ProChem Engineering Consultancy Sdn. Bhd.

Established engineering solutions provider

Design Project Memo 2

Date: 3rd September 2012
To:
Ms. Tan Yin Ling
From: Ko Zhijun (14571480), Mak Yin Yin (14570555), Ooi Wei Jin (14591103), Siew Shang Yee
(14571532) and Sim Yee Fang (14571493)
Re:
Plant Design for Ammonia Synthesis (Second Stage Design)
Executive Summary
The objective of the design project is to produce a plant design for ammonia synthesis with a
capacity of 400 kT/year. In this memo, the Process Flow Diagram (PFD) has been modified to include
cost saving innovations at ammonia loop and condensate stripping. Other than that, a manual mass
and energy balance is done to check the validity of the results from HYSYS simulation, and it is
found out that with exception of few equipment, both results generally agree with each other with a
slight variation. Heat integration is done which resulted in 76% and 62% savings of hot and cold
utilities respectively. The utilities requirements are specified. Besides that, an equipment schedule
for major equipment is also presented. Sizing is conducted to major piping and all equipment.
Furthermore, a preliminary EIA and safety review is done to investigate key issues pertaining
environment and safety and the readiness of the plant to minimise the resultant adverse impacts.
Based on the control objectives, a plant wide control exercise is done to the flow sheet and a Piping
and Instrumentation Diagram (P&ID) is developed. A detailed economic analysis is also carried out.
The plant has capital investment of $309 mil. and operating cost of $159 mil. The net profit is
calculated to be $76 mil., with payback period of 4.04 years. The plant is still profitable under worst
case scenario, which indicates the ability of the proposed plant to handle worst economic downturns.
Process Flow Diagram and Innovations
The PFD has been finalised and available in Appendix A, together with the stream table which is the
results from the process simulation using Aspen HYSYS. Initially, it is required to use a stripper unit
(V-100) to remove the impurities in the condensate water. The condensate water need to be pure as
it is used as feed water for boiler. However, it is found out from the process simulation that a flash
separator is sufficient to achieve the desired purity of condensate water. The replacement results in
utility savings. Other than that, a flash separator is also added to partially remove the ammonia
products from the outlet stream of the first ammonia converter (R-107) before it is reacted in
second ammonia converter (R-108). Higher conversion is resulted, and thus increasing the
production and also reduction in volume of the reactor is achieved.
Manual Mass and Energy Balances
A manual mass and energy balance is carried out to check the results of HYSYS simulation, which is
shown in Appendix B for selected items. Variations have been observed when HYSYS results are
compared with the manual simulation result. This is due to the assumption of isothermal operation
of reactor, whereas in HYSYS, the temperature changes across the reactors which will actually affect
the rate of reaction. For absorber and stripper, large difference exists in the number of tray required
to achieve the same degree of separation, which is caused by the assumption of ideal solutions and
also the existence of variation of the vapour and liquid flow rate at every stage. For energy balances,
the manual calculations agree closely to the results of HYSYS simulation. Generally, the HYSYS results
are legitimate when checked by the manual balance method.
Heat Integration and Utilities Specifications
Heat integration is conducted on the flow sheet to design a network for heat exchange between
streams to save utilities usage. The resulting heat exchange network done by Problem Table
Algorithm can be viewed in Appendix C. It is noted that as the furnace stream has been removed
after the heat integration, some violation of the pinch technology on purpose occurred. Before

performing the heat integration, total hot and cold utilities needed are 726 MW and 9536 MW
respectively. After the targeting, the hot and cold utilities usage are reduced to 180 MW and 3657
MW respectively, showing savings of 76% and 62% of utilities respectively. The utility targeting is
done based on the Grand Composite Curve, and the results of utility selection are shown in
Appendix D. The specification of electrical power requirement is also made based on the total power
needed for the operation of pump, compressor, expander and the mixers agitator from simulation.
Preliminary Equipment Schedule for Major Equipment
Preliminary equipment schedule is prepared in Appendix E for the major equipment, highlighting its
details such as objectives, material of construction, size and operating conditions.
Preliminary Pipe Sizing and Specifications
The size of pipes for major equipment piping is calculated in accordance of standard pipe schedule
size used in United States and is available in Appendix F, to enable easy purchase. For the pipes that
exceeds standard nominal pipe sizing, the flow rate is divided into a few smaller pipes, which will
then be combined by using pipe fittings before entering the required equipment. Piping material is
chosen based on the suitability to the operating conditions. (Peters, Timmerhaus and West 2004).
Preliminary Environmental Impact Assessment (EIA) and Effluent Disposal Strategies
EIA is carried out to study the potential adverse impacts that the proposed project will have to its
surrounding environment, which is around 10 km radius of the proposed plant site. The impact of
the plant to the surrounding receptors such as land, water and people is investigated in Appendix G.
Other than that, mitigation measures have also been outlined as a way to reduce the impact to the
receptors so as to achieve sustainability. The results from EIA can help in integrating the mitigation
measures in the detailed design of the plant so to reduce impacts to the environment. Appendix H
shows the waste disposal methods for three types of waste produced within the plant.
Initial Safety and Hazards Review
A Hazard and Operability (HAZOP) studies is outlined in Appendix I, which is aimed to identify major
hazards involved in selected high risk equipment due to certain process variations. The HAZOP
results gave the necessary information on the elements of the plant that should be controlled in
order to achieve a better process safety. Other than that, key issues regarding start up, shutdown,
cleaning and maintenance of the plant are outlined in Appendix J, which state the necessary steps
that should be taken during the operations of the plant. A hazard analysis on general process
material which is ammonia, carbon dioxide and refrigerants are also provided in Appendix K, which
will give a brief introduction to the level of risk involved in handling the process material. Besides
that, a contingency plan is prepared in Appendix L to address the low possibility high risk scenarios.
Process Control
A plant wide process control configurations is drafted to ensure that the plant operates at its optimal
conditions. Generally, the objectives of process control are as following; (a) To keep the purity of
carbon dioxide and ammonia product above the market purity of 99.5% and 99.3% respectively so
that it could be marketed. (b) Safe operations (c) To ensures the temperature fluctuation is lower
than 10% for reactors to maintain product quality. (d) To achieve complete combustion in the
primary reformer to reduce pollutants release. P&ID containing the final result of the plant wide
control is available in Appendix M. The process control configurations for selected equipment are
available in Appendix N (Luyben et. al. 1999).
Equipment Sizing and Costing
All the equipment is sized for the cost estimation on the later section. The calculated sizes and also
methods are provided in Appendix D and Appendix M.
Economic Analysis and Profitability Analysis
The total capital investment (TCI) (capital investment) is calculated using two methods in Appendix N,
which are Percentage of Delivered Equipment Cost and Lang Factors Approximation of TCI. The total
product cost (TPC) (operating cost) is calculated based on the first method only. To improve the first
method, the costs of equipment items, instrumentation items and land are calculated in detail. The
difference of results of TCI calculations is $22 mil., around 6.7%. By comparison, the calculated TCI

are roughly accurate. It is shown in Appendix O that the net profit of this project is roughly $76 mil.
per year with payback period of 4.04 years which proved the feasibility of the plant to be built. The
following economic assumptions are made in the profitability analysis (a) The salvage value is
estimated to be 9% of the original value of the plant properties (Ngu 2012). (b) An income tax rate of
35% is subjected as the gross profit ($78,683,069.27) for this ammonia plant exceeded $18K. (c) The
mar is estimated to be 8%/year for an ammonia plant with a new capacity due to the fact that it is
established process (Peters, Timmerhaus and West 2004).
Economic Sensitivity Analyses
In the best case scenario, ammonia price has been estimated to have increase of 30% to $0.85/kg
due to the current global price trend of Ammonia which have an increment every year. Ammonia
usage will estimated to increase due to the fertilizer demand based on world population growth rate.
Therefore, our government might take the profitable opportunity through encourage more
investment in Ammonia production by further reducing the local taxes. On the other hand, worst
case scenario has assumed ammonia market price will drop 20% to price of $0.52/kg due the
possibility of more ammonia production plant will be constructed especially in China which creates a
situation of supply higher than demand. Besides that, raw materials, utilities and tax rate might
increase by 20% and 10% each due to the high demand in raw materials and higher energy cost.
Based on the calculation in Appendix O, the plant still exhibits profit in both conditions, at $128 mil.
and $67 mil. respectively as shown in Appendix P.
Conclusions
In conclusion, the second stage of design has been carried out. The heat integration has assisted in
reducing utilities usage. Based on the results of the EIA, it is found out that the plant has only
manageable impacts on the surrounding. From the safety review, necessary mitigation measures
and key issues pertaining to managing process risks has been outlined as well. Process control
configurations suggested based on objectives has found to improve the process operability by
reducing fluctuations in pressure and temperature, while maintaining safety as the top priority.
Economic analysis has shown that the plant is profitable with low payback period, even in worst case
scenario. In the next stage, detailed equipment design will be conducted for major and minor
equipment as highlighted in Appendix Q.
References
Argus Media LTD. 2012. Argus FMB Ammonia Report. Accessed September 1, http://www.a
rgusmedia.com/Fertilizer/~/media/ Files/PDFs/Samples/Argus-FMB-Ammonia.ashx.
Ngu, Ling Ngee.2012. Analysis of Cost Estimation PowerPoint lecture note. http://moodle.curtin.edu.my/mod/
resource/view.php?id=16724.
Peters, Max S., Klaus D. Timmerhaus and Ronald E.West.2004. Plant Design and Economics for Chemical Engineers: Fifth
Edition. New York. Mc-Graw Hill.
James R.Couper, W.Roy Penney, James R.Fair and Stanley M.Walas. 2005. Chemical Process Equipment: Selection and
Design, Second Edition. USA: Elsevier Inc
th
R.K.Sinnot. 2005. Coulson & Richardsons Chemical Engineering: Chemical Engineering Design, Volume 6. 4 ed. India:
Elsevier Inc.
Safe Drinking Water Foundation. Wastewater Treatment. Accessed August 26,
http://www.safewater.org/PDFS/resourcesknowthefacts/WastewaterTreatment.pdf
Waste to Energy Research and Technology Council. 2010. Flue Gas Cleaning. Accessed August 26,
http://www.wtert.eu/default.asp?Menue=12&ShowDok=23
National Water Services Commission. 2012. Water Rates 2012. http://www.span.gov.my/index.php?option=com_content&
view=article&id=529&Itemid=424&lang=en.
P&M Invest. 2011. 1,2-Dichlorohexafluoropropane. Accessed August 30, http://fluorine1.ru/search/detail.php?query=0299.
th
Peters, Max S., Klaus D. Timmerhaus and Ronald E. West. 2004. Plant Design and Economics for Chemical Engineers. 5 ed.
New York: Mc-Graw Hill.
Cooling Water Treatment. n.d. IEC Fabchem Limited. Accessed September 1, http://iecfabchem.in/cwt.htm.
Quzhou DFS Chem Co. n.d. Refrigerant R407C Price. Accessed September 2, http://www.alibaba.com/productgs/582734983/refrigerant_r407c_price_good.html.
Johnston, Lucy, Ezra Hausman, Bruce Biewald, Rachel Wilson and David White. 2011. 2011 Carbon Dioxide Price Forecast.
Synapse Energy Economy Inc. http://www.synapse-energy.com/Downloads/SynapsePaper.2011-02.0.2011Carbon-Paper.A0029.pdf
Luyben, William L., Bjorn D. Tyreus and Michael L. Luyben. Plantwide Process Control. New York: Mc Graw Hill.

Appendix A Process Flow Diagram (PFD)

R-100
R-101
R-102
R-103
R-104
R-105
R-106
R-107
R-108
K-100
K-101
K-102
K-103
K-104
Pre-Reformer Primary Reformer Oxygen Combustion (2nd Reformer) 2nd Reformer High Temp Shift Low Temp Shift Methanator NH3 Converter 1 NH3 Converter 2 Air Compressor Natural Gas Compressor Water Boiler Condensate Flash Top Expander Pre Dryer Compressor
K-105
T-100
T-101
T-102
M-100
M-101
P-100
P-101
V-100
V-101
V-102
V-103
E-100
E-101
E-102
E-103
Syngas Compressor CO2 Absorber Regeneration Stripper Ammonia Storage MEA Mixer Product Mixer MEA Pump Product Pump Condensate Flash CO2 Flash 2nd Product Flash 1st Product Flash Air Heater Natural Gas Heater Water Boiler Primary Reformer Prod. Heater
E-104
E-105
E-106
E-107
E-108
E-109
E-110
E-111
E-112
E-113
E-114
E-115
E-116
Pre 2nd Reformer Heater 2nd Reformer Prod. Cooler HTS Prod. Cooler LTS Prod. Cooler Absorber Feed Heater Stripper Feed Heater CO2 Flash Feed Cooler Stripper Reboiler MEA Cooler Methanator Feed Heater Gas Rec. Heater 2nd NH3 Product Chiller 1st NH3 Converter Feed Cooler
E-117
E-118
E-119
2nd NH3 Converter Feed Heater 1st NH3 Product Chiller Ammonia Converter 1 Feed Cooler

21
11

10
K-100

12

13

14

R-103

15

16

17

18

20

19

AIR
V-100

E-100

NG
FEED

E-104
FLUE

E-101

E-105

E-106

R-102

K-101

E-107

CONDE
-NSATE

R-105

R-104

E-103

CO2

30

E-110

8
H2O

32

28

Purge2

K-102
E-102

R-100

22

MEAREC

25

K103

M100

24

FUEL

R-101

E-108

36

FH_AIR

E-113

E-119

E-109

V-101

23

33
E-118

43
44

R-107

E-116

42

41

27

K-105

40

REC

39

K-104

37

MEA
Purge1

35
E-117

R-108

45

46

P-100

E-112

E-115

26

T-101

T-101

E-111

38

49

V-103

R-106
M101

47

REBOUT

52

E-114
P-101

V-102

53

34

48

Amm
50

GREC

Project A001
51
T-102

Plant Design for Production of

400 kT/year of Ammonia in
Tanjung Langsat Industrial Park,
Johor

Drawing by
Checked by
Client

AKZ
MYY
CURTIN (M) SDN. BHD.

Date
Document Ref.
No.
Revision No.
Revisions

03/09/2012

A001/CURTIN/PFD/002
2
Added a product separator after first
ammonia reactor
Added a water boiler
Condensate flash replaces condensate stripper

Stream Tables
Vap. Frac.
Temp. (Celcius)
Pressure (kPa)
Mass Flow (kg/h)
Mol frac. (MEA)
Mol frac. (Methane)
Mol frac. (Ethane)
Mol frac. (CO2)
Mol frac. (Nitrogen)
Mol frac. (Propane)
Mol frac. (H2O)
Mol frac. (CO)
Mol frac. (Hydrogen)
Mol frac. (Oxygen)
Mol frac. (Ammonia)

NG
FEED
1
20
150
26660
0
0.92869
3
0.04076
1
0.01832
7
0.00450
7
0.00771
2
0
0
0
0
0

Vap. Frac.
Temp. (Celcius)
Pressure (kPa)
Mass Flow (kg/h)
Mol frac. (MEA)
Mol frac. (Methane)
Mol frac. (Ethane)
Mol frac. (CO2)
Mol frac. (Nitrogen)
Mol frac. (Propane)
Mol frac. (H2O)
Mol frac. (CO)
Mol frac. (Hydrogen)
Mol frac. (Oxygen)
Mol frac. (Ammonia)

15
1
821.45815
485
176335.21
0
0.003976
0
0.063454
0.12776
0
0.341436
0.073632
0.389741
0
0

Vap. Frac.
Temp. (Celcius)
Pressure (kPa)
Mass Flow (kg/h)
Mol frac. (MEA)
Mol frac. (Methane)
Mol frac. (Ethane)
Mol frac. (CO2)
Mol frac. (Nitrogen)
Mol frac. (Propane)
Mol frac. (H2O)
Mol frac. (CO)
Mol frac. (Hydrogen)
Mol frac. (Oxygen)
Mol frac. (Ammonia)

PURGE1
0
20
200
3889.25
53
0.99405
4
0
0
0.00539
3
0
0
0.00055
2
0
0
0
0

AIR
1
25
101.325
53052.3
1
0
0
0
0
0.79
0
0
0
0
0.21
0

H20
0
25
98.06652
96622.41
7
0
0
0
0
0
0
1
0
0
0
0

16
1
400
480
176335.21
0
0.003976
0
0.063454
0.12776
0
0.341436
0.073632
0.389741
0
0
REBOUT
0
193.4
202
3.664E+7
0.9999
0
0
0
0
0
0.0001
0
0
0
0

1
1
100
98.06652
96622.41
7
0
0
0
0
0
0
1
0
0
0
0

17
1
456.17571
480
176335.03
0
0.003976
0
0.113748
0.12776
0
0.291142
0.023338
0.440036
0
0
REC
0
26
110
3664421
0.78
0.9999
0
0
0
0
0
0.0001
0
0
0
0

2
1
133.7970
8
500
26660
0
0.928693
0.040761
0.018327
0.004507
0.007712
0
0
0
0
0

18
1
210
470
176335.03
0
0.003976
0
0.113748
0.12776
0
0.291142
0.023338
0.440036
0
0

MEAREC
0
26
110
18322105.
39
0.9999
0
0
0
0
0
0.0001
0
0
0
0

3
1
403.1546
5
500
123282.4
2
0
0.206376
0.009058
0.004073
0.001002
0.001714
0.777778
0
0
0
0

4
1
700
500
123282.4
2
0
0.206376
0.009058
0.004073
0.001002
0.001714
0.777778
0
0
0
0

19
1
235.47831
470
176334.96
0
0.003976
0
0.134754
0.12776
0
0.270136
0.002332
0.461041
0
0

20
0.733515
20
465
176334.96
0
0.003976
0
0.134754
0.12776
0
0.270136
0.002332
0.461041
0
0

PURGE2
0
26
110
18322105.3
9
0.9999
0
0
0
0
0
0.0001
0
0
0
0

33
1
280
110
53094.652
0
0.006672
0
0.000558
0.214599
0
0
0.003915
0.774256
0
0

5
1
609.1270
4
500
123282.5
5
0
0.197203
0
0.003892
0.000957
0
0.720985
0.022223
0.05474
0
0

21
1
20
465
121451.47
0
0.005421
0
0.183545
0.174172
0
0.005147
0.003179
0.628536
0
0
34
1
308.70849
105
53094.628
0
0.010671
0
0.000563
0.216292
0
0.003946
0
0.768528
0
0

FH-AIR
1
25
101.3
322136.0
4
0
0
0
0
0.79
0
0
0
0
0.21
0
CONDENSATE
0
20
465
54883.48414
0
0
0
0.000455
0.000011
0
0.999531
0
0.000003
0
0
35
1
308.20221
105
57865.103
0
0.01436
0.000161
0.000505
0.206897
0.000002
0.003543
0.001058
0.773449
0
0.000026

FLUE
1
1290
101.3
338810.2
5
0
0
0
0.082985
0.726193
0
0.158648
0
0
0.032173
0

FUEL
1
25
140
16674.21
6
0
0.9287
0.0408
0.0183
0.0045
0.0077
0
0
0
0
0

22
0.994946
-44.101411
115
121451.47
0
0.005421
0
0.183545
0.174172
0
0.005147
0.003179
0.628536
0
0
36
1
1848.699
6
7424
57865.10
3
0
0.01436
0.000161
0.000505
0.206897
0.000002
0.003543
0.001058
0.773449
0
0.000026

6
1
510.0316
4
1310
96622.41
7
0
0
0
0
0
0
1
0
0
0
0

23
1
40
110
121451.47
0
0.005421
0
0.183545
0.174172
0
0.005147
0.003179
0.628536
0
0
37
1
550
7419
57865.103
0
0.01436
0.000161
0.000505
0.206897
0.000002
0.003543
0.001058
0.773449
0
0.000026

8
1
693.5160
6
500
123283.3
1
0
0.036801
0
0.077105
0.000737
0
0.36597
0.058035
0.461352
0
0

24
0
26
110
3.665E+7
1
0
0
0
0
0
0
0
0
0
0
38
1
608.0754
15000
479.2375
5
0
0
0
0
0
0
1
0
0
0
0

9
1
1000
490
123283.3
1
0
0.036801
0
0.077105
0.000737
0
0.36597
0.058035
0.461352
0
0

25
1
25.98795
110
53094.652
0
0.006672
0
0.000558
0.214599
0
0
0.003915
0.774256
0
0
39
1
550
7419
57385.865
0
0.014411
0.000161
0.000507
0.207632
0.000002
0
0.001062
0.776199
0
0.000026

10
1
450
91.32499
7
53052.31
0
0
0
0
0.79
0
0
0
0
0.21
0

11
1
968.9726
5
500
53052.31
0
0
0
0
0.79
0
0
0
0
0.21
0

12
1
995.5589
490
176335.6
2
0
0.030765
0
0.064458
0.130186
0
0.305947
0.048516
0.385684
0.034443
0

26
0
27.332041
110
36715576
0.997365
0
0
0.002551
0.000002
0
0.000072
0
0.00001
0
0

27
0
27.372826
200
36715576
0.997365
0
0
0.002551
0.000002
0
0.000072
0
0.00001
0
0

28
0
104.5
200
36715576
0.997365
0
0
0.002551
0.000002
0
0.000072
0
0.00001
0
0

40
1
776.98876
15000
57385.865
0
0.014411
0.000161
0.000507
0.207632
0.000002
0
0.001062
0.776199
0
0.000026

41
1
250
15000
57385.865
0
0.014411
0.000161
0.000507
0.207632
0.000002
0
0.001062
0.776199
0
0.000026

42
1
764.3366
14995
2
57384.80
0
6
0.020106
0.000225
0.000708
0.092078
0.000003
0
0.001482
0.490125
0
0.395274

13
1
1420.619
9
490
176334.9
3
0
0.031863
0
0.066758
0.13483
0
0.388203
0.050247
0.3281
0
0

30
1
104.5
200
7.087E+4
0.0401
0
0
0.9552
0.0009
0
0
0
0.0039
0
0
43
0.602872
-100
14990
57384.806
0
0.020106
0.000225
0.000708
0.092078
0.000003
0
0.001482
0.490125
0
0.395274

14
1
980
485
176334.9
3
0
0.031863
0
0.066758
0.13483
0
0.388203
0.050247
0.3281
0
0
CO2
1
20
200
66981.234
0.000235
0
0
0.99481
0.000905
0
0.000003
0.000025
0.004023
0
0
44
1
-100
14990
21038.869
0
0.031934
0.000167
0.000048
0.152697
0.000001
0
0.002451
0.812459
0
0.000243

Unit
Vap. Frac.
Temp. (Celcius)
Pressure (kPa)
Mass Flow (kg/h)
Mol frac. (MEA)
Mol frac. (Methane)
Mol frac. (Ethane)
Mol frac. (CO2)
Mol frac. (Nitrogen)
Mol frac. (Propane)
Mol frac. (H2O)
Mol frac. (CO)
Mol frac. (Hydrogen)
Mol frac. (Oxygen)
Mol frac. (Ammonia)

C
kPa
kg/h

45
1
250
14985
21038.869
0
0.031934
0.000167
0.000048
0.152697
0.000001
0
0.002451
0.812459
0
0.000243

46
1
719.9385
14980
21038.44
0
0.04332
0.000226
0.000065
0.028875
0.000001
0
0.003325
0.567333
0
0.356854

47
0.641128
-100
14975
21038.445
0
0.04332
0.000226
0.000065
0.028875
0.000001
0
0.003325
0.567333
0
0.356854

48
1
-100
14975
6479.9664
0
0.064977
0.000162
0.000004
0.045029
0
0
0.005174
0.884411
0
0.000242

49
1
-100
14975
3239.9832
0
0.064977
0.000162
0.000004
0.045029
0
0
0.005174
0.884411
0
0.000242

PURGE
1
-100
14975
3239.9832
0
0.064977
0.000162
0.000004
0.045029
0
0
0.005174
0.884411
0
0.000242

51
0
-100
14975
14558.479
0
0.004629
0.000341
0.000174
0.000016
0.000003
0
0.000021
0.000872
0
0.993944

Note: The Energy Streams can be found in Appendix B (Energy Balances Part under HYSYS simulation results)

52
0
-99.99756
14995
14558.479
0
0.004629
0.000341
0.000174
0.000016
0.000003
0
0.000021
0.000872
0
0.993944

53
0
-100
14990
36345.937
0
0.00215
0.000314
0.001709
0.000052
0.000006
0
0.00001
0.000795
0
0.994965

GREC
1
300
14970
3239.9832
0
0.064977
0.000162
0.000004
0.045029
0
0
0.005174
0.884411
0
0.000242

AMM
0
99.998986
14990
50904.415
0
0.002861
0.000322
0.001269
0.000041
0.000005
0
0.000013
0.000817
0
0.994672

Appendix B Manual Mass and Energy Balance

Mass Balances Results for Selected Equipment
Mass and energy balances have been carried out for all equipment in the Process Flow Diagram with the assistance of
Microsoft Excel and Polymath. Some of the selected results are displayed, especially for the equipment that will change the
composition of chemicals, namely reactors, absorber and stripper. Energy balances result for heaters, coolers, compressors,
expander and pump is also shown, together with sample calculation.
Calculations method and example:
Comparison of HYSYS values and manual calculations for reactor mass balances
Outlet
R-101 Primary
R-103 Secondary
R-104 HTS
R-105 LTS
R-106 Methanator
Flow kg
Reformer
Reformer
mol/hr
HYSYS
Manual
HYSYS
Manual
HYSYS
Manual
HYSYS
Manual
HYSYS
Manual
CH4
344.94
340.28
45.43
46.04
45.43
45.43
45.43
45.43
71.94
71.45
CO
543.96
1217.78
841.22
962.75
266.62
274.97 26.6397
26.17
0
0.48
CO2
722.70
52.22
724.95
602.59 1299.54 1291.18 1539.53 1539.72
3.7945
3.7945
H2
4324.23
3664.19 4452.68
4328.28 5027.27 5018.94 5267.26 5267.84 5181.30 5339.40
H2O
3430.23
4096.14 3900.80
4023.72 3326.21 3333.64 3086.22 2941.78
26.60
26.12
O2
0
0
0
0
0
0
0
0
0
0
NH3
0
0
0
0
0
0
0
0
0
0
N2
6.91
6.91 1459.62
1459.62 1459.62 1459.62 1459.62 1459.62 1458.21 1458.21
st
nd
Outlet
R-107 1 Ammonia
R-108 2 Ammonia
Sample Calculation for Reactors
Flow kg
Converter
Converter
Reaction 1: CO+H2O H2 + CO2
mol/hr
HYSYS
Manual
HYSYS
Manual
Reaction 2: H2 + CO2 CO + H2O (Reversible reactions)
CH4
107.82
107.82
103.24
103.24
CO
7.94
7.94
7.9239
7.9239 Overall rate for each reactants and products (Example for CO):

CO2
3.79
3.79
0.16
0.16
H2
2628.3
3996.72 1352.09
2029.32 Mole balance equation:
H2O
0
0
0
0 Concentration expression:
O2
0
0
0
0 Equations for the rest of species are constructed in similar
NH3
2119.67
1207.44
850.47
398.88 fashion and solved with specified constant values.
N2
493.77
949.68
68.82
294.48

Sample Calculation for Stripper Unit (Example CO2 Stripper)

Percent stripped at each stage can be calculated from the stripping factor,
, where K is the vapor/liquid
equilibrium ratio which is obtained by dividing the vapor pressure of the stripped species (obtained from Antoine equation),
carbon dioxide with the total pressure. The Kremser equation for solute fraction stripped at stage N is,
. It is assumed that the stage efficiency is 1 and the components are ideal gases.
Results for Absorber and Stripper
Unit
Percent absorbed/stripped desired
Stages to achieved the desired percent
Stages in HYSYS

T-100 CO2 Absorber

99.75%
41
12

T-101 CO2 Stripper

99.99%
3
12

Sample Calculation of Energy Balance of Heater (Example E-100)

Enthalpy is calculated by using the mean heat capacity. The equation for mean heat capacity is:

The A, B, C and D are the equation constants while is the ratio between target temperature and reference temperature
o
(25 C). Heat duty for E-100 is obtained by subtracting the outlet enthalpy with the inlet enthalpy.
Energy Balances Result for Heaters, Coolers and Compressors (kJ/hour)
Equipment E-100
E-101
E-102
E-103
E-104
E-105
E-106
E-107
E-108
E-109
E-110
HYSYS
2.38E7 9.31E7 2.51E8 1.11E8 1.99E8 1.71E8 9.45E7 2.15E8 2.33E7 8.45E9 2.1E10
Manual
2.37E8 2.05E7 1.36E8 1.12E8 1.99E8 1.70E8 9.51E7 7.96E7 2.97E7 6.56E9 2.1E10
Equipment E-112
E-113
E-114
E-115
E-116
E-117
E-118
E-119
K-100
K-101
K-102
HYSYS
9.76E6 5.02E7 9.32E6 9.23E7 1.22E8 3.45E7 2.24E8 3.29E8 3.15E7 6.83E6 7.86E7
Manual
9.76E6 5.03E7 9.09E6 6.93E7 1.21E8 3.32E7 1.66E8 3.27E8 3.11E7 6.90e6 7.97e7
Equipment K-104
K-105
P-100
P-101
HYSYS
3.85E8 5.41E7 4.29E6 5.19E2
Manual
3.82E8 5.31E7 3.47E6 6.04E1

E-111
1.2E10
K-103
1.81E7
1.60e7

Appendix C Heat Exchange Network

H1
H2

H3
H4
H5

H6

H7

H8
H9
H10

1421

57.33 MW

980

821.5

400

456.2

447.38

210

235.5

193.4

116.13

77.95

6.37 MW

104.5

20
20

193.4

193.4

1849

1465.88

176.6

176.37

118.26

3575.85 MW

1169.13

26

550

777

738.86

250

764.3

193.4

719.9

421.07

260.07

62.23

193.4

140.73

100

9.73 MW

-100

7.22 MW

-100
25

9
700

403.2
23.74

450

183.4

25

2.67

1.58

1000

693.5
30.65

40

-19.96
4.2
1.69

280

183.4

-44.1
25.99

4.83

7.87

104.5

27.33
2252.59

193.4

179.51 MW

188.32

186.92
49.53

185.49
50.58

184.52
34.22

183.78
26.11

183.53

183.4

8.97

4.63

166.6
651.5

C1
C2

C3
C4
C5

C6
C7
C8

34.25
250

183.4

-100

2
279.9

8.5
183.4

0.97

-100
2.83

C9
C10

Appendix D Specifications of Major Utilities

Hot and Cold Utilities
Equipment
E-126
E-105
E-111
E-127
E-118
Heat Duty (MW)
179.51
57.33
6.37
3575.85
9.73
Stream (In Network) C8
H1
H4
H6
H9
Utility
HP Steam
HP steam gen
Cooling water Cooling water R-407C
T utility in /out(C)
205.00, 203.36 203.36, 205.00
10, 20
10, 20
-110, -90.52
Flow rate (kg/s)
64.24
20.53
152.03
85342.48
324.33
Power
Total power consumption from the use of compressors, expander, mixer agitations and pumps is calculated.
Equipment
Total Power
Calculation method
items
Consumption
Compressors
87522 kW
Using values from HYSYS and few equations by (Schultz 1962) below,
and Expander
where
at critical conditions,
(

Work,

For compression,
Pumps

1191 kW

Mixers

21.7 kW

Head pump,

Total Power

E-121
7.22
H10
R-407C
-110, -90.89
240.67

For expansion, Qe = 1/Q

(Sinnot 2005,212)

For viscosity lower than 5000cp, three-bladed Marine Propeller will be used in agitated
vessels. For calculation of power consumption of baffled vessel,
(Peters, Timmerhaus and West 2004, 544)
140598.7 kW

Appendix E Preliminary Equipment Schedule for Major Equipment and Equipment Costing
Methodologies
Equipment
Pre Reformer
R-100
Primary Reformer
R-101
nd
2 Reformer
R-102
HTS Reactor
R-103
LTS Reactor
R-104
CO2 Absorber
T-100
CO2 Stripper
T-101
Methanator
R-105
Ammonia Converter
R-106 & R-107

No.
1

Objective
Convert the higher hydrocarbons to H2 and CO to reduce
the load on the primary reformer.
Convert 65% of the methane to H2 and CO. CO2 is
produced from side reaction.
Convert 99% of the remaining methane to hydrogen.

Reduce the CO content to 3% and hydrogen is produced.

Produce H2 and further reduce the content of CO to 0.2% 0.4%.

Removes CO2 from the effluent gas from shift reactors to
100 2000 ppm.
Removes CO2 from the solvent MEA for recycle back to
absorber.
Converts the CO content in the syngas to methane for fuel.

Produces ammonia from N2 and H2

1
1

Costing Methodologies for Equipment (Douglas 1998) and (Couper et. al. 2005)
Reactor
(Douglas 1998)
Reformer (Couper et.
(
)
al. 2005)
Flash drum
Heat exchanger
,
Packed tower

Op. Cond.
0
700 C
500 kPa
0
693.5 C
500 kPa
o
980 C
480 kPa
o
400 C
480 kPa
o
210 C
470 kPa
0
26 C
110 kPa
0
104.5 C
200 kPa
0
280 C
110 kPa
0
250 C
15000 kPa

Material
Stainless steel
Stainless steel
Stainless steel
Carbon steel
Carbon steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel

Compressor
Vessels
Note: All symbols have their usual engineering meanings. The costing of the rest of the equipment is based on the costing
graphs obtained from Peters, Timmerhaus and West (2004)

Appendix F Pipe Sizing and Specifications

Calculation methods:
The design velocity is chosen for a pipe based on the dominant material flowing in it. By using the equation Q=VA, the cross
sectional area and subsequently the diameter of pipe is found.
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material

4
700
500
SS430
5
609
500
SS430
7
1290
500
Titanium
9
1000
490
SS309
12
995
490
SS309
15
821
485
SS430
16
400
480
CS
17
456
480
CS
18
210
470
CS
19
235
470
CS
20
20
465
CS
23
20
110
CS
24
25.99
110
CS
25
25.99
210
CS
26
27
110
CS

Cal. pipe diameter

Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes

26.0569
29.25
40s
3
26.0569
29.25
40s
3
29.20
29.25
40
4
35.13
35.25
40
3
33.217
35.25
40
3
28
28.75
30
5
34.88
35.25
40
2
22.96
23.25
40
5
21.096
22.624
40
4
21.65
22.062
60
4
28.32
28.75
30
1
34.75
35
40
1
34.97
35
40
1
26.45
28.75
30
4
32.98
35.25
40
6

Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material
Line
Temp. (C)
Pressure (kPa)
Material

28
105
200
CS
29
104.5
200
CS
30
20
200
CS
31
193.4
202
CS
CO2
20
200
CS
32
20
200
CS
33
280
110
CS
34
309
105
CS
37
550
7419
SS502
39
550
7419
SS502
41
250
15000
CS
42
764
14995
SS430
43
-100
14900
A353
45
250
15000
CS
46
720
14980
SS430

Cal. pipe diameter

Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes
Cal. pipe diameter
Ind. pipe diameter
Pipe Schedule
Number of pipes

33.37
35.25
40
6
21.37
21.56
80
1
18.44
19
30
1
32.57
35.25
40
8
18.44
19
30
1
0.8380
0.884
10
1
29.23
29.25
40
6
33.69
35.25
40
5
11.34
11.37
80
1
0.468
0.493
40
1
6.44
6.875
xx
1
7.61
7.63
80
1
2.58
2.635
10
1
4.24
4.313
160
1
4.96
5.047
40
1

Appendix G Preliminary EIA

Factors
Bio
physical

Aspects
Flora &
Fauna
Wetland,
Water
(Surface /
Ground,
Land

Pollution

Air, Soil,
Water and
Noise

Social

Heritage
and Visual

Potential Impacts
Clearing of land will some impact to local flora, however the dominant species is Imperata
Cylindrica (Lalang), is not a rare species. Some reptiles and birds such as mynah, sparrow and crows
are spotted on site which might be affected from the release of gas from the plant. (Perdana
Environmental Technology & Services SDN. BHD 2010). Pollutants from industries might affect the
quality of wetland which is the Sungai Mamam located approximately 2.25km from the plant site.
Surface and ground water can be polluted by unmanaged solid waste (primarily catalysts) and also
by accidental spillage of chemical toxics and oil. Clearing of land will expose the land to the sun,
which if prolonged will cause land degradation.
Decreasing air quality due to the pollutants from emissions from industry vehicles and machines.
Heat pollution exists from cooling water tower and other unit operations. Water quality will be
affected from accidental discharge of waste and oil. Soil will be contaminated by solid waste and
the nutrients will diminish due to prolonged exposure. Other than that, mechanical movements of
vehicles and equipment might produce noise.
There is no of indigenous population near plant site. There will be a visual change in the existing
landscape due to the proposed development.

Others

Decommis
sioning

A large amount of noise pollution will be produced during decommissioning and also solid wastes
will be produced from plant debris.

Mitigation Measures
Re-vegetate the surrounding unused area to provide a buffer
region for flora and fauna. A proper waste management system
is also to be designed to reduced impacts to flora and fauna.
Practice a zero spillage to the ground policy and ensure solid
wastes are properly managed. Only clear the required area for
factory complex. Use catalytic converter on vehicles. Purify the
gas emission before release to the atmosphere. Other than that,
efficient process control for reducing emissions will be
favorable. Besides that, silencer should be installed for
equipment that produces noise which exceeds the permitted
level, 70 dBa at day and 60 dBa at night (Jabatan Alam Sekitar
Malaysia 2004).
The visual impact of the plant can be minimized by selecting
colors for the plant buildings that suits the surrounding
landscape. Appropriate landscaping can also be done to screen
the plant and associated infrastructure from public visibility.
Ensure decommissioning will be done after careful planning. The
old equipment can be sold or recycled. Plant site could be
vegetated or used as a new project site.

Appendix H Effluent Disposal Method

Effluent type, amount and standards
Solid (Catalysts nickel) from Primary Reformer, Secondary Reformer,
HTS, LTS, Methanator. The amounts are respectively, 2515, 2515, 740,
740, 740 per change cycle. Standards limit for Nickel release is 0.2 mg/L.
Liquid (Condensate water) from condensate stripper. The amount is
55000 kg/hr. The condensate water contains dissolved nitrogen,
hydrogen and carbon dioxide. The standards limit for dissolved solids is
50 mg/L.

Treatment, Reuse or Disposal

Catalyst has to be replaced 2 to 6 years. (Nations Industrial Development Organization and International Fertilizer
Development Centre 1998). The most economical way is to send the spent catalysts to specialized company for
solid waste treatment, because the disposal cycle is very long.
From simulation result, the condensate water only contains dissolved gasses. In reality there might be dissolved
solids in the condensate water. Hence, settling tank is used to remove solid wastes present in the wastewater. This
will take up several hours for the solid wastes to settle and a scum to form on the top. Condensate water is then
recycled to produce steam for reformer feed and the surplus could be disposed to normal drainage. Safe Drinking
Water Foundation 2012)
Due to high temperature of the flue gas, it can be used to heat up some streams. This enables the waste heat
generated can be reused. The particles that are present in flue gas during incomplete combustion are removed
with the use of cyclone, fabric filters or electrostatic precipitator. Wet scrubber could be used to removes the
ammonia content in the purge gas.

Gas (Flue Gas) from the Primary Reformer and purge gas from the
ammonia synthesis loop. The amount is 340000 kg/hr and 3240 kg/hr.
The flue gas contains nitrogen, hydrogen, carbon dioxide and oxygen
for complete combustion and may contains carbon monoxide during
incomplete combustion while the purge gas contains ammonia,
nitrogen, carbon monoxide, hydrogen and hydrocarbons. The standards
limit for carbon monoxide release is 30 ppm.
Note: Standards limit are based on Environmental Quality Act 1974 by Malaysian government.

Appendix I HAZOP of Selected Equipment

Node
R-101
Primary
Reformer

R-103
HTS Reactor

T-100
CO2 Absorber

R-107
Ammonia
Converter

Deviation
LESS
Temperature

Possible Causes
- Airborne solids interfering with the
operation
- Not enough fuel feed

MORE
temperature

- Top fired Furnace tube failure

- Fired heater control failure

MORE
pressure

- Blockage of the tubular tubes

within the reformers due to
corrosion or accumulation of
impurities
- Fluctuations of inlet flow stream
-Failure of pressure controller
- Fluctuation of inlet temperature
due to failure of heat exchanger
control
- The inlet feed flow fluctuation

MORE
pressure
MORE
temperature
MORE flow
MORE
pressure
MORE
temperature

- Pump failure or increased feed gas

flow
- Defective heat exchanger control.

MORE
pressure

- Blockage of the tubular tubes

within the converters due to
corrosion or accumulation of
impurities
- Increased feed rate

Consequences
- Decreased conversion
- Potential disposal concerns for liquid hydrocarbon and
plant upset
- Potential incomplete combustion in reformer which can
cause release of pollutants such as carbon monoxide.
- Potential of explosion with flames coming out of the top
and bottom of the reactor
- Major injuries / fatality from the major explosion accident
- Pressure will rise to maximum allowable pressure or
exceed the design pressure which cause system breakdown

- Overpressure of the reactor

-Explosion risk
- The conversion percentage will be reduced and the
composition fraction might be affected. Less product formed
- Possible reduction in absorption efficiency.
- May cause flooding of the column.
- Reduction in absorption and possible of line fracture or
leakage
- Lower conversion rate resulting in less product.
- Might exceed the maximum temperature causing
mechanical failure.
- Pressure will rise to maximum pressure
- Decreased conversion rate
- Mechanical failure of reactor wall
-Explosion

Action Required
- Review the need for installing weather protection
over the natural gas feed.
- Install temperature control.

- Ensure the furnace wall material able to withstand

the higher temperature
- Install temperature control and high temperature
trip.
- Include the need of suction valve on the standby
pump open during the normal operations
- Maintenance to avoid corrosion.
- Install high pressure alarm/trip
- Install a temperature alarm and trip to ensure when
the temperature is too high, the process will be shut
down for safety reasons.
- Install pressure control to control the amount of gas
within the column.
- Ensure correct sizing on pressure relief system and
provide thermal expansion relief in the design
- Maintenance on the heat exchanger control
- Install high temperature alarm trip.
- Install pressure relief valve and pressure control
system/ high pressure trip system.

Appendix J Start-up, Shutdown, Cleaning and Maintenance Key Issues

Plant start-up procedure should be based on correct safe sequence for commissioning. Some of the key issue is to recheck every single equipment connection, control
system, any additional valves and bypass lines needed, availability of provisions to prevent any abnormal pressure, temperatures and rates of reaction and lines which
allow all the equipment to be started up safely. Besides that, equipment level activities and mechanical inspection should take into consideration as well. The general start
up procedures is listed as below:
1.)
Equipment and utilities switched on while inspecting the abnormalities of the system.
2.)
The raw materials are normally fed into the plant at reduced rate at the initial state until each equipment condition has been established.
3.)
Pre-reformer, primary reformer and secondary reformer are heated up to the process conditions.
4.)
The plant usually achieving the design flow rates slowly and operating data are evaluated for each step of equipment. The CO2 composition is analysed after the
process reaches low temperature shift reactor to ensure it reaches the required percentage.
5.)
CO2 removal system by absorber and stripper will be activated by circulation of MEA. This will follow by the rest of the equipment.
6.)
Once the plant is running at full capacity mode, performance run will be performed to ensure that the plant operations are at normal conditions.
The main key issue in the procedure is to shut down the plant properly without any problem or abnormalities occur on the process or the equipment.
1.)
Shutdown procedure planning should be done few weeks earlier to ensure there are proper procedures implemented and verified by third party contractors.
2.)
All controllers in the plant are switched to manual mode where operators could turn off the equipment section by section. Inlet feed stream will be stopped once
the shutdown procedures begin.
3.)
Once all equipment are switched off, pressure relief system will take place to ensure pressure been adjusted to normal conditions. Cooling water will be allowed
to continue for reducing the temperature of the high temperature equipment.
4.)
Ensure that flue gas or liquid in the reactor and flash drum will be drained out. Relief any internal pressure in piping connected to high pressure system.
5.)
Control valve will closed section by section to ensure the flue gas or liquid drained out form piping .
Plant cleaning is required to ensure that the process system is working on optimum conditions. Fouling or deposit will form in the equipment and piping eventually after a
period of operation. Some of the main features are to ensure the process of cleaning will not affect the ammonia production or cause any problem. Operators have to
ensure that every equipment which is under service been tagged properly to prevent others from operating it. Cleaning procedures are to be done separately section by
section and according to the legal regulations during disposal of any waste.
Plant maintenance play an important role in ensure that every equipment running at an optimum conditions. Major equipment is required to be inspected once a week at
least. The process conditions for rest of the equipment must be closely monitored to ensure there are no leakages or system and control failure. Regular good
housekeeping is required to ensure the safety of workers in the plant. Sampling products should be taken from time to time to ensure that production is within the range
of specification. Besides that, every maintenance done should include a formal written procedure to ensure every worker is well informed as well. This would reduce the
risk of any unnecessary situation to happen in the plant. A permit to work system also must be active and followed closely to avoid industrial disaster.

Appendix K Process Material Hazards

Process Materials
Hydrocarbon

Major hazards
Potential of toxic and fire/explosion

Potential Major Health Effects

- It will cause difficulty of breathing if it expose over a period

Carbon Dioxide

- Severe distress to almost everyone in the area

Hydrogen

Displaces oxygen in air down to dangerous

low levels
Highly flammable and combustible nature

Liquid ammonia

Potential of toxic and fire/explosion

Monoethanolamine

Fire/explosion hazard

R-407C

Vapour displaces air and cause asphyxiation

in confined spaces

- Individuals would face breathing problem due to oxygendeficient environment at high concentrations of H2
- Inhalation will cause burn eyes and any mucus membrane it
touches, poisoning and dizziness
- Inhalation will cause irritating, chemical burns and organs
damage
- May cause dizziness and loss concentration during
overexposure

First aid protocol

- Workers should be ready with oxygen mask
if there any possible leakage
- Put on oxygen mask and seek for medical
attention
- Artificial respiration may be needed and
medical attention.
- breathe in fresh air and seek medical
attention immediately
- Give CPR/oxygen if needed and drink at
least few glasses of water
- breathe in fresh air and seek medical
attention immediately

Appendix L Contingency Plans

Threat
Power Supply failure
Bomb threat/
Terrorist attack
Uncontrolled release
of ammonia
Natural gas pipe
failure causing release
of flammable gas into
air

Possibility of Occurrence
Likely
Very unlikely

Plans
- Backup power generator onsite using natural gas generator to supply power to critical units.
- Tight security

Unlikely

- Regular maintenance, ensure that proper procedures are followed, ensure the refrigeration system of ammonia is working.

Possible

- Firefighting devices should be ready all the time, ensure constant maintenance of the supply pipelines to prevent leakage.
- Emergency valve to close the supply line once leakage occurs.

Appendix M Piping and Instrumentation Diagram (P&ID)

TC
FC

CV-2

FT

Flue
Gas

K-102

TC

TT

E-100

E-101

CV-1

Cooling
Water

PC

PC

TT

CV-6
PC

FC

E-103
FC

CV-10
CV-7

K-101

LS

CV-3

E-128

CV-12

CV-14

Cooling
Water Out

TC

Project A001

TT

CV-13

TT

R-101
Ratio

PT

E-105

E-106

TT

FT

FT

Water

PT
TT

TT

CV-5
CV-4

TC

TC

O2
C

PT

Natural
Gas

CV-11

O2
T

TC

Plant Design for Production of 400 kT/year of

Ammonia in Tanjung Langsat Industrial Park,
Johor

TC

CV-15

E-102
HS

CV-8

FC

CV-26

FT

Air

CV-23
CV-24

CV-9

TC

E-108

PC

E-109

PT

V-100

TT
LC

TT

Condensate Water

CV-19

LT

CV-25

CV-18
PT

TT

K-103

CV-16

E-115

TC

TT

E-116

Water

PC

Date
Doc No.
Version

TT

TC

E-110
TC

TC

CV-17

TC

CV-21

TC

TT

E-107

TT

CV-20
TT

K-100

Drawing by
Checked by
Client

NG Fuel

TC

Cooling
Water

CV-22

Air

CT

E-112
CV-33

PC

TC

E-113

TC
CT

CV-50

TC

V-106

CO2
To MOX

CV-34

TT

Pure
MEA

PC

CV-60

Cooling
Water
Out

CV-40

CV-30

Legends:

PT

TC
TT
CC
CT
LC
LT
PC
PT
O2C
O2T

PT

TT
TC

CV-42

PC

CV-35

PC

PC

TC
TT

PT

CV-51

LC
TT

CV-52

TT

CV-49

E-114

CC

CV-41

CC

LT

MEA
Recycle

CV-27

V-103

PT

CV-43

E-119

PT

CV-59
TT

PC

Steam
In

PT

CV-32

TC

CV-39

M-100

T-100

TT

E-126

CV-37

K-105

TC

TT

TT

CV-48

E-125

FC

Purge
MEA

Cooling
Water

CV-57

Purge

CV-56

FT

PC

CV-55

PT

CV-53

TT

Steam
Out

E-124

V-102

PG
LT
LC

TT
TC

E-117

TT

Refrid
gerant
In

E-121
CV-47

Refrid
gerant
Out

CC

CT

CV-54

M101
FT

PG

CV-36

temperature controller
temperature transmitter
composition controller
composition transmitter
level controller
level transmitter
pressure controller
pressure transmitter
oxygen composition analyser
oxygen composition
transmitter
high selector
low selector
pressure gauge
ratio controller

FC

TC

E-122

Cooling
Water
Out

HS
LS
PG
Ratio

FC

TC

T-101

PG

CV-28

CV-58

Refrid
gerant
Out

CV-45
TT

CV-31

LC

E-120

LT

CV-29

V-101

TT

LC

FT

PC

PT
TT

E-118

LC
PG

CV-61

LT

TC

CV-38

FT
LT

Refrid
gerant
In

CV-44

K-104

FC

E-123

TC

AKZ
MYY
CURTIN (M) SDN.
BHD.
03/09/2012
A001/CURTIN/PID
1

P-101
CV-46

V-105

V-104

Note: the control configurations for

pump
follows
the
typical
configurations which contains pressure
gauge, no return valves, backup pump,
isolation valves, drain valves.

Process Control
Equipment
R-107
Second
Ammonia
Reactor

T-100
Absorber

E-100 Heat
Exchanger

R-101
Primary
Reformer

Details
Objectives: To produce a high purity ammonia product while maintaining the pressure and temperature
conditions of the ammonia reactor for safety and high conversion.
Strategies: A higher temperature will produce higher conversion. Hence, to be able to manipulate the
conversion value, temperature control is installed at the heat exchanger before the reactor. Pressure is
regulated within the reactor by measuring the reactor pressure and controlling the outlet gas flow.
Composition analyzer is installed only for second ammonia reactor to save cost,
Objectives: To produce a high purity ammonia product while maintaining the pressure and level conditions of
the ammonia reactor.
Strategies: The pressure within the absorber is regulated by measuring the absorber pressure and controlling
the outlet gas flow. The level of liquid is controlled by controlling the outlet liquid flow. To control the
composition of CO2 in outlet gas, the solvent MEA flow rate is manipulated.
Objectives: To produce the desired temperature in the outlet streams of heat exchanger and maintain
temperature fluctuation below 5% so as to not affect the conversion in the reactor R-100.
Strategies: A bypass stream is created at the cold stream. Controller and valve are placed at the cold stream
because it will be cheaper to control the stream with lower temperature. Any changes to the outlet
temperature of the cold stream will be regulated by manipulating the bypass flow rate. As the cold stream is
inlet stream for R-100, maintaining a constant temperature will ensure less fluctuation of conversion of the
reactions, hence reducing the load on separation equipment and maintaining constant production rate.
Objectives: To ensure that the combustion is complete and maintaining the temperature fluctuation of the
outlet stream to be less than 5%.
Strategies: Ratio control is employed to ratio the air flow with fuel flow by the information signal from the
excess oxygen controller which measures the composition of O 2 in flue gas. When the demand changes (outlet
temperature), it is preferable to change the air flow rate than the fuel flow rate because surplus of fuel will
cause rapid combustion. Hence, high selector and low selector are respectively placed for this objective.

Equipment Sizing
Equipment
R-100
R-101
R-102
R-103
R-104
R-105

R- 106
R-107

Size (D in m, V in
cubic m)
D = 3, L = 25, V = 178
D = 1.3, L = 10, V = 12
D = 5, L = 10, V = 550
D = 3, L = 23, V = 140
D = 3, L = 42, V = 120
D = 2.6, L = 21, V =
100
D = 0.4, L = 1.8, V =
0.16
D = 0.4, L = 1.7, V =
0.15

Equipment
V-100 (Flash)
V-101 (Flash)
V-102 (Flash)
V-103 (Flash)
V-106 (Dryer)
V-104
( Storage
Tank)
V-105(Storage
Tank)
MIX-101
MIX-102

Equipment

Equipment

E-100

Area
2
(m )
293

E-101
E-102
E-103
E-104
E-105
E-106
E-107
E-108
E-109
E-110

164
340
71
173
264
65
36
996
811
153

Size (D and H in
m, V in cubic m)
D = 9, H = 17
D = 1.8, H = 6.5
D = 1.2, H = 5.5
D = 7, L = 12
D = 1.4, H = 2
V = 13590

V = 13590

Methodologies:
Reactor
The sizing is based on trial and error and is done
together with the material balance for reactor
(Refer to Appendix B). An assumed volume is
inserted to solve the differential equations. The
iterations stopped when the desired conversion
value is reached.
Flash
L

V = 12
V=2

Equipment

E-111

Area
2
(m )
173

E-122

Area
2
(m )
119

E-112
E-113
E-114
E-115
E-116
E-117
E-118
E-119
E-120
E-121

106
3413
334
77
633
139
221
206
68
145

E-123
E-124
E-125
E-126
E-127
E-128

336
3650
64
6973
198
66

v v

Assume 10 minutes hold up time,

iq i
v m
v
L
Overall Height, H = hL + hv + 0.4Dv (for safety
margin), where hv = vapour height
(Sinnot 2005, 461)
Absorber and Stripper
Tray spacing is obtained from simulation result.
The height of the column is the sum of total tray
spacing and the assumed top and bottom spaces
(10 m)
Ammonia Storage Tanks)
Tanks are sized based on 15 days storage
capacity.
Heat Exchangers

where U us overall heat transfer coefficient and
is the log mean temperature difference. Q is
the heat duty obtained from simulation.
Mixer and Dryer
Sizing based on superficial velocity (Walas,
Couper, Penny and Fair 1988, 528)

Appendix N Economic Feasibility Analysis

Method I: Percentage of delivered equipment cost
Total Capital Investment

Item
Direct cost

Purchased Equipment
Land
Process Instrumentation and
control
Purchase Equipment Installation

Piping (include installation)

Electrical Equipment and Materials
Buildings
Yard Improvement
Service facilities
Indirect Cost
Engineering and Supervision
Construction expenses
Legal expenses
Contractors fee
Fixed capital Investment(FCI)
Working Capital
Total capital investment(TCI)
Method II: Lang Factor
Type of plant
Fluid

Total Production Cost

$(US Dollar)
55,272,312
2,036,735
588,839
25,977,987
36,479,726
6,079,954
9,949,016
5,527,231
38,690,618

Manufacturing expenses
Variable Production Cost
Raw material
Operating labor
Direct supervisory and
clerical
labor
Utilities
Maintenance and repairs
Operating supplies
Laboratory charges
Patents and Royalties
Catalyst and solvents
Fixed charges
Plant overhead charges
General expenses
Administrative
Distribution & marketing
Research & Development
Total Production Cost (TPC)

24,319,817

18,239,863
22,661,648
2,210,892
12,159,909
260,000,000
49,192,357
309,400,000

Factor for TCI

6.0

$(US Dollar)

TCI ($)
331, 600, 000

29,501,831
1,115,100
111,510
48,280,000
5,203,891
520,389
111,510
111,510
62,148,783
3,952,111
3,215,251
223,020
223,020
223,020
154, 900, 000

TCI = Purchased equipment Cost x Factor

Appendix O Profitability Analysis

Product/ by-product
Ammonia
Carbon dioxide

Amount (kg/year)
403163006
530491372

Summary of profit evaluation

Criteria (All in $)
Gross profit
Salvage
Average depreciation
Annual net profit (ANP)
Net cash flow (NCF)
Return on Investment (ROI)
Payback period
Reference Payback period
Present worth (pW)
Net Present Worth (NPW)
Discounted cash flow rate (DCFR)

Price ($/kg)
0.65 (Argus 2012)
0.01 (Johnson et al. 2012)
Total Annual Revenue

Base case

Sales
262055954
5464061
267,520,000

Best case
112,579,000
16,254,000
9,758,000
66,834,000
76,591,560
21.60
4.04
7.456
827,451,529
518,064,625
24.68%

193,212,000
16,254,000
9,758,000
128,418,000
138,175,000
41.51
2.24
7.456
1,484,845,811
1,175,458,907
44.66%

Worst Case
49,991,487
16,254,218
9,758,000
24,140,000
33,898,000
7.80
9.13
7.456
371,706,666
62,319,762
10.18%

Appendix P Cumulative Cash Flow Graph

mar, interest rate(i)=0.08
Discounted factor(DF)=0.15
Present worth
factor(PWF)=1.67

Cummulative Cash Flow

3500
3000

Land,salvage &
working capital
recovery

Cost, Million

2500
2000
1500
1000
500
Construction period

0
-5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10111213141516171819202122232425
-500
Fixed capital
Land

Zero Time
investment
Working capital line
investment

Base case
Best case
Worst
case

Appendix Q Major and Minor Equipment Design Distribution

Engineer
Ko Zhijun
Sim Yee Fang
Siew Shang Yee
Ooi Wei Jin
Mak Yin Yin

Major Design
R-101 Primary Reformer
T-100 CO2 Absorber
R-103 High Temperature Shift
T-101 CO2 Stripper
R-106 First Ammonia Converter

Minor Design
E-100 Heat Exchanger
E-111 Condensate Preflash Cooler
V-100 Condensate Flash
M-101Product Mixer
V-106 Ammonia Refrigerated Storage Tank