Faculty of Engineering

Department of Chemical Engineering

Title: Production heat and electricity from sewage

sludge : Section 2 Mass and Energy Balance

Course: Chemical Engineering Process Design 4

Code: PQD400S

Lecturer: Ademola Rabiu

Due Date: 05 September 2016

Student Number: 213255766

ii
Abstract

DME (dimethyl ether) is attracting great interest as an energy source for the 21st century
because of its multiple sources and excellent physical, chemical, and storage properties
Moreover, there are a lot of applications which use DME as raw materials to make new
chemicals or as aerosol propellant.

On the previous report, a process route was selected. The aim was to treat wastewater
using chemical engineering aspects and hence produce chemical compound, with economic
value. This is where DME was chosen. This report aims at performing material and energy
balance around the selected process route. Wastewater treatment is an important
component in the infrastructure of every country. However, with increasingly strict outlet
demands, wastewater treatment requires more and more energy. In this study mass and
energy balances are carried out in order to identify the needs for process optimization and
energy conservation.

From the material, the amount of raw materials was estimated, along with compositions
and flow rates of all intermediate streams. The total amount of wastewater to be treated
amounted to 150000 kg/hr (3600 tons/day). The amount of DME to be produced was found
to be 26207.61 kg/hr (629 tons/day), therefore the proposed design effectively produces DME
at a profitable amount. The amount of steam (utility) required if the reformer was found to
be 19057 kg/hr (457 tons/day), with an amount of 7504 kW used up in the reformer. The
plant had a net heat load of about 23220 kW, which can be used within the plant to as a
means of heating up other streams to cut down the energy consumption costs.

iii
iv
Table of Contents
Abstract ....................................................................................................................................................... iii
List of Figures ............................................................................................................................................... vi
List of Tables ................................................................................................................................................ vi
1. Introduction ........................................................................................................................................... 1
1.1 Background ..................................................................................................................................... 1
1.2 Aim and Objectives ........................................................................................................................ 1
2. Black Box Diagrams ............................................................................................................................ 2
2.1 Material and Energy Balances.................................................................................................... 3
2.1.1Separation Section ................................................................................................................... 3
2.1.2 Biogas Production Section .................................................................................................... 4
2.1.3 Biogas Cleaning ...................................................................................................................... 5
2.1.4 Reforming of Biogas Section................................................................................................. 6
2.15 Methanol Production Section ................................................................................................ 7
2.1.6 Dehydration of Methanol Section........................................................................................ 8
2.1.7 DME Production Section ....................................................................................................... 9
3. Block Flow and Process Flow Diagrams of the Process ............................................................. 14
4. Utilities and Energy Consumption................................................................................................. 18
5. Conclusion ............................................................................................................................................ 19
6. References ............................................................................................................................................ 20
7. Appendix .............................................................................................................................................. 22

v
List of Figures
Figure 1: Black box diagram for the settling, screening and gritting section......................... 3
Figure 2: Black box Biogas Production section ........................................................................ 4
Figure 3: Black box for the removal of H2S and NH3 from biogas........................................... 5
Figure 4: Black box diagram for syngas production section .................................................... 6
Figure 5: Black box diagram of methanol production section ................................................. 7
Figure 6: Black box diagram for the removal of water from methanol section ....................... 8
Figure 7: Black box diagram for the DME production ............................................................ 9
Figure 8: Black box diagram for the distillation column ........................................................10
Figure 9: Black box diagram for the methanol column ..........................................................10
Figure 10: Black box diagram for the heat exchanger 1 .........................................................11
Figure 11: Black box diagram for the heat exchanger 2.........................................................12
Figure 12: Block flow diagram for the methanol production ..................................................14
Figure 13: Block flow diagram for the DME production ........................................................15
Figure 14: PFD of the proposed design for the production of DME .......................................16
Figure 15: PFD for the DME Plant .........................................................................................17

List of Tables
Table 1: material and energy balances in the separation section ..........................................22
Table 2: Material and energy balances in the anaerobic digester..........................................22
Table 3: Material and energy balances in the reformer unit .................................................22
Table 4: Material and energy balances in the methanol reactor............................................23
Table 5: Material and energy balances for the dehydrator ....................................................23
Table 6: Material and energy balances for the DME synthesis reactor .................................23
Table 7: Material and energy balances on the DME distillation column...............................24
Table 8: Material and energy balances on the methanol distillation column ........................24
Table 9: Material and energy balances on heat exchanger 2 .................................................25
Table 10: Material and energy balances on heat exchanger 2 ...............................................25
Table 11: Summary of the amount of energy required and given off in each section ............25
Table 12: Specific heat capacities at different temperatures and molecular weights of each
component (Perry, 2008) .........................................................................................................26
Table 13: Group member’s contribution..................................................................................26

vi
1. Introduction

1.1 Background
Visitors, businesses as well as local residents are the prime contributors to this generation
of waste water. In modern times, ideally, it is desired to aim towards a balanced standard of
living, where recycling is prominent while maintaining comfortable living lifestyles.
However, current studies have shown that the city of Cape Town faces challenges due to
the on-growing population, which results into increasing waste water volume requiring
increase in investments and land use. This enforces action to be taken.

This processing route is required to improve the water quality and reduce the possible
negative impacts that hazardous sludge (obtained by DWW treatment) could have on the
health and safety of the city’s residents and to the environment as well as to produce a
valuable product with high economic value. From the previous proposed route selection, Di-
methyl ether (DME) was chosen as the preferred commodity chemical to be produced based
on its lucrative nature and its advantageous characteristic regarding the environment.

This report looks at the material and energy balances performed on the proposed design
idea. Such balances are the statement on the conservation of mass and energy, respectively.
Material and energy balances are crucial when designing a new chemical plant. The
material balance is a valuable tool to assess the performance of the (WWTP) and the control
of the process, particularly in the control of yields of the products while energy balance is
used to estimate the heat load of the various equipment in the process.

1.2 Aim and Objectives

The aim of this report is to present a brief summary of the significant aspects of the
material and energy balances involved in the selected process design route. The material
and energy balance is to be performed by slitting the process into major operating units,
and performing the conservation and mass and energy around individual unit. The mass
balance aims to give the idea of the plant size by determining the amount of raw material,
utilities and the product yield to be recovered, and energy balance gives an estimate of the
heat loads of various equipment and utilities used.

1
2. Black Box Diagrams
Material balances are the basis on which chemical processes are designed. When
implementing a black box method, a material balance takes into consideration the input
and output of the overall process. The unit operation whatever its nature is seen as a whole
and represented diagrammatically as a box (Sinnott, 1999). Black box diagrams have been
completed for both material and energy balance purposes.
According to the basic laws of thermodynamics, mass and energy are conserved within a
system. The form may change but the total quantity remains constant. If there is no
accumulation, what goes into a process must come out. This is true for batch operation and
also for continuous operation over any chosen time interval. The mass and energy balances
entering the box must balance the mass and energy coming out of the box. System
boundaries are implemented to separate each section. The black box approach was
applied to each essential section of the design namely:

 Domestic waste water separation

 Anaerobic Digestion (biogas production)

 Cleaning of Biogas

 Reforming of Biogas (syngas production)

 Methanol Production

 Dehydration of Methanol

 DME Synthesis
 DME Distillation Column
 Methanol Distillation Column
 Heat Exchanger 1
 Heat Exchanger 2

2
2.1 Material and Energy Balances

Material quantities, as they pass through processing operations, can be described by

material balances. Such balances are statements on the conservation of mass. Similarly,
energy quantities can be described by energy balances, which are statements on the
conservation of energy. If there is no accumulation, what goes into a process must come out.

Material and energy balances are very important in an industry. Material balances are
fundamental to the control of processing, particularly in the control of yields of the
products. The first material balances are determined in the exploratory stages of a new
process, improved during pilot plant experiments and then refined and maintained as a
control instrument as production continues. When any changes occur in the process, the
material balance has to be needs to be determined again.

The increasing cost of energy has caused the industries to examine means of reducing
energy consumption in processing. Energy balances are used in the examination of the
various stages of a process, over the whole process and even extending over the total
production system from the raw material to the finished product.

Energy balances were used to estimate the heat loads of various equipment in the process.
Therefore practical applications of energy balances tend to focus on particular dominant
aspects and so a heat balance, for example, can be a useful description of important cost
and quality aspects of process situation.

2.1.1Separation Section

Head feed: 150000 kg/hr

Screening

And
Water (95 %): 142500 kg/hr Solids
De-gritting
Solids (2.5 %): 3750 kg/hr 3750 kg/hr

Organics (2.5%): 3750 kg/hr

Organics (97%): 3750 kg/hr

Water (3%): 142500 kg/hr

Figure 1: Black box diagram for the settling, screening and gritting section

3
The above black box above shows the separation section that occurs before treatment of
organic and water in the digester. The total feed of domestic waste water used is 3600 tons
per day (150000 kg/hr). This was decided on by comparing to the capacity of other waste
water treating plant. The screening, gritting and settling section of the plant successfully
separates the organic fraction (chemical oxygen demand and biochemical oxygen demand)
of the domestic waste water. The solid fraction that comprises of metal, plastics, solids and
others will not be processed further. It was decided to recycle the plastics and metals
(arsenic, mercury, lead, etc) compositions. The removal of these materials is crucial to
extend the operational period between digester shut down for maintenance (Arceivala &
Asolekar, 2007). If these materials are not removed by they could cause problems such as
blockage of pipes and pumps and accumulation in the digester. The mass of organic
material to be processed further was found to be 3750 kg/hr whereas the total solids stream
comprised of 3750 kg of material per hour.

2.1.2 Biogas Production Section

Organics (3%): 3750 kg/hr

Anaerobic
Water (97%): 142500 kg/hr
Digestion
Biogas: 43875 kg/hr

CH4 (65%): 28518.75 kg/hr

Sludge CO2 (34%): 14917.50 kg/hr

102375 kg/hr NH3 (0.5%):219.38 kg/hr

H2S (0.5%): 219.38 kg/hr

Figure 2: Black box Biogas Production section

In this section organic molecules are converted into a gas rich in methane (biogas). The
anaerobic digester processes 3750 kilograms per hour (kg/hr) of organic material. It was
assumed that about 30% of the incoming stream was converted to biogas, and the rest goes
out as sludge. The total biogas produced was found to be 43875 kg/hr. This biogas is then

4
fed to the absorption column for removal of a collective mass of 219.38 kg consisting of H 2S
and NH3. The sludge fraction will then be sold to a composting industry.

2.1.3 Biogas Cleaning

Biogas: 43875 kg/hr

Absorption
CH4 65% H2O
Column
CO2 34% NaHS

H2S 0.5%

NH3 0.5% CH4

CO2

NaOH

Figure 3: Black box for the removal of H2S and NH3 from biogas

The raw biogas contains trace amounts of hydrogen sulphide (H2S) and ammonia (NH3)
resulting from the anaerobic digestion of organic material containing sulphur (Lastella et
al, 2002). These compounds are toxic to plant operators and corrosive to equipment,
therefore biogas is cleaned in an absorption column using NaOH solvent. Biogas is bubbled
in a solution of NaOH which forms sodium sulphide (NaHS). The absorption membranes
work at approx. atmospheric pressure (1 bar) which allows low-cost of construction. And the
temperature in the column ranges from 25-35oC. It is assumed that ammonia was also
removed since it is present only in small quantities. This procedure is necessary to prevent
fouling and blocking of the reformer unit.

5
2.1.4 Reforming of Biogas Section

Q = 498 kW

Biogas: 26061 kg/hr Reformer

CH4 (65%): 16940.138 kg/hr Unit Syngas: 47119 kg/hr

CO2 (35%): 9121.61 kg/hr CO (65.7%):29645 kg/hr

CO2 (20.2 %):9122 kg/hr

Steam H2 (14.1%): 6353 kg/hr

19057.7kg/hr

(7504 kW)

Figure 4: Black box diagram for syngas production section

The production of syngas (predominantly CO2, CO and H2) by steam reforming 26061 kg of
cleaned biogas was found to be 47119 kg/hr. Synthesis of syngas occurs at reaction
conditions with temperatures ranging from 700 0C – 900 0C (over a nickel catalyst) and
pressure ranging from 20-40 bars (Ryi et al, 2009). Fired burners supply heat for the
endothermic reaction (Huisman & Lathouder et al, 2009):
𝐍𝐢/𝟕𝟎𝟎−𝟗𝟎𝟎 𝐂
𝐂𝐇𝟒 + 𝐇𝟐 𝐎 ↔ 𝐂𝐎 + 𝟑𝐇𝟐 (1)

Reforming reaction is ‘endothermic’ this means it is heat demanding. The amount of heat
required in the reformer was found to be 498 kW, since 7504 kW, was provided by the
incoming stream already. The feed gases that pass through hundreds of catalyst filled
tubes in the reforming furnace need to be heated and maintained at about 840oC
(Tomishige & Matsuo et al, 2001). It is at these conditions, and in contact with the
necessary catalyst, that the reaction takes place.

After the steam reforming process, most of this heat is not wasted; it is recovered by use of
heat exchangers that transfer this energy to other parts of the process that require it.

In real situations not all reactants are converted to products, meaning that the conversion
is less than 100%; some of unreacted reactants remain in the product stream. However for
the sake of simplicity of this design 100% conversion was assumed.

6
2.15 Methanol Production Section
Q = - 15753 kW

Syngas: 45119.4 kg/hr

CO (23.8%): 1058.76 kg/hr Methanol H2 (1.9%): 873.66 kg/hr

CO2 (46.7%): 9121.61 kg/hr Production CH3OH (90%): 40514.18 kg/hr

H2 (71.5%): 6352.55 kg/hr H2O (8%): 3731.57 kg/hr

Figure 5: Black box diagram of methanol production section

An amount of 45119.5 kg of syngas was compressed to 300 bars and used to make up the
synthesis cycle. The operating temperature in reactor is 350 oC (Sánchez & Moreda, 2004).
Hydrogen, carbon monoxide and carbon dioxide reacted to form methanol. The reactions are
illustrated below (Sánchez. & Moreda, 2004):

𝐂𝐎𝟐 + 𝟑𝐇𝟐 ↔ 𝐂𝐇𝟑 𝐎𝐇 + 𝐇𝟐 𝐎 (2)

𝐂𝐎 + 𝟐𝐇𝟐 ↔ 𝐂𝐇𝟑 𝐎𝐇 (3)

These reactions are both exothermic. The methanol produced at this stage is in vapor form
and is too hot to become a liquid. Unlike the steam reforming reaction, methanol synthesis
creates heat. The amount of heat given off was 15753 kJ/s.

7
 2.1.6 Dehydration of Methanol Section

Q = - 8575 kW

CH3OH (89.8%): Dehydration CH3OH (98%): 40514.18 kg/hr

40514.18 kg/hr Of Methanol H2 (2%): 873.66 kg/hr

H2O (8.3%): 3731.57 kg/hr

H2 (1.9%): 873.66 kg/hr

H2O: 3731.57 kg/hr

Figure 6: Black box diagram for the removal of water from methanol section

At this stage methanol stream contains 3531.6 kg of H2O and 873.7 kg of H2. Before being
sent to the DME plant, the methanol is further dehydrated to remove to remove water. The
dehydration of methanol takes place at a low temperature of about 70-80 OC, at
atmospheric pressure. This is just enough to boil off the methanol (bpt. 65OC) and leave
water behind (bpt. 100OC). Since the incoming stream is at a higher temperature, and then
dropped to a lower temperature, this requires extraction of heat from the process, hence
rendering the operation exothermic, giving off 8575kW of energy. The water extracted from
methanol goes to the reboiler to produce 19057.655 kg/hr of steam, which is used in the
steam reformer unit.

8
 2.1.7 DME Production Section

2.1.7.1 DME Synthesis Reactor

Q = 3850 kW

CH3OH (98%): 40514.18kg/hr H2O (25%): 10255.15 kg/hr

DME
H2 (2%): 873.66 kg/hr H2 (2.1%):873.66
Synthesis
Reactor CH3OCH3 (63%): 4051.42 kg/hr

CH3OH (9.8%): 26207.61 kg/hr

Figure 7: Black box diagram for the DME production

It is possible to directly synthesis DME from syngas. In recent years a number of processes
have been developed, but we have chosen the indirect synthesis method where methanol is
used as feedstock. The synthesis pressure is 1-2 MPaG (Huiseman et al., 2009). The inlet
DME
temperature is 200-250 0C and the outlet 300-350 0C. The conversion of methanol to DME
follows the reaction below.

2CH3 OH ↔ CH3 OH + H2 O

The conversion was assumed to be 90%, having methanol and water as the by-products,
which are further removed in the methanol distillation column. The product which is a
mixture of the four components in the product stream: 25% DME, 9.8% CH3OH, 25% H2O,
and 2.1% H2 is fed to the first distillation column The DME production is an endothermic
reaction, with the reactor having a heat load of 3850 kW. The DME produced amounted to
4051.42 kg/hr. the remaining methanol is separated and then recycled back to the reactor.

9
2.1.7.2 DME Distillation

Q = 0.186 kW

H2 (100%): 873.66 kg/hr

DME Distillation
CH3OCH3 (100%): 26207.kg/hr
Column
CH3OCH3 (63%): 26208 kg/hr

CH3OH (10%):4051 kg/hr

H2 (2%): 874 kg/hr

H2O (25%): 10255 kg/hr CH3OH (28.32%): 4021.42 kg/hr

H2O (71.68%): 10255 kg/hr

Figure 8: Black box diagram for the distillation column

At this stage a mixture containing 63% DME, 10% methanol, 25% water and 2% hydrogen
is separated in a distillation column. A desired purity of 100% DME is produced and H 2 is
purged off. A stream containing 28.32% methanol and 71.68% water goes to secondary
distillation column in order to achieve a 100% removal of methanol from the water.

2.1.7.3 Methanol Distillation

Q = 316 kW

Methanol
Distillation

Column
CH3OH (72%): 4051.42 kg/hr CH3OH (100%): 4051.42 kg/hr

H2O (28%): 10255.15 kg/hr

H2O (100%): 10255.15 kg/hr

Figure 9: Black box diagram for the methanol column

10
 In the secondary distillation was assumed that 100% removal of methanol from water is
separated from the DME. And methanol then enters the methanol distillation column
where it is dehydrated to remove the water before being recycled. This process is
endothermic, with a heat load of 316kW.

2.1.7.4 Heat Exchanger 1

Q = 3825 kW

Heat Exchanger

Unit 1

CH3OH (98%): 40514.18 kg/hr CH3OH (97.9%): 40514.18 kg/hr

H2 (2%): 873.66 kg/hr H2 (2.1%): 873.66 kg/hr

Figure 10: Black box diagram for the heat exchanger 1

The amount of energy entering with the stream mixture of 98% CH3OH and 2% H2 into the
heat exchanger is 3.27E+09 J/hr and the same stream leaves at 1.70E+10 J/hr. Therefore,
the amount of energy needed to heat up the exchanger unit is the difference between the
both streams energies which gives 1.38E+10 J/hr (3825 kW).

11
 2.1.7.5 Heat Exchanger 2

Q = - 7381 kW

Heat Exchanger

CH3OCH3 (63%): kg/hr Unit 2 CH3O CH3 (63.3%): 26207.61 kg/hr

CH3OH (10%): 4051.42 kg/hr CH3OH (9.78%): 4051.42 kg/hr

H2O (25%): 10255.15 kg/hr H2O (24.78%): 10255.15 kg/hr

H2 (2%) 873.66 kg/hr H2 (2.1%) 873.66 kg/hr

Figure 11: Black box diagram for the heat exchanger 2

The amount of energy entering with the stream mixture of 63% CH3OCH3, 2% H2, 25% H2O
and 10% CH3OH into the heat exchanger is 2.698E+10 J/hr and it leaves at 4.05E+08J/hr.
Therefore, the amount of energy given off by the exchanger unit is 4.05E+08 J/hr (7381
kW).

12
3. Block Flow and Process Flow Diagrams of the Process

Biogas
Sewage
146250.00 kg/h 43875 Kg/h
150000 Kg/h
1 Separation Section 2 Digester 3
CH4 65%
Water 95% Water 97% CO2 34%
Organic 2.5% Organic 3% NH3 5%
Solids 2.5% H2S 5% Sludge
102375 Kg/h
4

5
Solids
3750 Kg/h
6
NaOH

Absorber
Syngas
45119 Kg/h Clean Biogas
26061.8 Kg/h
Methanol Reactor 12 Steam Reformer
9 8 Clean Biogas
7
CO2 65% CH4 65% NaHS
43436.25 Kg/h
CO 21% CO2 35% Water
H2 14% CH4 65%
CH3OH 90% 13 45119.40 Kg/h
CO2 35%
41387.84 Kg/h
H2O 8%
H2 2% 14
CH3OH 98%
H2 2%
(To DME Plant)
Clean Biogas
Steam
11 10 17374.5 Kg/h
Dehydration Unit 19057.655 Kg/h
CH4 65%
CO2 35%

15
Water

Water Supply Tank 16 17 Reboiler

Water

Figure 12: Block flow diagram for the methanol production

14
 Purged gas (H2)

436.8 Kg/h

41387.8 Kg/h 41387.84 Kg/h

DME
DME synthesis DME distillation
1 reactor 2 column 4
CH3OH 98% CH3OCH3 63% 26207.6 Kg/h
H2 2% CH3OH 25%
H2O 9.8%
H2 2.1%

14306.57 Kg/h CH3OH 28%

5 H2O 72%

CH3OH Methanol distillation H2O

column
7 6

4051.42 Kg/h 10255.15 Kg/h

Figure 13: Block flow diagram for the DME production

15
 Wastewater
from sewage
treatment plant

Organic matter Organic matter

Organic matter
Water Water
Water Tank
Settling debris
Tank

Bar Screens Grit Screens

Organic matter
Solids Sewage sludge Water
Stones
Git, sand, stones

Rags, plastic, paper,

large solids

NaOH
solution

To DME plant

Biogas
CH4 55-70%
CO2 30-45%
Reformer Absorber H2,H2S,NH3 1-2%
Methanol reactor

Condenser

320-380oC
300 bar 700-900oC,
Syngas 20-40 bars NaHS,H
(CO,CO2,H2 2O
,H2O)

20oC, 1atm
Anaerobic digester

Dehydrator
CH3OH, H2O

1 atm, Steam
70-80oC

P-11

H2O Dewatering
Tank

H2O
Water supply tank

Manure
Membrane
(250C, 400- Metal ions
600 kPa)
Boiler
Water Biogas
from H2O
Diep Treated water
river (irrigation)

Figure 14: PFD of the proposed design for the production of DME

16
 Purged
gas
Water from the
water tank
Recovered methanol

220-250oC 25OC
DME fuel
1atm
Methanol feed

DME synthesis DME distillation

reactor column
300-350Oc
1-2MPaG
70-80OC
1atm
Methanol distillation
Unreacted column
Methanol,water
DME
Methanol
water

Water Water as by-

product

Figure 15: PFD for the DME Plant

17
4. Utilities and Energy Consumption
Table 1: Summary of the amount of energy required and given off in each section

Unit Section Q (kJ/hr) P (kW)

Reformer 1792760 498
Methanol Reactor -56709951 -15753
Dehydration column -30871739 -8575
DME Synthesis Reactor 13859587 3850
Distillation Column 670 0.186
Methanol Distillation column 1136648 316
Heat Exchanger 1 13769129 3825
Heat Exchanger 2 -26569862 -7381
net heat load -83592758 -23220

The table above shows the summary of the head loads from the major units within the
plant. From the table, it can be seen that the methanol reactor gives off the most energy
compared to all other exothermic operations. Methanol synthesis reactor seems to be the
one that required more energy compared to other units. This is purely due to the fact that
the reactions that take place are highly endothermic. The net head load is negative,
showing that the plant gives of energy as a whole. This means that streams can be crossed
in such a way that energy can be used within the plant and hence reduce energy cost.

Here, heating utilities include several levels of steam, while cooling utilities include cooling
water. About 40% of the biogas produced from the anaerobic digester is used as source of
fuel in the reboiler to produce 19057 kg/hr of steam required in the reformer unit;
providing about 7504 kW of energy.

18
5. Conclusion
Based on the material and energy balance performed in the preceding sections, the
following conclusions were drawn:

 The total amount of wastewater to be treated amounted to 150000 kg/hr (3600

tons/day).
 The amount of DME to be produced was found to be 26207.61 kg/hr (629 tons/day),
therefore the proposed design effectively produces DME at a profitable amount.
 The amount of steam (utility) required if the reformer was found to be 19057 kg/hr
(457 tons/day), with an amount of 7504 kW used up in the reformer.
 The plant had a net heat load of about 23220 kW, which can be used within the
plant to as a means of heating up other streams to cut down the energy consumption
costs.

19
6. References
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and Reuse, 3rd ed. Tata McGraw-Hill Publishing Company Limited: New Delhi.

2. Butler. & Michael, R. 2011. Introduction to wastewater treatment. London: David

Butler and Ventus Publishing Aps.

3. Henze, M., Jansen, J., Arvin, E. 1995. Wastewater Treatment: Biological and
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4. Huertas, J.I., Giraldo, N., & Izquierdo, S. 2000. Removal of H2S and CO2 from
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Technolico de Monterrey: Mexico

5. Huisman, G.H., Lathouder, H. de, and Cornelissen, R.L., 2009. Clean Hydrogen-rich
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6. Imhoff, K. & Fair, G. M., 1956. Sewage Treatment, 2nd Ed. John Wiley & Sons, Inc:
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7. Jorgensen, P. 2009. BIOGAS- Gron Energi. International Journal of Hydrogen

Energy

8. Lastella, G. C., Testa, G., Voltasio, F. 2002. Anaerobic digestion of semi-solid organic
waste: Biogas production and its purification. Energy Conversion and Management

9. Lee, F. B. (2001). A Comparative Study of Fuels for On-Board Hydrogen Production

for Fuel-Cell-Powered Automobiles. International Journal of Hydrogen Energy.

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11. Nykova N., Muller T. G., Gyllenberg M., Timmer J. (2002). Quantitative Analyses of
Anaerobic

12. Ohno, Y., Yoshida, M., Shikada, T., Inokoshi, O., Ogawa, T., Inoue, N. 2006. New
Direct Synthesis Technology for DME (Dimethyl Ether) and Its Application
Technology. JFE Technical Report

13. Ryi, S.K., Park, J.S., Kim, D.K., Kim, T.H., Kim, S.H. 2009. Methane Steam
Reforming with a Novel Catalytic Nickel Membrane for Effective Hydrogen
Production. Journal of Membrane Science.

14. Sánchez, E. A. & Moreda, F. 2004. Anaerobic Processes: Methanol Production From
Biogas. Available from: http://www.iqtma.uva.es/EnvTech/ [Accessed 25 April 2013].

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15. Sinnott, R. K. 1999. Coulson & Richardson Chemical Engineering: Chemical
Engineering Design. Oxford: Butterworth Heinemann

16. Tomishige, K., Matsuo, Y., Sekine, Y., Fujimoto, K. 2001. Effective Methane
Reforming with CO2 and O2 under pressurized condition using NiO-MgO and
Fluidized Bed Reactor. Catalysis Communications.

17. Vage, A., Rippel-Petho, D., Horvath, G., Toth, I., Olah, K. 2011. Removal of
Hydrogen Sulphide from Natural Gas, A motor Vehicle Fuel. Vol 39. Hungary:
Hungarian Journal of Industrial Chemistry Veszprem

18. Perry, H. R. 2008. Perry’s Chemical Engineers’ Handbook. 8th Ed. New York:
McGraw-Hill

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7. Appendix
Table 1: material and energy balances in the separation section

3600 t/d
Tota l Feed 150000.00 kg/h

comp. ma s s fra c ma s s (Kg/h) Separation comp ma s s (Kg/h) ma s s fra c

wa ter 0.95 142500 wa ter 142500.00 0.97
Orga ni c 0.025 3750 Orga ni c 3750.00 0.03
s ol i ds 0.025 3750
Tota l 1 150000 comp. ma s s (Kg/h) Tota l 146250.00 1.00
s ol i ds 3750.00

Table 2: Material and energy balances in the anaerobic digester

m 146250.00 kg/h

Anaerobic Digester Biogas

comp. mass frac mass (Kg/h) comp mass (Kg/h) mass frac
water 0.97 142500 CH 4 28518.75 0.65
2
Organic 0.03 3750 CO 14917.50 0.34
Total 1 146250 NH 3 219.38 0.005
mass (Kg/h) H 2S 219.38 0.005
102375 Total 43875.00 1.00
102375.00

Table 3: Material and energy balances in the reformer unit

ΔT 5 oC ΔT 675 oC

comp. Mass Frac mass Kg/h moles mole frac ΔH (J/h) comp. moles mass Kg/h mass frac ΔH
CH4 0.65 16940.138 1058.759 0.836257 1.872E+08 Reformer CO 1058.759 29645 0.657 2.219E+10
CO2 0.35 9121.6125 207.309 0.163743 3.804E+07 CO2 207.309 9122 0.202 6.841E+09
H2 3176.276 6353 0.141 0.000E+00
Total 1 26061.75 1266.068 1 2.252E+08 Total 4442.344 45119 1 2.903E+10

moles mass Kg/h ΔH

steam 1058.759 19057.655 27014225520

22
Table 4: Material and energy balances in the methanol reactor
o o
ΔT 675 C ΔT 325 C

comp. Mass Frac mass Kg/h moles mole frac ΔH comp. moles mass Kg/hmass frac ΔH
H2 0.1407942 6352.552 3176.276 0.715 6.252E+10 Methanol Reactor CH3OH 1266.068 40514.18 0.90 28184192266
CO2 0.2021661 9121.613 207.309 0.04667 6.841E+09 H2O 207.309 3731.57 0.08 2522540475
CO 0.6570397 29645.24 1058.759 0.23833 2.219E+10 H2 436.8 873.66 0.019 4134163556
Total 1 45119.4 4442.344 1 9.155E+10 Total 1910.208 45119.40 1.00 34840896297

Table 5: Material and energy balances for the dehydrator

ΔT 325 oC ΔT 45

comp. moles mass Kg/h mass frac ΔH comp mass Kg/h mass frac mole ΔH
CH3OH 1266.068 40514.175 0.898 2.82E+10 Dehydration CH3OH 40514.18 0.98 1266.067969 2.7E+09
H2O 207.3094 3731.56875 0.083 2.52E+09 H2 873.66 0.02 436.8304688 5.67E+08
H2 436.8305 873.6609375 0.019 4.13E+09 Total 41387.84 1.00 1702.898438 3.27E+09
Total 1910.208 45119.40469 1.000 3.48E+10

comp mass Kg/hmole ΔH

H2O 3731.57 207.30938 7.03E+08

Table 6: Material and energy balances for the DME synthesis reactor
o o
ΔT 195 C ΔT 325 C

comp mass Kg/h mass frac mole ΔH comp. moles mass Kg/h mass frac ΔH
CH3OH 40514.18 0.98 1266.068 14564926941 DME synthesis Reactor CH3OCH3 569.731 26207.61 0.63 20282656692
H2 873.66 0.02 436.8305 2470276301 H2O 569.731 10255.15 0.25 3659550473
Total 41387.83594 1 1702.898 17035203242 CH3OH 126.61 4051.42 0.098 2818419227
H2 436.83 873.66 0.021 4134163556
90% CONVERSION Total 1702.898 41387.84 1.00 30894789948

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Table 7: Material and energy balances on the DME distillation column

ΔT 5 oC

comp. moles mass Kg/h mass frac ΔH

Q (J/h) 670431.1148 H2 436.83 873.66 1 62990954
ΔT 5 oC Total 436.83 873.66 1.00 62990954
m 41388 kg/h

comp. moles mass Kg/h mass frac ΔH comp. moles mass Kg/h mass frac ΔH
CH3OCH3 570 26208 0.63 186786201.1
DME Distillation Column CH3OCH3 569.731 26207.61 1.00 1.87E+08
H2O 570 10255 0.25 53326782.84 Total 569.731 26207.61 1.00 1.87E+08
CH3OH 127 4051 0.10 27746132.75
H2 437 874 0.02 62423073.98
Total 1702.898 41387.84 1.00 330282190.7

comp. moles mass Kg/h mass frac ΔH

H2O 569.731 10255.15 0.716814159 53429334
CH3OH 126.61 4051.42 0.283185841 27746133
Total 696.337 14306.57 1 81175467

Table 8: Material and energy balances on the methanol distillation column

Q (J/h) 1136647589
ΔT 5 oC ΔT 45.00 oC

comp. moles mass Kg/h mass frac ΔH comp. moles mass Kg/h mass frac ΔH
H2O 569.731 10255.15 0.72 214486474 CH3OH 126.607 4051.42 1.00 409768469
CH3OH 126.61 4051.42 0.28 27746133
Methanol Distillation Column Total 126.607 4051.42 1.00 409768469
Total 696.337 14306.57 1.00 242232606

comp. moles mass Kg/h mass frac ΔH

H2O 569.731 10255.15 1 969111727
Total 569.731 10255.15 1 969111727

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Table 9: Material and energy balances on heat exchanger 2

Q (J/h) 1.38E+10

o o
ΔT 45 C ΔT 195 C

comp mass Kg/h mass frac mole ΔH comp. moles mass Kg/h mass frac ΔH
CH3OH 40514.18 0.98 1266.068 2.7E+09 HEAT EXCHANGER 1 CH3OH 1266.07 40514.18 0.979 14564926941
H2 873.66 0.02 436.8305 5.67E+08 H2 436.83 873.66 0.021 2470276301
Total 41387.83594 1 1702.898 3.27E+09 Total 1702.898 41387.84 1.00 17035203242

Table 10: Material and energy balances on heat exchanger 2

Q (J/h) -26569861723
ΔT 325 oC
o
ΔT 5 C

comp. moles mass Kg/h mass frac ΔH comp. moles mass Kg/h mass frac ΔH
CH3OCH3 569.731 26207.61 0.63 10220966.71 HEAT EXCHANGER H2O 569.731 10255.15 0.247782 53326782.84
H2O 569.731 10255.15 0.25 3659550473 CH3OH 126.61 4051.42 0.097889 289473780.4
CH3OH 126.61 4051.42 0.10 19171307610 H2 436.83 873.66 0.021109 62423073.98
H2 436.83 873.66 0.02 4134163556 CH3OCH3 569.731 26207.61 0.63322 157245.6417
Total 1702.898 41387.84 1.00 26975242606 Total 1702.898 41387.84 1.00 405380882.8

Table 11: Summary of the amount of energy required and given off in each section

Unit Section Q (kJ/hr) P (kW)

Reformer 1792760 498
Methanol Reactor -56709951 -15753
Dehydration column -30871739 -8575
DME Synthesis Reactor 13859587 3850
Distillation Column 670 0.186
Methanol Distillation
column 1136648 316
Heat Exchanger 1 13769129 3825
Heat Exchanger 2 -26569862 -7381

25
Table 12: Specific heat capacities at different temperatures and molecular weights of each
component (Perry, 2008)

comp. Mr Cp (J/kgK)
o o
CH4 16 25 C 70 C 220oC 350oC 400oC
2
CO 44 221 2350 2771 3352 3508
CO 28 834 891 1011 1085 1111
H2 O 18 1040 1042 1057 1098 1109
N2 28 4183 4187 1986 2080 2100
H2 2 14290 14420 14500 14560 14580
CH3 OH 32 1369.7 1480.5 1843.6 2140.5 2247.6
CH3 OCH3 46 1425.435 2381.3

Table 13: Group member’s contribution

Group Members Participation of each member

Resetselitsoe Sekhonyana Sekhonyana has greatly contributed in

the calculations of the material and
energy balance, coming up with the
calculation spread sheet, introduction,
abstract and conclusion and re- editing
of the report.

Samya Elias Samya has greatly contributed with

the structuring of the report,
discussions and interpreting of results,
researched, writing up and re-editing
the report, helping with the
calculations of the material and energy
balance, cimng up with the black boxes
and coming up the declaration.

Mutanis Nellago Lamperth Nellago has greatly contributed with

the structuring of the report,
discussions and interpreting of results,
researched, writing up and re-editing
the report, helping with the
calculations of the material and energy
balance, coming up with the black
boxes, the overall black boxes and
coming up the group member’s
26
 participation page.

Folomo Kibwana Folomo has greatly helped with the

calculations of the material and energy
balance, drawing up the DME plant,
and editing of the report.

Group Members

1. Sekhonyana Retselisitsoe ………………………………

2. Samya Elias ……………………………..

3. Mutanis Nellago Lamperth ……………………………..

4. Folomo Kibwana ……………………………..

27