Cyla PD Rev. PDF - Design Information

CHAPTER I DESIGN INFORMATION This chapter discussed the rationale for the design and construction of the offshore processing plant. The designers identified the target location of the offshore processing plant and the available resources that can be used to...

CHAPTER I DESIGN INFORMATION This chapter discussed the rationale for the design and construction of the offshore processing plant. The designers identified the target location of the offshore processing plant and the available resources that can be used to run the plant. Introduction Carbon dioxide (CO2) is an important heat-trapping gas, also known as a greenhouse gas, that comes from the extraction and burning of fossil fuels (such as coal, oil, and natural gas), from wildfires, and natural processes like volcanic eruptions. Since the onset of industrial times in the 18th century, human activities have raised atmospheric CO2 by 50% – meaning the amount of CO2 is now 150% of its value in 1750. This human-induced rise is greater than the natural increase observed at the end of the last ice age 20,000 years ago (The National Aeronautics and Space Administration, n.d.) Nunes (2023) stated that the increasing levels of carbon dioxide (CO2) in the atmosphere have become a major environmental challenge due to their contribution to global warming. The primary drivers of the increase in atmospheric CO2 concentrations are the combustion of fossil fuels, deforestation, agricultural practices, or the production of cement, which play a significant role in the increase of CO2 concentration in the atmosphere. However, efforts are being made to mitigate the negative effects of CO2 emissions, including oxy-fuel carbon capture and storage (CCS) technologies that aim to capture CO2 from industrial processes and store it in underground geological formations. 1  Koohestanian and Shahraki (2021) explained that to reduce CO2 emissions, there are different approaches such as expanding renewable energies such as solar and wind energies fuel switching from coal to natural gas applying regulations on the total CO2 emission, utilizing CO2 as a raw material, enhancing plant efficiency to more energy saving, and applying oxy-fuel carbon capture and storage (CCS) approach. However, due to the great world energy demand and based on the fact that renewable energies still need more work to make them economically competitive to the fossil fuel price, more need is felt for the continuous use of reasonable and sustainable fossil fuels with decreased environmental consequences which requires the integration of the CCS technologies. CCS does not aim to decrease the formation of CO2, but rather to capture it from emissions and store it under the earth’s surface, for example in unused oil and gas fields, and deep saline formations. CCS consists of four key components: capture, transport, storage, and utilization. These components are critical to the success of technology. The capture process involves separating CO2 from other gases emitted during industrial processes. There are several capture technologies available, including post-combustion, pre-combustion, and oxy-fuel combustion captures. Post-combustion capture removes CO2 from the exhaust gas after combustion, while pre-combustion capture converts fossil fuels into a gaseous mixture of hydrogen and CO2 before combustion. Oxy-fuel combustion involves burning fossil fuels in a mixture of oxygen and recycled flue gas, producing a flue gas stream that is primarily composed of CO2 (Yasemi et al., 2023). Additionally, post-combustion capture involves capturing CO2 from power plant flue gasses, which is the easiest and most widely used technology. The efficiency of this 2 technology is relatively low compared to that of the other techniques, with capture rates between 85 and 90%, but it is cost-effective compared to other capture methods. Pre-combustion capture is used in gasification processes that turn fossil fuels into gas that can be burned cleanly. This technology can capture roughly 95% of the CO2 produced, making it very efficient; however, it is expensive to use. Oxy-fuel combustion capture involves burning fuels with pure oxygen, producing flue gas with a high concentration of CO2, which is easy to capture. It has the highest capture efficiency, up to 99%, and is a cost-effective method (Yasemi et al., 2023). Al-Abbas and Jamal Naser (2013) stated that all these three CO2 capture technologies have different outcomes, particularly with regards to reduction of power plant efficiency and in increasing the cost of electricity production. In general, to be successful post-combustion capture requires new developments in the process of chemical absorption of CO2 to adequately reduce energy consumption in the absorption process, but this is very expensive. In contrast, pre-combustion capture is achieved by the conversion of fuel into carbon monoxide (CO) and hydrogen fuel (H2) in which CO is converted to CO2 by the shift-conversion process. This CO2 capture approach can be developed by either physical or chemical absorption processes to avoid any extra complexity in chemical design of power generation. However, both processes are very expensive and chemically complicated. Finally, the capture of CO2 by the oxy-fuel combustion technique is less expensive than the other two processes and less complex. It can be carried out by burning the fossil fuel with a mixture of pure oxygen (99.5 vol. %), produced in ASU, and recycled flue gas (RFG). The products of this combustion will be only CO2 and H2O in the flue gas. After the condensation process, CO2 3 concentrations will be increased to a level more suitable for the separating and compression processes. In accordance with the study of Koohestanian and Shahraki (2021), the oxyfuel combustion method is beneficial for most combustion systems because it only requires O2 during the combustion process. Presence of N2 not only increases the formation of nitrogen oxide (NOX) as the major emission of concern, but also decreases the thermal efficiency through lowering the radiative heat transfer as well as, less heat can be transferred from the hot flue gases as more energy is wasted in heating N2 and more energy is carried out via the flue glasses. Several oxy-fuel industrial processes have been successfully operated worldwide, in which the flue gas stream with 90% of CO2 (on dry base) was generally achieved. 4  Table 1. Comparison of Combustion Methods Combustion Pre-combustion Post-combustion Oxy-fuel combustion Technology Efficiency 7-10 8-12 7-11 penalty% Separation task CO2/ H2 CO2/ N2 O2/ N2 Capture Chemical absorption Chemical absorption such as CO,CPU process Technology such as alkanolamines amine scrubbing process CLC technology Physical absorption such Physical absorption such as ionic as ionic liquids liquids Cryogenic distillation Membrane process Physical adsorption such as Physical adsorption such as using polymeric and zeolites, activated carbon, and zeolites and activated carbon ceramic membrane metal-organic frameworks Membrane process using Physical adsorption such Membrane process using polymeric and ceramic as zeolites, activated polymeric and ceramic membranes membranes carbon [SI), alumina, Ion transport membrane reactor and metal-organic Gas hydrate crystallization frameworksCryogenic Hybrid process distillation Cryogenic distillation Gas hydrate Hybrid process crystallization Hybrid process Advantage Producing a carbon-free Causing minimum changes in the Producing a highly concentrated H2 based fuel original configuration of the existing CO2 stream power plant Low NOx production Its maintenance does not stop the operation and can be controlled Increasing both the convective and radiative heat transfer Mature technology Capturing can be applied without additional material or solvent Disadvantage / Required additional cost High NOx production Requiring approximate pure O2 Limitation for the syngas generation Low CO2 purity in the flue gas leads to treatment of a high volume More costly in of gas to separate CO2 comparison with the other methods The Malampaya gas-to-power project primarily generates its electricity to support its operation using a portion of the natural gas it extracts. However, the process of Malampaya’s power generation still produces a significant amount of carbon dioxide for its operation. The researchers suggested operating the power generation for 5 Malampaya Gas Field using the raw natural gas it produces while capturing the carbon dioxide to reduce Malampaya's carbon emission. Therefore, this study is to design an oxyfuel carbon capture plant around Northwest Palawan Shelf, integrating with the Malampaya gas field reserves, employing an oxyfuel combustion process. Several methods to successfully design an oxyfuel carbon capture plant will be employed including assessment of various design alternatives, consideration of plant site and location, establishment of equipment design and specifications, administration of economic analysis, evaluation of environmental impacts and material handling system, creation and simulation of plant layouts, and development of project construction and execution proposition A. Target Location: Northwest Malampaya Offshore Platform Project The Malampaya project is a historic and monumental achievement for the Philippines, as it is one of the largest and most significant industrial endeavors in the country’s history. It is a collaborative effort between the Philippine national government and the private sector, spearheaded by the Department of Energy (DOE) and executed by Prime Energy on behalf of its joint venture partners Udenna Corporation and the Philippine National Oil Company-Exploration Corporation (PNOC EC). Since its inception in 2001, the project has produced cleaner-burning natural gas that powers four major power plants in Luzon, the country’s largest island, with a total capacity of 3,200 megawatts. The project has also generated over $12 billion in revenues for the Philippine government, while providing up to 20% of the country’s energy needs. 6  Figure 1. Malampaya Offshore Source: Securities and Exchange Commission (2005) B. Plant Site Considerations The following factors should be considered in selecting a semi-submersible rig as a plant site: 1. Raw materials availability In evaluating raw materials as a major factor for design consideration, attention should be given to the price of raw materials, distance from the source, availability and reliability of supply, and quality of raw materials. Primarily, the manufacturing units where the conversion of raw materials into finished products should be in a place where the raw materials availability is maximum and cheap. a. Air Air is readily available everywhere, making it an accessible and inexhaustible source for oxy-fuel carbon capture and sequestration (CCS). Since the combustion process requires oxygen, the abundant availability of air in the Palawan basin means that oxygen can be separated efficiently from it. 7  As air is widely available, including near the gas field and power plants utilizing its natural gas, there is no requirement to transport air over long distances. This streamlines the logistics of applying CCS, as oxygen for combustion can be produced on-site from the surrounding air, reducing costs and improving efficiency. b. Natural Gas Since the nature of the plant itself is a sub-unit in an LNG processing plant, the feedstock will still be the raw natural gas in the sequence of Malampaya’s natural gas processing properly that the proposed carbon capture plant is separate and more integrated. 2. Markets a. Nitrogen and Argon (Byproduct) According to the report of Industry Arc (2024), the South East Asia Industrial Gases Market size is estimated to reach $11.4 billion by 2030, growing at a CAGR of 6.9% during the forecast period 2024-2030. Indonesia is poised to emerge as the largest country in Southeast Asia for the Industrial Gases Market with a revenue share of 36.1% in 2023. The exploration of new applications for industrial gasses, such as additive manufacturing, food processing, and water treatment, opens up opportunities for market expansion in Indonesia. Innovation and collaboration drive the adoption of gases in unconventional sectors, fostering market growth. Additionally, the Nitrogen segment accounted for the largest share in 2023 at 37.2% share. Growing demand for chemical analysis drives the use of nitrogen 8 for sample preparation, spurring market growth for nitrogen gas suppliers catering to laboratories and research facilities. Nitrogen's versatile applications in fertilizer, nylon, and dye production fuel market growth in the chemical industry, with increasing demand for nitrogen as a key industrial gas. Nitrogen plays a critical role in steel manufacturing processes like melting, ladle treatment, and casting. It directly influences steel's hardness, formability, and aging properties, contributing to the production of high-quality steel products in various industries. b. CO2 for Enhanced Oil Recovery (EOR) The Global CCS Institute reported on the global market demand for carbon dioxide (CO2). In 2021, the total demand was estimated at 80 million tonnes per annum (Mtpa), with 50 Mtpa used primarily for Enhanced Oil Recovery (EOR), mostly in North America. The remaining 30 Mtpa covered other applications, mainly in mature industries like beverage carbonation and the food sector. As cited by Lopez and Moskal (2019), the recent oil price paid today for CO2 injection for CO2-EOR averages $50-per-ton. 9  Figure 2: Approximate proportion of current CO2 demand by end use Sources: National Energy Technology Laboratory The United States is the global leader in both the number of CO2 enhanced oil recovery (EOR) projects and the volume of oil produced through this method, largely due to favorable geological conditions. The Permian Basin, spanning West Texas and southeastern New Mexico, accounts for the majority of global CO2 EOR activity for two key reasons: its reservoirs are especially suited to CO2 flooding, and nearby natural sources of high-purity CO2 are readily available. However, more CO2 EOR projects are emerging in other regions, driven by access to low-cost CO2. 3. Energy availability Considering energy availability is critical for the offshore plant's operations. The plant relies on consistent and reliable energy sources to power 10 its equipment, machinery, and systems. In the proposed offshor present value locations, energy sources such as diesel generators and natural gas are sufficient. Several factors come into play when evaluating energy sources. These include the accessibility of the sources, the reliability of supply, and their cost-effectiveness. Diesel generators are known to provide reliable power, especially during emergencies or when primary power sources fail. However, they can be costly to operate and maintain, and their emissions raise environmental concerns. Natural gas, sourced from the Malampaya platform near our proposed site, will be utilized as a source of energy. Instead of Malampaya using their own produce to utilize electricity and provide energy for its operation, the proposed plant will be the one to utilize the natural gas to produce its own electricity while providing energy to Malampaya. The difference is that it is 99 percent cleaner and free of Carbon Dioxide emissions. 4. Climate a. Sea conditions Concerning sea conditions, seasonal variations driven by monsoon winds play a pivotal role. Sea surface temperatures typically range between 26 to 29 degrees Celsius, fostering a favorable environment for diverse marine activities. Salinity levels, averaging between 32 to 34 parts per thousand, contribute to the overall health of the marine ecosystem. 11  Sea currents predominantly exhibit weak speeds, measuring less than 0.5 meters per second, ensuring safe navigation and offshore operations. However, during the northeast monsoon season, currents intensify, reaching speeds of up to 1 meter per second, prompting cautious consideration for vessel stability and operational safety. Wave height and period, influenced by wind speed and direction, usually fluctuate between 1 to 2 meters and 5 to 7 seconds, respectively. These characteristics significantly impact offshore infrastructure design, mooring systems, and personnel safety measures. b. Weather patterns There are two distinct seasons and a tropical climate in Palawan. The rainy season, which runs from June to October, is distinguished by a lot of rainfall and frequent typhoons that bring with them higher humidity and colder temperatures. The dry season, from November to May, includes primarily sunny weather with occasional showers, warmer temperatures, and lower humidity. To ensure continuity and safety, these changing weather patterns must be considered when planning and scheduling CCS projects. 5. Transportation facilities Transportation facilities refers to the equipment and services that support the movement of people and products from one location to another. This may be in the form of tankers, barges and other vessels. Several considerations were taken into account in determining the most suitable type of transportation facility of the the following materials: 12 a. Raw Materials a. Air In oxy-fuel carbon capture and storage (OCCS) processes, air does not require a specialized transportation network since it is readily available at the capture site. Instead, air is simply drawn into the CCS facility through intake systems, where it undergoes a separation process to extract CO2. These intake ducts are designed to ensure a steady flow of air into the system for efficient CO2 removal. The process relies on the natural availability of air, eliminating the need for transportation logistics, unlike other raw materials in CCS systems. b. Natural gas Natural gas is processed before it can be safely transported through high-pressure pipelines in carbon capture and storage (CCS) systems. Initially, raw natural gas is gathered from production sites and sent to processing plants via small-diameter pipelines. At these plants, impurities such as water, sulfur, hydrogen sulfide, carbon dioxide, and hydrocarbon gas liquids (HGLs) are removed through various stages. These steps include separation of liquids, dehydration, and contaminant removal, ensuring the gas meets pipeline standards. After processing, clean, dry natural gas is ready for long-distance transport. 13 b. Product and Byproducts a. Carbon Dioxide (Product) The transport process involves moving the captured CO2 from the capture site to a storage site. CO2 can be transported via pipelines, ships, or trucks. Pipeline transportation is the most common method of CO2 transport and is cost-effective over long distances. Ships and trucks are typically used for short distances or in areas where pipelines are not feasible. b. Nitrogen and Argon (Byproduct) IndustryArc (2024) reported that Nitrogen and Argon are manufactured relatively in large quantities and are found in all three states of matter that are solid, liquid and gas. These gases are supplied to customers in the form of liquid or gas via cryogenic cylinders, gas cylinders, or glass bottles/ampules and are used in a variety of industries according to their physical and chemical properties. c. Manpower Operational effectiveness in the Palawan Basin depends on staff moving to and from offshore CCS facilities in an efficient manner. Rapid crew transfers, emergency medical evacuations, and the delivery of vital equipment are all common uses for helicopters. Their ability to immediately access offshore areas improves operational efficiency and 14  safety. The combination of sea and air transportation guarantees that offshore rigs are constantly staffed, and workers can be evacuated or rotated as necessary, highlighting the need for a well-integrated transportation system to support CCS activities in this region. Most employees are transported to and from the platform using either helicopters or crew boats, with the mode of transportation determined by prevailing weather conditions and weight limits. This means that if there are more employees to be transferred, a crew boat is the practical choice. 6. Water supply Water supply can be replenished through the treatment of the water generated during the capturing of carbon dioxide, with produced water being one of its resultant byproducts. Recycling produced water can significantly enhance water conservation efforts and reduce environmental impacts. Reports indicate that produced water holds potential for reuse in diverse applications, including irrigation, livestock watering, aquaculture, and industrial processes like cooling towers, fire suppression, and fracturing operations (Shahbaz et al., 2023). 7. Waste disposal For waste minimization, byproducts such as Argon and Nitrogen will be stored and transported to markets. However, the wastewater that will be produced during the oxyfuel carbon capture process can be captured and either treated for reuse or safely released into the environment, depending on the context and any contaminants present. 15 8. Labor supply Skilled and well-trained professionals in the oil and gas industry are essential for a productive processing operation. With the growing demand for energy supply, the industry experiences an expansion in job opportunities, presenting a promising outlook for skilled professionals seeking employment. 9. Taxation and legal restrictions According to the Department of Energy (DoE), the plant location of the Malampaya gas field governed by Presidential Decree (P.D.) 87, also referred to as the "Oil Exploration and Development Act of 1972," has an array of incentives that is extended to petroleum service contractors. These incentives encompass a service fee, which can reach up to 40% of net production, along with the reimbursement of costs, potentially covering up to 70% of gross production costs with the option to carry forward any unrecovered expenses. Additionally, there are FPIA grants available, amounting to up to 7.5% of gross proceeds for service contracts involving a minimum participation of 15% from Filipino companies. Furthermore, contractors benefit from exemption from all taxes except income tax, with the income tax being covered by the government's share. This tax exemption extends to all taxes and duties on imports of materials and equipment necessary for petroleum operations, streamlining logistical processes. Moreover, there are streamlined procedures for repatriating investments and profits, fostering a climate of investor confidence. The system allows for the 16 determination of crude oil prices through the dynamics of a free market, ensuring fair transactions between independent parties. However, there are also special income tax rates applicable, such as an 8% rate for subcontractors' gross Philippine income and a 15% rate for foreign employees of service contractors and subcontractors. These incentives collectively aim to not only encourage investment but also enhance operational efficiency and promote collaboration between local and foreign entities within the petroleum sector. 10.Site Characteristics The proposed plant location near the Malampaya platform is influenced by various site characteristics that impact its suitability for development. Understanding these factors is essential for effective planning, construction, and operation of the offshore facility. a. Topography The topography surrounding the offshore site near the Malampaya platform is characterized by the coastal landscape typical of offshore environments. The area may feature rugged terrain with undulating contours, influenced by the proximity to the shoreline and geological formations. Understanding the topography helps in determining suitable locations for infrastructure placement, anchorage points, and potential environmental impacts. b. Local Building Conditions Nearby to the offshore site, there may be limited local buildings, particularly on nearby coastal areas or islands. These structures could 17  include facilities related to marine operations, such as port facilities, dockyards, or support buildings for offshore activities. Understanding the proximity and functionality of these buildings is crucial for assessing logistical support, emergency response capabilities, and potential interactions with local communities c. Living Conditions Living conditions surrounding the offshore site near the Malampaya platform are primarily influenced by the presence of nearby coastal communities and marine activities. These communities may rely on fishing, marine transportation, and offshore industries for livelihoods. Understanding the socio-economic dynamics, cultural aspects, and living standards of these communities is essential for promoting positive stakeholder engagement, ensuring environmental stewardship, and addressing potential social impacts associated with plant development. Furthermore, living conditions may be affected by access to essential services such as healthcare, education, and infrastructure. Consideration of these factors helps in assessing the overall impact of the proposed plant on local communities and identifying opportunities for collaborative initiatives, capacity building, and community development. 11. Flood and fire protection Offshore platforms must address flood protection, especially during extreme weather events like typhoons or storm surges. These structures need to be engineered to endure high waves, rising sea levels, and water 18  intrusion. To reduce flood risks, the platforms should be elevated, ensuring critical equipment remains above possible flood levels. The structural design must incorporate drainage systems to manage excess water from rain or wave splashes. Additionally, regular inspection and maintenance of watertight seals, barriers, and mooring systems are important to maintain the platform's flood resilience. The plant will also utilize the Fire and Gas System and Burner Management System by Yokogawa, the same company that delivered all safety systems in Malampaya. A fire and gas safety system ensures the safety of personnel and plant equipment by detecting unsafe conditions before causing potentially serious harm. Meanwhile, the burner management system’s burner shut-off system is employed for incinerators, furnaces, and boilers, including a safety shut-off mechanism to prevent explosion and ensure plant safety. Rest assured that the necessary firewater system, emergency response equipment, and evacuation plans will be present in the design of the plant. 12.Community factors Sites selected for CO2 storage should be properly characterized. Site characterization is a continuous and iterative process that starts usually with existing data, particularly at the basin and/or regional scale, and proceeds with the acquisition of new data and information during all the stages of a CCS project relating to the site (Bachu et al., 2009). Distinguishing the parameters of the area is essential not only for exact 19  assessment of site features but also to improve the community’s state of infrastructures, thereby developing the overall quality of life. As these manufacturing sites emerge, the community will experience a boost in economy, increase job opportunities, and account to their collective taxes which may escalate their LGUs investments for better service. Community factors are necessary for ensuring positive relations and sustainable development. Understanding the socio-economic dynamics of nearby coastal communities is essential, as these areas often rely on marine resources for their livelihoods, such as fishing and tourism. Engaging with local stakeholders early in the planning process helps address community concerns, potential job opportunities, and the impact on local industries. Cultural practices within these communities must also be respected, ensuring that development does not disrupt traditional ways of life. C. Literature Review According to the study A review on the progress and prospects of oxy-fuel carbon capture and sequestration (CCS) technology of Yadav and Mondal (2021), the rapid increase in greenhouse gas concentrations has raised significant environmental concerns, as these gasses are primarily responsible for global warming. Reducing greenhouse gas levels can be achieved through more efficient energy use, adopting alternative fuels and renewable energy, and utilizing carbon capture and storage (CCS) technologies. CCS methods are categorized into pre-combustion, post-combustion, and oxy-fuel combustion 20 techniques, which are used to capture CO2 emissions. The oxy-fuel combustion technique, introduced by Abraham in 1982 for enhanced oil recovery (EOR), has gained growing attention due to its potential to significantly reduce CO2 emissions. As global awareness of climate change has increased, oxy-fuel combustion has emerged as a leading method among researchers for combating CO2 emissions. Oxyfuel combustion is a key technology for carbon dioxide (CO2) capture and storage (CCS) in fossil-fuel-based power systems, aimed at reducing global greenhouse gas (GHG) emissions. Integrating oxyfuel combustion into power systems alters the physical and chemical processes compared to traditional combustion, with the energy penalties associated with CCS significantly affecting system operation and performance, including combustion processes, heat transfer, flue gas characteristics, and emissions control. Over the past decade, numerous projects focused on oxyfuel technology have been initiated globally, and ongoing techno-economic assessments continue to compare it with other competing technologies such as pre- and post-combustion methods and newer innovations (Hu and Yan, 2015). One important method for capturing CO2 is oxyfuel combustion. By burning fuel with almost pure oxygen rather than air during this process, a flue gas high in CO2 and water vapor is produced. A percentage of the flue gas is recycled back into the boiler or furnace to control the flame temperature. The flue gas's high CO2 concentration makes it possible to separate it using low-temperature purification techniques and dehydration. An Air Separation Unit 21 (ASU) for producing oxygen, a boiler or gas turbine for fuel combustion and heat generation, a Flue Gas Processing Unit for cleaning or controlling gas quality, and a CO2 generator are the main parts of the oxyfuel combustion processing Unit (CPU) for the last stage of CO2 purification before storage and transportation. Oxyfuel combustion is used in two different ways in coal-fired power plants: as oxy-PC and oxy-CFB. In gas turbine-based power plants, it is classified as either CO2-based or water-based gas turbine cycles depending on the working fluid (Stanger et al., 2015). The study titled A Life Cycle Assessment Study of a Hypothetical Canadian Oxy-Fuel Combustion Carbon Dioxide Capture Process by Koiwanit et al. (2014) highlights that fossil fuels will continue to play a key role in global energy supply for the foreseeable future, but without proper controls, carbon dioxide (CO2) emissions will keep rising, posing significant risks to both human health and the environment. This underscores the need for effective CO2 capture technologies to reduce emissions. However, since these systems require additional energy and raw materials to operate, it is essential to assess the environmental impact across the entire CO2 capture life cycle. The study uses life cycle assessment (LCA) to compare a hypothetical oxy-fuel combustion CO2 capture system in Saskatchewan, Canada, with a lignite coal-fired power plant that lacks such a system. By applying the TRACI life cycle impact assessment (LCIA) method, the study translates inventory data into environmental outcomes. The findings reveal that capturing particulate matter, trace elements, CO2, and acid gasses results in reduced global warming potential and improved air quality. 22  However, the captured emissions, when landfilled, eventually leach into soil and groundwater, increasing environmental impacts related to water and soil contamination. D. Process Indicators and Reliability Process indicators are measurable parameters or metrics employed to evaluate the condition, effectiveness, and functionality of different processes within the facility. These indicators encompass elements like temperature, pressure, flow rates, concentrations of chemicals, equipment performance, and the output of production. Process reliability is the capacity of a process to consistently and efficiently fulfill its intended function throughout its operational lifespan without experiencing failures. This entails ensuring that the plant runs within designated parameters, achieves the desired output quality and quantity, and minimizes downtime and maintenance needs. 1. Separation Bulk production of atmospheric air is drawn into the ASU. The air is compressed from atmospheric pressure at 6 atm at the compressor to make the subsequent cooling and separation processes more efficient. The compressed air is cooled down to cryogenic temperature, ranging between -186°C to -197°C, to liquify the air, as cryogenic distillation relies on the differences in boiling points of the various components. The liquified air is then separated into oxygen, nitrogen, and argon based on their boiling points using a distillation column. As the air ascends the column, it is gradually warmed, and oxygen-rich vapor rises to the top of the column, nitrogen-rich liquid collects at the bottom, while the 23  argon is extracted as a side product at an intermediate point in the column (Cryospain, 2023). 2. Combustion A mixture of natural gas and pure oxygen, supplied from the air separation unit, is introduced into the combustion chamber, replacing air as the oxidizing agent. According to the National Energy Technology Laboratory (n. d.), advanced oxy-combustion systems can be configured in either low- or high-temperature boiler designs. In low-temperature designs, flame temperatures are like that of air-fired combustion (~3,000°F), while flame temperatures exceed 4,500°F in the advanced high-temperature design. Low-temperature designs for new or retrofit applications recycle combustion products to lower the flame temperature to approximate the heat transfer characteristics of air-fired boilers. In high-temperature oxy-fuel combustion processes, fuel and oxygen are mixed at the burner undiluted with recycled flue gas, except to motivate coal for coal-fired systems. This process can result in a high flame temperature (>4,500°F), which enhances heat transfer in the radiant zone of the boiler. By using pure oxygen instead of air, the combustion process occurs in an oxygen-rich environment, which enhances the efficiency of the reaction. When natural gas is combusted in this highly oxygenated atmosphere, it produces a flue gas primarily composed of carbon dioxide (CO2), water vapor and traces of impurities. In addition to these gases, a portion of the flue gas is recycled back into the system. This recycled flue gas plays a crucial role in moderating the high combustion temperatures generated during the process, preventing overheating and ensuring controlled 24  combustion. The water vapor produced in the boiler as a result of this combustion is then directed toward a steam turbine, where it is used to generate electricity by driving the turbine blades (Adams, 2014). 3. Filtration After the combustion process, the impurities contained in the natural gas are filtered in the gas filter. Subsequently, a large portion of the flue gas is recycled back to the boiler to control the flame temperature and to reconstitute the flue gas volume to ensure proper heat transfer (Wall et al., 2005). The gas that remains after these steps, primarily consisting of carbon dioxide (CO2) and water vapor, is then classified as treated flue gas, indicating that it has been properly processed and is now ready for disposal or further use. 4. Condensation The remaining flue gas passes through a condenser (Hongfen, 2023). The process involves separating CO2 from water vapor, which is commonly referred to as effluent water. This water vapor, having been removed from the gas stream, is typically considered a waste product and is designated for disposal or can be considered for plant use if treated. Meanwhile, the remaining CO2 is efficiently captured and directed toward the cryogenic compressor for further cooling and compression. 5. Compression For dry compression of CO2, the reciprocating compressor is particularly well-suited for this type of application because of its robust design and ability to handle gases under high pressures with remarkable efficiency. Unlike other types 25 of compressors, reciprocating compressors use a piston-driven mechanism, which allows for precise control over the compression process in each stage. This piston movement ensures that gases, such as CO2, are compressed in a controlled manner, gradually increasing the pressure to the desired levels. The design of the reciprocating compressor allows it to maintain consistent performance even under varying load conditions, making it highly reliable for industrial applications where high-pressure gas handling is critical. In addition to its efficiency at high pressures, the reciprocating compressor’s ability to deliver precise pressure regulation during each stage of compression ensures that the gas mixture is processed uniformly, minimizing the risk of inefficiencies or energy waste (Cengel, Y. A., & Boles, M. A., 2014) For the liquefied CO2 compression, a two-stage intercooler compressor is employed. In this system, the CO2 is compressed in two distinct stages. After the first stage of compression, the gas passes through an intercooler, which reduces its temperature before the second stage of compression. By cooling the gas between stages, the system reduces the energy needed for the second compression step and improves overall efficiency. By cooling and compressing the CO2 to its liquefaction point using this two-stage intercooler compressor, it becomes possible to isolate it from other gases with high efficiency. This method is particularly effective for producing CO2 with high purity, making it valuable in applications where a concentrated form of gas is required. The precision of temperature and pressure control in the compression stages ensures that the CO2 is separated with minimal impurities. 26 Additionally, the high-purity CO2 obtained from this process is often used in Enhanced Oil Recovery (EOR) to increase the extraction efficiency of oil reservoirs (Perry, R. H., & Green, D. W., 2008). 27  CHAPTER II DESIGN OBJECTIVES The main objective of this study is to Reduce Carbon Footprints Through Carbon capture and Sequestration Solutions in Palawan Basin. Specifically, this study aims to: 1. Formulate and design visual flow diagrams of the proposed plant, with several alternatives and detailed material balances in justification for their viability and efficiency. 2. Identify the technical specifications of the facilities/equipment involved in the process considering the various design alternatives, with remuneration on factors such as: 2.1 Reduction Efficiency 2.2. Design Specifications 3. Perform an economic analysis of the proposed designed plants, specifically to determine the following variables/measurements: 3.1. OPEX and CAPEX 3.2. Payback Period 3.3. ROI 3.4. Net Present Value 4. To develop an environmental and safety management of the project that assesses the different design options' environmental and social impact 4.1 Waste Treatment and Disposal Techniques 4.2 Amount of Waste Generated 28 5. To integrate sustainable practices into the design, prioritizing energy-efficient solutions to minimize resource consumption and environmental impact. 5.1 Energy Consumption Reduction 6. Develop a detailed project construction and execution plan. 29  CHAPTER III TECHNICAL DESIGN AND REQUIREMENTS This chapter shall include the preparation of the complete layout of the offshore processing plant taking into consideration the different equipment used in the processes. For each design option, mass balance and energy balance shall be done to come up with the required capacity and technical specifications. Standards and design trade-offs shall be used to come up with a technically viable design. Technical catalogs and other monographs shall be used to carefully identify the design specifications of each equipment. Provide the detailed calculations. Figure 3. Alternative 1 - Block Flow Diagram 30 Figure 4. Alternative 1 - Qualitative Process Flow Diagram 31 Figure 5. Alternative 1 - Quantitative Process Flow Diagram 32 Figure 6. Alternative 1 - Piping and Instrumentation Diagram 33  Figure 7. Alternative 2 - Block Flow Diagram Figure 8. Alternative 2 - Qualitative Process Flow Diagram 34 Figure 9. Alternative 2 - Quantitative Process Flow Diagram 35 Figure 10. Alternative 2 - Piping and Instrumentation Diagram 36  Figure 11. Alternative 3 - Block Flow Diagram Figure 12. Alternative 3 - Qualitative Process Flow Diagram 37 Figure 13. Alternative 3 - Quantitative Process Flow Diagram 38 Figure 14. Alternative 3 - Piping and Instrumentation Diagram 39  MATERIAL BALANCE Atmospheric Air Feed The composition of the atmospheric air mainly consists of nitrogen (78%), oxygen (21%), and argon (1%) (National Geographic Society, 2023). Given this composition, cryogenic air separation plants are able to extract and produce these gases, most importantly, oxygen. Modern cryogenic air separation units can generate up to 150 tons of oxygen per day (Wu et al., 2018). This data served as a basis for the amount of atmospheric air feed used. Determining the whole composition of air feed: Mass of Air Feed = 150 tons/0.21 = 714.2857 tons Mass of Nitrogen = 714.2857 tons (0.78) = 557.1428 tons Mass of Argon = 714.2857 tons (0.01) = 7.1429 tons Natural Gas Feed According to the Environmental Protection Agency (n.d.), pipeline quality natural gas must be composed of 98% methane and other hydrocarbons with traces of impurities. The amount of methane that is required for complete combustion is determined from the amount of oxygen given. The mol ratio of methane and oxygen is 1:2, as shown in the chemical formula below. CH4 + 2O2 → CO2 + 2H2O + Heat Converting mass of oxygen to mol: Mass of O2 = 146.775 tons = 146,775,000 g Molar Mass of O2 = 16 g/mol (2) = 32 g/mol 40  Mol of O2 = 146,775,000 g/32 g/mol Mol of O2 = 4,586,718.75 mol Determining the mol of methane required using the mol ratio: Mol of CH4 Required = 4,586,718.75 mol O2 (0.5) = 2,293,359.375 mol CH4 Converting mol of methane to mass: Molar Mass of CH4 = 12 g/mol + 1 g/mol (4) = 16 g/mol Mass of CH4 = 2,293,359.375 mol (16 g/mol) = 36,693,750 g = 36.6938 tons Determining the whole composition of natural gas: Mass of Natural Gas Feed = 36.6938 tons/0.98 = 37.4427 tons Mass of Other Hydrocarbons = 37.4427 tons (0.0199) = 0.7451 tons Mass of Impurities = 37.4427 tons (0.0001) = 0.0037 tons 41  Mass Balance Calculations Equipment: Air Separator with 91.11% Efficiency Purpose: To separate oxygen, argon, and nitrogen from the air feed. Design Alternative 1, 2 and 3 Computing for the mass balance of the equipment: MIN = MOUT + MLOSS Computing for input mass: MIN = MAir MAir = MN2 + MO2 + MAr MAir = 557.1428 tons/day + 150.0000 tons/day + 7.1429 tons/day MAir = 714.2857 tons/day 42  MIN = 714.2857 tons/day Computing for output mass: MOUT = MO2 + MAr + MN2 Oxygen has a recovery rate of 97.85% in the air separator (Wu et al., 2018). MO2 = 150.0000 tons/day (0.9785) MO2 = 146.7750 tons/day Argon has a recovery rate of 95% in the air separator (Comi Polaris Systems, n.d.). MAr = 6.7858 tons/day (0.95) MAr = 6.7858 tons/day Nitrogen has a recovery rate of 0.72 mol/mol of air (Agrawal & Woodward, 1991). Using the respective molar mass of nitrogen and air, the nitrogen recovery rate of 89.25% was determined. Molar Mass of N2 = 14 g/mol (2) = 28 g/mol Molar Mass of Air = 28.96 g/mol Nitrogen Recovery Rate (Mass) = (0.72 mol N2/1 mol Air) (28 g N2/1 mol N2) (1 mol Air/28.96 g Air) Nitrogen Recovery Rate (Mass) = 20.16 g N2/28.96 g Air Nitrogen Recovered = 714,285,700 g Air (20.16 g N2/28.96 g Air) Nitrogen Recovered = 497,237,559.1160 g N2 = 497.2376 tons Nitrogen Recovery Rate (Percent) = (497.2376 tons N2 Recovered/557.1428 tons N2 Feed) (100) Nitrogen Recovery Rate (Percent) = 89.25% 43  MN2 = 557.1428 tons/day (0.8925) MN2 = 497.2499 tons/day MOUT = 146.7750 tons/day + 6.7858 tons/day + 497.2499 tons/day MOUT = 650.8107 tons/day Computing for losses: MLOSS = MN2 + MO2 + MAr Unrecoverable gases are assigned as losses of the equipment. MLOSS = 557.1427 tons/day (0.1075) + 150.0000 tons/day (0.0215) + 7.1429 tons/day (0.05) MLOSS = 58.8929 tons/day + 3.2250 tons/day + 0.3571 tons/day MLOSS = 63.4750 tons/day 714.2857 tons/day = 650.8107 tons/day + 63.4750 tons/day 714.2857 tons/day = 714.2857 tons/day Equipment: Boiler with 99.60% Efficiency Purpose: To combust natural gas and oxygen for the production of steam and flue gas. Design Alternative 1 and 2 44 Computing for the mass balance of the equipment: MIN = MOUT + MLOSS Computing for input mass: MIN = MO2 + MNatural gas MNatural gas = MCH4 + MOther hydrocarbons + MImpurities MNatural gas = 36.6938 tons/day + 0.7451 tons/day + 0.0037 tons/day MNatural gas = 37.4426 tons/day MIN = 146.7750 tons/day + 37.4426 tons/day MIN = 184.2176 tons/day Computing for output mass: MOUT = MSteam + MFlue gas + MRecycled flue gas Complete combustion of methane and oxygen produces carbon dioxide, water vapor, and heat. CH4 + 2O2 → CO2 + 2H2O + Heat The amount of carbon dioxide and water vapor produced can be calculated based on the determined amount of methane and their respective molar mass. 16 g/mol CH4 + 64 g/mol O2 → 44 g/mol CO2 + 36 g/mol H2O + Heat Molar Mass of CH4 = 12 g/mol + 1 g/mol (4) = 16 g/mol Molar Mass of CO2 = 12 g/mol + 16 g/mol (2) = 44 g/mol Amount of CO2 = (36,693,750 g CH4/16 g/mol CH4) (44 g/mol CO2) Amount of CO2 = 100,907,812.5000 g = 100.9078 tons Molar Mass of H2O = 2 [1 g/mol (2) + 16 g/mol] = 36 g/mol 45  Amount of H2O = (36,693,750 g CH4/16 g/mol CH4) (36 g/mol H2O) Amount of H2O = 82,560,937.5000 g = 82.5609 tons 36,693,750 g CH4 + 146,775,000 g O2 → 100,907,812.5000 g CO2 + 82,560,937.5000 g H2O 183,468,750 g = 183,468,750 g Steam produced is 70% based on electric production efficiency of oxy-fuel combustion process (Kindra et al., 2023). MSteam = 82.5609 tons/day (0.70) MSteam = 57.7926 tons/day The flue gas recycle ratio is 70% in boiler designs of oxy-fuel combustion plants (Axelbaum et al., 2021). Therefore, the remaining water vapor will be further separated, as well as the carbon dioxide stream. MFlue gas = MCO2 + MH2O + MImpurities MFlue gas = 100.9078 tons/day (0.30) + 24.7683 tons/day (0.30) + 0.0037 tons/day MFlue gas = 37.7065 tons/day MRecycled flue gas = MCO2 + MH2O MRecycled flue gas = 100.9078 tons/day (0.70) + 24.7683 tons/day (0.70) MRecycled flue gas = 87.9733 tons/day MOUT = 57.7926 tons/day + 37.7065 tons/day + 87.9733 tons/day MOUT = 183.4724 tons/day Computing for losses: MLOSS = MUnburnt fuel Unburnt fuels are assigned as losses of the equipment. 46  MLOSS = 0.7451 tons/day 184.2176 tons/day = 183.4724 tons/day + 0.7451 tons/day 184.2176 tons/day = 184.2176 tons/day Equipment: Turbine with 75% Efficiency Purpose: To convert the steam produced by the boiler into electricity. Design Alternative 1, 2 and 3 Computing for the mass balance of the equipment: MIN = MOUT + MLOSS Computing for input mass: MIN = MSteam MIN = 57.7926 tons/day Computing for output mass: MOUT = MFlue gas The efficiency of a typical steam turbine is 75% (MacFarlane, 2021). MFlue gas = 57.7926 tons/day (0.75) MFlue gas = 43.3445 tons/day 47  MOUT = 43.3445 tons/day Computing for losses: MLOSS = MEntrained MEntrained = 57.7926 tons/day (0.25) MEntrained = 14.4482 tons/day MLOSS = 14.4482 tons/day 57.7926 tons/day = 43.3445 tons/day + 14.4482 tons/day 57.7926 tons/day = 57.7926 tons/day Equipment: Condenser with 87.05% Efficiency Purpose: To separate pure carbon dioxide with the waste water. Design Alternative 1 and 2 Computing for the mass balance of the equipment: MIN = MOUT + MLOSS Computing for input mass: MIN = MFlue gas MFlue gas = MCO2 + MH2O + MImpurities 48  MFlue gas = 30.2723 tons/day + 7.4305 tons/day + 0.0037 tons/day MFlue gas = 37.7065 tons/day MIN = 37.7065 tons/day Computing for output mass: MOUT = MCO2 + MEffluent water 90% of the carbon dioxide must be captured in this equipment (Moseman, 2021). MCO2 = 30.2723 tons/day (0.95) MCO2 = 27.2451 tons/day According to Takami et al. (2019), 75% of the water content in the flue gas stream can be condensed. Furthermore, the condensed water is separated along with the impurities present in the gases (Brunetti et al., 2019). MEffluent water = MH2O + MImpurities MEffluent water = 7.4305 tons/day (0.75) + 0.0037 tons/day MEffluent water = 5.5766 tons/day MOUT = 27.2451 tons/day + 5.5766 tons/day MOUT = 32.8217 tons/day Computing for losses: MLOSS = MEntrained MEntrained = 30.2723 tons/day (0.10) + 7.4305 tons/day (0.25) MEntrained = 4.8848 tons/day MLOSS = 4.8848 tons/day 49 37.7065 tons/day = 32.8217 tons/day + 4.8848 tons/day 37.7065 tons/day = 37.7065 tons/day Equipment: Reciprocating Compressor with 90% Efficiency Purpose: To pressurize pure carbon dioxide for storage and utilization purposes. Design Alternative 1 Computing for the mass balance of the equipment: MIN = MOUT + MLOSS Computing for input mass: MIN = MCarbon dioxide MCarbon dioxide = 27.2451 tons/day MIN = 27.2451 tons/day Computing for output mass: MOUT = MDry carbon dioxide 90% of the carbon dioxide can be produced in a dry base form (Peters et al., 2002). 50  MDry carbon dioxide = 27.2451 tons/day (0.90) MDry carbon dioxide = 24.5206 tons/day MOUT = 24.5206 tons/day Computing for losses: MLOSS = MEntrained MEntrained = 27.2451 tons/day (0.10) MEntrained = 2.7245 tons/day MLOSS = 2.7245 tons/day 27.2451 tons/day = 24.5206 tons/day + 2.7245 tons/day 27.2451 tons/day = 27.2451 tons/day Equipment: Two-Stage Intercooling Compressor with 99.99% Efficiency Purpose: To liquefy pure carbon dioxide for storage and utilization purposes. Design Alternative 2 and 3 51 Computing for the mass balance of the equipment: MIN = MOUT + MLOSS Computing for input mass: MIN = MCarbon dioxide MCarbon dioxide = 27.2451 tons/day MIN = 27.2451 tons/day Computing for output mass: MOUT = MDry carbon dioxide 99.99% of the carbon dioxide can be produced in a liquid base form (Lijin et al., 2024). MDry carbon dioxide = 27.2451 tons/day (0.9999) MDry carbon dioxide = 27.2424 tons/day MOUT = 27.2424 tons/day Computing for losses: MLOSS = MEntrained MEntrained = 27.2451 tons/day (0.0001) MEntrained = 0.0027 tons/day MLOSS = 0.0027 tons/day 27.2451 tons/day = 24.2424 tons/day + 0.0027 tons/day 27.2451 tons/day = 27.2451 tons/day 52 Equipment: Boiler with 99.60% Efficiency Purpose: To combust natural gas and oxygen for the production of steam and flue gas. Design Alternative 3 Computing for the mass balance of the equipment: MIN = MOUT + MLOSS Computing for input mass: MIN = MO2 + MNatural gas MNatural gas = MCH4 + MOther hydrocarbons + MImpurities MNatural gas = 36.6938 tons/day + 0.7451 tons/day + 0.0037 tons/day MNatural gas = 37.4426 tons/day MIN = 146.7750 tons/day + 37.4426 tons/day MIN = 184.2176 tons/day Computing for output mass: MOUT = MSteam + MFlue gas Complete combustion of methane and oxygen produces carbon dioxide, water vapor, and heat. CH4 + 2O2 → CO2 + 2H2O + Heat 53  The amount of carbon dioxide and water vapor produced can be calculated based on the determined amount of methane and their respective molar mass. 16 g/mol CH4 + 64 g/mol O2 → 44 g/mol CO2 + 36 g/mol H2O + Heat Molar Mass of CH4 = 12 g/mol + 1 g/mol (4) = 16 g/mol Molar Mass of CO2 = 12 g/mol + 16 g/mol (2) = 44 g/mol Amount of CO2 = (36,693,750 g CH4/16 g/mol CH4) (44 g/mol CO2) Amount of CO2 = 100,907,812.5000 g = 100.9078 tons Molar Mass of H2O = 2 [1 g/mol (2) + 16 g/mol] = 36 g/mol Amount of H2O = (36,693,750 g CH4/16 g/mol CH4) (36 g/mol H2O) Amount of H2O = 82,560,937.5000 g = 82.5609 tons 36,693,750 g CH4 + 146,775,000 g O2 → 100,907,812.5000 g CO2 + 82,560,937.5000 g H2O 183,468,750 g = 183,468,750 g Steam produced is 70% based on electric production efficiency of oxy-fuel combustion process (Kindra et al., 2023). MSteam = 82.5609 tons/day (0.70) MSteam = 57.7926 tons/day MFlue gas = MCO2 + MH2O + MImpurities MFlue gas = 100.9078 tons/day + 24.7683 tons/day + 0.0037 tons/day MFlue gas = 125.6798 tons/day MOUT = 57.7926 tons/day + 125.6798 tons/day MOUT = 183.4724 tons/day 54  Computing for losses: MLOSS = MUnburnt fuel Unburnt fuels are assigned as losses of the equipment. MLOSS = 0.7451 tons/day 184.2176 tons/day = 183.4724 tons/day + 0.7451 tons/day 184.2176 tons/day = 184.2176 tons/day Equipment: Electrostatic Precipitator (Gas Filter) with 98% Efficiency Purpose: To filter flue gas and remove impurities Design Alternative 3 Computing for the mass balance of the equipment: MIN = MOUT + MLOSS Computing for input mass: MIN = MFlue gas MFlue gas = MCO2 + MH2O + MImpurities MFlue gas = 100.9078 tons/day + 24.7683 tons/day + 0.0037 tons/day MFlue gas = 125.6798 tons/day 55  MIN = 125.6798 tons/day Computing for output mass: MOUT = MTreated Flue gas + MRecycled flue gas + MRemoved impurities The flue gas recycle ratio is 70% in boiler designs of oxy-fuel combustion plants (Axelbaum et al., 2021). Therefore, the remaining water vapor will be further separated, as well as the carbon dioxide stream. MTreated Flue gas = MCO2 + MH2O MTreated Flue gas = 100.9078 tons/day (0.30) + 24.7683 tons/day (0.30) MTreated Flue gas = 37.7028 tons/day MRecycled flue gas = MCO2 + MH2O MRecycled flue gas = 100.9078 tons/day (0.70) + 24.7683 tons/day (0.70) MRecycled flue gas = 87.9733 tons/day The impurities removal efficiency is 98% in electrostatic precipitators (Ke Sun et al., 2019). Therefore, the treated flue gas will be separated and pumped directly to the condenser while the remaining 70% of the flue gas will be recycled to the boiler. MRemoved impurities = 0.0037 tons/day (.98) MRemoved impurities = 0.0036 tons/day MOUT = 37.7028 tons/day + 87.9733 tons/day + 0.0036 tons/day MOUT = 125.6797 tons/day Computing for losses: MLOSS = MEntrained 2% of the unfiltered impurities are assigned to losses: 56  MLOSS = 0.001 tons/day 125.6798 tons/day = 125.6797 tons/day + 0.001 tons/day 125.6798 tons/day = 125.6798 tons/day Equipment: Condenser with 87.05% Efficiency Purpose: To separate pure carbon dioxide with the waste water. Design Alternative 3 Computing for the mass balance of the equipment: MIN = MOUT + MLOSS Computing for input mass: MIN = MFlue gas MFlue gas = MCO2 + MH2O MFlue gas = 30.2723 tons/day + 7.4305 tons/day MFlue gas = 37.7028 tons/day MIN = 37.7028 tons/day Computing for output mass: MOUT = MCO2 + MEffluent water 57  90% of the carbon dioxide must be captured in this equipment (Moseman, 2021). MCO2 = 30.2723 tons/day (0.95) MCO2 = 27.2451 tons/day According to Takami et al. (2019), 75% of the water content in the flue gas stream can be condensed. Furthermore, the condensed water is separated (Brunetti et al., 2019). MEffluent water = MH2O MEffluent water = 7.4305 tons/day (0.75) MEffluent water = 5.5729 tons/day MOUT = 27.2451 tons/day + 5.5729 tons/day MOUT = 32.8180 tons/day Computing for losses: MLOSS = MEntrained MEntrained = 30.2723 tons/day (0.10) + 7.4305 tons/day (0.25) MEntrained = 4.8848 tons/day MLOSS = 4.8848 tons/day 37.7028 tons/day = 32.8180 tons/day + 4.8848 tons/day 37.7028 tons/day = 37.7028 tons/day 58  ENERGY BALANCE During the process design phase, energy assessments are conducted to ascertain the energy demands of the operation, encompassing heating, cooling, and power necessities. In the operational phase, analyzing the energy distribution throughout the plant offers insights into usage patterns, pinpointing opportunities for conservation and cost savings. It is important to determine the feeds of the process, their mass flow rates, and specific heat capacity to accommodate the computation of energy balance. Table 2. Heat Capacities of Feed Materials Specific Heat Capacity , 𝐾𝐽 𝐾𝑔・𝐾 Air 1.005 Natural Gas 2.22 H2O 1.93 CO2 0.85 Impurities (H2S) 1.01 The flowrate in the previous mass balance (ton/day) is converted to kilograms per hour (kg/hr). 59 Equipment: Air Separator Design Alternative 1, 2 and 3 Conversion of mass input flow rates: MIN = 714.2857 tons/day MIN = 714.2857 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 29,761.9042 kg/hr Conversion of mass output flow rates: MOUT = 146.7750 tons/day + 6.7858 tons/day + 497.2499 tons/day MOUT = 146.7750 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 6,115.6250 kg/hr MOUT = 6.7858 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 282.7417 kg/hr MOUT = 497.2499 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 20,718.7458 kg/hr 60  Conversion for losses: MLOSS = 63.4750 tons/day MLOSS = 63.4750 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MLOSSES = 2,644.7917 kg/hr Q = mcpΔ T QIN = QOUT 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 QIN = ((29,761.9041 ℎ𝑟 ✕ 1.005 𝐾𝑔・𝐾 )) (205 K) ( 3600 𝑠 ) QIN = 1,703.2490 KW 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QOUT = ((6,115.6250 ℎ𝑟 ✕ 1.005 𝐾𝑔・𝐾 ) + (282.7417 ℎ𝑟 ✕ 1.005 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 (20,718.7458 ℎ𝑟 ✕ 1.005 𝐾𝑔・𝐾 ) + (2,644.7917 ℎ𝑟 ✕ 1.005 𝐾𝑔・𝐾 ) (205 K) ( 1 ℎ𝑜𝑢𝑟 3600 𝑠 ) QOUT = 1,703.2490 KW 1,703.2490 KW = 1,703.2490 KW Equipment: Boiler Design Alternative 1 and 2 61 Conversion of mass input flow rates: MIN = 146.7750 tons/day + 36.6938 tons/day + 0.7451 tons/day + 0.0037 tons/day MIN = 146.7750 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 6,115.6250 kg/hr MIN = 36.6938 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 1,528.9083 kg/hr MIN = 0.7451 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 31.0458 kg/hr MIN = 0.0037 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 0.1542 kg/hr Conversion of mass output flow rates: MOUT = 57.7926 tons/day + 30.2723 tons/day + 7.4305 tons/day + 0.0037 tons/day + 70.6355 tons/day +17.3378 tons/day MOUT = 57.7926 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 2,408.0250 kg/hr MOUT = 30.2723 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 1,261.3458 kg/hr MOUT = 7.4305 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 309.6042 kg/hr MOUT = 0.0037 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 0.1542 kg/hr MOUT = 70.6355 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 2,943.1458 kg/hr 62  MOUT = 17.3378 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 722.4083 kg/hr Conversion for losses: MLOSS = 0.7452 tons/day MLOSS = 0.7452 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MLOSS = 31.0500 kg/hr Q = mcpΔ T QIN = QOUT 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QIN = ((6,115.625 ℎ𝑟 ✕ 0.92 𝐾𝑔・𝐾 ) + (1,528.9083 ℎ𝑟 ✕ 2.22 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 (31.0458 ℎ𝑟 ✕ 2.22 𝐾𝑔・𝐾 ) + (0.1542 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 ) ) (120 K)( 3600 𝑠 ) QIN = 302.9923 KW 𝑘𝑔 𝐾𝐽 𝐾𝐽 QOUT = ((2,408.0250 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 ) + (1,261.3458 ✕ 0.85 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 (309.6042 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 ) + (0.1542 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 (2,943.1458 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 ) + (722.4083 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 ) 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 (31.05 ℎ𝑟 ✕ 0.92 𝐾𝑔・𝐾 ) ) (120 K)( 3600 𝑠 ) QOUT = 302.9923 KW 302.9923 KW = 302.9923 KW 63 Equipment: Turbine Design Alternative 1, 2 and 3 Conversion of mass input flow rates: MIN = 57.7926 tons/day MIN = 57.7926 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 2,408.0250 kg/hr Conversion of mass output flow rates: MOUT = 43.3445 tons/day MOUT = 43.3445 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 1,806.0208 kg/hr Conversion for losses: MLOSS = 14.4482 tons/day MLOSS = 14.4482 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MLOSS = 602.0083 kg/hr Q = mcpΔ T QIN = QOUT 64  𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 QIN = ((2,408.0250 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )) (30 K) ( 3600 𝑠 ) QIN = 38.7291 KW 𝑘𝑔 𝐾𝐽 𝐾𝐽 QOUT = ((1,806.0208 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 ) + (602.0083 kg/hr ✕ 1.93 𝐾𝑔・𝐾 )) (30 K) 1 ℎ𝑜𝑢𝑟 ( 3600 𝑠 ) QOUT = 38.7291 KW 38.7291 KW = 38.7291 KW Equipment: Condenser Design Alternative 1 and 2 Conversion of mass input flow rates: MIN = 30.2723 tons/day + 7.4342 tons/day MIN = 30.2723 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 1,261.3458 kg/hr MIN = 7.4305 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 309.6042 kg/hr MIN = 0.0037 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours 65 MIN = 0.1542 kg/hr Conversion of mass output flow rates: MOUT = 27.2451 tons/day + 5.5766 tons/day MOUT = 27.2451 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 1,135.2125 kg/hr MOUT = 5.5729 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 232.2041 kg/hr MOUT = 7.4305 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 309.6042 kg/hr Conversion for losses: MLOSS = 3.0272 tons/day + 1.8576 tons/day MLOSS = 3.0272 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MLOSS = 126.1333 kg/hr MLOSS = 1.8576 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MLOSS = 77.4000 kg/hr Q = mcpΔ T QIN = QOUT 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QIN = ((1,261.3458 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 ) + (309.6042 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 (0.1542 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )(5 K) ( 3600 𝑠 ) QIN = 2.3194 KW 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QOUT = ((1,135.2125 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 ) + ( 232.2041 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 (309.6042 ℎ𝑟 ✕ 1.01 𝐾𝑔・𝐾 ) + (126.1333 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 )+ 66  𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 ( 77.4000 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )) (5 K) ( 3600 𝑠 ) QOUT = 2.3194 KW 2.3194 KW = 2.3194 KW Equipment: Reciprocating Compressor Design Alternative 1 Conversion of mass input flow rates: MIN = 27.2451 tons/day MIN = 27.2451 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 1,135.2125 kg/hr Conversion of mass output flow rates: MOUT = 24.5206 tons/day MOUT = 24.5206 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 1,021.6917 kg/hr Conversion for losses: MLOSS = 2.7245 tons/day MLOSS = 2.7245 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours 67 MLOSS = 113.5208 kg/hr Q = mcpΔ T QIN = QOUT 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 QIN = ((1,135.2125 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 )) (100 K) ( 3600 𝑠 ) QIN = 26.8036 KW 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QOUT = ((1,021.6917 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 )+(113.5208 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 )) (100 K) 1 ℎ𝑜𝑢𝑟 ( 3600 𝑠 ) QOUT = 26.8036 KW 26.8036 KW = 26.8036 KW Equipment: Two-Stage Intercooling Compressor Design Alternative 2 and 3 Conversion of mass input flow rates: MIN = 27.2451 tons/day 68  MIN = 27.2451 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 1,135.2125 kg/hr Conversion of mass output flow rates: MOUT = 27.2424 tons/day MOUT = 27.2424 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 1,135.1000 kg/hr Conversion for losses: MLOSS = 0.0027 kg/hr MLOSS = 0.0027 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MLOSS = 0.1125 kg/hr Q = mcpΔ T QIN = QOUT 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 QIN = ((1,135.2125 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 )) (178 K) ( 3600 𝑠 ) QIN = 47.7105 KW 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QOUT = ((1,135.1000 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 )+(0.1125 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 )) (178 K) 1 ℎ𝑜𝑢𝑟 ( 3600 𝑠 ) QOUT = 47.7105 KW 47.7105 KW = 47.7105 KW Equipment: Boiler Design Alternative 3 69 Conversion of mass input flow rates: MIN = 146.7750 tons/day + 36.6938 tons/day + 0.7451 tons/day + 0.0037 tons/day MIN = 146.7750 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 6,115.6250 kg/hr MIN = 36.6938 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 1,528.9083 kg/hr MIN = 0.7451 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 31.0458 kg/hr MIN = 0.0037 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 0.1542 kg/hr Conversion of mass output flow rates: MOUT = 57.7926 tons/day + 100.9078 tons/day + 24.7683 tons/day + 0.0037 tons/day MOUT = 57.7926 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 2,408.0250 kg/hr MOUT = 100.9078 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours 70 MOUT = 4,204.4917 kg/hr MOUT = 24.7683 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 1,032.0125 kg/hr MOUT = 0.0037 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 0.1542 kg/hr Conversion for losses: MLOSS = 0.7452 tons/day MLOSS = 0.7452 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MLOSS = 31.0500 kg/hr Q = mcpΔ T QIN = QOUT 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QIN = ((6,115.625 ℎ𝑟 ✕ 0.92 𝐾𝑔・𝐾 ) + (1,528.9083 ℎ𝑟 ✕ 2.22 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 (31.0548 ℎ𝑟 ✕ 2.22 𝐾𝑔・𝐾 ) + (0.1542 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 ) ) (120 K)( 3600 𝑠 ) QIN = 302.9923 KW 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QOUT = ((2,408.0250 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 ) + (4,204.4917 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 (1,032.0125 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 ) + (0.1542 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 (31.05 ℎ𝑟 ✕ 0.92 𝐾𝑔・𝐾 ) ) (120 K)( 3600 𝑠 ) QOUT = 302.9923 KW 302.9923 KW = 302.9923 KW Equipment: Electrostatic Precipitator (Gas Filter) Design Alternative 3 71 Conversion of mass input flow rates: MIN = 100.9078 tons/day + 24.7683 tons/day + 0.0037 tons/day MIN = 100.9078 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 4,204.4917 kg/hr MIN = 24.7683 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 1,032.0125 kg/hr MIN = 0.0037 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 0.1542 kg/hr Conversion of mass output flow rates: MOUT = 30.2723 tons/day (30% separated) + 7.4305 tons/day (30% separated) + 0.0036 tons/day (98% removed) + 70.6355 tons/day (70% separated) + 17.3378 tons/day (70% separated) MOUT = 30.2723 tons/day (30% separated) ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 1,261.3458 kg/hr (30% separated) MOUT = 7.4305 tons/day (30% separated) ✕ 1000 kg/1 ton ✕ 1 day/24 hours 72 MOUT = 309.6042 kg/hr (30% separated) MOUT = 0.0036 tons/day (98% removed) ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 0.1500 kg/hr (98% removed) MOUT = 70.6355 tons/day (70% separated) ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 2,943.1458 kg/hr (70% separated) MOUT = 17.3378 tons/day (70% separated) ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 722.4083 kg/hr (70% separated) Conversion for losses: MLOSS = 0.0001 tons/day MLOSS = 0.0001 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MLOSS = 0.0042 kg/hr Q = mcpΔ T QIN = QOUT 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QIN = ((4,204.4917 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 ) + (1,032.0125 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 (0.1542 ℎ𝑟 ✕ 1.01 𝐾𝑔・𝐾 ) (50 K) ( 3600 𝑠 ) QIN = 77.3022 KW 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QOUT = ((1,261.3458 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 ) + ( 309.6042 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 𝑘𝑔 (0.1500 ℎ𝑟 ✕ 1.01 𝐾𝑔・𝐾 ) + (2,943.1459 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 ) + ( 722.4083 ℎ𝑟 ✕ 𝐾𝐽 𝐾𝐽 1 ℎ𝑜𝑢𝑟 1.93 𝐾𝑔・𝐾 ) + (0.0042 ✕ 1.01 𝐾𝑔・𝐾 ) (50 K) ( 3600 𝑠 ) QOUT = 77.3022 KW 77.3022 KW = 77.3022 KW 73 Equipment: Condenser Design Alternative 3 Conversion of mass input flow rates: MIN = 30.2723 tons/day + 7.4305 tons/day MIN = 30.2723 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 1,261.3458 kg/hr MIN = 7.4305 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MIN = 309.6042 kg/hr Conversion of mass output flow rates: MOUT = 27.2451 tons/day + 5.5766 tons/day MOUT = 27.2451 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 1,135.2125 kg/hr MOUT = 5.5729 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MOUT = 232.2042 kg/hr Conversion for losses: MLOSS = 3.0272 tons/day + 1.8576 tons/day MLOSS = 3.0272 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours 74 MLOSS = 126.1333 kg/hr MLOSS = 1.8576 tons/day ✕ 1000 kg/1 ton ✕ 1 day/24 hours MLOSS = 77.4000 kg/hr Q = mcpΔ T QIN = QOUT 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QIN = ((1,261.3458 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 ) + (309.6042 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )) (5 K) 1 ℎ𝑜𝑢𝑟 ( 3600 𝑠 ) QIN = 2.3190 KW 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 QOUT = ((1,135.2125 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 ) + ( 232.2042 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )+ 𝑘𝑔 𝐾𝐽 𝑘𝑔 𝐾𝐽 1 ℎ𝑜𝑢𝑟 (126.1333 ℎ𝑟 ✕ 0.85 𝐾𝑔・𝐾 ) + ( 77.4000 ℎ𝑟 ✕ 1.93 𝐾𝑔・𝐾 )) (5 K) ( 3600 𝑠 ) QOUT = 2.3190 KW 2.3190 KW = 2.3190 KW Summary of Energy Balances of each Alternatives Table 3. Energy Balance of each Alternatives 75  Components Alternative 1 Alternative 2 Alternative 3 Air Separator (In) 1,703.2490 KW 1,703.2490 KW 1,703.2490 KW Air Separator (Out) 1,703.2490 KW 1,703.2490 KW 1,703.2490 KW Boiler (In) 302.9923 KW 302.9923 KW 302.9923 KW Boiler (Out) 302.9923 KW 302.9923 KW 302.9923 KW Turbine (In) 38.7291 KW 38.7291 KW 38.7291 KW Turbine (Out) 38.7291 KW 38.7291 KW 38.7291 KW Electrostatic Precipitator 77.3022 KW (In) – – Electrostatic Precipitator 77.3022 KW (Out) – – Condenser (In) 2.3194 KW 2.3190 KW 2.3190 KW Condenser (Out) 2.3194 KW 2.3190 KW 2.3190 KW Reciprocating 26.8036 KW Compressor (In) – – Reciprocating 26.8036 KW Compressor (In) – – Two-Stage Intercooling 47.7105 KW 47.7105 KW Compressor (In) – Two-Stage Intercooling 47.7105 KW 47.7105 KW Compressor (Out) – 76  EQUIPMENT SELECTION EQUIPMENT SPECIFICATIONS Equipment selection and planning go hand-in-hand in the manner that the needs of the equipment in relation to the processes, flow direction, ease of operation and maintenance, etc. must be integrated into the overall plan. Also, with the ultimate goal of maximizing the productivity of each machine and minimizing handling. This includes all the equipment from design options needed for the Oxy-fuel Carbon Capture Process and Storage facility. 1. Air Separation Unit Figure 15. Cryogenic Air Separation Unit Cryogenic air separation unit is designed for production of oxygen, nitrogen and argon. The decision to utilize cryogenic air separation to separate atmospheric air compositions is determined by the high equipment reliability and production of air gasses, oxygen, nitrogen, and argon, with extremely low impurity content. The principle of operation is based on air separation by means of low temperature rectification. This 77 method is based on the boiling temperature difference for the air components and on the differences of the contents of the balanced liquid and steam mixtures. Design Data and Assumptions ASME PTC 47.1-2017: This Code applies to ASUs of any size, in either a single-train or multi train configuration. It can be used to measure the performance of an ASU in its normal operating condition, with all equipment in a new, clean, and fully functional condition. This Code provides methods and procedures explicitly for ASUs employing electric-motor-drive compression equipment, with or without the use of steam and/or electric power for internal regenerative processes. There is no intent to restrict the use of this Code for non-motor-driven compression equipment, nor for ASUs that use other heat inputs for internal regenerative processes, provided the explicit test procedures can be met. Design Calculations and Specifications PTC 47.1 provides a method to determine the optimum reflux ratio and the minimum number of stages required to separate gasses with high purity. For cryogenic ASU, the distillation column operates at cryogenic temperature, approximately -180°C, and pressure of 6 MPa. The heat integration between the columns is crucial to minimize energy consumption and is guided by the reflux ratio and operating pressure as specified in the PTC 47.1 standard. Compressor Design The compressor is a critical part of the system, and to optimize compressor selection and performance, compressor power and efficiency 78 is crucial. The adiabatic compression work for each gas was calculated as N2 at 106,126 kJ/h, O2 at 24,416 kJ/h, and Ar at 286 kJ/hour. To convert this work into actual power required by the compressors, compressor efficiency is calculated. The following formula is used to calculate the required power (in kW). 𝑊𝑐𝑜𝑚𝑝 𝑃𝑐?