Elemantal analysis of thar coal analysis in mass %age

C 62.18 621.8
H2 5.44 54.4 F1= 1000 kg/hr
O2 13.15 131.5
N2 0.78 7.8
S 3.97 39.7 F2 O2
Ash 8.2 82
Water 6.28 62.8

SYN.GASES

F5
COAL F1

CO2
CO
H2
N2
H2S
F3 STEAM ASH ASH
F4

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

N2:
0.27857143 kgmol/hr

S:
1.240625 kgmol/hr = NH2S

C:
51.8166667 = nco+nco2 5

H2:
30.6888889 = NH2+NH2S-F3

29.4482639 = NH2-F3 1
NH2= 178.651625
O2:
5.85381944 = 0.5NCO+NCO2-F2-0.5F3 2
chemical reaction
2.2 C+ 0.6 O2+h20 2.2 CO+H2
f2= 14.1318182 kgmol/hr o2 present in coal= 8.63181818
f2= 420.16 kg/hr So,this is the quantity of O2 which is needed,we use 0.045$% excess air to
for f3
f3= 23.5530303 kgmol/hr
f3= 423.954545 kg/hr
putting f3 in equation 1
nH2= 53.0012942 kgmol/hr
putting f2
0.5nCO+nCO2= 30.7603346 kgmol/hr 3

nCO= 42.1126641 kgmol/hr

nCO2= 9.70400253 kgmol/hr
COMPOSITION OF F5(SYNTHESIS GAS)
component kgmol/hr kg/hr Mole% mol wt
CO2 9.70400253 426.976111 9.12569301 44
CO 42.1126641 1179.1546 39.6029621 28
H2 53.0012942 106.002588 49.8426849 2
N2 0.27857143 7.8 0.26196998 28
H2S 1.240625 42.18125 1.16669002 34
TOTAL 106.337157 1762.11455 100

F5= 106.337157 kgmol/hr

Mol.wt of the syn gas can be calculated as
Mol wt of syn gas= 16.5710142 kg/kgmol FLOW OF SYN GAS= 1762.115
suppose ash present in f5 is 22% of f4 kg/hr
ash= 16.4 kg/hr
so f5 finally will be= 1778.51455 kg/hr

so f4 will be f4= 65.6 kg/hr

SUMMAR OF MATERIAL BALANCE AROUND GASSIFIER
Mass in Mass out
STREAM kg/hr STREAM2 kg/hr2
F1 1000 F4 65.6
F2 420.16 F5 1778.51455
F3 423.954545 0
TOTAL 1844.11455 TOTAL 1844.11455

BALANCE AROUND CYCLONE SEPARATOR

F6
F5

ASH F7

F5= 1778.51455 kg/hr having ash176.66 kg/hr

suppose the efficiency of cyclone separator is 98.5%
solid removed f7= 16.154 kg/hr
solid unremoved= 0.246 kg/hr
F6= 1762.36055 kg/hr

SUMMARY
MASS IN MASS OUT
STREAM kg/hr STREAM2 kg/hr2
F5 1778.51455 F6 1762.36055
0 F7 16.154
TOTAL 1778.51455 TOTAL 1778.51455

BALANCE AROUND EXCHANGER F8

F9
F6

F10
For F6
F6= 1762.36055 kg/hr
T6= 1200 K 926.85 ⁰C
for F9
F9= 1762.36055 kg/hr
T9= 400 K 126.85 ⁰C
for F8
F8=?
T8= 300 K 26.85 ⁰C

for F10
F10=? 549 K 275.85 ⁰C

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

m∗Cp gas∗ΔT=mCp H 2O∗ΔT +m∗λalignl¿ s ¿ ¿ ¿

F 6∗Cpgas∗(T 6−T 9 )=F 8∗(Cp H 2O∗(T 10 −T 8 )+ λ s ) 6

Where,
Cp,gas= 1.942 Kj/Kg⁰C
Cp,water= 4.6525 Kj/Kg⁰C
Latent heat= 1569.15 Kj/Kg

putting all values in Eq#6

1003.80582 =F8

SUMMARY
MASS IN MASS OUT
STREAM Kg/hr STREAM2 Kg/hr2
F6 1762.36055 F9 1762.36055
F8 1003.80582 F10 1003.80582
TOTAL 2766.16637 TOTAL 2766.16637

MATERIAL BALANCE AROUND H2S ABSORBER

F12(selexol in)

F11(syn.gases)
F9(syn. gases)

F13(selexol+h2s)
COMPOSITION OF F9
F9 kg/hr
CO2 426.976111
CO 1179.1546
H2 106.002588
N2 7.8
H2S 42.18125

TOTAL 1762.11455
efficiency is 98.5% so H2S removed
H2S removed= 41.5485313 kg/hr
now,
F11=F9-H2S removed
F11= 1720.56601 kg/hr

to find out the flowrate of the selexol we have to apply energy balance around the absorber
FOR GAS
F9= 1762.11455 kg/hr
Cp,gas= 1.942 kj/kg⁰C
T9= 400 K 126.85 ⁰C
T11= 388.15 K 115 ⁰C

Q=m∗Cp∗ΔT
So,

Q=F 9∗Cp gas∗( T 9−T 11 )

putting all values in the formula,

Q= 11.2641704 KW

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

Q=F 12∗Cp selexol∗( T 13 −T 12 )

F12= 2.74735863 kg/sec

F12= 9890.49107 kg/hr

F13=F12+H2S removed
F13= 9932.0396 kg/hr
 SUMMARY

MASS IN MASS OUT

STREAM kg/hr STREAM2 kg/hr2
F9 1762.11455 F11 1720.56601
F12 9890.49107 F13 9932.0396
TOTAL 11652.6056 TOTAL 11652.6056

Composition of F11
component kg/hr kgmol/hr %age
CO2 426.976111 9.7040025324.2308942
CO 1179.1546 42.1126641 66.917023
H2 106.002588 53.00129426.01564686
N2 7.8 0.27857143 0.44265
H2S 42.18125 1.240625
2.39378593
ash 0 0
TOTAL 1762.11455 106.337157 100

balance around shift converter

Steam F14

Syn. Gases F11

F11= 1762.11455 kg/hr

Composition of F11
component kg/hr kgmol/hr
CO2 426.976111 9.70400253
CO 1179.1546 42.1126641
H2 106.002588 53.0012942
N2 7.8 0.27857143
H2S
ash
TOTAL 1719.9333 105.096532

N2 BALANCE
0.27857143 kgmol/hr
O2 BALANCE
30.7603346 =nCO2+0.5nCO-0.5F14 7
C BALANCE
51.8166667 =nCO + nCO2 8

H2 BALANCE
53.0012942 =nH2s+nH2-F14 9

S BALANCE
0 =nH2S 10

the reaction in the shift reactor is the

CO+H2O CO2+H2

now from the chemical reaction equation

because the require efficency of the reactor is the 48%

for 1 mole of CO require=1mole of steam

20.2140788 mole of CO= 20.2140788 mole of H2O mass of H2O=

So F14= 20.2140788 kgmole/hr put this value in eq 9

73.215373 =Nh2 nH2= 146.430746 kg/hr

put F14 in eq7

40.867374 =0.5nCO+nCO2 11

by the calculation of eqs.8 & 10 nCO= 21.8985854 kgmol/hr

nCO=291.697768 kgmol/hr nCO2= 29.9180813 kgmol/hr
nCO2=231.301907 kgmol/hr
F15= 2083.78671 kg/hr
ash in = ash out
17.666=17.666 kg/hr

streams in kg/hr stream out kg/hr2

F11 1719.9333 F15 2083.78671
F14 363.853418
TOTAL 2083.78671 TOTAL 2083.78671

composition of F15

component kg/hr kmol/hr

CO2 1316.39558 29.9180813
CO 613.16039 21.8985854
 H2 146.430746 73.215373
N2 7.8 0.27857143

TOTAL 2083.78671 125.310611

Material balance on the compressor

MASS IN = MASS OUT

2083.78671 2083.78671 kg/hr

BALANCE AROUND CO2 ABSORBER

F16
DEPG(Solvent)

F15 F18
Syngas
Syngas
29.91808 CO2 CO2 9.63362218 423.8794
21.89859 CO CO 21.8985854 613.1604
73.21537 H2 H2 73.215373 146.4307
0.278571 N2 F17 N2 0.27857143 7.8
DEPG+Co2 Total 105.026152 1191.271
C02 to be removed= 20.27
so 67.8% Co2 is to be removed
Co2 in F15= 29.9180813
Co2 Removed= 20.2844591
Co2 Left= 9.63362218

Balance Around Reactor And Separator

F19
F18 Reactor Separator

CO2 9.63362218 423.879376

CO 21.8985854 613.16039
H2 73.215373 146.430746 Recycle Stream
N2 0.27857143 7.8
Total 105.026152 1191.27051
R CO2
CO
H2
N2
Overall Balance
CO2 Balance: Efficience Of the reactor 96%
Mass in = Mass out
 9.63362218 = M(0)+P(x)+(9.63362218)(0.96)
P(X) 0.38534489 kmole/hr
CO Balance
Mass in = Mass out

21.8985854 = M(0)+P(y)+(21.8985854)*(0.96)
P(y) 0.87594341 kmole/hr
N2 Balnce:
Mass in = Mass out

0.27857143 = E(0)+P(g)+(0.28)(0)
P(g) 0.27857143 kmole/hr
H2 Balanvce:
Mass in = Mass out

73.215373 = M(0)+P(y)+(2*221.8985854+3*9.63362218)*0.96
P(Z) 3.42525721 kmole/hr
So,
P(Z) 4.96511694 kmole/hr
%age of gases in Stream P
CO2 7.76104353
CO 17.6419493
H2 68.9864358
N2 5.61057135

Methanol From CO:

21.0226419 kmole/hr

Methanol From CO2:

9.2482773 kmole/hr
Water Produced from Co2 along with CH3OH
9.2482773 kmole/hr
Total No Of Moles Of Methanol
30.2709192
composition Of M(F20):
Methanol 30.2709192 76.5980128 %
Water 9.2482773 23.4019872 %
Total 39.5191965
CO2 Balance To Find out Recycle stream:
As Composition of R and P is same,So
(9..63362218+(0.0776104353*R))=0.14(9.64+0.0776104353*R)+(R+P)*(0.0776104353)
R= 66.0594936 -963362218 /0.0776104353
R= 727.03975 kmole/hr

Balance Around distillation Column

V

Feed F R
XF

kmole/hr
Methanol 30.2709192 968.669416
Water 9.2482773 166.468991
Total 39.5191965 1135.13841

Xf 0.64802886

Xd 0.98235943

Xb 0.01764057
Overall Balance
F=D+B 1
Balance on Methanol
30.2709192 = 0.99D+0.0 3W 2
D can be find out by solving above two equations
D 30.2936659

W= 9.22553066
Methanol in D 29.9907292 kmole/he
Water 0.3 kmole/hr

Methanol in W 0.27676592
Water in W= 8.94876474
Methano Balance:
Mass in = Mass Out

30.27092 = 30.2674951

Water Balance:
9.248277 = 9.24876474

ENERGY BALANCE
ENERGY BALANCE AROUND GASIFIER:
F2

Flow Rate 1000 Kg/hr

F1

F3 F4
For F1:
Flow rate 1000 Kg/hr
T1 313.15 K Cp 1.45 Kj/Kg-K
Tr 298.15 K
For F2:
Flow rate 420.16 Kg/hr
T2 600 K Cp 1.003 Kj/Kg-K
For F3:
Flow rate 423.954545 Kg/hr Cp 4.65 Kj/Kg-K
T3 549 K

Energy in Coal:
Q=mCpdT

Q= 6.04166667 KW

Energy In Oxygen:
 Q=mCpdT

Q= 35.3349366 kW

Energy In Steam:
Q=mCpdT+mλs
λs 1569.15 Kj/Kg
Q= 322.158643

Total Heat In:

Qt= 363.535246

Total Energy Generated:

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

1.22 [C+1/2O2 CO] dH= -111.3 Kj/Kmole -135.786

C+H2O CO+H2 dH= 135.3 Kj/Kmole

Overall Reaction
0.2C+0.6O2+H2O 2.2CO+H2 dH= 0 Kj/Kmole
CO2 is also formed along with CO

C+O2 CO dH= -393.5 Kj/Kmole

CO+1/2O2 CO2 dH= -283 Kj/Kmole

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

QA -0.63642083 KW

QB -0.30513697 KW

Qreac: -0.9415578 KW

Total Qin= Qt+Qreac

364.476804 KW

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

Energy in Flue Gas:

T5 1200 K
Tr 298.15 K
Flowrate 1778.51455 Kg/hr
Cp 1.942 Kj/Kg-K

Q=mCpdT

Q5= 865.24372 KW
Energy in Ash:
Flow rate = 65.6 Kg/hr
T4 1200 K
Cp 0.514 Kj/Kg-K
Q=mCpdT
Q4= 8.44692751
Total heat Out= 873.690647 KW
As Heat which is coming out of the gasifier is very large, so we have to incorporate burners to add the required heat.

Heat Required= Qin-Qout

-509.213843 KW
Heat from Burners= 512 KW
Losses= 2.78615656 KW
Energy Balance Around Cyclone Separator:
As All the Entering and exiting stream are at the same temperature So

Energy in=Energy out

And iti s equal to zero.

Energy Balance Around Heat exchanger:

F8

F6
F9

F10

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

For F6:
flow rate 1762.36055 Kg/hr
T6 1200 K
Tr 298.15 K
Cp 1.942 Kj/Kg-K
 Q=mCpdT
Q6= 857.384832 KW
For F8:
Flow rate 1003.80582 Kg/hr
T8 300 K
Cp 4.6525 Kj/Kg-K

Q=mCpdT+mλs
Q8 439.93383 KW
NOW
For F9:
T9 400 K
Flow rate 1762.36055 Kg/hr

Q=mCpdT
Q9 96.8283474 KW

For F10:
T10 549 K
Flow rate 1003.80582 Kg/hr
Cp 4.6525 Kj/Kg-K
Q=mCpdT+mλs
Q10 762.956452
eded,we use 0.045$% excess air to compensate co2 formation 13.13 kgmol/hr
F15
363.8534 kg/hr

613.1604
1316.396
 F20 M
eparator F

F21 P
x
y
z
g
 Xd
D

B
XB
F5
Kj/Kmole

3
4
o add the required heat.