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Methanol, Hydrogen and Synthesis Gas Plant Engineering Support
Chem-Engineering Services provides process engineering services and process engineering
support in Ammonia, Methanol, Hydrogen and Synthesis Gas plants for performance
evaluation, plant equipment design and ratings for the process areas including synthesis
gas preparation, carbon dioxide removal, ammonia synthesis process, refrigeration system,
steam system, fuel system, and the cooling water system.
Chem-Engineering Services has ammonia, methanol, hydrogen and synthesis gas process
engineering expertise to examine existing plant equipment and operating data and provide
clients with cost effective alternatives to improve plant efficiency, reliability and capacity.
The following list highlights areas of applications where Chem-Engineering Services has
worked to improve efficiency.
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Chem-Engineering Services has
developed the Integrated
Synthesis Loop Ultra Process for
energy savings in Ammonia
plants. The ISL technology
provides 0.7 to 1.0 Million Btu/Ton
Ammonia (0.2 to 0.28 mm
kcal/tonne Ammonia) energy
savings, or more, for plants that
use ammonia refrigeration
systems to condense the product
ammonia. This process has
outstanding economic benefits,
with payback of less than 2 years,
depending on natural gas cost.
engineering expertise to examine existing plant equipment and operating data and provide
clients with cost effective alternatives to improve plant efficiency, reliability and capacity.
The following list highlights areas of applications where Chem-Engineering Services has
worked to improve efficiency.
Lower Steam/Carbon Ratio
Feed Gas Steam Saturation
Upgrade Process Air Mixer in Secondary Reformer
Optimize/Eliminate Feed Gas Booster Compressor
Purge Gas Hydrogen Recovery
Ammonia Converter Replacement or Modification
Upgrade Synthesis Loop Process
Optimize Synthesis Process Hydrogen/Nitrogen Ratio
Synthesis Gas Integration with Other Plants
Furnace Combustion Air Preheater
Optimize Furnace Combustion Efficiency
Radiant Reformer Furnace Seals
Convection Coil Designs for Energy or Capacity
Reformer Tube Replacement/Upgrade
Higher Process Air Preheat Temperature
Optimize Carbon Dioxide Removal System
Optimize or Replace CO2 Removal Solvent
Packed CO2 Absorber/Stripper
Lean/Rich Solvent Exchanger Upgrade
Lean Solvent Cooler Upgrade
Hydraulic Turbine Power Recovery
Cooling Tower Revamp
Optimize, Upgrade Cooling Water System
Optimize Steam System Equipment Operation
New Steam System Exchangers
Higher Steam Superheating
Reduce Steam Pressure Losses
Higher Surface Condenser Vacuum
Process Air Compressor/Turbine Revamp
Refrigeration Compressor/Turbine Revamp
Synthesis Compressor/Turbine Revamp
Other Steam System Turbine Upgrades
Improve Steam Superheating Coils
Furnace Steam Superheat Burners
Steam System Integration with other plants at site
Optimize Catalyst Conditions
New Catalyst Shapes/Sizes/Compositions/Activities
Improved Compressor Intercooler Designs
Synthesis Compressor Suction Chilling
Replace Failing Process Exchangers with Improved Designs
Replace High Pressure Drop Exchangers
High Pressure Process Condensate Stripper
Upgrade High Pressure Drop Piping
Methanol, Hydrogen and Synthesis Gas Plant Engineering
support ammonia process engineering and simulations of equipment performance.
Heat-r-Rate-r
Heat-r-Rate-r software was developed to provide furnace engineering services for thermal
and mechanical design, rating and performance simulations in ammonia, methanol and
hydrogen plant furnaces. The program can simulate the performance of existing convection
preheat coils and develop new designs, determining flue gas and process fluid pressure
drop, heat transfer and maximum tube wall temperatures.
Heat-r-Rate-r software predicts the performance of complete convection section preheat
systems, simulating the combined effects of individual coils interactively and as a system.
Individual furnace coils can be replaced or modified, or existing coils may have new
calculations developed to simulate cleaning to show energy savings, efficiency improvement
and to design capacity upgrades.
Steam-Assist software was developed to produce heat and material balances for entire
steam systems. The program handles complex steam systems with multiple pressure
levels, utilizing process steam, heating loads, steam turbines of both back-pressure and
vacuum turbine types, vacuum steam surface condensing, boiler water pumping and
deaerator heating systems. The software rigorously simulates the performance of
individual turbines' drivers, assessing their steam requirements from point efficiencies or
efficiency curves via Turbine Pow-r Rate-r. The software performs heat balances for
blending the exhausts of turbines and let-down services, predicting header operating
temperature and pressure conditions. Flash calculations are included for prediction of
boiler blow-down recovery to lower pressure header systems. The software was written to
produce accurate steam system heat and material balance predictions for plant
performance evaluations in plant energy audits and retrofit design projects.
Chem-Engineering Services process engineering software, Turbine Pow-r-Rate-r, was
developed to simulate both back-pressure and vacuum exhaust steam turbines. The
program incorporates the steam properties module from Steam-Assist for thermodynamic
calculations including enthalpy, entropy, superheat and percent moisture for superheated
steam vapor, saturated and two phase steam conditions. The process engineering support
calculations include prediction of water rate for given supply steam conditions and
efficiency; efficiency for given supply steam conditions and water rate; and, water rate and
efficiency for given supply and exhaust steam conditions. The process engineering basis
may include the prediction of steam requirement for a given power requirement, or power
developed for a given steam flow.