Production of Syngas From Refinery Residual Waste

In The Name Of Allah the Most
Merciful, the Most Gracious and Beneficient
A DESIGN REPORT ON PRODUCTION OF 1000

MTPD OF SYNTHESIS GAS FROM REFINERY
RESIDUAL WASTE
Session
2006 2010
Project Advisors
Prof.Dr. Javaid Rabbani KHAN

Mr.Humbul Suleman
Submitted by
MUHAMMAD RIAZ*
ABD-UR-REHMAN
KHAWAR RIAZ
MUHAMMAD ALI
BILAL SAEED
2006-UET-IEFR/CHEM/FD-57
DEPARTMENT OF CHEMICAL ENGINEERING NFC

Institute of Engineering & Fertilizer Research, Faisalabad, Pakistan.
ii
A DESIGN REPORT ON PRODUCTION OF 1000

MTPD OF SYNTHESIS GAS FROM REFINERY
RESIDUAL WASTE
This project is submitted to

The Department of Chemical Engineering,
NFC Institute of Engineering & Fertilizer Research,
Faisalabad, Pakistan.
For the partial fulfillment of the

BACHELOR DEGREE IN CHEMICAL ENGINEERING
Approved on
Internal Examiner
External Examiner
-------------------Prof.Dr.Javaid Rabbani Khan

--------------------
DEPARTMENT OF CHEMICAL ENGINEERING

NFC Institute of Engineering & Fertilizer Research,
Faisalabad, Pakistan.
iii
DEDICATED
DEDICATED TO
TO
Our
Our
Beloved
Beloved Parents,
Parents,
Respected
Respected
Teachers
Teachers
&
&
Sincere
Sincere Friends
Friends
iv
Acknowledgement
ALLAH never spoils any effort every piece of work is awarded
according to the nature of devotion for it. We are extremely grateful to
the glory of Allah, the compassionate merciful His prophet
MUHAMMAD (Peace be upon Him) whose blessings enabled us to
complete the present studies.
We are thankful to our Director Prof.Dr. JAVAID RABBANI for
providing us encouraging environment & facilities regarding this
project.
We humbly express our gratitude to Mr. HUMBLE SULEMAN
for being greatly profited by his marvelous guidance & supervisory
intellectual.
Words do not come out easy to pay compliments firstly to our Parents
for their love, affection amiable attitude &prayers for our success &
secondly for our brothers & sweet sisters for their moral support and
timely backup.
Finally, as is customary, the error that remains are our.
(THE AUTHORS)
v
PREFACE
Some area of science & technology led by academias
other are paced by
industrialist chemical engineering
plant design has benefited from both inputs & at least in

the search areas, is practical at a high level of competence
Design is a creative activity, & such as can be one of the
almost rewarding & satisfying activities undertaken by an
engineer. It is the synthesis, the putting together of ideas
to achieve a desire purpose. The design starts with a
specific objective in a mind, a need & by developing &
evaluating possible design, arrives at what he consider the
best way of achieving that objective.
Authors
vi
Table of Contents
Chapter No 1....................................................................................................................................1
INTRODUCTION...........................................................................................................................1
1.1
Refinery Gasification............................................................................................................1
1.2
Emergence Of Refinery Gasification....................................................................................1
1.3
Benefits Of Refinery Gasification........................................................................................2
1.4
Why Syngas?........................................................................................................................2
1.5
Raw Materials.......................................................................................................................3
1.5.1
Other Residues..............................................................................................................4
1.6
Gasification Processes..........................................................................................................5
1.6.1
Fixed Bed Gasifiers.......................................................................................................6
1.6.2
Fluidized Bed Gasifier..................................................................................................6
1.6.3
Entrained Bed Gasifier.................................................................................................7
1.6.3.1
Texaco And Destec Gasifiers................................................................................7
1.6.3.2
Shell Gasifiers.......................................................................................................8
Chapter No 2..................................................................................................................................10
PROCESS DESCRIPTION...........................................................................................................10
2.1
Overall Process Description...............................................................................................10
2.2
Process Flow Diagram........................................................................................................11
2.3
Individual Equipment Description......................................................................................11
2.3.2
The Shell Gasification Process (Sgp)..........................................................................13
2.3.3
Bag Filter.....................................................................................................................14
2.3.4
Hydrolyser (Reactor)...................................................................................................15
2.3.5
Gas-Liquid Separators.................................................................................................16
2.3.5.1
Demister Pads:.....................................................................................................17
2.3.5.1
Advantage Of Vertical Separator.........................................................................18
Chapter No 3..................................................................................................................................19
MATERIAL BALANCE...............................................................................................................19
3.1 Material Balance Around The Gasifier...........................................................................19
3.2 Material Balance Around The Air Saperation Unit.........................................................22
3.3 Material Balance Around Bag Filter...............................................................................25
3.4 Material Balance Around Hydrolyser.............................................................................25
3.5 Material Balance Around Separator................................................................................26
3.6 Material Balance Around H2S Removal Unit.................................................................26
Chapter No 4..................................................................................................................................28
ENERGY BALANCE...................................................................................................................28
4.1
Gasifier Calculation...........................................................................................................28
4.2
Radiant Syngas Cooler (Rsc)Calculation..........................................................................29
4.3
Bag Filter Calculation.........................................................................................................30
4.4
Hydrolyser Calculation......................................................................................................30
4.5
Cooler Calculation..............................................................................................................31
4.6
H2S Removal Unit Calculation...........................................................................................32
4.7
Steam Calculation...............................................................................................................32
Chapter No 5..................................................................................................................................34
EQUIPMENT DESIGN.................................................................................................................34
5.1
Cryogenic Distillation Column Design..............................................................................34
vii
5.1.1
Diameter Evaluation For Columns With Sieve Trays.................................................37
5.1.2
Plate Effeciency...........................................................................................................38
5.1.3
Height Of The Column................................................................................................38
5.1.4
Check Weeping............................................................................................................39
5.1.5
Check Entrainment......................................................................................................39
5.1.6
Liquid Flow Pattern.....................................................................................................40
5.2
Gasifier Design...................................................................................................................40
5.2.1
Rate Of Reaction.........................................................................................................40
5.2.2
Coil Calculation...........................................................................................................42
5.2.3
Refractory (Fire Clay) Calculation..............................................................................43
5.2.4
Space Time..................................................................................................................44
5.2.5
Thickness Of Vessel....................................................................................................44
5.2.6
Thickness Of Hemi Spherical Heads...........................................................................45
5.3
Bag Filter Design................................................................................................................45
5.3.1
Area Of Bag.................................................................................................................45
5.3.2
Volume Of The Bag Filter...........................................................................................47
5.3.3
Thickness.....................................................................................................................47
5.4
Hydrolyser (Reactor) Design..............................................................................................48
(Fixed Bed Porous Catalyzed Isothermal P.F.R)............................................................................48
5.4.1
Weight Of Catalyst......................................................................................................48
5.4.2
Volume Of Catalyst.....................................................................................................49
5.4.3
Wall Thickness............................................................................................................49
5.4.4
Surface Area Of Reactor..............................................................................................50
5.4.5
Thickness Of The Hemispherical Head.......................................................................50
5.4.6
Space Time..................................................................................................................50
5.4.7
Space Velocity.............................................................................................................50
5.5
Vertical Separator Design...................................................................................................51
5.5.1
Terminal Velocity........................................................................................................52
5.5.2
Volume Of The Vessel.................................................................................................52
5.5.3
Thickness.....................................................................................................................53
5.5.4
Head Thickness...........................................................................................................53
5.6
Specification Sheets...........................................................................................................54
5.6.1
Cryogenic Distillation Column..................................................................................54
5.6.2
Gasifier........................................................................................................................54
5.6.3
Bag Filter.....................................................................................................................55
5.6.4
Hydrolyser (Reactor)...................................................................................................55
5.6.5
Vertical Separator........................................................................................................56
Chapter No 6..................................................................................................................................57
PLANT LOCATION......................................................................................................................57
6.1
Factors Affecting The Location Of Plant............................................................................57
6.1.1
Raw Materials Availability..........................................................................................58
6.1.2
Markets........................................................................................................................58
6.1.3
Energy Availability......................................................................................................58
6.1.4
Climate........................................................................................................................59
6.1.5
Transportation Facilities..............................................................................................59
6.1.6
Water Supply...............................................................................................................59
6.1.7
Waste Disposal............................................................................................................60
6.1.8
Labor Supply...............................................................................................................60
6.1.9
Taxation And Legal Restrictions.................................................................................60
6.1.10 Site Characteristics.....................................................................................................60
viii
6.1.11 Flood And Fire Protection..........................................................................................61

6.1.12 Community Factors....................................................................................................61
6.2
Location Of Our Plant........................................................................................................62
Chapter No 7..................................................................................................................................63
OVERALL PLANT COST ESTIMATION...................................................................................63
7.1
Fixed Capital Investment....................................................................................................63
7.1.1
Cost Of Air Separation Unit........................................................................................64
7.1.2
Cost Of Gasification Unit............................................................................................64
7.1.3
Cost Of Purification Unit............................................................................................65
7.1.4
Cost Of Hydrolyser Unit.............................................................................................65
7.2
Total Investment.................................................................................................................65
7.3
Total Product Cost..............................................................................................................65
7.3.1
Raw Material Costs.....................................................................................................65
7.3.2
Operating Cost.............................................................................................................65
7.3.3
Maintenance And Repairs (Including Repair Staff And Auxiliaries)..........................66
7.3.4
Laboratory Charges.....................................................................................................66
7.3.5
Fixed Charged.............................................................................................................66
7.3.6
Depreciation................................................................................................................66
7.3.7
General Expenses........................................................................................................67
7.3.8
Utilities........................................................................................................................67
7.4
Revenue From Product Sales..............................................................................................67
Chapter No 8..................................................................................................................................69
SAFETY AND HAZARDS CONSIDERATIONS........................................................................69
8.1 Health And Safety Hazards.............................................................................................69
8.2
Cryogenic Liquids..............................................................................................................69
8.3
Gas Products.......................................................................................................................70
8.4
Sources Of Exposure..........................................................................................................70
8.4.1
Mechanical Hazards....................................................................................................70
8.4.2
Material Hazards And Material Handling...................................................................71
8.4.3
Exposure Evaluation....................................................................................................71
8.4.4
Exposure-Hazard Control............................................................................................71
8.5
Fire Protection....................................................................................................................72
8.6
Waste Handling...................................................................................................................72
8.7
Electrical Requirements......................................................................................................72
8.8
Noise Control......................................................................................................................73
Chapter No 9..................................................................................................................................74
INSTRUMENTATION AND PROCESS CONTROL..................................................................74
9.1
Description Of The System.................................................................................................74
References......................................................................................................................................79
ix
Production of Syngas from Refinery Residual Waste
CHAPTER NO 1
INTRODUCTION
1.1 Refinery Gasification
The partial oxidation of carbon based material is called gasification. Gasification of the
refinery waste is called refinery gasification. The Refinery Industry is confronted with a difficult
challenge: crude oils are getting heavier and more contaminated while the demand and the
quality of light products, i.e. transportation fuels, are increasing. These two facts are in conflict
and force the industry to invest heavily to convert heavy products to light products and improve
their quality, to satisfy the requirements of progressively severe environmental regulations.
Conversion Technologies have been developed and improved over the years under the pressure
of this challenge. However the zero residue production still remains an impossible target.
Conversion, even in its most advanced and costly form leaves the refiner with a residual bottom
product reduced in volume but more contaminated with sulphur and metals, thus more difficult to
dispose. Yet the refiner must continue to produce high quality transportation fuels and find a
solution for the heavy residue, such as tar, coke, cracking bottoms, asphalt. Using these heavy
residues for production of electrical energy, steam, hydrogen and other syngas based chemicals,
is a solution to the problem, provided this conversion can be done in an environmentally friendly
manner. The recent interest in petroleum refinery-based gasification has been driven by a number
of issues currently facing refiners. The disposal of refinery generated hazardous wastes has
become a major issue for refiners Refiners are coming under increasing pressure to reduce
emissions of criteria pollutants and greenhouse gases generated at their facilities
1.2 Emergence of Refinery Gasification

Gasification has a long history of research, development and commercialization stretching
back more than 50 years. Over 129 plants have been constructed and operated worldwide, and as
many as 34 new plants are in various stages of planning and construction. The majority of the
existing plants were constructed for the production of synthesis gas or syngas, a mixture
1

containing carbon monoxide (CO) and hydrogen (H2), used in the manufacture of a wide variety
of chemicals. The second largest application has been the production of liquid fuels via the
Fischer-Tropsch synthesis. This application has been the subject of a number of commercial
ventures and demonstrations in recent years.
1.3 Benefits of Refinery Gasification

Benefits of refinery-based gasification are:
Source of power, steam and air products (oxygen and nitrogen) for refinery use or for
export and sale
Source of syngas for both hydrogen and refinery light products (FT synthesis)
Greater efficiencies for power generation than for the combustion of residuals in
conventional boilers
Much lower air emissions than for either direct combustion in conventional boilers or
Incineration
Smaller solid waste stream than for direct combustion
Low cost refinery waste.
Solution of disposal problems of refinery wastes.
1.4 Why Syngas?

Gasification with oxygen, by means of partial oxidation, converts the hydrocarbon structure into
a mixture of hydrogen and carbon monoxide, called syngas. Partial oxidation is a flexible process
that can handle any kind of refinery residue; liquid, solid and even refinery sludges and tank
bottoms. The composition of the clean syngas produced from a heavy residue is:
CO
45.5 % vol.
H2
43.0 "
CO2
8.2 "
Ar
1.0 "
N2
0.5 "
H2O
1.5 "
2
Clean syngas can be generated at any pressure between 20 and 70 bar, depending on the final use
of syngas. Syngas can be employed to produce pure H2.Syngas is used to synthesize various
chemicals such as methanol, ammonia, formaldehyde, MTBE, Oxo alcohols, etc. Syngas is also
an excellent fuel for gas turbines, thus providing a link between inexpensive residual fuels and
combined cycle, a technology with thermal efficiency well above 50 percent.
1.5 Raw Materials

A wide variety of feedstocks can be considered for gasification, ranging from solids to
liquids to gaseous streams. Although when the feed is a gas or liquid, the operation is frequently
referred to as partial oxidation. From a process perspective, partial oxidation of gases and liquids
is very similar to the gasification of solids. The major requirement for a suitable feedstock is that
it contains a significant content of carbon and hydrogen. Solid feedstocks include coal, petcoke,
biomass, and other solid waste streams. Refinery feedstocks often considered are process off-gas
streams and residual oils such as vacuum residue, visbreaker tar, and deasphalter pitch. These
residuals are often referred to generically as heavy oils.

Vacuum gas oil can be obtained if the atmospheric residue is subjected to vacuum
distillation. The vacuum residue usually meets the specifications of asphalt, a marketable
construction material. Thus, in the case of some conventional crudes, an almost complete
utilization may be achieved, leaving no residue. In such situations, there may be little economic
incentive for an additional conversion of vacuum residues to liquid products. Besides increasing
yields of liquid fractions by subjecting the atmospheric residue to vacuum distillation, the
additional liquids can be obtained by further upgrading the residue from vacuum distillation. In
this case, the upgrading processes generate the final residue such as coke and asphalt, which may
be converted to usable products, i.e., it can be either combusted or gasified to generate electricity
or other products. The type of crude oil processed by the refinery and the conditions to which the
crude oil is subjected determine the characteristics of the final residue. In the latter case, the
selected process is essential. For heavy crudes, the upgrading of vacuum residues can
significantly increase the yield of liquids per unit of crude entering the refinery. The best known
upgrading technologies which generate the final residues can be divided into thermal processes
and solvent extraction and/or precipitation processes. Thus, the residual pitch produced may be
further upgraded to liquid products and final residues, e.g., coke or asphalt. Visbreaking (thermal
or hydrogen) and coking (delayed, fluid and flexi) are typical thermal processes, whereas
deasphalting is the best known solvent treating process.
1.5.1 Other Residues

The asphalt from deasphalting, visbreaking tar and in some circumstances even vacuum
residues may be included among the final residues for gasification. The elemental analysis of
several gasification feedstocks tested as liquid feedstocks is shown in Table.
H/C ratio of these materials is significantly higher than that of cokes suggesting that some liquids
can still be produced, e.g., by coking. Nevertheless, for various reasons, the refiner may decide to
include these materials among the final residues. From the feeding point of view, physical
properties such as the softening point, viscosity and pumpability are equally important as is the
particle size for the solid feedstocks. In this regard, the asphalt from deasphalting deserves
attention because its properties can be, to a great extent, influenced by the operating conditions
applied during deasphalting.
Table 1.1 Propertiess of liquid and semi liquid residues
1.6 Gasification Processes

Gasification processes may be operated either at a near atmospheric pressure or at an
elevated pressure. The effect of pressure up to about 3.0 MPa (440 psi) on product composition
is small although the equilibrium considerations suggest on slowing down the decomposition of
steam and CO2 with increasing pressure. Many of the downstream units operate at elevated
pressures. Then, if the gasifier operates at a near atmospheric pressure, the raw gas has to be
compressed for the further processing. The cost of this compression may exceed the cost of an
atmospheric gasifier compared with the pressurized gasifier. Therefore, most of the advanced
commercial or near commercial gasifiers operate at elevated pressures.
The simplicity of gasification chemistry is overridden by the mechanical complexity as
well as the material requirements. A steady and uninterrupted feeding of the feedstock must be
maintained to ensure a continuous operation. Further, a proper mixing of the feedstock with
gasification medium in the gasifier must be achieved to obtain high conversions. Expensive
refractory linings are needed to prevent corrosions by slags in the advanced gasifiers.
Superalloys have to be used for some heat recovery systems to prevent corrosions by sulphur,
chlorine and alkalis and erosion by particulates. Several types of commercial gasifiers are
available to deal with these problems.
5
1.6.1 Fixed Bed Gasifiers

Fixed bed gasifier, also referred to as a moving bed gasifier, enquires a feedstock particle
size of 2 to 50 mm and can be used with air, oxygen and steam which are introduced into the
bottom of the reactor. Feedstock is fed from the top, ash or slag leaves the bottom and produced
gas exits at the top. Depending on the gasification medium, the bottom of the reactor can be
operated either in a dry mode or in a slagging mode. In the former case, temperature in the
gasification zone is in the range of 800 to 1050C whereas in the slagging mode, the temperature
may approach 1400C. Reactors can be operated at pressures ranging from 0.1 to 3.0 MPa
Residence time is in the order of 1 to 3 h. This type of gasifiers may not be suitable for
gasification of refinery residues, such as the fluid coke and flexi coke as well as visbreaking tar
and asphalt from deasphalting.
1.6.2 Fluidized Bed Gasifier

In the fluidized bed gasifier, feedstock is injected into the bottom and reactant gases can
be injected at two levels to maximize carbon conversion. The temperature in the fluidized bed
gasifier may approach 1200C if oxygen is used as gasification medium. The main problem of
the fluidized bed systems is the extent of carbon conversion and the carry-over of the fine
particles. Normally, this carry-over has high carbon content and has to be collected and recycled
to the gasifier. Also, the required average particle size (approximately 8 mm) of the feedstock
exceeds that of the fluid coke and flexi coke. For delayed coke, the suitable particle size may be
attained. However, low reactivity of the delayed coke may require a long residence time which
translates into lower throughputs. Little information indicates on the use of the fluid bed gasifier
for the gasification of the visbreaking tars and asphalt from deasphalting. High overall
conversions can be achieved if the fluid bed gasification is combined with the combustion of the
carried-over fines. In this case, both fluid coke and flexi coke can be used as feedstock. To a
certain extent, limestone can be injected into the fluidized bed of the feedstock for the in situ
sulphur capture. However, for feedstocks containing more than 5wt. % sulphur, the use of
limestone in the fluid bed combustor is not recommended .Several types of the fluid bed
gasifiers, e.g., U-Gas, HTW and KRW are available commercially. The gasification of petroleum
coke containing about 2wt. % sulphur with the limestone injection was successfully
demonstrated in KRW gasifier.
6
1.6.3 Entrained bed gasifier

Entrained bed gasifiers require a pulverized feedstock of which about 90% is less than
200 mesh. This suggests that the fluid coke and flexi coke require only a little preparation.
The feedstock can be injected either dry or in the form of a water slurry. Semisolid feedstocks,
such as visbreaking tars as well as the asphalt from deasphalting can be injected in a molten
phase. The injection ports can be either at the side or at the top of the reactor. In a dry feeding
mode, the feedstock is screw-fed from lock hoppers to burners where the gasification medium
(air, oxygen or steam) convey the feedstock at a velocity in excess of flame propagation rates
into the reactor. Pumps are used for the injection in a slurry mode and the feedsstocks in a molten
phase. The temperature of gasification flame may exceed 1500C. As the result of the high
temperature, most of the mineral matter in the feedstock is melted and removed in the form of a
slag. Residence time is in the order of 1 s. The units are usually operated at high pressures. As
indicated above, the combination of factors such as high temperatures, high content of
contaminants in the vapor phase and molten mineral matter results in special material
requirements.
Several types of the commercial entrained bed gasifiers are available for selection of one
which fulfills best the performance, economic and environmental requirements. With respect to
the gasification of refinery residues, the entrained bed gasifiers are the gasifiers of the choice.
For the purpose of this study, these gasifiers will be discussed in more details. The best known
slurry feeding entrained bed gasifiers are Texaco and Destec, whereas the best known dry feeding
systems are Shell and Prenflo gasifiers. High temperatures attained in these gasifiers make them
suitable for the gasification of less reactive feedstocks such as the petroleum coke and oil sand
coke.A wide range of liquid and semisolid materials can also be gasified.
1.6.3.1 Texaco and Destec Gasifiers
Texaco and Destec are the most advanced slurry fed gasifiers. In the Texaco process, the
solid feedstock such as coke is pulverized and slurried in a wet grinding mill to produce pump
able slurry containing between 55 and almost 70% of solids. The slurry water consists of the
recycled condensate from raw gas cooling and make-up water. The slurry is fed to the gasifier
through a specially designed nozzle together with oxygen. The slurry fed system provides high
feeding reliability which is critically important for pressurized systems. However, the use of the
7

slurry feeding system introduces a thermal penalty since some of the heat of combustion must be
utilized to convert the slurry water to steam. As the water requirements for the slurry production
increase, the oxygen consumption increases and quality of the gas decreases. It is therefore
critical for the economy of the Texaco process that the solid concentration in the slurry is high. In
this regard, in the solid concentration range, low rank coals and lignites are at the low end and
cokes at the high end. It is expected that for cokes, the solid concentration in the slurry can
approach 70% .Semisolid feedstocks such as vacuum residues and visbreaking tars as well as
liquid hydrocarbon feedstocks can be injected in a molten or liquid form without requiring the
slurry preparation.
Texaco Gasifier is a cylindary refractory lined vessel mounted on the top of the radiant
cooler. It has no movable parts, so its maintenance is simple. It operates at temperatures ranging
from 1200 to almost 1400C and pressure of about 30 atm.
At the bottom of the radiant cooler, slag drops into a quench pool of cooling water prior to its
removal, while gas flows to a convection type exchanger, where additional high pressure steam
is generated. Cooled gas is further treated to remove particulates and sulphur to make it suitable
for combustion turbine. High pressure steam generated in the radiant and convective coolers is
injected into the steam turbine. No convective cooler is provided. Also, both the slag and the gas
are quenched at the bottom. Cooled gas flows directly to the downstream units.
1.6.3.2 Shell Gasifiers
These are the most advanced dry fed entrained bed gasifiers. In this case, coal is first
pulverized and dried, if necessary, to less than 5% moisture content before is being conveyed
pneumatically under nitrogen and pressurized in the lockhoppers. Then, the coal is fed to the
gasifier together with oxygen and steam (if used) through two pairs of the horizontally opposed
burners. Temperature in the gasifier can readily exceed 1500C. At such temperatures, even a
high fusion temperature mineral matter can be slagged. Most of the molten slag is drained from
the gasifier through a slag tap at the bottom and collected in the water bath. Part of the slag is
entrained with the gas as a fly slag. The hot raw gas is first quenched with recycle product gas to
about 930C to solidify entrained fly slag. The gas and fly slag then flow to a convective gas
cooler where most of the sensible heat of the gas is recovered as a superheated high pressure
steam. Entrained fly slag and ash are then removed from the partially cooled raw gas using
cyclones and filters. Any feedstock which can be pulverized can be readily gasified. With respect
8

to the gasification of petroleum coke, the Shell gasifier is perhaps the most suitable, compared
with the other gasifiers. However, low ash content in the coke may require the addition of a
mineral matter to the coke to ensure formation of the protective layer of slag on the membrane
wall, at least during the initial stages of the operation. A significant modification of the feeding
system would be required to enable feeding of vacuum residues and visbreaking tar, as well as
that of refinery sludges. However, there are some indications on the Shells development of an
upscaled coannular burner to handle extremely viscous feedstocks such as visbreaking tars.
CHAPTER NO 2
PROCESS DESCRIPTION
2.1 Overall Process Description
The Refinery Residual Waste (Heavy Oil bottom) having composition as given in table
1.1 first enters the pulverizing section it is pulverized to a size of 40 micrometer. This size
reduction is done to make the feed easily entrainable in oxidant stream. The pulverized feed is
then sent to an intermediate storage tank. The feed through lock hopper system comes into mixer
at atmospheric pressure and temperature where it is mixed with oxidant stream coming from air
separation unit at 373 psi pressure and 25C temperature. The oxidant contains 99% oxygen
0.7% argon & 0.3% nitrogen.
A fully mixed mixture of the feed flow rate of 17.914 ton per hour and the oxidant flow
rate of 24.06 ton per hour from mixer is fed to the shell gasifier at 363 psi pressure and 25C
temperature . The mixture flows downward the Gasifier high pressure and temperature. The
synthesis gas leaves the Gasifier at 1500C. The raw syn gas enters the radiant syn gas cooler
where the gas is cooled to 250C. and pressure is 323 psi. This gas passes through the bag filter
where all the ash and the unreacted carbon is removed. The gas leaves the bag filter at 293 psi
and 250C temperature. The gas enters the HCN hydrolyser where steam of 293 psi is
introduced. In hydrolyser HCN reacts with steam to form ammonia and carbon monoxide. After
this gas will pass through cooler at 255C and pressure 280 psi where the gas is cooled to 25C.
All the heat is utilized to increase the temperature of water to generate steam. The gas comes to
reference temperature of 25C and pressure of 273 psi. From the cooler gas is passed through the
vertical separator where all the ammonia and water is separated. The gas comes out from
separator at 25C and pressure of 263 psi. The remaining the syn gas enters the H 2S removal unit
where all the H2S is removed by using Fe2O3 catalyst. The syn gas of required composition and
flow rate comes out of H2S removal unit at 25C and 253 psi pressure where it is sent to the
consumer.
10
2.2 Process Flow Diagram
oC
363
psi
Radiant syngas
cooler
T= 25 oC
2.3 Individual Equipment Description

2.3.1 Process Description- Air Separation Unit
All the unwanted particles are removed from the air mixture by filtration using air bag
filter. These unwanted particles might damage the equipment. Then it is sent to the de humidifier
to remove any sort of moisture in air stream. The moisture free filtered air is then sent for
compression to about 9 atm using two compressors in series with inter cooling arrangements. A
good amount of energy is needed for the efficient running of the compressor. After compression
the air becomes warm, thus the next stage is of precooling of the air stream. This air stream is
entered in first heat exchanger at about 30C and leave at -15.35C. The oxidant stream enters at
-194C and warms to 25C which is required for gasifier, and then the cooled air is further
cooled to -150C by the LP N2 stream loosing its temperature from -198C to -32C in HX2.the
11

cooled air is throttled to -194C (and about 1atm) the feed temperature of the cryogenic column.
The air cooled expands and gets more cooled when placed in a separation column. The gas
slowly turns to its liquid state. Air mixture may contain traces of argon, carbon dioxide and
hydrocarbons. These traces can be removed using pre purification units where these are further
liquefied and they freeze out. They become solid and can be easily removed. The liquid mixture
of products trickles down to meet the rising stream of gas. The liquid collects on the trays of
column and is penetrated by the vapor bubbles from beneath. Oxygen having higher boiling
point condenses out of the stream of gas. Nitrogen evaporates due to lower boiling point.
Gaseous nitrogen collects at the top of the separation column, while liquid oxygen collects at the
bottom of the column. The oxygen at the bottom is vaporized, while nitrogen in liquid form is
introduced at the top of the column. This process is continuous as long as is required to reach the
desired level of purity. The top product of the column with composition, N2 = 99.29 % & O2=
0.697 % is utilized to cool down air stream. From the bottom liquid O2 stream is obtained at
-194C which first use for the pre-cooling of the feed air and then goes to the Gasifier.
Figure 2.1 Air Separation Unit
12
2.3.2 The Shell Gasification Process (SGP)

The Shell Gasification Process (SGP) was developed in Shell s research center in
Amsterdam during the early 1950s, primarily as a means of manufacturing synthesis gas from
fuel oil. The first gasifier, using heavy fuel oil as feedstock, was brought on stream in 1956.Some
140150 units have been installed worldwide, with a processing capacity of some 7 million t/y of
residue. One typical reference plant processes about 240,000 t/y of residues of varying quality,
which are bought on the open market, for the production of ammonia. Another reference includes
a reduction gas plant for nickel furnaces, one of the few air-blown units in commercial, which
was started up in 1972, produces a mixed product slate of ammonia, methanol and hydrogen, and
is fed with about 350,000 t/y residue directly out of a visbreaker. An interesting operation.
Operating capability covers pressures up to about 65 bar and unit reactor sizes up to 1.8 million
Nm/d/ syngas capacity
Pulverized refinery residue (Heavy Oil) is first mixed with oxidant in the mixer at 25 C
and then fed to the shell gasifier through two horizontally opposed burners. Temperature in the
gasifier can readily exceed 1500C. At such temperatures, even a high fusion temperature
mineral matter can be slagged. Most of the molten slag is drained from the gasifier through a slag
tap at the bottom depending upon the % of ash present in the feed and collected in the water bath.
Part of the slag is entrained with the gas as a fly slag. If low in feed then all of slag will fly away
along with raw syngas. The hot raw gas is first quenched with recycle product gas to about
930C to solidify entrained fly slag. The gas and fly slag then flow to a convective gas cooler
where most of the sensible heat of the gas is recovered as a superheated high pressure steam.
Entrained fly slag and ash are then removed from the partially cooled raw gas using cyclones and
filters. The gas is then cooled further and scrubbed of any residual solids in a wet scrubber
system. Captured solids are recycled to the gasifier or mixed with the gasifier slag for disposal..
The clean fuel gas is normally reheated and may be saturated with water before being used in the
combustion turbine. Any feedstock which can be pulverized can be readily gasified. With respect
to the gasification of petroleum coke, the Shell gasifier is perhaps the most suitable, compared
with the other gasifiers. However, low ash content in the coke may require the addition of a
mineral matter to the coke to ensure formation of the protective layer of slag on the membrane
wall, at least during the initial stages of the operation. A significant modification of the feeding
system would be required to enable feeding of vacuum residues and visbreaking tar, as well as
13

that of refinery sludges. However, there are some indications on the Shells development of an
upscaled coannular burner to handle extremely viscous feedstocks such as visbreaking tars.
2.3.3 Bag Filter.

In a bag filter system, the particular laden gas stream passes through a woven of felted
fabric that filters out the particular matter and allows the gas to pass through. Small particles are
initially retained on fabric by direct inspection, inertial impaction, diffusion, electrostatic
attraction, and gravitational settling. After a dust mat has formed on the fabric, more efficient
collection of submicron particles (+99 percent) is accomplished by sieving.
Filter bag usually tubular or enveloped shaped, are capable of removing most particles
as small as 0.5 micrometer and will remove substantial quantities as small as 0.1 micrometer.
Filter bags ranging from 1.8 to 9 m (6 to 30 ft) long can be utilized in bag house filter
arrangement. The upper ends are closed and the lower ends are attracted to an inlet manifold. A
bag house arrangement may be small enough to fit into an ordinary room or large enough to
dwarf many industrial buildings. For example one bag house capable of removing 6 tons of
fumes and dust per hour from an automatic foundry consists of 16 compartments housing 4000
bags, each of which is 19.4 cm (7.64 in) in diameter and 6.9 m long.
A particulates buildup on inside surfaces of bags, the pressure drop increases. Before the
pressure drop becomes too severe, the bag must be relieved of some of particulate layer. Fabric
filters can be cleaned intermittently, periodically, or continuously. Because intermittent cleaning
means the unit must be shut down to prevent the discharge of raw gases directly into the
atmosphere, that method is seldom used. In periodic cleaning portion of the filter device are shut
down and cleaned for brief intervals, while the rest remains operational. In a continuous,
automatic cleaning operation, cleaning of some parts of the filter occurs at all times. In any of
these methods, a mechanical shaker, reverse air flow (below rings), or pulse jets may be used
to remove the dust cake.
Continuously cleaned filters that use traveling below ring of reverse air jets leave little
filter cake in place at any time. Although this result in some loss of collection efficiency, the
reduction in head loss allows faster filtering rates and collection efficiency, the reduction in head
loss allows faster filtering rates and decrease the size needed for the filter baghouse.
There are some problems associated with the use of fabric filters. The possibility of
explosion or fire exits if sparks are discharge in a baghouse area where organic dust is being
14

filtered. Space limitations may prohibit use of bag house large enough to handle very heavy
loads. There is always a slight possibility of rupture or other adverse effect because of
temperatures too high for the fabric medium or because of the moisture, acidity or alkalinity
content of the particulate laden gas stream. Judicious fabric choice can be minimizing these
problems.
Fabric filters have many applications, they have high collection efficiency over a broad
range of particle size extreme flexibility in design.
Figure 2.2 Bag Filter
2.3.4 Hydrolyser (Reactor)

A process for the removal of hydrogen cyanide from gas streams which comprises
contacting the gas stream in the presence of water in an amount at least sufficient to hydrolyze
the contained hydrogen cyanide with a catalyst consisting of at least one alkali metal hydroxide
deposited on a support selected from the group consisting of alumina, silica, alumina-silica and
the zeolites in which the alkali metal hydroxide deposited on the support as alkali metal is
present in an amount of from about 0.1 to about 10 percent by weight based on the total weight
of the alkali metal and the support at a temperature of from about 200F to about 800F for a
15

time sufficient to hydrolyze a substantial quantity of the hydrogen cyanide present in the gas
stream. Hydrolysis of the hydrogen cyanide is carried out at a temperature from about 200F to
about 400F. The catalyst contains from about 2 to about 10 percent alkali metal and the alkali
metal is selected from the group consisting of lithium, sodium, potassium, and mixtures.
Hydrolysis is carried out at a space velocity of from about 500 to about 5,000 volumes of gas per
unit volume of catalyst per hour.
To remove HCN (hydrogen cyanide) we install hydrolyser. Here gases from bag
filter react with water which we are giving as raw material to form ammonia. We can also install
an absorber to remove hydrogen cyanide but it may not be so much efficient because here in
hydrolyser we are converting hydrogen cyanide into ammonia up to 99% and the second thing to
install hydrolyser is that we are getting ammonia from hydrogen cyanide. Ammonia form in this
reaction may be used as a fertilizer and can be used to make urea which is added benefit for us.
We install isothermal catalytic fixed bed Plug flow reactor. We have selected isothermal reactor
because in our case inert are very much high and according to Octave Levenspiel third edition
when inert are present in very much amount then value of Cp (specific heat capacity) increases
with the increase in inert and slope becomes maximum as a result of that temperature-conversion
curve becomes vertical which will becomes special case of isothermal reactor.
We prefer Plug flow reactors because according to Octave Levenspiel third
edition if your slope (Cp/-Hr) is very high and inert are very much then Plug flow reactor will be
preferable and to ensure maximum contact between reactants we prefer fixed bed reactor.
Material of construction for our reactor is low alloy steel because low alloy steel is very much
similar to stainless steel but here we reduce the carbon contents and introduce other metals
instead of carbon just to increase corrosion resistance this is special material of construction for
reactor because according to Coulson and Richardson volume 6 lesser is the carbon contents
better will be its corrosion resistance.
2.3.5 Gas-Liquid Separators

A vertical separator for liquid-gas media comprising a cylindrical housing
accommodating a gas discharge pipe coaxial therewith, the pipe and the inner surface of the
housing define an annular space divided by a partition wall with openings for gas passage into a
liquid-gas space, and a gas space communicating with the internal space of the pipe. The liquidgas space accommodates blocks for separating the media into liquid and gas, the blocks
16

extending in the radial direction. Each separation block is provided with a gas discharge means
accommodated in spaces between adjacent separation blocks and embracing the gas-passage
openings in the partition wall.
2.3.5.1 Demister Pads:

Mist Eliminators or Demister Pads are very common & important things for process
engineers but they are often neglected. The importance of a demister pad comes from the
efficiency of separation & its impact on either product recovery or the indirect impact on
downstream processes. Usually later is more important than direct impacts & therefore they are
generally neglected peace of equipments.
17
Figure 2.3 Knitted materials with interlocking

The separation of entrained liquid droplets from a vapor / gas stream is called mist
elimination & the equipment used for the purpose is called De-mister. Demister pads are
fabricated from knitted materials with interlocking asymmetrical loops of metal or plastic with
typical diameters being 0.1 0.3mm. By careful choice of wire diameter, DA have produced
pads with extremely high free volumes (typically 98 99%) along with very high removal
efficiency and low pressure drop.
Along with wire diameter and mesh density, another important parameter in design and
operation of a demister pads the vapor velocity. This can be controlled by careful selection of the
eliminator area. Optimal area will depend on operating temperature, pressure and pressure drop.
Under normal operating conditions, 99% ++ removal efficiency can be achieved with a pressure
drop of less than 250 kPa
2.3.5.1 Advantage of Vertical Separator
Vertical vessels can handle more sand. Liquid level control is not as critical in a vertical
separator. The tendency of the liquid to re-vaporize is also minimized, because less surface area
is available to the liquid for evaporation.
It occupies less floor space, a particularly important advantage for operations on an offshore
platform where floor area is at a premium. A much greater gas-liquid interface area, permitting
higher gas velocities. They can, therefore, handle large gas volumes economically and efficiently.
They are cheaper to fabricate and ship than vertical separator. They are also easier and cheaper to
install and service.
18
CHAPTER NO 3
MATERIAL BALANCE
3.1 Material balance around the gasifier
19
Now;
20
21
3.2 Material Balance Around The Air Separation Unit(ASU)
A stream
22
H2S formation
23
Sr. No
Components
1
2
3
4
5
6
7
8
9
CO
CO2
H2
Ar
N2
Ash
C
HCN
H2S
Molecular
mass
28.0
44.0
2.016
40.0
28.0
48.72
12.0
27.0
34.0
Mass (ton)
Ton Moles
30.666
8.624
1.63
0.21
0.063
0.036
0.078
0.243
0.438
1.095
0.0196
0.815
0.005
0.00225
0.0007
0.0065
0.009
0.01288
3.3 Material Balance Around Bag Filter
24
3.4 Material Balance Around Hydrolyser
25
3.5 Material Balance Around Separator
3.6 Material Balance Around H2S Removal Unit

3 mol of H2S form H2O = 3 mol H2O
1 mol of H2S form H2O = 1 mol H2O
0.01288 mol of H2S form H2O = 0.011288 mol H2O= 0.232 ton
Mol of
formed
= 0.011288
/3 mol
F o =0.6864
2 3
= 0.00429 mol
26
Fe2S3 =0.892
Sr.
No
Components
.
1
2
3
4
5
6
CO
CO2
H2
Ar
N2
H2O
Molecular
mass
28.0
44.0
2.016
40.0
28.0
18.0
Mass (ton)
Mass % age
Ton Moles
Mole % age
30.912
8.62
1.638
0.212
0.0637
0.232
Total = 41.667
73.3
20.5
3.9
0.5
0.1
1.7
Total = 100
1.104
0.196
0.819
0.005
0.0023
0.013
Total = 2.134
51.1
9.1
37.6
0.2
0.1
1.8
Total = 99.9
CHAPTER NO 4
ENERGY BALANCE
27
4.1 Gasifier Calculation
Components
CO
CO2
H2S
HCN
Mass (tons)
30.66
8.624
0.438
0.243
Mol.wt
28
44
34
27
Hf (at 25 0C)
-110525
-393509
-86351
-135100
Q
-121024.875
-77127.764
-1112.404059
1215.9
-198049.14
Calculation for CP
Where A,B,C & D are the constants for specific species
Comp.
C
CO
H2
CO2
N2
H2S
Ash
Ar
HCN
Mass
0.078
30.66
1.63
8.624
0.063
0.438
0.036
0.21
0.243
Mol.wt.
12
28
2
44
28
34
48.7
40
27
A
B
1.771
0.000771
3.376
0.000557
3.249
0.00042
5.457
0.001045
3.28
0.000593
3.931
0.00149
-0.111
0.006111
2.5
0
4.736
0.001359
Net CP
D
-86700
-3100
8300
-115700
4000
-23200
115000
0
-72500
CP
23.908
35.28
32.58
57.83
35.03
51.85
79.76
20.78
56.35
Wt.CP
0.155
38.64
26.55
11.3
0.078
0.667
0.058
0.109
0.507
78.113
28
4.2
Radiant Syngas Cooler (RSC) Calculation
4.3 Bag Filter Calculation
4.4
Hydrolyser Calculation
29
Sr.No
1
2
3
4
Components
HCN
H2O
NH3
CO
Hf
130.51
-241.82
-46.191
-110.52
Moles
0.009
0.009
0.009
0.009
30
4.5 Cooler Calculation
4.6 H2S removal unit Calculation
31
4.7 Steam Calculation
This heat is used to super heat the steam 32.375 ton from 159.15 0C to 1302.97 0C
32
CHAPTER NO 5
EQUIPMENT DESIGN
5.1 Cryogenic Distillation Column Design
BASIS:
3.555 ton mole/ hr of air
Overall material balance

F=D+W
F=3.555=D+W
N2 balance:
3.555*0.78151=0.99D+0.003W
W=
0.751 ton mole
D=
2.804 ton mole
Using optimum reflux ratio = R =
(By Under Wood method)
Relative volatility of N2 w.r.t O2 = 2.9561

33

Relative volatility of Ar w.r.t O2 = 1.2619
R= Ln/d
Ln=
5.608 ton mole
Vn=
8.412 ton mole
Below the feed point:

Lm=Ln+F
Lm= 5.608 +3.555 = 9.163
Vm=Lm-W
Vm= 9.163 - 0.751 = 8.412
Equations for the Bottom operating line:

Ym=Lm/Vm*Xm+1-W/Vm*X
Ym=
1.08
Xm+1
-0.089 *Xw
Ym,N2= 1.08
Xm+1
-0.00026
Ym,O2= 1.08
Xm+1
-0.0883
Ym,Ar= 1.08
Xm+1
-0.00062
Equations for the Top operating line:

Yn=Ln/Vn*Xn+1+D/Vn*Xd
Yn=
0.666 Xn+1
+0.333 *Xd
Yn,N2= 0.666 Xn+1
+0.33
Yn,O2= 0.666 Xn+1
+0.001
Yn,Ar= 0.666 Xn+1
+0.00233
34

Calculation of number of plates required by Lewis and Matheson Method
Plate composition below the feed point:Error! Not a valid link.
components
N2 2.961
O2 1
Ar 1.2619
total
components
N2 2.961
O2 1
Ar 1.2619
total
components
N2 2.961
O2 1
Ar 1.2619
total
xs
xs
ys
x1
x1
y1
x2
x2
y2
0.003
0.99
0.007
1
0.008883
0.99
0.008833
1.007716
0.008815
0.982419
0.008766
1
0.008338
0.983041
0.008621
1
0.02469
0.983041
0.010879
1.018609
0.024239
0.965081
0.01068
1
0.022498
0.967124
0.010378
1
0.066618
0.967124
0.013097
1.046838
0.063637
0.923852
0.012511
1
x3
x3
y3
x4
x4
y4
x5
x5
y5
0.058668
0.929273
0.012059
1
0.173715
0.929273
0.015217
1.118206
0.155352
0.83104
0.013609
1
0.142866
0.844067
0.013067
1
0.423027
0.844067
0.016489
1.283583
0.329567
0.657586
0.012846
1
0.302804
0.684829
0.012367
1
0.896602
0.684829
0.015606
1.597037
0.561416
0.428812
0.009772
1
x6
x6
y6
x7
x7
y7
x8
(feed
plate)
0.515652 1.526846 0.758232 0.696338 2.061857 0.871045 0.799906
0.474803 0.474803 0.235787 0.297597 0.297597 0.125722 0.196552
0.009545 0.012045 0.005981 0.006065 0.007653 0.003233 0.003542
1
2.013694 1
1
2.367107 1
1
Plate composition above feed point
components
N2 2.961
O2 1
Ar 1.2619
total
components
N2 2.961
O2 1
Ar 1.2619
total
x8
x8
y8
x9
x9
y9
x10
x10
y10
0.799906
0.196552
0.003542
1
2.368522
0.196552
0.004469
2.569544
0.921768
0.076493
0.001739
1
0.887651
0.113239
0
1.000891
2.628336
0.113239
0
2.741575
0.958696
0.041305
0
1
0.943043
0.060457
0
1.0035
2.792352
0.060457
0
2.852808
0.978808
0.021192
0
1
x11
x11
y11
x12
0.973212
0.030288
0
1.0035
2.881681
0.030288
0
2.911969
0.989599
0.010401
0
1
Total no of theoretical stages =12
35
5.1.1 Diameter Evaluation For Columns With Sieve Trays

First required, net vapor (gas) Velocity:
Using equation
vnf=Csb ( /20)0.2{(l-v)/v}0.5
vnf=Net vapor (gas) Velocity
Csb=Souder & Brown factor
(Souder and Brown factor is obtained from fig 15.5
After specifying the reasonable tray spacing)
Using tray spacing =0.15 m
(L/V)(L-v) 0.5= 0.05 (from fig. 15.5 of Richardson and Coulson, volume 2)
Csb=0.03
=
Surface tension
=12.2 dyne/cm
L =
Density of liquid
=802.5 kg/m3
v=
Density of vapor
= 4.614
vnf =
0.357 m/s
kg/m3
Actual vapor velocity = vn = 50-90% of vnf.

vn= 0.5*0.035=0.178 m/s
Net column area= An = Qv/vn
Qv
= volumetric flow rate of vapor=Vn*Mv/v

=(8.412*28.025)/(3600*4.614)=0.01412
An=
Qv/vn = 0.01412/0.178 =
m3/sec
0.079 m2
(For sieve trays using table

Down corner area = 0.05-0.3m2
Assume down corner occupies 30% of cross sectional area of the column
Ac=An+Ad
Ad= Down corner area
Ac=An/0.7= 0.079 /0.7=
0.1135 m2
Now
Dia of column =
D= (4*Ac/)0.5
D=(4*0.1135/3.14)0.5
=0.380 m or 1.247 ft.
36
5.1.2 Plate Effeciency

Using the relation
Eo=
0.492(*avg) -0.245
Eo=
Overall tray effeciency
avg= Average relative volatility between light and heavy key components
= 2.9561
L=
Liquid viscosity of feed mixture = 0.0545 centipoises
Eo=0.492(0.0545*2.9561) -0.245
Eo=
0.77 or 77 %
No. of actual plates = no. of ideal plates / Efficiency = 12/0.77
=16
5.1.3 Height Of The Column

Using the relationship:
Hc=(Nact-1)*Hs+H
Hc = height of the column
Nact = actual no. of plates
Hs= plate spacing = 0.15 m
Assumptions:
1)
There is no mist eliminator in the column
2)
There is no wash plate or filter sieve
So,H= additional height of required for column operation = 0

Height of the column = Hc= (16-1)*0.15+0 = 2.25 m
Height to Dia. ratio= H/D = 2.25/0.38=5.92
As the total height of this column is small so weir height should be minimum i.e. 10 mm
And sieve hole diameter is selected to be 5 mm
lw = 10 mm , dh = 5mm
5.1.4 Check Weeping

Maximum liquid rate
Lw= 5.608 tone/hr. = 1.56kg/sec
37
= 25 mm liquid
Minimum liquid rate at 70% turn down ratio
Ln, min = 0.70
1.56
=1.092 kg/sec
= 19 mm liquid
hw + how = 10 + 19 =29
From figure 11.30 Coulson vol. 6, K2 = 28.5
For Weep point
= 0.13 m/s
Actual minimum vapor velocity
Vn = 0.17868 m/s
Since, actual minimum vapor rate is well above the weep point
5.1.5 Check Entrainment

Assuming 85% flooding for this process:
=0.082
From figure 11.29 Coulson vol. 6
Fractional Entrainment = = 0.07
This is well below 0.1
So, process is satisfactory
38
5.1.6 Liquid flow pattern

Maximum liquid flow rate = 0.0032 m3/sec
Dia. of the column = 0.38 m
From figure 11.28 of Richardson & Coulson vol. 6
Flow pattern: cross flow single pass
5.2 Gasifier Design

Design parameter
Volume
Diameter
Cross Sectional Area
Mass Flow Rate

Rate of Reaction
Kg
s
Units
Kg
m2 s
Area
5.2.1 Cross Sectional Area

Rate of Reaction is given by:
R s K t Psi Ni e
Ei
)
R T
Rs=Rate of Reaction
Ks=Rate Constant
Psi=Partial pressure based on carbon based reaction
Ni=order of reaction
Et/RT=temperature dependence of reaction rate Et=Activation energy
Et=Activation energy
Partial pressure of carbon products that form due to partial or complete oxidation:
39

Comp M.W
Mass
Mole
M.F
Par.
Total
Pressure
Pressure
Co
28
30.666
1.09521429 0.51111363 185.9738
CO2
44
8.624
0.196
0.091469106 33.28195
HCN
27
0.243
0.009
0.004200112 1.528253
363.86
220.784
Ni
15.01932
P N i 15.01932 atm
Activation
Energy=E=
100483
kg/ mole
Value of
Kt
=1404
kg/
(m2*s*atm)
Ni=1
R K t Psi Ni e
Calculating Reaction Rate= s
Ei
)
R T
21087.126 0.001095967
23.1108 kg/m2.sec
Feed flow rate=flow rate of residue + flow rate of oxidant

= 11.6594 kg/sec
Area required for reaction
=0.504502 m2
Dia 0.8016718 m 2.63012 ft

length 2.4 m 7.89 ft
Volume 1.61778 m 3
d
2
Volume of hemispherical head 2 3
2
3
3
0.26963m
40
5.2.2 Coil Calculation

Area of Coil
Q = U.A.LMTD Q = Rate of heat transfer
A = Area for heat transfer
U = Overall design coefficient
LMTD =Log mean Temp.difference (k)
U = 50
Btu /hr.F.ft2
=1.022008 MJ/hr.k.m2
Q =90820.14 MJ/ hr.
Ta Tb
Ta
LMTD =
ln( )
Tb
T1 =2833.556 (k)
T2 =1773.15
(k)
t1= 1575.9
(k)
t2= 432.3
(k)
Tb =T1-t1=1257.656 (k)
Ta =T2-t2 1340.85 (k)
Tb =T1-t1 =1257.656 k
Ta =T2-t2 = 1340.85 k
LMTD = 1298.80895 k
A = 68.4198963 m2 =736.4477 ft2 (For 1 inch tube OD,BWG =12)
= 0.2618 ft2 / lin-ft
Length of tube = 6 ft
Area of one tube=1.5078 m2
No. of tubes=468.8360856 tubes
Outer dia. of tubes =I.D + thickness
I.D = 0.782 inch
=0.0109 ft
O.D=0.7929 in
=0.066075 ft
41

Outer area of tube=0.013709
Volume of tube= 0.082254
Total volume of coil= 38.56348
= 1.092036
Volume of gasifier = volume + vol.of hemispherical heads + vol of coil
=
2.97945
suface area of gasifier d l area of hemispherical head = 10.09004 m2
5.2.3 Refractory (Fire Clay) calculation

Fusion temperature = 1750 C
Thermal conductivity at 1500 C or 2732 F
K at 1832 = 0.95 Btu /hr.F.ft
K at 2552 = 1.02Btu /hr.F.ft
K at 2732 = 1.0375Btu /hr.F.ft
=0.006463 MJ/hr.K.m
Heat transfer Coefficient = h = ( B .009(Th Ta )) 10
B = 0.87, Th =1773.15 k, Ta =700 k
h=
J
sec .k .m 2
kJ
.1052835
sec k m 2
MJ
0.3790206
hr.m 2 .k
10.52835
Critical radius =
= 0.01705184 m
= 1.70518 cm
=The thickness of refractory= 1.70518 cm
5.2.4 Space time

Feed flow rate in=feed flow rate out = 11.6594444 kg/sec
Density of synthesis gas = 3.333 kg/m3
Comp.
M.W
Mass
Mole
MF
42

CO
28
30.666
1.09521429
0.51111363
CO2
44
8.624
0.196
0.091469106
H2
1.63
0.815
0.380343476
Ar
40
0.21
0.00525
0.002450065
N2
28
0.063
0.00225
0.001050028
Ash
48.72
0.036
0.00073892
0.000344837
12
0.078
0.0065
0.003033414
HCN
27
0.243
0.009
0.004200112
H2S
34
0.438
0.01288235
0.006011925
41.9882
1.928355
1.0000165
Volume of Gasifier 2.97944622 m3

So
Feed flow rate out = 11.6594444 kg/ sec
Vol flow rate 3.4981832m3/sec
Space time=vol/vol flow rate=0.85171247 sec
= 0.000237 hr
Space velocity = 4226.778541/hr
5.2.5 Thickness of Vessel

Low Alloy Steel, we are using for gasifier it gives high strength at elevated pressures along with
corrosion resistance towards H2s and high temperatures.
Thickness of Vessel Walls Strength of Low Alloy Steel at 425 c, S= 94500 kPa
Joint Efficiency,
Ej= 1 fully radio graphed; vessel is critical
Operational pressure= 363 psi
= 2502.107143 kPa
Maximum Allowable Pressure, Pm = 1.2*P = 435.6 psi = 3002.529 kPa

Internal radius= ri
dia
critical radius = 0.014813 =0.41565 m
2
Corrosion Allowance= 2 mm= 0.002 m

Thickness = (
Pm ri
) Cc == 0.015463 m =1.5462963 cm
S E j 0.6 Pm
43

Thickness of the gasifier heads
5.2.6 Thickness Of Hemi Spherical Heads

1.2 p
Pm= 435.6 psi
3002.529 kpa
Internal radius = ri
dia
critical radius
2
=0.415648428 m
Corrosion Allowance= 2 mm= 0.002 m for steel alloy
Thickness = (
Pm ri
) Cc
S E j 0.2 Pm
= 0.015291 m
=1.5290767 cm
Hemi spherical heads are frequently used for high pressure applications since the spheres have
high stability.
5.3 Bag Filter Design

5.3.1 Area Of Bag Fabric
Mass flow rate of gases coming from gasifier = 41.988 ton/hr= 11.6633 kg/hr
Flow rate of ash = 0.122 ton/hr = 0.0311 kg/hr
Density of incoming gases = 3.33343 kg/m3
Volumetric flow rate of gases = MFR/Density = 7413.453 ft3/min
Fabric = Teflon
Air permeability of Teflon = 20 ft3/(minft2)
VFR ft
7413.453
min
Area of taflon
370.672 ft 2
20
3
Air permibility ft
2
min ft
P K1v f K 2v f
44

P Pr essure drop in of H 2O
in of H O
2
ft
min
K1 Re sis tan ce coefficient of fabric
kg
2
ft
Dust load
in of H 2O
ft min kg
K1 Re sis tan ce coefficient of dust layer
V f Filtering velociry (m/min)

Vf
0. 3 3
m
ft
1.65
5.4133
2
min
min
load on filter
112 kg
kg
0.302153 2
2
fabric area
370.67 ft
ft
K1 40K 2
K2
Pt
0.5
in of H 2O. ft . min
0.305
v f 1.65 0.302
kg
K1 40 0.305 12.2275
in of water
ft
min
P 66.1955 in of H 2O 2.438 psi
Area:
L 4
B 3
Length of bag 6.5 ft
Bridth of bag 5 ft
Area of bag 6.5 5 32.37 ft 2
Total area of fabric 370.67
No. of bags
11.75 12 bags
area of one bag
32.37
Length of bag house 6.5 2 8.5 ft
Bridth of bag house 5 2 7 ft
Width of bag house thickness of bag distance b/w the bags no.of bags side distance 2
45
5.3.2 Volume Of The Bag Filter

Thickness of bag 1cm
Distance b/w bags 1cm
No. of bags 12
Side distance 1 1 2ft
Width of bag house 2.0665 ft
Area of bag house length bridth 8.5 7 60 ft 2
Volume of bag filter Area Width of bag house
60 2.0665 124 ft 3
5.3.3 Thickness of Bag Filter

e
Pm ri
Cc
S E j 0.6 Pm
Pm Max. Pressure 1.2 operating perssue 1.2 323(psi) 2671.671kPa

ri hydralic mean radius
d a db
8.5 7
3.83 ft
d a d b 8.5 7
Cc CorrosionA llownce 2mm

S strength of material 94500 kPa
E j Jo int efficiency 1
e 3cm
5.4 Hydrolyser (Reactor) Design

(Fixed Bed Porous Catalyzed Isothermal P.F.R)
5.4.1 Weight of Catalyst
Where
46
Now, Thiele modulus
5.4.2 Volume of Catalyst
47
5.4.3 Wall Thickness
Material of construction; Low alloy steel
Now;
5.4.4 Surface Area of Reactor
5.4.5 Thickness of the Hemispherical Heads
48

Vol. of hemispherical head;
5.4.6 Space Time
5.4.7 Space Velocity
49
5.5 Vertical Separator Design
Component
Total
Mass(ton)
1.63
8.62
30.198
0.438
0.21
0.063
41.879
M.W
2
44
28
34
40
28
Mole
0.815
0.195909
1.104214
0.012882
0.00525
0.00225
2.135506
50
5.5.1 Terminal Velocity
Temperature=537
P=283 psi
Mol.Wt. = 19.61081
d=
0.049 ton of water per hour
Density of liquid = 1000
= 0.558602
Vv = Gas flow rate = 41.879
= 11.63306
= 0.752435
5.5.2 Volume of Cylindrical Vessel

Now Using Demister Pads,
Area =1.346998
The height of separator from top to demister pads = 0.4 m
51

Length from Demister pads to feed point =
= 1.309932 m
Feed point to liquid level =
= 0.654966 m
Bottom to liquid level = 0.4 m
Total height of separator =2.764897 m
Volume of separator =
Volume of hemi spherical heads =
= 1.17632
Vol. of separator = volume +volume of hemispherical heads
= 4.90063
The surface area of separator = Area of hemispherical heads
=(
=16.76053
Radius = 0.654966 m
5.5.3 Cylindrical Thickness

Thickness for cylindrical vessel =
Operating Pressure = P = 283 psi
= 1950.679 kpa
= 2340.814 kpa
The vessel can be made with any type of steel but we are using low alloy steel for this purpose
because it gives high strength at elevated pressure along with corrosion resistance towards
and high temperature strength at -33 C to 427 C
52

At p=94500 kPa
Thickness =
= 0.016469
Corrosion Allowance =2 mm
=0.02 m
Total thickness = 0.018469 m
5.5.4 Hemispherical Head Thickness

Head Thickness
Using hemispherical heads (that is used in high pressure)
T=
= 0.016305
Corrosion Allowance = 2 mm=0.02 m
Thickness = 0.018305 m =1.830462 cm
5.6 Specification Sheets

5.6.1 Cryogenic Distillation Column
Parameter
Type
Optimum reflux ratio
Actual stages
Efficiency
Column diameter (m)
Column height (m)
Tray type
Weir height (mm)
Tray spacing (m)
Entrainment
Weeping
Liquid flow pattern
Value
Continuous
2
16
77%
0.38 m
2.25 m
Sieve
10
0.15m
Satisfactory
Not occurring
Cross flow single pass
53
5.6.2 Gasifier
Parameters
Operating pressure
Operating temperature
Carbon conversion
Diameter of the gasifier
Length of the gasifier
Space time
Corrosion allowance
Gasifier wall thickness
Gasifier head thickness
Values
363 psi
1500 oC
99.5 %
2.63 ft
7.89 ft
0.852 sec
0.02 m
0.015463 m
0.015291 m
5.6.3 Bag Filter

Parameters
Vol. flow rate of syngas
Filter Fabric
Type of Filter Unit
Dimensions of bag
No. of bags
Dimensions of Baghouse
Material of Construction
Strength of the material
Wall thickness
Values
7413.453 ft3/min
Teflon
Multibags Filter Unit
L = 6.5 ft; B = 5 ft
12
L = 8.5ft; B = 7ft; W = 2.065ft
Low Alloy Steel
94500 kPa
3 cm
5.6.4 Hydrolyser (Reactor)

Parameters
Type of reactor
Volumetric flow rate
Density of the catalyst
Thiele modulus
Diameter
Length
Material of construction
Maximum allowable pressure
Thickness
Surface area
Volume
Values
Fixed bed porous catalyzed isothermal P.F.R
4162 m3/hr.
1600kg/m3
Mt = 0.359
D=1.389 m
L=4.167 m
Low alloy steel
Pm = 2423 kPa
25.0 mm
24.232 m2
1.40m3
54

Space time
Space velocity
4.14 sec
900 vol. of gas / vol. cat-hr.
5.6.5 Vertical Separator

Parameter
Temperature
Pressure
Density of vapors
Settling velocity
Vessel diameter
Radius
Length
Pm
S
Ej
Corrosion allowance
Thickness of cylindrical vessel
Hemispherical head
Value
25 oC
283 psi
15.46 kg/m3
0.558602 m/s
1.309932 m
0.655 m
2.764897 m
2340.814 kPa
94500 kPa
1
0.002 m
0.018469 m
0.018305 m
55
CHAPTER NO 6
PLANT LOCATION
The geographical location of the final plant can have strong influence on the success of
an industrial venture. Considerable care must be exercised in selecting the plant site, and many
different factors must be considered. Primarily, the plant should be located where the minimum
cost of production and distribution can be obtained, but other factors, such as room for expansion
and safe living conditions for plant operation as well as the surrounding community, are also
important.
6.1 Factors Affecting the Location of Plant

A general consensus as to the plant location should be obtained before a design project
reaches the detailed estimate stage, and a firm location should be established upon completion of
the detailed-estimate design. The choice of the final site should first be based on a complete
survey of the advantages and disadvantages of various geographical areas and, ultimately, on the
advantages and disadvantages of available real estate. The following factors should be
considered in selecting a plant site:
1. Raw materials availability
2. Markets
3. Energy availability
4. Climate
5. Transportation facilities
6. Water supply
7. Waste disposal
8. Labor supply
9. Taxation and legal restrictions
10. Site characteristics
56

11. Flood and fire protection.
12. Community factors
The factors that must be evaluated in a plant-location study indicate the need for a vast
amount of information, both quantitative (statistical) and qualitative. Fortunately, a large number
of agencies, public and private, publish useful information of this type greatly reducing the actual
original gathering of the data.
6.1.1 Raw Materials Availability

The source of raw materials is one of the most important factors influencing the selection
of a plant site. This is particularly true if large volumes of raw materials are consumed, because
location near the raw-materials source permits considerable reduction in transportation and
storage charges. Attention should be given to the purchased price of the raw materials, distance
from the source of supply, freight or transportation expenses, and reliability of supply, purity of
the raw materials, and storage requirements.
6.1.2 Markets
The location of markets or intermediate distribution centers affects the cost of product
distribution and the time required for shipping. Proximity to the major markets is an important
consideration in the selection of a plant site, because the buyer usually finds it advantageous to
purchase from nearby sources. It should be noted that markets are needed for by-products as well
as for major final products.
6.1.3 Energy Availability

Power and steam requirements are high in most industrial plants, and fuel is ordinarily
required to supply these utilities. Consequently, power and fuel can be combined as one major
factor in the choice of a plant site. Electrolytic processes require a cheap source of electricity,
and plants using electrolytic processes are often located near large hydroelectric installations. If
the plant requires large quantities of coal or oil, location near a source of fuel supply may be
essential for economic operation. The local cost of power can help determine whether power
should be purchased or self-generated.
57
6.1.4 Climate
If the plant is located in a cold climate, costs may be increased by the necessity for
construction of protective shelters around the process equipment, and special cooling towers or
air-conditioning equipment may be required if the prevailing temperatures are high. Excessive
humidity or extremes of hot or cold weather can have a serious effect on the economic operation
of a plant, and these factors should be examined when selecting a plant site.
6.1.5 Transportation Facilities

Water, railroads, and highways are the common means of transportation used by major
industrial concerns. The kind and amount of products and raw materials determine the most
suitable type of transportation facilities. In any case, careful attention should be given to local
freight rates and existing railroad lines. The proximity to railroad centers and the possibility of
canal, river, lake, or ocean transport must be considered: Motor trucking facilities are widely
used and can serve as a useful supplement to rail and water facilities. If possible, the plant site
should have access to all three types of transportation, and, certainly, at least two types should be
available. There is usually need for convenient air and rail transportation facilities between the
plant and the main company headquarters, and effective transportation facilities for the plant
personnel are necessary.
6.1.6 Water Supply

The process industries use large quantities of water for cooling, washing, steam
generation, and as a raw material. The plant, therefore, must be located where a dependable
supply of water is available. A large river or lake is preferable, although deep wells or artesian
wells may be satisfactory if the amount of water required is not too great. The level of the
existing water table can be checked by consulting the state geological survey, and information on
the constancy of the water table and the year-round capacity of local rivers or lakes should be
obtained. If the water supply shows seasonal fluctuations, it may be desirable to construct a
reservoir or to drill several standby wells. The temperature, mineral content, silt or sand content,
bacteriological content, and cost for supply and purification treatment must also be considered
when choosing a water supply.
58
6.1.7 Waste Disposal

In recent years, many legal restrictions have been placed on the methods for disposing of
waste materials from the process industries. The site selected for a plant should have adequate
capacity and facilities for correct waste disposal. Even though a given area has minimal
restrictions on pollution, it should not be assumed that this condition will continue to exist. In
choosing a plant site, the permissible tolerance levels for various methods of waste disposal
should be considered carefully, and attention should be given to potential requirements for
additional waste-treatment facilities.
6.1.8 Labour Supply

The type and supply of labor available in the vicinity of a proposed plant site must be
examined. Consideration should be given to prevailing pay scales, restrictions on number of
hours worked per week, competing industries that can cause dissatisfaction or high turnover rates
among the workers, and variations in the skill and productivity of the workers.
6.1.9 Taxation and Legal Restrictions

State and local tax rates on property income, unemployment insurance and similar items
vary from one location to another. Similarly, local regulations on zoning, building codes,
nuisance aspects, and transportation facilities can have a major influence on the final choice of a
plant site. In fact, zoning difficulties and obtaining the many required permits can often be much
more important in terms of cost and time delays than many of the factors discussed in the
preceding sections.
6.1.10 Site Characteristics

The characteristics of the land at a proposed plant site should be examined carefully. The
topography of the tract of land and the soil structure must be considered, since either or both
may have a pronounced effect on construction costs. The cost of the land is important, as well as
local building costs and living conditions. Future changes may make it desirable or necessary to
expand the plant facilities. Therefore, even though no immediate expansion is planned, a new
plant should be constructed at a location where additional space is available.
59
6.1.11 Flood and Fire Protection.

Many industrial plants are located along rivers or near large bodies of water, and there
are risks of flood or hurricane damage. Before selecting a plant site, the regional history of
natural events of this type should be examined and the consequences of such occurrences
considered. Protection from losses by fire is another important factor in selecting a plant
location. In case of a major fire, assistance from outside fire departments should be available.
Fire hazards in the immediate area surrounding the plant site must not be overlooked.
6.1.12 Community Factors.
The character and facilities of a community can have quite an effect on the location of the
plant. If a certain minimum number of facilities for satisfactory living of plant personnel do not
exist, it often becomes a burden for the plant to subsidize such facilities. Cultural facilities of the
community are important to sound growth. Churches, libraries, schools, civic theaters, concert
associations, and other similar groups, if active and dynamic, do much to make a community
60

progressive. The problem of recreation deserves special consideration. The efficiency, character,
and history of both state and local government should be evaluated. The existence of low taxes is
not in itself a favorable situation unless the community is already well developed and relatively
free of debt.
6.2 Location of Our Plant

After considering all these factors we have selected that this plant should be installed near
the Byco Oil Pakistan Limited in the Karachi. We have selected this location because this
refinery has a capacity of 20,000 bbl. /d (19,000 m3/d). In case if there is shortage of heavy oil in
Pakistan then we can also be able to import the heavy oil outside using Karachi seaport.
Following table will prove that this is ideal location.
Factor
1. Raw materials availability
Assessment
Byco Oil Pakistan Limited is 0.20 km far from site
2. Markets
3. Energy availability
4. Climate
5. Transportation facilities
6. Water supply
7. Waste disposal
8. Labor supply
9. Taxation and legal restrictions
10. Site characteristics
11. Flood and fire protection.
12. Community factors
HUB Oil Field is 2.50 km far from site

Syngas will be transmitted through pipelines
HUB power plant 1.5 km far (323 MW capacity)
Moderate, (Sea shore: preffered for chemical plant)
HUBCO road 0.5 km far
Arabian sea 2.20 km far
Arabian sea 2.20 km far
Easily available
No restrictions
Topography is sound and dependable
Safe
Residential colonies are 15 km far
61
CHAPTER NO 7
OVERALL PLANT COST ESTIMATION
The overall plant cost estimation is done to analyze the economics demands of the project
and devise and possible profit from it. It also ensures the economic feasibility of the project and
possible profit from it. The cost of the plant can be divided into fixed capital and operating cost.
7.1 Fixed capital investment

1)
2)
3)
4)
5)
6)
7)
Detailed cost estimate

Unit cost estimate
Percentage of delivered equipment cost
Lang Factor Approximation of Capital investment
Power factor applied to plant capacity ratio
Investment cost per unit capacity
Turnover ratio
We prefer to use the method of power factor applied to plant capacity ratio, because it
offers very close approximation and is very easy to use. This method includes a ratio formula
that incorporates the calculation from the cost of fixed capital investments of previously built
plants by exponential ratio. It means that for a similar process, the previously built facility, C
adjusted by cost index, f multiplied by the ratio, R (which is defined as the capacity of newly
built plant to previously built facility), raised the power, x, the exponent that relates both costs.
C = C.f.Rx
For out plant estimation this can be easily written as:
Our FCI = baseline cost * cost index ratio * (our capacity /baseline capacity) X
The baseline calculations are based upon in-side battery limits (ISBL) Capital Cost Data for year
2000, which is given for different plant sections installed at a typical gasification plant.
Table 7.1: Capital costs for gasification components
62
Air
separation
unit
Gasification
Purification
Hydrolyser
unit(reactor)
Base
capacity
2000
Units
Representative
units
TPD
O2
23.00
$M/TPD
Normal range
17.88
2000
TPD
34.12
$M/TPD >20.59
feed
100
MM
27.75
$/M
SCFD
SCFD
syngas
100
MM
167
$/M
SCFD
SCFD
syngas
Inside battery limit investment, U.S Gulf coast 2000
28.12
Scaling
exp.
0.70
0.76
0.55
0.65
For nomenclature, TPD stands for tons per day, M stands for 1000, MM stands for 1000,000, and
SCFD stands for standard cubic feet per day.
From the data above, now we can calculate the fixed capital investment of different components
of out plant. For purpose of calculation we have taken some values as follows:
Marshall and swift All industry index for the year 2010 (3rd quarter) = 1501.3
Marshall and swift All industry index for the year 2000 (total year) = 1089.0
Cost index ratio = index value 2010 / index value 2000=1.379
Currency exchange rate: $1 = PKR 86
7.1.1 Cost of Air Separation Unit

Oxygen production (TPD) = 574
Our cost = $23000/TPD*(574/2000)0.7*1.379
=$13237.60/TPD
Plant cost = 13237.60*574 = $ 7.60 million = PKR 0.653 billion
7.1.2 Cost of Gasification Unit

Feed to gasifier (TPD) = 429.93
Our cost = $ 34120 / TPD *(429.93/2000)0.76 *1.379
=$151347
Plant cost = 151347*429.93 = $ 6.51 million =PKR 0.56 billion
63
7.1.3 Cost of Purification Unit

Feed to purification unit (TPD) = 79.88
Our cost = $27.75 /MSCFD *(79.88/100)0.55 *1.379
=$33.82 / MSCFD
Plant cost = 33.82*79.88*1000 = $2.70 million = PKR 0.232 billion
7.1.4 Cost of Hydrolyser Unit

Synthesis gas fed to AGR unit (MMSCFD) = 79.88
Out cost = $167 /MSCFD *(79.88/100)0.65 *1.379
= $199 /MSCFD
Plant cost = 199*79.88*1000 = $15.90 million = PKR 1.37 billion
7.2 Total Investment

0.653+0.56+0.232+1.37= PKR 2.815 billion
Working capital = 20% of investment
Total fixed capital investment = 1.2*2.815 = PKR 3.378 billion
7.3 Total Product Cost

The total product cost can be categorized into following basis of calculation = 1 hour
7.3.1 Raw Material Costs

The price of heavy oil (refinery residue) ranges between 300 to 400 rupees per ton (without
transportation) since the plant will be situated near the refinery so transportation cost will not be
included.
Price of heavy oil = PKR 16000 / ton
Feed rate = 17.914
Cost of raw material = 17.914*16000 = PKR 286624
7.3.2 Operating Cost

The operating cost can be calculated by the data available from National Energy Technology
Laboratorys paper about refinery product gasification, published on 30/06/2003. So after
64

equating with cost index (Marshall and Swift cost index for all industry), we can calculate the
labor costs for different gasification components, as given below
Table 7.2: Direct Operating Labor for refinery gasification

Single train
Unit
Air separation unit
Gasification unit
Purification unit
Hydrolyser unit
Operating staff
6
14
12
10
$/cd
1116
2604
2232
1860
Cost of All gasification components:

From table 7.2 = 1116+2604+2232+1860= $7812/ day
Equating for cost index ratio (for the year 2010(3rdquarter) / 2000) =1.379
Operating labor costs / hr. = 7812*1.379/24*86 = PKR 38602
7.3.3 Maintenance and Repairs (including repair staff and auxiliaries)

(2 to 10 % of fixed capital investment)= 0.06 *3.378/service life =0.195/365/24/20= PKR 1157
7.3.4 Laboratory Charges

(10 to 20 % of operating labor) = 0.15 *38602 = PKR 5790
7.3.5 Fixed Charged

It excludes depreciation
(10 to 20 % of total product cost)= 0.10 X
It is taken less because it is assumed that the government will give a tax holiday and financial aid
for the establishment and running plant.
7.3.6 Depreciation
Assuming straight line method and 20 year service life for plant:
5% of FCI =0.05*3.378= 0.163/ year = PKR 19292
65
7.3.7 General Expenses

It includes three costs
Administrative costs ( 20 %of operating labor) = 0.2 *38602=PKR 7720
Distribution costs(2% of total product cost ) = 0.02 X
R&D costs (5% of total product cost)= 0.05 X
7.3.8 Utilities
(10 to 20% of total product cost) = 0.15 x
So the total product cost can be calculated by summing all above values of process
{(0.15+0.02+0.05+0.1)X + other costs }= X / hr
0.32X +286624+5790+38602+1157+7720+19292= X
0.68X= 359185
Total product cost = X = 528213
7.4 Revenue from Product Sales

Amount of syngas produced per hour = 41.7 tons
Price of syngas per ton = $286
Sales of syngas per hour = 41.7*286=$11926.2 = PKR 1025653
Gross annual sales =Sales of syngas per year = 1025653*330*24= PKR 8.12 billion
Total product cost per hour = PKR 528213
Income per hour= 1025653-528213 = PKR 497440
Direct and indirect taxes on direct income levied by Government of Pakistan is 42% of direct
income
= 0.42*497440 = 208924
Profit per hour = 497440 -208924 = 288515
Profit per day = 288515*24 = PKR 6.92 million
Annual profit taking 330 stream days = PKR 2.285 billion
66

Payback period = 3.378/2.285 = 1.47 year
Turnover ratio = Gross annual sales /FCI = 8.12/3.378 = 2.40
67
CHAPTER NO 8
SAFETY AND HAZARDS CONSIDERATIONS
8.1 Health and Safety Hazards
The potential health hazard to an individual by a material used in any chemical process is
a function of the inherent toxicity of the material and the frequency and duration of exposure. It
is common practice short-term and long-term effects of a material. A highly toxic material that
causes immediate injury is classified as a safety hazard while a material whose effect is only
apparent after long exposure at low concentrations is considered as an industrial health and
hygiene hazard. The permissible limits and the precautions to be taken to ensure that such limits
will not be exceeded are quite different for these two classes of toxic materials. Information on
the effects of many chemicals and physical agents is accessible through computer databases such
as MEDLAR and TOXLINE. A number of health effects noted in these sources besides that of
cancer are dermatitis, neuropathy, irritation, reproductive damage, and acute poisoning.
8.2 Cryogenic liquids

The products of a cryogenic air separation plant have associated hazards such as:
Cryogenic injuries or burns resulting from skin contact with very cold vapor, liquid, or
surfaces. Effects are similar to those of a heat burn. Severity varies with the temperature and time
of exposure. Exposed or insufficiently protected parts of the body can stick to cold surfaces due
to the rapid freezing of available moisture, and skin and flesh can be torn on removal;
Risk of frostbite or hypothermia (general body and brain cooling) in a cold environment. There
can be warning, in the case of frostbite, while the body sections freeze. As the body temperature
drops, the first indications of hypothermia are bizarre or unusual behavior followed, often
rapidly, by loss of consciousness;
68

Respiratory problems caused by the inhalation of cold gas. Short-term exposure generally
causes discomfort; however, prolonged inhalation can result in effects leading to serious illness
such as pulmonary edema or pneumonia; and
Hazardous concentrations and/or reduced visibility can also occur at considerable distances
from the point of discharge, depending on topography and weather conditions. Cold gases are
heavier than air, tend to settle and flow to low levels, and can create a dense water vapors fog.
8.3 Gas Products

Nitrogen and argon are simple asphyxiates and if present in sufficient quantity can reduce
the oxygen in the local atmosphere below that required to support life. If there are any
appreciable quantities of hydrocarbon contaminants, there can be some nausea, narcosis, or
dizziness. Removal from exposure generally results in return to normal body and behavioral
functions. Oxygen-enriched atmospheres increase susceptibility to ignition and combustibility
rates can be many times that of normal atmospheres.
8.4 Sources of Exposure

The main objective of health-hazard control is to limit the chemical dosage of a chemical
by minimizing or preventing exposure. It is not practical to measure or control the chemical
dosage directly; rather, exposure is measured and limits are set for the control of such exposure.
The most common and most significant source of workplace exposure to chemicals and also the
most difficult to control is inhalation. Workers become exposed when the contaminant is picked
up by the air they breathe. Other sources may be mechanical and electrical hazards.
8.4.1 Mechanical Hazards

In typical well-maintained plants, pumps and valves are probably the major source of
fugitive emissions. Monitoring and maintenance efforts are therefore generally focused on these
sources. Taken as a whole, fugitive emissions, even without major seal failure, are the origin of
the continuous background exposure of workers. This source of exposure may not, by itself,
result in overexposure; but its presence reduces the margin within which other emissions may
vary while still remaining under the acceptable TLV.
69
8.4.2 Material Hazards and Material Handling

The continuous movement of materials through a process unit generally does not involve
any situations for emission release and consequent exposure. However, some material-handling
steps are difficult to accomplish with total containment. For example, whenever quantities of
materials are allowed to accumulate in storage and then are removed for further processing, the
possibility of release needs to be considered; for example, liquids entering fixed tankage
generally displace air that must be vented to avoid over pressuring the tank. Control of such
liquid-transfer operations can be achieved by using variable.
Solids handling can provide considerable exposure to contaminants whenever the
operation is performed in an open atmosphere. Where possible, such operations should be
retrofitted with a closed system. Even then, potential release problems exist, particularly during
maintenance and repair of the system.
8.4.3 Exposure Evaluation

If health hazards are to be controlled, they must be recognized and evaluated. A logical
place to initiate the process of health-hazard recognition is with a total inventory of all materials
present in the various stages of the process. Even when materials are present in only trace
amounts, there is more than enough present to produce a potentially hazardous situation in a
localized work area. Generally, feedstocks and products of a process are well known.
Intermediates, by-products, and waste materials may be less conspicuous and may not even have
been identified. Other materials, such as catalysts, additives, cleaning agents, and maintenance
materials need to be identified to complete the inventory.
8.4.4 Exposure-Hazard Control

When it is concluded that an exposure problem exists, decisions need to be made
regarding the implementation of hazard-control measures for the purpose of reducing exposure
and correspondingly reducing the risks. However, a given set of exposure conditions does not
lead to a fixed set of control strategies. There are many options. Since zero risk is not attainable,
a, decision must be made relative to the degree of risk reduction that is to be attained. Then a
series of choices must be made from a wide range of options.
70
8.5 Fire Protection

Besides toxic emissions, fire and explosion are the two most dangerous events likely to
occur in a chemical plant. Considerable resources are expended to prevent both of these hazards
or control them when they do occur because of an accident. These two hazards account for the
major loss of life and property in the chemical and petroleum industry.
For a fire to occur there must be a fuel, an oxidizer, and an ignition source. In addition, the
combustion reaction must be self-sustaining. If air is the oxidizer, a certain minimum
concentration of fuel is necessary for the flame to be ignited. While the minimum concentration
required depends on the temperature of the mixture and to a lesser extent on the pressure, most
interest generally is focused on the ignition conditions necessary at ambient temperature. The
minimum concentration of fuel in air required for ignition at ambient temperature is known as
the lower flammable limit (LFL).with a meaning analogous to the LFL.
8.6 Waste Handling

In the same vein, certain waste-handling procedures, even those performed intermittently,
can result in very serious contaminant exposure without proper precautions. Workers need to be
instructed in the proper procedures for cleaning up spills and accumulated debris. Spilled
materials can become airborne and pose an inhalation hazard. Spills and chemical process wastes
may end up in the waste-water treatment facilities where they again can be volatilized into the air
and result in unexpected worker exposure.
8.7 Electrical Requirements

Applicable codes shall be followed. In the US, air separation plants are not considered
hazardous locations for electrical equipment as defined by Article 500 of NFPA 70, National
Electrical Code Europe is in the same situation Therefore, general purpose or weatherproof
types of electrical wiring and equipment are acceptable depending on whether the location is
indoors or outdoors.
In areas where high oxygen concentrations could be expected, electrical equipment with open or
unprotected make-and-break contacts should be avoided. The simple expedient of locating
electrical equipment away from areas where high oxygen concentrations can occur eliminates
potential hazards in these situations.
71

Some plants might have specific areas or equipment such as a refrigeration system using a
hydrocarbon or ammonia refrigerant or one including an argon purification unit involving the use
and handling of hydrogen that necessitate special consideration. In these cases, the design
considerations specified in the appropriate industry codes should be followed.
8.8 Noise Control

The noise produced by compressors and their drives; by expansion turbines; by high gas
velocities through piping and valves; and by pressure relief valves, vents, or bypasses shall be
considered from the standpoint of potential hazard of hearing damage to employees. To assess
the hazard, noise surveys should be performed after initial inspection or when modifications are
made that could change the noise emitted Noise abatement and use of personnel ear protection
shall follow national government guidelines available (In US, 29
CFR Part 1910.95 is followed).
New equipment and varying operating conditions require a continuing program of noise level
surveillance.
72
CHAPTER NO 9
INSTRUMENTATION AND PROCESS
CONTROL
Instrumentation and Process control is a statistics and engineering discipline that deals
with architectures, mechanisms, and algorithms for controlling the output of a specific process.
See also control theory. In our design we have applied the instrumentation and process control on
the distillation column.
9.1 Description of the System

This column can be operated in a constant recycle mode. This allows the column to
operate for a long time with a relative small amount of feed. In this mode, after appropriate
measurements and analysis of each stream, the distillate and bottom products are recombined and
directed to the feed tank. Fig. 1 shows the piping and instrumentation diagram of the distillation
column and the major components of this system are briefly described below:
A.
Feed Tank Reservoir. A stainless steel tank with a sloping bottom for proper drainage is
provided to use the column in the recycle mode. This reservoir is fitted with a liquid-level sightglass, a drainage valve, and a safety filler cap.
B.
Reboiler. A cylindrical stainless steel tank with a capacity of approximately 3.8 - 4.0 gal
at operating level. The boiler, covered with foam rubber insulating material, is encased top and
sides with stainless steel sheet metal. The tank is fitted with a quick-disconnect coupling port for
feed or pressure measurement and a sight-glass for visual liquid level indication. The main
heating element is a stainless steel sheathed bayonet-type 3-phase electric heater with a nominal
power rating of 15 Kilowatts at 240 VAC
(but operating at 208 VAC). Thermal-overload
protection is provided by a manual-reset, pilot-lighted power switch located in an auxiliary

1
73

heater and by a level switch that will not allow the heater to turn on until the liquid level is
completely covering the heaters. The auxiliary heater power rating is 200 watts at 240 VAC (but
operating at 208 VAC). The power to the two heating elements is controlled by an electronic
switch which operates by cycling the heater on and off in 1 to 3 seconds intervals. The relative
times the heaters are on or off determine the amount of power supplied to the reboiler. Liquid
level control is obtained by means of a second level switch that actuates a solenoid-operated
valve. This valve recycles excess liquid from the still boiler to the feed reservoir (or to the
alternate bottoms receiver). The reboiler also has a drainage stop-cock. A stainless steel flangetype fitting directly connects the distillation column to the boiler.
16
PRV
V-1
14
13
Q-3
Cooling
Water
7
8
6
Column
Feed
Preheater
s
Reflux
Preheater
5
4
Q-2
F -4
Distillate
Rec eiver
3
2
Q-1
F-5
Reboiler
R-4
0
F -2
B-1
B-2
11
15
R-1
R-3
10
R-2
Graduated
flow meter
12
s
F
B-3
C-1
Feed Pump
Feed Tank
D-4
Reflux Pump
D-1
Thermocouple
s
Sample Port
Feed Port
Turbine Flow-meter
74

Figure 9.1: Distillation Column and instrumentation diagram
C.
Three-way Ball-valves for switching service. These valves are generally used either to
switch a particular flow into 2 possible directions or to direct either one of 2 different flows into
a desired destination. Fig, 4 shows a schematic representation of these valves and how they
operate. Valves F-1, B-3 and R-6 are used to select either the Production mode or the Feedrecycle mode of operation
D.
Condenser. Pyrex and stainless steel shell-and tube type heat exchanger, which contains
the equivalent of 1.3 sq. ft. of spiral-tube heat exchange surface. The tube side coolant is water
from the municipal water supply. Thermocouples are placed in the tube side to monitor the inlet
and outlet temperatures of the cooling water. For pressure safety, a spring-loaded relief valve set
for 1.0 psig is connected to the shell side of the condenser. The spiral condensing tube is 160
inches long coiled to a length of 18 inches. The tube is 3/8-inch OD, with 0.019-inch wall and it
is constructed of 304 stainless steel. The shell side condensate drains through a 3/8-inch line to
the distillate receiver. The cooling water supply to the condensed is equipped with a flow-switch
that will cut the power to the reboiler if there is a loss of water flow to the unit.
E.
Feed and Reflux Pumps. Two stainless steel pumps are used for the feed and reflux
streams. The reflux pump is equipped with a cooling jacket to prevent "vapor lock" caused by
overheating and boiling of the pumped fluids when operating at very low flow rates. These
pumps are equipped with carbon/ceramic mechanical seals.
F.
Distillate Receiver. A 3-inch OD by 12-inch long Pyrex glass tube that is flanged top
and bottom with stainless steel caps. Condensate enters from the condenser through a 3/8-inch
stainless steel tube into the top, which is fitted with a thermocouple. There are three connections
at the bottom of the receiver: a valve drain, a valve inlet to the reflux pump, and a valve
connecting to the distillate flow flowmeter.
G.
VAC
Feed and Reflux Immersion Preheaters. Cartridge-type rated at 1500 Watts at 240
2
and sealed in a stainless steel type enclosure. Each unit has a thermocouple for a
temperature indication and a thermistor probe heat-sensing control element (rated at 100 to 275
F). Each preheater is controlled from an ON-OFF type temperature controller.
75

Instrumentation and Control Panel. A voltmeter and ammeter for power input indication, a
boiler liquid level control switch for automatic operation, on/off electrical switches for feed and
reflux pumps, and continuously variable control elements for the main boiler heater, feed and
reflux preheaters. There is a main power switch and a main power indicator light. In addition,
indicator lights are on circuits for the feed pump, feed preheater, reflux pump, and reflux
preheater. The ammeter is calibrated with a 0-100% scale which corresponds approximately to
0-100% of the maximum power of the reboiler heater. The maximum power for the reboiler
heaters is approximately 11.1 kW at 208 VAC. This ammeter does not provide any information
on the power used by the preheaters, pumps, or the rest of the system, only on the power used in
the reboiler. On the back side of the Distillation apparatus there is a 3-phase power meter which
is connected directly to the power supply to the reboiler heaters. This power meter has two
digital indicators. The main power counter (non-resettable) located on top, records cumulative
power in 100 watt-hour increments (0.1 kWh). The auxiliary power counter (user resettable)
located below, records cumulative power in 1 watt-hour increments.
Thermocouples. A total of 17 type K (chromel-alumel) thermocouples (TC) are installed at
various locations throughout the distillation column system. These thermocouples are connected
to a computer for monitoring and dataloging. Thermocouples 1, 2, 4, 5, 6 and 16 are fixed to the
exterior glass surface of the column wall and under the insulation. These 6 thermocouples are
slow to respond to temperature changes and record temperatures that are slightly lower than the
stream inside the column. All other thermocouples are inserted in the stream being measured.
All temperature values are displayed and saved to file in degrees Celcius.
TC No.
0
1
2
3
4
5
6
7
8
9
10
11
12
Location
Reboiler
Column wall (external) 4.0 inches above lower packing support.
Column wall (external) 8.0 inches above lower packing support.
Column interior, between lower and upper packing sections.
Column wall (external) 4.5 inches above upper packing support.
Column interior, above upper packing section.
Reflux stream at entrance to the column.
Feed stream at entrance to the column.
Liquid temperature at the reflux flow meter.
Liquid temperature at the feed flow meter.
Liquid temperature at the bottoms flow meter.
76

13
Cooling water temperature entering condenser
14
Cooling water temperature leaving condenser
15
Liquid temperature at distillate flow meter.
16
Column wall (external) at vapor riser
Rotameters. Mounted on the main panel, and are used to meter the feed, reflux and coolant
flows. The feed and reflux rotameters are nominally rated at 700 cc/min for a liquid with a
specific gravity of 1.0 at standard conditions. The scale reads from 10 to 100. The floats inside
the glass tubes are glass and tungsten carbide (carballoy) with a diameter of 0.25 inches and
densities of 2.53 and 14.98 g/ml respectively. Flow rate data for a generalized calibration of
these rotameters is available in the Calibration of Distillation Column Rotameters memo in the
appendix to this section. The condenser cooling water rotameter has a nominal rating of 0 to 1.6
gpm.
Turbine Flow Meters. There are four volumetric turbine flow meters to measure the feed,
reflux, distillate and bottoms flows. Tree of these flow meters (Cole-Parmer models E-3225000) and their associated instrumentation have a range of approximately 50 to 1600 ml/min for
feed and reflux and 50 to 800 ml/min for the distillate. The expected accuracy of these flow
meters is 20 ml/min. The bottoms flow meter (Cole-Parmer model E-32250-30) has a range of
approximately 500 to 20,000 ml/min, with an accuracy of 200 ml/min. These flow meters
exhibit a non-linear behavior below the stated range. The signals from these flow meters are sent
to a computer for monitoring and dataloging. All units of flow in the monitor and data files are
in ml/min.
L.
Piping and Valving. All piping is either 1/4-inch or 3/8-inch stainless steel tubing. All
tube connections are made with standard stainless steel tube type compression fittings. Process
valves are stainless steel 1/4-inch or 3/8-inch needle or bar stock valves. Quick-disconnect
couplings are used on the flexible hose feed line, packed column, and reboiler. These couplings,
of the double-ended, shut- off variety, are constructed of stainless steel with high temperature,
solvent-resistant, synthetic gaskets and seals.
M.
Differential Pressure Gauge. The high-pressure tap is connected to the vapor space
above the reboiler (below the stripping section) and the low-pressure side is connected to the
vapor space above the enriching section of the column. This gauge is useful to predict flooding
conditions in the packed column. Values of differential pressure displayed and stored are in
inches of water column.
77
78
REFERENCES
1)
Tamburrano, F. (1994) Disposal of Heavy Oil Residues, Part 1. Hydroc. Proc., 79.
2)
Tamburrano, F. (1994) Disposal of Heavy Oil Residues. Part2. Hydroc. Proc., 77.
3)
Mahagaokar, U., Hauser, N. and Creme, G.A. (1993) Gasification of Petroleum Coke in
the Shell Coal Gasification Process. Petroleum Coke as a Utility Fuel, EPRI Workshop, Ft.
Lauderdal, Fla.
4)
Furimsky, E. (1996) Spent Refinery Catalysts. Environment, Safety and Utilization.
Catal. Today, 30, 223.
5)
Peries, J.P., Renard, P., Des Courieres, T. and Rossarie, J. (1988) ASVAHL New Routes
for Processing Heavy Oils. 4th UNITAR/UNDP Intern. Conf. on Heavy Crudes and Tar Sands,
Edmonton Canada, 2, Paper no.95.
6)
Elliot, J.D., Godino, R.L. and McGrath, M.J. (1985) Noncatalytic Heavy Crude
Upgrading. 3rd UNITAR/UNDP Intern. Conf. on Heavy Crude and Tar Sands, Long Beach,
CA, 3, 1698.
7)
Geosits, R.F. and Mohammed-Zadeh, Y. (1993) Coke Gasification Power Generation:
Options and Economics. Power Gen., Americas 93, Dallas, TX.
8)
Rhodes, A.K. (1996) Kansas Refinery Starts up Coke Gasification Unit. Oil & Gas J.
9)
Clarke, L.B. (1991) Management of By-Products from IGCC Power Generation. IEA
Coal Research, Report IEACR/38, London, UK.
10)
Kristiansen, A. (1996) Understanding Coal Gasification. IEA Coal Research, Report
IEACR/86, London, UK.
11)
Takematsu, T. and Maude, C. (1991) IEA Coal Research,
Report IEACR/37, London, UK.
12)
McKetta, J.J. (1992) Petroleum Processing Handbook. Marcel Dekker, New York.
13)
Murphy, J.R., Whittington, E.L. and Chang, C.P. (1979) Review Ways to Upgrade
Residues. Hydroc. Proc., 58, 9,
119.
14)
Speight, J.G. (1991) Chemistry and Technology of Petroleum. Second Ed., Marcel
Dekker, New York.
79

15)
Hamilton, G.L., Fitzgerald, M. and DAmico, V. (1986) Retrofitting Heavy Oil
Processes. Proc. AIChE Meeting, Miami, Florida.
16)
Schulman, B.L. and Dickenson, R.L. Upgrading Heavy Crudes: a Wide Range of
Excellent Technologies Now Available. 5th UNITAR/UNDP Intern. Conf. on Heavy Crude
and Tar Sands, 4, Caracas, Venezuela.
17)
Handbook of Refractories by D.N.Nandi, Tata McGraw, New Dehli, 1987
18)
Lupa and Kleisch, Simulation of a Texaco Gasifier, Vol.1 A Steady State Model, EPRI
Report AF-1179, Vol.1 Research Project 1073-1. Final Report, 1979
19)
O.P Gupta, Fuel, Combustion and Refractories, 3rd Impression, 2004
20)
Kohl, A., Nielson, R., Gas Purification Fifth Edition, p.1202-1203, Gulf Publishing
Company, Houston , Texas, 1997
20)
C. Higman and M. Vander Burgt, Gasification:, Elsevier, 2003
21)
M.S Peters, K.D Timmerhaus @ R.C West, Plant Design and Economics for Chemical
Engineers, Fifth Edition, 2005
22)
J.M Smith, H.G.Van-ness,M.M. abbot, Introduction To Chemical Engineering
Thermodynamics, Seventh Edition
23)
Octave Levenspiel, Chemical Reaction Engineering, 3rd Edition
80

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In The Name Of Allah the Most

Merciful, the Most Gracious and Beneficient

A DESIGN REPORT ON PRODUCTION OF 1000

Prof.Dr. Javaid Rabbani KHAN

DEPARTMENT OF CHEMICAL ENGINEERING NFC

A DESIGN REPORT ON PRODUCTION OF 1000

This project is submitted to

For the partial fulfillment of the

-------------------Prof.Dr.Javaid Rabbani Khan

DEPARTMENT OF CHEMICAL ENGINEERING

industrialist chemical engineering

plant design has benefited from both inputs & at least in

6.1.11 Flood And Fire Protection..........................................................................................61

Production of Syngas from Refinery Residual Waste

1.2 Emergence of Refinery Gasification

Production of Syngas from Refinery Residual Waste

1.3 Benefits of Refinery Gasification

1.4 Why Syngas?

Production of Syngas from Refinery Residual Waste

1.5 Raw Materials

Production of Syngas from Refinery Residual Waste

1.5.1 Other Residues

Production of Syngas from Refinery Residual Waste

Table 1.1 Propertiess of liquid and semi liquid residues

1.6 Gasification Processes

Production of Syngas from Refinery Residual Waste

1.6.1 Fixed Bed Gasifiers

1.6.2 Fluidized Bed Gasifier

Production of Syngas from Refinery Residual Waste

1.6.3 Entrained bed gasifier

Production of Syngas from Refinery Residual Waste

Production of Syngas from Refinery Residual Waste

Production of Syngas from Refinery Residual Waste

Production of Syngas from Refinery Residual Waste

2.2 Process Flow Diagram

2.3 Individual Equipment Description

Production of Syngas from Refinery Residual Waste

Figure 2.1 Air Separation Unit

Production of Syngas from Refinery Residual Waste

2.3.2 The Shell Gasification Process (SGP)

Production of Syngas from Refinery Residual Waste

2.3.3 Bag Filter.

Production of Syngas from Refinery Residual Waste

Figure 2.2 Bag Filter

2.3.4 Hydrolyser (Reactor)

Production of Syngas from Refinery Residual Waste

2.3.5 Gas-Liquid Separators

Production of Syngas from Refinery Residual Waste

2.3.5.1 Demister Pads:

Production of Syngas from Refinery Residual Waste

Figure 2.3 Knitted materials with interlocking

Production of Syngas from Refinery Residual Waste

3.1 Material balance around the gasifier

Production of Syngas from Refinery Residual Waste

Production of Syngas from Refinery Residual Waste

Production of Syngas from Refinery Residual Waste

3.2 Material Balance Around The Air Separation Unit(ASU)

Production of Syngas from Refinery Residual Waste

Production of Syngas from Refinery Residual Waste

3.3 Material Balance Around Bag Filter

Production of Syngas from Refinery Residual Waste

3.4 Material Balance Around Hydrolyser

Production of Syngas from Refinery Residual Waste

3.5 Material Balance Around Separator