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Elemantal analysis of thar coal analysis in mass %age

C 62.18 621.8
H2 5.44 54.4 F1=
O2 13.15 131.5
N2 0.78 7.8
S 3.97 39.7 F2
Ash 8.2 82
Water 6.28 62.8

COAL F1

F3 STEAM

MATERIAL BALANCES
MASS IN=MASS OUT
ASH:
f4= 82 kg/hr

N2:
0.28 kgmol/hr

S:
1.24 kgmol/hr = NH2S

C:
51.82 = nco+nco2

H2:
30.69 = NH2+NH2S-F3

29.45 = NH2-F3
NH2= 178.65
O2:
5.85 = 0.5NCO+NCO2-F2-0.5F3
chemical reaction
2.2 C+ 0.6 O2+h20 2.2
f2= 14.13 kgmol/hr o2 present in coal=
f2= 420.16 kg/hr So,this is the quantity of O2 which is needed,we
for f3
f3= 23.55 kgmol/hr
f3= 423.95 kg/hr
putting f3 in equation 1
nH2= 53 kgmol/hr
putting f2 & f3 in eq2
0.5nCO+nCO2= 30.76 kgmol/hr 3

nCO= 42.11 kgmol/hr


nCO2= 9.7 kgmol/hr
COMPOSITION OF F5(SYNTHESIS GAS)
component kgmol/hr kg/hr Mole%
CO2 9.7 426.98 9.13
CO 42.11 1179.15 39.6
H2 53 106 49.84
N2 0.28 7.8 0.26
H2S 1.24 42.18 1.17
TOTAL 106.34 1762.11 100

F5= 106.34 kgmol/hr


Mol.wt of the syn gas can be calculated as
Mol wt of syn gas= 16.57 kg/kgmol FLOW OF SYN GAS=
suppose ash present in f5 is 22% of f4
ash= 16.4 kg/hr
so f5 finally will be= 1778.51 kg/hr

so f4 will be f4= 65.6 kg/hr


SUMMAR OF MATERIAL BALANCE AROUND GASSIFIER
Mass in Mass out
STREAM kg/hr STREAM2
F1 1000 F4
F2 420.16 F5
F3 423.95
TOTAL 1844.11 TOTAL

BALANCE AROUND CYCLONE SEPARATOR


F5

ASH F7

F5= 1778.51 kg/hr having ash176.66 kg/hr


suppose the efficiency of cyclone separator is 98.5%
solid removed f7= 16.15 kg/hr
solid unremoved= 0.25 kg/hr
F6= 1762.36 kg/hr

SUMMARY
MASS IN MASS OUT
STREAM kg/hr STREAM2 kg/hr2
F5 1778.51 F6 1762.36
0 F7 16.15
TOTAL 1778.51 TOTAL 1778.51

BALANCE AROUND EXCHANGER F8

F6

F10
For F6
F6= 1762.36 kg/hr
T6= 1200 K 926.85 ⁰C
for F9
F9= 1762.36 kg/hr
T9= 400 K 126.85 ⁰C
for F8
F8=?
T8= 300 K 26.85 ⁰C

for F10
F10=? 549 K 275.85 ⁰C

to find out the flow rate of cooling water we have to apply energy balance
ENERGY IN(GAS)-ENERGY OUT(GAS)=ENERGY IN((WATER)-ENERGY OUT(WATER)
s

m∗C
p g
as ∗Δ
T =m
Cp H
2O ∗Δ
T  m∗ λa
lig
nl ¿ ¿¿ ¿

F 6∗C pg a ∗
s T 6 −T 9 =F 8∗C pH 2 O∗T 1 0−T 8  λ s 
Where,
Cp,gas= 1.94 Kj/Kg⁰C
Cp,water= 4.65 Kj/Kg⁰C
Latent heat= 1569.15 Kj/Kg

putting all values in Eq#6


1003.81 =F8

SUMMARY
MASS IN MASS OUT
STREAM Kg/hr STREAM2 Kg/hr2
F6 1762.36 F9 1762.36
F8 1003.81 F10 1003.81
TOTAL 2766.17 TOTAL 2766.17

MATERIAL BALANCE AROUND H2S ABSORBER

F12(selexol in)

F9(syn. gases)

F13(selexol+h2s)
COMPOSITION OF F9
F9 kg/hr
CO2 426.98
CO 1179.15
H2 106
N2 7.8
H2S 42.18

TOTAL 1762.11
efficiency is 98.5% so H2S removed
H2S removed= 41.55 kg/hr
now,
F11=F9-H2S removed
F11= 1720.57 kg/hr

to find out the flowrate of the selexol we have to apply energy balance around the absorbe
FOR GAS
F9= 1762.11 kg/hr
Cp,gas= 1.94 kj/kg⁰C
T9= 400 K 126.85 ⁰C
T11= 388.15 K 115 ⁰C

Q=m∗Cp∗ΔT
So,

Q= F 9∗Cp gas ∗ T 9−T 11 

putting all values in the formula,


Q= 11.26 KW

for selexol
F12=?
Cp,Sselexol= 2.05 kj/kg⁰C
T12= 298.15 K 25 ⁰C
T13= 300.15 K 32 ⁰C

Q= F 12 ∗Cp selexol ∗ T 13 −T 12 

F12= 2.75 kg/sec


F12= 9890.49 kg/hr

F13=F12+H2S removed
F13= 9932.04 kg/hr
SUMMARY

MASS IN MASS OUT


STREAM kg/hr STREAM2 kg/hr2
F9 1762.11 F11 1720.57
F12 9890.49 F13 9932.04
TOTAL 11652.61 TOTAL 11652.61

Composition of F11
component kg/hr kgmol/hr %age
CO2 426.98 9.7 24.23
CO 1179.15 42.11 66.92
H2 106 53 6.02
N2 7.8 0.28 0.44
H2S 42.18 1.24 2.39
ash 0 0
TOTAL 1762.11 106.34 100

balance around shift converter


Steam F14

Syn. Gases F11

F11= 1762.11 kg/hr


Composition of F11
component kg/hr kgmol/hr
CO2 426.98 9.7
CO 1179.15 42.11
H2 106 53
N2 7.8 0.28
H2S
ash
TOTAL 1719.93 105.1

N2 BALANCE
0.28 kgmol/hr
O2 BALANCE
30.76 =nCO2+0.5nCO-0.5F14
C BALANCE
51.82 =nCO + nCO2 8

H2 BALANCE
53 =nH2s+nH2-F14 9

S BALANCE
0 =nH2S 10

the reaction in the shift reactor is the

CO+H2O CO2+H2

now from the chemical reaction equation

because the require efficency of the reactor is the 48%

for 1 mole of CO require=1mole of steam


20.21 mole of CO= 20.21 mole of H2O

So F14= 20.21 kgmole/hr put this value in eq 9

73.22 =Nh2 nH2= 146.43


put F14 in eq7

40.87 =0.5nCO+nCO2 11

by the calculation of eqs.8 & 10 nCO=


nCO=291.697768 kgmol/hr nCO2=
nCO2=231.301907 kgmol/hr
F15= 2083.79 kg/hr
ash in = ash out
17.666=17.666 kg/hr

streams in kg/hr stream out kg/hr2


F11 1719.93 F15 2083.79
F14 363.85
TOTAL 2083.79 TOTAL 2083.79

composition of F15

component kg/hr kmol/hr


CO2 1316.4 29.92
CO 613.16 21.9
H2 146.43 73.22
N2 7.8 0.28

TOTAL 2083.79 125.31

Material balance on the compressor

MASS IN = MASS OUT


2083.79 2083.79 kg/hr

BALANCE AROUND CO2 ABSORBER


F16
DEPG(Solvent)

F15

Syngas
29.92 CO2 CO2
21.9 CO CO
73.22 H2 H2
0.28 N2 F17 N2
DEPG+Co2 Total
C02 to be removed= 20.27
so 67.8% Co2 is to be removed
Co2 in F15= 29.92
Co2 Removed= 20.28
Co2 Left= 9.63

Balance Around Reactor And Separator

F18 Reactor

CO2 9.63 423.88


CO 21.9 613.16
H2 73.22 146.43 Recycle Stream
N2 0.28 7.8
Total 105.03 1191.27

Overall Balance
CO2 Balance: Efficience Of the reactor
Mass in = Mass out
9.63 = M(0)+P(x)+(9.63362218)(0.96)
P(X) 0.39 kmole/hr
CO Balance
Mass in = Mass out

21.9 = M(0)+P(y)+(21.8985854)*(0.96)
P(y) 0.88 kmole/hr
N2 Balnce:
Mass in = Mass out

0.28 = E(0)+P(g)+(0.28)(0)
P(g) 0.28 kmole/hr
H2 Balanvce:
Mass in = Mass out

73.22 = M(0)+P(y)+(2*221.8985854+3*9.63362218)*0.96
P(Z) 3.43 kmole/hr
So,
P(Z) 4.97 kmole/hr
%age of gases in Stream P
CO2 7.76
CO 17.64
H2 68.99
N2 5.61

Methanol From CO:


21.02 kmole/hr

Methanol From CO2:


9.25 kmole/hr
Water Produced from Co2 along with CH3OH
9.25 kmole/hr
Total No Of Moles Of Methanol
30.27
composition Of M(F20):
Methanol 30.27 76.6 %
Water 9.25 23.4 %
Total 39.52
CO2 Balance To Find out Recycle stream:
As Composition of R and P is same,So
(9..63362218+(0.0776104353*R))=0.14(9.64+0.0776104353*R)+(R+P)*(0.0776104353)
R= 66.06 -963362218 /0.0776104353
R= 727.04 kmole/hr

Balance Around distillation Column


V

Feed F
XF

kmole/hr
Methanol 30.27 968.67
Water 9.25 166.47
Total 39.52 1135.14

Xf 0.65

Xd 0.98

Xb 0.02
Overall Balance
F=D+B 1
Balance on Methanol
30.27 = 0.99D+0.0 3W
D can be find out by solving above two equations
D 30.29

W= 9.23
Methanol in D 29.99 kmole/he
Water 0.3 kmole/hr

Methanol in W 0.28
Water in W= 8.95
Methano Balance:
Mass in = Mass Out

30.27 = 30.27

Water Balance:
9.25 = 9.25

ENERGY BALANCE
ENERGY BALANCE AROUND GASIFIER:
F2

Flow Rate 1000 Kg/hr

F1

F3
For F1:
Flow rate 1000 Kg/hr
T1 313.15 K Cp 1.45 Kj/Kg-K
Tr 298.15 K
For F2:
Flow rate 420.16 Kg/hr
T2 600 K Cp 1 Kj/Kg-K
For F3:
Flow rate 423.95 Kg/hr Cp 4.65 Kj/Kg-K
T3 549 K

Energy in Coal:
Q=mCpdT

Q= 6.04 KW

Energy In Oxygen:
Q=mCpdT

Q= 35.33 kW

Energy In Steam:
Q=mCpdT+mλs
λs 1569.15 Kj/Kg
Q= 322.16

Total Heat In:


Qt= 363.54

Total Energy Generated:


this will be calculated from reactions
Only those reactions wil be considered which involve syngas.

1.22 [C+1/2O2 CO] dH= -111.3

C+H2O CO+H2 dH= 135.3


Overall Reaction
0.2C+0.6O2+H2O 2.2CO+H2 dH=
CO2 is also formed along with CO

C+O2 CO dH= -393.5


CO+1/2O2 CO2 dH= -283

Let,
Co2 Produced from reaction 3 is 60% and from reaction 4 is 40%.So

QA -0.64 KW

QB -0.31 KW

Qreac: -0.94 KW

Total Qin= Qt+Qreac


364.48 KW

NOW
Toal Energy Out= Energy in Flue Gas+Energy in Ash

Energy in Flue Gas:


T5 1200 K
Tr 298.15 K
Flowrate 1778.51 Kg/hr
Cp 1.94 Kj/Kg-K

Q=mCpdT

Q5= 865.24 KW
Energy in Ash:
Flow rate = 65.6 Kg/hr
T4 1200 K
Cp 0.51 Kj/Kg-K
Q=mCpdT
Q4= 8.45
Total heat Out= 873.69 KW
As Heat which is coming out of the gasifier is very large, so we have to incorporate burners to add the

Heat Required= Qin-Qout


-509.21 KW
Heat from Burners= 512 KW
Losses= 2.79 KW
Energy Balance Around Cyclone Separator:
As All the Entering and exiting stream are at the same temperature So

Energy in=Energy out


And iti s equal to zero.

Energy Balance Around Heat exchanger:

F8

F6

F10

Energy in F6(Syngas)+Energy in F8(Water)=Energy in F9(Syngas)+Energy in F10(steam)


For F6:
flow rate 1762.36 Kg/hr
T6 1200 K
Tr 298.15 K
Cp 1.94 Kj/Kg-K
Q=mCpdT
Q6= 857.38 KW
For F8:
Flow rate 1003.81 Kg/hr
T8 300 K
Cp 4.65 Kj/Kg-K

Q=mCpdT+mλs
Q8 439.93 KW
NOW
For F9:
T9 400 K
Flow rate 1762.36 Kg/hr

Q=mCpdT
Q9 96.83 KW

For F10:
T10 549 K
Flow rate 1003.81 Kg/hr
Cp 4.65 Kj/Kg-K
Q=mCpdT+mλs
Q10 762.96
1000 kg/hr

O2

SYN.GASES

F5

CO2
CO
H2
N2
H2S
ASH ASH
F4

2
CO+H2
8.63
ntity of O2 which is needed,we use 0.045$% excess air to compensate co2 formation

mol wt
44
28
2
28
34

W OF SYN GAS= 1762.11


kg/hr

E AROUND GASSIFIER

kg/hr2
65.6
1778.51
0
1844.11

F6
F9
nergy balance
NERGY OUT(WATER)

F11(syn.gases)
gy balance around the absorber
F15

7
mass of H2O= 363.85 kg/hr

kg/hr

21.9 kgmol/hr 613.16


29.92 kgmol/hr 1316.4
F18
Syngas

9.63 423.88
21.9 613.16
73.22 146.43
0.28 7.8
105.03 1191.27
F19 F20 M
F
Separator

ycle Stream

F21 P
R CO2 x
CO y
H2 z
N2 g

96%
9.63362218)*0.96

53*R)+(R+P)*(0.0776104353)
Xd
R D

B
XB

2
F5

F4
Kj/Kmole -135.79 Kj/Kmole

Kj/Kmole

0 Kj/Kmole

Kj/Kmole 3
Kj/Kmole 4
incorporate burners to add the required heat.

F9

rgy in F10(steam)
13.13 kgmol/hr