Production of Ammonium

Sulfate
Group-1

1
 PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM
SULFATE FROM ACID GASE WASTE STREAM

Group # 01
Supervisors:
Dr. Saleem Iqbal
Mr. Rashid Javed
Group members:
Ahmer Sohail UW-15-Ch.E-BSC-007
Humais Roafi UW-15-Ch.E-BSC-031
Kamran Ahmed UW-15-Ch.E-BSC-009
Waleed bin Shakeel UW-15-Ch.E-BSC-035
2
Process flow diagram

3
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Furnace
F-301

4
Diagram
T = 950oF
P = 1 atm
34 SO2 = 9195.75 kg/hr

F-301

32

T = 77oF 31
P = 1 atm
Air = 8338.32 kg/hr
29

T = 131oF
P = 1 atm
H2S = 857.12 kg/hr

5
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Design of Furnace
Furnace is thermal equipment which preheats the reactor feed to carry out the reaction. It
generates the control heat with the help of flue gases to perform the work. Combustion of
fuel is the source of production of heat in the furnace. In our case, the feed is H2S. We are
using the Lobo and Evans method from Process Heat Transfer by D. Q. Kern.
Heat is supplied by combustion gases. Heat produced by combustion gases mainly CO2 is
transferred to the tubes by radiation and convection and the required temperature is
achieved.

6
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Furnace Design Calculations

Methods for heat absorption calculations
There are four common methods for calculating heat absorption in furnace radiant sections
that are given below:
1. Method of Lobo and Evans
2. Method of Wilson, Lobo, and Hottel
3. The Orrok-Hudson Equation
4. Wohlenberg Simplified Method
We are going to use Lobo and E vans method for calculating heat absorption in furnace
radiation section. Lobo and Evans method makes the use of the overall exchange factor ‘f’
and a Stefan-Boltzmann type equation. It has a good theoretical basis and is used
extensively in refinery furnaces design work. It is also recommended for oil or gas fired
boilers.
7
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Design Steps of Furnace

1. Following are the design steps of Furnace

2. Average Radiant Heat Flux

3. Heat Balance
• Heat liberated by fuel Qf

• Heat loss through Wall Qw

• Air Required for Burning Fuel

• Sensible Heat of Incoming Air Qa
• Total Heat Content Q

4. Dimensions of Furnace

8
5. Layout of Tubes

6. Gas Emissivity Calculation

7. Heat Balance

8.

9
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Assumptions
Average heat flux = 525 Btu/lb.ft2
Efficiency = 0.75.
Overall exchange factor = 0.6.
Temperature of inlet air = 674.6 oF = 357 oC.
Tube length = 35 ft.
Tube Diameters = 5 in.
Center-Center Distance = 8.5 in = 0.708 ft.
Lower heating value of Fuel = 21500 Btu/lb.

10
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Average Radiant Heat Flux

Radiant heat flux for different stocks is available in the literature for sulfur hydro treated
charge heater average radiant heat flux. Overall exchange factor (ℱ) is assumed to be 0.6.
𝛴𝑄
= 2 × 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐹𝑙𝑢𝑥
𝛼𝐴𝑐𝑝
𝛴𝑄
= 2 × 1050
𝛼𝐴𝑐𝑝
ℱ = 0.6
𝛴𝑄
= 1750
𝛼𝐴𝑐𝑝 ℱ
Where,
Acp = equivalent cold plane surface (ft2)
𝛼 = effectiveness factor 11
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

∑Q = heat transferred (Btu/hr)

Tube Surface Temperature depends upon the desired temperature of the fluid lets = Ts
Temperature of the Gases Leaving the Radiant Section = Tg
Process gas outlet temperature in the tube side = 887 oF
Tube surface temperature Ts can be assumed to be = 900 oF
From figure 19.14 of D. Q. Kern, Tg is found out to be = 950 oF

Q   T 
4
 Ts  
4

= 0.173×    + 7×(Tg - Ts )
g
 -
αAcp f  100   100  

12
13
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Heat Balance
The heat balance is as follow
Q = Qa + Qf - Qw - Qg

Where,
Q = total radiant section duty (Btu/hr)
Qa = sensible heat of entering air (Btu/hr)
Qf = heat liberated by fuel (Btu/hr)
Qw = heat loss through furnace wall (Btu/hr)
Qg = heat leaving the furnace radiant section by flue gases (Btu/hr)

14
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Heat liberated by fuel Qf

Fuel required = 94 kg/hr = 206.8 lb/hr
LHV of fuel = 21500 Btu/lb
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐹𝑢𝑒𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑
𝑄= = 4446200 Btu/hr
𝐿𝐻𝑉
Efficiency = η = 0.75
𝑄
𝑄𝑓 = = 5928266.667 Btu/hr
η
Heat loss through Wall Qw
Heat loss through wall is taken as 2% of Qf, this is a good estimation for design purposes

Qw = 118565.3333 Btu/hr

15
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Air Required for Burning Fuel

CH4 + 2O2 CO2 +2H2O
1 mole Methane required = 2 moles of Oxygen
94 kg fuel/hr = 3.125 kmol fuel/hr
Oxygen required = 6.25 kmol Oxygen/hr = 200 kg Oxygen/hr
Air required = Required Oxygen/0.21 = 952.3809524 kg Air/hr
= 2095.238095 lb Air/hr
25% access Air = 2619.047619 lb Air/hr
Components Kg/hr
CO2 Produced 137.5
H2O Produced 56.25
Unreacted O2 50
N2 940.47
16
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Sensible Heat of Incoming Air Qa

T1 = 77oF
Tref = 60oF

Comp. a b c d H' m' H

J/mol kj/kg kg/hr Kj/hr
N2 31.15 -0.01357 2.68E-05 -1.2E-08 454.1311 14.191 940.47 13346.86
O2 8.106 -3.68E-06 1.75E-05 -1.1E-08 143.8235 4.494 250 1123.621

Qa = 14470.4787 kj/hr = 13703.54333 Btu/hr

Heat Carried Over by Gas Qg
T1 = 950oF
Tref = 60oF

17
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Comp. a b c d H' m' H

J/mol kj/kg kg/hr Kj/hr
CO2 19.795 0.073436 0.00602 1.72E-08 905394.1 26629.2 137.5 3661520
O2 8.106 -3.68E-06 1.75E-05 -1.1E-08 5092.379 159.13 50 7956.842
N2 31.15 -0.01357 2.68E-05 -1.2E-08 13010.39 406.57 940.4762 382373.9
H2O 32.243 0.0019238 1.06E-05 -3.6E-09 15646.82 244.48 56.25 13752.08

Total Heat = 4065602.911 kj/hr

Qg = 3850125.957 Btu/hr

Total Heat Content Q

Q = Qf + Qa - Qw - Qg
Q = 1973278.92 Btu/hr

18
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Surface area
Tube Height = 35 ft
OD = 5 in = 0.416666667 ft
Surface area per tube = 𝐴𝑠 = πDL
𝐴𝑠 = 3.14 × 0.4167 × 35
𝐴𝑠 = 45.83 ft2
Number of Tubes
𝑄
Number of tubes (NT) =
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐹𝑙𝑢𝑥 𝑥 𝐴𝑠
1973278.92
NT =
525 x 45.83
NT = 82 tubes

19
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Equivalent cold plane area surface Acp

Center to center distance = 8.5 in
𝐶2𝐶 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒
Acp per tube = × 𝑇𝑢𝑏𝑒 𝐻𝑒𝑖𝑔ℎ𝑡 = 24.79 ft2
12

To find α
𝐶2𝐶
= 1.7
𝑂𝐷 𝑜𝑓 𝑇𝑢𝑏𝑒
α = 0.937
α.𝐴𝑐𝑝
= 23.22
𝑇𝑢𝑏𝑒
α. 𝐴𝑐𝑝 = 1905.02 ft2

20
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Volume of Furnace
Length
Length = (C2C Distance × 41) + 2 × Clearance from wall

Let clearance from wall to be = 8.5 in

Length = 357 in
= 29.75 ft
Width
Width = Tube OD + (2 × Clearance from wall)
Clearance from wall to be = 8.5 in
Width = 22 in
= 1.833 ft
21
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Height
Height = Tube height + (2 × Clearance from wall)
Clearance from wall to be = 8.5 in
Height = 36.417 ft
Volume
Volume = Length × Width × Height
Volume = 1986.2256 ft2
Volume of both sections = 2 × 1986.2256 ft2 = 3972.4513 ft2
Refractory Surface
Ar = At - α. 𝐴𝑐𝑝 = 2067.425 ft2
𝐴𝑟
= 1.085
α.𝐴𝑐𝑝

22
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Geometry of Tubes

× ×
× ×

× ×

× ×
× ×

× ×

× ×
× ×

× ×
× ×
× ×

× ×

Top view: Double walled radiation section

23
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

3D Layout of Furnace

24
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Mean Beam Length

23 23
Mean Beam Length = 𝑉𝑜𝑙𝑢𝑚𝑒 = 3972.45
3 3
Mean Beam Length = 10.27 ft
Gas Emissivity
Operating Pressure = 1 atm
Let us assume that air at 60 F is 50% saturated.

Per pound of dry air will have moisture = 40 grains

Total air in pounds = 2619.047 lb/hr
Moisture in air = 104761.9048 grains/hr
= 14.9659 lb/hr
= 6.80272 kg/hr
25
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

26
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Flue Gas Composition

Components Flowrate (kg/hr)
CO2 137.5
H2O 63.052
O2 50
N2 940.476
Total 1191.028
Partial Pressure Calculations
Operating Pressure = 1 atm

Components Moles Mole Fraction Partial

Pressure
ni xi pi
CO2 3.125 0.074 0.074
H2O 3.50 0.0838 0.083
O2 1.56 0.0373 0.037
N2 33.58 0.803 0.803
Total 41.77 1 1
27
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

𝑝𝐶𝑂2 = 0.0747
𝑝𝐻2𝑂 = 0.0838
𝑝𝐶𝑂2 𝐿 = 0.7682
𝑝𝐻2𝑂 𝐿 = 0.8611
Emissivity of Gas 𝜺𝑮
At Tg
Tg = 950oF
From Figure 19.12 and 19.13 of D. Q. Kern
𝑞𝐶𝑂2 𝑎𝑡 𝑝𝐶𝑂2 𝐿 = 950
𝑞𝐻2𝑂 𝑎𝑡 𝑝𝐻2𝑂 𝐿 = 2000
𝑇 4
𝑞𝑏 = 0.173 ( ) = 1409.09
100
28
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM
At Ts
Ts = 900oF
From Figure 19.12 and 19.13 of D. Q. Kern
𝑞𝐶𝑂2 𝑎𝑡 𝑝𝐶𝑂2 𝐿 = 800
𝑞𝐻2𝑂 𝑎𝑡 𝑝𝐻2𝑂 𝐿 = 1800
𝑇 4
𝑞𝑏 = 0.173 ( ) = 1135.053
100
% Correction
Percentage Correction is found out from figure 19.12 or 19.13 of D. Q. Kern
𝑝𝐶𝑂2
= 0.4717
𝑝𝐶𝑂2 + 𝑝𝐻2𝑂
𝑝𝐶𝑂2 𝐿 + 𝑝𝐻2𝑂 𝐿 = 1.6293
29
 PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Emissivity of Gas 𝜺𝑮
𝑞𝐶𝑂2 𝑎𝑡 𝑝𝐶𝑂2 𝐿 + 𝑞𝐶𝑂2 𝑎𝑡 𝑝𝐻2𝑂 𝐿 − 𝑞𝐶𝑂2 𝑎𝑡 𝑝𝐶𝑂2 𝐿 + 𝑞𝐶𝑂2 𝑎𝑡 𝑝𝐻2𝑂 𝐿 100 − %
𝑇𝑔 𝑇𝑠
𝜀𝐺 =
𝑞𝑏 𝑇𝑔 − 𝑞𝑏 𝑇𝑠 100

𝜀𝐺 = 0.55
Overall Exchange Factor 𝓕
Overall Exchange factor ℱ will be found out from figure 19.15 of D. Q. Kern
𝜀𝐺 = 0.55
𝐴𝑟
= 1.085
α. 𝐴𝑐𝑝
Exchange factor is found out to be
ℱ = 0.68
30
31
32
33
 PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM
Check Assumptions
𝛴𝑄
Checking value of using above calculated ℱ
𝛼𝐴𝑐𝑝 ℱ

𝛴𝑄 𝐵𝑡𝑢
= 1523.27
𝛼𝐴𝑐𝑝 ℱ ℎ𝑟. 𝑓𝑡 2
If Ts remains same = 900oF
Tg becomes = 940oF
This indicate that more duty will be performed, since our duty Q = 1973278.92 Btu/hr, cools the
gas down to 950oF, but according to assumed average flux, gasses will be cooled down to 940oF.
For final iteration Tg will be taken = 945oF
At this gas temperature the furnace duty becomes = Q = 2015880 Btu/hr
2015880−1973278.92
Error = × 100
2015880
Error = 2.1%
34
PRODUCTION OF 163 TONNS PER DAY OF AMMONIUM SULFATE FROM ACID GASE WASTE STREAM

Specification Sheet
Identification
Item Furnace F-301
Type Rectangular Furnace
Function
To Combust H2S and form Sulfur Dioxide
Number of Tubes 82
Height of Furnace 36.41 ft
Length of Furnace 29.75 ft
Width of Furnace 1.833 ft
Mean Beam Length 10.27 ft
OD of Tube 5 1n.
C-C Distance 8.5 in
Refractory Surface 2067 ft2
Cold Plane Surface 1905 ft2

35