Cells for Input Cells for Auto calcs

Natural Gas Composition (mol%) Methane Ethane Propane Butane Nitrogen Carbondiox
ide Total Pressure Temperature Basis Desired Production Rate Stream Factor Opera
ting hours Max. Hydrocarbon conc. in Steam reformer outlet gas Steam to hydrocar
bon ratio in Primary Reformer
92 2 2 1 2 1 100 900 120 100 3000 345 8280 0.50% 3

ells for Input ells for Auto calcs

psig F lbmol/hr of Natural Gas Feed Tonnes/day days hours

Primary Reformer
Temperature Pressure Pressure Drop HC to Steam Ratio 727 C 900 psig 10 psig 3 Natu
ral Gas Steam 1
2
Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5
Reactions in Primary Reformer CH4 + H2O = CO + 3H2 C2H6 + 2H2O = 2CO + 5H2 C3H8
+ 3H2O = 3CO + 7H2 C4H10 + 4H2O = 4CO + 9H2 CO+H2O = CO2 + H2
75% 100% 100% 100% 40%
Stream 1 (Natural Gas) Components Mol. Wt 16 30 44 58 28 44 28 2 32 18 Mol% 92 2
2 1 2 1 100 7016 Mole Flow (mol/hr) 92 2 2 1 2 1 100 lb/hr Mass Flow (lb/hr) 14
72 60 88 58 56 44 1778
Methane Ethane Propane Butane Nitrogen Carbon dioxide Carbon monoxide Hydrogen O
xygen Steam
Total Total Primary Reformer Inlet CO Production Reaction 1 Reaction 2 Reaction
3 Reaction 4 Total CO Consume
69 lbmol/hr 4 lbmol/hr 6 lbmol/hr 4 lbmol/hr 83 lbmol/hr

Reaction 5 CO2 Produced Reaction 5 H2 Produced Reaction 1 Reaction 2 Reaction 3

Reaction 4 Reaction 5 Total Steam consumption Reaction 1 Reaction 2 Reaction 3 R
eaction 4 Reaction 5 Total
33.2 lbmol/hr
33.2 lbmol/hr
207 lbmol/hr 10 lbmol/hr 14 lbmol/hr 9 lbmol/hr 33.2 lbmol/hr 273.2 lbmol/hr
69 lbmol/hr 4 lbmol/hr 6 lbmol/hr 4 lbmol/hr 33.2 lbmol/hr 116.2 lbmol/hr

Secondary Reformer
Exit Temperature Pressure Pressure Drop Primary Reformer 4 based on CH4 based on
C2H6 based on C3H8 based on C4H10 based on CO 3 Secondary Reformer Air 5 1000 8
90 10
Reaction 1 Reaction 2 Reaction 3 Reaction 4
Reactions in Secondary Reform CH4 + H2O = CO + 3H2 CH4 + 2O2 = CO2 + 2H2O 2CO +
O2 = 2CO2 CH4 + 2CO + 3O2 = 3CO2 + 2H2
Stream 2 (Steam) Mol% 100 100 Mole Flow (mol/hr) 291 291 Mass Flow (lb/hr) 5238
5238 Mol% 4.13 0.00 0.00 0.00 0.36 6.14 8.94 49.05 31.38 100
Stream 3 Mole Flow (mol/hr) 23.00 0.00 0.00 0.00 2.00 34.20 49.80 273.20 174.8 5
57
Total Secondary Reformer Inlet Nitrogen in Total air O2 with Air CH4 Consumption
Reaction 4 Reaction 1 113.83 144.09 30.26
10.09 10.98

CO Production Reaction 1 CO Consumption Reaction 4 CO2 Production Reaction 4 H2

production Reaction 1
10.98
20.17
30.26
32.93
Steam Consumption Reaction 1 Steam Production Reaction 4
10.98
20.17

C psig psig
Reactions in Secondary Reformer CH4 + H2O = CO + 3H2 CH4 + 2O2 = CO2 + 2H2O 2CO
+ O2 = 2CO2 CH4 + 2CO + 3O2 = 3CO2 + 2H2O
85% based on remaining CH4 after Reaction 4
100% based on O2
eam 3 Mass Flow (lb/hr) 368.00 0.00 0.00 0.00 56.00 1504.80 1394.40 546.40 3146.
4 7016 Mol% 79 21 100
Stream 4 (Air) Mole Flow (mol/hr) 113.83 30.26 144.09 Mass Flow (lb/hr) 3187.33
968.30 4155.64 Mol% 0.27 16.25 9.04 5.70 42.94 0.00 25.81 100
Stream 5
11171.64 lb/hr lbmol/hr lbmol/hr lbmol/hr
lbmol/hr lbmol/hr

lbmol/hr
lbmol/hr
lbmol/hr
lbmol/hr
lbmol/hr
lbmol/hr

after Reaction 4
Stream 5 Mole Flow (mol/hr) 1.94 115.83 64.46 40.60 306.13 0.00 184.00 712.96 Ma
ss Flow (lb/hr) 30.99 3243.33 2836.22 1136.90 612.26 0.00 3311.94 11171.64

High Temperature Shift Converter

Temperature Pressure Pressure Drop 400 C 880 psig 10 psig
SR outlet stream 5 Reactions in HTS CO+H2O = CO2 + H2
Reaction 1
80%
Stream 5 (SR outlet) Components Mol. Wt 16 28 44 28 2 18 Mol% 0.27 16.25 9.04 5.
70 42.94 25.81 100 Mole Flow (mol/hr) 1.94 115.83 64.46 40.60 306.13 184.00 713.
0 Mass Flow (lb/hr) 30.99 3243.33 2836.22 1136.90 612.26 3311.94 11171.6
Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Steam
Total CO Consume Reaction 1 CO2 Produced Reaction 1 H2 Produced Reaction 1 Steam
Consume Reaction 1
32.48 lbmol/hr 32.48 lbmol/hr 32.48 lbmol/hr 32.48 lbmol/hr

Low Temperature Shift converter

Exit Temperature Pressure Pressure Drop 200 870 10
6 HTS LTS
7
based on CO
Reaction 1
Reactions in LTS CO+H2O = CO2 + H2
Stream 6 (HTS outlet) Mol% 0.27 16.25 13.60 1.14 47.49 21.25 100 Mole Flow (mol/
hr) 1.94 115.83 96.94 8.12 338.61 151.51 712.96 CO Consume Reaction 1 CO2 Produc
ed Reaction 1 H2 Produced Reaction 1 Steam Consume Reaction 1 Mass Flow (lb/hr)
30.99 3243.33 4265.46 227.38 677.22 2727.25 11171.64 Mol% 0.27 16.25 14.51 0.23
48.41 20.34 100
Stream 7 (LTS outlet) Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 145.02 7
12.96
6.50 lbmol/hr 6.50 lbmol/hr 6.50 lbmol/hr 6.50 lbmol/hr

C psig psig
80% based on CO
(LTS outlet) Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 2610.31 11171.
64

Cooler Separator
Temperature Pressure Pressure Drop Assumptions: Water Condensed CO2 Solubility i
n Water 120 C 860 psig 10 psig
LTS outlet stream 8
100% 0% Stream 8 (LTS outlet)
Components
Mol. Wt 16 28 44 28 2 18 Mol% 0.27 16.25 14.51 0.23 48.41 20.34 100
Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Steam
Total
Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 145.02 713.0
Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 2610.31 11171.6
CO2 Removal
Temperature Pressure Pressure Drop Assumptions: Solvent Used Solvent Loading Sol
ution Strength 120 C 850 psig 10 psig Stream from Cooler Separator Lean Solvent K2
CO3 2 lbmol of Acid gas /lbmol of pure solvent 80% by weight Stream 9 (Feed Gas)
Components Mol. Wt 16 28 44 28 2 138 18 Mol% 0.34 20.40 18.21 0.29 60.76 0.00 0
.00 100.00 Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 0.00 0.00 567.9 Mas
s Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 0.00 0.00 8561.3 9 11
Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Potassium Carbonate Wat
er
Total

Total Mass in Total Mass out

17482.93 lb/hr 17482.93 lb/hr

Cooler Condenser 10
9
Stream 9 Mol% 0.34 20.40 18.21 0.29 60.76 0.00 100 Mole Flow (mol/hr) 1.94 115.8
3 103.44 1.62 345.11 0.00 567.94 Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 6
90.22 0.00 8561.33 11171.64
Stream 10 (Condensed Water) Mol% 0.00 0.00 0.00 0.00 0.00 100.00 100 Mole Flow (
mol/hr) 0.00 0.00 0.00 0.00 0.00 145.02 145.02
12 CO2 Removal 13
Treated Gas
Rich Solvent
Stream 11 (Lean Solvent) Mol% 0.00 0.00 0.00 0.00 0.00 34.29 65.71 100.00 Mole F
low (mol/hr) 0.00 0.00 0.00 0.00 0.00 51.72 99.13 150.85 Mass Flow (lb/hr) 0.00
0.00 0.00 0.00 0.00 7137.28 1784.32 8921.60 Mol% 0.42 24.94 0.00 0.35 74.30 0.00
0.00 100
Stream 12 (Treated Gas) Mole Flow (mol/hr) 1.94 115.83 0.00 1.62 345.11 0.00 0.0
0 464.50

ondensed Water) Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 0.00 2610.31 2610.31
(Treated Gas) Mass Flow (lb/hr) 30.99 3243.33 0.00 45.48 690.22 0.00 0 4010.02 M
ol% 0.00 0.00 40.68 0.00 0.00 20.34 38.98 100
Stream 13 (Rich Solvent) Mole Flow (mol/hr) 0.00 0.00 103.44 0.00 0.00 51.72 99.
13 254.29 Mass Flow (lb/hr) 0.00 0.00 4551.31 0.00 0.00 7137.28 1784.32 13472.91

Methanator
Temperature Pressure Pressure Drop 400 C 840 psig 10 psig
From CO2 Removal Unit 12 Reactions in Methanator CO+3H2 = CH4 +H2O Stream 12 (CO
2 Removal outlet) Components Mol. Wt 16 28 28 2 18 Mol% 0.42 24.94 0.35 74.30 0.
00 100 Mole Flow (mol/hr) 1.94 115.83 1.62 345.11 0.00 464.5 Mass Flow (lb/hr) 3
0.99 3243.33 45.48 690.22 0.00 4010.0
Reaction 1
100%
Methane Nitrogen Carbon monoxide Hydrogen Steam
Total CO Consume Reaction 1 H2 Consume Reaction 1 CH4 Produced Reaction 1 Steam
Produced Reaction 1
1.62 lbmol/hr 4.87 lbmol/hr 1.62 lbmol/hr 1.62 lbmol/hr

14 Methanator
Cooler and Separator
16
15 based on CO Stream 14 (Methanator outlet) Mol% 0.77 25.11 0.00 73.76 0.35 100
Mole Flow (mol/hr) 3.56 115.83 0.00 340.24 1.62 461.25 Mass Flow (lb/hr) 56.98
3243.33 0.00 680.47 29.23 4010.02 Mol% 0.77 25.20 0.00 74.02 0.00 100 Stream 16
Mole Flow (mol/hr) 3.56 115.83 0.00 340.24 0.00 459.63

Knock out water

eam 16 Mass Flow (lb/hr) 56.98 3243.33 0.00 680.47 0 3980.78
Stream 15 (Knock out Water) Mol% 0.00 0.00 0.00 0.00 100.00 100 Mole Flow (mol/h
r) 0.00 0.00 0.00 0.00 1.62 1.62 Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 29.23 29.
23

Ammonia Conversion Loop

Temperature Pressure Pressure Drop 400 C 840 psig 10 psig From Methanator 16 React
ions in Ammonia Converter N2+3H2 = 2NH3
21
Reaction 1 Iteration No. 1
75%
Stream 16 (Methanator Outlet) Components Mol. Wt 16 28 2 17 Mol% 0.77 25.20 74.0
2 0.00 100 Mole Flow (mol/hr) 3.56 115.83 340.24 0.00 459.6 Mass Flow (lb/hr) 56
.98 3243.33 680.47 0.00 3980.8
Methane Nitrogen Hydrogen Ammonia
Total H2 Consume Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1 Iterat
ion No. 2
Calculations for Purge stream 20 Rate 255.18 lbmol/hr 85.06 lbmol/hr 170.12 lbmo
l/hr Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flo
w Recycle Stream 21 Flow
Stream 16 (Methanator Outlet) Components Mol. Wt 16 28 2 17 Mol% 0.78 25.20 74.0
2 0.00 100 Mole Flow (mol/hr) 3.58 116.01 340.73 0.00 460.3 Mass Flow (lb/hr) 57
.31 3248.31 681.45 0.00 3987.1
Methane Nitrogen Hydrogen Ammonia
Total H2 Consume Reaction 1
Calculations for Purge stream 20 Rate 255.55 lbmol/hr Feed Stream Flow

N2 Consume Reaction 1 NH3 Produced Reaction 1 Iteration No. 3

85.18 lbmol/hr 170.36 lbmol/hr
Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Fl
ow
Stream 16 (Methanator Outlet) Components Mol. Wt 16 28 2 17 Mol% 0.78 25.20 74.0
2 0.00 100 Mole Flow (mol/hr) 3.59 116.06 340.87 0.00 460.5 Mass Flow (lb/hr) 57
.40 3249.76 681.74 0.00 3988.9
Methane Nitrogen Hydrogen Ammonia
Total H2 Consume Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1 Iterat
ion No. 4
Calculations for Purge stream 20 Rate 255.65 lbmol/hr 85.22 lbmol/hr 170.44 lbmo
l/hr Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flo
w Recycle Stream 21 Flow
Stream 16 (Methanator Outlet) Components Mol. Wt 16 28 2 17 Mol% 0.78 25.20 74.0
2 0.00 100 Mole Flow (mol/hr) 3.59 116.08 340.91 0.00 460.6 Mass Flow (lb/hr) 57
.43 3250.19 681.83 0.00 3989.4
Methane Nitrogen Hydrogen Ammonia
Total H2 Consume Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1
Calculations for Purge stream 20 Rate 255.68 lbmol/hr 85.23 lbmol/hr 170.46 lbmo
l/hr Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flo
w Recycle Stream 21 Flow
Note: This indicates that at the start-up, until the system get stabilized, recy
cle is required after that all the stream sh

Scale up Factor Calculations NH3 production based on 100 lbmol/hr of Natural Gas
Feed Scale up Factor All the stream flow should be multiplied by this factor to
get the desired production rate.

Recycle Stream
20
Ammonia Converter
17
Cooler and Ammonia Separator
18
19 based on H2
Stream 17 (Converter outlet) Mol% 1.23 10.63 29.38 58.76 100 Mole Flow (mol/hr)
3.56 30.77 85.06 170.12 289.51 Mass Flow (lb/hr) 56.98 861.68 170.12 2892.01 398
0.78 Mol% 2.98 25.78 71.24 0.00 100
Stream 18 Mole Flow (mol/hr) 3.56 30.77 85.06 0.00 119.39 Purge Stream 20
stream 20 Rate 459.6 lbmol/hr 0.77 mol% 3 mol% 118.71 lbmol/hr 0.69 lbmol/hr Mol
% 2.98 25.78 71.24 100.00
Methane Nitrogen Hydrogen
Mole Flow (mol/hr) 3.54 30.60 84.57 118.71
Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100 Mole Flow (mol/hr)
3.58 30.83 85.18 170.36 289.96 Mass Flow (lb/hr) 57.31 863.22 170.36 2896.18 398
7.07 Mol% 2.99 25.78 71.23 0.00 100
Stream 18 Mole Flow (mol/hr) 3.58 30.83 85.18 0.00 119.59 Purge Stream 20
stream 20 Rate 460.3 lbmol/hr Mol%
Mole Flow (mol/hr)

0.78 mol% 3 mol% 119.39 lbmol/hr 0.20 lbmol/hr

Methane Nitrogen Hydrogen
2.99 25.78 71.23 100.00
3.58 30.78 85.04 119.39
Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100 Mole Flow (mol/hr)
3.59 30.85 85.22 170.44 290.09 Mass Flow (lb/hr) 57.40 863.67 170.44 2897.41 398
8.91 Mol% 3.00 25.78 71.22 0.00 100
Stream 18 Mole Flow (mol/hr) 3.59 30.85 85.22 0.00 119.65 Purge Stream 20
stream 20 Rate 460.5 lbmol/hr 0.78 mol% 3 mol% 119.59 lbmol/hr 0.06 lbmol/hr Mol
% 3.00 25.78 71.22 100.00
Methane Nitrogen Hydrogen
Mole Flow (mol/hr) 3.59 30.83 85.18 119.59
Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100 Mole Flow (mol/hr)
3.59 30.85 85.23 170.46 290.12 Mass Flow (lb/hr) 57.43 863.80 170.46 2897.76 398
9.45 Mol% 3.00 25.78 71.22 0.00 100
Stream 18 Mole Flow (mol/hr) 3.59 30.85 85.23 0.00 119.67 Purge Stream 20
stream 20 Rate 460.6 lbmol/hr 0.78 mol% 3 mol% 119.65 lbmol/hr 0.02 lbmol/hr Mol
% 3.00 25.78 71.22 100.00
Methane Nitrogen Hydrogen
Mole Flow (mol/hr) 3.59 30.85 85.22 119.65
d after that all the stream should be purged.

2897.76 lb/hr 31.6 Tonnes/day 95.1

he desired production rate.

Purge Stream
Liquid Ammonia
eam 18 Mass Flow (lb/hr) 56.98 861.68 170.12 0 1088.78
Stream 19 (Liquid Ammonia) Mol% 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.0
0 0.00 0.00 170.12 170.12 Recycle Stream 21 Mass Flow (lb/hr) 56.65 856.71 169.1
4 1082.49 Mol% 2.98 25.78 71.24 100.00 Mole Flow (mol/hr) 0.02 0.18 0.49 0.69 Ma
ss Flow (lb/hr) 0.33 4.97 0.98 6.28 Mass Flow (lb/hr) 0.00 0.00 0.00 2892.01 289
2.01
Stream 20
eam 18 Mass Flow (lb/hr) 57.31 863.22 170.36 0 1090.89
Stream 19 (Liquid Ammonia) Mol% 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.0
0 0.00 0.00 170.36 170.36 Recycle Stream 21 Mass Flow (lb/hr) Mol% Mole Flow (mo
l/hr) Mass Flow (lb/hr) Mass Flow (lb/hr) 0.00 0.00 0.00 2896.18 2896.18
Stream 20

57.21 861.76 170.08 1089.04

2.99 25.78 71.23 100.00
0.01 0.05 0.14 0.20
0.10 1.46 0.29 1.84
eam 18 Mass Flow (lb/hr) 57.40 863.67 170.44 0 1091.51
Stream 19 (Liquid Ammonia) Mol% 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.0
0 0.00 0.00 170.44 170.44 Recycle Stream 21 Mass Flow (lb/hr) 57.38 863.24 170.3
5 1090.97 Mol% 3.00 25.78 71.22 100.00 Mole Flow (mol/hr) 0.00 0.02 0.04 0.06 Ma
ss Flow (lb/hr) 0.03 0.42 0.08 0.53 Mass Flow (lb/hr) 0.00 0.00 0.00 2897.41 289
7.41
Stream 20
eam 18 Mass Flow (lb/hr) 57.43 863.80 170.46 0 1091.69
Stream 19 (Liquid Ammonia) Mol% 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.0
0 0.00 0.00 170.46 170.46 Recycle Stream 21 Mass Flow (lb/hr) 57.42 863.68 170.4
3 1091.53 Mol% 3.00 25.78 71.22 100.00 Mole Flow (mol/hr) 0.00 0.00 0.01 0.02 Ma
ss Flow (lb/hr) 0.01 0.12 0.02 0.15 Mass Flow (lb/hr) 0.00 0.00 0.00 2897.76 289
7.76
Stream 20

3980.78
1088.78