Heat & Mass Balance Across Booster and Hyper Compressors in an LDPE plant

Roll No. : 09010738

Department of Chemical Engineering Indian Institute of Technology, Guwahati

ACKNOWLEDGEMENT
I would like to sincerely thank the Organization, for giving me the opportunity of this industrial training at their Manufacturing Division.

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TABLE OF CONTENTS
1. AIM........................................................................................................................................................... 1 2. INTRODUCTION ........................................................................................................................................ 2 i. LDPE Plant .............................................................................................................................................. 2 ii. Applications of LDPE.............................................................................................................................. 2 iii. Grades of LDPE Generated ................................................................................................................... 3 iv. Grade Nomenclature ............................................................................................................................ 3 v. Sections of LDPE .................................................................................................................................... 4 vi. Polymerization...................................................................................................................................... 4 vii. Specifics of the Polymerization Process in the Plant........................................................................... 5 viii. Process Summarized Description .................................................................................................... 6 3.DETAILED DESCRIPTIONS .......................................................................................................................... 8 i. Ethylene Storage Vessels: V01, V02, V03 ............................................................................................... 8 ii. Tail Gas Compressor (K01) .................................................................................................................... 9 ii. Combined Compressor (K02) ................................................................................................................ 9 iii. Hyper Compressor (K03) .................................................................................................................... 10 iv. Final Stage Coolers ............................................................................................................................. 11 v. Reactor ................................................................................................................................................ 12 vi. MP/ LP Separator/Extrusion Hopper (V12/V14/V15) ........................................................................ 15 vii. Extruder ............................................................................................................................................. 16 4. CALCULATIONS ....................................................................................................................................... 17 i. PART- 1 ................................................................................................................................................. 19 a. Sample Calculations: .................................................................................................................. 20 b. Result ......................................................................................................................................... 23 ii. PART 2 .............................................................................................................................................. 24 a. Sample Calculations: .................................................................................................................. 25 ii | P a g e

b. Result ......................................................................................................................................... 28

LIST OF FIGURES
FIGURE 1: POLYMERIZATION REACTION .................................................................................................... 2 FIGURE 2: ETHYLENE STORAGE VESSELS AND COMBINED COMPRESSOR ........................................................... 8 FIGURE 3: HYPER COMPRESSOR ............................................................................................................ 10 FIGURE 4: FINAL STAGE COOLERS .......................................................................................................... 11 FIGURE 5: REACTOR ........................................................................................................................... 12 FIGURE 6: GAS SEPARATORS AND EXTRUDER ........................................................................................... 15

LIST OF TABLES
TABLE 1:READINGS OF COMBINED COMPRESSOR ..................................................................................... 19 TABLE 2: READINGS OF HYPER COMPRESSOR ........................................................................................... 19 TABLE 3: COMBINED COMPRESSOR MOLLIERE CHART VALUES ..................................................................... 22 TABLE 4: HYPER COMPRESSOR MOLLIERE CHART VALUES ........................................................................... 22 TABLE 5: RESULTS OF EFFICIENCY CALCULATIONS ...................................................................................... 23 TABLE 6: TEMPERATURE READINGS FOR K02 COOLERS .............................................................................. 24 TABLE 7: TEMPERATURE READINGS FOR K03 INTERSTAGE COOLERS.............................................................. 24 TABLE 8: TEMPERATURE READINGS FOR FINAL STAGE COOLERS .................................................................... 25 TABLE 9: HEAT LOAD CALCULATIONS FOR K02 COOLERS ............................................................................ 26 TABLE 10: HEAT LOAD CALCULATIONS FOR K03 INTERSTAGE COOLERS .......................................................... 27 TABLE 11: HEAT LOAD CALCULATIONS FOR FINAL STAGE COOLERS ................................................................ 28

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AIM

The Aim of this project was to study the workings of the LDPE plant, focusing on the Booster (K02) and Hyper (K03) compressors in the process, and mass/energy calculations across these two units of equipment. This project had three objectives. 1. Mass and Energy balance calculations across the K02 and K03 compressors. 2. Efficiency calculations for the K02 and K03 compressors. 3. The calculation of heat load across the inter stage and final coolers for both K02 and K03 compressors.

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INTRODUCTION
LDPE Plant The LDPE production plant at -- is designed for producing 1,10,000 tons per annum of low density polyethylene and it is built under license from -- . This plant is responsible for a daily production of around 13 tons per hour of low density polyethylene. Low density polyethylene is a polymer generated from the monomer of ethylene, subject to specified settings of temperature, pressure etc. to enhance the branching in the polymer generated and produce specifically 3 different grades of low density polyethylene as the end product from this plant.

Figure 1: Polymerization Reaction

Applications of LDPE The applications of the pellets produced in this plant are not the final product as sold in the market; they are further to be manufactured to produce various applications of food packaging and plastic bags. The secondary products fashioned from LDPE include: 1. 2. 3. 4. Heavy duty bags Carrier bags Milk sachets Juice and milk cartons is made of liquid packaging board, a laminate of paperboard and LDPE (as the water-proof inner and outer layer), and often with of a layer of aluminum foil
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5. 6. 7.

Shrink film for wrapping Covers for outdoor storage of grains or silage Food and pharmaceutical packaging

Grades of LDPE Generated The different grades produced by this plant vary in mainly 3 different polymer properties with each other, namely: Melt flow Index, Density and the Molecular weight distribution. The melt flow index can be described as the number of grams of the polymer resin which can be forced through 2.095 mm orifice when subjected to a 2.16 kg load in 10 minutes at a temperature of 190 degrees Celsius. Density is the ratio of mass per occupied volume and the molecular weight distribution gives the general picture of the degree to which polymerization has taken place to produce long chains. Based on the density criteria, the value for LDPE ranges from 0.916 to .930 g/cc; other types of polyethylene exhibit higher than 0.930gm/cc densities. Grade Nomenclature The different grades produced are denoted separately with separate codes. This code or name comprises of an eight numbered alphanumeric name.
1

070

17

Complex Number Melt Flow Index 070: 0.70 g/10 min Application F: Film L: Lamination

2 and 3 decimals of Density (0.917) Additive System: A: No additive Y: Slip

nd

rd

According to naming convention as briefed above, the LDPE plant produces 3 variants: 1005FY20, 1070LA17 and 1020FA20. It should be noted that this plant generates one grade of polymer one at a time and not simultaneously. The grade to be produced is decided based on
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the market demand, and generally in one month of production, around 3 grade changes occur. Changes in grade, signify different running conditions required in sections of the plant such as maintained temperature and pressure levels, although the basic feed of ethylene remains the same. It should be noted that two of these are of the film grade; they are cheaper to produce and sold at a lesser price in the market. Subsequently, the other one is of the lamination grade that is likewise costlier to produce and in return fetches a higher price in the market. S.No. 1. 2. 3. Sections of LDPE For understanding the running of the plant, its separate sections can be understood to give a clearer picture of how it functions. Generally, LDPE plant covers 7 sections with each having its own duty and function. The Utilities section takes care of monitoring all the utilities required in running the plant, and is in charge of the Catalyst preparation also. Under the polymerization section come the reactor, the catalyst injection, and the gas and wax separators. In the Extrusion section, the activities of the extruder, and the drying and conveying of pellets to the silos is monitored. The Compressor section houses the different ethylene vessels and Grade 1005FY20 (Film grade) 1070LA17 (Lamination grade) 1020FA20 (Film grade) MFI 0.5g/10min 7.0g/10min 2.0g/10min

compressors (tail gas, booster, primary and hyper), that are responsible for the compression of the gas before entering the reactor. The Bunker section houses and stores the catalysts CA, C1, C2 and C5 and the Bagging section is responsible for packaging the pellets into the final packed products.

Polymerization Polymerization of ethylene into LDPE is a highly pressured addition polymerization reaction. Firstly, it should be known that addition polymerization takes place in three steps, namely:
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initiation, propagation and termination. In the first step, external catalysts are used, that decompose into initiators that react with inactive monomer molecules to transfer the activated site onto them. This activated site could either be a free radical, a cation or an anion. In our case, free radical initiation is followed. In the propagation step, this activated molecule keeps adding monomers, and other molecules found in the immediate vicinity and causes in the growth of the resulting polymer chain. Lastly, this process ends with the termination step that occurs when the active site in the macromolecule chain is destroyed and suspends it from further reaction or chain growth. Specifics of the Polymerization Process in the Plant The above stated polymerization reaction takes place in an autoclave reactor in this plant. It is designed to specifically withstand very high pressures and moderately high temperatures, and is divided into 5 separate but interconnected chambers called zones, through which five separate points of input of initial feed is possible. Most of the volume inside this autoclave reactor is taken up by the powered stirrer, which ensures optimal mixing in the reactor within each zone to resemble a continuously stirred mixed flow reactor to a certain degree. With all the specifications of temperature and pressure in consideration, the conversion into polymer comes to a value of around 18% in this reactor. In addition, the catalyst initiators that are necessary as mentioned above come in 4 different chemical species: S.No. 1. 2. 3. 4. Name CA C1 C2 C5 Species Di-tertiary-butyl peroxide tertiary-butyl-peroxybenzoate tertiary-butyl-peroxy-2-ethylhexanoate tert-butyl peroxypivalate

Different combinations of these in specific concentrations as per the design conditions are injected at the 5 separate entry points to the reactor in pressurized conditions.

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Process Summarized Description Fresh ethylene makes its way into our plant from GC and is fed to the V03 ethylene vessel at around 70 bars. The flow rate of ethylene may vary a little from one day of production to another but is tried to be maintained at a range kept around 12-13 tons per hour. This fresh flow rate joins the recycled ethylene, flowing at a rate of 7-8 tons per hour and together enters the primary compressor at a flow rate of 20tonnes per hour. Across the primary compressor the gas is compressed and the pressure of flow is increased to 250 bars in two stages. After the gas exits the primary compressor, it is joined by the recycle gas that comes from the medium pressure separator at the same pressure of 250 bars. The flow of this combined stream becomes 70 tons per hour and goes into the hyper compressor after being divided into 4 streams to be fed into the 4 separate cylinders in the first stage of the hyper compressor. In the hyper compressor the ethylene gas is compressed to the final pressure of 1300-1500 bars (specific for each grade) in two stages. After exiting each stage the flow streams go through coolers to bring down the increased temperature of the gas to enable the compressing in the next stage, or to maintain the temperatures of streams before reaching the reactor vessel. After the streams of gas have exited the second stage of the hyper compressor, they are separated into 5 streams, and each of these streams goes through a train of heat exchangers. These five streams are cooled to specific temperatures and enter the reaction vessel at 5 strategic points in the reactor vessel, characterized by each zone. Along with the ethylene gas feed, at the input point, each stream is injected with pressurized catalyst specific for that stream. After the polymerization process that takes place in the reactor, the exit stream enters the medium pressure separator (V12). At this point, the temperature of the feed is approximately around 270-280 degrees Celsius and at a pressure of 250 bars. There is a letdown valve at the bottom of the reactor vessel, and across it flashing of the stream occurs. Due to this flashing, the expanded, unreacted gas escapes the polymer mass and escapes through the top of the separator vessel and is led through various exchangers and filters to filter out residual wax and then fed to the mainstream at the suction side of the hyper compressor. The polymer at the bottom of V12 is exited through and flashed across to the low pressure separator (V14) at a pressure of 15 bars. Again, the left over unreacted gas in the
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polymer mass expands, and escapes through the top to be recycled and fed into the mainstream process into the V02 ethylene gas holding vessel. From the V02 holding vessel it is fed into the Booster compressor to raise the pressure of the recycled stream to 68-70 bars. The polymer that exits the low pressure separator is then again flashed to the next vessel called the extrusion hopper. Gas separation from the polymer mass takes place in this also and the recycled gas is returned back to the starting of this process, it is called tail gas. It is taken to V01 (pressure: 0.4-0.5), and from there compressed in the tail gas compressor to 15 bars. This further joins the recycle gas from the low pressure gas separator and with it enters into the booster compressor. The polymer that is left at the bottom of the extrusion hopper is directly fed into the extruder, and turned into consistent melt as it is screwed through the body of the extruder. It is pushed through the die into a water tank and cut into small pellets by the rotating cutter. The fluidized pellets are transported to the dryer with the help of an external motor P15, and the cyclone separator setup in the dryer, dries the excess water off the pellets and them into the conveying section of the plant. Here, the pellets through a number of dusters etc. are transported to the silos for storage. There are three types of silos. The control silos, the storage silos and the off grade silos. Pellets are routinely kept in a control silo for an hours time, so that a sample of it can be taken to the lab, and tested for the required quality. From the control silos it is then transported to the other storage silos. From these silos, it is driven to the bagging section of the plant, where the pellets are packed in measured sacks of 25 kgs as the finished product, and transferred to the logistics department of the site.

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DETAILED DESCRIPTIONS
Ethylene Storage Vessels: V01, V02, V03 As can be seen clearly below in the diagram, these vessels hold the ethylene that comes fresh from the GC plant along with the recycled ethylene gas that remains unreacted at the end of the process. V01: It holds the largest volume and holds the least pressured gas i.e. the recycled gas separated from the extrusion hopper (V15). The discharge from this vessel is fed to the suction side of the tail gas compressor (K01). V02: It takes the gas from the discharge of K01 and takes in the recycled gas from the LP separator (V14) in its volume. The discharge from this vessel is fed to the suction side of the Booster compressor. V03: It holds the least capacity and most flow rate hence in effect explaining the high pressure withstood. The discharge from the booster compressor and the fresh ethylene from GC plant is held in it and fed to the primary compressor.

Figure 2: Ethylene storage vessels and Combined Compressor

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Tail Gas Compressor (K01) The recycled gas collected in V01 is compressed from 0.5 bars to 15 bars in 3 stages. It is a reciprocating compressor with 3 stages of 0.5 to 2.8 bars, 2.8 to 7.5 bars and lastly from 7.5 to 15 bars. Practically, as a gas is compressed, the temperature increases, and hence limits the gas compressibility with increased temperature. In order to optimize the compression work, the gas is cooled before it goes to the next stage in the compressor. For this purpose inter-stage coolers are used. After stages one and two in K01, shell and tube type exchangers E02 and E03 are used. After the gas exits K01, a final stage cooler (STHE) of E04 is used.

Combined Compressor (K02) The combined compressor combines the booster compressor and the primary compressor together by both being driven by the same motor MK 02. They are both reciprocating compressors. The booster compressor compresses the feed from the V02 vessel. It incorporates two stages of 15 to 30, and from 30 to 70 bars. Inter-stage cooler used is E08 (STHE) and final stage cooler of E09 (STHE). From discharge of E09, it makes its way to V03 to join the fresh ethylene input. The primary compressor working on the same shaft of the MK02 motor compresses the gas from 70 to 250 bars in two stages: 70-95 and 95-250, using the reciprocating compressing mechanism. The inter- and final stage coolers used for this compressor include the shell and tube type exchangers E12, E13 and E14.

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Hyper Compressor (K03)

Figure 3: Hyper Compressor

The hyper-compressor performs its compression of 250 to 1500 bars in two stages. Each stage comprises of 4 cylinders, through which where the gas stream is divided equally. In all, the hyper compressor consists of 8 cylinder pistons attached to one shaft which is powered by one motor, namely MK 03. Stage one compress the gas stream from 250 to 940-50 bars. The discharge from each cylinder of Stage one is divided into three streams by a bifurcation block (W06/1/2/3/4) and each of these divided streams goes through 2 double pipe heat exchangers (one from the E15 series and one from the E16 series) for the inter stage cooling. Hence, the four cylinders of stage one, give rise to 12 individual streams, and there are 12 heat exchangers in each of the E15 and the E16 series, 24 in total. The 12 streams come together to make 4 streams again and enter the Stage two where compression from 940-950 to 1500 bars.

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Final Stage Coolers

Figure 4: Final Stage Coolers

The four discharge streams from the Stage two of K03, come together in the bifurcation block of W08 and are then divided into six streams. These consist of the five streams that lead to the final stage coolers and one recycle stream. Normally, under running condition the recycle stream doesnt hold any substantial gas flow, so it can be ignored for mass balance calculations. Each of the five streams branching from W08 is to enter the reactor at different points in different zones; hence they all need to be cooled to different temperatures that are specified by the design calculations. Except for the stream that enters the reactor from the top, for stirrer motor cooling, all other streams again are cooled using a series arrangement of two double pipe heat exchangers one from each the E18 and E19 series. Depending on the grade of the polymer that is being produced, the temperature of these various streams is adjusted by using
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chilled water (WCH)/DM-water (WDM) or hot water (WH) in DPHEs. If WCH is being used, the exchangers are said to be functioning in the cooling mode and if WH is being used, the exchangers are said to be in the heating mode.

Reactor

Figure 5: Reactor

It is an autoclave type reactor which consists of a normal vessel which is divided into 5 separate zones. The reactor also consists of a motorized stirrer, which supports optimizing the conversion obtained from the quasi-continuously stirred mixed flow type reactor that it is. The feed includes streams of ethylene that are injected with catalysts and are inputted to the reactor in the first four zones from top; the last zone at the bottom is not fed with any ethylene; however, catalyst alone is injected into it. Also, the hottest stream from the final stage coolers is not injected with any catalyst and is fed from the very top of the reactor vessel to cool the stirrer motor mounted at the top of the stirrer. Each zone is fed gas streams maintained at different specific temperatures and injected with different cocktails of the catalysts, each specified in the design instructions of the plant. These specifications cater to the
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need to produce low density polyethylene with the precise properties of the polymer required to be manufactured. Specifics that should be noted about the reactor: The reactor maintains its operation in spite of the immense pressure of around 1300-1500 bars (depending from grade to grade) it withstands due to the pressurized feed inputs. Due to the exothermic nature of the polymerization reaction, the temperatures in each zone escalate also ranging from 180 to 285 degrees Celsius. In such extreme conditions of pressure and temperature involving hydrocarbon gases, there is constant threat of the process disintegrating to uncontrollable run away reactions such as:

( (

) )

These reactions are explosive in nature and can lead to tremendously dangerous situations like bursting of the reactor vessel; consequently, many safety systems are in place to avoid this, or worst case scenario, relieve the pressure using the pyrotechnic safety system if such a reaction does take place. The letdown valve: One of the main features of the reactor is the letdown valve that is placed at the bottom of the reactor. Through this valve the polymer slurry discharges out and enters the MP separator. It is of importance to note that this is responsible for controlling all the pressures of the gas streams leading from the final discharge of the hyper compressor. After the discharge, other than the letdown valve, only 5 UDHE isolation valves are present after exiting the final stage coolers. The purpose of the UDHE valves is to stop the ethylene feed from reaching the reactor in the case of tripping of the plant. They dont contribute to the controlling the streams in running condition; this being left to the sole letdown valve in the reactor bottom. Also, across the letdown valve, the flashing of the product slurry in the medium pressure separator occurs.
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The pyrotechnic safety system: This safety system reacts when the pressure inside the reactor has exceeded well above a safe limit. It relieves the vessel of all its contents by expelling them through the stacks that are connected to the body of the reactor. The stacks contain Rupture Discs (RDs) that otherwise block the entry of the contents in the reactor to the stacks. However, in high pressure conditions, these discs are the first to burst, and provide an alternative exit to the explosive nature of the contents of the reactor. Hence it prevents hazards from bursting of the reactor vessel in an uncontrolled manner. The stacks are maintained under 10-mbar nitrogen pressure and balloons are placed in each stack to hold the pressure. A water tank is placed between these two stacks (externally). It is also maintained under nitrogen pressure. The outlets of this tank are discharged through a nozzle, which is used for spraying water inside the stacks. When the RD bursts (at 1700 bar) due to excess pressure inside the reactor, the water from the tank is ejected outwards towards the nozzles inside the reactor. Due to this action the high pressure ethylene gas ejected out of the stacks gets cooled down and reduces the likelihood of fires/flares due to minor sparks, once discharged into the atmosphere. This way, not only does the gas gets cooled, but it also gets diluted with the steam generated due to contact of water with the high temperature gas.

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MP/ LP Separator/Extrusion Hopper (V12/V14/V15)

Figure 6: Gas separators and Extruder

The conversion obtained in the reactor is just around 20%, so a large amount of the discharge from the reactor still includes unreacted ethylene gas that must be separated and recycled back. The molten waxy product LDPE from the reactor plus the unreacted gas comes to the MP separator V 12 which is operating under 250 bars of pressure. This vessel is also provided with the pyrotechnic safety system as described in the previous section. The product drains out from the bottom of the tank whereas the unreacted gas flows out from the top of the vessel. The product still contains some unreacted gas that is recovered in the LP separator V 14. The last traces of the gas are recovered as Tail Gas in the extrusion hopper V 15. The product goes to the extruder from where the pellets are pneumatically conveyed to drying section and then to the storage silos. In each of these three separation vessels a technique of radioactive decay of Cesium- 137 is used to measure the height of polymer level at the bottom of the vessel.

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Extruder Basically extrusion is the process by which a material is forced to flow in continuous manner due to the motion of an internal screw through the length of the vessel. It is then forced into a forming die shaped particularly for the polymer melt to be finally cast into. Hence in this piece of equipment, the LDPE polymer separated from ethylene gas (by 3 gas separators) is softened by heat and injected with additives to a melt of uniform consistency. This melt is then drawn through a die and immediately cut as it passes through the die into a water tank. The purpose of the tank is to cool the melt and cast it into the pellet form by hardening due to temperature drop in the water. These pellets are carried out so that it can be readily conveyed and formed without destroying the desirable final properties of the material to the bagging section where the final packaging details of the product are carried out.

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CALCULATIONS
The first objective was to study the compression process that was taking place in the K02 and the K03 compressors. The compressors are of the reciprocating type. Assumption: In the reciprocating compressor, the compression process that is followed is a POLYTROPIC PROCESS, which means the gas in the compressor would follow the following equation in the compressor:

Assumption: Equation of state of the gas in such extreme temperatures and pressures will surely deviate from the ideal gas law; hence compressibility factor must be accounted for:

To find the polytropic coefficient (n), however the compressibility factor is not considered: ( )

( ( )

) ( )

( ) ( ( ( ) ) )

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( ( )

) ( )

The work done by polytropic compression: (( ) )

The real work done observed: ( ) ( )

Hence the value of efficiency, , is given by:

For the next objective, the heat load calculations were done based on the amount of heat gained/ lost from the main stream of ethylene across the inter-stage and final coolers that were used. ( )

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PART- 1 Efficiency Calculations Readings taken: Combined Compressor K02 Pressure(bars) Suction BOOSTER stage I stage II stage I PRIMARY stage II 14.51 30.4 61.3 94.7 Discharge 30.4 64.7 94.7 259.2 Temperature(C) Suction 30.4 35.4 24.1 35.7 Discharge 89.7 92.8 56.3 83.4

Table 1: Readings of Combined Compressor

Hyper Compressor K03 Pressure(bars) Suction 1A1 STAGE 1 1B1 1A2 1B2 2A1 STAGE 2 2B1 2A2 2B2 249 249 247 247 932 956 936 933 Discharge 955 955 960 960 1552 1552 1552 1552 Temperature(C) Suction 31.7 31.7 31.5 31.5 35.2 38.5 35 35.4 Discharge 81.2 80.8 81.2 81.2 59.2 63.1 54 54.8

Table 2: Readings of Hyper compressor

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Sample Calculations: Taking the readings for cylinder 1A1, in the first stage of K03 Step one, value of Z needed for both suction and discharge side To find value of Z,

Corresponding to values of P and T, readings for specific Volume (V) and Enthalpy (H) are taken from the Mollier Chart of Ethylene. ( ( ) ) ( ) ( )

Step two, after value of Z has been found, the values of n are found: ( ( ( ) ) ( ))

Step three, to calculate the polytropic work:

((

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From the values of Hsuction and Hdischarge taken from the Mollier chart, Wobs can be found:

Efficiency then is got by,

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Values read from the Mollier chart: Pressure (kg/cm) Psuc BOOSTER 15.820 32.028 63.546 97.614 Pdis 32.028 67.014 97.614 265.40 Tsuc 30.4 35.4 24.1 35.7 Temperature (C) Tdis 89.7 92.8 56.3 83.4 Vsuc 0.056 0.024 0.0065 0.0035 Specific Volume (m/kg) Vdis 0.031 0.013 0.005 0.003 Hsuc 159 154 120 104 Enthalpy (kcal/kg) Hdis 182 170 126 124

K02

Compressor

Combined

Table 3: Combined Compressor Mollier chart values

PRIMARY

Pressure

Temperature (C) Tsuc 31.7 31.7 31.5 31.5 35.2 38.5 35 35.4 Tdis 81.2 80.8 81.2 81.2 59.2 63.1 54 54.8

Specific Volume (m/kg) Vsuc 0.00245 0.00245 0.00245 0.00245 0.00195 0.00194 0.00195 0.00195 Vdis 0.00208 0.00208 0.00204 0.00204 0.00186 0.001865 0.00185 0.00185

Enthalpy (kcal/kg) Hsuc 87 87 87 87 102 104 102 102 Hdis 129 129 130 130 134 135 130 131

K03
Psuc

(kg/cm) Pdis 975.12 975.12 980.22 980.22 1584.06 1584.06 1584.06 1584.06

255 Hyper Compressor STAGE I 255 252.96 252.96 951.66 STAGE II 976.14 955.74 952.68

Table 4: Hyper Compressor Mollier chart values

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Using these values of V and H, continuing with the calculations leading to final results: Pressure(bars) Temperature(C) P1 P2 31 66 96 260 956 956 961 961 1553 1553 1553 1553 T1 30.4 35.4 24.1 35.7 31.7 31.7 31.5 31.5 35.2 38.5 35 35.4 T2 89.7 92.8 56.3 83.4 81.2 80.8 81.2 81.2 59.2 63.1 54 54.8 Z1 0.9641 0.8230 0.4590 0.3654 0.6770 0.6770 0.6720 0.6720 1.9881 2.0073 1.9979 1.9889 n 1.339 1.301 1.315 1.168 1.126 1.125 1.126 1.126 1.173 1.186 1.134 1.136 Work(J/mol) Wobs 2694 1874 703 2343 4920 4920 5038 5038 3749 3632 3280 3397 Wpoly 1878 1699 513 1009 2482 2481 2488 2488 2695 2615 2664 2674 69.70 90.63 72.93 43.06 50.45 50.42 49.39 49.39 71.90 72.00 81.21 78.70 Efficiency

Combined Compressor
Result:

16 31 62 96 250 250 248 248 933 957 937 934

Table 5: Results of efficiency calculations

Following the calculations done based on the previously shown tables, it is calculated that the average efficiency noted in the combined compressor comes out to be 69% and the efficiency of the hyper compressor comes out to be approximately 63%.

Hyper Compressor

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PART 2 Heat load Calculations Readings taken: Combined Compressor Inlet(C) E08 E09 E10 E12 E13 E14 89.6 92.8 92.8 56 83.7 44 Outlet(C) 35.2 39.6 30.5 35 43 29

Table 6: Temperature readings for K02 coolers

Hyper Compressor INTERSTAGE COOLERS E15 1 2 3 4 5 6 7 8 9 10 11 12 Inlet(C) 78 82 80 78 82 81 79 78 80 80 80 82 Outlet(C) 63 63 62 63 62 62 65 66 67 65 64 63 E16 1 2 3 4 5 6 7 8 9 10 11 12 Inlet(C) 63 63 62 63 62 62 65 66 67 65 64 63 Outlet(C) 34 35 35 33 35 34 37 36 39 36 35 35

Table 7: Temperature readings for K03 interstage coolers

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FINAL STAGE COOLERS E18 1 2 3 4 5 6 7 8 9 10 Inlet(C) 63 63 59 60 63 65 64 60 59 58 Outlet(C) 70 70 54 54 53 53 48 48 47 47

Table 8: Temperature readings for final stage coolers

E19 3 4 5 6 7 8 9 10

Inlet(C) 54 54 53 53 48 48 47 47

Outlet(C) 55 52 31 34 26.4 25.5 27 25

Sample Calculations: Taking the heat load across E08 Step one, value for CP is determined at inlet and outlet conditions using the Aspen property analysis program CP at inlet: 1967 J/kgK CP at outlet: 1955 J/kgK
( )

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Heat load for inter and final stage coolers of the Combined Compressor: Temperature Inlet(C) Outlet(C) Inlet(J/kgK) E08 E09 E12 E13 E14 89.6 92.8 56 83.7 44 35.2 39.6 35 43 29 1967 2341 3952 2922 2806 Cp Outlet(J/kgK) 1955 3651 5001 2801 2724 Flow rate Heat load M (tph) 7 7 20 20 20 H(kJ/hr) 746748.8 1115710.4 1880130 2329261 829500

Table 9: Heat load calculations for K02 coolers

Heat load for inter stage coolers of the Hyper compressor: E 15 Exchanger No. 1 2 3 4 5 6 7 8 9 10 11 12 Temperature Inlet(C) Outlet(C) 78 82 80 78 82 81 79 78 80 80 80 82 63 63 62 63 62 62 65 66 67 65 64 63 Inlet(J/kgK) 2359 2371 2365 2359 2371 2368 2362 2359 2365 2365 2365 2371 Cp Outlet(J/kgK) 2312 2312 2308 2312 2308 2308 2317 2320 2324 2317 2314 2312 Flow rate Heat load M (tph) 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 H(kJ/hr) 204356 259516 245333 204356 272942 259128 191059 163765 177791 204838 218353 259516

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E 16 Exchanger No. 1 2 3 4 5 6 7 8 9 10 11 12

Temperature Inlet(C) Outlet(C) 63 63 62 63 62 62 65 66 67 65 64 63 34 35 35 33 35 34 37 36 39 36 35 35 Inlet(J/kgK) 2312 2312 2308 2312 2308 2308 2317 2320 2324 2317 2314 2312

Cp Outlet(J/kgK) 2220 2224 2224 2217 2224 2220 2230 2227 2236 2227 2224 2224

Flow rate Heat load M (tph) 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 5.833 H(kJ/hr) 383332 370440 356895 396288 356895 369787 371338 397863 372400 384347 383839 370440

Table 10: Heat load calculations for K03 interstage coolers

Heat load for final stage coolers of the Hyper compressor: E18 Exchanger No. 1 2 3 4 5 6 7 8 9 10 Temperature Inlet(C) Outlet(C) 63 63 59 60 63 65 64 60 59 58 70 70 54 54 53 53 48 48 47 47 Inlet(J/kgK) 2223 2223 2211 2214 2223 2230 2226 2214 2211 2208 Cp Outlet(J/kgK) 2245 2245 2196 2196 2193 2193 2177 2177 2174 2174 Flow Rate Heat load M(tph) 7 7 7 7 7 7 7 7 7 7 H(kJ/hr) -109466 -109466 77123 92610 154560 185766 246568 184422 184170 168707
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E19 Exchanger No. 3 4 5 6 7 8 9 10 Result:

Temperature Inlet(C) Outlet(C) 54 54 53 53 48 48 47 47 55 52 31 34 26.4 25.5 27 25

Cp Inlet(J/kgK) 2196 2196 2193 2193 2177 2177 2174 2174 Outlet(J/kgK) 2199 2190 2126 2135 2112 2110 2114 2108

Flow Rate Heat load M(tph) 7 7 7 7 7 7 7 7 H(kJ/hr) -15383 30702 332563 287812 324248 337601 300160 329714

Table 11: Heat load calculations for final stage coolers

As required by objective, the heat loads across all heat exchangers has thus been calculated. In conclusion, Interstage coolers for K02: Final stage coolers for K02: Interstage coolers for K03: Final stage coolers for K03:

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