EMS510U Process Design and Simulation Extended individual assessment on design principles DESIGN BRIEF ChemPlus Consulting Group is looking for independent contractors to submit a bid for a client within the Fertilizers industry. The client is looking for a design of an ammonia production plant that produces low-carbon ammonia. ChemPlus Consulting Group has requested an analysis of your company's suggested reaction process, and further manufacturing requirements associated with such a proposal. You have been shortlisted to develop a proposal to persuade ChemPlus Consulting Group you should be selected to complete the work. DELIVERABLES You work for an independent contractor team that has expertise in conducting analysis of process equipment, identifying safety risks and environmental requirements for processes. As a junior chemical engineer in the team, you receive four personal tasks: 1. Background Prior to evaluating specific process requirements, ChemPlus Consulting Group would like to know more information about the use of Ammonia. You need to answer the following questions: İ. What are the possible uses of ammonia and which industries, apart from fertilizer producers, may be interested by purchasing low-carbon NH3? ii. What are the current trends in the strategies for optimization of energy efficiency and emissions of ammonia plants? 2. Technical design (Aspen Plus) İ. ii. iii. Design, simulate and optimise the Haber-Bosch section of an ammonia production plant, i.e. the production of NH3 from streams of pure N2 and H2. The feed gas mixture is at 25 bar, 35 °C. The plant should have a capacity of XX ton/day of ammonia (see below for individual specifications). The design should be accompanied with a Process Flow Diagram (PFD) and description of the process that you simulated on Aspen Plus. Use a tool of your choice (e.g., MATLAB, Excel, Maple or paper-based calculation) to provide a comparison on a process-wide mass balance with your simulation stream results, including a degree of freedom analysis. (You might need to relax some constraints, if you feel you need to then use your sound engineering judgement and don't forget to justify any assumptions made). ChemPlus have identified some advanced optimisation tasks to supplement your initial design. You should only attempt one of the following tasks: Compare the process at three different pressures. At each pressure, you need to optimise a new reactor temperature and recycle. Compare designs with a monolith adiabatic PFR vs two equal sized PFRs in series with cooling stage between them. Design the cascade of compressors, turbines and heat exchangers in the Haber- Bosch section of the plant to optimize the energy duties. 3. Environmental and Safety In order to continue evaluating the proposed processing plant, all environmental and safety issues must be identified and assessed. At this current design stage, ChemPlus Consulting Group has requested: i. ii. iii. Environmental considerations are very important to the client; you will need to conduct an environmental assessment and then to attempt to optimise your plant to achieve emission reductions or efficiency increases. Based on material safety data sheets for the components involved in the process, discuss the safety and risks associated with this process. Based on your simulation results, identify where you can improve and optimise the initial design based on heat and energy utilization, in comparison to your original simulation. 4. Economic Evaluation In order to assess the feasibility of your designed process, the economics must be calculated, and any suitable recommendations made. i. Calculate your economic values (income, costs and profit) in a spreadsheet (Aspen/Excel). Describe your calculations and assumptions made. ii. Reading list: Based on your calculations, discuss your profit/loss values and state any suitable recommendations for your process based on these values. 1. R. M. Felder and R. W. Rousseau, 2016, Elementary principles of chemical processes, John Wiley & Sons. 2. M. Appl, Ammonia – principles and industrial practice, Wiley 1999 You will be required to conduct your own research also utilising other sources! Appendix A: Technical details Economic values used in the process Stream Nitrogen feedstock Hydrogen feedstock Ammonia product Cooling water Power Purge hydrogen content Purge methane content Energy Cooling Value $110/tonne $250/tonne $850/tonne $2.78×10-8/kJ $0.12/kWh $210/tonne $310/tonne 0.10 $ /kWh 0.001 $ /kWh Individual specification of feedstock conditions and required product rates and purity: ID number capacity ton-NH³/day 220238247 1480 220065469 2160 210236235 1980 220647128 1430 220402158 310 220966133 2470 220372998 1790 220142830 1880 220049595 440 220383684 1540 221080650 2300 220569509 1870 210604548 520 220103336 950 210807714 910 210091357 2740 210371824 1830 220098087 1420 220103532 1170 220485472 2420 220313717 1350 220150754 660 220463001 1750 220388140 500 210932625 1650 220436739 700 220542395 1710 220091505 2670 221116904 2630 220630681 1490 210385290 2610 220272023 2130 220616869 2530 210492831 1620 220475831 1710 220062022 2610 220524612 640 220318206 1280 210230200 2450 220020457 2230 220395562 2190 220352484 1290 180364930 2150 220368669 1740 210292183 2630 220927156 2300 220092797 1470 220289663 1940 Appendix B: Assessment Information This assessment accounts for 60% of your total EMS510U module. The deadline is Friday 29th March 2024, 23.59pm. Technical proposal The maximum by number of pages for the technical proposal is 10. This excludes references, title page, or appendices. The information in the proposal should reflect the data calculated and the KEY information found. The key headings to include are: • • . • • Abstract - an overall summary of the report including highlights and key results Introduction - summary of the findings from the background section Project brief detail on the design including the specific conditions, feedstock and product of your plant Basis of design – justification of your choices in design and strategy Process description and Process flow diagram – including stream information and comparison of hand/simulated calculations Environmental analysis • • Economic evaluation • Conclusion The submission document is a competitive technical proposal, which should be clearly written and must argue for why your design is the best. Your main aim is to persuade the client that you have the correct expertise to be selected for the contract. The proposal should explain, as briefly and as succinctly as possible, the main aspects of your assessment. It should have a minimum font size of 11 pt (Times or Arial), single paragraph spacing, and a minimum of 2 cm margins. Make sure you proof-read your work and that the presentation is consistent throughout. You should also submit a single Aspen Plus simulation file, a separate calculation file (GAMS, Excel etc), and/or scan of your hand calculation. Process flow diagram (or simulation) A good process flow diagram will have all the raw materials on the left hand side of the diagram and all the products to the right, as well as pressure, temperature and quality (liquid fraction) for the key streams. For columns/vessels, make sure the gas phase is shown to go out at the top and the liquid through the bottom. Note: There is no "model" flowsheet you must find, as all the optimised flowsheets will be different based on the different decisions made, therefore focus on using your engineering judgement. Appendix You are allowed to use appendices but note that the reader may not read these so all your key points need to be included in your main report. The appendix should be used as a source of additional relevant material, e.g. hand calculation (with a summary in main report), degrees of freedom table etc. Detailed calculations are not needed in the main report but you must explain assumptions and decisions made. It is also recommended you put your "original" process diagram into the appendix and the improved version into the main body of the report.