Cells for Input

Cells for Auto calcs

Natural Gas Composition (mol%)

Methane 83.4
Ethane 3.2
Propane 3.2
Butane 3.2
Nitrogen 2.9
Carbondioxide 4.1
Total 100

Pressure 900 psig

Temperature 1418 °F
Basis 796 lbmol/hr of Natural Gas Feed
Desired Production Rate 300 Tonnes/day

Stream Factor 334 days

Operating hours 8016 hours

Max. Hydrocarbon conc. in Steam reformer outlet gas 0.50%

Steam to hydrocarbon ratio in Primary Reformer 3
of Natural Gas Feed
Primary Reformer

Temperature 770 °C
Pressure 900 psig
Pressure Drop 10 psig
HC to Steam Ratio 3

Natural Gas 1
Primary
Steam Reformer
2

Reactions in Primary Reformer

Reaction 1 CH4 + H2O = CO + 3H2 75% based on CH4
Reaction 2 C2H6 + 2H2O = 2CO + 5H2 100% based on C2H6
Reaction 3 C3H8 + 3H2O = 3CO + 7H2 100% based on C3H8
Reaction 4 C4H10 + 4H2O = 4CO + 9H2 100% based on C4H10
Reaction 5 CO+H2O = CO2 + H2 40% based on CO

Stream 1 (Natural Gas) Stream 2 (Steam)

Components Mol. Wt Mole Flow Mass Flow
Mol% (mol/hr) (lb/hr) Mol%
Methane 16 83.4 663.864 10621.824 -
Ethane 30 3.2 25.472 764.16 -
Propane 44 3.2 25.472 1120.768 -
Butane 58 3.2 25.472 1477.376 -
Nitrogen 28 2.9 23.084 646.352 -
Carbon dioxide 44 4.1 32.636 1435.984 -
Carbon monoxide 28 - - - -
Hydrogen 2 - - - -
Oxygen 32 - - - -
Steam 18 - - - 100
Total 100 796 16066.464 100

Total Primary Reformer Inlet 56041.584 lb/hr

CO Production
Reaction 1 497.898 lbmol/hr
Reaction 2 50.944 lbmol/hr
Reaction 3 76.416 lbmol/hr
Reaction 4 101.888 lbmol/hr
Total 727.146 lbmol/hr

CO Consume
Reaction 5 290.8584 lbmol/hr

CO2 Produced
Reaction 5 290.8584 lbmol/hr

H2 Produced
Reaction 1 1493.694 lbmol/hr
Reaction 2 127.36 lbmol/hr
Reaction 3 178.304 lbmol/hr
Reaction 4 229.248 lbmol/hr
Reaction 5 290.8584 lbmol/hr
Total 2319.4644 lbmol/hr

Steam consumption
Reaction 1 497.898 lbmol/hr
Reaction 2 50.944 lbmol/hr
Reaction 3 76.416 lbmol/hr
Reaction 4 101.888 lbmol/hr
Reaction 5 290.8584 lbmol/hr
Total 1018.0044 lbmol/hr
 Secondary Reformer

Exit Temperature 1000 °C

Pressure 890 psig
Pressure Drop 10 psig

3 5
Primary Secondary
Reformer Reformer

4 Air

Reactions in Secondary Reformer

ed on CH4 Reaction 1 CH4 + H2O = CO + 3H2 85%
ed on C2H6 Reaction 2 CH4 + 2O2 = CO2 + 2H2O
ed on C3H8 Reaction 3 2CO + O2 = 2CO2
ed on C4H10 Reaction 4 CH4 + 2CO + 3O2 = 3CO2 + 2H2O 100%

Stream 2 (Steam) Stream 3 Stream 4 (Air)

Mole Flow Mass Flow Mole Flow Mass Flow Mole Flow
(mol/hr) (lb/hr) Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
- - 3.71 165.97 2655.46 - -
- - 0.00 0.00 0.00 - -
- - 0.00 0.00 0.00 - -
- - 0.00 0.00 0.00 - -
- - 0.52 23.08 646.35 79 966.44
- - 7.24 323.49 14233.75 - -
- - 9.76 436.29 12216.05 - -
- - 51.88 2319.46 4638.93 - -
- - - - - 21 256.90
2220.84 39975.12 26.90 1202.8356 21651.0408 - -
2220.84 39975.12 100 4471.132 56041.584 100 1223.35

Total Secondary Reformer Inlet 91322.89 lb/hr

Nitrogen in 966.44 lbmol/hr

Total air 1223.35 lbmol/hr
O2 with Air 256.90 lbmol/hr

CH4 Consumption
Reaction 4 85.63 lbmol/hr
Reaction 1 68.28 lbmol/hr
CO Production
Reaction 1 68.28 lbmol/hr

CO Consumption
Reaction 4 171.27 lbmol/hr

CO2 Production
Reaction 4 256.90 lbmol/hr

H2 production
Reaction 1 204.85 lbmol/hr

Steam Consumption
Reaction 1 68.28 lbmol/hr

Steam Production
Reaction 4 171.27 lbmol/hr
 based on remaining CH4 after Reaction 4

based on O2

eam 4 (Air) Stream 5

Mass Flow Mole Flow Mass Flow
(lb/hr) Mol% (mol/hr) (lb/hr)
- 0.21 12.05 192.80
- - - -
- - - -
- - - -
27060.418 17.22 989.53 27706.77
- 10.10 580.40 25537.47
- 5.80 333.30 9332.43
- 43.94 2524.31 5048.62
8220.89 0.00 0.00 0.00
- 22.73 1305.82 23504.80
35281.30 100 5745.41 91322.89
High Temperature Shift Converter

Temperature 360 °C
Pressure 880 psig
Pressure Drop 10 psig

SR outlet stream
5 HTS

Reactions in HTS
Reaction 1 CO+H2O = CO2 + H2 80% based on CO

Stream 5 (SR outlet) Stream 6 (HTS outlet)

Components Mol. Wt Mole Flow Mass Flow
Mol% (mol/hr) (lb/hr) Mol%
Methane 16 0.21 12.05 192.80 0.21
Nitrogen 28 17.22 989.53 27706.77 17.22
Carbon dioxide 44 10.10 580.40 25537.47 14.74
Carbon monoxide 28 5.80 333.30 9332.43 1.16
Hydrogen 2 43.94 2524.31 5048.62 48.58
Steam 18 22.73 1305.82 23504.80 18.09
Total 100 5745.4 91322.9 100

CO Consume
Reaction 1 266.64 lbmol/hr
CO2 Produced
Reaction 1 266.64 lbmol/hr
H2 Produced
Reaction 1 266.64 lbmol/hr
Steam Consume
Reaction 1 266.64 lbmol/hr
 Low Temperature Shift converter

Exit Temperature 210 °C

Pressure 870 psig
Pressure Drop 10 psig

6 7
HTS LTS

Reactions in LTS
Reaction 1 CO+H2O = CO2 + H2 80% based on CO

Stream 6 (HTS outlet) Stream 7 (LTS outlet)

Mole Flow Mass Flow Mole Flow Mass Flow
(mol/hr) (lb/hr) Mol% (mol/hr) (lb/hr)
12.05 192.80 0.21 12.05 192.80
989.53 27706.77 17.22 989.53 27706.77
847.04 37269.67 15.67 900.37 39616.11
66.66 1866.49 0.23 13.33 373.30
2790.95 5581.90 49.51 2844.28 5688.56
1039.18 18705.26 17.16 985.85 17745.35364
5745.41 91322.89 100 5745.41 91322.89

CO Consume
Reaction 1 53.33 lbmol/hr
CO2 Produced
Reaction 1 53.33 lbmol/hr
H2 Produced
Reaction 1 53.33 lbmol/hr
Steam Consume
Reaction 1 53.33 lbmol/hr
Cooler Separator

Temperature 40 °C
Pressure 860 psig LTS outlet stream
Pressure Drop 10 psig Cooler
8 Condenser
Assumptions:
Water Condensed 100%
CO2 Solubility in Water 0%

Stream 8 (LTS outlet) Stream 9

Components Mol. Wt Mole Flow Mass Flow
Mol% (mol/hr) (lb/hr) Mol%
Methane 16 0.21 12.05 192.80 0.25
Nitrogen 28 17.22 989.53 27706.77 20.79
Carbon dioxide 44 15.67 900.37 39616.11 18.92
Carbon monoxide 28 0.23 13.33 373.30 0.28
Hydrogen 2 49.51 2844.28 5688.56 59.76
Steam 18 17.16 985.85 17745.35 0.00
Total 100 5745.4 91322.9 100

CO2 Removal

Temperature 40 °C Stream from

Pressure 850 psig Cooler Separator 9
Pressure Drop 10 psig CO2 Removal
Lean Solvent
11
Assumptions:
Solvent Used MDEA
Solvent Loading 2 lbmol of Acid gas /lbmol of pure solvent
Solution Strength 100% by weight

Stream 9 (Feed Gas) Stream 11 (Lean Solven

Components Mol. Wt Mole Flow Mass Flow
Mol% (mol/hr) (lb/hr) Mol%
Methane 16 0.25 12.05 192.80 0.00
Nitrogen 28 20.79 989.53 27706.77 0.00
Carbon dioxide 44 18.92 900.37 39616.11 0.00
Carbon monoxide 28 0.28 13.33 373.30 0.00
Hydrogen 2 59.76 2844.28 5688.56 0.00
Potassium Carbonate 138 0.00 0.00 0.00 99.24
Water 18 0.00 0.00 0.00 0.76
Total 100.00 4759.6 73577.5 100.00
Total Mass in 135764.99 lb/hr
Total Mass out 135764.99 lb/hr
 9
Cooler
Condenser

10

Stream 9 Stream 10 (Condensed Water)

Mole Flow Mass Flow Mole Flow Mass Flow
(mol/hr) (lb/hr) Mol% (mol/hr) (lb/hr)
12.05 192.80 0.00 0.00 0.00
989.53 27706.77 0.00 0.00 0.00
900.37 39616.11 0.00 0.00 0.00
13.33 373.30 0.00 0.00 0.00
2844.28 5688.56 0.00 0.00 0.00
0.00 0.00 100.00 985.85 17745.35364
4759.55 73577.53 100 985.85 17745.35

91322.89

12
Treated Gas
O2 Removal

13 Rich Solvent

Stream 11 (Lean Solvent) Stream 12 (Treated Gas) Stream 13 (Rich Solvent)

Mole Flow Mass Flow Mole Flow Mass Flow Mole Flow
(mol/hr) (lb/hr) Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
0.00 0.00 0.31 12.05 192.80 0.00 0.00
0.00 0.00 25.64 989.53 27706.77 0.00 0.00
0.00 0.00 0.00 0.00 0.00 66.50 900.37
0.00 0.00 0.35 13.33 373.30 0.00 0.00
0.00 0.00 73.70 2844.28 5688.56 0.00 0.00
450.18 62125.27 0.00 0.00 0.00 33.25 450.18
3.45 62.19 0.00 0.00 0 0.26 3.45
453.64 62187.45 100 3859.19 33961.42 100 1354.00
3 (Rich Solvent)
Mass Flow
(lb/hr)
0.00
0.00
39616.11
0.00
0.00
62125.27
62.19
101803.57
Methanator

Temperature 325 °C
Pressure 840 psig
Pressure Drop 10 psig

From CO2 Removal Unit

12 Methanator

Reactions in Methanator
Reaction 1 CO+3H2 = CH4 +H2O 100% based on CO

Stream 12 (CO2 Removal outlet) Stream 14 (Methanator outlet

Components Mol. Wt Mole Flow Mass Flow
Mol% (mol/hr) (lb/hr) Mol%
Methane 16 0.31 12.05 192.80 0.66
Nitrogen 28 25.64 989.53 27706.77 25.82
Carbon monoxide 28 0.35 13.33 373.30 0.00
Hydrogen 2 73.70 2844.28 5688.56 73.17
Steam 18 0.00 0.00 0.00 0.35
Total 100 3859.2 33961.4 100

CO Consume
Reaction 1 13.33 lbmol/hr
H2 Consume
Reaction 1 40.00 lbmol/hr
CH4 Produced
Reaction 1 13.33 lbmol/hr
Steam Produced
Reaction 1 13.33 lbmol/hr
 14 16
Cooler and
Methanator Separator
15 Knock out water

Stream 14 (Methanator outlet) Stream 16 Stream 15 (Knock out Water)

Mole Flow Mass Flow Mole Flow Mass Flow Mole Flow
(mol/hr) (lb/hr) Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
25.38 406.11 0.66 25.38 406.11 0.00 0.00
989.53 27706.77 25.91 989.53 27706.77 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00
2804.28 5608.57 73.43 2804.28 5608.57 0.00 0.00
13.33 239.98 0.00 0.00 0 100.00 13.33
3832.52 33961.42 100 3819.19 33721.45 100 13.33
Knock out Water)
Mass Flow
(lb/hr)
0.00
0.00
0.00
0.00
239.98
239.98
Ammonia Conversion Loop

Temperature 400 °C
Pressure 840 psig
Pressure Drop 10 psig 21

From Methanator
Ammonia
16 Converter

Reactions in Ammonia Converter

Reaction 1 N2+3H2 = 2NH3 26% based on H2

Iteration No. 1
Stream 16 (Methanator Outlet) Stream 17 (Converter outlet)
Components Mol. Wt Mole Flow Mass Flow
Mol% (mol/hr) (lb/hr) Mol%
Methane 16 0.66 25.38 406.11 0.76
Nitrogen 28 25.91 989.53 27706.77 22.40
Hydrogen 2 73.43 2804.28 5608.57 62.26
Ammonia 17 0.00 0.00 0.00 14.58
Total 100 3819.2 33721.4 100

H2 Consume Calculations for Purge stream 20 Rate

Reaction 1 729.11 lbmol/hr Feed Stream Flow 3819.2

N2 Consume Feed Stream Inert 0.66
Reaction 1 243.04 lbmol/hr Required Inert Conc. 3
NH3 Produced Purge Stream 20 flow 846.06
Reaction 1 486.08 lbmol/hr Recycle Stream 21 Flow 2000.98

Iteration No. 2
Stream 16 (Methanator Outlet) Stream 17 (Converter outlet)
Components Mol. Wt Mole Flow Mass Flow
Mol% (mol/hr) (lb/hr) Mol%
Methane 16 0.74 43.22 691.53 0.85
Nitrogen 28 26.02 1514.18 42397.08 22.53
Hydrogen 2 73.24 4262.77 8525.54 62.08
Ammonia 17 0.00 0.00 0.00 14.54
Total 100 5820.2 51614.2 100

H2 Consume Calculations for Purge stream 20 Rate

Reaction 1 1108.32 lbmol/hr Feed Stream Flow 5820.2

N2 Consume Feed Stream Inert 0.74
Reaction 1 369.44 lbmol/hr Required Inert Conc. 3
NH3 Produced Purge Stream 20 flow 1440.70
Reaction 1 738.88 lbmol/hr Recycle Stream 21 Flow 2901.72

Iteration No. 3
Stream 16 (Methanator Outlet) Stream 17 (Converter outlet)
Components Mol. Wt Mole Flow Mass Flow
Mol% (mol/hr) (lb/hr) Mol%
Methane 16 0.83 72.10 1153.64 0.95
Nitrogen 28 26.13 2279.13 63815.60 22.67
Hydrogen 2 73.04 6370.66 12741.32 61.89
Ammonia 17 0.00 0.00 0.00 14.50
Total 100 8721.9 77710.6 100

H2 Consume Calculations for Purge stream 20 Rate

Reaction 1 1656.37 lbmol/hr Feed Stream Flow 8721.9

N2 Consume Feed Stream Inert 0.83
Reaction 1 552.12 lbmol/hr Required Inert Conc. 3
NH3 Produced Purge Stream 20 flow 2403.41
Reaction 1 1104.25 lbmol/hr Recycle Stream 21 Flow 4109.99

Iteration No. 4
Stream 16 (Methanator Outlet) Stream 17 (Converter outlet)
Components Mol. Wt Mole Flow Mass Flow
Mol% (mol/hr) (lb/hr) Mol%
Methane 16 0.92 117.60 1881.59 1.05
Nitrogen 28 26.25 3368.88 94328.58 22.82
Hydrogen 2 72.83 9345.40 18690.80 61.68
Ammonia 17 0.00 0.00 0.00 14.45
Total 100 12831.9 114901.0 100

H2 Consume Calculations for Purge stream 20 Rate

Reaction 1 2429.80 lbmol/hr Feed Stream Flow 12831.9

N2 Consume Feed Stream Inert 0.92
Reaction 1 809.93 lbmol/hr Required Inert Conc. 3
NH3 Produced Purge Stream 20 flow 3919.97
Reaction 1 1619.87 lbmol/hr Recycle Stream 21 Flow 5672.17

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.
 20
Recycle Stream Purge Stream

17 18
Cooler and
Ammonia Ammonia
Converter Separator
19 Liquid Ammonia

Stream 17 (Converter outlet) Stream 18 Stream 19 (Liquid Ammonia)

Mole Flow Mass Flow Mole Flow Mass Flow Mole Flow
(mol/hr) (lb/hr) Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
25.38 406.11 0.89 25.38 406.11 0.00 0.00
746.49 20901.71 26.22 746.49 20901.71 0.00 0.00
2075.17 4150.34 72.89 2075.17 4150.34 0.00 0.00
486.08 8263.29 0.00 0.00 0 100.00 486.08
3333.12 33721.45 100 2847.04 25458.16 100 486.08

Purge Stream 20 Recycle Stream 21

Mole Flow Mass Flow Mole Flow
lbmol/hr Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
mol% Methane 0.89 7.54 120.68 0.89 17.84
mol% Nitrogen 26.22 221.84 6211.40 26.22 524.65
lbmol/hr Hydrogen 72.89 616.68 1233.36 72.89 1458.49
lbmol/hr 100.00 846.06 7565.45 100.00 2000.98

Stream 17 (Converter outlet) Stream 18 Stream 19 (Liquid Ammonia)

Mole Flow Mass Flow Mole Flow Mass Flow Mole Flow
(mol/hr) (lb/hr) Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
43.22 691.53 1.00 43.22 691.53 0.00 0.00
1144.74 32052.76 26.36 1144.74 32052.76 0.00 0.00
3154.45 6308.90 72.64 3154.45 6308.90 0.00 0.00
738.88 12560.97 0.00 0.00 0 100.00 738.88
5081.29 51614.16 100 4342.41 39053.19 100 738.88

Purge Stream 20 Recycle Stream 21

Mole Flow Mass Flow Mole Flow
lbmol/hr Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
 mol% Methane 1.00 14.34 229.43 1.00 28.88
mol% Nitrogen 26.36 379.79 10634.24 26.36 764.95
lbmol/hr Hydrogen 72.64 1046.56 2093.12 72.64 2107.89
lbmol/hr 100.00 1440.70 12956.80 100.00 2901.72

Stream 17 (Converter outlet) Stream 18 Stream 19 (Liquid Ammonia)

Mole Flow Mass Flow Mole Flow Mass Flow Mole Flow
(mol/hr) (lb/hr) Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
72.10 1153.64 1.11 72.10 1153.64 0.00 0.00
1727.00 48356.13 26.51 1727.00 48356.13 0.00 0.00
4714.29 9428.58 72.38 4714.29 9428.58 0.00 0.00
1104.25 18772.21 0.00 0.00 0 100.00 1104.25
7617.64 77710.55 100 6513.40 58938.34 100 1104.25

Purge Stream 20 Recycle Stream 21

Mole Flow Mass Flow Mole Flow
lbmol/hr Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
mol% Methane 1.11 26.61 425.69 1.11 45.50
mol% Nitrogen 26.51 637.26 17843.14 26.51 1089.75
lbmol/hr Hydrogen 72.38 1739.55 3479.09 72.38 2974.74
lbmol/hr 100.00 2403.41 21747.92 100.00 4109.99

Stream 17 (Converter outlet) Stream 18 Stream 19 (Liquid Ammonia)

Mole Flow Mass Flow Mole Flow Mass Flow Mole Flow
(mol/hr) (lb/hr) Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
117.60 1881.59 1.23 117.60 1881.59 0.00 0.00
2558.94 71650.40 26.68 2558.94 71650.40 0.00 0.00
6915.60 13831.20 72.10 6915.60 13831.20 0.00 0.00
1619.87 27537.79 0.00 0.00 0 100.00 1619.87
11212.01 114900.97 100 9592.14 87363.19 100 1619.87

Purge Stream 20 Recycle Stream 21

Mole Flow Mass Flow Mole Flow
lbmol/hr Mol% (mol/hr) (lb/hr) Mol% (mol/hr)
mol% Methane 1.23 48.06 768.94 1.23 69.54
mol% Nitrogen 26.68 1045.75 29281.00 26.68 1513.19
lbmol/hr Hydrogen 72.10 2826.16 5652.32 72.10 4089.44
lbmol/hr 100.00 3919.97 35702.26 100.00 5672.17

equired after that all the stream should be purged.

 27537.79 lb/hr
299.9 Tonnes/day
1.0
he desired production rate.
(Liquid Ammonia)
Mass Flow
(lb/hr)
0.00
0.00
0.00
8263.29
8263.29 33721.45

le Stream 21
Mass Flow
(lb/hr)
285.42
14690.31
2916.98 25458.16
17892.71

(Liquid Ammonia)
Mass Flow
(lb/hr)
0.00
0.00
0.00
12560.97
12560.97

le Stream 21
Mass Flow
(lb/hr)
 462.10
21418.52
4215.78
26096.40

(Liquid Ammonia)
Mass Flow
(lb/hr)
0.00
0.00
0.00
18772.21
18772.21

le Stream 21
Mass Flow
(lb/hr)
727.95
30512.98
5949.48
37190.42

(Liquid Ammonia)
Mass Flow
(lb/hr)
0.00
0.00
0.00
27537.79
27537.79

le Stream 21
Mass Flow
(lb/hr)
1112.65
42369.41
8178.87
51660.93