CO Shift Reaction Processing

The CO shift reaction is commonly used in processes to produce hydrogen from synthesis gas. Synthesis gas, in turn, is commonly produced by reforming natural gas or heavier hydrocarbons, or by gasification/pyrolysis. The CO shift reaction (also known as the water-gas shift reaction) is CO + H2O = CO2 + H2 The heat of reaction at 25 C is 9,838 cal/gmol (17,708 Btu/lbmol), based on water in a vapor state (You should do your own homework to confirm this value). As a slightly exothermic reaction, lower temperatures favor higher conversion. To maximize the production of hydrogen, a two-stage system is normally used, consisting of a high-temperature shift reactor and a low-temperature shift reactor. The temperatures of the feeds to high-temperature and low-temperature shift reactors are 700 F and 500 F, respectively. (In real life, you'd have to do a reaction engineering analysis and find these values!) Two different catalysts are used, and the reactors are designed as fixed beds. The reactors operate adiabatically. These catalysts are very selective and only the CO shift reaction occurs (no methanation, reforming, or other side reactions). Prepare a process flow diagram with a material balance for the system. This system is part of a process to produce 500 tons per day of ammonia from refinery fuel gas (primarily propane). Prepare the material balance and a simplified process flow diagram first using manual (i.e., spreadsheet) calculations. (Describe this calculation clearly in the Appendix; summarize what you consider is essential in helping with your design in the report.) Only afterward do you use a computer process simulator to obtain the rigorous solution and compare the final report. Design Data Feed gas Component lbmol/hr H2 3,756.6 N2 1,424.0 Ar 17.5 CO 665.9 CO2 895.8 H2O 6,273.9 CH4 28.4 Temperature = 700F Pressure = 260 psia High-Temperature Shift (HTS) Reactor The reactor consists of a vertical cylindrical vessel containing HTS catalyst pellets. The reactor can be considered as adiabatic. Assume that the HTS effluent is at reaction equilibrium at the effluent temperature. Assume a 3-psi pressure drop through the reactor. HTS Effluent Steam Generator Steam/water is on the shell side and the HTS effluent is on the tube side. The HTS effluent is cooled from the HTS Reactor effluent temperature to the LTS Reactor feed temperature. Saturated steam is available at 65 psia (~50 psig). Boiler feedwater temperature is 250 F. Assume a 5% blowdown. This is saturated water released to prevent the build-up of inorganic impurities in the exchanger. The blowdown rate is 5% of the steam generation rate. Assume a 2-psi pressure drop for the HTS effluent through this exchanger.

CENG 124 A

Greg Lorton

Low-Temperature Shift (LTS) Reactor The reactor consists of a vertical cylindrical vessel containing LTS catalyst pellets. Assume adiabatic operation with no heat loss. Assume that the LTS effluent is at reaction equilibrium at the effluent temperature. Assume a 2-psi pressure drop through this reactor. LTS Effluent Steam Generator Steam/water is on the shell side and the LTS effluent is on the tube side. The LTS effluent is cooled from the LTS Reactor effluent temperature down to 50F above the saturated steam temperature. (50 approach) Saturated steam is available at 65 psia (~50 psig). Boiler feedwater temperature is 250F. Assume a 5% blowdown. This is saturated water released to prevent the build-up of inorganic impurities in the exchanger. The blowdown rate is 5% of the steam generation rate. Assume a 2-psi pressure drop through this exchanger. LTS Effluent Cooler Cooling water is on the shell side and the LTS effluent is on the tube side. The LTS effluent is cooled down to 115 F. The cooling water temperature rises from 80F to 115 F. Assume a 3-psi pressure drop through this exchanger. LTS Effluent KO Drum Condensed water is separated from the LTS effluent in this drum. This is a vertical cylindrical vessel. Assume that the LTS effluent is saturated with water, but all additional water condenses. Assume that none of the other LTS constituents dissolve in the condensed water. Assume no pressure drop in this vessel. In your report, include at least the following minimum design information: Material balance block Use lb-mole per hour for the seven constituents. Show total lb-mole per hour and total pound per hour for each of the following streams: HTS Feed HTS Effluent LTS Effluent CO2 Absorber Feed (this is the vapor from the LTS Effluent KO Drum) LTS Effluent Condensate On the process flow diagram, show temperature and pressure before and after each piece of equipment. Show mode of control on the flow diagram. For the heat exchangers, show quantities of cooling water, boiler feedwater, steam generated, and blowdown. Also, show the duty (in Btu per hour).

Greg Lorton