Simulation and Economic Evaluation of Syngas Generation Plant Using DMR/SMR Reactors and Carbon Capture Unit

Overview

This project presents a comprehensive study, simulation, and economic evaluation of a syngas generation plant utilizing Dry Methane Reforming (DMR) and Steam Methane Reforming (SMR) reactors, coupled with a carbon capture unit. The study begins with an analysis of the global and Middle Eastern syngas markets, followed by a detailed explanation of the rationale behind using DMR and SMR reactors to achieve the optimal hydrogen to carbon monoxide ratio in syngas production.

The project encompasses a thorough investigation of reactor sensitivity to temperature and pressure variations, visualized through detailed analyses. A complete Process Flow Diagram (PFD) is developed, including conceptual process diagrams both with and without the carbon capture unit, elucidating its role in the overall process.

The simulation, conducted using Aspen HYSYS, addresses key challenges such as convergence issues, fluid package selection for the carbon capture unit, identification and resolution of reference PFD inconsistencies, and scale-up considerations. The project further includes comprehensive equipment sizing and costing estimations for all major units.

The economic feasibility study employs the Lang method to calculate direct production costs, fixed charges, and general expenses. This analysis provides insights into the plant's economic viability and sensitivity to various factors.

Throughout the project, visualization and documentation were accomplished using Microsoft Office suite (Word, Excel, PowerPoint) and Visio, ensuring clear and professional presentation of findings.

This project demonstrates advanced capabilities in process simulation, design, and economic analysis of complex chemical engineering systems, showcasing proficiency in industry-standard tools and methodologies.

Project Highlights

• Comprehensive market analysis of syngas production and utilization
• Detailed study of DMR and SMR reactors for optimal syngas composition
• Temperature and pressure sensitivity analysis of reactors
• Development of complete PFD with and without carbon capture unit
• Simulation using Aspen HYSYS, addressing complex convergence and scale-up challenges
• Equipment sizing and costing estimation
• Economic feasibility study using the Lang method

Repository Structure

This repository is organized into the following directories:

1. /DIG: Contains Process Flow Diagrams (PFD) and Conceptual PFDs

   • Detailed visual representations of the syngas generation process
   • Conceptual diagrams illustrating key process concepts

2. /SIM: Houses all Aspen HYSYS simulation files

   • Complete simulation models of the syngas generation plant
   • Includes both base case and sensitivity analysis simulations

3. /MISC: Additional files related to the project

   • Supplementary calculations
   • Data sheets
   • Other relevant materials

4. /DOCS: Documentation and presentation materials

   • Comprehensive project report
   • Seminar lecture files
   • Presentation slides

Key Skills Demonstrated

• Process Simulation (Aspen HYSYS)
• Chemical Engineering Fundamentals
• Process Design and Optimization
• Economic Analysis of Chemical Plants
• Data Visualization and Analysis
• Technical Report Writing
• Problem-Solving in Complex Systems

How to Use This Repository

1. Clone the repository to your local machine
2. Explore the /DIG folder for visual representations of the process
3. Open the Aspen HYSYS files in the /SIM folder to examine the simulation details
4. Refer to the /MISC folder for additional calculations and data
5. Review the comprehensive report and presentation materials in the /DOCS folder

Future Work

• Integration of renewable energy sources in the syngas production process
• Optimization of the carbon capture unit for enhanced efficiency
• Life cycle assessment (LCA) of the entire syngas production chain
• Exploration of alternative catalysts for improved reactor performance

Contact

For any queries, feel free to reach out via email at pooriamotahari@gmail.com or through GitHub.

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