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SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE

SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE. NORTH CAROLINA STATE UNIVERSITY DEPARTMENT OF CHEMICAL ENGINEERING SPRING 2004 R. BARNHILL E. FABRICIUS A. HERRMANN D. JONES. PROJECT OVERVIEW. Objective: make 3000 metric tons of liquid ammonia per day

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SUPERPRO-BASED AMMONIA PLANT RETROFIT REACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE

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  1. SUPERPRO-BASED AMMONIA PLANT RETROFITREACTOR OPTIMIZATION THROUGH ASPEN ASSISTANCE NORTH CAROLINA STATE UNIVERSITY DEPARTMENT OF CHEMICAL ENGINEERING SPRING 2004 R. BARNHILL E. FABRICIUS A. HERRMANN D. JONES

  2. PROJECT OVERVIEW • Objective: make 3000 metric tons of liquid ammonia per day • Two options for SuperPro simulation • Single-pressure process • Dual-pressure process • Compare and contrast • Economics (capital and operational) • Environmental (emissions and solid/liquid) • Determine the most profitable process

  3. KINETICS SUPPLIED • Equation: • Constants: • K1 = k01exp(-E1/RT) • K2 = k02exp(-E2/RT) • K01 = 1.78954*104 kgmol/m3-hr-atm1.5 • K02 = 2.5714*1016 kgmol-atm0.5/m3-hr • E1 = 20,800 kcal/kgmol • E2 = 47,400 kcal/kgmol

  4. CHALLENGES WITH SUPERPRO • Rate equation proves to be incompatible with given data • SuperPro only accepts simplified kinetics • However, SuperPro offers extent of reaction option

  5. ASPEN THEORY • Supply SuperPro with extent of reaction • Optimize through analysis of critical parameters that affect the rate of reaction • Advantages • Basic Aspen simulation with one piece of equipment • Aspen supports supplied kinetics • Disadvantages • Basic knowledge of Aspen required • Iterative process between two simulation systems

  6. ASPEN SIMULATION: STEP 1 • Setup Aspen to run ammonia reaction with supplied kinetics

  7. ASPEN SIMULATION: STEP 2 • Run simulations varying critical parameters • Temperature • Pressure • Reactor Size • Composition of inlet stream • Study the relationship between the different parameters of the reaction • Plotting the information and studying trends works well

  8. ASPEN SIMULATION: STEP 3 • Simulate the reactor at an “initial composition” obtained • Record SuperPro required Data • Temperature • Pressure • Reactor Size • Extent of Reaction

  9. SUPERPRO SIMULATION: STEP 1 • Plug the results from Aspen reactor simulation into SuperPro simulation (shown on next two slides) • Conduct mass and energy balances

  10. SUPERPRO SIMULATION: STEP 1a • Set Aspen operating temperature of the reactor

  11. SUPERPRO SIMULATION: STEP 1b • Set the extent of reaction that agrees with the Aspen data

  12. SUPERPRO SIMULATION: STEP 2 • Study the effects that the new outlet stream (from the reactor) has on the inlet stream • Take new inlet stream data and plug back into Aspen and re-run the simulations • This step is the final step in the cycle between Aspen and SuperPro – this cycle is to be repeated several times until optimal results are obtained

  13. SUMMARY AND KEY POINTS • Iterations between Aspen and SuperPro require the use of multiple sets of data • Keep accurate records • Optimize the system based on costs • Cost of pressurizing the feed stream • Cost of compressors • Energy cost of the compressors • Cost of cooling the reactor to the optimal temperature • Cost of the reactor (size dependent)

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