1. Mentor: Dennis O’ Brien
CHE 397
Group Charlie
Priya Chetty, Scott Morgan, Brian Mottel, Daniyal Qamar, Sukhjinder Singh
Mentor: Dennis O’ Brien
Dr. Jeffery Perl

2. BLOCK FLOW DIAGRAM HX Reactor Flash Distillation I Distillation II
Hot Feed
Recycle Stream MS
Compressor HX
Splitter
Reactor
Condenser
Flash
Water
Cold Syngas
Crude Methanol
Grade AA Methanol
Low Key impurities
Distillation I
Distillation II
Higher Alcohols

3. Schematic Flow Diagram

4. MATERIAL AND ENERGY BALANCES REACTOR

5. Material and Energy Balance
Material Balance Reactor
Component
Mole Flow
Composition In
Feed to Reactor (lbmol/hr)
Purge (lbmol/hr)
Recycle (lbmol/hr)
Product Out (lbmol/hr)
M Tons per day CO
lbmol/hr
.32 H2
.66
CO2
.02
479.74
CH3OH
H2O

6. Material and Energy Balance
Energy Balance Reactor
Component
Temperature (F) in
Pressure (psi) in
Enthalpy (Btu/lbmol) in
Temp(F) out
Enthalpy (Btu/lbmol) out CO
482
1200
E+08
489.23
2.616E+08 H2
1.5378E+09
1.56E+09
CO2
1.19E+08
1.215E+08
CH3OH
E+08
H2O
E+06
Reaction 1
Reaction 2
Total
2.2E+09
2.18E+09

7. HAND CALCULATIONS AND DATA REACTOR

8. Reactor Material Balance
Assumptions:
100% separation of all feed gases (CO, H2, CO2) and products (CH3OH, H2O)
Purge Concentrations are controllable for now
No Nitrogen or Water in feed syngas
Other side reactions ignored
Pressure effects on Cp

9. Hand Calculations Reactor
Reaction 1: CO +H2 ↔ CH3OH ΔHrxn = Btu/lbmol
Reaction 2: CO2 +3H2 ↔ CH3OH + H ΔHrxn = Btu/lbmol
Reaction 1 Conv = 0.5 Reaction 2 Conv = .04
Material Balance:
COout = COfeed + COrec– .5(COfeed + COrec) – COpurge
CO2out = (CO2 feed + CO2rec) – 0.04 (CO2 feed + CO2rec) – CO2 purge
CH3OHout = .5(COout + COfeed) + .04(CO2out + CO2 feed)
Energy Balance
Enthalpy in (BTU) : H = Δ Href + ∫Cpdt for each component
Where Cp was used for gases: Cp = A + BT + CT2 +DT3
Enthalpy of reaction = .5(ΔHrxn1)COin + .04(ΔHrxn2)CO2in

10. Data Reactor 100 + Component IN (lbmol/hr) Reaction 1 2 3 4 5 6 7 CO H2
CO2
479.74
CH3OH
H2O
Enthalpies In
Btu/lbmol
Flows In (lbmol/hr)
Total In (Btu) CO
1.72E+04
E+08 H2
1.68E+04
E+09
CO2
2.37E+04
E+08
CH3OH
3.08E+04
E+00
H20
3.13E+04
1.20E+05
1.11E+05
E+09
Purge (lbmol/hr) CO H2
CO2

11. MATERIAL AND ENERGY BALANCES DISTILLATION COLUMN

12. Material Balance Material Balance Distillation Column Component
Feed Composition
Amount in feed (LB-MOL/Hr)
Distillate Composition
Amount in Distillate (LB-Mol/Hr)
Bottoms Composition
Amount in Bottoms (LB-Mol/Hr)
Methanol
0.9764
0.995
0.172
37.442
Water
0.0236
0.005
0.906
0.828
Total
1.00
217.74

13. Energy Balance

14. HAND CALCULATIONS AND DATA DISTILLATION COLUMN

15. Distillation Column Material Balance
Assumptions
lb-Moles/Hr of Methanol/H20 in feed
Feed composition 97.6% Methanol, 2.4% H20
Feed Pressure is 14.7psia
99.5% Methanol in Distillate

16. Hand Calculations Distillation Column
Material Balance
F = B + D
Fz = BxB + DxD
Energy Balance
Fhf + QC + QR = DhD +BhB
Q = mCPΔT

17. MATERIAL AND ENERGY BALANCE HEAT EXCHANGER

18. MATERIAL BALANCE AND DATA for HEAT EXCHANGER
Crude In
Temperature (F)
Flow-Rate
lbmol/hr (in/out)
Temperature Out (F)
MeOH
515
31.22
482
Water
.7554
Syngas In
Temperature (F)
Flow-Rate
lbmol/hr
(in/out)
Temperature Out (F) H2
482
6.6
505 CO
3.2
CO2 2

19. Hand Calculations HX Cp Values (Btu/lbmol°F Methanol 267 H2O 271
Q = Σ miCpiΔT
T(Syngas in) = 482 ˚F
T(Crude MeOH in) = 515 ˚F
Crude MeOH in = lbmol/hr
Water in = lbmol/hr
Syngas Compositions ( H2 = 6.6, CO = 3.2, CO2 = 2)
Q = 31.22lbmol/hr(267)( ) lbmol/hr(271)( )
Q = Btu/hr
= 6.6(122)(T-482) + 3.2(126)(T-482) + 2(188)(T-482)
= 8052T T – T –
Btu/hr = 100 (125) (T-482)
T(Syngas out) = 505 ˚F

20. ECONOMIC ANALYSIS

21. Fixed Capital Cost Table 1
Fixed Capital Cost Table 1.1: Estimate costs of specific units in the process flow diagram
Unit Type
Description
Base Cost/unit
No. of units
Total Cost $
Pumps
P-100
Pump
17,237,109 3
51,711,327
Compressors
CMP-200
Compressor
46,311,255 1
Reactors
R-300
MSR
16,392,569
HEX
C-200
Heat Exchanger
8,948,014
C-300
182,177
Separators
U-200
Flash unit
698,198 2
1,396,396
D-100
Distillation tower
581,086
1,162,172
Storage Tanks
Floating roof
Storage Tank
430,558 7
3,013,906
Total
$169,507,011
Amirkhas, Elton , and Raj Bedi. "METHANOL PRODUCTION IN TRINIDAD & TOBAGO." Phase II Design Report n. pag. Web. 15 Feb 2011.

22. Table 1.2: Estimate plant costs and operations
Operating Cost
Table 1.2: Estimate plant costs and operations
Cost Factor
Annual Cost
Feed stocks (raw materials)
Syngas
Feed water make-up
Total
$ 6,102
$ 364,001
$ 370,103
Utilities
Electricity
Cooling water, 90F, 65psig (CW)
Chilled cooling water, 60F
$7,634,000
$7,769,894
$90,009,785
$105,413,679
Operations (labor-related)
Direct wages and benefits
Direct salaries and benefits
Operating supplies and services
Control laboratory
$1,048,320
$209,664
$4,504,177
$78,624
$5,840,785
Maintenance
Wages and benefits
Materials and services
$15,260,000
$18,767,405
$34,027,405
Depreciation
$665,018,119 (entire plant life)
Cost of Manufacture
$183,764,004
Total General Expenses
$10,764,720
Total Production Cost
$155,622,979
Sales
Methanol Product
Total Sales
$215,294,400
Harkins, John. "WHAT IS UNDERGROUND COAL GASIFICATION (UCG)? ." Clean Global Energy (2010): n. pag. Web. 15 Feb 2011

23. Capital Investment Table 1.3: Annual costs
Cost Factor
Typical factor in American engineering units
Utilities
Steam, 300psig
$2.40/ 1000lbs
Electricity
$0.04/KWh
Cooling water
$0.05/ 1000gal
Waste treatment
$3.00/ 1000gal
MSR catalyst price
$6.00/ lb
feed water make-up
$1.50/ 1000gal
Bell, David, and Brian Towler. Coal Gasification and Its Applications. William Andrew, Print.

24. Future Goals Include side reactions Account for by products
Refine calculations using more accurate conditions
Reaction kinetics
Economics consistent with our project
Distillation column specifics
Sizing of equipment
Heat exchangers and pumps
Compressor

25. QUESTIONS?