Group Meeting # 2 Mentor: Shannon Brown, PE Michael Bentel Jeremy David Erik Peterson Arpit Shah 1

Questions from Group Meeting #1 What are the specifications for fuel? ~ 80 – 85% - C 2 + ~ 10% - CH 4 ~ 5 % - N 2 ~ 2 % - CO 2 What is the primary heat source for the boiler? Combustion gases from Gas Turbine along with Natural Gas Boiler – Heat Recovery Steam Generator (H.R.S.G.) What is the cheapest source of fuel for this plant? Waste hydrocarbons from **Team Alpha** 2

Questions (Cont’d) What is the minimum water purity required for boiler feed water (BFW)? Dissolved O2: < ppm Total Fe: < 0.01 ppm Total Cu: <0.01 ppm Total Hardness: 0.05 pH: Silica: <2.00 ppm Conduction < 150 Total Dissolved Solids (TDS): 0.1 How is the effluent stream from the boiler being addressed? The Effluent stream will be sent through the flue gas purification system 3

Group Meeting 2 Objectives Flow Sheets Material & Energy Balances Process Flow Sheet Frozen Data Hand Calculations Rough Economics 4

Outline 1. Design Basis √ 2. Block Flow Diagram √ 3. Process Flow Diagram  IN PROGRESS 4. Material and Energy Balance  IN PROGRESS 5. Calculations  IN PROGRESS 6. Annotated Equipment List (Data Sheet)  IN PROGRESS 7. Economic Evaluation factored from Equipment Costs 8. Utilities 9. Conceptual Control Scheme 10. General Arrangement – Major Equipment Layout 11. Distribution and End-use Issues Review 12. Constraints Review 13. Applicable Standards  IN PROGRESS 14. Project Communications File  IN PROGRESS 15. Information Sources and References  IN PROGRESS 5

Pumps and Compressors As stated before, compressor is going to be used to provide plant air Because instrument air must be very dry to avoid plugging and corrosion, a rotary screw oil free air compressor is commonly put through a dryer 6 Block Number UnitSteam Number Stream Label 16CompressorS-16Air - In 17DryerS-17Plant Air 24Surge TankS-18Compressed Air S-19Compressed Air S-30Instrument Air

Air Compressor Material Balance Oil - Free Air Compressor Refrigerated Air Dryer P1, T1 Wet (cfm) P2, T2, Wet (cfm) H2O (cfm) Dry (cfm) Conditions P111.8Psi T178F % Rel. Humidity90 Air Density0.0738lb/ft 3 1 lb Dry Air13.92ft 3 1 lb Dry Air0.0192lb H2O H20 Density62.25lb/ft 3 n (Heat Capacity Ratio)1.4 7

Compressed Air – Energy Balances Dryer Mass Balance ft 3 * 1 lb DA/ ft 3 * lb H 2 O/ lb DA = lb H2O * ft 3 /lb = cfm H 2 O Work Done in Compressed Air -W=P 1 ν 1 (n/(n-1))[(P 2 /P 1 ) (n-1)/n -1] =ZRT(n/(n-1))[(P 2 /P 1 ) (n-1)/n -1] Heat of Compression: T2=T1(P2/P1) (n-1/n) Team P 2 Required (psi)Dry (cfm)Wet (cfm)T2 FH2O (cfm)HP India

Compressor Costs Annual Electricity Cost = One of the most expensive sources of energy of plant 10% of electricity consumption goes to compressed air generation Several compressors may be installed for maintenance purposes as a stand-by spare 9

Williston, ND - Data Dry Bulb Temperature : 92°F Wet Bulb Temperature: 66°F Highest Relative Humidity: 90% 10

Induced – Draft Cooling Tower PFD 11

Cooling Tower – General Material Balance Dry Air Mass Balance ṁ a1 = ṁ a2 = ṁ a Water Mass Balance ṁ hw + ṁ a1 ∙ω 1 = ṁ cw + ṁ a2 ∙ω 2 = ṁ hw - ṁ cw = ṁ a (ω 2 - ω 1 ) Also, ṁ MU = ṁ a (ω 2 - ω 1 ) + ṁ BD 12

Cooling Tower – Energy Balance 13

Data Used to Calculate M&E Balance StreamEnthalpy (h) (Btu/lb DA) ω (lb H 2 O/lb DA) 1/ρ (ft 3 /lb) Air – In Air – Out Hot Return Water Cold Process Water

Results from M&E Balance - ECT 15 StreamTemperature (°F) Humidity Flowrate ( ṁ ) (lb/hr) Energy (Btu/hr) Air – In70~ 25 %232,0675,312,950 Air – Out90~ 90 %232,06717,983,714 Hot Return Water ,46522,973,275 Cold Process Water 85307,22710,328,954 Make Up Water 8510,238344,209 **Calculated at 11.8 psi

Turbine & Boiler System 16

Block Labels Block NumberBlock Name 1Pre-Water Treatment 2Pump 3Membrane Assembly 4EDI Module 5Resistivity Cell 6Compressor 7Combustion Chamber 8Gas Turbine 9Steam Turbine 10Processes 11Condenser 12Stacks 13Economizer 14Evaporator 15Super heater 22Deaerator 23Header 25Separator 17 Stream Labels LabelStream Name S-1Plant Water S-2Pre - Treated Water S-3Pre - Treated Water S-4Brine Discharge S-5Fresh Water S-6Pure Water S-7Ultrapure Water S-8Reheated Steam S-9Turbine Exhaust Steam S-10Low Pressure Steam S-11Condensed Steam S-12Hot Combustion Gases S-13Superheated Steam S-14Air S-15Compressed Air S-28Waste/Discharge S-29Natural Gas S-31Boiler Feed Water S-32Boiler Feed Water - Processes

Results from Boiler Material Balance StreamFlowrate ((lb/hr) Water – In107,000 Steam – Out107, *Based on ideal system (100% efficiency/recovery, no lose of water/steam due to system leakage)

Results from Boiler Energy Balance 19 Sensible Heat (Btu/lb) ΔT (°F)Latent Heat (Btu/lb) Phase Change Compression (Btu/lb) ΔP (psig)  Liquid  Vapor   Liquid  Vapor   Liquid  Vapor   Liquid  Vapor   Liquid  Vapor  1050 Superheated *Calculated using steam tables and superheated steam tables for latent heat and superheated work, respectively; averaged heat capacity over temperature ranges for sensible heat; PV work for compression.

Flue Gas Clean Up Particle Removal Gaseous Contaminates Removal Wet Scrubber – Utilizes water for removal Wet-Dry Scrubber – Utilizes aqueous spray for removal Dry Scrubber – Utilizes dry powder for removal Nitrogen Oxide Removal – Utilizes catalysis for removal Stack – Measures contaminates in out flowing combustion gases

USEPA & NDEPA Flue Gas Requirements NOx: 100 ppb, averaged over one hour SOx: 1 - hour standard at a level of 75 parts per billion CO: 8 - hour primary standard at 9 parts per million (ppm)

Turbine Material Balance Gas Turbine Air in + Fuel in = Exhaust Gas out m Air + m fuel = m Exhaust Steam Turbine High Pressure Steam in = Process Steam out + Condensing Steam out m High-P = m Process + m condensed 22

Turbine Energy Balance Gas Turbine Combustion Gas in = Work out + Exhaust Gas out (m*H) Combustion = (eff turbine *(m*H) Combustion + ((m*H) Combustion - eff turbine *(m*H) Combustion )) Steam Turbine High Pressure Steam in = Process Steam out + Condensing Steam out + Work out (m*H) high P. = Σ(m*H) process + (m*H) condensed + eff turbine *(Σ((m*H) high P – (m*H) process ) + ((m*H) high P. – (m*H) condensed )) 23

Relating Turbine and Boiler Energy & Material Balance Energy - Combustion Gas in – Work out = Exhaust Gas out = Exhaust Gas in = Steam out + Exhaust Gas out – Feed Water in Material – Air in + Fuel in = Exhaust Gas out = Exhaust Gas in = Steam out + Exhaust Gas out – Feed Water in 24

Results from M&E Balance – Gas Turbine StreamsFlow (MMSCFD)Energy Air0.028N/A Fuel ,366 Btu/mol Combusted Gas ,257,129 Btu/day 25

Equipment List EquipmentQuantity Reverse Osmosis System1 Electrodeionization System1 Water Tube Boiler1 Gas Turbine2 Steam Turbine1 Compressor1 Dryer1 H.R.S.G System1 Induced – Draft Cooling Tower1 26

CHP - Rough Economics 27

Equipment Cost Table EquipmentabS upper 0.8*S upper nC e ($) Cooling Tower170,0001,50010,0008, ,055,100 **Calculated Using Cost Estimation Equation in “Chemical Engineering Design”, Towler **Calculated Using “Plant Design and Economics for Chemical Engineers” Online Simulator, 5 th Edition **Estimated Cost from GE EquipmentCost ($) Compressor127,496 Steam Turbine308,856 Gas Turbine706,734 H.R.S.G~20,000,000 Water Purification System N/A 28

Equipment Cost EquipmentQuantityCost ($) Reverse Osmosis System1Waiting for Siemens to respond Electrodeionization System 1Waiting for Siemens to respond Gas Turbine21,413,468 Steam Turbine1308,856 Compressor2254,992 Dryer110,000 H.R.S.G System120,000,000 Induced – Draft Cooling Tower 15,055,100 29

Economics – Cont’d Total Equipment Cost: $27,032,416 Total Cost of Installation: $117,861,333 *Assumption: 4.36*(Cost of Equipment) Total Cost of Engineering: $8,109,724 *Assumption: Engineering costs = 0.30(Cost of Equipment) Total Cost = Cost of Equipment + Installation + Engineering = $153,003,474 30

QUESTIONS??? 31