Front End Material Balance

Date
Ammonia production MTPD
Feed gas to Primary Reformer MT/hr
Steam to Primary Reformer MT/hr
Recycle Gas flow Nm3/hr
Purge gas to PGRU Nm3/hr
Air Flow to Secondary Reformer Nm3/hr
Air Flow to Secondary Reformer Nm3/hr
Steam to Secondary Reformer with Air MT/hr
Quench to HTS MT/hr
SH steam to HTS MT/hr
Back Burning of Make up Gas Nm3/hr

S/C Kmoles/kmoles
Total mass Flow to Reforming MT/hr
Total Dry gas Flow to HTS Nm3/hr
Mass of Dry gas MT/hr
Total Steam Flow MT/hr
Total Steam flow to HTS MT/hr
CO sli p at HTS outlet kmoles/h
CO slip at LTS outlet kmoles/h
Outlet temperature of LTS O
C
Quench added to PG rebolier MT/h
Temperature of PGR inlet O
C
Outlet temperature of PGR O
C
Saturation pressure of steam this temparature kg/cm2
Absorber inlet pressure kg/cm2A
Total water at absorber inlet kmoles/hr
Total water removed by PGR MT/h
Partial pressure of steam at inlet of PGR kg/cm2
Steam inlet at PGR inlet Kcal/kg
Steam inlet at PGR outlet Kcal/kg
Heat Capacity of process gas at PGR inlet kcal/kmoles oC
Heat Capacity of process gas at PGR outlet kcal/kmoles oC
Heat duty by PGR Gcal/h
SL steam to SL reboiler MT/h
SL steam temperature kg/cm2
SL steam Pressure Kcal/kg
Heat Duty by SL rebolier Gcal/h
CO2 removed by absorber kmoles/h
Process Gas inlet to Mist trap O
C
Partial pressure of steam at inlet of Mist trap kg/cm2
LPC chiller process gas outlet temperature O
C
Partial pressure of steam at outlet of LPC chiller kg/cm2
LPC chiller outlet pressure kg/cm2
Make up gas Flow Nm3/hr
Total Carbon input to Front End kgmoles/h
Total Carbon output from Front End kgmoles/h
Total CO2 out by Absorber Nm3/hr
CO2 regeneration energy Kcal/Nm3
Enthalpy of the Quench kcal/kg
CO2 regeneration energy method II Kcal/Nm3
H2/N2 in Make up Gas
Make up gas flow Nm3/hr
Make up Gas Flow/Tonne of Product Nm3/MT

Total Flow to LPC Nm3/hr

Make up Gas Flow/Tonne of Product Nm3/hr

Total water added to Absorber MT/hr

Regenerator Top tempearute O
C
Saturation temperature of steam kg/cm2
Top pressure of CO2 regenerator kg/cm2G
Total saturated water MT/hr
Reflux added to Regenerator MT/hr
Total Flow to Pump MT/hr
Total Flow From Absorber Mt/hr
21/08/2016
858.00 Natural Gas Analysis:
15.30 Component % Vol.
56.40 CH4 94.86
800.00 C2H6 4.09
6500.00 C3H8 0.69
31500.00 C4H10 0.23
30064.92 C5H12 0.00
2.00 C6H14 0.00
0.00 CO2 0.01
5.00 N2 0.13
0.00 Other 0.00
Other 0.00
3.26 Other 0.00
114.61 Other 0.00
103329.55 Other 0.00
67.70 Total 100.00
46.91 MW
51.91 Natural Gas C/H (Wt/Wt)
116.29 Parameters
5.17 Primary reformer outlet temperature O
C
213.50 Primary reformer inlet pressure Kg/cm2
9.37 Process Air indication O
C
175.66 Process Air indication Kg/cm2
121.40 Secondary Reformer outlet temperature O
C
2.07 HTS inlet temperature O
C
24.89 HTSoutlet temperature O
C
469.49 LTS inlet temperature O
C
42.78 LTS outlet temperature O
C
8.84 Mist Trap outlet temperature O
C
661.47 Methanator inlet temperature O
C
647.36 Methannator outlet temperature O
C
5.30 Methanator outlet pressure Kg/cm2
5.21 Absorber pressure drop Kg/cm3
29.95
10.60 Fractional Conversoin
2.00 Flow of Benefield Solution MT/h
526.70 K2CO3
 5.58 KHCO3
930.62 Equivalent K2CO3
62.50 F.C.)in
0.22 Total CO2 aabsorbed MT/h
10.53 Equivalent KHCO3 MT/h
0.01 Total KHCO3 in the system MT/h
24.30 Total K2CO3 in the System MT/h
94195.69 Total K2CO3 equivalent of KHCO3 MT/h
961.89 F.C)out
33.80
20858.95 928.09
1703.70
119.38
1458.89
2.99
94195.69
2634.84

94195.69
2634.84

7.76
91.10
0.89
0.44
14.39
9.00
949.37
995.71
% Vol. Dry Gas
94.86 HTS)inlet LTS)inlet
4.09 CO2 8.20 16.30
0.69 CO 12.20 2.30
0.23 H2 56.20 60.06
0.00 CH4 0.52 0.47
0.00 N2 22.60 20.61
0.00 Ar 0.28 0.26
0.13 NH3 0.00 0.00
0.00 Total 100.00 100.00
0.00 M.W. 14.69 14.98
0.00
0.00
0.00 HTS)inlet LTS)inlet
100.00 9634.00 CO2 378.02 824.16
16.92 CO 562.43 116.29
3.07 0.7161 H2 2590.85 3036.98
9827.063 CH4 23.97 23.97
759.60 8876.482 N2 1041.87 1041.87
30.11 Ar 12.91 12.91
547.20 13723.02 NH3 0.00 0.00
29.40 12395.58 Total 4610.04 5056.18
954.70 H2O 2881.23 2435.10
342.68 S/G 0.62 0.48
406.37
200.00 Calculate
213.50 HTS)inlet LTS)inlet
62.30 CO2 8.20 16.30
269.00 CO 12.20 2.30
293.00 H2 56.20 60.06
23.66 CH4 0.52 0.47
0.15 N2 22.60 20.61
Ar 0.28 0.26
NH3 0.00 0.00
947.00
18.22 CO2 5.05 11.00
12.59 CO 7.51 1.55
26.92 H2 34.58 40.54
0.32 CH4 0.32 0.32
40.95 N2 13.91 13.91
186.12 Ar 0.17 0.17
305.35 NH3 0.00 0.00
172.54 H2O 38.46 32.51
210.69 15.96 15.96
0.83 100.00 100.00

65.51 16.32
 Dry Gas Analysis
LTS)outlet Absorber inlet Mist trap Methanator)out LPC inlet
18.10 18.10 0.11 0.00 0.00
0.10 0.10 0.16 0.00 0.00
60.92 60.92 0.00 73.46 74.10
0.46 0.46 0.58 0.83 0.80
20.16 20.16 0.00 25.40 24.79
0.25 0.25 0.00 0.31 0.31
0.00 0.00 0.00 0.00 0.00
100.00 100.00 0.00 100.00 100.00
15.04 15.04 0.19 8.85 8.69

Molar Flow rate

LTS)outlet PGR inlet Absorber inlet Mist trap inlet Methanator)out
935.28 935.28 935.28 4.66 0.00
5.17 5.17 5.17 5.17 0.00
3148.10 3148.10 3148.10 3148.10 3113.96
23.97 23.97 23.97 23.97 33.80
1041.87 1041.87 1041.87 1041.87 1041.87
12.91 12.91 12.91 12.91 12.91
0.00 0.00 0.00 0.00 0.00
5167.30 5167.30 5167.30 4236.68 4202.54
2323.97 2843.95 469.49 38.34 52.83
0.45 0.55 0.09 0.01 0.01

Calculated analysis
LTS)outlet PGR inlet Absorber inlet Mist trap inlet Methanator)out
18.10 18.10 18.10 0.11 0.00
0.10 0.10 0.10 0.12 0.00
60.92 60.92 60.92 74.31 74.10
0.46 0.46 0.46 0.57 0.80
20.16 20.16 20.16 24.59 24.79
0.25 0.25 0.25 0.30 0.31
0.00 0.00 0.00 0.00 0.00

12.48 11.67 16.59 0.11 0.00

 0.07 0.06 0.09 0.12 0.00
42.02 39.30 55.85 73.64 73.18
0.32 0.30 0.43 0.56 0.79
13.91 13.01 18.48 24.37 24.48
0.17 0.16 0.23 0.30 0.30
0.00 0.00 0.00 0.00 0.00
31.02 35.50 8.33 0.90 1.24
15.96 16.09 15.29 8.77 8.81
100.00
Recycle Gas
18.10 0.11 0.00
0.10 0.12 0.00
65.20 60.92 74.31 74.10
7.90 0.46 0.57 0.80
21.60 20.16 24.59 24.79
2.70 0.25 0.30 0.31
2.60 0.00 0.00 0.00
100.00
10.15

LPC inlet
0.00
0.00
3113.96
33.80
1041.87
12.91
0.00
4202.54
1.90
0.00

LPC inlet
0.00
0.00
74.10
0.80
24.79
0.31
0.00
 Quench Flow Calculation
Composition LTS outlet
CO2 935.28 12.48
CO 5.17 0.07
H2 3148.10 42.02
CH4 23.97 0.32
N2 1041.87 13.91
Ar 12.91 0.17
NH3 0.00 0.00
H 2O 2323.97 31.02
Total 7491.28 100.00

Outlet temperature of LTS o

C 213.50
Absorber inlet pressure kg/cm2g 24.69
pressure drop across PGR 0.30
Inlet pressure at PGR kg/cm2A 26.02
Partial Pressure of Steam at LTS outlet kg/cm2A 9.24
Saturation temperature of Steam o
C 175.66
o
C 213.50
Outlet temperature of LTS
K 486.65
Heat capacity of Process Gas at LTS inlet Kcal/kgmoles OC 7.95
Heat of Dry Process Gas Gcal/h 8.77
Enthalpy of Steam at LTS outlet KJ/kg 2870.00
Temperature of PG at outlet o
C 175.66
K 448.81
Heat Capacity of DryProcess Gas Kcal/kgmoles OC 5.30
Heat of Dry Process Gas Gcal/h 4.81
Enthalpy of Saturated Steam KJ/kg 2760.00
Total Heat of Wet Process Gas Gcal/h 4.81
Enthalpy of Quench KJ/kg 499.00

Quench Required Kg/hr 9367.39

Temeperature at PGR outlet 121.00

K 392.15
Heat capacity Kcal/kgmoles OC 5.21
 PGR inlet Heat Capacity Estimate
935.28 12.48 10.89 10.64 10.17
5.17 0.07 7.18 7.14 7.07
3148.10 42.02 7.01 6.98 6.94
23.97 0.32 11.14 10.61 9.80
1041.87 13.91 7.12 7.09 7.03
12.91 0.17 4.80 4.80 4.80
0.00 0.00 10.28 9.94 9.43
2843.95 0.00 8.40 8.31 8.18
8011.25 68.98
acity Estimate
135.94 132.85 126.99
0.50 0.49 0.49
294.76 293.47 291.54
3.57 3.40 3.13
99.08 98.55 97.79
0.83 0.83 0.83
0.00 0.00 0.00
260.54 0.00 0.00
N2 0.00
CO2 0.00
O2 0.00 #DIV/0!
Ar 0.00
H 2O 0.00 #DIV/0!

CO 4.25
CO2 5.98 #DIV/0!
H2 36.66
CH4 8.24
 Approach to Equilibrium
Feed Flow to Primary reformer MT/h 15.300
Steam Flow to Primary Reformer MT/h 56.400
Recycle Gas Flow Nm3/h 800.000
Air Flow to Secondary Reformer Nm3/h 31500.000
Steam injected to Secondary reformer with Air MT/h 2.000
Temperature indication outlet Secondary Reformer C
O
954.700
Pressure indication kg/cm2 A 30.000
Calculation For Reforming
Total dry Feed to Primary Reformer kgmoles/h 908.765
Total Carbon inlet kgmoles/h 964.421
Dry Gas Flow out Nm3/h 103329.548
Air Required calculated Nm /h
3
29621.257
Steam at secondary reformer outlet MT/h 45.089
S/G 0.543

Temperature indication 954.700

Kreforming
2898.627
Temperature 939.000

ATE 15.700

Calculation for HTS

Inlet temperature of HTS 342.680
Outlet temperature of HTS 406.370
Temperature rise 63.690
Estimated temperature rise 54.450
Estimated outlet temperature 397.130

Calculation of LTS
Inlet temperature of LTS 200.000
Outlet temperature of LTS 213.500
Temerature rise 13.500
Estimated temperature rise 12.100
Estimated outlet temperature 212.100

Calculation of Methanator
Inlet temperature of Methanator 269.000
Outlet temperature of Methanator 293.000
Temperature difference 24.000
Estimated temperature rise 18.230
Estimated Outlet temperature 287.230
 Natural Gas Analysis:
Component % Vol.
CH4 94.858
C2H6 4.091
C3H8 0.688
C4H10 0.231
C5H12 0.000
C6H14 0.002
CO2 0.005
N2 0.127
Other 0.000
Other 0.000
Other 0.000
Other 0.000
Other 0.000
Total 100.002

MW
Natural Gas C/H (Wt/Wt)

HTS)inlet
CO2 8.200
CO 12.200
H2 56.200
CH4 0.520
N2 22.600
Ar 0.280
NH3 0.000
Total 100.000
M.W. 14.686

Kshift 0.604
Tshift
ATE
Gas Analysis:
% Vol.
92.439
5.809
1.290
0.370
0.002
0.000
0.000
0.090
0.000
0.000
0.000
0.000
0.000
100.000

17.385
3.114

LTS)inlet LTS)outlet Absorber inlet Mist trap Methanator)out LPC inlet

16.300 18.100 18.100 0.110 0.000 0.000
2.300 0.100 0.100 0.160 0.000 0.000
60.065 60.924 60.924 0.000 73.460 74.097
0.474 0.464 0.464 0.580 0.830 0.804
20.606 20.163 20.163 0.000 25.400 24.791
0.255 0.250 0.250 0.000 0.310 0.307
0.000 0.000 0.000 0.000 0.000 0.000
100.000 100.000 100.000 0.000 100.000 100.000
14.979 15.045 15.045 0.186 8.854 8.691

8.839 245.186
411.000 215.000
4.630 1.500
Recycle Gas
0.000
0.000
65.200
7.900
21.600
2.700
2.600
100.000
10.154
 Syn Gas compressor
LPC HPC RC
Flow Nm3/hr 98999.44 102638.18 527164.18
Suction Pressure kg/cm2G 23.00 62.00 121.30
Discharge pressure kg/cm G2
63.00 121.30 130.40
Suction temperature O
C 12.90 -19.50 46.20
Discharge temperature O
C 141.00 62.60 57.60
Gas composition
H2 % 73.46 70.73 65.20
CH4 % 0.83 0.80 7.90
N2 % 25.40 24.46 21.60
Ar % 0.31 0.30 2.70
NH3 % 0.00 3.72 2.60
M.W. kg/kmole 8.85 9.16 10.15

Reduced pressure 2.66 1.94 1.07

Reduced temperature 1.45 1.32 1.04
n/n-1 2.65 2.36 2.05
n 1.61 1.73 1.96
k 1.40 1.40 1.39
k/k-1 3.49 3.49 3.54
k-1/k 0.29 0.29 0.28
n-1/n 0.38 0.42 0.49
Polytropic Efficiency % 75.93 67.68 57.75
Compressibility factor 1.01 0.99 0.98
Head Required KNm/kg 320.42 173.63 18.72
Power required kW 4584.09 2988.28 2150.58
Total compression power kW 9722.96
Ideal power consumption 3480.53 2022.54 1242.04
Ideal power consumption 6745.11
Overall Polytropic Efficiency % 69.37

Turbine Calculation
Steam Flow to HPT MT/hr 198.20
Steam Flow to LPT MT/hr 19.80
SX pressure kg/cm2G 92.70
SX temperature O
C 480.00
SH pressure kg/cm2G 37.70
SH temperature O
C 389.00
Hotwell temperature O
C 53.00
Enthalpy of SX KJ/kg 3335.42
Entropy KJ/kg C
O
6.60
Enthalpy of SH KJ/kg 3193.44
Enthalpy of exhaust KJ/kg 2546.47 2%wetness
Enthalpy of Steam isentropically KJ/kg 3089.43
Enthalpy of steam isentropically KJ/kg 2187.11

Power delievered by HPT kW 7816.66

Power delivered by LPT kW 3558.34
Total Power delivered kW 11374.99
Specific Power delievered by HPT kW 39.44
Specific Power delievered by LPT kW 179.71
Overall Efficiency % 85.48
Thermodynamic Efficiency of LPT % 57.72
Thermodynamic Efficiency of HPT % 64.29
 Process Calculation

Make up Gas Flow from Front End Nm3/hr 94195.69 37207.22

Recycle Gas to BA 102 Nm3/hr 800.00
Thrust balance leak % 6.00
HPC chiller outlet temperature C
O
10.65
K 283.80
Ammonia flow to dehydrator MT/h 6.20
dehydrator temperature)process side C
O
-19.70
K 253.45
heat capacity of process gas out HPC chiller kcal/kmol OC 6.88
heat capacity of process gas out Dehydrator kcal/kmol C
O
6.86
Heat duty required Gcal/hr 0.88
Latent heat of Ammonia Kcal/kg 317.22
Ammonia vaporised kg/hr 2759.83
Volume of Ammonia vaporised Nm3/hr 3638.75
Flow to Product let down tank kg/hr 3440.17
HPC thrust balance leak % 6.00
 Heat capacity estimate

H2 6.85 6.83 6.85 6.83

CH4 8.16 7.68 8.19 7.68
N2 6.95 6.94 6.95 6.94
Ar 4.80 4.80 4.80 4.80
NH3 8.46 8.19 8.48 8.19
12.90 -19.50
286.05 253.65
6.88 6.91
LPC HPC RC
Average heat capacity 6.94 6.95 7.05
Gas constant 1.99 1.99 1.99
Cv 4.95 4.96 5.06
Adiabatic constant 1.40 1.40 1.39

Compressibility factor calculation

LPC HPC
CH4 1.50 2.17 1.33
H2 8.62 12.47 7.64
N2 2.27 3.28 2.01
Ar 1.90 2.75 1.68
H2 O 0.44 0.64 0.39
NH3 0.71 1.02 0.63

Reduced temperature 6.92 10.02 5.93

CH4 0.51 1.35 1.33

H2 1.81 4.83 4.76
N2 0.70 1.85 1.82
Ar 0.48 1.29 1.27
H2 O 0.11 0.28 0.28
NH3 0.21 0.56 0.55

Reduced pressure 1.51 4.04 3.85

 Bi
0.11 0.13 0.09
0.14 0.14 0.14
0.13 0.14 0.13
0.13 0.14 0.12
-5.16 -0.98 -8.65
-0.61 -0.02 -1.10

Bo
-0.14 -0.04 -0.18
0.07 0.08 0.07
-0.03 0.02 -0.06
-0.07 0.00 -0.10
-1.47 -0.78 -1.81
-0.65 -0.33 -0.81

Pr/Tr
0.34 0.62 1.00
0.21 0.39 0.62
0.31 0.56 0.91
0.26 0.47 0.75
0.24 0.44 0.71
0.30 0.55 0.88

Pr/Tr 0.22 0.40 0.65

Z
0.95 0.96 0.80
1.01 1.02 1.02
0.98 0.99 0.92
0.98 0.99 0.90
0.92 0.75 1.07
0.85 0.82 0.50

Average z 1.00 1.01 0.98

 6.88 6.96 6.89 6.89
8.71 10.12 8.96 8.88
6.97 7.05 6.98 6.98
4.80 4.80 4.80 4.80
8.78 9.63 8.93 8.88
46.20 141.00 62.60 57.60
319.35 414.15 335.75 330.75
7.04 7.00 7.00 7.06

r calculation
RC
1.76 1.68 1.74
10.11 9.62 9.84
2.66 2.53 2.62
2.23 2.12 2.19
0.52 0.49 0.51
0.83 0.79 0.82

7.85 7.03 7.20

2.59 2.59 2.78

9.23 9.23 9.92
3.54 3.54 3.80
2.46 2.46 2.65
0.54 0.54 0.58
1.06 1.06 1.14

7.46 7.08 7.61

 0.12 0.12 0.12
0.14 0.14 0.14
0.14 0.14 0.14
0.13 0.13 0.13
-2.57 -3.20 -2.74
-0.24 -0.33 -0.27

-0.09 -0.10 -0.09

0.07 0.07 0.07
-0.01 -0.01 -0.01
-0.03 -0.04 -0.04
-1.12 -1.22 -1.15
-0.49 -0.54 -0.50

1.47 1.54 1.60

0.91 0.96 1.01
1.33 1.40 1.45
1.11 1.16 1.21
1.05 1.10 1.14
1.28 1.35 1.40

0.95 1.01 1.06

0.83 0.80 0.81

1.04 1.04 1.04
0.95 0.94 0.95
0.93 0.92 0.92
0.42 0.43 0.37
0.44 0.37 0.38

0.99 0.98 0.98

 PROCESS AIR COMPRESSOR
I II III IV
Flow of Air kg/h 42716.111 42716.111 42991.699 42991.699
Suction pressure kg/cm g 2 -0.02 2.30 5.80 14.90
Discharge pressure kg/cm2g 2.40 5.80 15.00 34.00
Suction temperature O
C 21.00 51.00 19.80 47.10
Discharge temperature O
C 186.40 158.40 149.80 172.50

Reduced pressure 3.389 2.050 2.346 2.199

Reduced temparature 1.562 1.331 1.444 1.392

n/n-1 2.736 2.509 2.322 2.384

n-1/n 0.366 0.399 0.431 0.419
k 1.400 1.401 1.405 1.402
k-1/k 0.286 0.286 0.288 0.287
M.W. Kg/kmole 28.635 28.635 28.808 28.808

Polytropic efficiency % 78.214 71.740 66.927 68.347

Compressibility factor 0.998 0.998 0.998 0.998

Polytropic head KNm/kg 130.890553803 77.93726597 86.810412002 85.97804531

Polytropic power kW 1985.69483425 1289.056193 1548.9953316 1502.26699

Total Power required kW 6326.01
Ideal Power consumption kW 1553.09318462 924.7713688 1036.7019848 1026.761746
Ideal Total Power kW 4541.32828447842
Overall Polytropic Efficiency % 71.7881552533402

TURBINE CALCULATION
Mass flow rate of steam MT/hr 34.60
SH steam temperature 0
C 391.00
SH steam pressure Kg/cm2 38.53

Enthalpy of SH steam Kcal/kg 765.26

Entropy of SH steam Kcal/kg C 1.62

Hotwell temperature 53.00 98% dry steam out

Pressure 0.14
Enthalpy of saturated steam kcal/kg 609.16
Isentropically Enthalpy 523.25
Power delivered kW 6271.03

Overall Efficiency % 100.88

Thermodynamic Efficiency % 64.50
Ammonia production MTPD 858
Make up gas back burning Nm3/hr 0.00
Tail gas burning Nm3/hr 13900.00
Total Air required Nm3/hr 33319.15
Saturation pressure of water at inlet of LPC kPa 1.99
Moisture content Nm3/hr 675.48
Total mass Flow rate kg/hr 43429.26
Thrust balance leak % 4.00
leak flow Nm3/hr 1359.79
Total Flow to LPC kg/hr 45171.01
Temperature outlet of HPC chiller 0
C 19.00
Saturated pressure of water at after HPC chiller kPa 2.19
Moisture content Nm3/hr 130.95
Total moisture removed by HPC Nm3/hr 544.53
Total Flow to HPC Nm3/hr 33450.10

Compostion of Air
LPC
N2 26015.59076
O2 6980.361508
Ar 310.8676509
H 2O 675.4798751

N2 6.956
O2 7.005
Suction
Ar 4.800
H2O 8.380
N2 7.096
O2 7.479
Discharge
Ar 4.800
H2O 8.572
Cp)mix suction 6.975
Cp)mix discharge 6.946

Average Cp kcal/kmol K 6.960

Average Cv kcal/kmol K 4.970
Compostion of Air
HPC
76.556298 26015.591 77.803009
20.541169 6980.3615 20.875679
0.9147929 310.86765 0.9296902
1.9877403 130.94955 0.3916217

6.975 6.955 6.972

7.127 7.000 7.113
4.800 4.800 4.800
8.409 8.379 8.405
7.069 7.060 7.082
7.422 7.404 7.452
4.800 4.800 4.800
8.534 8.523 8.553
7.015 6.950 6.987
6.902 6.860 6.898

6.958 6.905 6.943

4.968 4.915 4.953
 Refrigeration Compressor
LPC
I II
Flow Nm /hr
3
30805.88 44358.07
Suction pressure kg/cm2G 0.36 3.10
Discharge pressure kg/cm2G 3.31 5.51
Suction temparature O
C -23.30 31.27
Discharge temperature O
C 81.20 73.70
Reduced pressure 3.11 1.58
Reduced temperature 1.42 1.14
heat capacity of Ammonia at suction kcal/kmoleOC 8.16 8.65
Heat capacity of Ammonia at discharge kcal/kmole C
O
9.10 9.03
Average heat capacity kcal/kmoleOC 8.63 8.84
Cv 6.64 6.85
k 1.30 1.29
k-1/k 0.2307 0.2251
n/n-1 3.25 3.51
n-1/n 0.31 0.28
Polytropic Efficiency % 75.00 79.13
Compressibilty factor 0.99 0.97
Head required KNm/kg 163.14 70.79
Power required kW 1411.81 836.02
Total Power required kW 5820.52
1058.80 661.54
Turbine calculation
Steam Flow to Turbine MT/hr 36.20
Steam pressure 37.70
Steam temperature 385.00
Hotwell temperature 52.70

Enthalpy of SH 3184.00
6.77
Enthalpy of Exhaust 2548.48
Enthalpy of Exhausr ∆S=0 2178.85 2%wetness

Power delivered kW 6390.51

Overall Efficiency % 91.08
Thermodynamic Efficiency % 63.23
 HPC
III IV V
75163.95 76734.46 76734.46
5.30 8.80 13.83
8.80 13.83 15.58
42.20 46.00 86.56
86.10 87.52 107.20
1.55 1.51 1.12
1.14 1.13 1.06
8.75 8.78 9.14
9.14 9.15 9.33
8.94 8.97 9.24
6.95 6.98 7.25
1.29 1.29 1.27
0.2225 0.2219 0.2154
3.38 3.38 1.99
0.30 0.30 0.50
75.11 75.00 42.93
0.96 0.95 0.94
69.60 64.66 18.89
1467.36 1393.80 711.53
5820.52
1102.19 1045.28 305.45
total 4173.26
overall % effic 71.70
 Process Calculation
Refrigeration ammonia flow from II super cooler Nm3/hr 26139.00
Corrected Flow from II super cooler Nm /hr
3
29621.04
Refrigeration ammonia from I supercooler Nm /hr
3
56892.00
Corrected Flow from I supercooler Nm3/hr 72273.03
Thrust balance leak LPC % 4.00
Thrust balance leak HPC % 4.00
Suction temperature from I supercooler O
C 3.60
Assumed polytropic efficiency of I stage % 75.00
Assumed polytropic Efficincy of IV stage % 75.00
Economiser top temperature C
O
39.30
Saturated pressure of Ammonia kg/cm 2
15.72
Heat capacity of Ammonia kcal/kmoleOC 8.63
Cv kcal/kmoleOC 6.64
k 1.30
k-1/k 0.23
n-1/n 0.31
n 1.44
n/n-1 3.25
T2 C
O
81.20
heat capacity of ammonia kcal/kmoleOC 8.40
heat capacity of ammonia kcal/kmole C O
9.10
Temperature of mixture C
O
31.27

heat capacity of Ammonia kcal/kmoleOC 8.97

Cv 6.98
k 1.29
k-1/k 0.22
n-1/n 0.30
T3 87.52
heat capacity of Ammonia kcal/kmoleOC 9.15
Temperature of Economiser C
O
37.30
heat capacity of Ammonia 8.70
Bottom temperature of Economiser C
O
34.30
Saturation pressure kg/cm 2
14.85
Reciever temperature C
O
39.20
Reciever pressure kg/cm2 15.68
Enthalpy of Ammonia kcal/kg 144.34
Enthalpy of Liquid ammonia at economiser kcal/kg 138.48
Enthalpy of vapor ammonia kcal/kg 408.15
% ammonia Flashed % 2.17
Ammonia through LIC540 kg/hr 1191.16
Heat capacity of ammonia kcal/kmoleOC 8.70
Temerature of the mixture C
O
86.56

Stage 0.00
Reduced pressure Suction 0.01
discharge 0.04

Reduced temperautre Suction 0.62

discharge 0.87

Pr/Tr Suction 0.02

discharge 0.04

Bo Suction -0.83
discharge -0.44

Bi Suction -1.18
discharge -0.16

Z)average Suction 0.99

discharge 0.98
 II III IV V
0.04 0.06 0.09 0.13
0.06 0.09 0.13 0.14

0.75 0.78 0.79 0.89

0.86 0.89 0.89 0.94

0.05 0.07 0.11 0.15

0.07 0.10 0.15 0.15

-0.58 -0.55 -0.54 -0.43

-0.46 -0.43 -0.43 -0.38

-0.44 -0.36 -0.33 -0.15

-0.19 -0.15 -0.14 -0.09

0.98 0.97 0.95 0.94

0.97 0.96 0.94 0.94
 Catalyst pressure drop LTS
Shape of the catalyst Viscosity Estimate
Diameter of the particle mm 9.00 CO2
Height of the particle mm 4.80 CO
Volume of the particle 305.21 H2
Surface area of the particle 262.82 CH4
Diameter of the equivalnet particle 4.18 N2
Surface area of the equivalent sphere 219.18 Ar
Sphericity 0.83 NH3
porosity 0.38
Diameter of the bed m 3.20 average viscosity
temperature of the gas at inlet 200.00
temperature of the gas at outlet 213.50
Assuming neglisible pressure drop
Pressure inlet kg/cm2A 23.03
Density of the gas at inlet kg/m3 8.57
Density of the gas at outlet 8.37
average density of the gas 8.47
Mass Flow rate inlet 119594.25
Mass Flow rate outlet 119594.85
Cross section area of the bed m2 8.04
Superficial velocity m/s 0.49
Viscosity of inlet 0.02
Viscosity of outlet 0.02
Bed length m 0.20
NRe 604678.98
pressure drop Pa 2002.32
kg/cm2 0.02042
Bed length 2.52
25229.29
Pressure drop 0.26
Bed length 2.52
25229.29
Pressure drop 0.26
Total Pressure drop kg/cm2 0.53
Viscosity Estimate
717.20 47.93 796.40 52.9867 0.022 1.054359 1.165707
64.40 4.30 2.80 0.186292 0.024 0.103282 0.004471
120.13 8.03 121.85 8.106822 0.012 0.096329 0.097282
7.59 0.51 7.42 0.493856 0.016 0.008111 0.007902
576.96 38.55 564.56 37.56153 0.024 0.925308 0.901477
10.21 0.68 9.99 0.664806
0.00 0.00 0.00 0
1496.49 100.00 1503.02 100.00
average viscosity 0.021874 0.021768
 Catalyst pressure drop HTS
Shape of the catalyst Viscosity Estimate
Diameter of the particle mm 6.00 CO2
Height of the particle mm 6.00 CO
Volume of the particle 169.56 H2
Surface area of the particle 169.56 CH4
Diameter of the equivalnet particle 3.43 N2
Surface area of the equivalent sphere 148.12 Ar
Sphericity 0.87 NH3
porosity 0.40
Diameter of the bed m 3.20 average viscosity
temperature of the gas at inlet 330.00
temperature of the gas at outlet 360.00
Assuming neglisible pressure drop
Pressure inlet kg/cm2A 29.31
Density of the gas at inlet kg/m3 8.56
Density of the gas at outlet 8.19
average density of the gas 8.37
Mass Flow rate inlet 119594.25
Mass Flow rate outlet 119594.85
Cross section area of the bed m2 8.04
Superficial velocity m/s 0.49
Viscosity of inlet 0.02
Viscosity of outlet 0.02
Bed length m 0.00
NRe 604888.72
pressure drop Pa 0.00
kg/cm2 0.00
Bed length 2.39
23310.46
Pressure drop 0.24
Bed length 2.39
23310.46
Pressure drop 0.24
Total Pressure drop kg/cm2 0.48
Viscosity Estimate
717.20 47.93 796.40 52.9867 0.022 1.054359 1.165707
64.40 4.30 2.80 0.186292 0.024 0.103282 0.004471
120.13 8.03 121.85 8.106822 0.012 0.096329 0.097282
7.59 0.51 7.42 0.493856 0.016 0.008111 0.007902
576.96 38.55 564.56 37.56153 0.024 0.925308 0.901477
10.21 0.68 9.99 0.664806
0.00 0.00 0.00 0
1496.49 100.00 1503.02 100.00
average viscosity 0.021874 0.021768
 Catalyst pressure drop Secondary Reformer
Shape of the catalyst
Diameter of the particle mm 20.00
Height of the particle mm 13.00
Volume of the particle 4082.00
Surface area of the particle 1444.40
Diameter of the equivalnet particle 9.92
Surface area of the equivalent sphere 1234.98
Sphericity 0.86
porosity 0.40
Diameter of the bed m 2.80
temperature of the gas at inlet 1000.00
temperature of the gas at outlet 940.00
Assuming neglisible pressure drop
Pressure inlet kg/cm2A 29.13
Density of the gas at inlet kg/m3 4.59
Density of the gas at outlet 4.15
average density of the gas 4.37
Mass Flow rate inlet 114607.40
Mass Flow rate outlet 114607.40
Cross section area of the bed m2 8.04
Superficial velocity m/s 0.91
Viscosity of inlet 0.04
Viscosity of outlet 0.05
Bed length m 2.44
NRe 295683.34
pressure drop Pa 14573.30
kg/cm2 0.15
Bed length 0.07
1073.65
Pressure drop 0.01095
Bed length 0.10
1073.65
Pressure drop 0.01
Bed length 0.10
1073.65
Pressure drop 0.01
Total Pressure drop kg/cm2 0.18

Pressure drop of Secondary Reformer catalyst

SOR kg/cm2G 0.24
2
EOR kg/cm G 0.32
Indicated kg/cm2G 1.34
Calculated considering SOR kg/cm2G 0.19
Viscosity Estimate
CO2 8.20 8.20 796.40 52.986695 0.022 0.1804 1.1657073
CO Outlet #VALUE! 2.80 0.1862917 0.024 #VALUE! 0.004471
H2 12.20 12.20 121.85 8.1068219 0.012 0.1464 0.0972819
CH4 56.20 56.20 7.42 0.4938558 0.016 0.8992 0.0079017
N2 0.52 0.52 564.56 37.56153 0.024 0.01248 0.9014767
Ar 0.00 0.00 9.99 0.6648058
H2O 0.28 0.28 0.00 0
O2 22.60 22.60
average viscosity 100.00 #VALUE! 1503.02 100.00 #VALUE! 0.0217684
31500.00
Inlet Flow to Second Reformer
Inlet Outlet
CO2 7.30 8.20 296.41
CO 4.65 12.20 188.98
H2 43.15 56.20 1752.60
CH4 10.31 0.52 418.70
N2 27.02 22.60 1097.4126
Ar 0.32 0.28 13.069956
O2 7.25 0.00 294.5659
Total 100.00 100.00 4061.74
H2O 17.06 14.69 8123.48
 Direct Method
Total Steam produced MT/hr 0.00
Enthalpy of steam Kcal/kg 0.00
Total Fuel Fired MT/hr 8.10
Temperature of Flue Gas OC 900.00
Heat in Flue gas Gcal/hr 52.12
temperature of BFW OC 32.00
Heat in air Gcal/hr 1.30
Total heat in Flue gas)out Gcal/hr 6.48
Stack temperature 131.30
Boiler Efficiency % 89.89

Combustion Calculation
Total O2 required to burn C kg/kg 2.01
Total O2 required to burn H kg/kg 1.96
Total O2 required to burn S kg/kg 0.00

Total O2 required kg/kg 3.97 17.26

Total O2 required to burn the Fuel Kg/hr 32151.77
Total O2 present in the Fuel Kg/hr 0.77

Total dry Air required Kg/hr 138581.93

Total Volume of Air Nm3/hr 107279.91
Relative humidity of Air % 80.00
Air temperature 32.00
Vapor pressure of water kPa 4.57
Baromatric pressure mmHg 760.00
% moles of water % 3.73
Total water Kg/hr 3371.26
Actual wet air required Kg/hr 114236.80
Volume of air required Nm3/hr 111477.87
%excess air % 15.00
Total Air supplied Nm3/hr 128199.55
Total Air supplied Kg/hr 163248.53
CO2 produced due to Combustion kg/hr 22353.22
H2O produced due to Combustion kg/hr 17881.74
Total N2 in the Flue Gas kg/hr 120351.17
Total Ar in the Flue Gas Kg/hr 1996.39
Total O2 in the Flue Gas Kg/hr 4748.61
Total CO2 from Air Kg/hr 72.66
Total H2O in water Kg/hr 3876.94
Total Mass of the Flue Gas Kg/hr 171280.73
Total mass of Flue gas by material balance Kg/hr 171348.53
Theoritical Air Requirment Kg/kg 17.27
Excess Air % 16.47
Actual Air Supplied Kg/kg 20.11
Natural Gas Analysis: Ultimate Analysis
Component % Vol. % Vol.
CH4 94.86 94.86 C 75.26
C2H6 4.09 4.09 H 24.53
C3H8 0.69 0.69 O 0.01
C4H10 0.23 0.23 S 0.00
C5H12 0.00 0.00 N 0.21
C6H14 0.00 0.00
CO2 0.01 0.00
N2 0.13 0.13
S 0.00 0.00
Other 0.00 0.00
Other 0.00 0.00
Other 0.00 0.00
Other 0.00 0.00
Total 100.00 100.00
MW 16.92
Natural Gas C/H (Wt/Wt) 3.07
Density 0.71

Dry Air analysis Wet Air analysis Wet Flue Gas analyis Dry Flue Gas
N2 78.09 75.15 69.16 85.86 508.03
O2 20.95 20.16 2.39 2.96 993.43
CO2 0.03 0.03 8.20 10.18 4298.26
Ar 0.93 0.89 0.80 1.00 49.97
H2O 0.00 3.77 19.45 0.00 148.39
Total 100.00 100.00 100.00 100.00 1.65
M.W. 28.95 28.54 27.56 29.87 215.39
6215.12
O
Temperature C 32.000 131.300 900.000
K 305.150 404.450 1173.150
Components Reformer
N2 0.249 0.252 0.282
CO2 0.205 0.234 0.298
O2 0.220 0.230 0.262
Ar 0.120 0.120 0.120
H2O 0.446 0.456 0.572

Average Cp kcal/kgOC 0.249 0.288 0.338

 Direct Method
Total Steam produced MT/hr 87.70
Enthalpy of steam Kcal/kg 796.00
Total Fuel Fired MT/hr 8.38
GCV kcal/kg 7935.13
NCV Kcal/kg 6778.74
temperature of BFW OC 289.20 10.46
Heat in BFW Gcal/hr 25.36 56.84
Total heat in steam Gcal/hr 69.81 12.39
Total heat in steam)GCV basis Gcal/hr 66.53
Boiler Efficiency % 66.80
Purge gas Flow 14121.00
Combustion Calculation
Total O2 required to burn C kg/kg 0.80
Total O2 required to burn H kg/kg 1.51
Total O2 required to burn S kg/kg 0.00

Total O2 required kg/kg 2.31

Total O2 required to burn the Fuel Kg/hr 19368.83
Total O2 present in the Fuel Kg/hr 36.43

Total dry Air required Kg/hr 83329.30

Total Volume of Air Nm3/hr 64507.40
Relative humidity of Air % 80.00
Air temperature 32.00
Vapor pressure of water kPa 4.57
Baromatric pressure mmHg 760.00
% moles of water % 3.73
Total water Kg/hr 2027.14
Actual wet air required Kg/hr 68690.58
Volume of air required Nm3/hr 67031.63
%excess air % 17.00
Total Air supplied Nm3/hr 78427.01
Total Air supplied Kg/hr 99868.48
CO2 produced due to Combustion kg/hr 9207.28
H2O produced due to Combustion kg/hr 14256.71
Total N2 in the Flue Gas kg/hr 77279.52
Total Ar in the Flue Gas Kg/hr 1824.82
Total O2 in the Flue Gas Kg/hr 3205.25
Total CO2 from Air Kg/hr 44.45
Total H2O in water Kg/hr 2371.75
Total Mass of the Flue Gas Kg/hr 108189.77
Total mass of Flue gas by material balance Kg/hr 108253.04

Indirect Method
Theoritical Air Requirment Kg/kg 10.03
Excess Air % 18.11
Actual Air Supplied Kg/kg 11.85
Stack temperature 358.00
Heat Loss due to Flue Gas % 6.78
Heat loss due to evaporation of water % 7.93
Heat loss due to moisture in air % 0.35
Heat loss due to radiation % 1.00
Boiler Efficiency % 83.94

Evaporation ratio % 21.00

Heat to Convection Duct Gcal/hr 12.01

Total Mass of Flue Gas MT/hr 279.60

3
Volumetric Flow Nm /hr 229944.60

Heat Loss in Flue Gas Gcal/hr 7.46

Natural Gas Analysis: Ultimate Analysis
Component % Vol. % Vol.
CH4 27.09 27.09 C
C2H6 0.89 0.89 H
C3H8 0.15 0.15 O
C4H10 0.05 0.05 S
C5H12 0.00 0.00 N
C6H14 0.00 0.00 Ar
CO2 0.00 0.00 GCV kcal/kg
N2 18.42 18.42 NCV kcal/kg
S 0.00 0.00
NH3 0.00 0.00
H2 53.24 53.24
O2 0.16 0.16
Ar 2.18 2.18
Total 100.00 100.00
MW 11.84
Natural Gas C/H (Wt/Wt) 3.05
Density 0.50

Dry Air analysis Wet Air analysis Wet Flue Gas analyis Dry Flue Gas
N2 78.09 75.15 68.32 88.57
O2 20.95 20.16 2.48 3.21
CO2 0.03 0.03 5.20 6.75
Ar 0.93 0.89 1.13 1.47
H2O 0.00 3.77 22.87 0.00
Total 100.00 100.00 100.00 100.00
M.W. 28.95 28.54 26.78 29.38

O
Temperature C 32.000 358.000
K 305.150 631.150
Components Reformer
N2 0.249 0.260
CO2 0.205 0.263
O2 0.220 0.242
Ar 0.120 0.120
H2O 0.446 0.487
Average Cp kcal/kgOC 0.249 0.310

CH4 94.86
C2H6 4.09
C3H8 0.69
C4H10 0.23
C5H12 0.00
C6H14 0.00
CO2 0.00
N2 0.13
S 0.00
Other 0.00
Other 0.00
Other 0.00
Other 0.00
0.00
M.W. 16.92
C/H 3.07
density 0.71
GCV 9800.00
NCV 8300.00
Fuel Flow 2.00
mate Analysis

29.95
18.89
0.43
0.00
43.58
7.20
7935.13 Fuel Analysis Tail Gas from Vent Gas fromMake up Gas
6778.74 H2 % 66.94 33.80 74.10
CH4 % 8.11 8.60 0.80
N2 % 22.18 49.16 24.79
Ar % 2.77 0.40 0.31
NH3 % 0.00 0.04 0.00
O2 % 0.00 8.00 0.00

H2 133.88 67.60 148.19

CH4 129.77 137.60 12.87
N2 620.94 1376.59 694.16
Ar 110.88 16.00 12.29
NH3 0.00 0.61 0.00
209.26 O2 0.00 256.00 0.00
792.04 Total 995.48 1854.40 867.51
2759.98 M.W. 9.95 18.54 8.68
45.68 density 0.44 0.82 0.39
100.16 H2 % 13.45 3.65 17.08
1.01 CH4 % 13.04 7.42 1.48
131.76 N2 % 62.38 74.23 80.02
4039.89 Ar % 11.14 0.86 1.42
NH3 % 0.00 0.03 0.00
O2 % 0.00 13.80 0.00
Total 100.00 100.00 100.00

NCV Kcal/kg 5408.22 1932.08 5067.11

GCV Kcal/kg 6293.88 2223.28 5994.92

Fuel Flow Nm3/hr 7881.30 350.00 0.00

kg/hr 3488.78 288.61 0.00
H2 5275.78 118.30 0.00
CH4 639.24 30.10 0.00
N2 1747.80 172.07 0.00
Ar 218.48 1.40 0.00
NH3 0.00 0.13 0.00
O2 0.00 28.00 0.00

Total NG fired Nm3/hr 3799.61 Total

Volumetric Flow
CH4 3604.16 4751.21
C2H6 155.44 155.44
C3H8 26.14 26.14
C4H10 8.78 8.78
C5H12 0.00 0.00
C6H14 0.08 0.08
CO2 0.19 0.19
N2 4.83 3230.84
S 0.00 0.00
NH3 0.00 0.13
H2 0.00 9336.67
O2 0.00 28.00
Ar 0.00 383.14
Sum 17537.47
Washed Gas from DA 601
66.94
8.11
22.18
2.77
0.00
0.00

133.88
129.77
620.94
110.88
0.00
0.00
995.48
9.95
0.44
13.45
13.04
62.38
11.14
0.00
0.00
100.00

5408.22
6293.88

5889.70
2607.17
3942.59
477.71
1306.13
163.27
0.00
0.00
 ID fan power calculation
Flue gas flow Nm3/hr 229944.60
suction pressure 1.00
discharge pressure 1.03
Difference mmWC 413.00
average pressure kg/cm2A 1.02
M.W. 27.26
density kg/m3 0.81
O
Stack temperature C 130.00
Volume of the flue gas 279.66
Head Pa 4130.00
Power required kW 395.57
Exact Power Required kW 659.28
Turbine Calculation
Steam Mass flow rate Mt/hr 12
2
Steam pressure kg/cm G 38
O
Steam temperature C 380.00
Enthalpy of inlet steam Kcal/kg 758.77
Entropy of Inlet steam Kcal/kg C 6.73
Outlet steam pressure kg/cm2G 2.08
O
Outlet steam temperature C 240.00
Enthalpy of outlet steam 697.77
Isentropical enthalpy 626.78
Power consumption kW 849.95
Thermodynamic Efficiency 46.22
Overall Efficiency 77.57
 FD fan power calculation
Flue gas flow Nm3/hr 206626.56
suction pressure 1.00
discharge pressure 1.03
Difference mmWC 195.00
average pressure kg/cm2A 1.02
M.W. 28.54
density kg/m3 1.12
O
Stack temperature C 32.00
Volume of the flue gas 263.12
Head Pa 1950.00
Power required kW 127.03
Exact Power required kW 211.72
Turbine Calculation
Steam Mass flow rate Mt/hr 5
2
Steam pressure kg/cm G 38
O
Steam temperature C 380.00
Enthalpy of inlet steam Kcal/kg 758.77
Entropy of Inlet steam Kcal/kg C 6.73
Outlet steam pressure kg/cm2G 2.08
O
Outlet steam temperature C 240.00
Enthalpy of outlet steam 697.77
Isentropical enthalpy 626.78
Power consumption kW 354.15
Thermodynamic Efficiency 46.22
59.78
 BFW Pump
Total BFW flow MT/hr 192.09
suction pressure 1.42
discharge pressure 112.50
Difference kg/cm2 111.08

M.W. 18.02
density kg/m3 954.00
O
Pumping temperature C 110.00
Volume of the flue gas m3/hr 201.35
Head m 1164.36
Power required kW 608.86
Exact Power required kW 811.81
Turbine Calculation
Steam Mass flow rate Mt/hr 5.9
2
Steam pressure kg/cm G 38
O
Steam temperature C 380.00
Enthalpy of inlet steam Kcal/kg 758.77
Entropy of Inlet steam Kcal/kg C 6.73
Outlet steam pressure kg/cm2G 0.15
O
Outlet steam temperature C 54.00
Enthalpy of outlet steam 567.22
Isentropical enthalpy 521.70
Power consumption kW 1312.22
Thermodynamic Efficiency 80.80
61.87
 Benefield Pump
Total BFW flow MT/hr 1239.26
suction pressure 1.67
discharge pressure 28.00
Difference kg/cm2 26.33

M.W. 18.02
density kg/m3 1310.00
O
Pumping temperature C 93.60
Volume of the flue gas m3/hr 946.00
Head m 200.98
Power required kW 678.00
Exact Power required kW 968.58
Turbine Calculation
Steam Mass flow rate Mt/hr 7.83
2
Steam pressure kg/cm G 38
O
Steam temperature C 380.00
Enthalpy of inlet steam Kcal/kg 758.77
Entropy of Inlet steam Kcal/kg C 6.73
Outlet steam pressure kg/cm2G 0.15
O
Outlet steam temperature C 54.00
Enthalpy of outlet steam 567.22
Isentropical enthalpy 521.70
Power consumption kW 1741.47
Thermodynamic Efficiency 80.80
55.62
 Refrigeration Loop
Total Flow from IInd super Cooler Nm3/hr 24725.000
Pressure indication from II supercooler Kg/cm2G 0.290
O
Temperature indication from II supercooler C -18.700
Corrrected Flow from IInd supercooler Nm3/hr 27057.672

Total Flow of Ammonia in Refrigeration looop Nm3/hr 55895.000

Indicated temperature OC 42.200
Indicated pressure Kg/cm2G 5.505
Nm3/hr 72146.574
Ammonia Circulated kg/hr 54755.303

Flashing Cross LIC 540

O
Receiver bottom temperature C 40.800
Liquid Enthaply kJ/kg 608.274
Vapor Enthalpy kJ/kg 1709.940
Economiser Temperature OC 36.000
Liquid Enthalpy 589.585
Vapor Enthalpy 1708.466

% vaporised 1.670
Total Ammonia vaporised 914.574

Total Ammonia flow down from economiser kg/hr 53840.729

Heat duty by LPC

Inlet temperature of process gas 53.800
Outlet temperature of process gas 10.530
Total dry gas flow 4202.538
Total moisture 950.993
Saturation pressure of water at outlet of LPC chiller kg/cm2 0.012
2
Total pressure kg/cm 24.863
Total water kg/hr 37.153
Total moisture removed kg/hr 913.840
Enthalpy of water in inlet kJ/kg 2576.703
Enthalpy of water at outlet kJ/kg 2516.247
kJ/kg 33.605
Gcal/hr 0.557
heat capacity of process gas kcal/kgmoles oC 6.918
kcal/kgmoles oC 6.880
heat duty by process gas 1.255
Total heat duty Gcal/hr 1.811
Shell Side
Pressure indication kg/cm2G 3.173
O
Saturation temperature C -1.096
Enthalpy of liquid ammonia kJ/kg 414.033
Enthalpy of vapor ammonia kJ/kg 1679.934
Latent heat kJ/kg 1265.901
Ammonia flow kg/hr 5979.991
Heat duty shell side Gcal/hr 1.809
HPC chiller
Shell side
Pressure indication kg/cm2G 3.171
Saturation temperature OC -1.108
Latent heat 1265.901
Ammonia flow kg/hr 3357.000
heat duty shell side Gcal/hr 1.016
Tube side
Flow of make up gas Nm3/hr 94195.694
kgmoles/hr 4202.538
Inlet temperature of process gas OC 43.000
Outlet temperature of process gas OC 10.710
heat capacity of process gas 6.894
heat duty 0.936

A EA 504 ( product heater)

Total Flow of ammonia MT/hr 33.890
heat capacity of ammonia 1.070
inlet temperature -17.300
outlet temperature 13.800
Heat duty tube side 1.128
Refrigerant ammonia 50777.000
inlet temperature 36.000
outlet temperature 16.700
heat capacity 1.150
heat duty 1.127
CO2 0.0 9.4 8.6 9.2 8.6 8.4 #REF! 0.0
CO 0.0 7.0 6.9 7.0 6.9 6.9 #REF! 0.0
H2 73.5 6.9 6.8 6.9 6.8 6.8 #REF! 505.8
CH4 0.8 8.8 8.2 8.7 8.2 8.0 #REF! 7.3
N2 25.4 7.0 7.0 7.0 7.0 6.9 #REF! 177.2
Ar 0.3 4.8 4.8 4.8 4.8 4.8 4.8 1.5
NH3 0.0 8.8 8.5 8.8 8.5 8.4 #REF! 0.0
 0.0 0 0 0 #REF!
0.0 0 0 0 #REF!
503.2 505.1169 503.1956 393.5317 #REF!
6.8 7.185055 6.770609 72.31714 #REF!
176.5 177.0227 176.5419 132.1128 #REF!
1.5 1.488 1.488 14.81578 14.81578
0.0 0 0 95.06378 #REF!
 Recycle Gas Flow Calculation
Flow to Convertor A Nm3/h 299242.70
Flow to Convertor B Nm /h 3
315373.90
Outlet Temperature A O
C 312.20
Outlet Temperature B O
C 333.60
Convertor A NH3 concentration % 11.00
Convertor B NH3 concentration % 11.70

Assuming 100 kgmoles basis

Iterative conversion 11.36

Weightage Average concentration 9.93
Total N2 Consumed 4.96
Total H2 Consumed 14.89
Outlet concentraion H2 50.31
CH4 7.90
N2 16.64
Ar 2.70
NH3 9.93

Mass Flow Rate Kg/h 135567.18

Kg/h 142875.17
Weightage average temperature outlet O
C 323.18
K 596.33
Heat capacity of Outlet of Convertor Kcal/kgmoles OC 8.03
Water Flow to A-EB 501 MT/h 88.19
Inlet temperature of Water O
C 115.00
Outlet temperature of Water O
C 292.30
Outlet temerature of Process Gas O
C 239.60
K 512.75
Heat capacity of Outlet of EB 501 Kcal/kgmoles OC 7.79
Process Gas Flow outlet Nm3/h 530275.11
Synthesis Converter Effluent pressure 128.50
Vapor pressure of Ammonia 14.58
Saturation temperature of Ammonia 36.58
Total ammonia in Effluent 60170.39
Total of Ammonia MT/h 45.69

Pressure drop in the Exchangers

Synthesis Economiser tube side 1.00
Syn loop Boiler tube side pressure drop 0.42
Synthesis Hot Exchanger tube side pressure drop 0.48
Synthesis BFW heater tube side pressure drop 0.31
Synthesis First Cold Exchanger tube side pressure drop 0.47
Ist Supercooler tube side pressure drop 0.60
Synthesis Second Cold Excnahger shell side pressure drop 0.401
II nd Supercooler tube side pressure drop
 Convertor inlet Convertor Outlet
CO2 0.00 0.00 11.44
CO 0.00 0.00 7.32
H2 65.20 57.52 7.10
CH4 7.90 9.03 12.61
N2 21.60 19.02 7.24
Ar 2.70 3.09 4.80
NH3 2.60 11.35 11.26
H 2O 0.00 0.00 8.68
Total 100.00 100.00
M.W. 10.15 11.10

Volumetric Flo
Converter inlet Converter out A-EB 501
CO2 0.00 0.00 0.00
CO 0.00 0.00 0.00
H2 400730.02 304991.30 304991.30
CH4 48554.71 47890.34 47890.34
N2 132757.19 100855.49 100855.49
Ar 16594.65 16367.59 16367.59
NH3 15980.03 60170.39 60170.39
H 2O 0.00 0.00 0.00
Total 614616.60 530275.11 530275.11
53266.89
970.75
 0.00 11.04 0.00
0.00 7.22 0.00
408.54 7.04 404.64
113.91 11.50 103.89
137.75 7.15 136.02
14.82 4.80 14.82
127.81 10.51 119.31
0.00 8.46 0.00

Volumetric Flow
A-EB 506 A-EA 501 A-EB 505 A-EA 502 A-EB 503A/B A-EA 503 A-EB 504 A/B
0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00
304991.30 304991.30 304991.30 304991.30 304991.30 304991.30 304991.30
47890.34 47890.34 47890.34 47890.34 47890.34 47890.34 47890.34
100855.49 100855.49 100855.49 100855.49 100855.49 100855.49 100855.49
16367.59 16367.59 16367.59 16367.59 16367.59 16367.59 16367.59
60170.39 60170.39 60170.39 40117.54 20182.63 18509.50 6903.50
0.00 0.00 0.00 0.00 0.00 0.00 0.00
530275.11 530275.11 530275.11 510222.26 490287.36 488614.23 477008.22
 Synthesis loop heat balance
A-EB 501
Converter Effluent gas Nm3/hr 530275.11
O
Inlet temperature of Gas C 323.18
O
Outlet temperature of Gas C 239.60
Heat capacity Kcal/kgmole OC 7.91
BFW flow MT/hr 88.19
O
inlet temperature of BFW C 115.00
O
Outlet temperature of BFW C 292.30
Heat duty shell side Gcal/hr 15.64
Haet duty tube side Gcal/hr 15.64
A-EB 506
Converter Effluent Nm3/hr 530275.11
O
Inlet temperature of Process Gas C 239.60
O
Outlet temperature of Process Gas C 231.80
O
Heat capacity of Porcess Gas Kcal/kgmole C 7.78
Heat duty by Process Gas Gcal/hr 1.43
Flow indication MT/hr 2.42
O
Inlet temperature of BFW C 117.00
O
Outlet temperature of BFW C 186.50
Sensible heat duty Gcal/hr 0.17
Latent heat at saturation temperature Kcal/kg 475.47
Heat duty by BFW Gcal/hr 1.15
Total Heat duty Shell side Gcal/hr 1.32
A- EA 501
Tube Side
Converter effluent total flow Nm3/hr 530275.11
O
Inlet temperature of Synthesis hot Exchanger C 231.50
O
Outlet temperature of Synthesis hot Exchanger C 87.50
O
Heat capacity of Process Gas Kcal/kgmole C 7.55
Tube side heat duty Gcal/hr 25.72

A-EB 505
Design pressure drop kg/cm2 0.30
3
Converter effluent total flow Nm /hr 530275.11
O
inlet temeperature of Syn BFW heater C 88.10
O
Outlet temperature of Syn BFW heater C 49.20
O
Heat capacity of Process Gas Kcal/kgmole C 7.28
Heat duty Gcal/hr 6.70

A-EA 502
2
Design pressure drop kg/cm 0.24
Converter Effluent total flow Nm3/hr 530275.11
O
Inlet temperature C 49.20
O
Outlet temperature C 24.10
2
Saturation pressure of Ammonia kg/cm 10.01
Total Ammonia in Vapor phase Nm3/hr 40117.54
Ammonia Separated in A-EA 502 MT/hr 15.23
Latent heat of Ammonia Kcal/kg 278.66
Heat capacity of inlet Process Gas Kcal/kgmole OC 7.22
Tube side heat inlet to A-EA 502 Gcal/hr 8.41
Heat capacity of outlet Process Gas Kcal/kgmole OC 7.09
Tube side outlet heat to A-EA 502 Gcal/hr 4.05
Latent heat duty of Condensation Gcal/hr 4.24
Total Heat duty tube side Gcal/hr 8.60

A-EB 503 A,B

Design pressrure drop kg/cm2 0.60
Converter Effluent Gas Nm3/hr 510222.26
O
Inlet temperature of Prcoess Gas C 21.50
O
Outlet temperature of Process Gas C 5.82
Saturation pressure of Liquid Ammonia kg/cm2 5.42
3
Total Ammonia in Vapor phase Nm /hr 20182.63
Ammonia Saparated in Ist Supercooler MT/hr 15.14
Latent heat of Ammonia Kcal/kg 300.00
Latent heat duty Gcal/hr 4.54
Tube side heat capacity inlet Kcal/kgmole OC 7.09
Tube side heat inlet Gcal/hr 3.47
Tube side heat capacity outlet Kcal/kgmole OC 6.98
tube side out heat Gcal/hr 0.89
Total heat duty by A- EB 503 A/B Gcal/hr 7.12
A-EA 503
Design pressure drop kg/cm2 0.50
Total Shell side flow Nm3/hr 490287.36
O
Inlet temperature C 5.82
O
Outlet temperature C 2.30
Saturation pressure of Ammonia kg/cm2 4.77
Ammonia in Vapor phase Nm3/hr 18509.50
Total Ammonia condesed MT/hr 1.27
Latent heat of Ammonia kCal/kg 300.00
Latent heat duty Gcal/hr 0.38
Heat capacity at inlet Kcal/kgmole OC 6.98
Heat capacity at outlet Kcal/kgmole OC 6.97
Shell side heat inlet Gcal/hr 0.89
Shell side heat outlet Gcal/hr 0.35
Total heat duty by A-EA 503 Gcal/hr 0.92
A-EB 504 A/B

Design pressrure drop kg/cm2 0.60

3
Converter Effluent Gas Nm /hr 488614.23
O
Inlet temperature of Prcoess Gas C 2.30
O
Outlet temperature of Process Gas C -21.30
2
Saturation pressure of Liquid Ammonia kg/cm 1.82
Total Ammonia in Vapor phase Nm3/hr 6903.50
Ammonia Saparated in Ist Supercooler MT/hr 8.81
Latent heat of Ammonia Kcal/kg 300.00
Latent heat duty Gcal/hr 2.64
Tube side heat capacity inlet Kcal/kgmole OC 6.97
Tube side heat inlet Gcal/hr 0.35
Tube side heat capacity outlet Kcal/kgmole OC 6.88
tube side out heat Gcal/hr -3.12
Total heat duty by A- EB 503 A/B Gcal/hr 6.11
Total Ammonia Condensed 40.45
 CO2
CO
H2
CH4
N2
Ar
NH3

Exit
CO2
CO
H2
CH4
N2
Ar
NH3
H2O
Total
M.W

CO2
A- EA 501 CO
Shell Side H2
Converter inlet gas flow Nm3/hr 576812.00 CH4
Inlet temperature of Process Gas O
C 56.80 N2
Outlet temperature of Process Gas O
C 201.30 Ar
Heat capacity of Process Gas Kcal/kgmole C O
7.21 NH3
Heat duty shell side Gcal/hr 26.82

A-EB 505 CO2

Design pressure drop kg/cm2 0.50 CO
Shell side Flow rate MT/hr 179.61 H2
Shell side inlet temperature O
C 35.00 CH4
Shell side outlet temperature O
C 72.00 N2
heat capacity of BFW Kcal/kg OC 1.00 Ar
 Heat duty Shell side Gcal/hr 6.65 NH3

A-EA 502
Design pressure drop kg/cm2 0.50
3
Total Shell side Flow Nm /hr 477008.22
O
Inlet temperature C -2.70
O
Outlet temperature C 43.30
O
Heat capacity of Process Gas Kcal/kgmole C 6.98

Heat Duty tube side Gcal/hr 6.83

EB 503 A,B

A-EA 503
Design pressure drop 0.50
Total Tube side flow 477008.22
Inlet temperature -21.47
Outlet temperature -2.70
Heat capacity of Process Gas 6.90
 Heat Duty tube side Gcal/hr 2.76
EB 504 A/B
 11.44 11.04 11.00 9.84 9.31 8.87
7.32 7.22 7.21 7.03 6.99 6.96
Heat Capacity

7.10 7.04 7.03 6.91 6.88 6.86

12.61 11.50 11.40 9.33 8.75 8.37
7.24 7.15 7.14 7.00 6.97 6.96
4.80 4.80 4.80 4.80 4.80 4.80
11.26 10.51 10.44 9.15 8.81 8.58

Converter)in Converter)out A-EB 501 A-EB 506 A-EA 501 A-EB 505 A-EA 502
0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00
65.20 57.52 57.52 57.52 57.52 57.52 59.78
7.90 9.03 9.03 9.03 9.03 9.03 9.39
21.60 19.02 19.02 19.02 19.02 19.02 19.77
2.70 3.09 3.09 3.09 3.09 3.09 3.21
2.60 11.35 11.35 11.35 11.35 11.35 7.86
0.00 0.00 8.68 0.00 8.46 0.00 Err:509
100.00 100.00 100.00 100.00 100.00 100.00 100.00
10.15 11.10 11.10 11.10 11.10 11.10 10.87

7.76 8.28 9.22

6.90 6.92 6.98
6.82 6.84 6.88
7.65 7.95 8.66
6.94 6.94 6.97
4.80 4.80 4.80
8.18 8.34 8.76

Converter)inlet Makeup Gas Recylcle Gas Converter)inlet Makeup Gas

0.00 0.00 0.00 CO2 0.00
0.00 0.00 0.00 CO 0.00
67.61 70.73 67.00 H2 66622.55
5.80 0.80 6.79 CH4 752.75
22.59 24.46 22.22 N2 23035.84
1.88 0.30 2.19 Ar 281.15
2.12 3.72 1.80 NH3 3503.41
94195.69 477008.22 94195.69

2.99 2.89
 8.49 8.40 7.76 10.81 9.43 0.00 0.00 0.00
6.93 6.93 6.90 7.17 7.00 0.00 0.00 0.00
6.85 6.84 6.82 7.00 6.89 408.54 404.64 404.28
8.08 8.03 7.65 10.97 8.87 113.91 103.89 102.93
6.95 6.95 6.94 7.11 6.98 137.75 136.02 135.87
4.80 4.80 4.80 4.80 4.80 14.82 14.82 14.82
8.42 8.39 8.18 10.17 8.88 127.81 119.31 118.52

A-EB 503A/B A-EA 503 A-EB 504 A/B

0.00 0.00 0.00
0.00 0.00 0.00
62.21 62.42 63.94
9.77 9.80 10.04
20.57 20.64 21.14
3.34 3.35 3.43
4.12 3.79 1.45
0.00 0.00 0.00
100.00 100.00 100.00
10.62 10.60 10.44

0.00 0.00 0.00

0.00 0.00 0.00
436.31 437.28 439.66
76.81 79.79 86.96
146.72 146.83 147.36
16.47 16.47 16.47
11.83 12.08 12.67

Recylcle Gas Total

0.00 0.00
0.00 0.00
319595.51 386218.06
32388.86 33141.60
105991.23 129027.07
10446.48 10727.63
 8586.15 12089.56
477008.22 571203.92

3.02 2.99
 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
397.56 395.77 410.11 425.86 427.14 436.32 456.68 456.68 449.05
84.26 79.04 78.52 78.93 78.66 76.84 86.70 86.70 70.05
133.20 132.64 137.53 142.93 143.39 146.72 153.61 153.61 150.75
14.82 14.82 15.40 16.02 16.08 16.47 12.96 12.96 12.96
103.85 99.95 67.49 34.66 31.78 11.83 26.45 26.45 23.08
 HTS inlet temperature
Process gas flow Kmoles/hr 4552.04
Outlet temperature of Waste heat boiler O
C 340.00 CO2
K 613.15 CO
Inlet pressure of HTS Kg/cm2G 27.50 H2
Outlet pressure of WHB Kg/cm2A 28.03 CH4
Heat at WHB outlet Gcal/hr 11.85 N2
Vapor pressure of Water kg/cm2A 10.87 Ar
Saturation temperature of water O
C 182.69 NH3
total quench added Kg/hr 0.00 H2O
Total Steam Added Kg/hr 1500.00 Total
Enthalpy of water Kcal/kg 121.77
Enthalpy of Water in process gas Kcal/kg 750.62
Total heat at inlet Gcal/hr 50.78
Temperature of process gas at inlet of HTS O
C 327.00
Heat of process gas K 600.15
Gcal/hr 11.37
Saturation pressure of water Kg/cm2A 11.25
184.24
Enthalpy of steam 744.63
Total heat 51.11
 Process Gas analysis
378.02 8.30 11.51 95.57 5.09 58.53 11.45 95.13
562.43 12.36 7.34 90.64 7.57 55.50 7.32 90.44
2590.85 56.92 7.12 405.05 34.85 248.05 7.11 404.45
23.97 0.53 12.83 6.76 0.32 4.14 12.66 6.67
1041.87 22.89 7.26 166.19 14.02 101.77 7.25 165.86
12.91 0.28 4.80 1.36 0.17 0.83 4.80 1.36
0.00 0.00 11.41 0.00 0.00 0.00 11.30 0.00
2881.23 8.73 38.76 338.21 8.69
4552.04 100.00 7.66 8.07 7.64

Heat of inlet 20396211.24

Heat of quench 0.00
20396211.24
20.40
 Inlet
Natural Gas Steam
Mass Flow rate kg/hr 15300.00 56400.00 K1
Mole Flow rate Kgmoles/hr 904.10 3129.86 ΔH1)298
Inlet Pressure Kg/cm2G 31.55 K2
Outlet Pressure Kg/cm2G 30.85 ΔH2)298
Inlet Temperature O
C 475.00
Outlet Temperature O
C 750.00

S/C 3.26

Total Fuel kg/hr 8100.00

NCV of Fuel Kcal/SCM 8820.00
Q Gcal/h 99.77

Heat of Reaction
Heat of Reaction 1 kcal/kmol -49320.57

Heat of Reaction 2 kcal/kmol -39473.68

Heat of Reaction 3 kcal/kmol 9844.50

Extent of Reaction 1 0.27

Extent of Reaction 2 0.26
Extent of Reaction 3 0.07

Total heat of Reaction Gcal/h -21.02

Total Feed 71700.00
O
Temperature C 475.00
o
Cp kcal/kg C 0.59
Heat inlet Gcal/hr 19.99
Air inlet
Combustion Air kg/hr 163248.53
Cp Kcal/kg OC 0.26
Inlet temperature O
C 258.00
 Gas Outlet
Mass Flow kg/hr 71700.00
Temperature 750.00
Cp Kcal/kg OC 0.69
Outlet Energy Gcal/hr 37.20

Heat in Feed Gcal/hr 19.99

Heat outlet Gcal/hr 37.20
Heat by burning Gcal/hr 99.77
Heat in Combustion Air Gcal/hr 10.91
Heat of Reaction Gcal/hr -21.02
Balamce heat Gcal/hr 70.99

Total Flue Gas Flow kg/hr 171348.53

O
Heat capacity of Flue Gas kcal/kg C 0.34
O
Temperature C 1207.88
 Primary Reformer
Considering Following system of reaction
1) CH4 + H2O ↔ CO + 3H2

2) CO + H2O ↔ CO2 + H2
3) CH4 + 2 H2O ↔ CO2 + 4H2
fractional conversion for above reactions e1,e2,e3

moles/kmol of CH4 pp K1 xCO.xH23.P2

xCO e1-e2 0.21 1.24 xCH4.xH2O.ntotal 2
xCO2 e1+e3 0.33 1.94
xH2 3e1+e2+4e3 1.94 11.47 K2 xCO2.xH2
xH2O a-e1-e2-2e3 2.39 14.16 xCO.xH2O
xCH4 1-e1-e3 0.46 2.74
ntotal 5.33 K3 xCO2.xH24.P3
e1 e2 e3 xCH4.xH2O2.ntotal3
0.27 0.07 0.26

Formulating literature value

K1 48.12 50.77
K2 1.27 1.31
K3 61.15 66.37
 Outlet

mole % no of moles
Solution Dry basis kmoles
xCO 3.92 7.11 188.98 0.04 109.78
xCO2 6.15 11.16 296.41 0.06 270.59
xH2 36.36 65.97 1752.60 0.34 72.72
xH2O 44.88 - 2163.26 0.42 807.86
xCH4 8.69 15.76 418.70 0.08 138.99
total)dry basis 55.12 2656.69 1399.95
100.00 7476.65

Methane Reformed 53.69 %

Equilibruim Methane Slip 15.76 %

 Mass Flow
%
7.84 5622.71
19.33 13858.40
5.19 3724.58
57.71 41375.81
9.93 7118.50
71700.00