Cells for Input Cells for Auto calcs

Natural Gas Composition (mol%) Methane Ethane Propane Butane Nitrogen Carbondioxide Total Pressure Temperature Basis Desired Production Rate Stream Factor Operating hours Max. Hydrocarbon conc. in Steam reformer outlet gas Steam to hydrocarbon ratio in Primary Reformer

92 2 2 1 2 1 100 900 120 100 3000 345 8280 0.50% 3

ells for Input ells for Auto calcs

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

Primary ReformerTemperature Pressure Pressure Drop HC to Steam Ratio 727 C 900 psig 10 psig 3 Natural Gas Steam 1

2

Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5

Reactions in Primary Reformer CH4 + H2O = CO + 3H2 C2H6 + 2H2O = 2CO + 5H2 C3H8 + 3H2O = 3CO + 7H2 C4H10 + 4H2O = 4CO + 9H2 CO+H2O = CO2 + H2

75% 100% 100% 100% 40%

Stream 1 (Natural Gas) Components Mol. Wt 16 30 44 58 28 44 28 2 32 18 Mol% 92 2 2 1 2 1 100 7016 Mole Flow (mol/hr) 92 2 2 1 2 1 100 lb/hr Mass Flow (lb/hr) 1472 60 88 58 56 44 1778

Methane Ethane Propane Butane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Oxygen SteamTotal Total Primary Reformer Inlet CO Production Reaction 1 Reaction 2 Reaction 3 Reaction 4 Total CO Consume

69 lbmol/hr 4 lbmol/hr 6 lbmol/hr 4 lbmol/hr 83 lbmol/hr

Reaction 5 CO2 Produced Reaction 5 H2 Produced Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5 Total Steam consumption Reaction 1 Reaction 2 Reaction 3 Reaction 4 Reaction 5 Total

33.2 lbmol/hr

33.2 lbmol/hr

207 lbmol/hr 10 lbmol/hr 14 lbmol/hr 9 lbmol/hr 33.2 lbmol/hr 273.2 lbmol/hr

69 lbmol/hr 4 lbmol/hr 6 lbmol/hr 4 lbmol/hr 33.2 lbmol/hr 116.2 lbmol/hr

Secondary ReformerExit Temperature Pressure Pressure Drop Primary Reformer 4 based on CH4 based on C2H6 based on C3H8 based on C4H10 based on CO 3 Secondary Reformer Air 5 1000 890 10

Reaction 1 Reaction 2 Reaction 3 Reaction 4

Reactions in Secondary Reform CH4 + H2O = CO + 3H2 CH4 + 2O2 = CO2 + 2H2O 2CO + O2 = 2CO2 CH4 + 2CO + 3O2 = 3CO2 + 2H2

Stream 2 (Steam) Mol% 100 100 Mole Flow (mol/hr) 291 291 Mass Flow (lb/hr) 5238 5238 Mol% 4.13 0.00 0.00 0.00 0.36 6.14 8.94 49.05 31.38 100

Stream 3 Mole Flow (mol/hr) 23.00 0.00 0.00 0.00 2.00 34.20 49.80 273.20 174.8 557

Total Secondary Reformer Inlet Nitrogen in Total air O2 with Air CH4 Consumption Reaction 4 Reaction 1 113.83 144.09 30.26

10.09 10.98

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

10.98

20.17

30.26

32.93

Steam Consumption Reaction 1 Steam Production Reaction 4

10.98

20.17

C psig psig

Reactions in Secondary Reformer CH4 + H2O = CO + 3H2 CH4 + 2O2 = CO2 + 2H2O 2CO + O2 = 2CO2 CH4 + 2CO + 3O2 = 3CO2 + 2H2O

85% based on remaining CH4 after Reaction 4

100% based on O2

eam 3 Mass Flow (lb/hr) 368.00 0.00 0.00 0.00 56.00 1504.80 1394.40 546.40 3146.4 7016 Mol% 79 21 100

Stream 4 (Air) Mole Flow (mol/hr) 113.83 30.26 144.09 Mass Flow (lb/hr) 3187.33 968.30 4155.64 Mol% 0.27 16.25 9.04 5.70 42.94 0.00 25.81 100

Stream 5

11171.64 lb/hr lbmol/hr lbmol/hr lbmol/hr

lbmol/hr lbmol/hr

lbmol/hr

lbmol/hr

lbmol/hr

lbmol/hr

lbmol/hr

lbmol/hr

after Reaction 4

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

High Temperature Shift ConverterTemperature Pressure Pressure Drop 400 C 880 psig 10 psig

SR outlet stream 5 Reactions in HTS CO+H2O = CO2 + H2

Reaction 1

80%

Stream 5 (SR outlet) Components Mol. Wt 16 28 44 28 2 18 Mol% 0.27 16.25 9.04 5.70 42.94 25.81 100 Mole Flow (mol/hr) 1.94 115.83 64.46 40.60 306.13 184.00 713.0 Mass Flow (lb/hr) 30.99 3243.33 2836.22 1136.90 612.26 3311.94 11171.6

Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen SteamTotal CO Consume Reaction 1 CO2 Produced Reaction 1 H2 Produced Reaction 1 Steam Consume Reaction 1

32.48 lbmol/hr 32.48 lbmol/hr 32.48 lbmol/hr 32.48 lbmol/hr

Low Temperature Shift converterExit Temperature Pressure Pressure Drop 200 870 10

6 HTS LTS

7

based on CO

Reaction 1

Reactions in LTS CO+H2O = CO2 + H2

Stream 6 (HTS outlet) Mol% 0.27 16.25 13.60 1.14 47.49 21.25 100 Mole Flow (mol/hr) 1.94 115.83 96.94 8.12 338.61 151.51 712.96 CO Consume Reaction 1 CO2 Produced Reaction 1 H2 Produced Reaction 1 Steam Consume Reaction 1 Mass Flow (lb/hr) 30.99 3243.33 4265.46 227.38 677.22 2727.25 11171.64 Mol% 0.27 16.25 14.51 0.23 48.41 20.34 100

Stream 7 (LTS outlet) Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 145.02 712.96

6.50 lbmol/hr 6.50 lbmol/hr 6.50 lbmol/hr 6.50 lbmol/hr

C psig psig

80% based on CO

(LTS outlet) Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 2610.31 11171.64

Cooler SeparatorTemperature Pressure Pressure Drop Assumptions: Water Condensed CO2 Solubility in Water 120 C 860 psig 10 psig

LTS outlet stream 8

100% 0% Stream 8 (LTS outlet)

Components

Mol. Wt 16 28 44 28 2 18 Mol% 0.27 16.25 14.51 0.23 48.41 20.34 100

Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen SteamTotal

Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 145.02 713.0

Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 2610.31 11171.6

CO2 RemovalTemperature Pressure Pressure Drop Assumptions: Solvent Used Solvent Loading Solution Strength 120 C 850 psig 10 psig Stream from Cooler Separator Lean Solvent K2CO3 2 lbmol of Acid gas /lbmol of pure solvent 80% by weight Stream 9 (Feed Gas) Components Mol. Wt 16 28 44 28 2 138 18 Mol% 0.34 20.40 18.21 0.29 60.76 0.00 0.00 100.00 Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 0.00 0.00 567.9 Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 0.00 0.00 8561.3 9 11

Methane Nitrogen Carbon dioxide Carbon monoxide Hydrogen Potassium Carbonate WaterTotal

Total Mass in Total Mass out

17482.93 lb/hr 17482.93 lb/hr

Cooler Condenser 10

9

Stream 9 Mol% 0.34 20.40 18.21 0.29 60.76 0.00 100 Mole Flow (mol/hr) 1.94 115.83 103.44 1.62 345.11 0.00 567.94 Mass Flow (lb/hr) 30.99 3243.33 4551.31 45.48 690.22 0.00 8561.33 11171.64

Stream 10 (Condensed Water) Mol% 0.00 0.00 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.00 0.00 0.00 0.00 0.00 145.02 145.02

12 CO2 Removal 13

Treated Gas

Rich Solvent

Stream 11 (Lean Solvent) Mol% 0.00 0.00 0.00 0.00 0.00 34.29 65.71 100.00 Mole Flow (mol/hr) 0.00 0.00 0.00 0.00 0.00 51.72 99.13 150.85 Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 0.00 7137.28 1784.32 8921.60 Mol% 0.42 24.94 0.00 0.35 74.30 0.00 0.00 100

Stream 12 (Treated Gas) Mole Flow (mol/hr) 1.94 115.83 0.00 1.62 345.11 0.00 0.00 464.50

ondensed Water) Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 0.00 2610.31 2610.31

(Treated Gas) Mass Flow (lb/hr) 30.99 3243.33 0.00 45.48 690.22 0.00 0 4010.02 Mol% 0.00 0.00 40.68 0.00 0.00 20.34 38.98 100

Stream 13 (Rich Solvent) Mole Flow (mol/hr) 0.00 0.00 103.44 0.00 0.00 51.72 99.13 254.29 Mass Flow (lb/hr) 0.00 0.00 4551.31 0.00 0.00 7137.28 1784.32 13472.91

MethanatorTemperature Pressure Pressure Drop 400 C 840 psig 10 psig

From CO2 Removal Unit 12 Reactions in Methanator CO+3H2 = CH4 +H2O Stream 12 (CO2 Removal outlet) Components Mol. Wt 16 28 28 2 18 Mol% 0.42 24.94 0.35 74.30 0.00 100 Mole Flow (mol/hr) 1.94 115.83 1.62 345.11 0.00 464.5 Mass Flow (lb/hr) 30.99 3243.33 45.48 690.22 0.00 4010.0

Reaction 1

100%

Methane Nitrogen Carbon monoxide Hydrogen SteamTotal CO Consume Reaction 1 H2 Consume Reaction 1 CH4 Produced Reaction 1 Steam Produced Reaction 1

1.62 lbmol/hr 4.87 lbmol/hr 1.62 lbmol/hr 1.62 lbmol/hr

14 Methanator

Cooler and Separator

16

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

Knock out water

eam 16 Mass Flow (lb/hr) 56.98 3243.33 0.00 680.47 0 3980.78

Stream 15 (Knock out Water) Mol% 0.00 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.00 0.00 0.00 0.00 1.62 1.62 Mass Flow (lb/hr) 0.00 0.00 0.00 0.00 29.23 29.23

Ammonia Conversion LoopTemperature Pressure Pressure Drop 400 C 840 psig 10 psig From Methanator 16 Reactions in Ammonia Converter N2+3H2 = 2NH3

21

Reaction 1 Iteration No. 1

75%

Stream 16 (Methanator Outlet) Components Mol. Wt 16 28 2 17 Mol% 0.77 25.20 74.02 0.00 100 Mole Flow (mol/hr) 3.56 115.83 340.24 0.00 459.6 Mass Flow (lb/hr) 56.98 3243.33 680.47 0.00 3980.8

Methane Nitrogen Hydrogen AmmoniaTotal H2 Consume Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1 Iteration No. 2

Calculations for Purge stream 20 Rate 255.18 lbmol/hr 85.06 lbmol/hr 170.12 lbmol/hr Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow

Stream 16 (Methanator Outlet) Components Mol. Wt 16 28 2 17 Mol% 0.78 25.20 74.02 0.00 100 Mole Flow (mol/hr) 3.58 116.01 340.73 0.00 460.3 Mass Flow (lb/hr) 57.31 3248.31 681.45 0.00 3987.1

Methane Nitrogen Hydrogen AmmoniaTotal H2 Consume Reaction 1

Calculations for Purge stream 20 Rate 255.55 lbmol/hr Feed Stream Flow

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

85.18 lbmol/hr 170.36 lbmol/hr

Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow

Stream 16 (Methanator Outlet) Components Mol. Wt 16 28 2 17 Mol% 0.78 25.20 74.02 0.00 100 Mole Flow (mol/hr) 3.59 116.06 340.87 0.00 460.5 Mass Flow (lb/hr) 57.40 3249.76 681.74 0.00 3988.9

Methane Nitrogen Hydrogen AmmoniaTotal H2 Consume Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1 Iteration No. 4

Calculations for Purge stream 20 Rate 255.65 lbmol/hr 85.22 lbmol/hr 170.44 lbmol/hr Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow

Stream 16 (Methanator Outlet) Components Mol. Wt 16 28 2 17 Mol% 0.78 25.20 74.02 0.00 100 Mole Flow (mol/hr) 3.59 116.08 340.91 0.00 460.6 Mass Flow (lb/hr) 57.43 3250.19 681.83 0.00 3989.4

Methane Nitrogen Hydrogen AmmoniaTotal H2 Consume Reaction 1 N2 Consume Reaction 1 NH3 Produced Reaction 1

Calculations for Purge stream 20 Rate 255.68 lbmol/hr 85.23 lbmol/hr 170.46 lbmol/hr Feed Stream Flow Feed Stream Inert Required Inert Conc. Purge Stream 20 flow Recycle Stream 21 Flow

Note: This indicates that at the start-up, until the system get stabilized, recycle is required after that all the stream sh

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

Recycle Stream

20

Ammonia Converter

17

Cooler and Ammonia Separator

18

19 based on H2

Stream 17 (Converter outlet) Mol% 1.23 10.63 29.38 58.76 100 Mole Flow (mol/hr) 3.56 30.77 85.06 170.12 289.51 Mass Flow (lb/hr) 56.98 861.68 170.12 2892.01 3980.78 Mol% 2.98 25.78 71.24 0.00 100

Stream 18 Mole Flow (mol/hr) 3.56 30.77 85.06 0.00 119.39 Purge Stream 20

stream 20 Rate 459.6 lbmol/hr 0.77 mol% 3 mol% 118.71 lbmol/hr 0.69 lbmol/hr Mol% 2.98 25.78 71.24 100.00

Methane Nitrogen Hydrogen

Mole Flow (mol/hr) 3.54 30.60 84.57 118.71

Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100 Mole Flow (mol/hr) 3.58 30.83 85.18 170.36 289.96 Mass Flow (lb/hr) 57.31 863.22 170.36 2896.18 3987.07 Mol% 2.99 25.78 71.23 0.00 100

Stream 18 Mole Flow (mol/hr) 3.58 30.83 85.18 0.00 119.59 Purge Stream 20

stream 20 Rate 460.3 lbmol/hr Mol%

Mole Flow (mol/hr)

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

Methane Nitrogen Hydrogen

2.99 25.78 71.23 100.00

3.58 30.78 85.04 119.39

Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100 Mole Flow (mol/hr) 3.59 30.85 85.22 170.44 290.09 Mass Flow (lb/hr) 57.40 863.67 170.44 2897.41 3988.91 Mol% 3.00 25.78 71.22 0.00 100

Stream 18 Mole Flow (mol/hr) 3.59 30.85 85.22 0.00 119.65 Purge Stream 20

stream 20 Rate 460.5 lbmol/hr 0.78 mol% 3 mol% 119.59 lbmol/hr 0.06 lbmol/hr Mol% 3.00 25.78 71.22 100.00

Methane Nitrogen Hydrogen

Mole Flow (mol/hr) 3.59 30.83 85.18 119.59

Stream 17 (Converter outlet) Mol% 1.24 10.63 29.38 58.75 100 Mole Flow (mol/hr) 3.59 30.85 85.23 170.46 290.12 Mass Flow (lb/hr) 57.43 863.80 170.46 2897.76 3989.45 Mol% 3.00 25.78 71.22 0.00 100

Stream 18 Mole Flow (mol/hr) 3.59 30.85 85.23 0.00 119.67 Purge Stream 20

stream 20 Rate 460.6 lbmol/hr 0.78 mol% 3 mol% 119.65 lbmol/hr 0.02 lbmol/hr Mol% 3.00 25.78 71.22 100.00

Methane Nitrogen Hydrogen

Mole Flow (mol/hr) 3.59 30.85 85.22 119.65

d after that all the stream should be purged.

2897.76 lb/hr 31.6 Tonnes/day 95.1

he desired production rate.

Purge Stream

Liquid Ammonia

eam 18 Mass Flow (lb/hr) 56.98 861.68 170.12 0 1088.78

Stream 19 (Liquid Ammonia) Mol% 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.00 0.00 0.00 170.12 170.12 Recycle Stream 21 Mass Flow (lb/hr) 56.65 856.71 169.14 1082.49 Mol% 2.98 25.78 71.24 100.00 Mole Flow (mol/hr) 0.02 0.18 0.49 0.69 Mass Flow (lb/hr) 0.33 4.97 0.98 6.28 Mass Flow (lb/hr) 0.00 0.00 0.00 2892.01 2892.01

Stream 20

eam 18 Mass Flow (lb/hr) 57.31 863.22 170.36 0 1090.89

Stream 19 (Liquid Ammonia) Mol% 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.00 0.00 0.00 170.36 170.36 Recycle Stream 21 Mass Flow (lb/hr) Mol% Mole Flow (mol/hr) Mass Flow (lb/hr) Mass Flow (lb/hr) 0.00 0.00 0.00 2896.18 2896.18

Stream 20

57.21 861.76 170.08 1089.04

2.99 25.78 71.23 100.00

0.01 0.05 0.14 0.20

0.10 1.46 0.29 1.84

eam 18 Mass Flow (lb/hr) 57.40 863.67 170.44 0 1091.51

Stream 19 (Liquid Ammonia) Mol% 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.00 0.00 0.00 170.44 170.44 Recycle Stream 21 Mass Flow (lb/hr) 57.38 863.24 170.35 1090.97 Mol% 3.00 25.78 71.22 100.00 Mole Flow (mol/hr) 0.00 0.02 0.04 0.06 Mass Flow (lb/hr) 0.03 0.42 0.08 0.53 Mass Flow (lb/hr) 0.00 0.00 0.00 2897.41 2897.41

Stream 20

eam 18 Mass Flow (lb/hr) 57.43 863.80 170.46 0 1091.69

Stream 19 (Liquid Ammonia) Mol% 0.00 0.00 0.00 100.00 100 Mole Flow (mol/hr) 0.00 0.00 0.00 170.46 170.46 Recycle Stream 21 Mass Flow (lb/hr) 57.42 863.68 170.43 1091.53 Mol% 3.00 25.78 71.22 100.00 Mole Flow (mol/hr) 0.00 0.00 0.01 0.02 Mass Flow (lb/hr) 0.01 0.12 0.02 0.15 Mass Flow (lb/hr) 0.00 0.00 0.00 2897.76 2897.76

Stream 20

3980.78

1088.78