Simulation of Ammonia Production using HYSYS Software (original) (raw)
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Simulation of ammonia synthesis
Ammonia is prodeuced to give a final product named urea which is a very important fertilizer for higher nitrogen content.Several processes has been invented for optimum production of ammonia. Now-a-days, Ammonia production is mainly done by Haber process in which nitrogen andhydrogen react in the presence of an iron catalyst to form ammonia. The hydrogen is formedby reacting natural gas and steam at high temperatures and the nitrogen is supplied from theair. Other gases (such as water and carbon dioxide) are removed from the gas stream andthe nitrogen and hydrogen passed over an iron catalyst at high temperature and pressure toform the ammonia. In our work, simulation of ammonia synthesis process is done on Aspen Hysys 7.1. By using 1.07e+005kmole/hr methane, 2.8e+005kmole/hr hydrogen, 1.02e+005kmole/hr nitrogen, we haveproduced4.6e+004 kmole/hr ammonia.It has also been found that ammonia production increases with the rise of pressure of fresh feed.
Simulation of Ammonia Production from Synthesis Gas
The International Conference on Chemical and Environmental Engineering
Ammonia is a compound of nitrogen and hydrogen with the formula NH 3. It is a colorless gas with a characteristic pungent smell. Several processes have been invented for optimum production of ammonia. Now-a-days, Haber process is a mainly process for Ammonia production in which the reaction between nitrogen and hydrogen done in the presence of an iron catalyst to form ammonia. In our work, simulation of ammonia synthesis process is done on Aspen Hysys V8.8. By using 333.1 kmole/h of steams, 100 kmole/hr of nitrogen, we have produced 74.62 kmole/hr ammonia. It has also been found that ammonia production increases with the rise of pressure & mass flow of steam& decrease of the temperature of the feed of nitrogen.
1 Comparison of Chemical Process Simulators : Aspen vs . HYSYS
2008
Since 2007, Aspentech provides to universities, a single closed software package, joining two process simulators: Aspen Plus/Dynamics and HYSYS. This work provides a comparison, analysing the integration between them and other products included into the software package. As a case study, it was selected “Ammonia Converter Design”, with available tutorials for both Aspen Plus and HYSYS, from multimedia CD “Using Process Simulators in Chemical Engineering” by Seider, Seader & Lewin. Each of these steady-state simulations has its own thermodynamic model and specific database. Using, for reference, an ammonia synthesis process published on “Ullmann's encyclopedia of industrial chemistry”, it has been realized that none of the thermodynamic models simulate accurately the ammonia condensation. A new Aspen Plus thermodynamic model, published by AspenTech in April/2008, provided good agreement with the reference. But only the next version (V7.0) will allow the implementation of the same...
Simulation and Optimization of an Ammonia Plant: A Case Study of Indorama Ammonia Plant
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Quick Response Code Abstract: A functional industrial ammonia plant has been simulated using the plant data. All the unit operations, including definition and formation of reactions set have been performed in Aspen HYSYS V8.8. The simulated results compared with the plant data indicate reasonable agreement. The process optimization was performed using the optimization techniques such as BOX, Mixed and Sequential Quadratic Programming in Aspen HYSYSV8.8. The SQP, Mixed and BOX optimization algorithms gave optimum variables at quick convergence with reasonable iterative numbers. It was therefore deduced that the SQP, Mixed and BOX algorithms were more appropriate for the multi-step ammonia process. From the algorithms, the optimum operating conditions that increased the yield of ammonia production are 43.97C, 4839kPa and 25670kg/hr for natural gas and 280.6C 21490.0kPa for the ammonia production respectively given the percentage of ammonia to increase from 24.37 to 41.04 mole percent....
Journal of Technology Innovations and Energy
Optimal production of ammonia (NH3) using natural gas is necessary in order to make it available for wide range of applications including the manufacture of fertilizers, fuel for transportation and during synthesis of some chemicals. Achieving this would require strategic implementation of a control scheme to simulated ammonia production, capable of ensuring adequate realization of production targets. The work involves ASPEN Plus modeling, simulation, sensitivity analysis and control of NH3 production process. Steam/carbon ratio, conversion of CH4, removal of carbon dioxide (CO2) and carbon monoxide (CO), hydrogen/nitrogen ratio and heat exchanger and separator temperatures were identified as requiring control in units any of these specifically impacts. As a result, approximately 176 tons of NH3 was realized daily based on the simulation results and can be scaled-up using a calculated factor equivalent to 1.1375 to 200 tons/day capacity, in this design. Sensitivity analysis resultin...
Chemical Engineering Transactions, 2020
To support the demand growth in the agriculture sector from increasing population, ammonia and urea productions have been continuously increasing. Methane from natural gas can be used as feedstock in the production process. The conventional plant using natural gas feedstock produces cabon dioxide as a by-product of the process. This proposed plant contains two processes, producing ammonia and urea can be more efficient in the production, where the by-products of CO2 can be used to produce more urea and reduce CO2 emission. This research proposes ammonia and urea synthesis process using PROII software to simulate workflow and estimate the energy consumption. To be marketable and profitable for the agricultural industry, the techno-economic and stochastic analysis are applied to deal with uncertain demand from the market. This work is comprised of three main parts; the first part is the simulation of the base case process of the proposed ammonia/urea plant. The input data and paramete...
Simulation of an ammonia synthesis converter
Steady state one dimensional pseudo-homogeneous models of an axial flow industrial catalytic packed bed ammonia converter have been developed. The converter is a vertical four catalytic bed reactor with varying volumes of catalysts. Effects of temperature changes on the catalyst surface and in its interior were incorporated in the model by an effectiveness factor. The models were used to predict conversions, concentrations of reactant/product mixtures and temperature profiles along the catalyst beds. The developed models consisted of ordinary differential equations which were solved numerically using the 4 th order Runge-Kutta algorithm implemented with MatLab ode45 solver. The accuracy of the models was ascertained with industrial plant data from Notore Chemical Industry, Onne, Rivers State. The results obtained from solutions to the models compared favorably with output plant data of the ammonia converter with a maximum deviation between models predictions and actual plant data of 6.7%. Consequently, simulation studies of the converter was performed varying operating parameters such as feed flow rates, inlet temperatures and pressures to determine their effects on the performance of the converter.
The Simulation and Control of Ammonia Unit of Shiraz Petrochemical Complex, Iran
journal of Chemical and Petroleum Engineering, 2018
The aim of this paper is the steady-state and dynamic simulations of the ammonia unit of Shiraz petrochemical complex and system behavior study versus the feed flow rate change for producing a good quality product. The ammonia unit consists of the reformer units, shift converter units, carbon dioxide absorption unit, methanation unit, and ammonia synthesis unit. For this purpose, in the first step, the ammonia unit is simulated at a steady state using the Aspen Plus 2006.5 simulator. In the following stage, the required parameters are entered into the software for the dynamic simulation. The Aspen Plus was exported to Aspen dynamic. In this study, PI and PID controllers, as basic controllers, were automatically added and tuned by the Tyreus–Luyben tuning method. Finally, in order to ensure the accuracy of the proposed control structure, the feed flow rate increased by 5%. The results show that, first of all, the simulation accuracy at steady and dynamic states are optimal so that th...