Process Design A

Group 10
TOK KIAT WEI (H00231592)
AKMAL RAFIQ BIN ARIFFEN (H00230335)
SEAH CHIUN CHAO (H00214028)
DANISSHAH DARSHINI KARTHIGESU (H00236390)

Pressure Swing
Adsorption

Introduction
Main objective: extract methane from biogas using
pressure swing adsorption.
Biogas produced by an anaerobic digester.
Biogas contains other components
So it must be separated

Anaerobic Digester
Microorganisms break down biodegradable
materials

Livestock manure, wastewater solids, food waste, industrial wastewater,

etc. (Organic waste stream)

Goes into storage tank deprived of oxygen

Biogas produced from the waste-products
biodegrading

Biogas contains: oxygen, nitrogen, methane, carbon dioxide, hydrogen

sulphide, and water

Combusted to generate electricity and heat

Processed into natural gas and transportation fuels
Co-product includes livestock bedding and fertilizer.
Producing 10,000 m3/day of biogas

Project Main Equipment and

Utilities
Main Equipment

Utilities

Shell & tube heat exchangers

Cooling water at 10 degrees Celsius

Fired heater
Compressors
Desulphurizer
Gas conditioner

Pressure swing adsorption (PSA) unit

Saturated steam at 1 bar

Saturated steam at 10 bar

Process Flow
Diagram

CMP01

Compressor1

HX01

Heatexchanger1

HX04

Heatexchanger4

CMP02

Compressor2

HX02

Heatexchanger2

HX05

Heatexchanger5

CMP03

Compressor3

HX03

Heatexchanger3

GV01

Glovevalve1

CMP04

Compressor4

GV04

Glovevalve4

GV02

Glovevalve2

DS

Desulphurizer

GV05

Glovevalve5

GV03

Glovevalve3

FH1- Fired Heater

Direct-fired heat exchanger
Used to increase the temperature of the
biogas

Shell and tube heat exchangers were not

powerful enough

Fuel and air are fed from under the

furnace

Combustion will occur

DS- Desulphurizer

Biogas contains hydrogen sulphide

Highly corrosive thus bad for the plant
Will be removed using iron oxides, in this case ZnO
ZnO + H2S ZnS + H2O
ZnO is reactive towards H2S and has relatively
large surface area- effective with H2S

H2S adsorption in PSA unit is irreversible which

will saturate adsorbents more quickly.

Pressure Swing Adsorption (PSA)

Tan
k1

Tan
k2

Contains zeolites (adsorbents)

Crystalline structure made of silicon, aluminum, and oxygen

Stable at high pressure and temperature

Structurally designed to adsorb all components of biogas except

for Methane

Tank 1 pressurizes whilst tank 2 depressurize

Pressurization (10 bar) allows adsorption to occur

Adsorbs oxygen, carbon dioxide, nitrogen, and the remaining

H2S and water

97% pure Methane goes exits the tank and into stream S14
and S15

Depressurization (0-4 bar) allows zeolites to desaturate to

regenerate the zeolites.

Desorbed components go through S11 and S13 for further

gas treatment.

Produced methane is then pumped into a product line; delivered,

PFD Table
Name of
Streamline

S01

S02

S03

S04

S05

S06

S07

S08

S09

S10

S11

S12

S13

S14

S15

S16

S17

S18

S19

CH4

0.426754

0.426754

0.426754

0.426754

0.426754

0.432936

0.432936

0.432936

0.432936

0.432936

0.022391

0.432936

0.022391

0.022391

0.022391

CO2

0.451375

0.451375

0.451375

0.451375

0.451375

0.457914

0.457914

0.457914

0.457914

0.457914

0.789436

0.457914

0.789436

0.789436

0.789436

N2

0.080427

0.080427

0.080427

0.080427

0.080427

0.081592

0.081592

0.081592

0.081592

0.081592

0.140663

0.081592

0.140663

0.140663

0.140663

H2S

0.034879

0.034879

0.034879

0.034879

0.034879

0.0046

0.0046

0.0046

0.0046

0.0046

0.00793

0.0046

0.00793

0.00793

0.00793

O2

0.006565

0.006565

0.006565

0.006565

0.006565

0.006661

0.006661

0.006661

0.006661

0.006661

0.011483

0.006661

0.011483

0.011483

0.011483

H2O

0.016298

0.016298

0.016298

0.016298

0.016298

0.028097

0.016298

0.028097

0.028097

0.028097

12977.34

12977.34

12977.34

12977.34

12977.34

12792.03

12792.03

12792.03

12792.03

12792.03

7420.04

12792.03

7420.04

5371.991

5371.991

5371.991

5371.991

7420.04

7420.04

Temperature (c)

25

25

120

170

404.053

400

200

100

24.3675

24.3675

38

38

38

38

38

38

38

38

38

Pressure (bar)

1.01325

4.6

3.8

2.2

1.6

0.8

7.6

0.8

7.6

0.8

10

10

10

20

10

20

Mass
Compositi
on (kg)

Mass Flowrate
(kgday-1)

MASS AND ENERGY BALANCE

ANALYSIS
Streamline
S10
Mass Balance Analyisis of
PSA
Streamline S10
* the values of the molar flow
rate and mass flow rates of S10
= S06

Assumptions made for the

desulphurizer : the efficiency
of the desulphurizer is 87%.
total mass flow rate at S10
= summation of mass flow
rates of each component.

ACCUMULATION
Mass flow rate of H2S at S05
mass flow rate H2S at S06

PSA

Streamline
S16

The molar flow rates of the

other components at
streamline S06 remains
constant from streamline
S05 (inlet of the
desulphurizer) except H2S
and H2O.

mass flow rate of H2O

Initial mass flow rate x
87%
Mass flow rate of H2S
Initial mass flow rate x
13%

molar flow rate of H2O

Initial molar flow rate x
87%
Molar flow rate of H2S
Initial molar flow rate x
13%
The mass flow rates of
other components in the
process fluid except for
H2S and H2O is the same
as that of streamline S05.

Mass Balance Analysis of PSA

Streamline S16
Assumptions made for
the PSA - the efficiency
of the PSA is 97%

ACCUMULATION
Mass flow rate of each
component at S10
mass flow rate of each
component at S16
Sum of the difference.

The molar flow rates of

the components of S16 is
obtained by
molar flow rates of S10 x
97%
Only applies to H2S and
H2O.

To obtain mass flow rates

of H2S and H2O, the
following equation is used.

The other components

besides H2S and H20 at
S16 is considered ZERO,
because this components
are reduced from the
process fluid through PSA

Energy Balance Analysis

Temperature at S10 (assumption) 25C
Temperature at S16 (optimum) 38C

Calculate the enthalpy of

each component at
streamline S10 and S16,
using the respective
temperatures. Equation

A, B, C and D are
constants.

The actual total enthalpy

at S10 is obtained. Using
the function GOAL SEEK,
the actual temperature
at streamline S10 is
obtained which is
24.38C.

The following formula is

applied
Q = H16-H10
Process is adiabatic, Q =
0.
Therefore, H16 = H10.

To obtain the total

enthalpy at each
streamline (H10 & H16)
1. Enthalpy of each
component x
number of moles.
2. Sum the production.

HAZOP
A hazard and operability study (HAZOP) is a
structured and systematic examination of a planned or
existing process or operation in order to identify and
evaluate problems that may represent risks to
personnel or equipment, or prevent efficient operation

Compan Bio-methane Sdn. Bhd.

y
Node
Line
Intentio
n
Guide

PSA
S10 and S12
For the removal of carbon dioxide, water, nitrogen and oxygen
Deviation

Consequences

Causes

Existing protection

Action items
or
recommenda

Flow
More of

Increased

Efficiency of PSA

-Malfunction of

Pressure indicators

tions
-Install high

of gas flow

will drop

control valve

are installed before

pressure

PSA and at PSA

alarm on

-Faulty flow ratio

controller

upstream
pipelines /
PSA
-Install
pressure
relief valves
on upstream
pipelines

 Regular
maintenance

Pipe leakages
Decreased
Less of

of gas flow

More bio-methane

Connection between

and cleaning
Pressure indicators are

on pipeline

will be absorb by

flanges and pipes are

installed before PSA and

and auxiliary

absorbent

not sealed tightly

at PSA

controllers

Malfunction on control

Install high

valves

pressure
alarm on the

Malfunction on flow

upstream

ratio controller

pipelines to

detect
pressure build
up due to
blockages in
pipe

If concentration of

None

methane exceeds the

No gas flow

lower flammability

Pipe rupture
Pipe blockage

limits, explosion

Control valve failure

might occur when in

contact with ignition

Install pressure

Install an

indicators before PSA and

alarm and

at the PSA

sensor to
detect flow of
gas

Pressure
Decrease in yield
More of

Increased
of gas
pressure

strength of the PSA

material, causing
mechanical failure

Failure of pressure
relief valve

Install backup pressure

relief valve

Regular
maintenance
of pressure

Rupture of PSA due

indicators

to significant

and pressure

pressure build-up

relief valves

Bursting of tubes

Regular
Less of

Decreased

Duration of gas

of gas

inside PSA

pressure

increased

Malfunction of
pressure relief valve

Install backup pressure

relief valve

maintenance
of pressure
indicators
and pressure
relief valves

Temperatu
re

Reduce adsorbent

Install temperature

lifetime.
Increased
of biogas
temperatur
e
More of

Risk of thermal
runaway, causing

Faulty temperature
controller.

rupture of PSA
Decrease in yield

No/Low flow of cooling

water in HX.

strength of PSA
material, causing
mechanical failure
Less adsorption of
CO2, N2, O2 and H2O

Regular

sensors and indicators on

maintenance

the PSA and pipelines of

of

entering gas and cooling

temperature

water.

indicators and

-Emergency trip system

will be activated if PSA

controllers.
Install visual

temperature detected is

high

higher than the design

temperature

temperature

alarms on
pipelines and
PSA for
notification of
high
temperatures.

 Regular
maintenance
of
temperature
Reduce adsorbent
lifetime.
Decrease in yield
Less of

Decreased

strength of PSA

of gas

material, causing

temperatu

mechanical failure

re

Less adsorption of
CO2, N2, O2 and H2O

indicators

Install temperature
Faulty temperature
controller.
High flow of cooling
water in HX.
Fouled exchanger
tubes

sensors and indicators

and

on the PSA and

controllers.

pipelines of entering

Install visual

gas and cooling water.

low
temperature

Emergency trip system

will be activated if PSA

alarms on

temperature detected is

pipelines and

lower than the design

PSA for

temperature

notification of
low
temperatures
.

P&ID for Pressure Swing

Absorption of Methane

Fee
d

Heat Exchanger Design

10
W/m2
o
C

22.12
26 kW

K1
=0.24
9
N1
=2.20
7

0.453
9 cm

0.510
9 cm

99.98
91 oC

0.102
2
cm

22.12
50 m2

hi=17.1 W/m2
o
C
ho=36.8 W/m2
o
C

100

10.74
W/m2
o
C

110
Pa

Dimension of Heat Exchanger

Db
Ds
=0.45 =0.5
m
1m

LB=0.1022m

Ds=0.51m

L=2.44m

Db=0.45m
Clearance=0.057m
do=0.03m

Heat Exchanger Data Sheet

Equipment No.
Function

Duty Specifications
10.7412
Duty (kW)
22.1250
Mean Temperature (C)

Process Operating Conditions

Overall U (W/m2K)
Area (m2)

HX01
Heat up biogas

22.1226
99.9891

Tube Side

Shell Side

In

Temperature (C)
Fluid Type
Mass Flow (kg/s)
Enthalpy (kJ/kg)
Density (kmol/m3)
Viscosity (cP)
Thermal Conductivity (W/m K)
Molar Heat Capacity (kJ/mol K)
Stream No.

25
Gas
12977.34099
-6097
2.393
0.014
3.2E-05
0.04386
S2

Out
120
Gas
12977.34099
-5931
1.649
0.0171
4.21E-05
0.04296
S3

In

Temperature (C)
Fluid Type
Mass Flow (kg/s)
Enthalpy (kJ/kg)
Density (kg/m3)
Viscosity (cP)
Thermal Conductivity (W/m K)
Specific Heat Capacity (kJ/kg K)
Stream No.

Vapour
0.011

5.14447
0.015
3.6428E-06
0.0349
H1

Out

Liquid
0.011

886.7373
0.1546
0.000675
0.0754
H2

Mechanical Layout
Tube Side
Design Pressure (bar)
No. of Tubes
Tube Arrangement
Pitch (m)
Internal Diameter (m)
Outer Diameter (m)
Thickness (m)
Length (m)
Corrosive Allowance (mm)
Fluid Velocity (m/s)
Heat Transfer Coefficient
(W/m K)
Pressure Drop (N/m2)

4.6
100
Triangular
0.0375
0.0268
0.03
0.0016
2.44
1
4.1035
17.1

Design Pressure (bar)

Arrangement
Baffle Spacing (m)

Internal Diameter (m)

Outer Diameter (m)

Corrosive Allowance (mm)

Fluid Velocity (m/s)
Heat Transfer Coefficient
(W/m K)
Pressure Drop (N/m2)

109.061

Shell Side
10
1 pass shell
0.1022

0.5109
0.5148

1
2.36E-03
36.8
0.966

Materials of Construction
Tubes
Shell Ends

Cost

Tube Side
Carbon steel
Carbon steel

Shell Side
Shell

Dept. Chemical & Petroleum Engineering

Carbon steel

HAZOP TABLE
Company
Node
Line
Intention
Guide
Flow
More of

Bio-methane Sdn. Bhd.

HX 01
S02, S03, H01, H02
For heating process fluid
Deviation
Consequences
Increased of

Causes

Discharge temperature of -Malfunction of control

utility fluid gas process fluid increased

valve

flow

-Faulty flow ratio controller

Existing protection
Pressure indicators are
installed before HX and at HX

Action items or
recommendations
-Install high
pressure alarm on
suction side / HX
-Install pressure

relief valves on
Less of

Decreased of

Discharge temperature of -Pipe leakages

-Connection between
utility fluid gas process fluid decreased
flanges and pipes are not
flow
sealed tightly
-Malfunction on control
valves
-Malfunction on flow ratio
controller

Pressure indicators are

installed before HX and at HX

None

No gas flow in
utility stream.

No temperature change
in process stream.

-Pipe rupture
-Pipe blockage
-Control valve failure

suction side
-Regular
maintenance and
cleaning on
pipeline and
auxiliary
controllers
-Install high
pressure alarm on
the upstream
pipelines to detect
pressure build up
due to blockages
in pipe

Install pressure indicators

Install an alarm

before HX and at the HX.

and sensor to

HAZOP TABLE
Pressure
More of

Increased of

-Discharge

Failure of control valve

utility fluid

temperature of

gas pressure

process fluid

Install backup pressure

control valve, pressure
indicator and pressure
alarm.

increased.

-Pipe rupture.
Less of

Decreased of

Discharge temperature

utility fluid

of process fluid

gas pressure

decreased.

Malfunction of pressure
relief valve

Install backup pressure

control valve, pressure
indicator and pressure
alarm.

Regular
maintenance of
pressure
indicators and
pressure
control valves

Regular
maintenance of
pressure
indicators and
pressure control
valves

HAZOP TABLE
Temperatu Increased of

-Discharge

re

utility fluid

temperature of

gas

process fluid

temperature

increased.

More of

-Faulty temperature
controller.

-Fluid be overheated.

-Install temperature
sensors and indicators on
the HX and pipelines of
entering gas and cooling
water.
-Emergency trip system
will be activated if HX
temperature detected is
higher than the design
temperature

Less of

Decreased of

Discharge temperature

utility fluid

of process fluid

gas

decreased.

temperature

-Faulty temperature
controller.
- Fouled exchanger tubes

-Regular
maintenance of
temperature
indicators and
controllers.
-Install visual
high
temperature
alarms on
pipelines and
HX for
notification of
high
temperatures.

-Install temperature sensors -Regular

and indicators on the HX and maintenance of
pipelines of entering gas and temperature
cooling water.
indicators and
-Emergency trip system will
controllers.
be activated if HX
-Install visual low
temperature detected is
temperature
lower than the design
alarms on
temperature
pipelines and HX
for notification of

low
temperatures.

HV003

P&ID for heat

exchanger

TCV00
3

FCV00
2
HX01

Compresso
r Design

Reciproca
ting
compress
or

Suction
7.2928 cu
in
Discharge
4.1911 cu
in

1.192826
cfm

Suction
1.67 in
Discharge
1.39 in

Suction
57.18525
%
Discharge
31.4568 %

Suction
3.33 in
Discharge
2.77 in

137.6554
o
C

82 %

6000
ft/min

53.9055
kW

Compressor Data Sheet

Equipment No.
Function

CMP01
Increase the pressure of
S1.

Process Operating Conditions

Fluid Type
Normal Capacity (m3/hr)

Temperature (K)

Newtonian
416.67
Suction
298

Phase
Design Capacity (m3/hr)

Temperature (K)

Gas
416.67
Discharge
410.6554

Density (kg/m3)

1.297734

Density (kg/m3)

1.297734

Viscosity (Ns/m2)

1.4E-05

Viscosity (Ns/m2)

1.4E-05

Line Data

Pipe Inner Diameter

(inch)
Pipe Outer Diameter
(inch)
Roughness (mm)

Suction
0.27

Pipe Inner Diameter (inch)

Discharge
0.27

0.41

Pipe Outer Diameter (inch)

0.41

0.05

Roughness (mm)

0.05

Technical Design Data

Suction Pressure (N/m2)
Suction volumetric
efficiency (%)

200000
57.18525

Discharge Pressure (N/m2)

Discharge volumetric
efficiency (%)

500000
31.4568

Suction bottle volume (cu 7.2829

in)

Discharge bottle volume (cu

in)

4.1911

Suction bottle length (in)

Suction bottle length (in)

2.773139

Piston speed (ft/min)

6000

3.333985

Piston displacement (cfm) 1.192826

Number of Stages

Actual Power (kW)

Efficiency (%)

Cost
Designed by
Date

Pump Specifications

53.9055

82

TOK KIAT WEI

17/3/2016

Dept. Chemical & Petroleum Engineering

Heriot-Watt University, Malaysia 62200
Process Design A 2016

Company
Node
Line
Intention
Guide
Flow
More of

HAZOP TABLE

Bio-methane Sdn. Bhd.

CMP 01
S01
For increment of pressure of process fluid
Deviation
Consequences

Causes

Existing protection

Increased of

Discharge pressure

-Malfunction of control

Pressure indicators are

gas flow

decreased

valve

installed before CMP and at

-Faulty flow ratio controller

CMP

Action items or
recommendations
-Install high
pressure alarm on
suction side / CMP
-Install pressure

relief valves on
Less of

Decreased of

Discharge pressure

gas flow

increased

-Pipe leakages
-Connection between
flanges and pipes are not
sealed tightly
-Malfunction on control
valves
-Malfunction on flow ratio
controller

Pressure indicators are

installed before CMP and at
CMP

None

No gas flow

-Emission of methane to
surrounding due to pipe
rupture
-If concentration of
methane exceeds the
lower flammability limits,

-Pipe rupture
-Pipe blockage
-Control valve failure

suction side
-Regular
maintenance and
cleaning on
pipeline and
auxiliary
controllers
-Install high
pressure alarm on
the upstream
pipelines to detect
pressure build up
due to blockages
in pipe

Install pressure indicators

Install an alarm

before CMP and at the CMP

and sensor to
detect flow of gas

HAZOP TABLE
Pressure
More of

Increased

Discharge pressure Failure of pressure

relief valve
decreased

Install backup pressure Regular

relief valve
maintenance
of pressure

indicators
and pressure
relief valves

Decreased

Discharge pressure

of gas

increased

Malfunction of
pressure relief valve

Install backup pressure

relief valve

of gas
pressure

Less of

pressure

Regular
maintenance of
pressure
indicators and
pressure relief
valves

HAZOP TABLE
Temperatur Increased of

Faulty in anaerobic

digester.

gas
More of

temperature

-Faulty temperature
controller.
-No/Low flow of cooling
water in HX.

-Install temperature
sensors and indicators on
the CMP and pipelines of
entering gas and cooling
water.
-Emergency trip system will
be activated if CMP
temperature detected is
higher than the design
temperature

Less of

Decreased of

Faulty in anaerobic

gas

digester.

temperature

-Faulty temperature
controller.
-High flow of cooling water
in HX.
- Fouled exchanger tubes

-Install temperature sensors

and indicators on the CMP and
pipelines of entering gas and
cooling water.
-Emergency trip system will be
activated if CMP temperature
detected is lower than the
design temperature

-Regular
maintenance of
temperature
indicators and
controllers.
-Install visual
high
temperature
alarms on
pipelines and
CMP for
notification of
high
temperatures.

-Regular
maintenance of
temperature
indicators and
controllers.
-Install visual low
temperature
alarms on
pipelines and CMP
for notification of

P&ID for
CMP01

RV001

CMP0
1

Waste treatment
Hydrogen Sulphide
Usage of THIOPAC. H2S is absorbed in a caustic solution which
is regenerated in a bioreactor where colourless sulphur
bacteria transform the H2S into elemental sulfur. It can be sold
to the agriculture sector for further usage.
Nitrogen
Usage of post treatment system such as stripping to optimise
and convert the excess nitrogen into ammonium sulphate that
can be used in agriculture sector. This can be marketed outside
with great potential in terms of economical suitability.
Carbon dioxide
Carbon Capture and Storage (CCS). The carbon dioxide is
compressed and stored deep within the earth permanently as
the trees will capture the carbon dioxide and eventually
formation of humus

Oxygen
It can be filtered to clear off any excess chemical residue and
release into the environment or it can be stored and mixed
into the digester of raw materials to accelerate the processes
of biogas because biogas is from the initial biological process
of anaerobic process.

Water
Can be stored and recycle at the system or heat exchanger
equipment for cooling down. It can also reduce any cost or
can be just expel into the environment after clean filtration.

Thank you