SOLVAY VISHNU BARIUM (P) LIMITED

URANDUR, SRIKALAHASTI.

ENERGY BALANCE FOR CO2 PLANT:

Flue gas analysis:

Inlet Outlet

Component Composition % Mol.wt kg/kmol Temp. Cp Cp Temp Temp.

Cp J/molk
Cp
Temp. C k J/molk kJ/kgk . C k kJ/kgk
CO2 18% 0.18 44 7.92 65 338 39.656 0.1622 40 313 38.8855 0.159077
CO 0.50% 0.005 28 0.14 65 338 29.549 0.0053 40 313 29.11513 0.005199
SO2 0.015% 0.00015 64 0.0096 65 338 29.672 7E-05 40 313 40.60779 9.52E-05
H2O 5.00% 0.05 18 0.9 65 338 33.925 0.0942 40 313 33.7167 0.093657
O2 1.00% 0.01 32 0.32 65 338 29.517 0.0092 40 313 29.55578 0.009236
N2 Balance 0.75485 28 21.1358 65 338 29.338 0.7909 40 313 29.09155 0.784277
Flue gas Mol.wt 30.4254 Cp kJ/kgk 1.062 Cp kJ/kgk 1.051542

Basis: 1ton/hr of CO2 1100 kg/hr

Flue gas contains 18% of CO2 and 95% absorption.
Flue gas
m3/hr 5000
Volumetric flowrate of CO2 (dry), m3/hr 2977.1398192451

Caustic Scrubber:

Flue gas Temp vapor pr atm Humidty( Enthalpy H2O Cp of FG Heat transferred
C molH2O/ vapor kJ/kgk kJ/kg
molFG)

65 0.2490720271 0.195109 2477.4692823217 1.06196763 552.4049494322

40 0.076451399 0.048694 2460.4321499277 1.05154203 161.8703257611

Total Heat transferred in caustic scrubber Q kJ/hr 1952673.12

Caustic flow rate, m3/hr 40
mass flow rate of caustic, kg/hr 40400
Inlet temp of Caustic, C 40
Outlet temp of Caustic, C 53.8332836373
Inlet temp of Cooling water, C 32
Outlet temp of Cooling water, C 38
Cooling water mass flow rate, kg/hr 77727.6139780044
Cooling water vol.flow rate, m3/hr 77.727613978
Water Condensed in Caustic Scrubber:
Flue gas molar flow rate, kmol/hr 223.004463
Inlet flue gas to Caustic scrubber contains SO2, kmol/hr 0.03345067
Outlet flue gas from Caustic scrubber contains SO2,kmol/hr 0.00066901
Mole fraction of water in NaoH 0.909
Partial pr of H2O at the absorber, atm 0.06949432
Total pr in the absorber, atm 1.382
Water vapor in I/L FG to Scrubber, kmol/hr 49.0271006
Water vapor in O/L FG to Scrubber, kmol/hr 11.8076014
Total water condensed in the Scrubber, kg/hr 669.950986

MEA Scrubber:
PHE2/1
MEA flow rate, m3/hr 55
mass flow rate of MEA, kg/hr 57750
Inlet temp of RMEA, C 55
Outlet temp of RMEA, C 90
Inlet temp of LMEA, C 100
Heat tranferred in the PHE2/1, kJ/hr 6492255
Outlet temp of LMEA, C 65
PHE2/2
Outlet temp of LMEA, C 40
Inlet temp of Cooling water, C 32
Outlet temp of Cooling water, C 38
Heat tranferred in the PHE2/2, kJ/hr 4637325
Cooling water mass flow rate, kg/hr 184592.190112252
Cooling water vol.flow rate, m3/hr 184.5921901123

Gas Cooler:
Humidty
Flue gas Temp Enthalpy H2O Cp of CO2 Heat transferred
vapor pr atm (molH2O/
C vapor kJ/kgk kJ/kg
molCO2)
95 0.8316508633 1.103362 2497.3915191547 0.92179545 2843.0981789138
40 0.076451399 0.029407 2460.4321499277 0.88381818 107.706189623

Total Heat transferred in Gas Cooler, Q kJ/hr 3008931.19 719.15 Mcal/hr

Cooling water mass flow rate, kg/hr 119772.756 28.7516966968 m2
Cooling water vol. flow rate, m3/hr 119.772756
Compressor:
Stage-1
Suction pressure,kg/cm2g 0.1
Discharge pressure,kg/cm2g 1.55
Suction temperature, C 40 564 R
Discharge temperature,C 110.84

INTER COOLER
CO2 I/L temp, C 110.84
CO2 O/L temp, C 40
Cooling water I/L temp, C 30
Cooling water O/L temp, C 35
Heat tranferred in the Stage-1, kJ/hr 70131.5894516907
Cooling water mass flow rate, kg/hr 3349.9684476566
Cooling water vol. flow rate, m3/hr 3.3499684477

Stage-2
Suction pressure,kg/cm2g 1.5
Discharge pressure,kg/cm2g 4
Suction temperature, C 40 564 R
Discharge temperature,C 97.33

AFTER COOLER
CO2 I/L temp, C 97.33
CO2 O/L temp, C 40
Cooling water I/L temp, C 32
Cooling water O/L temp, C 38
Heat tranferred in the Stage-1, kJ/hr 56760.0295730383
Cooling water mass flow rate, kg/hr 2259.3754308191
Cooling water vol. flow rate, m3/hr 2.2593754308

Total Heat transferred in the Compresor, kJ/hr 126891.619

Total Cooling water vol. flow rate, m3/hr 5.60934388

CO2 Plant:
Total Heat transferred in the CO2 Plant, kJ/hr 9725820.93
Cooling water mass flow rate, kg/hr 290357.682
Cooling water vol. flow rate, m3/hr 290.357682

Reboiler:
Steam mass flowrate, kg/hr 3000
Vapor pr at 110C, atm 1.416
Vapor pr at 65C, atm 0.2491
Total pr in the Reboiler, atm 3.10880829
Water vapor in I/L steam to Reboiler, kg/hr 2509.43951
Water vapor in O/L steam to Reboiler, kg/hr 261.32036
Total water condensed in the Reboiler, kg/hr 2248.11915
 SOLVAY VISHNU BARIUM (P) LIMITED
URANDUR, SRIKALAHASTI.

2nd Compressor for CO2 Plant:

Compressor Details:

Serial No : 9751004
Make : INGER SOLL-RAND
Size : Bore Diameter - 11" & Stroke Length - 7"
Speed : 650rpm
Discharge Pressure: 100psig
Capacity : 522Nm3/hr 1024.72 kg/hr

Suction pressure,kg/cm2g 0.1

Discharge pressure,kg/cm2g 6.803 100psi

Suction temperature, C 40 564 R

Discharge temperature,C 230.49 (Therotical Adiabatic)

After Cooler :

CO2 I/L temp, C 230.49

CO2 O/L temp, C 40

Cooling water I/L temp, C 30

Cooling water O/L temp, C 35

Heat transferred , kJ/hr 175678.00097663

Cooling water mass flow rate, kg/hr 8391.5930726837

Cooling water vol. flow rate, m3/hr 8.3915930727

CO2 gas I/L CO2 gas O/L

Counter current flow direction 230.5oC 40oC
195.49 C
10 C CW O/L CW I/L
LMTD 62.393 C 35oC 30oC

Heat transferred Q 41988 kCal/hr

Heat transfer area As 1.34592 m2

Plate Heat Exchanger Design:

Capacity of CO2 gas 1100 kg/hr

CO2 gas inlet temperature 95 C
CO2 gas outlet temperature 40 C
Cooling water inlet temperature 30 C
Cooling water outlet temperature 35 C
Counter Current Flow , Pass 1:1

Gas Cooler:

Heat
Flue gas vapor pr Humidty Enthalpy Cp of CO2
transferred
Temp C atm (molH2O/molCO2) H2O vapor kJ/kgk
kJ/kg
95 0.83165086 1.3169032113 2497.391519 0.921795455 3376.39348
40 0.0764514 0.0308574964 2460.43215 0.883818182 111.275504

Total Heat transferred in Gas Cooler, Q kJ/hr 3591629.774 858.42

Cooling water mass flow rate, kg/hr 171561.0114 34.3196449
Cooling water vol. flow rate, m3/hr 171.5610114

LMTD 27.90553133 C
NTU 1.970935416
Correction factor Ft 0.96
Corrected LMTD 26.78931007 C

Assume overall heat transfer coefficient 800 kCal/hrm2C

Heat transfer area 40.05422852 m2

Plate length 1 m
Plate width 0.5 m
No. of plates 80
No.of channel per pass 40
No.of effective plates 78
Plate spacing 0.003 m
Channel cross section area 0.0015 m2
Hydraulic mean diameter 0.0060 m

CO2 gas properties at mean temperature: Liquid

Density 555.6166436 kg/m3 976.5
Viscosity 0.000276549 kg/ms 0.0004755
Sp.heat capacity 0.690051457 kCal/kgC 1.00025
Thermal conductivity 0.327470092 W/mC 0.563

Heat transfer coefficient for CO2 gas:

Channel velocity 0.021475271 m/s

Nre 258.8766701
Pr 2.438224812
Nu 13.75033378
Heat transfer coefficient hp 750.4705115 W/m2C

Cooling water properties at mean temperature:

Density 993.55 kg/m3 993.55
Viscosity 0.000761 kg/ms 0.000761
Sp.heat capacity 0.9985 kCal/kgC 0.9985
Thermal conductivity 0.5335 W/mC 0.5335

Heat transfer coefficient for Cooling water:

Channel velocity 0.808429573 m/s

Nre 6332.839967
Pr 5.959227674
Nu 157.0682384
Heat transfer coefficient hp 13965.9842 W/m2C

Fouling Factor
CO2 gas 0.0002 m2C/W
Cooling water 0.000125 m2C/W
Plate Thickness 0.0005 m
Thermal conductivity of SS 16 W/m2C

Overall heat transfer coefficient 568.0688703 W/m2C

488.7781867 kCal/hrm2C
Heat transfer area 65.55812777 m2
Mcal/hr
m2

Vapor 2548.594 kg/hr

1.354 0.431611 0.568389
1.455E-05
0.28155
0.0173
CO2 Plant Plate Heat Exchanger II

MEA Scrubber:(Jan 2005)

PHE2/1
MEA flow rate 55 m3/hr
mass flow rate of MEA 55000 kg/hr
Inlet temp of RMEA 55 O
C
Outlet temp of RMEA 93 O
C
Inlet temp of LMEA 100 O
C
Heat transferred in the PHE2/1, 8569000 kJ/hr 2048040 kCal/hr
Outlet temp of LMEA, 51.494396 C 45 41.5056
LMTD, 43.2292657 C
KS I, 198222.196 kCal/hrC 2457648
2500000
PHE2/2
Outlet temp of LMEA, C 40 O
C
Inlet temp of Cooling water, C 32 O
C
Outlet temp of Cooling water, C 40 O
C
Heat transferred in the PHE2/2, 2591986.3 kJ/hr 619499.6 kCal/hr
Cooling water mass flow rate, 77381.9651 kg/hr
Cooling water vol.flow rate, 77.3819651 m3/hr 11.4944 8
LMTD, C 9.6418923 O
C
KSII, 8025.5994 kCal/hrC

MEA Scrubber:(Mar 2005)

PHE2/1
MEA flow rate 55 m3/hr
mass flow rate of MEA 55000 kg/hr
Inlet temp of RMEA, C 60
Outlet temp of RMEA, C 98
Inlet temp of LMEA, C 103
Heat transferred in the PHE2/1, kJ/hr 8569000 2048040 kCal/hr
Outlet temp of LMEA, C 54.494396 43 43.5056
LMTD, C 43
KS I, kCal/hrC 199279.07
PHE2/2
Outlet temp of LMEA, C 50
Inlet temp of Cooling water, C 32
Outlet temp of Cooling water, C 42
Heat transferred in the PHE2/2, kJ/hr 1013486.3 242229 kCal/hr
Cooling water mass flow rate, kg/hr 24205.5482
Cooling water vol.flow rate, m3/hr 24.2055482 12.4944
LMTD, C 15.0800648 18
KSII, kCal/hrC 1605.13555

Q1 KSI Q2 KSII
Jan-05 2048040.15296 198222.196 619499.6 8025.599
Mar-05 2048040.15296 199279.07 242229 1605.136

PHE-II Section-I KSII (kJ/hroC) PHE-II Section-II

KS-I (KJ/hroC)

10000
240000

8000

Jan-05 6000
5-Mar
200000 Jan-05
4000
Mar-05

2000

160000
0
1000000 2000000 Q1
3000000 200000 300000 400000 500000 600000 700000
Q2 (kJ/hr)
(kJ/hr) 4000000 5000000