Mass Balance Hand calculation

Mass Balance across Desulphurization Tank

S1 = 100 kmol/h S2 = 99.85 kmol/h
CH4,1 = 84.8725 kmol/h CH4,2 = 84.8725
kmol/h
CO2,1 = 14.9775 kmol/h CO2,2 = 14.9775
kmol/h
H2S,1 = 0.1500 kmol/h

Basis set, S1= 100 kmol/h
CH4,1 ( )

CO2,1 ( )

H2S,1

Desulphurization
Since desulphurization is only meant to remove the H2S from the dry natural gas, therefore
the flow rate of CH4 and CO2 remain unchanged from stream 1 to stream 2.
Mass Balance across Mixer


S2 = 99.85 kmol/h Mixer S3(a) = 235.2886 kmol/h
CH4,2 = 84.8725 kmol/h CH4,3(a) = 84.8725 kmol/h
CO2,2 = 14.9775 kmol/h CO2,3(a) = 14.9775 kmol/h
H2O, 3(a) = 135.4386 kmol/h

Given relative humidity of S3(a) is 62%;

To find

interpolation using values from the steam table has to be done,

Taking 22 bar and 24 bar with their saturated temperatures as reference,

Pressure at S3(a) is 25 bar,

0.5758
Mole fraction of water in S3(a)= 0.5758
S3= 0.5758 * S3(a)
S3= 135.53 kmol/h
Therefore, the flow rate of hot water entering in is 135.53 kmol/h.
Hot Water
Mass Balance around mixing point Steam
S4 = 164.1114 kmol/h

S3 (a) = 235.2886 kmol/h S4 (a) = 399.4 kmol/h
H2O,3(a) = 135.4386 kmol/h H2O,4(a) = 299.55 kmol/h
CH4,3(a) = 84.8725 kmol/h CH4,4(a) = 84.8725 kmol/h
CO2,3(a) = 14.9775 kmol/h CO2,4(a) = 14.9775 kmol/h

After steam is added, the water to carbon molar ratio is 3.0.

n(H2O)= 3n(C)
CH4 and CO2 molecules contain one carbon atom each.
n(H2O)= 3(n(CH4 + CO2)
= 3(84.873 + 14. 9775)
= 299.55 kmol/h









Mass Balance around reformer


S4 (a) = 399.4 kmol/h Reformer S5 = 547.5001 kmol/h
H2O,4(a) = 299.55 kmol/h H2O,5 = 203.5261
kmol/h
CH4,4(a) = 84.8725 kmol/h CH4,5 = 10.8224 kmol/h
CO2,4(a) = 14.9775 kmol/h CO2,5 = 36.9513 kmol/h
CO,5 = 52.0762 kmol/h
H2,5 = 244.1240 kmol/h

Since there are 5 unknowns in stream 5, 5 equations are needed in order to solve the
unknowns.

C ,

C ,
Pressure at equilibrium state= 23.5 bar
Hence,

C.
Kp = K.10
n

From Table 1: Equilibrium Constants for Methane-Steam Reforming Reaction,
At C, we obtained Kp value for methane-steam reforming reaction is 1.578 *

.
Using given equation, we get

Therefore,

)
(

)
(

)(

)
(

Using the same method, another equation can be formed using the Kp value of shift
reaction.
Reaction temperature for shift reaction is C ,
From Table 2: Equilibrium Constants for Carbon Monoxide Shift Reaction,
We get Kp value for shift reaction is 0.8511,

For the remaining 3 equations, those are created using atomic balance of C, H and O
respectively.



(

)() (

)()
(

)() (

)()

)(

)
(

)(

) ,




(

)(

)
(

)(

)
(

)

(Kp)(P
2
)
(

)
(

)
(

)(

)
(

)

()()
(

)
(

)
(

)(

)
(

)


()(

)
(

)
(

)
(

)(

)
(

= 0


Carbon atom balance :

Hydrogen atom balance :
() () ()

Oxygen atom balance:
()

Now with 5 unknowns and 5 equations obtained, the 5 unknowns can be determined by
using a tool in Microsoft Excel called solver.
1. Cells for function

and

are set.
f1 -1.350772222
f2 -1.5489
f3 -20.1500
f4 658.59
f5 179.505

2. An initial guess for the 5 solution were taken. (20,30,40,50,60 respectively)
Component Reactor effluent
H20 20
CH4 30
CO2 40
CO 50
H2 60
Total 200

3. An objective cell was set. (

)
objective cell 466373.0793

4. The solver window was opened and all the information was set. ( constraints = 0
and objective function = 0)


5. Therefore using solver , we get

nH2O,5

= 203.5261 kmol/h

nCH4,5

= 10.8224 kmol/h

nCO2,5

= 36.9513 kmol/h

nCO5

= 52.0762 kmol/h

nH2,5 = 244.1240 kmol/h

Mass Balance around Dryer S6

S5 = 547.5001 kmol/h
H2O,5 = 203.5261 kmol/h Dryer
CH4,5 = 10.8224 kmol/h
CO2,5 = 36.9513 kmol/h S7 = 343.9740 kmol/h
CO,5 = 52.0762 kmol/h CH4,7 = 10.8224 kmol/h
H2,5 = 244.1240 kmol/h CO2,7 = 36.9513 kmol/h
CO,5 = 52.0762 kmol/h
H2,5 = 244.1240 kmol/h

Since stream 5 passes through a dryer, it is assumed that all the water is removed from
stream 5, meaning there is no water in stream 7. The flow rates of CH4, CO2, CO and H2
remains unchanged from stream 5 to stream 7.
S5= 203.526 kmol/h








Water


Mass balance around methanol synthesis loop






















CO2 : 0.005 x S
13

H2 : 0.003 x S
13

CH4 : 0.005 x S
13

CH3OH : 0.7a+0.7b
H2O : 0.7b
S
10

S
11

S
12

CO : 0.3a
CO2 : 0.3b
H2 : c-1.4a-2.1b
CH4 : d
CH3OH : 0.7a+0.7b
H2O : 0.7b
CO : a
CO2 : b
H2 : c
CH4 : d
S
13

CO : 0.3a
CO2 : 0.3b-0.005S
13

H2 : c-1.4a-2.1b-0.003S
13

CH4 : d-0.005S
13
S
9
S
7
S
8

zCO(7)=52.08kmol/h
zO2(7)=36.95kmol/h
zH2(7)=244.12kmol/h
zCH4(7)=10.82kmol/h

REACTOR
SEPARATOR


The total and component flowrates S7 are calculated.
"z" represents the component flowrates.

As the recycle loop is operated by a recycle ratio of 0.4 (ratio of dry recycle gas to dry MUG)
thus the total flowrates for S8 and S11 can be found by the equations below.

S11 = 0.4S7
S11 = 0.4 x 343.97
S11 = 137.588 kmol/h

S8 = S7 + S11
S8 = 343.97 + 137.588
S8 = 481.558 kmol/h

"S" represent total flowrate of each stream while "a", "b", "c" and "d" are terms used to
represent the component flowrates of CO, CO2, H2 and CH4 respectively in Stream 8.
The equations formed for component flowrates of other streams are termed with respect to
"a", "b", "c" and "d" as shown in the diagram above.

The recycle loop is solved by using "Solver" from Microsoft Excel.
6 equations are formed with 6 unknowns.

Unknowns set for solving are: S10, S13, a, b, c, d

Total flowrate S10: S10 = c + d - 0.4a - 0.4b - 0.013S13

Total flowrate S13: S13= 0.7a + 1.4b + 0.013S13

Total flowrate S8: S8 = a + b + c + d

Component balance at mixing point,

CO balance:

CO
2
balance:

CH
4
balance:







a
S
a
a
S
a
a sCO S
S
a
= +
|
|
.
|

\
|
= +
|
|
.
|

\
|
= +
|
|
.
|

\
|
08 . 52
2764 . 41
) 08 . 52 ( 588 . 137
3 . 0
3 . 0
10
10
) 7 ( 11
10
( )
( )
b
S
S b
b
S
S b
b zCO S
S
S b
= +
|
|
.
|

\
|
= +
|
|
.
|

\
|
= +
|
|
.
|

\
|
95 . 36
68794 . 0 2764 . 41
95 . 36 588 . 137
005 . 0 3 . 0
005 . 0 3 . 0
10
13
10
13
) 7 ( 2 11
10
13
( )
( )
d
S
S d
d
S
S d
d zCH S
S
S d
= +
|
|
.
|

\
|
= +
|
|
.
|

\
|
= +
|
|
.
|

\
|
82 . 10
68794 . 0 588 . 137
82 . 10 588 . 137
005 . 0
005 . 0
10
13
10
13
) 7 ( 4 11
10
13
( )
( )
a
S
a
a
S
a
a zCO S
S
a
= +
|
|
.
|

\
|
= +
|
|
.
|

\
|
= +
|
|
.
|

\
|
08 . 52
2764 . 41
08 . 52 588 . 137
3 . 0
3 . 0
10
10
) 7 ( 11
10


All the equations derived are rearranged such that they are equated to "0".

c + d - 0.4a - 0.4b - 0.013S

13
- S
10
= 0

0.7a + 1.4b + 0.013S

13
- S
13
= 0

a + b + c + d - S
8
= 0

All the unknowns to be calculated are put into a table with an initial guess of value for each
term as shown below.









A B
1 Terms Values
2 S10 200
3 S13 100
4 a 65
5 b 45
6 c 340
7 d 30
0 95 . 36
68794 . 0 2764 . 41
10
13
= +
|
|
.
|

\
|
b
S
S b
0 82 . 10
68794 . 0 588 . 137
10
13
= +
|
|
.
|

\
|
d
S
S d
0 08 . 52
2764 . 41
10
= +
|
|
.
|

\
|
a
S
a


Another table for functions are set. The 6 equations derived are then typed into the cells
from H1-H7 by substituting the unknowns in the equation from the variable cells (B2-B7).











Objective cells are then typed in with the formula
=(H2^2)+(H3^2)+(H4^2)+(H5^2)+(H6^2)+(H7^2)

Open "Solver" and set all the parameters. In the set objective column the objective cell is
inserted then setting the value of "0". The cells from B2-B7 are taken for the column "By
Changing Variable Cells" in the solver parameter. Cells from H2-H7 are then taken for the
column "Subject to the Constraints" where all the constraints are set to "= 0".

G H
1 Function Equations
2 F1
3 F2
4 F3
5 F4
6 F5
7 F6


After it is solved, the values for all the unknown terms will be shown in the variable cells.













A B
1 Terms Values
2 S10 219.0879
3 S13 109.4874
4 a 64.1696
5 b 45.1038
6 c 344.1224
7 d 28.1622

The component flowrates for stream 8 are directly taken from the variable cells.









The component flowrates for S9, S10 and S13 are then calculates by substituting the known
values of S10, S13, a, b, c, d into the equation in the diagram above.

Stream 9
Componen
t
Equations Flowrate
(kmol/h)
Mole Fraction
CO = 0.3a 19.2509 0.05859
CO2 = 0.3b 13.5311 0.04118
H2 = c - 1.4a - 2.1b 159.567 0.4856
CH4 = d 28.1622 0.08571
CH3OH = 0.7a + 0.7b 76.4914 0.2328
H2O = 0.7b 31.5727 0.09609
Total 328.5752 1

Stream 8
Componen
t
Flowrate
(kmol/h)
Mole
Fraction
CO 64.1696 0.133254
CO
2
45.1038 0.093662
H
2
344.1224 0.714602
CH
4
28.1622 0.058481
Total 481.558 1

Stream 10
Componen
t
Equations Flowrate
(kmol/h)
Mole
Fraction
CO = 0.3a 19.2509 0.087868
CO2 = 0.3b - (0.005S13) 12.9837 0.059263
H2 = c - 1.4a - 2.1b -
(0.003S13)
159.239 0.726825
CH4 = d - 0.005S13 27.6148 0.126044
Total 219.0879 1


Stream 13
Componen
t
Equations Flowrate
(kmol/h)
Mole Fraction
CO2 = 0.005S13 0.5474 0.005
H2 = 0.003S13 0.3285 0.003
CH4 = 0.005S13 0.5474 0.005
CH3OH = 0.7a + 0.7b 76.4914 0.6896
H2O = 0.7b 31.5727 0.2884
Total 109.4874 1





The composition of S10, S11 and S12 are the same.
Thus the component flowrates for Stream 11 can be calculated by the relationship,

[xY(10)]S11 = zY(11)

Where,"xY(10)" represents the mole fraction of component "Y" in Stream 10
while "zY(11)" represents the component flowrate "Y" in Stream 11

Stream 11
Component Equations Flowrate
(kmol/h)
Mole Fraction
CO =0.087868 x S
11
19.2509 0.087868
CO2 =0.059263 x S
11
13.5311 0.059263
H2 =0.726825 x S
11
159.567 0.726825
CH4 =0.126044 x S
11
28.1622 0.126044
Total 137.588 1


At purge point, S10 = S11 + S12
S12 = S10 - S11
S12 = 219.0879 - 137.588
S12 = 81.4999 kmol/h



Component flowrates for Stream 12 are also calculated the same way as Stream 11,

[xY(10)]S12 = zY(12)

Where "xY(10)" represents the mole fraction of component "Y" in Stream 10 while "zY(12)"
represents the component flowrate "Y" in Stream 12.

Stream 12
Component Equations Flowrate
(kmol/h)
Mole Fraction
CO =0.087868 x S
12
7.16128 0.087868
CO2 =0.059263 x S
12
4.829903 0.059263
H2 =0.726825 x S
12
59.23612 0.726825
CH4 =0.126044 x S
12
10.27256 0.126044
Total 81.49986 1










Mass balance across Distillation Columns
























xCH3OH(16) : 0.001
S
13

S
16

S
17

S
15

S
14

Light Gas

DC1
DC2
CH3OH :
76.4914kmol/h
H2O :
31.5727kmol/h
CO2 : 0.5474kmol/h
H2 : 0.3285kmol/h
CH4 : 0.5474kmol/h


xCH3OH(17) : 0.9972
Distillation Column 1
We assume all the gases (CO2, H2 and CH4) are distilled out from the crude methanol at the
first distillation column. Thus, component flowrates for CO2, H2 and CH4 in Stream 13 and
Stream 15 are the same while the component flowrates for CH3OH and H2O in Stream 13
and Stream 14 are the same.

Stream 15
Component Flowrate
(kmol/h)
Mole Fraction
CO2 0.5474 0.3846
H2 0.3285 0.2308
CH4 0.5474 0.3846
Total 1.4233 1


Stream 14
Component Flowrate
(kmol/h)
Mole Fraction
CH3OH 76.4914 0.7078
H2O 31.5727 0.2922
Total 108.064 1





Distillation Column 2
The design specification given is 0.28 mole % impurities thus 99.72 mole % methanol
produced from S17. The flowrates for S16 and S17 are calculated using 2 equations
simultaneously,

Overall mass balance: S14 = S16 + S17 ------ (1)
Component mass balance : zCH3OH(14)=[xCH3OH(16)]S16 + [xCH3OH(17)]S17 ----- (2)

Where,"xCH3OH(16)" represents the mole fraction of CH3OH in Stream 16;
"xCH3OH(17)" represents the mole fraction of CH3OH(in Stream 17;
while "zCH3OH(14)" represents the CH3OH flowrate in Stream 14.

From equation (1),
S16 = S14 - S17 ------- (3)

Substitute equation (3) into (2),
zCH3OH(14) = [xCH3OH(16)]( S14 - S17 ) + [xCH3OH(17)]S17 -----------(4)
76.4914 = 0.001 ( 108.064 - S17 ) + ( 0.9972 ) S17
76.4914 = 0.108064 - ( 0.001 ) S17 + ( 0.9972 ) S17
76.4914 - 0.108064 = ( 0.9962 ) S17
S17 = 76.675 kmol/h
Substitute S17 = 76.675 kmol/h into equation (1),
S16 = S14 - S17
S16 = 108.064 - 76.675
S16 = 31.389 kmol/h
Component flowrates for CH3OH in Stream 16 and Stream 17 are calculated by multiplying
stream flowrate with mole fraction of CH3OH for the same stream.
zCH3OH(16) = [xCH3OH(16)]( S16 )
= 0.001 ( 31.389 )
= 0.3139 kmol/h

zCH3OH(17) = [xCH3OH(17)]( S17 )
= 0.9972 ( 76.675 )
= 76.4603 kmol/h

Component flowrates for H2O in Stream 16 and Stream 17 are calculated by subtracting
flowrate of CH3OH from stream flowrate.
zH2O(16) = S16 - zCH3OH(16)
= 31.389 - 0.3139
= 31.358 kmol/h

zH2O(17) = S17 - zCH3OH(17)
= 76.6747 - 76.4603
= 0.3137 kmol/h






Scaling up

Mr (CH3OH) = 32.04 kg/kmol
Mr (H2O) = 18.016 kg/kmol

Average molecular mass of crude methanol,
= [ xCH3OH(17) x Mr(CH3OH)] + [xH2O(17) x Mr(H2O)]
= (0.9972 x 32.04) + (18.016 x 0.0028)
= 32.0007 kg/kmol

Methanol production,

(CH
3
OH)
T




Scale up Factor, k
(CH3OH)T = k [zCH3OH(17)]
703.1089 = k (76.4603)
k = 9.1958




hour
kmol
hours
year
kg
kmol
tonne
kg
year
tonnes
1089 . 703
8000 0007 . 32
1000 180000
=
=
All the stream and component flowrates obtained from the basis are then multiplied by the
scale up factor to get the scaled up figures.
For Stream flowrates,
e .g: S1 = 100 kmol/h (basis)
= 100k
= 100 x 9.1958
= 919.58 kmol/h (scaled up)

For component flowrates,
e.g: zCH4(1) = 84.8725 kmol/h (basis)
= 84.8725k
= 84.8725 x 9.1958
= 780.4682 kmol/h (scaled up)












Appendix on Energy Balance
Assumptions made on calculating Energy Balance

1. Ideal gas is assumed in our calculation. Hence, volume fraction equals to molar
fraction can be used in our calculation. Ideal gas is assumed due to the high reaction
temperature in our plant.

2. For turbines and compressors, we take

which means the required work of compression or expansion is equal to the
enthalpy rise or drop of the fluid. This can be proven using the First Law of
Thermodynamic for the steady state open system.

Where and is negligible as the initial fluid velocity is low and the
equipment are at the same datum level as the fluid. Q is negligible because the flow
and power terms are large in comparison to the surface area of the machine, so heat
transfer is negligible.

3. For compressors, as we assume ideal condition,
-W isothermal < -W polytropic < -W isentropic relationship is taken into account.

4. The steady flow performance of turbines and compressors are idealized by
assuming that in an ideal case, the working fluid does work reversibly by expanding
or compressing at a constant entropy. This is to provide a basis for analyzing the
performance of equipment.

5. Plant is well insulated from disturbances is assumed. Hence, for an example from
this assumption, outlet temperature of E1 equals to inlet temperature of E2.

6. No boundary work done is assumed.

7. Mixer, sulphur guard, knock out pot, separator have relatively low difference in
heat. Hence Q required or released is negligible by assuming they are isothermal
devices.

8. For the reformer part, the operating temperature for the reforming and shift
reactions to be at 860 C. Hence, superheated liquid to be assumed as the outlet
temperature is 860 C.

9. When theres mixture of steam with other gases, we assume ideal mixing taking
place. Hence, condensation point of the steam to be the saturated temperature at
that particular temperature.


10. At mixing points, assumption of no heat loss to the surrounding is made. Hence,
relationship of can be used in our calculation.

11. Methanol synthesis catalytic reactor is assumed to be adiabatic.

12. The composition of the reformer gas is calculated by assuming chemical equilibrium
at the exit where the temperature is 858 C and pressure at 23.5 bar.

13. It is assumed that only water and methanol is in the feed for the distillation column
(II) as all light gas has been removed in distillation column (I).


Table 3. Cp values for components involved
Components Mr State a b c d
Methanol CH3OH 32.04 Liquid 0.07586 0.0001683 - -
Gas 0.04293 0.00008301 1.87E-08 8.03E-12
Hydrogen H2 2.016 Gas 0.02884 7.65E-08 3.288E-09 -8.698E-
13
Methane CH4 16.04 Gas 0.03431 0.00005469 3.661E-09 -1.1E-11
Hydrogen
Sulphate
H2S 34.08 Gas 0.03351 0.00001547 3.012E-09 -3.292E-
12
Carbon
Monoxide
CO 28.01 Gas 0.02895 0.00000411 3.548E-09 -2.22E-
12
Carbon
Dioxide
CO2 44.01 Gas 0.03611 0.00004233 -2.887E-08 7.464E-
12
Water H2O 18.016 Gas 0.03346 0.00000688 7.604E-09 -3.593E-
12
Liquid 0.0754 - - c










E-1 (Compressor)
To solve the compressors, solver method is used.
The two equations below are the constraints for the solver
)

( )

From substituting the both equations, we can know that

By setting the 1
st
and 2
nd
equations as constraints, the objective function of the solver will
be
(

And the changing variable will be our unknown variable, which is outlet temperature, T2
Below picture is the example of solver

By getting the outlet temperature, T2 the formula below is used to find out the power
requirement for the compressor.

( )

While

= 3031.32 kW



Heat exchanger (E-2)
To calculate the power requirement of heat exchanger, this formula is used

While

By integrating the Cp, we can get

=(Tout-Tin)
Since we have the values of outlet temperature and inlet temperature, by substituting the
both values inside the equations, we can get the value of q.
By getting the value q, the formula below is used to get the power requirement.

= 1426.25 kW
m=molar flowrate
E-3 & E-18
Few assumptions are made for E-3 & E-18:
- Assume both are isothermal reactors







At mixing point for reformer feed
Few assumptions are made
- All the heat released by stream 4 is absorbed by stream 3
- The pressure of stream is assumed to be 42.5 bars
- Steam in stream 4 assumed to be saturated steam rather than superheated steam
because by mixing superheated steam with another fluid, heat transfer is bad as the
heat transfer coefficient is very low. Hence, relationship of All the heat released by
stream 4 is absorbed by stream 3 cannot be applied.
- The temperature of stream 4 will be taken as 253.0C which the value is taken from
steam table
Solver method is used to find the outlet temperature of mixing point

Below are the constraints equations for solver

After integration, the formulas become,

)
Having the two constraints formula, the objective formula is set to (

and
changing variable as Tout
Using the solver, we can find out that Tout is 232.95C
Then these two formulas are used again by substituting the Tout to find out the power of
both streams.

)

Reformer
At this part the formulas below are used

Since we have the inlet temperature and outlet temperature which is 232.95C and 860C
respectively, Q for outlet of mixing point and Q for stream 5 are calculated. After that, the
total Q is calculated by finding the difference of Q of the both streams.
Then, formula below is used because the heat of reactions must be considered in order to
get the total heat of the reformer reactions.

)
The h for the reforming and shift reactions are given which are

and

.
Hence Q= (moles of CH4 consumed)*

+(moles of CO consumed )*

= 65307.66 kJ/s
Heat Exchanger E-7, E-8 & E-9
Assumptions
- No pressure drop across the unit, remain 23.5 bars
- Latent heat is taken into consideration to find the total heat
Same formulas as shown in below to use to find out the heat for each component except
water

It is because from temperature change from 860 C to 35 C, phase change has occurred for
water. So, latent heat of water must be considered in order to get the total heat of water.

Hence, Q total= -61343.30 kJ/s
Knock out pot
Assumptions:
- It is assumed to be isothermal.
- Q=0

Inter stage Cooling
For Inter stage cooling, E12-E14-E13, the way of finding the work done for E12 is similar to
the previous compressor.
Inlet temperature, T1= 35 C
Inlet pressure, P1
Outlet pressure, P2
Using formula (

k= 1.60
Using solver method,
We get T2= 110.57 C
Average Cp =0.030318 kJ/mol.K

() ( ( )
()

()

()

= 80.01 kJ/s


() ( ( )
()

()

()

= 1360.225 kJ/s

() ( ( )
()

()

()

= 294.25


() ( ( )
()

()

()

= 278.38 kW
Total Heat for E12= Total Work (proven in assumption part)
= 2012.87 kJ/s

Since it involves inter cooling, hence, both compressors E12 and E13 should share the
similar work done.
Using solver, we get T2 = 126.6 C
Using formula (

k= 1.73

Both k values of the compressors have almost the same value. Hence, it complies with the
requirement of inter stage cooling technique.


() ( ( )
()

()

()

= 91.72 kJ/s


() ( ( )
()

()

()

= 1647.80 kJ/s

() ( ( )
()

()

()

= 35460


() ( ( )
()

()

()

= 324.72 kJ/s
Total Heat= Total Work (proven in assumption part)
= 2418.80 kJ/s








Heat Exchanger E-14
Having the both value of inlet and outlet temperatures, we can use this formula to get total
heat

*
= -2012.87 kJ/s


Hence, heat loads for inter stage compressor cooling load =( 2012.87 -2012.87 +2418.80)
= 2418.80 kJ/s












Methanol synthesis reactor
Assumption: The catalytic reactor is assumed to be adiabatic
Inlet temperature given: 145 C
Outlet temperature: unknown T2
For adiabatic reaction:

Reactions that are involved in this reactor:
CO + 2H2 CH3OH Ah = -94 MJ/kmol CH3OH
Methanol produced in this reaction= moles of CO used
= 590.09 kmol/h- 177.03 kmol/h
= 413.06 kmol/h
for this reaction =

= 10785.46 kW
CO2 + 3H2 CH3OH + H2O Ah= -53 MJ/kmol CH3OH
Methanol produced in this reaction= moles of CO2 used
= 414.6 kmol/h- 124.43 kmol/h
= 290.17 kmol/h
for this reaction

= 4271.95 kJ/s
for both reactions= 10785.46 kW + 4271.95 kW
= 15059.9 kJ/s

)^

+
(

)^

+
(

)^

)^

-
(

)^

-
(

)^

We take reference temperature at 25 C in our calculation.
Values of a, b, c and d for each components can be obtained from Table 1 above.

( ( )
()

()

()

)

= 3463.20

( ( )
()

()

()

)
= 3505.521

( ( )
()

()

()

)
= 4621.73

( ( )
()

()

()

)
27810.15

( ( )
()

()

()

)
= 16369.33

( ( )
()

()

()

)
= 17048.07

( ( )
()

()

()

)
( ( )
( )

+
( )

+
( )

)
= 25415.17

( ( )
()

()

()

)
= 38465.40

( ( )
()

()

()

)
= 20220.23

= (258.97*28055.03 + 1467.34* 16164.43 +177.03 *16878.02 +
124.43*25404.40 + 703.40* 39060.46 + 290.33 *20060.45 3164.47
*3464.80 258.97* - 590.09 * 3519.26 414.76 *4736.60 ) / 3600
(kW)
= 15059.89 kJ/s

Applying solver method to get T2,
We set objective function as (

)^2 - () ^2 to the value of 0,
Changing variable as T2, we get T2 = 578.53 C.
Hence, exit temperature for methanol reactor is 593.15 C.





Turbine
1
st
Turbine
We know that the efficiency of the turbine is 65% and the formula below is use to find out the
h
2
of the turbine

By given inlet and outlet pressure and temperature, we can use interpolation method to find
out the h' value. Below are the ways of doing it
Inlet pressure=105 bars
Outlet pressure= 42.5 bars
Temperature= 450C
Pressure 105 bars
Hg 3233
Sg 6.3885

Pressure 42.5 bars
Hg 2799.5 Sg 6.044
Hf 1105.25 Sf 2.8295

We assume that the turbine is isentropic, so s
1
= s
2
'
But from the table above, we can know that the value of entropy is , so this
reaction is superheated.
Interpolation to find out h' will be using the enthalpy value of superheated steam from steam
table.
At 42.5
6.326 6.3885 6.55075
2954 h' 3094

2992.9321

After getting the h' value, h
2
can be found using formula above and below formula will be used
to find out the steam requirement of turbine, m

)
( )



2
nd
Turbine
From information given, we know that, this turbine efficiency is 75%, P
out
=0.13bars and
P
in
=42.5bars.
Since the stream from 1
st
turbine is connected to this turbine we can find the temperature of
the stream using interpolation
300 T
2
350
2954 3076.956 3088

T
2
345.8791
And we assume that this turbine is isentropic, so s
1
= s
2
'
At 42.5
bars

Hg Sg
S
2

3076.956 6.530523 6.530523

At 0.13
Sg 0.7165
Sf 8.058

So,

It is saturated reaction, interpolation is used to find out the value of h'

At 0.13
0.7165 6.530523 8.058
213.5 h' 2593
h'= 2097.9198

These formulas are then used to find out the steam requirement of the turbine

)
( )












Reference list
1. Richard M Felder and Ronald W Rousseau (1999), Elementary Principles of Chemical
Processes, Third Edition, published by John Wiley and Sons INC. (1999).
2. Rao, YVC Rao, Chemical Engineering Thermodynamic (1997), published by University
Press (India) Private Limited (1997).
3. RK Sinnott (1999), Coulson and Richardsons Chemical Engineering, Third Edition,
published by Buterworth Heinemann (1999).
4. Robert H.Perry and Don W. Green (1997), Perrys Chemical Engineers Handbook,
Seventh Edition, published by RR Donnelley and Sons Company.