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In this module, you will simulate a Synthesis Gas Production facility. This will introduce you to the powerful reaction modelling capability of HYSYS. The production of synthesis gas is an important step in the production of ammonia. Synthesis gas is comprised of hydrogen and nitrogen at a molar ratio of 3:1. The main role of the synthesis gas plant is to convert natural gas, primarily methane, into hydrogen. In most synthesis gas plants, four reactors are used. However, in our simulation five reactors will be used to model this process. This is because the combustor, a single vessel, will be modelled as two reactors in series, with two different reaction types. The first reactor is a Conversion reactor and the second is an Equilibrium reactor.
Conversion - given the stoichiometry of all the reactions occurring and the conversion of the base component, calculates the composition of the outlet stream. Equilibrium - determines the composition of the outlet stream given the stoichiometry of all reactions occurring and the value of equilibrium constant (or the temperature dependant parameters that govern the equilibrium constant) for each reaction. Gibbs - evaluates the equilibrium composition of the outlet stream by minimizing the total Gibbs free energy of the effluent mixture. CSTR - assumes that the reactor contents are completely mixed in computing the outlet stream conditions, given the stoichiometry for all the reactions that are occurring and the kinetic rate constant (or the temperature dependence parameters for determining the kinetic constant) for each reaction. PFR - assumes that the reaction stream passes through the reactor in plug flow in computing the outlet stream composition, given the stoichiometry of all the reactions occurring and a kinetic rate constant for each reaction.
Note that the required input is different depending on the type of reactor that is chosen. The last two types (CSTR and PFR) must have kinetic rate constants (or the formula to determine the kinetic rate constant) as inputs, as well as the stoichiometry of the reactions. All of the reactor types, except for the Gibbs type, must have the reaction stoichiometry as inputs. The Tank, Separator, and Three Phase Separator Unit Operations can also process reactions if a reaction set is attached.
Note that Kinetic, Kinetic (Rev Eqb), and LangmuirHinshelwood reactions can be modelled in the CSTR, PFR and Separator.
Process Overview
The first step in simulating a synthesis gas plant is choosing an appropriate fluid package. We will be using the Peng Robinson (PR) EOS in this simulation. Add the following components to the simulation: CH4, H2O, CO, CO2, H2, N2, and O2. Press the Add Rxn button, and choose Conversion as the type from the displayed list. Enter the necessary information as shown:
Repeat Steps 5 and 6 for two more Conversion reactions. Use the following data. 8. Add an Equilibrium reaction by selecting the reaction type as Equilibrium rather than Conversion. Under the Library tab, highlight the reaction with the form CO + H2O --> CO2 + H2. Press the Add Library Rxn button. This adds the reaction and all of the reactions data to the simulation.
When entering the values for the Stoichiometeric Coefficients, it is important to remember that "Products are
Create two more reaction sets with the following information: Reaction Set Name Active Reactions
Combustor Rxn Set Rxn-1, Rxn-2, Rxn-3 Shift Rxn Set Rxn-4
Pressure, kPa(psia)
3500 (500) 90 (200)
On the Worksheet tab, enter a temperature of 930 oC (1700 oF) for the outlet stream Combustor Feed.
The second reactor in a synthesis gas plant is the Combustor. The Combustor will be modelled as a Conversion reactor and an Equilibrium reactor in series. This is because Conversion reactions and Equilibrium reactions cannot occur in reactors of the opposite type, i.e. conversion reactions cannot be associated with equilibrium reactors, and vice versa.
Add another Conversion Reactor with the following data: In This Cell... Enter...
Name Feeds Vapour Product Liquid Product Reaction Set Rxn-1 Conversion Rxn-2 Conversion Rxn-3 Conversion Combustor Combustor Feed, Air,Combustor Steam Mid Combust Combustor LP Combustor Rxn Set 35% (Default Value) 65% (Default Value) 100% (Default Value)