1 Improved Nitric Acid Production via Cobalt Oxide Catalysis for use in Ammonia- based Fertilizers University of Illinois at Chicago Department of Chemical Engineering CHE 397 Senior Design II March 6, 2012 Thomas Calabrese (Team Leader) Cory Listner Hakan Somuncu David Sonna (Scribe) Kelly Zenger
Improved Nitric Acid Production via Cobalt Oxide Catalysis for use in Ammonia-based Fertilizers
Dec 30, 2015
Improved Nitric Acid Production via Cobalt Oxide Catalysis for use in Ammonia-based Fertilizers. University of Illinois at Chicago Department of Chemical Engineering CHE 397 Senior Design II March 6, 2012 Thomas Calabrese (Team Leader) Cory Listner Hakan Somuncu David Sonna (Scribe) - PowerPoint PPT Presentation
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Improved Nitric Acid Production via Cobalt Oxide Catalysis for use in Ammonia-based Fertilizers
University of Illinois at ChicagoDepartment of Chemical Engineering
CHE 397 Senior Design IIMarch 6, 2012
Thomas Calabrese (Team Leader)Cory Listner
Hakan SomuncuDavid Sonna (Scribe)
Kelly Zenger
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Today’s Agenda Recap of Questions from the Second Meeting Process Flow Diagram
NH3 Oxidation NO Oxidation Absorption Tail Gas Treatment
Energy and Sizing Ammonia Burner Columns Compressors Heat Exchangers
ASPEN Icarus Cost Simulator Report Progress References
3
Revisiting Last Session’s Questions Using ammonia as a refrigerant
Ammonia will now be received as a vapor to eliminate the need for evaporation
Replace steam compressors with electric compressorsHigh-pressure steam will be exported to CHP in return for
electricity to drive compressors Single or dual pressure plant
Dual pressure plant for optimum performance
4
Overall Process
NH3 Oxidation NO Oxidation Absorption Tail Gas Treatment
5
NH3S2T = 250 F T = 40FP = 1350 psia P = 72.5 psia
NH3FILTER T =
P=
T = 480FP = 72.5 psia
T = T = 60F T = 60F COMPRESSOR P =
P = 14.7 psia P = 14.7 psia
T = 113FP = 143.59 psia HX07
CWOUT01T = 100F
HX04 HX03
VAPS5A VAPS4A/4B VAPS4A VAPS3B/3CT = 356F T = 486.9F T = 428F T = 617FP = 62.73 psia P = 63.38 psia P = 63.67 psia P = 64.4 psia
HX05T = 80FCWIN01 VAPS8A
T = 389.7F T = 230F T = 179.6FP = 62.51 psia P = 61.79 psia P = 61.1 psia
CWOUT02T = 100F
,CWIN02 CWIN03T = 80F T =80F
T = 179FP = 61.1 psia
CWOUT03T= 100F
NAACIDS1
AIRS6
AIRFILTER
AIRS4
VAPS5B/5C
OXI03
VAPS6A/6B/6C
AIR
AIRS3
CONDENSER1
OXI04
OXI01OXI02
BLEACAIR
NH3
AIRAIRS1
NH3S1
AIRS2
STREAMMIXER
T = 420FP = 72.5 psia
T = 480FP= 72.5 psia
STREAMSPLITTER
T = 480F VAPS1P = 72.5 psia T = 1634F
P = 66 psiaSTEAMOUT HX01 STEAMINT = 900F T = 250F
VAPS2T = 824FP = 65.27 psia
HX02
HX06
T = 378.2FVAPS3A P= 145.04 psia
T = 536FP = 64.54 psia
T = 246.2F CWOUT04P = 60.92 psia T = 100F
T = 179.3FP = 145.04 psia
NAACIDS2
AIRS4
PUMP01
AMMONIA
NH3 + AIR
OXI04
VAPS8A/8B
VAP9A/9B/9C
BURNER
OXI01
BLEACAIR
HX13 HX14TGS3A/3B TGS4A TGS5A/5B
T = 312.3F T = 478.1F T = 822.8FP = 130.53 psia P = 129.81 psia P = 129 psia
HX12STEAMOUT STEAMIN
T = 328F T = 375F
TGS2A/2BT = 125.3FP = 131.26 psia
T = TGS1 P =
T = 71.6FP = 132 psia
T = 68FP = 145.04 psia
HX06VAPS10A/10B/10C T = 197.5F
T = 257F P= 143.59 psia145.04 psia P = 144.31 psia
NAACIDS4T = 198.2F
CWIN04 P = 143.59 psiaT = 80F
CWOUT04 T = 122.7FT = 100F P = 143.59 psia
HX10T = 197.5F
P = 143.59 psia T = 197.6F T = 126.7FP = 143.59 psia P= 143.59 psia
ACID MIXER
CWIN06T = 80F
CWOUT
HX11
CWOUT05T = 100F
CWIN05T = 80F
AIRS5
VAPS11A/11B/11C/11DVAPS12A
NAACIDS3
TAIL GAS TREATMENT TURBINE
NAACIDS5 NAACIDS6
WATER
ABSORPTION COLUMN
CONDENSER2
HX13 HX14TGS3A/3B TGS4A TGS5A/5B
T = 312.3F T = 478.1F T = 822.8FP = 130.53 psia P = 129.81 psia P = 129 psia
HX12STEAMIN
T = 375F
TGS2A/2BT = 125.3FP = 131.26 psia
EXITGAST = 340F
TGS1 P = 14.5 psiaT = 71.6FP = 132 psia
NAACIDS4T = 198.2FP = 143.59 psia
T = 122.7FP = 143.59 psia
HX10
T = 197.6F T = 126.7FP = 143.59 psia P= 143.59 psia
ACID MIXER
CWIN06T = 80F
CWOUT
AIRS5
BLEACHER COLUMN
TAIL GAS TREATMENT TURBINE
NAACIDS5 NAACIDS6
EXITGAS
ABSORPTION COLUMN
T = 122.7FP = 143.59 psia
T = 100F
HNO3 63 wt% HNO3
Inlet StreamsInlet Streams NH3 OxidationNH3 Oxidation NO OxidationNO Oxidation NO2 AbsorptionNO2 Absorption Tail Gas TreatmentTail Gas TreatmentFinal Product
TreatmentFinal Product Treatment
NH3 Oxidation
AIRS1 AIRS2 AIRS3 AIRS4 BLEACAIR NH3S1 NH3S2 AIR+NH3 VAPS1 VAPS2From AIRFILT AIRCOMP AIRSPLIT AIRSPLIT NH3FILT MIXER BURNER HX01To AIRFILT AIRCOMP AIRSPLIT MIXER BLEACHER NH3FILT MIXER BURNER HX01 HX02Temperature °F 60.0 60.0 480.1 480.1 480.1 250 250 419.9 1634 824Pressure psi 14.7 14.7 72.5 72.5 72.5 72.5 71.3 72.5 66.0 65.2Phase: Vapor Vapor Vapor Vapor Vapor Vapor Mixed Vapor Vapor VaporComponent Mass Flow (TPD) H2O 0 0 0 0 0 0 0 0 907 907 NO 0 0 0 0 0 0 0 0 987 987 N2O4 0 0 0 0 0 0 0 0 0 0 O2 2,410 2,410 2,410 2,130 280 0 0 2,130 797 797 N2 7,936 7,936 7,936 7,014 922 0 0 7,014 7,021 7,021 H3N 0 0 0 0 0 572 572 572 0 0 N2O 0 0 0 0 0 0 0 0 4 4TOTAL FLOW (TPD) 10,345 10,345 10,345 9,143 1,202 572 572 9,715 9,715 9,715
7
NO Oxidation
VAPS3A VAPS3B VAPS3C VAPS4A VAPS4B VAPS4C VAPS5A VAPS5B VAPS5C VAPS6A VAPS6B VAPS6C VAPS7A VAPS7B VAPS7C L+VS1From HX02 O101A O101B HX03 O102A O102B HX04 O103A O103B HX05 O104A O104B HX06 O105A O105B NARCTRTo O101A O101B HX03 O102A O102B HX04 O103A O103B HX05 O104A O104B HX06 O105A O105B NARCTR NASEP1Temperature °F 536.0 617.0 617.0 428.0 486.9 486.9 356.0 389.7 397.7 230.0 230.0 230.0 179.6 179.0 179.0 179.0Pressure psi 64.5 64.4 63.7 63.4 63.4 62.7 62.5 62.5 61.8 61.8 61.8 61.2 61.1 61.1 61.1 61.1Phase: Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Mixed Vapor Vapor MixedComponent Mass Flow (TPD) H2O 907 907 907 907 907 907 907 907 907 907 907 907 907 907 907 888 HNO3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 132 NO2 0 333 333 333 640 640 640 810 810 810 824 811 811 907 699 699 NO 987 770 770 770 570 570 570 458 458 458 449 449 449 386 386 418 N2O4 0 0 0 0 0 0 0 0 0 0 0 13 13 13 222 78 O2 797 681 681 681 574 574 574 515 515 515 510 510 510 477 477 477 N2 7,021 7,021 7,021 7,021 7,021 7,021 7,021 7,021 7,021 7,021 7,021 7,021 7,021 7,021 7,021 7,021 N2O 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4TOTAL FLOW (TPD) 9,715 9,715 9,715 9,715 9,715 9,715 9,715 9,715 9,715 9,715 9,715 9,715 9,715 9,715 9,715 9,715
NO Oxidation Continued
VAPS8A VAPS8B VAPS8C VAPS9A VAPS9B VAPS9C VAPS9D VAPS10A VAPS10B VAPS10CVAPS11A VAPS11B VAPS11C
VAPS11D NAACIDS1 NAACIDS2 AIRS6
From NASEP1 O106A O106B COMP01 RCTR01 RCTR02 RCTR03 HX07 O107A O107B HX08 O108A O108B O108C NASEP1 PUMP01 HX10
To O106A O106B COMP01 RCTR01 RCTR02 RCTR03 HX07 O107A O107B HX08 O108A O108B O108C NASEP2 PUMP01 ABSORPC1 COMP01
Temperature °F 178.9 185 246.2 508.5 378.3 378.2 378.2 257.0 257.0 257.0 197.6 197.5 197.5 197.5 180.0 179.3 113
Pressure psi 61.1 60.9 60.9 145.0 145.0 145.0 145.0 144.3 144.3 144.3 143.6 145.0 143.6 145.0 61.1 145.0 143.6
Phase: Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor Liquid Liquid Vapor
Mass Flow (TPD)
H2O 506 506 506 1,723 1,723 1,723 1,723 1,723 1,723 1,723 1,723 1,723 1,723 1,711 382 382 1,217
HNO3 0 0 0 6 6 7 7 7 7 7 7 7 7 89 132 132 6
NO2 699 904 876 878 1,033 1,033 1,033 1,033 1,111 1,074 1,074 1,083 953 953 0 0 2
NO 418 284 284 284 284 284 284 284 233 233 233 227 227 247 0 0 0
N2O4 78 78 106 169 13 13 13 13 13 50 50 50 180 90 0 0 63
O2 477 405 405 685 685 685 685 685 658 658 658 655 655 655 0 0 280
N2 7,021 7,021 7,021 7,943 7,943 7,943 7,943 7,943 7,943 7,943 7,943 7,943 7,943 7,943 0 0 922
N2O 4 4 4 4 4 4 4 4 4 4 4 4 4 4 0 0 0
TOTAL FLOW (TPD) 9,201 9,201 9,201 11,692 11,692 11,692 11,692 11,692 11,692 11,692 11,692 11,692 11,692 11,692 514 514 2,490
9
Absorption
NAACIDS2 NAACIDS3 VAPS12A ABS01 ABS02 ABS03 ABS03A WATERFrom PUMP01 NASEP2 NASEP2 ABSRCTR1 ABSRCTR2 ABSRCTR3 NOSEP To ABSORPC1 MIXER02 ABSRCTR1 ABSRCTR2 ABSRCTR3 NOSEP ABSORPC1 ABSRCTR3Temperature °F 178.9 197.5 197.5 197.5 197.5 197.5 197.5 68Pressure psi 145.0 145.0 145.0 143.6 143.6 143.6 143.6 145.0Phase: Liquid Vapor Vapor Vapor Vapor Mixed Mixed LiquidComponent Mass Flow (TPD) H2O 382 1,388 323 323 323 665 665 607 HNO3 132 89 0 0 0 1,858 1,858 0 NO2 0 0 952 2,009 2,036 2 2 0 NO 0 0 247 14 14 456 0 0 N2O4 0 32 59 59 31 31 31 0 O2 0 0 655 288 288 288 288 0 N2 0 0 7,943 7,943 7,943 7,943 7,943 0 N2O 0 0 4 4 4 4 4 0TOTAL FLOW (TPD) 514 1,509 10,183 10,639 10,639 11,246 10,790 607
10
Bleaching
NAACIDS3 NAACIDS4 NAACIDS5 NAACIDS6 BLEACAIR AIRS5 HNO3From NASEP2 ABSORPC1 MIXER02 HX09 AIRSPLIT BLEACHER BLEACHERTo MIXER02 MIXER02 HX09 BLEACHER BLEACHER HX10 Temperature °F 197.5 198.2 197.6 126.7 480.1 122.7 122.7Pressure psi 145.0 143.6 145.0 143.6 72.5 143.6 143.6Phase: Vapor Liquid Mixed Liquid Vapor Mixed LiquidComponent Mass Flow (TPD) H2O 1,388 1,046 2,434 2,434 0 1,217 1,217 HNO3 89 1,989 2,078 2,078 0 6 2,072 NO2 0 2 2 2 0 2 0 N2O4 32 31 63 63 0 63 0 O2 0 0 0 0 280 280 0 N2 0 0 0 0 922 922 0TOTAL FLOW (TPD) 1,509 3,068 4,578 4,578 1,202 2,490 3,289
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Tail Gas
TG4B TGS2A TGS2B TGS3A TGS3B TGS4A TGS5A TGS5B EXITGASFrom GTREAT3 HX11 GTREAT1 HX12 GTREAT2 HX13 HX14 GTREAT4 TURBINE1To HX14 GTREAT1 HX12 GTREAT2 HX13 GTREAT3 GTREAT4 TURBINE1 Temperature °F 478.1 125.3 125.3 312.3 312.3 478.1 822.8 822.8 340.3Pressure psi 129.8 131.3 131.3 130.5 130.5 129.8 129.1 129.1 14.5Phase: Vapor Vapor Vapor Vapor Vapor Vapor Vapor Vapor VaporComponent Mass Flow (TPD) H2O 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1 HNO3 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 NO2 0.05 0.02 0.04 0.04 0.05 0.05 0.05 0.05 0.05 N2O4 0.00 0.03 0.00 0.00 0.00 0.00 0.00 0.00 0.00 O2 288 288 288 288 288 288 288 288 288 N2 7,943 7,943 7,943 7,943 7,943 7,943 7,943 7,943 7,943 N2O 4 4 4 4 4 4 4 4 4TOTAL FLOW (TPD) 8,235 8,235 8,235 8,235 8,235 8,235 8,235 8,235 8,235
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Catalytic Reactor Catalyst Bed
Volume = 400 ft3
Diameter = 9.6 ft Catalyst Depth = 5.5 ft
Column Analysis Absorption Column
Sizing Height = 230 ft Diameter = 13 ft Trays = 100
Energy 130,000,000 Btu/hr
Bleacher Column Sizing
Height = 72 ft Diameter = 4 ft
Energy 1,000,000 Btu/hr
13
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Compressor Analysis
Specification Units Air Compressor NOx Compressor
Operating Pressure Psia 72.5 145
Stage 1 Work Btu/hr 38,000,000 26,000,000
Stage 2 Work Btu/hr 43,000,000 30,000,000
Total Work Btu/hr 81,000,000 56,000,000
Inlet Pressure Psia 14.7 72.5
Interstage Pressure Psia 32.7 102.5
Outlet Pressure Psia 72.5 145
Stage 1 Inlet Temp. °F 60 257
Stage 1 Outlet Temp. °F 242 358
Stage 2 Inlet Temp. °F 120 332
Stage 2 Outlet Temp. °F 323 471
Efficiency % 76 78
Interstage Cooling Water TPD 15,000 2,300
15
Pinch Analysis
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Heat Exchanger EnergyHX Purpose Hot Stream Cold Stream Hot In [°F] Hot Out [°F] Cold In [°F] Cold Out [°F]
Energy [Btu/hr]
NH3 Oxidation Reactor Gas Steam 1634 824 250 900 196,000,000
NO Oxidation 1-1 Process Gas Tail Gas 2 824 748 125 227 17,000,000
NO Oxidation 1-2 Process Gas Tail Gas 4 748 536 478 747 48,000,000
NO Oxidation 2 Process Gas Cooling H2O 617 428 80 100 42,000,000
NO Oxidation 3 Process Gas Tail Gas 3 486 356 312 487 28,000,000
NO Oxidation 4 Process Gas Cooling H2O 390 230 80 100 35,000,000
NO Oxidation 5 Process Gas Cooling H2O 378 257 80 100 34,000,000
Condenser 1 Process Gas Cooling H2O 230 179 80 100 36,000,000
Condenser 2 Process Gas Cooling H2O 257 197 80 100 16,000,000
Nitric Acid Cooler Weak HNO3 Cooling H2O 198 127 80 100 139,000,000
Secondary Air Cooler
Secondary Air
Tail Gas 1 480 113 72 124 9,000,000
Tail Gas Preheater
Steam Tail Gas 2 375 328 227 312 15,000,000
TOTAL 524,000,000
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Heat Exchanger SizingHX Purpose Energy [Btu/hr] ΔTLM U [Btu/ft2-hr-°F] Area [ft2]
NH3 Oxidation 196,000,000 651 5 57,000
NO Oxidation 1-1 17,000,000 610 5 5,400
NO Oxidation 1-2 48,000,000 12.5 5 728,000
NO Oxidation 2 42,000,000 427 28 3,500
NO Oxidation 3 28,000,000 21 5 260,000
NO Oxidation 4 35,000,000 212 28 5,800
NO Oxidation 5 34,000,000 114 28 11,500
Condenser 1 36,000,000 224 28 5,400
Condenser 2 16,000,000 136 28 4,200
Nitric Acid Cooler 139,000,000 69 203 10,000
Secondary Air Cooler 9,000,000 146 5 11,600
Tail Gas Preheater 17,000,000 80 5 34,600
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ICARUS Equipment CostEquipment Cost [USD] Equipment Cost [USD]
Absorption Column 1,000,000 Nitric Acid Cooler HX 679,000
Bleacher Column 213,000 Condenser 1 144,000
Weak Acid Pump 42,000 Condenser 2 157,000
Air Compressor 22,000,000 Secondary Air Cooler 454,000
NOx Compressor 6,700,000 Tail Gas Preheater 365,000
Tail Gas Expander 9,000,000 Ammonia Burner 5,000,000
NH3 Oxidation HX 874,000 Nitric Acid Tank 1,000,000
NO Oxidation HX1-1 312,000 Boiler Feed Pump 47,000
NO Oxidation HX2 277,000 Product Pump 56,000
NO Oxidation HX4 241,000 Flash Drums 1,500,000
NO Oxidation HX5 256,000 Acid Storage Tank 800,000
TOTAL (Direct and Equipment Costs, ASPEN) 65,000,000
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ICARUS Installed CostsMaterial Cost [USD]
Equipment 65,000,000
Piping 1,900,000
Civil 530,000
Steel 100,000
Instrumentation 1,000,000
Electrical 2,500,000
Paint 100,000
Other 4,500,000
G&A Overheads 1,000,000
Contingencies 7,000,000
TOTAL 84,000,000
TOTAL Est. (x5) 418,000,000
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ICARUS Yearly Operating CostsMaterial Cost [USD/yr]
NH3 112,000,000
Air 0
Cobalt Oxide 463,000
Process Water 6,000
Boiler Feed Water -1,072 @ $TPD
Cooling Water 1,650,000
Process Steam 1,900,000
HNO3 Sales +163,000,000
Steam Sales +1,072 @ $TPD
TOTAL 47,000,000
Material Cost [USD/yr]
Operating Labor 640,000
Maintenance 905,000
Supervision 200,000
Operating Charges 230,000
Plant Overhead 912,000
TOTAL 2,900,000
TOTAL PROFIT $44,000,000 per year
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Report Progress Open Report www.che397-nitric-acid.wikispaces.com
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Looking Ahead Process Flow Diagram Initial Control Scheme Plant Layout Calculations Refined Economics Report
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References http://www.uic-che.org/pinch/ Ullman’s Encyclopedia of Industrial Chemistry. Volume A17. VCH. Towler, Gavin. Chemical Engineering Design. 2008. Perry, Robert and Don Green. Perry’s Chemical Engineers’ Handbook 8th Edition. McGraw-Hill 2008. Felder, Richard and Ronald Rousseau. Elementary Principles of Chemical Processes 3rd Edition. John Wiley
& Sons Inc. 2005.
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