Group Meeting # 2
Mentor: Shannon Brown, PE
Michael Bentel
Jeremy David
Erik Peterson
Arpit Shah
1
Questions from Group Meeting #1
 What are the specifications for fuel?
 ~ 80 – 85% - C2+
 ~ 10% - CH4
 ~ 5 % - N2
 ~ 2 % - CO2
 What is the primary heat source for the boiler?
 Combustion gases from Gas Turbine along with Natural
Gas
 Boiler – Heat Recovery Steam Generator (H.R.S.G.)
 What is the cheapest source of fuel for this plant?
 Waste hydrocarbons from **Team Alpha**
2
Questions (Cont’d)
 What is the minimum water purity required for boiler
feed water (BFW)?
 Dissolved O2: < 0.007 ppm
 Total Fe: < 0.01 ppm
 Total Cu: <0.01 ppm
 Total Hardness: 0.05
 pH: 8.8-9.6
 Silica: <2.00 ppm
 Conduction < 150
 Total Dissolved Solids (TDS): 0.1
 How is the effluent stream from the boiler being
addressed?
 The Effluent stream will be sent through the flue gas
purification system
3
Group Meeting 2 Objectives
 Flow Sheets
 Material & Energy Balances
 Process Flow Sheet Frozen
 Data
 Hand Calculations
 Rough Economics
4
Outline
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Design Basis √
Block Flow Diagram √
Process Flow Diagram  IN PROGRESS
Material and Energy Balance  IN PROGRESS
Calculations  IN PROGRESS
Annotated Equipment List (Data Sheet)  IN PROGRESS
Economic Evaluation factored from Equipment Costs
Utilities
Conceptual Control Scheme
General Arrangement – Major Equipment Layout
Distribution and End-use Issues Review
Constraints Review
Applicable Standards  IN PROGRESS
Project Communications File  IN PROGRESS
Information Sources and References  IN PROGRESS
5
Pumps and Compressors
 As stated before,
compressor is going to be
used to provide plant air
 Because instrument air
must be very dry to avoid
plugging and corrosion, a
rotary screw oil free air
compressor is commonly
put through a dryer
Block
Number
Unit
Steam
Number
Stream
Label
16
Compressor
S-16
Air - In
17
Dryer
S-17
Plant Air
24
Surge Tank
S-18
Compressed
Air
S-19
Compressed
Air
S-30
Instrument
Air
6
Air Compressor Material Balance
H2O (cfm)
P1 , T1
Wet (cfm)
Oil - Free
Air
Compressor
P2, T2,
Refrigerated
Air Dryer
Dry (cfm)
Wet (cfm)
Conditions
P1
11.8
T1
78
% Rel.
Humidity
90
Psi
F
Air Density
0.0738
lb/ft3
1 lb Dry Air
13.92
ft3
1 lb Dry Air
0.0192
lb H2O
62.25
lb/ft3
H20 Density
n (Heat
Capacity Ratio)
1.4
7
Compressed Air – Energy Balances
 Dryer Mass Balance
 ft3 * 1 lb DA/ ft3 * lb H2O/ lb DA = lb H2O * ft3/lb = cfm H2O
 Work Done in Compressed Air
 -W=P1ν1(n/(n-1))[(P2/P1) (n-1)/n-1]
=ZRT(n/(n-1))[(P2/P1) (n-1)/n-1]
 Heat of Compression: T2=T1(P2/P1)(n-1/n)
Team
P2
Required (psi)
Dry (cfm)
Wet (cfm)
T2 F
H2O (cfm)
HP
India
100.00
500.000
500.20
112.96
0.01109
8.34
8
Compressor Costs
Annual Electricity Cost =
• One of the most expensive sources
of energy of plant
• 10% of electricity consumption
goes to compressed air generation
• Several compressors may be
installed for maintenance purposes
as a stand-by spare
9
Williston, ND - Data
 Dry Bulb Temperature : 92°F
 Wet Bulb Temperature: 66°F
 Highest Relative Humidity: 90%
10
Induced – Draft Cooling Tower PFD
11
Cooling Tower – General Material
Balance
Dry Air Mass Balance
ṁa1 = ṁa2 = ṁa
Water Mass Balance
ṁhw + ṁa1∙ω1 = ṁcw + ṁa2∙ω2
= ṁhw- ṁcw = ṁa(ω2- ω1)
Also,
ṁMU = ṁa(ω2- ω1) + ṁBD
12
Cooling Tower – Energy Balance
Ėin – Ėout = ΔĖsys
ΔĖsys = 0
0 = (ṁa2∙ha2) + (ṁcw∙hcw) – (ṁa1∙ha1) – (ṁhw∙hhw)
ṁℎ𝑤(ℎℎ𝑤−ℎ𝑐𝑤)
ṁa =
ℎ𝑎2 −ℎ𝑎1 −(ω𝑎2 − ω𝑎1 )(ℎ𝑐𝑤 )
**Assuming Steady State and Adiabatic System**
13
Data Used to Calculate M&E
Balance
Stream
Enthalpy (h)
(Btu/lb DA)
ω
(lb H2O/lb DA)
1/ρ (ft3/lb)
Air – In
22.8940
0.01706
18.2149
Air – Out
77.4935
0.1146
Hot Return Water
72.3646
Cold Process
Water
33.6199
14
Results from M&E Balance - ECT
Stream
Temperature
(°F)
Humidity
Flowrate (ṁ)
(lb/hr)
Energy
(Btu/hr)
Air – In
70
~ 25 %
232,067
5,312,950
Air – Out
90
~ 90 %
232,067
17,983,714
Hot Return
Water
105
317,465
22,973,275
Cold Process
Water
85
307,227
10,328,954
Make Up
Water
85
10,238
344,209
**Calculated at 11.8 psi
15
Turbine & Boiler System
16
Stream Labels
Block Labels
Block Number
Block Name
Label
Stream Name
1
Pre-Water Treatment
S-1
Plant Water
2
Pump
S-2
Pre - Treated Water
3
Membrane Assembly
S-3
Pre - Treated Water
4
EDI Module
S-4
Brine Discharge
5
Resistivity Cell
S-5
Fresh Water
6
Compressor
S-6
Pure Water
7
Combustion Chamber
S-7
Ultrapure Water
8
Gas Turbine
S-8
Reheated Steam
9
Steam Turbine
S-9
Turbine Exhaust Steam
10
Processes
S-10
Low Pressure Steam
11
Condenser
S-11
Condensed Steam
12
Stacks
S-12
Hot Combustion Gases
13
Economizer
S-13
Superheated Steam
14
Evaporator
S-14
Air
15
Super heater
S-15
Compressed Air
22
Deaerator
S-28
Waste/Discharge
23
Header
S-29
Natural Gas
S-31
Boiler Feed Water
25
Separator
S-32
17
Boiler Feed Water - Processes
Results from Boiler Material
Balance
Stream
Flowrate ((lb/hr)
Water – In
107,000
Steam – Out
107,700
*Based on ideal system (100% efficiency/recovery, no lose of water/steam
due to system leakage)
18
Results from Boiler Energy Balance
Sensible
Heat
(Btu/lb)
ΔT (°F)
Latent
Heat
(Btu/lb)
Phase
Change
Compression
(Btu/lb)
ΔP (psig)
247.077
100  212
1908.300
Liquid 
Vapor
185.541
0  150
331.510
212  358
1905.334
Liquid 
Vapor
183.857
150  300
139.909
358  417
1785.464
Liquid 
Vapor
187.209
300  600
170.453
417  486
1615.044
Liquid 
Vapor
184.698
600  1200
222.199
486  567
1349.883
Liquid 
Vapor
802.285
567  1050
Superheated
*Calculated using steam tables and superheated steam tables for latent heat and superheated work,
respectively; averaged heat capacity over temperature ranges for sensible heat; PV work for
compression.
19
Flue Gas Clean Up
 Particle Removal
 Gaseous Contaminates Removal
 Wet Scrubber – Utilizes water for removal
 Wet-Dry Scrubber – Utilizes aqueous spray for removal
 Dry Scrubber – Utilizes dry powder for removal
 Nitrogen Oxide Removal – Utilizes catalysis for
removal
 Stack – Measures contaminates in out flowing
combustion gases
USEPA & NDEPA Flue Gas
Requirements
 NOx: 100 ppb, averaged over one hour
 SOx: 1 - hour standard at a level of 75 parts per billion
 CO: 8 - hour primary standard at 9 parts per million
(ppm)
Turbine Material Balance
 Gas Turbine
Airin + Fuelin = Exhaust Gasout
mAir + mfuel = mExhaust
 Steam Turbine
High Pressure Steamin = Process Steamout +
Condensing Steamout
mHigh-P = mProcess + mcondensed
22
Turbine Energy Balance
 Gas Turbine
Combustion Gasin = Workout + Exhaust Gasout
(m*H)Combustion = (effturbine *(m*H)Combustion +
((m*H)Combustion - effturbine *(m*H)Combustion))
 Steam Turbine
High Pressure Steamin =
Process Steamout + Condensing
Steamout + Workout
(m*H)high P. = Σ(m*H)process + (m*H)condensed + effturbine
*(Σ((m*H)high P – (m*H)process) + ((m*H)high P. –
(m*H)condensed))
23
Relating Turbine and Boiler
Energy & Material Balance
 Energy - Combustion Gasin – Workout =
Exhaust Gasout =
Exhaust Gasin =
Steamout + Exhaust Gasout – Feed Waterin
 Material – Airin + Fuelin =
Exhaust Gasout =
Exhaust Gasin =
Steamout + Exhaust Gasout – Feed Waterin
24
Results from M&E Balance – Gas
Turbine
Streams
Flow (MMSCFD)
Energy
Air
0.028
N/A
Fuel
0.0016
553,366 Btu/mol
Combusted Gas
0.03
362,257,129 Btu/day
25
Equipment List
Equipment
Quantity
Reverse Osmosis System
1
Electrodeionization System
1
Water Tube Boiler
1
Gas Turbine
2
Steam Turbine
1
Compressor
1
Dryer
1
H.R.S.G System
1
Induced – Draft Cooling Tower
1
26
CHP - Rough Economics
𝐶𝑒 = 𝑎 + 𝑏𝑆 𝑛
Where,
 Ce= Purchased Equipment Cost
 a & b = Cost Constants
 S = Size Parameter
 n = Exponent for that type of equipment
**All equipment costs are based on U.S. Gulf Coast Basis,
Jan 2010 (CEPCI index = 532.9)**
27
Equipment Cost Table
Equipment
a
Cooling Tower 170,000
b
Supper
0.8*Supper
n
Ce($)
1,500
10,000
8,000
0.9
5,055,100
Equipment
Cost ($)
Compressor
127,496
Steam Turbine
308,856
Gas Turbine
706,734
H.R.S.G
~20,000,000
Water Purification
System
N/A
**Calculated Using Cost
Estimation Equation in “Chemical
Engineering Design”, Towler
**Calculated Using “Plant Design
and Economics for Chemical
Engineers” Online Simulator, 5th
Edition
**Estimated Cost from GE
28
Equipment Cost
Equipment
Quantity
Cost ($)
Reverse Osmosis System
1
Waiting for Siemens to
respond
Electrodeionization
System
1
Waiting for Siemens to
respond
Gas Turbine
2
1,413,468
Steam Turbine
1
308,856
Compressor
2
254,992
Dryer
1
10,000
H.R.S.G System
1
20,000,000
Induced – Draft Cooling
Tower
1
5,055,100
29
Economics – Cont’d
 Total Equipment Cost: $27,032,416
 Total Cost of Installation: $117,861,333
*Assumption: 4.36*(Cost of Equipment)
 Total Cost of Engineering: $8,109,724
*Assumption: Engineering costs = 0.30(Cost of Equipment)
Total Cost = Cost of Equipment + Installation +
Engineering = $153,003,474
30
QUESTIONS???
31