.0087 0.2291 2.41
18 46005 48092 1.3534 0.0087 0.2289 2.41
19 46011 48098 1.3533 0.0087 0.2287 2.41
20 46017 48104 1.3531 0.0087 0.2286 2.40
21 46023 48110 1.3529 0.0087 0.2284 2.40
22 46029 48116 1.3527 0.0088 0.2282 2.40
23 46035 48122 1.3525 0.0088 0.2280 2.40
24 46041 48128 1.3524 0.0088 0.2278 2.40
25 46047 48134 1.3522 0.0088 0.2276 2.40
26 46053 48140 1.352 0.0088 0.2274 2.40
27 46059 48146 1.3518 0.0089 0.2272 2.39
28 46064 48152 1.3516 0.0089 0.2270 2.39
120
29 46070 48158 1.3515 0.0089 0.2268 2.39
30 46076 48163 1.3513 0.0089 0.2266 2.39
31 46082 48169 1.3511 0.009 0.2264 2.39
32 46088 48175 1.3509 0.009 0.2263 2.39
33 46094 48181 1.3507 0.009 0.2261 2.39
34 46099 48187 1.3506 0.009 0.2259 2.38
35 46105 48192 1.3504 0.009 0.2257 2.38
36 46111 48198 1.3502 0.0091 0.2255 2.38
37 46117 48204 1.35 0.0091 0.2253 2.38
38 46122 48210 1.3498 0.0091 0.2251 2.38
39 46128 48215 1.3497 0.0091 0.2249 2.38
40 46134 48221 1.3495 0.0092 0.2247 2.38
41 46139 48227 1.3493 0.0092 0.2245 2.37
42 46145 48232 1.3491 0.0092 0.2243 2.37
43 46150 48238 1.3489 0.0092 0.2241 2.37
44 46156 48243 1.3487 0.0092 0.2240 2.37
45 46161 48249 1.3486 0.0093 0.2238 2.37
46 46167 48254 1.3484 0.0093 0.2236 2.37
47 46172 48260 1.3482 0.0093 0.2234 2.37
48 46177 48265 1.348 0.0093 0.2232 2.36
49 46183 48271 1.3478 0.0093 0.2230 2.36
50 46188 48276 1.3477 0.0094 0.2227 2.36
51 46193 48281 1.3475 0.0094 0.2225 2.36
52 46198 48286 1.3473 0.0094 0.2223 2.36
53 46203 48291 1.3471 0.0094 0.2221 2.36
54 46208 48296 1.3469 0.0095 0.2219 2.36
55 46213 48301 1.3467 0.0095 0.2217 2.35
56 46218 48306 1.3465 0.0095 0.2214 2.35
57 46222 48311 1.3463 0.0095 0.2212 2.35
58 46227 48316 1.3461 0.0095 0.2210 2.35
59 46231 48320 1.3459 0.0096 0.2207 2.35
60 46236 48324 1.3457 0.0096 0.2205 2.35
121
61 46240 48329 1.3455 0.0096 0.2202 2.35
62 46244 48333 1.3453 0.0096 0.2199 2.34
63 46247 48337 1.3451 0.0096 0.2197 2.34
64 46251 48340 1.3449 0.0097 0.2194 2.34
65 46254 48344 1.3447 0.0097 0.2191 2.34
66 46257 48347 1.3445 0.0097 0.2188 2.34
67 46260 48350 1.3442 0.0097 0.2184 2.34
68 46262 48353 1.344 0.0097 0.2181 2.34
69 46264 48355 1.3438 0.0098 0.2177 2.33
70 46266 48357 1.3435 0.0098 0.2173 2.33
71 46267 48359 1.3433 0.0098 0.2169 2.33
72 46268 48360 1.343 0.0098 0.2164 2.33
73 46268 48361 1.3427 0.0099 0.2160 2.33
74 46268 48361 1.3424 0.0099 0.2154 2.33
75 46267 48361 1.3421 0.0099 0.2149 2.33
76 46265 48360 1.3418 0.0099 0.2143 2.32
77 46263 48358 1.3415 0.0099 0.2136 2.32
78 46260 48356 1.3411 0.01 0.2129 2.32
79 46256 48353 1.3408 0.01 0.2122 2.32
80 46251 48349 1.3404 0.01 0.2113 2.32
81 46245 48344 1.34 0.01 0.2104 2.32
82 46242 48338 1.3396 0.01 0.2094 2.31
83 46234 48335 1.3391 0.01 0.2083 2.31
84 46224 48327 1.3386 0.0101 0.2070 2.31
85 46219 48317 1.3381 0.0101 0.2057 2.31
86 46204 48312 1.3376 0.0101 0.2042 2.31
87 46187 48297 1.337 0.0101 0.2025 2.31
88 46169 48281 1.3363 0.0101 0.2007 2.30
89 46148 48262 1.3356 0.0102 0.1987 2.30
90 46125 48241 1.3349 0.0102 0.1966 2.30
91 46098 48218 1.3341 0.0102 0.1943 2.30
92 46069 48192 1.3332 0.0102 0.1920 2.29
122
93 46036 48162 1.3322 0.0102 0.1895 2.29
94 45998 48129 1.3312 0.0102 0.1871 2.29
95 45956 48091 1.3301 0.0102 0.1848 2.29
96 45909 48049 1.3288 0.0102 0.1826 2.28
97 45856 48002 1.3274 0.0103 0.1805 2.28
98 45796 47949 1.3259 0.0103 0.1787 2.28
99 45729 47889 1.3243 0.0103 0.1771 2.27
100 45653 47822 1.3225 0.0103 0.1757 2.27
101 45569 47747 1.3205 0.0103 0.1746 2.27
102 45473 47662 1.3182 0.0103 0.1736 2.26
103 45366 47566 1.3158 0.0103 0.1729 2.26
104 45245 47459 1.313 0.0103 0.1723 2.26
105 45109 47339 1.31 0.0103 0.1718 2.25
106 44956 47203 1.3066 0.0103 0.1713 2.25
107 44784 47049 1.3028 0.0102 0.1710 2.24
108 44589 46877 1.2985 0.0102 0.1707 2.24
109 44369 46682 1.2937 0.0102 0.1705 2.23
110 47874 46455 1.2884 0.0103 0.1703 2.22
111 47915 46616 1.2923 0.0103 0.1695 2.22
112 47902 46657 1.2929 0.0103 0.1687 2.22
113 47863 46644 1.2924 0.0103 0.1680 2.22
114 47807 46605 1.2912 0.0103 0.1675 2.22
115 47737 46550 1.2897 0.0103 0.1671 2.22
116 47653 46480 1.2878 0.0103 0.1668 2.21
117 47551 46395 1.2856 0.0103 0.1665 2.21
118 47430 46294 1.283 0.0103 0.1663 2.21
119 47286 46172 1.28 0.0103 0.1661 2.20
120 47115 46029 1.2765 0.0103 0.1659 2.20
121 46914 45858 1.2724 0.0103 0.1658 2.19
122 46679 45657 1.2677 0.0102 0.1657 2.19
123 46403 45421 1.2621 0.0102 0.1655 2.18
124 46081 45145 1.2557 0.0101 0.1654 2.17
123
125 45709 44823 1.2483 0.0101 0.1653 2.16
126 45285 44452 1.2399 0.01 0.1652 2.15
127 44806 44027 1.2304 0.0099 0.1651 2.14
128 44277 43549 1.22 0.0098 0.1650 2.13
129 43705 43019 1.2086 0.0097 0.1650 2.11
130 43103 42447 1.1966 0.0096 0.1649 2.10
131 42491 41846 1.1842 0.0095 0.1648 2.08
132 41890 41233 1.1721 0.0094 0.1647 2.06
133 41322 40632 1.1604 0.0093 0.1646 2.05
134 40807 40065 1.1498 0.0092 0.1645 2.03
135 40356 39549 1.1403 0.0091 0.1644 2.02
136 39975 39099 1.1323 0.0091 0.1643 2.00
137 39664 38718 1.1256 0.009 0.1643 1.99
138 39415 38406 1.1201 0.009 0.1642 1.98
139 39220 38157 1.1158 0.009 0.1641 1.97
140 39071 37963 1.1125 0.0089 0.1640 1.97
141 38959 37814 1.1099 0.0089 0.1639 1.96
142 38875 37701 1.1079 0.0089 0.1638 1.96
143 38813 37617 1.1063 0.0089 0.1637 1.96
144 38768 37555 1.1052 0.0089 0.1637 1.95
145 38736 37510 1.1043 0.0089 0.1636 1.95
146 38713 37478 1.1036 0.009 0.1635 1.95
147 38698 37456 1.103 0.009 0.1634 1.95
148 38688 37440 1.1026 0.009 0.1633 1.95
149 38681 37430 1.1022 0.009 0.1632 1.94
150 38678 37424 1.1019 0.009 0.1632 1.94
151 38676 37420 1.1017 0.009 0.1631 1.94
152 38677 37419 1.1015 0.009 0.1630 1.94
153 38678 37419 1.1013 0.0091 0.1629 1.94
154 38680 37421 1.1011 0.0091 0.1628 1.94
155 38683 37423 1.101 0.0091 0.1627 1.94
156 38687 37426 1.1008 0.0091 0.1627 1.94
124
157 38690 37429 1.1007 0.0091 0.1626 1.94
158 38694 37433 1.1005 0.0091 0.1625 1.94
159 38698 37437 1.1004 0.0092 0.1624 1.93
160 1258 37441 1.1003 0.1623
Table L.7. Input parameter of the third column
Liquid Vapor Liquid Vapor

density Viscosity Diameter
Stage flow flow density
of Liquid (m)
(kg/h) (kg/h) (g/cm3) (g/cm3)
1 13001 0 0.828 0.0062 0.1485 0.00
2 13283 13868 0.875 0.0064 0.1573 1.07
3 13780 14149 0.9635 0.0067 0.1741 1.12
4 14454 14647 1.0934 0.007 0.1983 1.18
5 15064 15320 1.2176 0.0074 0.2192 1.24
6 15435 15930 1.2926 0.0076 0.2297 1.29
7 15607 16301 1.3258 0.0077 0.2334 1.31
8 15676 16473 1.3383 0.0077 0.2345 1.32
9 15704 16543 1.3427 0.0078 0.2346 1.32
10 15716 16571 1.3441 0.0078 0.2345 1.32
11 15722 16583 1.3443 0.0079 0.2342 1.32
12 15727 16589 1.3442 0.0079 0.2338 1.32
13 15730 16594 1.344 0.0079 0.2335 1.31
14 15734 16597 1.3437 0.008 0.2331 1.31
15 15737 16601 1.3434 0.008 0.2328 1.31
16 15740 16604 1.343 0.008 0.2325 1.31
17 15744 16607 1.3427 0.0081 0.2321 1.31
18 15747 16610 1.3424 0.0081 0.2318 1.31
19 15750 16614 1.3421 0.0081 0.2314 1.31
20 15754 16617 1.3418 0.0082 0.2311 1.30
21 15757 16620 1.3414 0.0082 0.2308 1.30
22 15760 16623 1.3411 0.0082 0.2304 1.30
125
23 15763 16627 1.3408 0.0083 0.2301 1.30
24 15766 16630 1.3405 0.0083 0.2298 1.30
25 15770 16633 1.3402 0.0084 0.2294 1.30
26 15773 16636 1.3399 0.0084 0.2291 1.30
27 15776 16640 1.3396 0.0084 0.2288 1.30
28 15779 16643 1.3392 0.0085 0.2285 1.29
29 15782 16646 1.3389 0.0085 0.2282 1.29
30 15786 16649 1.3386 0.0085 0.2278 1.29
31 15789 16652 1.3383 0.0086 0.2275 1.29
32 15792 16656 1.338 0.0086 0.2272 1.29
33 15795 16659 1.3377 0.0086 0.2269 1.29
34 15798 16662 1.3374 0.0087 0.2266 1.29
35 15801 16665 1.3371 0.0087 0.2263 1.28
36 15805 16668 1.3368 0.0087 0.2260 1.28
37 15808 16671 1.3365 0.0088 0.2257 1.28
38 15811 16674 1.3362 0.0088 0.2254 1.28
39 15814 16678 1.3359 0.0088 0.2251 1.28
40 15817 16681 1.3356 0.0089 0.2248 1.28
41 15820 16684 1.3353 0.0089 0.2245 1.28
42 15823 16687 1.335 0.0089 0.2242 1.28
43 15826 16690 1.3347 0.009 0.2239 1.27
44 15830 16693 1.3344 0.009 0.2236 1.27
45 15833 16696 1.3341 0.009 0.2233 1.27
46 15836 16699 1.3338 0.0091 0.2230 1.27
47 15839 16702 1.3335 0.0091 0.2227 1.27
48 15842 16706 1.3332 0.0091 0.2224 1.27
49 15845 16709 1.3329 0.0092 0.2221 1.27
50 15848 16712 1.3326 0.0092 0.2218 1.27
51 15851 16715 1.3323 0.0092 0.2215 1.27
52 15854 16718 1.3321 0.0093 0.2213 1.26
53 15857 16721 1.3318 0.0093 0.2210 1.26
54 15861 16724 1.3315 0.0093 0.2207 1.26
126
55 15864 16727 1.3312 0.0094 0.2204 1.26
56 15867 16730 1.3309 0.0094 0.2201 1.26
57 15870 16733 1.3306 0.0094 0.2199 1.26
58 15873 16737 1.3303 0.0095 0.2196 1.26
59 15874 16740 1.33 0.0095 0.2193 1.26
60 15955 14648 1.3442 0.0097 0.2206 1.17
61 15991 14729 1.3495 0.0098 0.2209 1.18
62 16006 14764 1.3514 0.0098 0.2208 1.18
63 16014 14780 1.3519 0.0099 0.2206 1.18
64 16019 14788 1.3519 0.0099 0.2204 1.18
65 16023 14793 1.3518 0.0099 0.2201 1.17
66 16027 14797 1.3516 0.01 0.2199 1.17
67 16030 14800 1.3513 0.01 0.2196 1.17
68 16034 14804 1.3511 0.01 0.2194 1.17
69 16037 14807 1.3508 0.0101 0.2191 1.17
70 16040 14811 1.3506 0.0101 0.2189 1.17
71 16044 14814 1.3503 0.0101 0.2186 1.17
72 16047 14817 1.3501 0.0102 0.2184 1.17
73 16050 14821 1.3498 0.0102 0.2181 1.17
74 16054 14824 1.3495 0.0102 0.2179 1.17
75 16057 14827 1.3493 0.0103 0.2176 1.16
76 16060 14831 1.349 0.0103 0.2174 1.16
77 16064 14834 1.3488 0.0103 0.2171 1.16
78 16067 14837 1.3485 0.0104 0.2169 1.16
79 16070 14841 1.3483 0.0104 0.2166 1.16
80 16074 14844 1.348 0.0104 0.2164 1.16
81 16077 14847 1.3478 0.0105 0.2161 1.16
82 16080 14851 1.3475 0.0105 0.2159 1.16
83 16084 14854 1.3473 0.0106 0.2157 1.16
84 16087 14857 1.347 0.0106 0.2154 1.16
85 16090 14860 1.3468 0.0106 0.2152 1.16
86 16093 14864 1.3465 0.0107 0.2150 1.15
127
87 16097 14867 1.3463 0.0107 0.2147 1.15
88 16100 14870 1.346 0.0107 0.2145 1.15
89 16103 14874 1.3458 0.0108 0.2142 1.15
90 16106 14877 1.3455 0.0108 0.2140 1.15
91 16110 14880 1.3453 0.0108 0.2138 1.15
92 16113 14883 1.3451 0.0109 0.2136 1.15
93 16116 14887 1.3448 0.0109 0.2133 1.15
94 16119 14890 1.3446 0.0109 0.2131 1.15
95 16123 14893 1.3443 0.011 0.2129 1.15
96 16126 14896 1.3441 0.011 0.2126 1.15
97 16129 14899 1.3438 0.011 0.2124 1.14
98 16132 14903 1.3436 0.0111 0.2122 1.14
99 16136 14906 1.3434 0.0111 0.2120 1.14
100 1226 14909 1.3431 0 0.2117
128
L.6. Packed Column Design Results
L.4 for each column.
Table L.8. Design results of all columns
Calculated Selected Packing Column

Column
Diameter (m) Diameter (m) Height (m) Height (m)
T-101 6.48 6.6 36 46.5
T-102 2.44 2.5 48 57.65
T-103 1.41 1.5 30 36.75
129
L.7. Material of Construction and Thickness Design
Fractionation units in air separation system is consisted of all distillation columns, T-101, T-102 and T-103. These units are
also operated in cryogenic condition, so the material used in construction is stainless steel. MOC is still designed based on design
temperature which is could be calculated. The design temperature and MOC of the fractionation units are shown in Table L.9.
Table L.9. MOC of the fractionation units in the process
Toperating Toperating Design T Design T

Unit MOC
(C) (F) (F) (C)
T-101 -192.05 -313.69 -338.69 -205.94 SS-304

T-102 -188.22 -306.80 -331.80 -202.11 SS-304
T-103 -192.52 -314.54 -339.54 -206.41 SS-304
The procedures determining the thickness for hoop stress and longitudinal stress is the same as those of separator drum and
reflux drum. The calculation of vessel thickness is demonstrated in Table L.10. If the thickness is lower than the minimum thickness
of 0.0063 m, the minimum thickness is used instead.
Table L.10. Calculation of fractionation unit thickness
Diameter Normal Design P S S t for t for Choose higher Vessel thickness

Unit
(m) P (bar) (N/m2) (ksi) (N/m2) Hoop Stress (m) Longitudinal (m) value of t (m) with C.A. (m)
T-101 6.60 2.28 2.01105 20 1.38108 0.0053 0.0027 0.0053 0.0068

T-102 2.50 2.21 1.92105 20 1.38108 0.0019 0.0010 0.0019 0.0034
T-103 1.50 2.07 1.73105 20 1.38108 0.0010 0.0005 0.0010 0.0025
130
L.8. Economic Costing Method
To determine cost of distillation columns, bare module factor method is used
according to analysis, synthesis and design of chemical processes (Turton, fourth
edition). The bare module cost of the column can be estimated as shown in Eq. (L.16).
CBM = Cp FBM (L.16)
The factor Cp calculation method for horizontal and vertical is the same,
however, the parameters of each type of vessel are unlike as shown in Eq. (L.17).
logCP = K1 +K2 log(V) +K3 (log(V))2 (L.17)
D2 H
V= (L.18)
4
where V is the volume of the column and packing (m3) and Cp is the cost for
ambient pressure and carbon steel (USD). K parameters used for tower and packing
are shown in Table L.11.
Table L.11. K parameters for distillation columns
Parameters Tower Packing

K1 3.4974 2.4493
K2 0.4485 0.9744
K3 0.1074 0.0055
The bare module factor of towers can be determined from Eq. (L.19).
FBM = B1 +B2 FM FP (L.19)
factor. B parameters used for distillation columns are shown in Table L.12.
Table L.12. B parameters for a tower
Parameters Horizontal
B1 2.25
B2 1.82
131
The pressure factor of a distillation column could be calculated by using the
same method as pressure vessels following Eq. (L.20).
P+1 D +0.00315
2 SE-0.6 P+1
FP,vessel = (if t > 6.3 mm) (L.20)
0.0063

The material factor (FM) of each column is determined from the correlation
chart of Turton, 2013 shown in Fig. L.3. The material factor of stainless steel is 3.1
and the factor of nickel is 7.1.
Fig. L.4. Material Factors for Equipment (Turton, 2013)

The bare module factor (FBM) of packings could be obtained from the
correlation chart of Turton, 2013 shown in Fig. L.4.
132
Fig. L.5. Bare Module Factors for Equipment (Turton, 2013)
The estimated cost of each column is the summation of tower and packing
costs. It can be calculated on the basis of price in 2001 (CEPCI = 397). In 2014, the
CEPCI is estimated to be 576.1, the equation which is used to convert the price is
shown below.
CBM,2014 576.1
= (L.21)
CBM,2001 397
133
L.9. Costing Parameters
Table L.13 shows all input parameter used to estimate capital cost by using
bare module method.
Table L.13. Input parameters of all distillation columns
T-101 T-102 T-103

Tower
Parameter Value Parameter Value Parameter Value
D (m) 6.6 D (m) 2.5 D (m) 1.5
H (m) 46.5 H (m) 57.65 H (m) 36.75
V (m3) 1,591 V (m3) 283 V (m3) 65
t (m) 0.0068 t (m) 0.0063 t (m) 0.0063
P (barg) 1.21 P (barg) 1.206 P (barg) 1.07
MOC SS-304 MOC SS-304 MOC SS-304
Packing
D (m) 6.6 D (m) 2.5 D (m) 1.5
H (m) 36 H (m) 48 H (m) 30
V (m3) 1,232 V (m3) 236 V (m3) 53
Type SS-304 Type SS-304 Type SS-304
134
L.10. Costing Results
L.6 for each distillation column.
Table L.14. Input parameters of all distillation columns
T-101 T-102 T-103

Tower
Cp ($) 1,082,000 Cp (USD) 174,800 Cp (USD) 46,000
CBM,2001 ($) 13,817,700 CBM,2001 ($) 1,395,000 CBM,2001 ($) 309,000
CBM,2014 ($) 20,051,400 CBM,2014 ($) 2,025,100 CBM,2014 ($) 448,310
Packing
Cp ($) 326,000 Cp (USD) 61,900 Cp (USD) 14,000
CBM,2001 ($) 2,314,500 CBM,2001 ($) 439,500 CBM,2001 ($) 99,300
CBM,2014 ($) 3,358,600 CBM,2014 ($) 637,800 CBM,2014 ($) 141,200
Overall 23,410,000 2,662,900 592,500
135
L.11. New Equipment Summary
The new equipment summary after performing column design is shown in
Table L.15.
Table L.15. Equipment Summary
Vessels/Tower/
T-101 T-102 T-103
Reactors
Temperature (oC) -192.05 -188.22 -192.52
Pressure (bar) 2.28 2.21 2.07
Orientation Vertical Vertical Vertical
MOC TP304 TP304 TP304
Size
Height/Length (m) 46.5 57.65 36.75
Diameter (m) 6.6 2.5 1.5
Internals 120 trays 160 trays 100 trays
Feed on tray 80 Feed on tray 110 Feed on tray 60
References for Appendix L

[1] Henley, E. J., Seader, J. D., & Roper, D. K. (2011). Separation process principles.
Hoboken, NJ: Wiley.
136
Appendix M.
Heat Exchanger
Design
137
M.1. Heat Exchanger Design Method
M.1.1. Heat Exchanger Specification
The criteria that we use to specify the type of heat exchangers in the process
is heat transfer area. The simplest heat exchanger is double pipe heat exchanger;
however, it is practical for the heat exchanger of which the heat transfer area is less
than 10 m2. Therefore, in chemical industries, shell and tube heat exchanger is more
commonly used.
Firstly, we assume that all heat exchangers are shell and tube type so we can
change it when the heat transfer area calculated is less than 10 m2. Then, the allocation
of streams in shell and tube would be considered. The guideline for consideration is
shown below in Table M.1. Also, the allocation of streams is shown in Table M.2.
Table M.1. Guidelines for streams allocation in shell and tube heat exchanger.
Sequence Guidelines
1 High pressure fluid goes in the tubes.
2 Corrosive fluid goes in the tubes.
3 More seriously fouling fluid goes in the tube.
The stream with the lower allowable pressure drop usually
4
goes on the shell side
The stream with the lower heat transfer coefficient goes on
5
the shell side.
6 More viscous fluid is more suitable for the shell side.
Table M.2. Allocation of streams.
Heat Shell Side Tube Side

Exchanger Inlet Stream P (bar) Inlet Stream P (bar)
E-101 Low Pressure Steam 1.42 3 10
E-102 Cooling Water 1 4 10
E-103 Chilled Water 1 5 10
138
E-108 16 1.52 Liquid Nitrogen 0.3
E-109 Bottom from T-101 2.21 66 136.5
E-110 22 2.21 60 136.5
E-116 21 1.38 61 136.5
E-117 32 1.52 Liquid Nitrogen* 0.3
E-118 Bottom from T-102 2.21 65 136.5
E-119 37 1.38 Liquid Nitrogen* 0.3
E-120 Bottom from T-103 2.07 64 136.5
E-121 41 2.07 59 136.5
E-127 19 1.52 67 136.5
E-130 62 136.5 57 136.5
E-131 68 136.5 Liquid Propane* 0.7
E-132 79 1.01 63 136.5
*Refrigerant
139
M.1.2. Heat Transfer Area Determination
Heat transfer area, A, could be calculated using Eq. (M.1).
Q UAFt Tlm (M.1)
where Q = heat transferred per unit time (W), U = the overall heat transfer
coefficient (W/m2C), Ft = the temperature correction factor, the correction factor
can be obtained from Fig. M.1 to M.3, Tlm= the log mean temperature difference
(C), the log mean temperature difference can be obtained from Eq. (M.2).
(T1 t 2 ) (T2 t1 )
Tlm
T t (M.2)
ln 1 2
T2 t1
where T1 = shell-side temperature, inlet (C), T2 = shell-side temperature,

outlet (C), t1 = tube-side temperature, inlet (C), t2 = tube-side temperature, outlet
(C). It is noted that overall heat transfer coefficient (U) is obtained from Towler [1].
Fig. M.1. Temperature correction factor: one shell pass, two or more tube passes [2]
140
Fig. M.2. Temperature correction factor: two shell passes, four or more
tube passes [2]
Fig. M.3. Temperature correction factor: four shell passes, eight or

more tube passes [2]
M.1.3. TEMA Designations for Shell and Tube Heat Exchanger

Type of shell and tube heat exchanger are illustrated by TEMA (Tubular
Exchanger Manufacturers Association). This nomenclature is defined in terms of
shell diameter and length of tube following by three letters which describe the front
header type, shell type and rear header type, respectively. The information of most
common TEMA types is shown below.
141
1. Front End
Table M.3. Front end types information.
Type Information
A Removable channel with removable cover plate.

May be used with fixed or removable tube bundles.
Tube cleaning easier since no piping disassembly required.
Flanged channel end is costly and prone to leakage.
Most commonly used.
B Removable channel with integral cover.

May be used with fixed or removable tube bundles.
Used for low tube side fouling services or where chemical cleaning is
specified. Mechanical cleaning requires piping disassembly.
Less costly and less prone leakage than type A.
C Channel integral with tubesheet and with removable cover.

Two types: removable bundle and fixed bundle.
D Special closures for high pressure applications.
2. Shell
Table M.4. Shell types information.
Type Information
E One pass shell.
Most common type used.
F Two pass shell with longitudinal baffle.

Used to improve cross flow correction factor.
Equivalent to two shells in series.
Max. shell-side pressure drop of 10 psi.
Max. shell-side temperature range of 350 F.
G/H Split flow arrangements.

Use internal baffles to split the shell-side flow.
Used to minimize pressure drop.
142
J Divided flow.
Also used to minimize pressure drop.
No internal baffle.
K Kettle type.
Used for vaporizing services (reboilers, steam generators and
refrigeration services)
X Cross flow.
No baffles.
Low pressure drop.
3. Rear End
Table M.5. Rear end types information.
Type Information
S Floating tubesheet sandwiched between split ring and tubesheet cover.
Tubesheet assembly moves within shell cover to absorb expansion of
the tubes.
Requires removing rear shell cover and floating tubesheet cover for
bundle removal but results in a smaller diameter shell for the same heat
transfer surface.
Usually first choice for removable bundles if mechanical cleaning of
shell-side will be infrequent.
Pull through floating head.

T Floating tubesheet cover bolted directly to floating tubesheet.
Does not require rear head disassembly for bundle removal.
Results in larger diameter shell for same heat transfer surface than
type S
Preferred where frequent mechanical cleaning of shell-side is
anticipated.
143
U-tube bundle.
U No floating head. Tube bundle consists of U-tubes.
Not recommended where mechanical cleaning of tube-side is
anticipated.
Good for high pressure, clean services or where chemical cleaning of
tube-side is specified.
M.2. Input Parameters of All Heat Exchangers

Table M.6 shows all input parameters obtained from Aspen and Chemical
Engineering Design textbook in order to design the heat exchanger.
Table M.6. Input parameters of all heat exchangers
E-101 E-102
Q (kW) 8217.92 Q (kW) 2056.74
U (W/m2C) 300 U (W/m2C) 300
Ft 1 Ft 0.88
T1 (C) 110 T1 (C) 40
T2 (C) 110 T2 (C) 60
t1 (C) 394 t1 (C) 120
t2 (C) 120 t2 (C) 50
144
Table M.6. Input parameters of all heat exchangers (cont)
E-103 E-104
Q (kW) 735.29 Q (kW) 2566.75
U (W/m2C) 300 U (W/m2C) 300
Ft 0.82 Ft 1
T1 (C) 10 T1 (C) 110
T2 (C) 25 T2 (C) 110
t1 (C) 50 t1 (C) 205.15
t2 (C) 25 t2 (C) 120
E-105 E-106
Q (kW) 2897.56 Q (kW) 1608.39
U (W/m2C) 300 U (W/m2C) 300
Ft 0.86 Ft 1
T1 (C) 10 T1 (C) 110
T2 (C) 25 T2 (C) 110
t1 (C) 120 t1 (C) 170.54
t2 (C) 25 t2 (C) 120
E-107 E-108
Q (kW) 3155.73 Q (kW) 28938
U (W/m2C) 300 U (W/m2C) 1200
Ft 0.86 Ft 1
T1 (C) 10 T1 (C) -192.05
T2 (C) 25 T2 (C) -192.05
t1 (C) 120 t1 (C) -203
t2 (C) 25 t2 (C) -203
145
E-109 E-110
Q (kW) 22541 Q (kW) 2589.9
U (W/m2C) 100 U (W/m2C) 50
Ft 1 Ft 1
T1 (C) -174.96 T1 (C) -174.96
T2 (C) -174.96 T2 (C) 25
t1 (C) 19.12 t1 (C) 399.79
t2 (C) -3.96 t2 (C) 393.74
E-111 E-112
Q (kW) 1395.8 Q (kW) 444.65
U (W/m2C) 300 U (W/m2C) 300
Ft 1 Ft 0.88
T1 (C) 110 T1 (C) 40
T2 (C) 110 T2 (C) 60
t1 (C) 333 t1 (C) 120
t2 (C) 120 t2 (C) 50
E-113 E-114
Q (kW) 1994.8 Q (kW) 525.89
U (W/m2C) 300 U (W/m2C) 300
Ft 1 Ft 0.88
T1 (C) 110 T1 (C) 40
T2 (C) 110 T2 (C) 60
t1 (C) 401 t1 (C) 120
t2 (C) 120 t2 (C) 50
146
E-115 E-116
Q (kW) 200.73 Q (kW) 589.55
U (W/m2C) 300 U (W/m2C) 50
Ft 0.82 Ft 1
T1 (C) 10 T1 (C) -192.87
T2 (C) 25 T2 (C) 25
t1 (C) 50 t1 (C) 393.74
t2 (C) 25 t2 (C) 392.36
E-117 E-118
Q (kW) 2116.7 Q (kW) 2115.6
U (W/m2C) 1200 U (W/m2C) 100
Ft 1 Ft 1
T1 (C) -185.72 T1 (C) -174.98
T2 (C) -188.22 T2 (C) -174.98
t1 (C) -203 t1 (C) 20.93
t2 (C) -203 t2 (C) 19.12
E-119 E-120
Q (kW) 742.99 Q (kW) 642.48
U (W/m2C) 1200 U (W/m2C) 100
Ft 1 Ft 1
T1 (C) -191.95 T1 (C) -178.52
T2 (C) -192.52 T2 (C) -178.52
t1 (C) -203 t1 (C) 21.47
t2 (C) -203 t2 (C) 20.93
147
E-121 E-122
Q (kW) 89.63 Q (kW) 81.62
U (W/m2C) 50 U (W/m2C) 300
Ft 1 Ft 1
T1 (C) -178.52 T1 (C) 110.00
T2 (C) 25.00 T2 (C) 110.00
t1 (C) 400 t1 (C) 575.18
t2 (C) 399.79 t2 (C) 120
E-123 E-124
Q (kW) 12.84 Q (kW) 103.17
U (W/m2C) 300 U (W/m2C) 300
Ft 0.98 Ft 1
T1 (C) 40 T1 (C) 110
T2 (C) 60 T2 (C) 110
t1 (C) 120 t1 (C) 583.05
t2 (C) 50 t2 (C) 120
E-125 E-126
Q (kW) 16 Q (kW) 6.27
U (W/m2C) 300 U (W/m2C) 300
Ft 0.98 Ft 0.82
T1 (C) 40 T1 (C) 10
T2 (C) 60 T2 (C) 25
t1 (C) 120 t1 (C) 50
t2 (C) 50 t2 (C) 25
148
E-127 E-128
Q (kW) 5666.9 Q (kW) 3147.8
U (W/m2C) 50 U (W/m2C) 300
Ft 1 Ft 1
T1 (C) -192.1 T1 (C) 110
T2 (C) -100 T2 (C) 110
t1 (C) -3.96 t1 (C) 270.06
t2 (C) -11.1 t2 (C) 120
E-129 E-130
Q (kW) 422.98 Q (kW) 162028
U (W/m2C) 300 U (W/m2C) 150
Ft 0.98 Ft 0.8
T1 (C) 40 T1 (C) 392.36
T2 (C) 60 T2 (C) 21.96
t1 (C) 120 t1 (C) -15.7
t2 (C) 100 t2 (C) 350
E-131 E-132
Q (kW) 18987.4 Q (kW) 586.45
U (W/m2C) 1200 U (W/m2C) 50
Ft 1 Ft 1
T1 (C) -11.1 T1 (C) -36.66
T2 (C) -40 T2 (C) -33.33
t1 (C) -50 t1 (C) 21.96
t2 (C) -50 t2 (C) 21.47
149
E-132
Parameter Value
Q (kW) 586.45
U (W/m2C) 300
Ft 1
T1 (C) -36.66
T2 (C) -33.33
t1 (C) 21.96
t2 (C) 21.47
150
M.3. Design Results
Table M.7 shows the results calculated from the design method mentioned in
part 1 for each heat exchanger.
Table M.7. Design results of all heat exchangers
E-101 E-102
Area (m2) 335 Area (m2) 279
Shell & Tube Shell & Tube
Type (one shell pass, two or Type (two shell passes, four or
more tube passes) more tube passes)
TEMA TEMA
AKT AFT
Nomenclature Nomenclature
E-103 E-104
Area (m2) 153 Area (m2) 226
Type (one shell pass, two or Type (one shell pass, two or
TEMA TEMA
AET AKT
E-105 E-106
Area (m2) 259 Area (m2) 191
TEMA TEMA
AET DKU
151
Table M.7. Design results of all heat exchangers (cont)
E-107 E-108
Area (m2) 282 Area (m2) 2,202
TEMA TEMA
DEU AKT
E-109 E-110
Area (m2) 1,237 Area (m2) 111
TEMA TEMA
DHU DEU
E-111 E-112
Area (m2) 68 Area (m2) 60
TEMA TEMA
AKT AFT
152
E-113 E-114
Area (m2) 80 Area (m2) 199
TEMA TEMA
DKU DFU
E-115 E-116
TEMA TEMA
DEU DEU
E-117 E-118
Area (m2) 138 Area (m2) 108
TEMA TEMA
AKT DHU
153
E-119 E-120
TEMA TEMA
AKT DHU
E-121 E-122
Area (m2) 4 Area (m2) 2.3
Type Double pipe Type Double pipe
TEMA TEMA
- -
E-123 E-124
Area (m2) 1.6 Area (m2) 3
TEMA TEMA
- -
E-125 E-126
Area (m2) 2 Area (m2) 1.3
TEMA TEMA
- -
154
E-127 E-128
Area (m2) 834 Area (m2) 194
TEMA TEMA
DEU DKU
E-129 E-130
Area (m2) 24 Area (m2) 3,379
Shell & Tube
Shell & Tube
(four shell passes, eight
Type (one shell pass, two or Type
or more tube passes)
more tube passes)
10 exchangers
TEMA TEMA
DEU DHU
E-131 E-132
Area (m2) 697 Area (m2) 34
more tube passes) more tube passes.)
TEMA TEMA
DKU DEU
155
Internal Heat Exchanger in Reactor

Parameter Value
Area (m2) 5,021
Shell & Tube
Type (one shell pass, two or more
tube passes)
TEMA Nomenclature DEU
156
M.4. Material of Construction and Thickness Design
M.4.1. Material of Construction (MOC) Considerations
As the air separation and ammonia synthesis system are cryogenic processes, the material which is normally used in air-
separation-system construction is aluminum alloy and stainless steel. MOC is designed based on design temperature which is could
be calculated using Eq. (M.3) and (M.4). MOC of heat exchangers are shown in Table M.8. The detail of each material is shown in
Table M.9.
Maximum Temperature = Operating Temperature + 50oF (M.3)
Minimum Temperature = Operating Temperature - 25oF (M.4)
Table M.8. MOC of heat exchangers in the process.
Unit Type Thot (C) Tcold (C) Tmax (C) Tmin (C) MOC
E-101 Shell 110.00 110.00 137.78 96.11 CS

Tube 394.00 120.00 421.78 106.11 SS-304
E-102 Shell 60.00 40.00 87.78 26.11 CS
Tube 120.00 50.00 147.78 36.11 CS
E-103 Shell 25.00 10.00 52.78 -3.89 CS
Tube 50.00 25.00 77.78 11.11 CS
E-104 Shell 110.00 110.00 137.78 96.11 CS
Tube 205.15 120.00 232.93 106.11 CS
157
E-105 Shell 25.00 10.00 52.78 -3.89 CS
Tube 120.00 25.00 147.78 11.11 CS
E-106 Shell 110.00 110.00 137.78 96.11 CS
Tube 170.54 120.00 198.32 106.11 CS
E-107 Shell 25.00 10.00 52.78 -3.89 CS
Tube 120.00 25.00 147.78 11.11 CS
E-108 Shell -192.05 -192.05 -164.27 -205.94 SS-304
Tube -203.00 -203.00 -175.22 -216.89 SS-304
E-109 Shell -174.96 -174.96 -147.18 -188.85 SS-304
Tube 19.12 -3.96 46.90 -17.85 SS-304
E-110 Shell 25.00 -174.96 52.78 -188.85 SS-304
Tube 399.79 393.74 427.57 379.85 SS-304H
E-111 Shell 110.00 110.00 137.78 96.11 CS
Tube 333.00 120.00 360.78 106.11 CS
E-112 Shell 60.00 40.00 87.78 26.11 CS
Tube 120.00 50.00 147.78 36.11 CS
E-113 Shell 110.00 110.00 137.78 96.11 CS
Tube 401.00 120.00 428.78 106.11 SS-304H
E-114 Shell 60.00 40.00 87.78 26.11 CS
Tube 120.00 50.00 147.78 36.11 CS
158
E-115 Shell 25.00 10.00 52.78 -3.89 CS
Tube 50.00 25.00 77.78 11.11 CS
E-116 Shell 25.00 -192.87 52.78 -206.76 SS-304
Tube 393.74 392.36 421.52 378.47 SS-304
E-117 Shell -185.72 -188.22 -160.44 -205.94 SS-304
Tube -203.00 -203.00 -175.22 -216.89 SS-304
E-118 Shell -174.98 -174.98 -147.20 -188.87 SS-304
Tube 20.93 19.12 48.71 5.23 CS
E-119 Shell -191.95 -192.52 -164.17 -206.41 SS-304
Tube -203.00 -203.00 -175.22 -216.89 SS-304
E-120 Shell -178.52 -178.52 -150.74 -192.41 SS-304
Tube 21.47 20.93 49.25 7.04 CS
E-121 Shell 25.00 -178.52 52.78 -192.41 SS-304
Tube 400.00 399.79 427.78 385.90 SS-304H
E-122 Shell 110.00 110.00 137.78 96.11 CS
Tube 575.18 120.00 602.96 106.11 SS-304H
E-123 Shell 60.00 40.00 87.78 26.11 CS
Tube 120.00 50.00 147.78 36.11 CS
E-124 Shell 110.00 110.00 137.78 96.11 CS
Tube 583.05 120.00 610.83 106.11 SS-304H
159
E-125 Shell 60.00 40.00 87.78 26.11 CS
Tube 120.00 50.00 147.78 36.11 CS
E-126 Shell 25.00 10.00 52.78 -3.89 CS
Tube 13.00 25.00 40.78 11.11 CS
E-127 Shell -100.00 -192.05 -72.22 -205.94 SS-304
Tube -3.96 -11.10 23.82 -12.98 SS-304
E-128 Shell 110.00 110.00 137.78 96.11 CS
Tube 270.06 120.00 297.84 106.11 CS
E-129 Shell 60.00 40.00 87.78 26.11 CS
Tube 120.00 100.00 147.78 86.11 CS
E-130 Shell 392.36 21.96 420.14 8.07 SS-304
Tube 350.00 -15.70 377.78 -29.59 SS-304
E-131 Shell -11.10 -40.00 21.05 -53.89 SS-304
Tube -50.00 -50.00 -22.22 -63.89 SS-304
E-132 Shell -36.66 -33.33 -8.88 -47.22 SS-304
Tube 21.96 21.47 49.74 7.58 CS
Internal Heat Shell 250 250 277.78 236.11 CS
Tube 500 300 527.78 486.11 SS-304H
160
Table M.9. Detail of each material
SS-304 Stainless Steel 0.07% C, 2% Mn, 0.75% Si, 0.045% P, -101oC or Lower /
19.5% Cr, 10.5% Ni, 0.1% N 425oC Maximum
0.1% C, 2% Mn, 0.75% Si, 0.045% P,
20% Cr, 10.5% Ni
161
M.5. Economic Costing Method
To determine cost of heat exchangers, bare module factor method is used
according to analysis, synthesis and design of chemical processes, Turton [3]. The
bare module cost of the heat exchanger can be estimated as shown in Eq. (M.5).
CBM = Cp FBM (M.5)

The factor Cp for heat exchangers could be obtained from Eq. (M.6).
logCP = K1 +K2 log(A) +K3 (log(A))2 (M.6)

where A is the area of the heat exchanger (m2) and Cp is the cost for ambient
pressure and carbon steel (USD), K parameters used for each type of heat exchangers
are shown in Table M.10.
Table M.10. K parameters for heat exchangers
Parameters Fixed tube sheet U-tube Floating-head

K1 4.3247 4.1884 4.8306
K2 -0.303 -0.2503 -0.8509
K3 0.1634 0.1974 0.3187
The bare module factor can be determined from Eq. (M.7).

FBM = B1 +B2 FM FP (M.7)
factor. B parameters of heat exchanger are shown in Table M.11.
Table M.11. B parameters for heat exchangers
Parameters Heat exchanger

B1 1.74
B2 1.55
The pressure factor of the heat exchanger is determined by using Eq. (M.8).
logFP = C1 +C2 log(P) +C3 (log(P))2 (M.8)
162
where FP,heat exchanger is pressure factor, P is the operating pressure (barg), C
parameters used for each type of heat exchangers are shown in Table M.12.
Table M.12. C parameters for heat exchangers
Pressure
P<5 5<P<140
range
C1 0 0.03881
C2 0 -0.11272
C3 0 0.08183
The material factor (FM) of each heat exchanger is determined according to

material factors for equipment in analysis, synthesis and design of chemical processes
(fourth edition), the material factor of heat exchangers depends on the material of
shells and tubes.
The estimated cost of each heat exchanger is calculated on the basis of price
in 2001 (CEPCI = 397). In 2014, the CEPCI is estimated to be 576.1, the Eq. (M.9)
which is used to convert the price is shown below.
CBM,2014 576.1
= (M.9)
CBM,2001 397
163
M.6. Costing Parameters
Table M.13 shows all input parameter used to estimate capital cost.by using
bare module method.
Table M.13. Input parameters of all heat exchangers
E-101 E-102
A (m2) 335 A (m2) 279
FM 1.8 FM 1
PShell (barg) 0.42 PShell (barg) 0.42
PTube (barg) 9 PTube (barg) 9
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.8306 K1 4.8306
K2 -0.851 K2 -0.851
K3 0.3187 K3 0.3187
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
164
E-103 E-104
A (m2) 153 A (m2) 226
FM 1 FM 1
PShell (barg) 0 PShell (barg) 0.42
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.8306 K1 4.8306
K2 -0.851 K2 -0.851
K3 0.3187 K3 0.3187
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
165
E-105 E-106
A (m2) 259 A (m2) 191
FM 1 FM 1
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.8306 K1 4.1884
K2 -0.851 K2 -0.25
K3 0.3187 K3 0.1974
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
166
E-107 E-108
A (m2) 282 A (m2) 2,202
FM 1 FM 2.7
PTube (barg) 126 PTube (barg) -0.7
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.1884 K1 4.8306
K2 -0.25 K2 -0.8509
K3 0.1974 K3 0.3187
C1 0.0388 C1 0
C2 -0.113 C2 0
C3 0.0818 C3 0
167
E-109 E-110
A (m2) 1,237 A (m2) 111
FM 2.7 FM 2.7
PTube (barg) 135.5 PTube (barg) 135.5
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.1884 K1 4.1884
K2 -0.2503 K2 -0.25
K3 0.1974 K3 0.1974
C1 0.03881 C1 0.0388
C2 -0.11272 C2 -0.113
C3 0.08183 C3 0.0818
168
E-111 E-112
A (m2) 68 A (m2) 60
FM 1 FM 1
PShell (barg) 0.42 PShell (barg) 0
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.8306 K1 4.8306
K2 -0.851 K2 -0.851
K3 0.3187 K3 0.3187
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
169
E-113 E-114
A (m2) 80 A (m2) 199
FM 1.8 FM 1
PShell (barg) 0.42 PShell (barg) 0
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.1884 K1 4.1884
K2 -0.25 K2 -0.25
K3 0.1974 K3 0.1974
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
170
M.13. Input parameters of all heat exchangers (cont)
E-115 E-116
A (m2) 42 A (m2) 20
FM 1 FM 1.8
PTube (barg) 199 PTube (barg) 135.5
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.1884 K1 4.1884
K2 -0.25 K2 -0.25
K3 0.1974 K3 0.1974
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
171
E-117 E-118
A (m2) 138 A (m2) 108
FM 2.7 FM 1.8
PTube (barg) -0.7 PTube (barg) 135.5
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.8306 K1 4.1884
K2 -0.851 K2 -0.25
K3 0.3187 K3 0.1974
C1 0 C1 0.0388
C2 0 C2 -0.113
C3 0 C3 0.0818
172
E-119 E-120
A (m2) 58 A (m2) 32
FM 2.7 FM 1.8
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.8306 K1 4.1884
K2 -0.851 K2 -0.25
K3 0.3187 K3 0.1974
C1 0 C1 0.0388
C2 0 C2 -0.113
C3 0 C3 0.0818
173
E-121 E-122
A (m2) 4 A (m2) 2
FM 2.7 FM 1.8
PTube (barg) 135.5 PTube (barg) 19
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.3247 K1 4.3247
K2 -0.303 K2 -0.303
K3 0.1634 K3 0.1634
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
174
E-123 E-124
A (m2) 1.6 A (m2) 3
FM 1 FM 1.8
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.3247 K1 4.3247
K2 -0.303 K2 -0.303
K3 0.1634 K3 0.1634
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
175
E-125 E-126
A (m2) 2 A (m2) 1.3
FM 1 FM 1
PShell (barg) 0 PShell (barg) 0
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.3247 K1 4.3247
K2 -0.303 K2 -0.303
K3 0.1634 K3 0.1634
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
176
E-127 E-128
A (m2) 834 A (m2) 194
FM 2.7 FM 1
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.1884 K1 4.1884
K2 -0.25 K2 -0.25
K3 0.1974 K3 0.1974
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
177
E-129 E-130
A (m2) 24 A (m2) 3,379
FM 1 FM 2.7
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.1884 K1 4.1884
K2 -0.25 K2 -0.2503
K3 0.1974 K3 0.1974
C1 0.0388 C1 0.03881
C2 -0.113 C2 -0.11272
C3 0.0818 C3 0.08183
178
E-131 E-132
A (m2) 697 A (m2) 207
FM 2.7 FM 1.8
B1 1.74 B1 1.74
B2 1.55 B2 1.55
K1 4.1884 K1 4.1884
K2 -0.25 K2 -0.25
K3 0.1974 K3 0.1974
C1 0.0388 C1 0.0388
C2 -0.113 C2 -0.113
C3 0.0818 C3 0.0818
179
E-132
Parameter Value
A (m2) 34
FM 1.8
PShell (barg) 0.01
PTube (barg) 135.5
B1 1.74
B2 1.55
K1 4.1884
K2 -0.25
K3 0.1974
C1 0.0388
C2 -0.113
C3 0.0818
180
M.7. Costing Results
Table M.14 shows the results calculated from the design method mentioned
in part 5 for each heat exchanger.
Table M.14. Estimated costs of all heat exchangers
E-101 E-102
Cp (USD) 51,700 Cp (USD) 45,300
CBM,2001 (USD) 236,000 CBM,2001 (USD) 149,900
CBM,2014 (USD) 342,700 CBM,2014 (USD) 218,100
E-103 E-104
Cp (USD) 31,100 Cp (USD) 39,300
CBM,2001 (USD) 102,800 CBM,2001 (USD) 139,300
CBM,2014 (USD) 149,200 CBM,2014 (USD) 202,200
E-105 E-106
Cp (USD) 43,000 Cp (USD) 44,100
CBM,2001 (USD) 152,500 CBM,2001 (USD) 176,300
CBM,2014 (USD) 221,300 CBM,2014 (USD) 255,800
E-107 E-108
Cp (USD) 57,600 Cp (USD) 352,800
CBM,2001 (USD) 230,200 CBM,2001 (USD) 2,090,500
CBM,2014 (USD) 334,100 CBM,2014 (USD) 3,033,500
181
Table M.14. Estimated costs of all heat exchangers (cont)
E-109 E-110
Cp (USD) 200,400 Cp (USD) 31,800
CBM,2001 (USD) 1,590,400 CBM,2001 (USD) 252,800
CBM,2014 (USD) 2,307,900 CBM,2014 (USD) 366,800
E-111 E-112
Cp (USD) 21,900 Cp (USD) 21,200
CBM,2001 (USD) 74,500 CBM,2001 (USD) 71,900
CBM,2014 (USD) 108,100 CBM,2014 (USD) 104,400
E-113 E-114
Cp (USD) 26,700 Cp (USD) 45,300
CBM,2001 (USD) 167,800 CBM,2001 (USD) 193,400
CBM,2014 (USD) 243,500 CBM,2014 (USD) 280,700
E-115 E-116
Cp (USD) 20,000 Cp (USD) 15,800
CBM,2001 (USD) 85,300 CBM,2001 (USD) 92,900
CBM,2014 (USD) 123,800 CBM,2014 (USD) 134,800
182
E-117 E-118
Cp (USD) 29,500 Cp (USD) 31,400
CBM,2001 (USD) 174,600 CBM,2001 (USD) 184,300
CBM,2014 (USD) 253,400 CBM,2014 (USD) 267,400
E-119 E-120
Cp (USD) 20,900 Cp (USD) 18,200
CBM,2001 (USD) 123,800 CBM,2001 (USD) 106,700
CBM,2014 (USD) 179,700 CBM,2014 (USD) 154,900
E-121 E-122
Cp (USD) 16,000 Cp (USD) 17,200
CBM,2001 (USD) 126,900 CBM,2001 (USD) 81,400
CBM,2014 (USD) 184,100 CBM,2014 (USD) 118,100
E-123 E-124
Cp (USD) 18,700 Cp (USD) 16,600
CBM,2001 (USD) 63,500 CBM,2001 (USD) 104,400
CBM,2014 (USD) 92,100 CBM,2014 (USD) 151,500
183
E-125 E-126
Cp (USD) 17,800 Cp (USD) 19,600
CBM,2001 (USD) 76,000 CBM,2001 (USD) 83,600
CBM,2014 (USD) 110,200 CBM,2014 (USD) 121,300
E-127 E-128
Cp (USD) 138,600 Cp (USD) 44,500
CBM,2001 (USD) 1,100,300 CBM,2001 (USD) 160,900
CBM,2014 (USD) 1,596,700 CBM,2014 (USD) 233,500
E-129 E-130 (10 Heaxt Exchangers)
Cp (USD) 16,600 Cp (USD) 5,797,500
CBM,2001 (USD) 59,800 CBM,2001 (USD) 46,009,700
9CBM,2014 (USD) 86,800 CBM,2014 (USD) 66,766,200
E-131 E-132
Cp (USD) 118,100 Cp (USD) 46,500
CBM,2001 (USD) 937,500 CBM,2001 (USD) 272,900
CBM,2014 (USD) 1,360,400 CBM,2014 (USD) 396,000
184
E-132
Parameter Value
Cp (USD) 18,600
CBM,2001 (USD) 109,400
CBM,2014 (USD) 158,700
185
M.8. New Equipment Summary
The new equipment summary after performing heat exchanger design is shown
in Table M.15
Table M.15. Equipment Summary

Type Floating Floating Floating Floating
Area (m2) 3,345 279 153 226
Duty (MJ/h) 8,218 2,057 735 2,567
Shell
Pressure (bar) 1.42 1 1 1.42
MOC CS CS CS CS
Tube
MOC SS-304 CS CS CS
186
Type Floating U-tube U-tube Floating
Area (m2) 259 191 282 2,202
Duty (MJ/h) 2,898 1,608 3,156 28,938
Shell
Temperature (oC) 25 110 25 -192.05
Pressure (bar) 1 1.42 1 1.52
MOC CS CS CS SS-304
Tube
Temperature (oC) 25 120 25 -203
Pressure (bar) 40 127 127 0.3
MOC CS CS CS SS-304
Type U-tube U-tube Floating Floating
Area (m2) 1,237 111 68 60
Duty (MJ/h) 22,541 2,590 1,396 445
Shell
Temperature (oC) -174.96 25 110 60
Pressure (bar) 2.21 2.21 1.42 1
Phase Liq. Liq. Vap. Liq.
MOC SS-304 SS-304 CS CS
Tube
Temperature (oC) -3.96 393.74 120 50
Pressure (bar) 136.5 136.5 20 20
MOC SS-304 SS-304H CS CS
187
Area (m2) 80 199 42 20
Duty (MJ/h) 1,995 526 201 590
Shell
Pressure (bar) 1.42 1.00 1.00 1.38
MOC CS CS CS SS-304
Tube
Temperature (oC) 120 50 25 392.36
Pressure (bar) 200 200 200 136.5
MOC SS-304H CS CS SS-304
Type Floating U-tube Floating U-tube
Area (m2) 138 108 58 32
Duty (MJ/h) 2,117 2,116 743 642
Shell
Temperature (oC) -188.22 -174.98 -192.52 -178.52
Pressure (bar) 1.52 2.21 1.38 2.07
MOC SS-304 SS-304 SS-304 SS-304
Tube
Temperature (oC) -203 19.12 -203 20.93
Pressure (bar) 0.3 136.5 0.3 136.5
MOC SS-304 CS SS-304 CS
188
Type Fixed Fixed Fixed Fixed
Area (m2) 3.8 2.3 1.6 3
Duty (MJ/h) 89.6 81.6 123 103
Shell
Pressure (bar) 2.07 1.42 1.00 1.42
MOC SS-304 CS CS CS
Tube
Temperature (oC) 399.79 120 50 120
Pressure (bar) 136.50 20 20 200
MOC SS-304H SS-304H CS SS-304H
Type Fixed Fixed U-tube U-tube
Area (m2) 2 1.3 834 194
Duty (MJ/h) 16 6 5667 3148
Shell
Temperature (oC) 60 25 -100 110
Pressure (bar) 1 1 1.52 1.42
Phase Liq. Liq Liq. Vap.
MOC CS CS SS-304 CS
Tube
Temperature (oC) 50 25 -11.1 120
Pressure (bar) 200 200 136.5 50
MOC CS CS SS-304 CS
189
Area (m2) 24 101,359 180 207
Duty (MJ/h) 423 162,028 18,987 586
Shell
Temperature (oC) 60 21.96 -40 -33.33
Pressure (bar) 1 136.5 136.5 1.01
MOC CS SS-304 SS-304 SS-304
Tube
Temperature (oC) 100 350 -50 21.47
Pressure (bar) 50 136.5 0.7 136.5
Phase Vap. Vap. Liq. Vap.
MOC CS SS-304 SS-304 CS
Heat exchangers Internal Heat Exchanger in Reactor
Type U-tube
Area (m2) 5,021
Duty (MJ/h) 86,913
Shell
Pressure (bar) 40
Phase Vap.
MOC CS
Tube
Phase Vap.
MOC SS
190
References for Appendix M
[1] Towler, G. P., & Sinnott, R. K. (2013). Chemical engineering design principles,
practice, and economics of plant and process design. Oxford: Butterworth-
Heinemann.
[2] Perry, R. H., & Green, D. W. (2008). Perry's chemical engineers' handbook.
New York: McGraw-Hill.
191
Appendix N.
Reactor Design
192
N.1. Reactor Selection
N.1.1. Type Selection
First of all, a suitable type of a reactor is selected. The packed-bed reactor is
selected for ammonia production process from hydrogen and nitrogen.
N.1.2. Catalyst Selection

Ferro-oxide catalyst is normally used for ammonia production process in a
commercial scale. So, iron catalyst is used for this process as well.
N.1.3. Packed-Bed Reactor Selection

An adiabatic packed-bed reactor with three beds of catalysts shown in Fig.
N.1. is based on the results of Dashti, et al [1]. In this work, we use two packed bed
reactors in series with one heat exchanger between. However, we show only one
reactor in a process flow diagram.
Fig. N.1. Ammonia Synthesis Reactor - Kellogg method [1]
193
N.2. Packed-Bed Reactor Design Method
Packed-bed reactor design method is based on space velocity. The selected
method is from Silla [2].
N.2.1. Bed Volume Calculation

Catalyst bed volume VB is calculated from Eq. (N.1) and (N.2).
Q
VB (N.1)
SV
Q
VB STP (N.2)
GHSV
where Q is a volumetric flow rate, SV is a space velocity, QSTP is a volumetric
flow rate at STP and GHSV is a gas hourly space velocity.
N.2.2. Bed Area Calculation

Bed area AB is calculated from Eq. (O3).
Q
AB (N.3)
v
where v is a superficial velocity normally used 1 m/s.
N.2.3. Reactor Diameter Calculation

The reactor diameter D is calculated from Eq. (N.4). Then, it is round up to a
standard value (0.152 m increments). The diameter should not be higher than 4.11 m
(shipping diameter).
D 2
AB (N.4)
4
N.2.4. Bed and Reactor Length Calculation

The bed length LB is calculated from Eq. (N.5) which has the minimum value
of 0.5D and the maximum value of 7.62 m. Then, the reactor length LR is obtained
from Eq. (N.6). Finally, LR is round off to 0.25 ft in increments.
LB VB / A B (N.5)
194
LR LB 0.914 m (N.6)
N.2.5. Pressure Drop Determination

The pressure drop (P) across reactors can be calculated from Eq. (N.7).
P PB LR (N.7)
where PB is 0.0252 bar/m.
N.2.6. Catalyst Weight Calculation

After obtaining actual diameter and length, the catalyst weight WB could be
determined from Eq. (N.8).
WB VB B (N.8)
where B is a bulk density of the catalyst.
195
N.3. Input Parameters for Reactor Design
Table N.1 shows all input parameters obtained from Aspen and Chemical
Engineering Design textbook [3] in order to design a reactor.
Table N.1. Input parameters of a reactor
R-101
Parameter Value
Q (m3/h) 21,101.4
QSTP (m3/h) 21,818.87
GSHV (h-1) 7,800
N.4. Reactor Design Results

The reactor design is performed based on methods mentioned in part 2 for both
reactors. The diameter calculated is 2.73 m which is not higher than a shipping
diameter. It is round off to 3.152 m. However, the calculated diameter is 0.478 m
which is lower than 0.5D or the minimum value. Therefore, it is round off to the
minimum value for each bed. The reactor length of each bed is a summation of bed
length and 0.914 m. The overall length is a summation of each bed. Ferro-oxide bulk
density of 0.25 g/cm3 [4] is used. The actual volume is calculated from corrected
diameter and length. The results obtained from reactor design are shown in Table N.2.
Table N.2. Reactor design results
R-101
Parameter Value
Type Packed-Bed Reactor

Catalyst Volume 9.72 m3
Catalyst Weight 2,429 kg
Diameter 2.914 m
Bed Length 1.457 m
Reactor Length 2.439 m
Pressure Drop 0.06 bar
196
N.5. Material of Construction and Thickness Design
N.5.1. Material of Construction (MOC) Considerations
Since the reactor has the highest possible temperature of 500 C and the pressure of 136.5 bar, the material choices are Nickel
alloy or stainless steel. MOC is designed based on design temperature which is could be calculated using Eq. (N.9), (N.10) and Table
N.3, respectively.
Maximum Temperature = Operating Temperature + 50oF (N.9)
Minimum Temperature = Operating Temperature - 25oF (N.10)
Table N.3. MOC of the reactor in the process.

Reactor MOC
R-101 500 527.78 486.11 SS-304H
N.5.2. Reactor Wall Thickness Considerations

from the value of normal operating pressure and max operating pressure using simple correlations, Eq. (N.11) and (N.12).
Maximum Operating Pressure = 1.2 x Operating Pressure (N.11)
Design Pressure = 1.1 x Maximum Operating Pressure (N.12)
197
and longitudinal stress could be expressed as Eq. (N.13) and (N.14), respectively.
Pi Di
t (N.13)
2SE 1.2Pi
Pi Di
t (N.14)
4SE 0.8Pi

temperature)
in Table N.4. However, a thickness of each vessel should follow the minimum thickness guideline shown in Table N.5. The detail of
each material is shown in Table N.6.
198
Table N.4. Thickness of reactor
Vessel
C.A. (m)
R-101 2.914 1.79107 20 1.38108 0.2104 0.1022 0.2119 0.2119
Table N.5. Minimum thickness guideline

1 5
1 to 2 7
2 to 2.5 9
2.5 to 3 10
3.0 to 3.5 12
199
Table N.6. Detail of each material
-101oC or Lower /
425oC Maximum
0.1% C, 2% Mn, 0.75% Si, 0.045% P,
20% Cr, 10.5% Ni
200
N.6. Economic Costing Method
To determine cost of reactor, we cost it as a pressure vessel and then add an
extra cost for mixers, internals, controls, etc. Therefore, bare module factor method
is used according to analysis, synthesis and design of chemical processes [5]. The
bare module cost of the vessel can be estimated as shown in Eq. (N.15).
CBM = Cp FBM (N.15)
The factor Cp for a reactor could be obtained from Eq. (N.16).
logCP = K1 +K2 log(V) +K3 (log(V))2 (N.16)
D2 H
V= (N.17)
4
vessels are shown in Table N.7.
Table N.7. K parameters for pressure vessels

K1 3.5565 3.4974
K2 0.3776 0.44851
K3 0.0905 0.1074
The bare module factor can be determined from Eq. (N.18).

FBM = B1 +B2 FM FP (N.18)
factor. B parameters used for horizontal and vertical vessels are shown in Table N.8.
Table N.8. B parameters for pressure vessels

B1 1.49 2.25
B2 1.52 1.82
201
The pressure factor of the vessel, which is thicker than 6.3 mm is determined
by using Eq. (N.19).
P+1 D +0.00315
2 SE-0.6 P+1
FP,vessel = (N.19)
0.0063

Finally, internal costing is included.
used to convert the price is shown in Eq. (N.20).
CBM,2014 576.1
= (N.20)
CBM,2001 397
202
N.7. Costing Parameters
Table N.9 shows all input parameter used to a reactor cost by using bare
module method.
Table N.9. Input parameters for reactor costing
R-101
Parameter Value
D (m) 2.914
L (m) 2.439
FM 3.1
P (barg) 135.5
B1 2.25
B2 1.82
K1 3.4974
K2 0.44851
K3 0.1074
203
N.8. Costing Results
Table N.10 shows the results calculated from the design method mentioned in
part 6 for a reactor.
Table N.10. Reactor costing results
R-101
Parameter Value
Cp (USD) 15,800
CBM,2001 (USD) 4,820,000
CBM,2014 (USD) 6,995,000
Since the market price of ferro-oxide which is the catalyst bed is $700-900 per
ton, total cost of the reactor is 6,995,000+ (2.43)(800) = $7,000,000. However, we
have two identical reactors in our system, so cost of our reactor is $14,000,000.
204
N.9. New Equipment Summary
The new equipment summary after performing reactor design is shown in
Table N.11.
Table N.11. Equipment Summary
Vessels/Tower/Reactors R-101
Temperature (oC) 350 - 500
MOC SS-304H
Size
Height/Length (m) 2.439
Diameter (m) 2.914
Internals Two identical reactors in
series with one heat
exchanger between
205
References for Appendix N
Coal, 48(2), 15-23.
[2] Silla, H. (2003). Chemical process engineering design and economics.
New York: M. Dekker.
[3] Couper, J. R. (2012). Chemical process equipment selection and design.
Amsterdam: Elsevier/Butterworth-Heinemann.
[4] BULK MATERIAL DENSITY GUIDE. (n.d.). Retrieved May 12, 2017, from
http://www.hapman.com/resources/bulk-material-density-guide
206
Appendix O.
Process Hydraulic
Design
207
O.1. Compressor Type Selection
The selection of compressor type is done by using Fig. O.1, the diagram shows
that the discharge pressure and the volumetric flow rate determine the type of the
compressor.
Fig. O.1. Approximate ranges of application for each type of compressor [1]
The type of the compressor is also required to estimate the efficiency and the
range of compression ratio.
208
O.2. Compressor Design Method
The required power of each compressor can be calculated by using Eq. (O.1)
and electrical power can be calculated by using Eq. (O.2).
1
1

nRT1 P2
1
P2
Ws,min nCP T1 1 (O.1)
P1 1 P1

Ws,min
W (O.2)

where CP is an isobaric heat capacity, T1 is the inlet temperature (K), is the

ratio of the isobaric heat capacity to the heat capacity of constant volume system, P1
and P2 are inlet and outlet pressure, is the efficiency of the compressor, n is molar
flow rate of the gas, Ws,min is the work required (W) and W is the input work (W).
However, the results in this calculation are obtained from Aspen.
209
O.3. Input Parameters for Compressor Design
Table O.1 shows all input parameters obtained from Aspen and Chemical
Engineering Design textbook in order to design the compressor.
Table O.1. Input parameters of each compressor
C-101 C-102
Q (L/min) 146,891 Q (L/min) 146,891
Discharge pressure Discharge pressure
40 40
(bar) (bar)
Compression ratio 10 Compression ratio 10
Inlet temperature (K) 298.15 Inlet temperature (K) 298.15
Efficiency 0.8 Efficiency 0.8
C-103 C-104
Q (L/min) 36,305.1 Q (L/min) 11,412
127 2.28
(bar) (bar)
Compression ratio 10 Compression ratio 0.018
210
Table O.1. Input parameters of each compressor (cont)
C-105 C-106
Q (L/min) 140,023 Q (L/min) 16,596.6
20 200
(bar) (bar)
Compression ratio 9.05 Compression ratio 10
C-107 C-108
Q (L/min) 6,115.9 Q (L/min) 679.06
20 200
(bar) (bar)
Compression ratio 9.66 Compression ratio 10
C-109 C-110
Q (L/min) 389,840 Q (L/min) 25,893
50 136.5
(bar) (bar)
Compression ratio 32.9 Compression ratio 2.73
211
Table O.1. Input parameters of each compressor (cont)
C-111
Parameter Value
Q (L/min) 110,378
Discharge pressure
136.5
(bar)
Compression ratio 1.001
Inlet temperature (K) 233.15
Efficiency 0.8
212
O.4. Compressor Design Results
The compressor design is performed based on methods mentioned in O.2. The
results obtained from reactor design are shown in Table O.2.
Table O.2. Compressor design results
C-101 C-102
Type Reciprocating Type Reciprocating

Shaft Power (kW) 5241.28 Shaft Power (kW) 5241.28
Fluid Power (kW) 4193.44 Fluid Power (kW) 4193.44
C-103 C-104

C-105 C-106

C-107 C-108

213
Table O.2. Compressor design results (cont)
C-109 C-110

C-111
Parameter Value
Type Reciprocating
Shaft Power (kW) 29.26
Fluid Power (kW) 23.41
214
O.5. Material of Construction
There are six compressors and one turbine in this process. Since the air-separation unit is mostly cryogenic, materials of
construction have to be able to deal with very low temperatures. On the other hand, the ammonia production exists at high
temperature, so materials of construction should be able to deal with high temperatures. Reasonably, MOC is designed based on
temperatures of fluids that enter and come out of each compressor. Design temperature used to design compressors are calculated
based on following Equations. MOC Design is shown in Table O.3. The detail of each material is shown in Table O.4.
Tmax = Thot + 50 [oF] (O.3)

Tmin = Tcold - 25 [oF] (O.4)
Table O.3. MOC of process hydraulic equipment in the process
Thot Tcold Tmax Tmin

Unit MOC
(C) (C) (C) (C)
C-101 394 40.00 421.78 26.11 SS-304H

C-102 205.15 25.00 232.93 11.11 CS
C-103 170.54 25.00 198.32 11.11 CS
C-104 25.00 -148.53 52.78 -162.42 TP-304
C-105 333.00 25.00 360.78 11.11 CS
C-106 401.00 50.00 410.77 36.11 SS-304H
C-107 578.18 25.00 580.96 11.11 TP-304
C-108 583.05 50.00 610.83 36.11 SS-304L
215
C-109 270.06 -100.00 297.84 -113.89 TP-304
C-110 253.93 100.00 281.71 86.11 CS
C-111 -40.00 -40.00 -12.22 -53.89 31/2 Ni
Table O.4. Detail of each material
-101oC or Lower /
425oC Maximum
0.1% C, 2% Mn, 0.75% Si, 0.045% P,
20% Cr, 10.5% Ni
216
O.6. Economic Costing Method
To determine cost of hydraulic equipment, bare module factor method is used
according to analysis, synthesis and design of chemical processes [1] The bare
module cost of the hydraulic equipment can be estimated as shown in Eq. (O.5).
CBM = Cp FBM (O.5)
The factor Cp can be determined by using Eq. (O.6).
logCP = K1 +K2 log(P) +K3 (log(P))2 (O.6)

where P is fluid power (kW) and Cp is the cost for ambient pressure and
carbon steel (USD). K parameters for compressors and turbine are shown in Table
O.5.
Table O.5. K parameters for hydraulic equipment
Parameters Compressor Turbine

K1 2.2897 2.7051
K2 1.3604 1.4398
K3 -0.1027 -0.1776
Also, the bare module factor can be obtained from Fig. O.2. Identification
number could be obtained from Table O.6.
Bare Module
Factor, FBM
Identification
Number
Fig. O.2. Bare Module Factors
217
Table O.6. Identification of bare module factors used with Fig. O.2.
Identification
Equipment Type Equipment Description MOC
Number
10 Compressor Reciprocating compressor CS
11 Compressor Reciprocating compressor SS
12 Compressor Reciprocating compressor Ni alloy
Power recovery
58 Turbines SS
equipment
The estimated cost of each hydraulic equipment is calculated on the basis of

price in 2001 (CEPCI = 397). In 2014, the CEPCI is estimated to be 576.1, Eq. 20
which is used to convert the price is shown below.
CBM,2014 576.1
= (O.7)
CBM,2001 397
218
O.7. Costing Parameters
Table O.7 shows all input parameter used to a hydraulic equipment cost by
using bare module method.
Table O.7. Input parameters for hydraulic equipment costing
C-101 C-102
P (kW) 4193.44 P (kW) 4193.44
Identification No. 11 Identification No. 10
K1 2.2897 K1 2.2897
K2 1.3604 K2 1.3604
K3 -0.1027 K3 -0.1027
C-103 C-104
P (kW) 3395.66 P (kW) 5322.03
K1 2.2897 K1 2.7051
K2 1.3604 K2 1.4398
K3 -0.1027 K3 -0.1776
219
Table O.7. Input parameters for hydraulic equipment costing (cont)
C-105 C-106
P (kW) 1964.12 P (kW) 1827.31
K1 2.2897 K1 2.2897
K2 1.3604 K2 1.3604
K3 -0.1027 K3 -0.1027
C-107 C-108
P (kW) 78.17 P (kW) 87.86
K1 2.2897 K1 2.2897
K2 1.3604 K2 1.3604
K3 -0.1027 K3 -0.1027
C-109 C-110
P (kW) 5980.12 P (kW) 2561.42
K1 2.2897 K1 2.2897
K2 1.3604 K2 1.3604
K3 -0.1027 K3 -0.1027
220
Table O.7. Input parameters for hydraulic equipment costing (cont)
C-111
Parameter Value
P (kW) 3395.66
Identification No. 13
K1 2.2897
K2 1.3604
K3 -0.1027
221
O.8. Costing Results
Table O.8 shows the results calculated from the design method mentioned in
O.6 for compressors and turbine.
Table O.8. Hydraulic equipment costing results
C-101 C-102
Cp (USD) 741,500 Cp (USD) 741,500
CBM,2001 (USD) 5,190,500 CBM,2001 (USD) 2,521,100
CBM,2014 (USD) 7,532,100 CBM,2014 (USD) 3,658,500
C-103 C-104
Cp (USD) 649,800 Cp (USD) 402,000
CBM,2001 (USD) 2,209,200 CBM,2001 (USD) 2,411,700
CBM,2014 (USD) 3,205,900 CBM,2014 (USD) 3,499,700
222
Table O.8. Hydraulic equipment costing results (cont)
C-105 C-106
Cp (USD) 452,800 Cp (USD) 430,900
CBM,2001 (USD) 1,539,700 CBM,2001 (USD) 3,016,500
CBM,2014 (USD) 2,234,300 CBM,2014 (USD) 4,377,300
C-107 C-108
Cp (USD) 31,400 Cp (USD) 35,200
CBM,2001 (USD) 219,800 CBM,2001 (USD) 246,100
CBM,2014 (USD) 319,000 CBM,2014 (USD) 357,100
C-109 C-110
Cp (USD) 917,600 Cp (USD) 541,300
CBM,2001 (USD) 6,423,500 CBM,2001 (USD) 1,840,500
CBM,2014 (USD) 9,321,300 CBM,2014 (USD) 2,670,800
C-111
Parameter Value
Cp (USD) 649,800
CBM,2001 (USD) 9,031,900
CBM,2014 (USD) 13,106,500
223
O.9. New Equipment Summary
The new equipment summary after performing hydraulic equipment design is
shown in Table O.9. The data cannot be specified at this time is leaving.
Table O.9. Equipment Summary
Pumps/
Turbine
Flow (kg/h) 103,489 103,489 103,489 103,489
Fluid density
11.74 11.74 47.51 151.15
(kg/m3)
Power (shaft) (kW) 5,241 5,241 4,245 4,258
MOC SS-304H CS CS TP-304
Temp. (in) (oC) 25 25 25 25
Pres. (in) (bar) 10 10 40 127
Pres. (out) (bar) 40 40 127 2.28
224
Table O.9. Equipment Summary (cont)
Pumps/
Turbine
Flow (kg/h) 24,016 24,016 1,226 1,226
Fluid density
2.86 24.12 3.34 30.1
(kg/m3)
Power (shaft) (kW) 1,964 2,284 98 109
MOC CS SS-304H SS-304 SS-304L
Temp. (in) (oC) 25 50 25 50
Pres. (in) (bar) 2.21 20 2.07 20
Pres. (out) (bar) 20 200 20 200
Pumps/
C-109 C-110 C-111
Compressors
Flow (kg/h) 69,646 69,646 186,480
Fluid density
2.98 44.83 28.16
(kg/m3)
Type/Drive Screw Reciprocating/ Reciprocating/
Electric Electric
Power (shaft) (kW) 7,475 3,201 29
Efficiency 80 80 80
MOC SS-304 CS 31/2 Ni
Temp. (in) (oC) -100 100 -40
Pres. (in) (bar) 1.52 50 136.35
Pres. (out) (bar) 50 136.5 136.5
225
References for Appendix O
[2] Rules of Thumb for Chemical Engineers. (2017). Butterworth-Heinemann.
226
Appendix P.
Economic Analysis
227
P.1 Capital Cost Calculation
To estimate total capital costs, the prices of all equipment are integrated. The
total module, CTM, and grassroots cost, CGR, could be obtained from following Eq.
(P.1) and (P.2).
n
CTM =1.18 C BM,i (P.1)
i=1
n
CGR = CTM 0.50 C0BM, i (P.2)
i=1
Table P.1. Cost summary
Equipment C0BM ($) CBM ($)
Vessel
V-101 11,300 17,300
V-102 11,300 17,300
V-103 11,300 17,300
V-104 11,300 17,300
V-105 80,300 226,000
V-106 29,300 87,600
V-107 21,200 63,200
V-108 184,2000 16,000,000
V-109 167,700 432,000
Tower/Column
T-101 6,718,000 23,400,000
T-102 1,151,000 2,660,000
T-103 286,000 671,000
Heat Exchanger
E-101 170,100 342,700
E-102 149,000 218,100
E-103 102,200 149,200
E-104 129,200 202,200
E-105 141,400 221,300
E-106 145,100 255,800
228
E-107 189,500 334,100
E-108 1,161,000 3,033,500
E-109 659,300 2,307,900
E-110 104,800 366,800
E-111 72,100 108,100
E-112 70,000 104,400
E-113 87,800 243,500
E-114 149,000 280,700
E-115 65,800 123,800
E-116 52,100 134,800
E-117 97,000 253,400
E-118 103,300 267,400
E-119 68,800 179,700
E-120 59,800 154,900
E-121 52,500 184,100
E-122 56,700 118,100
E-123 61,500 92,100
E-124 54,600 151,500
E-125 58,600 110,200
E-126 64,500 121,300
E-127 456,000 1,596,700
E-128 147,000 233,500
E-129 54,500 86,800
E-130 1,907,000 66,766,200
E-131 389,000 1,360,400
E-132 61,300 158,720
Reactor Internal
3,040,000 7,881,600
Heat Exchanger
Reactor
R-101 66,000 7,000,000
Compressor
C-101 3,658,500 7,532,100
C-102 3,658,500 3,658,500
229
C-103 3,206,000 3,206,000
C-104 1,983,200 3,499,700
C-105 2,234,300 2,234,300
C-106 2,126,100 4,377,300
C-107 154,900 319,000
C-108 173,500 357,100
C-109 4,527,500 9,321,300
C-110 2,670,800 2,670,800
C-111 3,205,900 12,729,300
Summation 40,198,300 188,652,900
n
Total module cost CTM = 1.18 C BM,i = 1.18(188,652,900) = $339,600,000
i=1
n
Grassroot cost (FCI) = CTM 0.50 C0BM, i =
i=1
339,600,000 + 1.18(40,198,300)(576,1/397) = $408,400,000
P.2. Manufacturing Cost Calculation

Factors that affecting the cost of manufacturing is divided into three
categories; direct costs, fixed costs and general expenses. The total manufacturing
cost can be obtained by adding these three cost categories together and solving for
the total manufacturing cost, COM. The result equation is shown in Eq. (P.3).
COMd = 0.180FCI + 2.73COL + 1.23(CUT + CWT + CRM) (P.3)
where COMd is cost of manufacture without depreciation, FCI is fixed capital
cost investment (total module or grassroots), COL is cost of operating labour, CUT is
cost of utilities, CWT is cost of waste treatments and CRM is cost of raw materials.
P.2.1. Cost of Operating Labour (COL)

The operating labour requirement for chemical process plants can be
determined by using Eq. (P.4).
NOL = (6.29 + 31.7P2 + 0.23Nnp)0.5 (P.4)
230
where NOL is the number of operators required per shift, P is the number of
processing steps involving the handling of particulate solids and Nnp is the number of
nonparticulate processing steps and include compression, heating, cooling, mixing
and reaction.
The operating labour is equal to 4.5 times NOL and round up to the nearest
integer. Chemical plant operators are highly paid, the data from the Bureau of Labour
Statistics [1] give the estimation of cost of labour at $59,580 per year.
Table P.1 shows all input parameter used to an operating labour costing (COL)
by using method mentioned above.
Table P.1. Input parameters for operating labour costing
Parameter Value
P 4
Nnp 48
231
Using parameters in Table P.1, the result shows that number of operators
required per shift is equal to 22.9
As a result, operating labour = (4.5)(22.9) = 103.05 (rounding up to the nearest
integer yields 104 operators)
Labour Costs = 104 ($59,580) = $6,196,300
P.2.2. Cost of Utilities (CUT)

The cost of utilities can be calculated using the energy requirement from PFD
and the cost of utilities per energy unit from Table P.2 [1].
Table P.2. Utilities with multiple process units
Utilities Description Cost ($/GJ)

Cooling Water Process cooling water: 40C to 60C 0.354
Chilled Water Chilled water in at T = 10C and 4.43
returned at 25C
Refrigerant Propane Refrigerant available at T = -50C 13.11
Refrigerant Liquid Refrigerant available at T = -203C 96.77 [2, 3]
Nitrogen
Electricity Electric Distribution 16.8
a. 110 V
b. 220 V
c. 440 V
Steam Generation Estimate saving as avoid cost pf burning 12.33
natural gas in boiler
It is noted that electricity required is determined by including all electric devices

which are compressors in the process and divined by its efficiency.
232
Table P.3 shows all input parameter used to utilities costing (CUT) by using
utilities cost shown above. Table P.4 shows cost of all utilities required in one year.
Table P.3. Input parameters for utilities costing
Utility Duty (kW)
Cooling Water 3,479.10
Chilled Water 7,008.41
Refrigerant Propane 18,980.00
Refrigerant Liquid Nitrogen 31,797.40
Electricity 42,681.25
Steam Generation 106,029.1
Table P.4. Utilities costing results
Utility Cost ($/yr)
Cooling Water 38,800
Chilled Water 979,100
Refrigerant Propane 7,847,000
Refrigerant Liquid Nitrogen 88,618,000
Electricity 22,612,700
Steam Generation -37,650,000
Therefore, the total cost of utilities is approximately $82,445,600
P.2.3. Cost of Raw Materials (CRM)

Raw materials in this process are consisted of hydrogen gas and air. For air
feedstock, we can use the ambient air so the cost could be disregarded.
For the hydrogen gas, since the hydrogen gas market price is about $2.70 per
kilogram [4], 161,000-ton hydrogen gas feed costs:
233
$2.70 1,000 kg 161,000 ton
$434,700,000 / yr
kg 1ton year
P.2.4. Cost of Waste Treatments (CWT)

Due to the fact that our process has no solid or liquid waste stream, and the
gas purge stream is not hazardous, the cost of waste treatments could be assumed to
be negligible.
P.2.5. Manufacturing Cost Analysis

After substituting those value from part 2.1-2.3 and the FCI value from part 1
and Eq. (P.1), the cost of manufacturing would be equal to
COMd = 0.180(408,400,000) + 2.73(6,196,300) + 1.23(82,445,600+434,700,000)
= $727,000,000
P.2.6. Revenue
The production rate of primary product and valuable by-products obtained
from Aspen Plus. After calculating with the market prices, the revenue is shown in
Table P.5.
Table P.5. Production rate of all products
Production Rate Price Revenue

Component
(tpy) ($/ton) ($/yr)
Ammonia 816,300 1,000 [5] 816,300,000
Argon 11,900 5,000 [6] 59,500,000
Oxygen 231,900 210 [7] 48,699,000
Sum 924,499,000
234
P.3. Profitability Analysis
P.3.1. Time Value of Money
In this work, compound interest is used to determine the future value of an
investment. Let us determine the future value of an investment, Fn, after n years at an
interest rate of i per year for an initial investment of P when the interest earned is
reinvested each year. It should be noted that an interest rate of 10% is used in this
work. Also, Fn could be determine from Eq. (P.5).
Fn = P(1 + i)n (P.5)
P.3.2. Depreciation of Capital Investment

When a company builds and operates a chemical process plant, the physical
plant (equipment and buildings) associated with the process has a finite life. The value
or worth of this physical plant decreases with time. This is what we call depreciation,
dk. When the plant is closed, the plant equipment can be salvaged and sold for only a
fraction of the original cost. The salvage value of 20 x 106 $ is used in this work.
There are several methods to determine deprecation of the plant; however, MACRS
method [1] with a half-year convention is normally used. It is assumed that the
depreciation schedule is 5-year recovery period. The bigger value obtained from Eq.
(P.6) and (P.7) is selected for each-year depreciation.
2 k-1
DDB
d DDB
k = FCI L j
- d (P.6)
5 j=0
undepreciated capital
dSL
k = (P.7)
remaining time for depreciation
P.3.3. Taxation, Cash Flow, and Profit

Taxation has a direct impact on the profits realized from building and
operating a plant. For large corporations, the overall taxation rate is often in the range
of 40% to 50%. In this work, we use 45% taxation rate. Evaluations of cash flows and
profits in terms of revenue (R), cost of manufacturing excluding depreciation
(COMd), depreciation (d) and tax rate (t) are shown in Eq. (P.8) (P.11).
Expense = COMd + d (P.8)
Income Tax = (R COMd d)(t) (P.9)
235
After-Tax Net Profit = (R COMd d)(1 t) (P.10)
After-Tax Cash Flow = (R COMd d) (1 t) + d (P.11)
P.3.4. Working Capital

Working capital is the amount of capital required to start up the plant and
finance the first few months of operation before revenues from the process start.
Typically, this money is used to cover salaries, raw material inventories, and any
contingencies. The working capital will be recovered at the end of the project and
represents a float of money to get the project started.
P.3.5. Land Value

Land value is the cost of land that we use for our construction. In this work,
the value of 20 x 106 $ is used.
P.3.6. Profitability Analysis

Table P.6 shows all input parameters we use in our calculation. Table P.7
shows discounted after-tax cash flow analysis for our process.
Table P.6. Input parameters for profitability analysis
Parameter Value
FCIL ($) 408,400,000

Land ($) 30,000,000
Working Capital ($) 30,000,000
Salvage ($) 20,000,000
Revenue ($) 924,499,000
COMd ($) 727,000,000
Taxation Rate 45%
Interest Rate 10%
Working Time 12 years
236
Table P.7. Profitability Analysis
Cumulative Non- Cumulative

Non-Discounted Discounted
End of Year (k) Investment dk FCIL - d k R COMd (R COMd d) (1 t) + d Discounted Cash Discounted Cash
Cash Flow Cash Flow
Flow Flow
0 -30000000 0 408400000 0 0 0 -30000000 -30000000 -30000000 -30000000
1 -150000000 0 408400000 0 0 0 -150000000 -136363636 -180000000 -166363636.4
2 -288400000 0 408400000 0 0 0 -288400000 -238347107 -468400000 -404710743.8
3 0 81680000 326720000 924,499,000 727,000,000 145380450 145380450 109226484 -323019550 -295484260
4 0 130688000 196032000 924,499,000 727,000,000 167434050 167434050 114359709 -155585500 -181124550.9
5 0 78412800 117619200 924,499,000 727,000,000 143910210 143910210 89356918 -11675290 -91767632.92
6 0 47047680 70571520 924,499,000 727,000,000 129795906 129795906 73266405.2 118120616 -18501227.76
7 0 47047680 23523840 924,499,000 727,000,000 129795906 129795906 66605822.9 247916522 48104595.12
8 0 23523840 0 924,499,000 727,000,000 119210178 119210178 55612427.8 367126700 103717023
9 0 0 0 924,499,000 727,000,000 108624450 108624450 46067370.5 475751150 149784393.5
10 0 0 0 924,499,000 727,000,000 108624450 108624450 41879427.8 584375600 191663821.3
11 0 0 0 924,499,000 727,000,000 108624450 108624450 38072207.1 693000050 229736028.3
12 60000000 0 0 944,499,000 727,000,000 119624450 179624450 57233885.4 872624500 286969913.7
237
According to Table P.7, following data could be obtained.
1. Discounted value of land + working capital = 30 + 30/1.12 = 54.8 million dollars, so

a discounted payback period can be determined from Table P.7 by specifying the year
that discounted cumulative cash flow is less than $54,800,000. Thus, a discounted
payback period (DPBP) for this system is 6 years since the beginning or 4 years after
starting a factory.
2. Net present value (NPV) = $287,000,000
3. Present value ratio (PVR) = 1.71
References for Appendix P

(2016). Analysis, synthesis, and design of chemical processes. UP, India: Pearson
India Education Services.
[2] Elert, G. (n.d.). Price of Liquid Nitrogen. Retrieved May 14, 2017, from
http://hypertextbook.com/facts/2007/KarenFan.shtml
[3] Energy density. (2017, May 09). Retrieved May 14, 2017, from
https://en.wikipedia.org/wiki/Energy_density
[4] Doty, F. D. (2004). A Realistic Look at Hydrogen Price Projections. Inc. Columbia,
SC. Retrieved May 14, 2017.
[5] Ammonia price, https://www.alibaba.com/showroom/price-of-liquid-ammonia-
nh3.html
[6] Argon Element Facts. (n.d.). Retrieved May 14, 2017, from http://www.chemicool.
com/elements/argon.html
[7] Oxygen. (2017, May 11). Retrieved May 14, 2017, from https://en.wikipedia.
org/wiki/Oxygen
238
2105464 Chemical Plant Design
To. Dr. Palang Bamroongsakulsawat
Nuttawat Suwattanapongtada 5630194021
Prakitr Srisuma 5630355721
Poom Sittisomwong 5630488521
239

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Design Report

Air Separation Unit and

Nuttawat Suwattanapongtada 5630194021

Table 1.1. Properties of air [1]

Table 1.2. Typical compositions of air [1]

Components vol% Boiling point (oC)

Table 1.3. Liquid nitrogen specifications [1, 2]

Table 1.4. Argon specifications [1, 3]

Table 1.6. Specifications of hydrogen [5]

Table 1.7. Ammonia specifications [6]

N 2 (g) 3H 2 (g) 2NH 3 (g)

Table 2.1. Operating conditions [7]

2.2. Kinetics and Equilibrium Data

NH3 =0.1438996+0.202853810-2 T-0.448767210-3 P-0.114294510-5 T2 +

T is in term of Kelvin and P is in term of atmosphere.

2.3. Heat of Reaction

2.4. Stream Information

Table 2.2. Overall material balance for each stream

Stream Input (tpy) Output (tpy)

Heat exchangers E-101 E-102 E-103 E-104

A.1. Feed Specifications

Table A.2. Typical compositions of air [1]

Components vol% Boiling point (oC)

Table A.5. Argon specifications [1, 4]

A.2.2. Ammonia Production Process

Component Production Rate (tpy)

A.3. Storage Conditions

Guidelines Process Consideration

Reference for Appendix B

Feed Stream Component Classification

C.2. Output Structure

Fig. C.1. Input-Output Diagram

Components Input (tpy) Output (tpy)

Table D.2. Overall material balance for each stream

Stream Input (tpy) Output (tpy)

References for Appendix D

Vent (19.1 tpy)

Recycle System Purge

161,000 tpy Hydrogen

VBP 1 (12,700 tpy)

VBP 2 (230,000 tpy)

Waste (753 tpy)

Fig. E.1. Block flow diagram of general process design

3. Phase Separation System

Reference for Appendix G

Air To the Reactor

Remove Solid Increase

Fig. F.1. Consideration for air

Fig. F.2. Consideration for hydrogen

E-101 E-102 E-103

Fig. F.3. Filter process flow diagram

F.2. Adsorber: CO2 Removal

V-101 V-102 V-103 V-104

Fig. F.4. Adsorber process flow diagram

LPS CHW LPS CHW

Fig. F.5. Low temperature production

F.5. Cryogenic Distillation

Fig. F.6. Cryogenic distillation

According to the experimental data, the ammonia synthesis reaction has

G.2. Heat of Reaction

G.3. Heat Effect of Reactor

Flow rate, F Heat Capacity, Cp FCp

From Feed To Phase

Fig G.1. Reactor system considerations