CHAPTER SEVEN OF A DESIGN PROJECT FOR
DESIGN OF A PLANT FOR THE PRODUCTION OF 240,000 CUBIC METERS OF
LIQUEFIED BIOGAS PER ANNUM FROM AGRO WASTES
PRESENTED TO THE DEPARTMENT OF CHEMICAL ENGINEERING
BY
GROUP G
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE COURSE
CHG 545: CHEMICAL ENGINEERING PROCESS DESIGN II
GROUP MEMBERS & THEIR INDIVIDUAL CONTRIBUTIONS
NAMES MAT. NO CONTRIBUTION TO CHAPTER SIGNATURE
ADETUNMIBI, PEACE 170401017 Process Simulation
ADEGBOYEGA
EZEOKOYE, IFUNANYA 170401044 Process Simulation
BENEDICTA
ORIMOLOYE, ARAMIDE DESOLA 170401032 Process Simulation
KABIAWU, ANJOLAIYA INNOCENT 170401047 Process Simulation
DADA, TAIWO OLAMIDE 170401072 Process Simulation
ADEDEJI, ADETILEWA 170401061 Process Simulation
OLUWAFUNMILAYO
AMODU, SULEMAN BABANGIDA 170401075 Process Simulation
UDOH, IMMAOBONG ESSIEN 180401505 Process Simulation
NNABUIHE OLISEMEKA VICTOR 180401510 Process Simulation
OKUNLOLA, JOSEPH KAYODE 170401048 Process Simulation
7.0 DWSIM SIMULATION
7.1 INTRODUCTION
The Pretreatment and liquefaction process to produce 240,000 cubic meters of Liquefied Biogas
using Corn stalk and Cow dung as biomass was simulated using DWSIM. Approximations were
made where necessary and the results are tabulated by equipment in this chapter.
Although plate and frame heat exchangers were designed in the last chapter, shell-and-tube heat
exchangers were used in this simulation due to its availability on DWSIM.
7.2 DWSIM SIMULATION
Figure 7.2.1: Dwsim simulation of the production unit
Figure 7.2.2: Dwsim simulation of all processes from scrubber to the liquefaction unit
7.3 MIXER
The simulation is done assuming perfect mixing with very little change in temperature and no
reaction
.
Table 7.3.1: Properties of material stream around the mixer
Master Property Table for Mixer
Biomass
Object Peroxide Ground cobs Cow dung Slurry
Temperature 298.301 298.15 298.694 292.498 K
Pressure 2.00E+07 101325 4.22E+06 101325 Pa
Mass Flow 5.51 35.22 17.61 199.22 kg/s
Volumetric
Flow 0.00547339 0.0175308 0.0165069 0.197416 m3/s
Density
(Mixture) 1006.69 2009.03 1066.83 1009.14 kg/m3
7.4 Heat Exchanger
The heat exchanger was approximated using a counter current heat exchanger with a log mean
temperature difference of 123.118k, thermal efficiency of 63.86%, and maximum heat exchange
of 2891.79kW . The results are shown in Table 7.3 below.
Table 7.4.1: Properties of material stream around the Heat Exchanger
Master Property Table
Biomass
Object Steam Out Steam In Slurry BMS
Temperature 373.132 473.15 292.498 294.884 K
Pressure 101325 101325 101325 101325 Pa
Mass Flow 1 1 199.22 199.22 kg/s
Volumetric
Flow 0.491493 2.1453 0.197416 0.197526 m3/s
Density
(Mixture) 2.03462 0.466136 1009.14 1008.57 kg/m3
7.5 Biodigester
The reactions that takes place in the digester are:
1. CH₃COOH + H₂ → CH₃COO⁻ + H⁺ + e⁻
2. 4H₂ + CO₂ → CH₄ + 2H₂O
3. CO2 +4 H2 ⟶ CH4 + 2H2O
4. CH3COOH ⟶ CH4 + CO2
Table 7.5.1: Properties of material stream around the Bio-Digester
Master Property Table
Biomass Bio-digester
Object Slurry product Digestate
Temperature 292.498 40 40 C
Pressure 101325 9.86923 9.86923 atm
Mass Flow 199.22 5.36 193.86 kg/s
Mass Flow (Mixture) / Methane 0 3.56976 0 kg/s
Mass Flow (Mixture) / Carbon dioxide 0 1.47936 0 kg/s
Mass Flow (Mixture) / Hydrogen sulfide 0 0.00536 0 kg/s
Mass Flow (Mixture) / Water 0 0.1608 0 kg/s
Mass Flow (Mixture) / Oxygen 0 0.03216 0 kg/s
Mass Flow (Mixture) / Nitrogen 0 0.04288 0 kg/s
Mass Flow (Mixture) / Ammonia 0 0.06968 0 kg/s
7.6 DEA Cooler
This was simulated using a cooler with a cooling duty of 333.879kw and a temperature
change of 258.15 K. The results are presented in table 7.5 below
Table 7.6.1: Properties of material stream around the Cooler
Master Property Table
Object DEA Feed Cooled DEA
Temperature 25 10 C
Pressure 1 1 atm
Mass Flow 21.0271 21.0271 kg/s
Mass Flow (Mixture) / Methane 0 0 kg/s
Mass Flow (Mixture) / Carbon dioxide 0 0 kg/s
Mass Flow (Mixture) / Hydrogen sulfide 0 0 kg/s
Mass Flow (Mixture) / Water 0 0 kg/s
Mass Flow (Mixture) / Oxygen 0 0 kg/s
Mass Flow (Mixture) / Nitrogen 0 0 kg/s
Mass Flow (Mixture) / Ammonia 0 0 kg/s
7.7 Scrubber
The scrubber was simulated using an absorption column with 6 stages. This removes carbon
dioxide, nitrogen, oxygen and water to a large extent. It also drops the stream temperature to 195
k. The property package is Peng-Robinson (PR) and the column solver used is burningham-
otto(sum Rates). The results are presented in Table 7.6 below.
Table 7.7.1: Properties of material stream around the Scrubber
Master Property Table
Cooled Bio-digester
Object Rich DEA DEA Clean Gas product
Temperature -55.3115 10 -78.8743 40 C
Pressure 1 1 1 9.86923 atm
Mass Flow 21.3645 21.0271 5.02256 5.36 kg/s
Mass Flow (Mixture) / Methane 0.00176854 0 3.568 3.56976 kg/s
Mass Flow (Mixture) / Carbon
dioxide 0.101006 0 1.37834 1.47936 kg/s
Mass Flow (Mixture) / Hydrogen
sulfide 0.00415693 0 0.00120305 0.00536 kg/s
Mass Flow (Mixture) / Water 0.1608 0 6.20E-28 0.1608 kg/s
Mass Flow (Mixture) / Oxygen 1.20E-05 0 0.032148 0.03216 kg/s
Mass Flow (Mixture) / Nitrogen 2.06E-06 0 0.0428782 0.04288 kg/s
Mass Flow (Mixture) / Ammonia 0.0696799 0 6.20E-08 0.06968 kg/s
7.8 DEA Heater
This was simulated using a Heater with heating duty of 10491.8 kW duty of and a
temperature change of 465.87 K with outlet vapor fraction of 0.0325682 . The results are
presented in table 7.7 below:
Table 7.8.1: Properties of material stream around the DEA Heater
Master Property Table
Object Rich DEA H DEA
Temperature -55.3115 137.411 C
Pressure 1 1 atm
Mass Flow 21.3645 21.3645 kg/s
Mass Flow (Mixture) / Methane 0.00176854 0.00176854 kg/s
Mass Fraction (Vapor) / Methane 0 0.00943503
Mass Fraction (Overall Liquid) / Methane 8.28E-05 1.69E-06
Mass Flow (Mixture) / Carbon dioxide 0.101006 0.101006 kg/s
Mass Fraction (Vapor) / Carbon dioxide 0 0.508218
Mass Fraction (Overall Liquid) / Carbon dioxide 0.00472774 0.000361939
Mass Flow (Mixture) / Hydrogen sulfide 0.00415693 0.00415693 kg/s
Mass Fraction (Vapor) / Hydrogen sulfide 0 0.0182125
Mass Fraction (Overall Liquid) / Hydrogen sulfide 0.000194571 3.83E-05
Mass Flow (Mixture) / Water 0.1608 0.1608 kg/s
Mass Fraction (Vapor) / Water 0 0.157887
Mass Fraction (Overall Liquid) / Water 0.00752649 0.00622271
Mass Flow (Mixture) / Oxygen 1.20E-05 1.20E-05 kg/s
Mass Fraction (Vapor) / Oxygen 0 6.46E-05
Mass Fraction (Overall Liquid) / Oxygen 5.64E-07 8.64E-09
Mass Flow (Mixture) / Nitrogen 2.06E-06 2.06E-06 kg/s
Mass Fraction (Vapor) / Nitrogen 0 1.12E-05
Mass Fraction (Overall Liquid) / Nitrogen 9.66E-08 6.81E-10
Mass Flow (Mixture) / Ammonia 0.0696799 0.0696799 kg/s
7.9 Separation Tank
This is simulated using a gas-liquid separation tank. The calculation is based on the
minimum inlet pressure. The results are presented in table 7.7 below:
Table 7.9.1: Properties of material stream around the Separation Tank
Master Property Table
Recycle
Object Waste Gas DEA H DEA
Temperature 137.411 137.411 137.411 C
Pressure 1 1 1 atm
Mass Flow 0.183661 21.1809 21.3645 kg/s
Mass Flow (Mixture) / Methane 0.00173284 3.57E-05 0.00176854 kg/s
Mass Fraction (Vapor) / Methane 0.00943503 0 0.00943503
Mass Fraction (Overall Liquid) / Methane NaN 1.69E-06 1.69E-06
Mass Flow (Mixture) / Carbon dioxide 0.0933397 0.0076662 0.101006 kg/s
Mass Fraction (Vapor) / Carbon dioxide 0.508218 0 0.508218
Mass Fraction (Overall Liquid) / Carbon
dioxide NaN 0.000361939 0.000361939
Mass Flow (Mixture) / Hydrogen sulfide 0.00334491 0.000812018 0.00415693 kg/s
Mass Fraction (Vapor) / Hydrogen sulfide 0.0182125 0 0.0182125
Mass Fraction (Overall Liquid) / Hydrogen
sulfide NaN 3.83E-05 3.83E-05
Mass Flow (Mixture) / Water 0.0289975 0.131802 0.1608 kg/s
Mass Fraction (Vapor) / Water 0.157887 0 0.157887
Mass Fraction (Overall Liquid) / Water NaN 0.00622271 0.00622271
Mass Flow (Mixture) / Oxygen 1.19E-05 1.83E-07 1.20E-05 kg/s
Mass Fraction (Vapor) / Oxygen 6.46E-05 0 6.46E-05
Mass Fraction (Overall Liquid) / Oxygen NaN 8.64E-09 8.64E-09
Mass Flow (Mixture) / Nitrogen 2.05E-06 1.44E-08 2.06E-06 kg/s
Mass Fraction (Vapor) / Nitrogen 1.12E-05 0 1.12E-05
Mass Fraction (Overall Liquid) / Nitrogen NaN 6.81E-10 6.81E-10
Mass Flow (Mixture) / Ammonia 0.0517807 0.0178992 0.0696799 kg/s
7.10 Liquefaction Unit
The heat exchanger was approximated using a counter current heat exchanger with a log mean
temperature difference of 346.468k, thermal efficiency of 42.8%, and maximum heat exchange
of 3520.79 kW . The results are shown in Table 7.9 below.
Table 7.10: Properties of material stream around the Liquefaction unit
Master Property Table
Cooled
Nitrogen Nitrogen Biomethan
Object Outlet Inlet e Clean Gas
Temperature -195.795 -196 -153.805 -78.8743 C
Pressure 1 1 1 1 atm
Mass Flow 15.8587 15.8587 5.02256 5.02256 kg/s
Mass Flow (Mixture) / Methane 0 0 3.568 3.568 kg/s
Mass Fraction (Vapor) / Methane 0 0 0.975881 0.710394
Mass Fraction (Overall Liquid) /
Methane 0 0 0.304016 NaN
Mass Flow (Mixture) / Carbon dioxide 0 0 1.37834 1.37834 kg/s
Mass Fraction (Vapor) / Carbon dioxide 0 0 2.25E-05 0.274429
Mass Fraction (Overall Liquid) / Carbon
dioxide 0 0 0.694459 NaN
Mass Flow (Mixture) / Hydrogen sulfide 0 0 0.00120305 0.00120305 kg/s
Mass Fraction (Vapor) / Hydrogen
sulfide 0 0 2.90E-08 0.00023953
Mass Fraction (Overall Liquid) /
Hydrogen sulfide 0 0 0.00060613 NaN
Mass Flow (Mixture) / Water 0 0 6.20E-28 6.20E-28 kg/s
Mass Fraction (Vapor) / Water 0 0 1.80E-44 1.24E-28
Mass Fraction (Overall Liquid) / Water 0 0 3.13E-28 NaN
Mass Flow (Mixture) / Oxygen 0 0 0.032148 0.032148 kg/s
Mass Fraction (Vapor) / Oxygen 0 0 0.0101955 0.00640072
Mass Fraction (Overall Liquid) / 0.00059216
Oxygen 0 0 7 NaN
Mass Flow (Mixture) / Nitrogen 15.8587 15.8587 0.0428782 0.0428782 kg/s
Mass Fraction (Vapor) / Nitrogen 1 1 0.013901 0.00853711
Mass Fraction (Overall Liquid) /
Nitrogen 1 1 0.00032674 NaN
Mass Flow (Mixture) / Ammonia 0 0 6.20E-08 6.20E-08 kg/s
Table 7.11: Comparing Simulated and Calculated Results
CALCULATED SIMULATED
ITEM RESULT RESULT
Cooled Biomethane(kg/s) 3.572 3.568
Liquefaction energy(KW) 812.503 1506.8
Required DEA 3.56 20.1