Integration of commercial CO2 capture plant with primary reformer stack of ammonia plant

  • Peyvand Valeh-e-Sheyda
  • Hamed Rashidi
  • Farkhondeh Ghaderzadeh
Article
  • 7 Downloads

Abstract

The safety of primary reformers is essential to safe operation of large-scale petrochemical processes, especially when carbon dioxide is going to be recovered from an ammonia plant. In this study, a preliminary assessment is made to model an industrial stack as the stack gases are introduced into CO2 capture plant, during ammonia production. A CFD model was first developed in the absence of a commercial carbon dioxide recovery (CDR) unit to validate the model against industrial data under normal operation. At full capacity of the ammonia plan, the results provided by the CFD model match the measurement results well within about 3.87% margin of relative error. The calibrated model was then applied in combination with post-combustion, as part of the process, to verify the process safety constraints in reformer furnace. The effect of starting up and shutting down of CDR plant was explored in the event of emergency operation. From an operational view, in the event of startup or unplanned failure of the CO2 capture plant, the pressure fluctuations do not exceed the maximum allowable pressure of the firebox. Upon reaching the required operating conditions, both subsystems can be integrated operationally to continue production safely.

Keywords

CO2 capture Post-combustion Ammonia plant Emergency Operation 

List of symbols

C

k − ε model constants

C

k − ε model constants

Cμ

k − ε model constants

h

Time (hour)

P

Static pressure (Pa)

S

Source term

T

Temperature (K)

t

Time (s)

u

Velocity vector (m s−1)

x

x-coordinate (m)

Abbreviations

CDR

Carbon dioxide recovery

ESD

Emergency shutdown system

FD

Forced draft

GHG

Greenhouse gas

ID

Induced draft

KPIC

Kermanshah petrochemical industries company

MEA

Monoethanolamine

RANS

Reynolds-averaged Navier–Stokes

Greek symbols

Ρ

Density (kg m−3)

ε

k − ε model dissipation energy

μ

Dynamic viscosity (Pa s)

μt

Turbulent viscosity (Pa s)

\(\overline{\overline{\tau }}\)

Shear stress tensor (Pa)

σk, σε

Turbulent Prandtl numbers for k − ε

I

Stress tensor

k

Turbulence kinetic energy

Subscripts

t

Turbulent

Notes

Acknowledgements

Authors would like to acknowledge the financial support of Kermanshah University of Technology for this research under Grant Number S/P/T/1115.

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Copyright information

© Akadémiai Kiadó, Budapest, Hungary 2018

Authors and Affiliations

  1. 1.Chemical Engineering DepartmentKermanshah University of TechnologyKermanshahIran
  2. 2.Kermanshah Petrochemical Industries CompanyKermanshahIran

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