4.1 Electrolyzer:: 2H O 2H + O 4H + 4e 2H

4.
1 Electrolyzer :
2H2O → 2H2 + O2
4H+ + 4e- → 2H2

Ion Conduction (Oxygen)
Electronic Insulation (Hydrogen)
Anode & Cathode area = 5cm2
4.1.2 Electrode Material:

 8 mol-% Y₂O, stabilized ZrO, (BYSZ)
 Sc₂O, stabilized Zro, (ScSZ)
 Ce based oxides, doping e.g. with Sm, Gd oxides
 Perovskites, e.g. La ,So, Ga.
Calculations:
ton
Water = 9
day
Efficiency = 75%
9 ton
Electrolyzer capacity = day
0.75
ton
= 12
day
Now we have,
9 ton water
9000 kg
= g 1000 kg
18 ×
mole g
= 0.5 moles of water
= 2×0.5 = 1 moles of water
Faraday Constant =94685C
Charge Q = I × t
Q 1× 96485
I= = = 268.01A
t 3600
Q = 96485C
Q
Moles of Hydrogen =
Faraday consatant
ton
=1
day
4.2 Distillation Column :
Feed :
Nitrogen , Oxygen , Argon
(-195.79) , (-182.96) , (-185.86)
Temperature = -195.8 ℃
Pressure = 3 bar
Number of stages calculation:
 We used Fenske Underwood Equation
Xd
log
Xb
N_min= /log ⁡(α )
Xc
Xd
N_min= no of stages
Xd=Mole Fraction of heavy key component = 0.21
Xb= Mole Fraction of lighter key component = 0.78
Xc= Mole Fraction of heavy non key component = 0.01
Vapor Pressure of nitrogen = 0.00000063
Vapor Pressure of oxygen = 0.0000013
Relative Volatility = 0.00000063 / 0.0000013 = 0.48
α = Relative Volatility = 0.48
0.21
log
0.78
N_min= /log ⁡( 0.48)
0.01
0.21
N_min≈ 5.14
N_min= 6
Actual no of Plates (N) = N_min / E
E = Efficiency of the plate ( 0.5 to 0.7 ) for Sieve Tray
N = 6/ 0.6
N = 10
4.2.1 Column Diameter :

kg
Volumetric flow rate of vapour ( V) =248,468000
hr
kg
Volumetric flow rate of liquid (L) =232,566
hr
kg
Density of air ( ρ )= 1.29 3
m
kg
Density of liquid ( ρ )= 1000 3
m
m
Vapour velocity (u) = 10
s
m
liquid velocity (u) = 1.5
s
D = √(4 * (V / (ρV * uV) + L / (ρL * uL)) / π)
D ≈ √(4 * (248469 / (1.29 * 10) + 232566 / (1000 * 1.5)) / π)
D ≈ √(4 * (19205.35 + 15571.07) / π)
D ≈ √(4 * 34776.42 / π)
D ≈ √(43970.53 / π)
D ≈ √(13993.23)
D ≈ 3.74 m
D=4m
4.2.2 Height of the column :

∆ P = 101325 Pa
ΔPT = ΔP * N (number of stages)
ΔPT = 101325 Pa * 5 (stages) = 506,625 Pa
m
g = 9.8 2
s
∆P
H = ¿
ρL g
H = ΔPT / (ρL * g)
H = 506625 Pa / (1000 kg/m³ * 9.81 m/s²)
H ≈ 51.63 m
H = 52 m
4.2.3 Condenser duty (Qc):

Heat transfer area (A) ≈ π × D × L = π × 3.74 m × 10.33 m ≈ 122.5 m²
Heat transfer coefficient (U) ≈ 0.01 kW/m²K
Temperature difference (ΔT) ≈ 20 K
Qc ≈ U × A × ΔT ≈ 0.01 kW/m²K × 122.5 m² × 20 K ≈ 245 kW
4.2.4 Reboiler duty (Qr):

Heat transfer area (A) ≈ π × D × L = π × 3.74 m × 10.33 m ≈ 122.5 m²
Heat transfer coefficient (U) ≈ 0.01 kW/m²K
Temperature difference (ΔT) ≈ 20 K
Qr ≈ U × A × ΔT ≈ 0.01 kW/m²K × 122.5 m² × 20 K ≈ 245 kW
4.3 Heat exchanger:

Ammonia inlet temperature in the exchanger = 454 °C
Ammonia outlet temperature from the exchanger = 150 °C
Cooling water inlet temperature = 25 °C
Specific heat of ammonia = 2.1636 kJ/kg.°C
Specific heat of water = 4.18 kJ/kg.°C
Flow rate of ammonia = 42,330 kg/hr
Flow rate of water = 95,000 kg/hr
4.3.1 Energy required for heat exchange:

Q = mCpΔT
Q = 42330 × 2.1636 × (150 – 454)
Q = - 27,841,897.15 kJ/hr
Q = 2.78 × 107 kJ/hr × 1hr/3600s
Q = 7735 kW
Outlet temperature of cooling water:

Q = mCp (Tout – Tin)
2.78 × 107 = 95,000 × 4.18 × (Tout – 25)
2.78 × 107 = 397,100 × (Tout – 25)
70.01 = (Tout – 25)
Tout = 70.01 + 25
Tout = 95 °C
ΔTLMTD for counter current flow:

Th1 = 454 °C Tc1 = 95 °C
Th2 = 150 °C Tc2 = 25 °C
ΔT1 = Th1 - Tc1 = 454 – 95 = 359 °C
ΔT2 = Th2 - Tc2 = 150 – 25 = 125 °C
Δ T 2−Δ T 1
ΔTLMTD =
ln (
ΔT2
ΔT 1 )
125−349
=
ln
125
349 ( )
−224
=
ln ( 0.35817 )
= 218.16 °C
Overall heat transfer coefficient:

Heat transfer coefficient of ammonia = 500 W/m2.°C
Heat transfer coefficient of water = 2000 W/m2.°C
Thermal conductivity of Stainless steel = 15 W/m.°C
So, the overall heat transfer coefficient is found to be 370.4 W/m2.°C
4.3.2 Area of the Heat exchanger:

Q = UA ΔTLMTD
Q
A=
U Δ T LMTD
7,735,000
A=
330× 218.16
A = 95.7 m2
4.4 Ammonia Convertor:

Inlet Temperature = 300℃
Outlet Temperature = 500℃
Feed = 30057 kmol/hr
Product = 2490 kmol/hr -
Pressure = 15- 30 bar
Catalyst = Chromium Iron Based
Density of Catalyst = 2650 kg/m³
Molar density of gas = 0.414 kmol/m³
Density of gas 36.82 kmol/m³
No. of Catalyst Beds = 4
Volume = 30057/0.414
=72601.5
4.4.1 Catalyst Required
For Bed-1:
Space Time=T=0.0010 hr
Volume = 72601.5*0.0010 (T=V/Vo)
V=72.601m²
For Bed-2:
Space Time=T 0.00141 hr

Volume V = 72601.5*0.00141
V=102.36 m²
For Bed-3:
Space Time = T = 0.0018 hr
Volume =72601.5*0.0018
v=130.68m3
For Bed-4:
Space Time=T=0.0028 hr
Volume = 72601.5*0.0028
v=203.28m3
Total Volume of Catalyst = 72.601+102.36+130.68+203.28
=508.923m3
Density 2650 kg/m³
4.4.2 Weight of Catalyst
Weight of Catalyst = 2650*30.1

W.O.C=494649 kg
W.O.C=494 tons
4.4.3 Volume of Reactor
For stainless Steed
L/D=5
L=5*D
V=A*L
V=π/4d2 *5D
508.923m3 = 0.785 D2 *5D
D3 = 129.66m
D = 5.06m
L = 25.3m
Given 14% allowance = 25.3*0.14+25.3 = π/4d2 *28.842

28.842 = 0.785 (5.06)2 * 28.842
Volume = 579.69m3
Volume= A*L
4.4.4 Height of Reactor
Cross Sectional Area = π/4d2 = 0.785 (5.06)² = 20.1m2

Height of Reactor = V/A =579.69/20.1=28.8m
4.4.5 Wall Thickness

I = Pri / SEj – 0.6P + CeEj = 0.85
S = 12500 Psi
P = 147 atm = 2160 Psi
10% safety allowance = 10% (2160) P = 2376 Psi
Ce = 5mm = 0.1968 in ri = D/2 = 5.06/2 = 2.53m = 99.6 inch
I = 2376(99.6) / 12500(0.85)-0.6(2376)+ 0.1968
I = 21.56 in
I = 0.547m
O.D = I.D + 2I
O.D = 5.06+2*0.547
O.D = 6.154m

4.1 Electrolyzer:: 2H O 2H + O 4H + 4e 2H

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4.

4H+ + 4e- → 2H2

4.1.2 Electrode Material:

4.2 Distillation Column :

4.2.1 Column Diameter :

4.2.2 Height of the column :

4.2.3 Condenser duty (Qc):

4.2.4 Reboiler duty (Qr):

4.3 Heat exchanger:

4.3.1 Energy required for heat exchange:

Outlet temperature of cooling water:

ΔTLMTD for counter current flow:

Overall heat transfer coefficient:

4.3.2 Area of the Heat exchanger:

4.4 Ammonia Convertor:

Density of gas 36.82 kmol/m³

No. of Catalyst Beds = 4

4.4.1 Catalyst Required

Volume = 72601.5*0.0010 (T=V/Vo)

Space Time=T 0.00141 hr

Space Time = T = 0.0018 hr

Total Volume of Catalyst = 72.601+102.36+130.68+203.28

Density 2650 kg/m³

4.4.2 Weight of Catalyst

Weight of Catalyst = 2650*30.1

4.4.3 Volume of Reactor

For stainless Steed

Given 14% allowance = 25.3*0.14+25.3 = π/4d2 *28.842

4.4.4 Height of Reactor

Cross Sectional Area = π/4d2 = 0.785 (5.06)² = 20.1m2

4.4.5 Wall Thickness

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Given 14% allowance = 25.30.14+25.3 = π/4d2 28.842