Beruflich Dokumente
Kultur Dokumente
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Dedicate
d
To
Beloved
parents for
providing us
inspiration,
education,
confidence,
fortitude and
infinite love
affection.
Esteemed
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Contents
CHAPTER 1................................................................................7
NATURAL GAS SWEETINING.............................................................................7
1.1 OBJECTIVE..................................................................................................................... 7
1.2 Calculations................................................................................................................... 9
1.3 INTRODUCTION.............................................................................................................. 9
1.4 PAKISTAN NATURAL GAS PRODUCTION........................................................................12
1.5 OIL AND GAS POTENTIAL OF PAKISTAN........................................................................12
1.6 INTRODUCTION TO NATURAL GAS...............................................................................13
1.7 TYPE OF NATURAL GAS................................................................................................13
1.8 CLASSIFICATION OF NATURAL GAS..............................................................................13
1.8.1 Dry Natural Gas:................................................................................................... 13
1.8.2 Wet Natural Gas.................................................................................................... 14
1.8.3 Sour Natural Gas................................................................................................... 14
1.9 GENERAL NATURAL GAS IMPURITIES............................................................................14
1.9.1 Types of impurities................................................................................................ 14
1.9.2 Organic sulfur compounds......................................................................................14
1.9.3Other impurities..................................................................................................... 15
1.10 PROPERTIES OF NATURAL GAS...................................................................................16
1.10.1 Physical and Chemical Properties of CH4.............................................................16
1.10.2 Domestic and Industrial Uses of Natural Gas......................................................17
1.10.5 Natural gas in Ceramic and Pottery Industry...................................................17
Chapter 2................................................................................19
DESIGN BASIS............................................................................................... 19
2.1 OBJECTIVE................................................................................................................... 19
2.2 SCOPE......................................................................................................................... 19
2.3 DELIVERABLES............................................................................................................. 19
2.5 PLANT LOCATION AND SELECTION...............................................................................20
2.6 Factors Affecting Plant Location:..............................................................................21
2.6.1 Marketing area.................................................................................................. 21
2.6.1 Raw materials................................................................................................... 21
2.6.2 Transport........................................................................................................... 21
2.6.4 Availability of labor...........................................................................................21
2.6.5 Utilities (services)............................................................................................. 21
2.7 Environmental impact and effluent disposal.............................................................22
2.7.1.......................................................................................................................... 22
2.7.2 Land (site considerations).................................................................................22
2.7.3 Climate............................................................................................................. 22
2.7.3 Political and strategic considerations................................................................23
Conclusion..................................................................................................................... 25
CHAPTER 3..............................................................................26
PROCESS SELECTION.....................................................................................26
3 CHEMICAL PROCESS....................................................................................................... 26
3.1 AMINE PROCESSES...................................................................................................... 26
3.1.1 MONOETHANOLAMINE (MEA)............................................................................27
3.1.2 DIETHANOLAMINE (DEA)...................................................................................28
3.1.3 Methydiethanolamine (MDEA)...........................................................................28
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CHAPTER 04............................................................................. 45
PROCESS DISCRIPTION OF NATURAL GAS SWEETINING BY MDEA......................45
4.1 INLET GAS KNOCKOUT................................................................................................. 45
4.2 ABSORBER................................................................................................................... 45
4.3 THREE/TWO PHASE FLASH TANK.................................................................................46
4.4 BENEFITS OF FLASH TANK SEPARATOR........................................................................47
4.5 LEAN/RICH HEAT EXCHANGER.....................................................................................47
4.6 REGENERATOR............................................................................................................. 47
4.7 FILTRATION.................................................................................................................. 48
CHAPTER 05............................................................................. 50
HYSYS SIMULATION & OPTIMIZATION.............................................................50
5.1 HYSYS SIMULATION OF AMINE PROCESS....................................................................50
CHAPTER 6..............................................................................54
EQUIPMENT DESIGN......................................................................................54
6.1 SEPARATOR.................................................................................................................. 54
6.1.1 Horizontal Separator............................................................................................. 54
Vertical Separator Designing [4]......................................................................58
Table-5.2 Iteration for Calculating
Vt .....................................................................................59
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Chapter 9..............................................................................139
HEALTH SAFETY ENVIRONMENT....................................................................139
9.1 SAFETY OF THE PERSONNEL......................................................................................140
9.2 HEALTH HAZARDS...................................................................................................... 140
9.3 PROTECTIVE EQUIPMENT...........................................................................................140
9.3.1 Eye Protection........................................................................................................ 140
9.3.2 Respiratory Protection............................................................................................140
9.3.3 Foot Protection....................................................................................................... 141
9.3.4 Head Protection...................................................................................................... 141
9.3.5 Body Skin and Hand Protection...............................................................................141
9.4 Fire Protection............................................................................................................ 142
9.5 SOURCES OF IGNITION...............................................................................................142
9.6 FIRE EXTINGUISHERS.................................................................................................142
In case of Fire,................................................................................................................. 142
9.8 CHEMICAL HAZARDS................................................................................................. 143
9.9 VENTILATION............................................................................................................. 144
9.10 LABOR..................................................................................................................... 144
9.11 DRAIN & WASTES..................................................................................................... 144
9. 12 HAZARDS AND RISK................................................................................................145
9.13.1 Air Pollution.......................................................................................................... 147
9.13.2 Particulate Matter:................................................................................................ 147
9.14 Effects of Natural Gas on Environment....................................................................148
9.15 HYDROGEN SULFIDE IN THE ENVIRONMENT............................................................149
9.15.1 Hydrogen Sulfide and Gas................................................................................149
9.16 Carbon dioxide in the environment..........................................................................151
Normal CO2 Levels........................................................................................................... 151
Extreme and Dangerous CO2 Levels................................................................................152
Principle air pollution issues............................................................................................152
Acid Rain......................................................................................................................... 152
9.17 CO/Ozone Pollution Levels.......................................................................................153
Atmospheric Emissions Guidelines in Pakistan................................................................153
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References............................................................................164
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CHAPTER 1
NATURAL GAS SWEETINING
1.1 OBJECTIVE
Consider raw gas (See Table-1.1) is coming from the gas compression unit; to carry out the gas
sweetening process using simulation software (HYSYS) to get sales gas specification as given
below (See Table-1.2).
The amine solvent for gas sweetening process shall be selected based on Techno Economic
comparison between MDEA (Methyldiethanolamine) & DEA (Diethanolamine) to minimize the
energy.
Table-1.1 Raw Gas Specification
Components
C1
C2
C3
i-C4
in-C4
i-C5
n-C5
n-C6
N2
CO2
H2S
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Feed Composition
Mol%
73
12
4.5
2.5
0.6
0.03
0.23
0.04
2.5
4
0.1
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Mol Fraction
0.73
0.12
0.045
0.025
0.006
0.0003
0.0023
0.0004
0.025
0.04
0.001
0.5
Feed conditions
MMSCFD
oF
Psig
0.005
50
125
1000
H2S Content
CO2 Content
Heating Value
Temperature
Pressure
Product Specifications:
ppmv
mol%
BTU/SCF
0F
Psig
4
2
950
120
850
1.2 Calculations
1. Acid gas partial pressure in the feed gas = (1000+14.7)*(.001+.04) = 41.6027 psia.
2. Acid gas partial pressure in the sales gas = (850+14.7)*(.000004+.002) = 17.3286 psia.
3. Sulfur in the regenerator off-gas as (H2S) = to be calculated by simulation.
4. Amount of water present in feed = 25000000* .005= 125000 std moles/day
1.3 INTRODUCTION
Natural gas is generally considered a non renewable fossil fuel. (There are some renewable
sources of natural gas; well discuss these later.) Natural gas is called a fossil fuel because most
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Country/Region
Natural gas
proven reserves
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% of total
[2]
[33]
Date of
information
World
190,163,119,460,000
100%
Russia
47,570,000,000,000
25.02%
1 Jan2010 est.
Iran
29,610,000,000,000
15.57%
Qatar
25,470,000,000,000
13.39%
Turkmenistan
7,504,000,000,000
3.95%
Saudi Arabia
7,461,000,000,000
3.92%
United States
6,928,000,000,000
3.64%
6,071,000,000,000
3.19%
Nigeria
5,246,000,000,000
2.76%
Venezuela
4,983,000,000,000
2.62%
10
Algeria
4,502,000,000,000
2.37%
11
Iraq
3,170,000,000,000
1.67%
12
Australia
3,115,000,000,000
1.64%
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13
China
3,030,000,000,000
1.59%
1 Jan2010 est.
14
Indonesia
3,001,000,000,000
1.58%
15
Kazakhstan
2,407,000,000,000
1.27%
16
Malaysia
2,350,000,000,000
1.24%
17
Norway
2,313,000,000,000
1.22%
European Union
2,250,000,000,000
1.18%
18
Uzbekistan
1,841,000,000,000
0.97%
19
Kuwait
1,798,000,000,000
0.95%
20
Canada
1,754,000,000,000
0.92%
1 Jan2010 est.
21
22
Egypt
Libya
1,656,000,000,000
1,539,000,000,000
0.87%
0.81%
23
Netherlands
1,416,000,000,000
0.74%
24
Ukraine
1,104,000,000,000
0.58%
25
India
1,075,000,000,000
0.57%
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26
Azerbaijan
849,500,000,000
0.45%
27
Oman
849,500,000,000
0.45%
28
Pakistan
840,200,000,000
0.44%
29
Bolivia
750,400,000,000
0.39%
1 Jan2010 est.
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2.
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treatment
(S=C=O)
2. Carbon disulfide
(S=C=S)
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(C4H4S)
4. Mercaptans
(-C-SH or R-SH)
5. Organic sulfides
1.9.3Other impurities
1. H2O
2. HCN
3. NH3
4. Hydrocarbons
5. Particulates
6. SO2
7. SO3
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2.1 OBJECTIVE
The objective of our project is to remove Acid-Gases (i-e CO2 and H2S) from the Raw-Gas
which is coming from compression unit. Project includes the techno-economical comparison
between DEA (Di-ethanol amine) and MDEA (Methyl-di-ethanol amine) and also the selection
of best suitable process for the given Raw-Gas composition by using Hysys simulation.
2.2 SCOPE
The of the project will be comprises of following tasks
1. Selection of the best possible optimize process scheme for the removal of Acid-Gases
from the Raw-Gas by maintaining its heating value and other parameters as required.
Sweetening with DEA
Sweetening with MDEA
2. Simulation modeling by using Hysys.
3. Sizing of major equipments of the selected scheme such as Separators, Heat Exchangers
and Hydraulics.
2.3 DELIVERABLES
The deliverable which shall be submitted along with the process design are:
1. PFD (Process flow diagram) and P&ID (Process and Instrumentation Diagram) of
selected scheme.
2. Sizing of Equipments.
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2.4
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2.7.3.1
DESIGN AMBIENT
CONDITIONS
Design Maximum Ambient Temperature, F
Design Minimum Ambient Temperature, F
Temperature for Thermal Rating of Air Coolers,
F
Maximum Wet Bulb Temperature for Thermal
F
Design Wind Velocity, (km/hr.)
2.3.7.2
122
83
65
75 - 86
75
65
75 - 85
128
CLIMATIC
CONDITIONS
As per data on Hydrabad by Pakistan Met. Department
Average)
Relative Humidity (Maximum Monthly Average)
Maximum in 24
Rainfall:
(mm)
hours
Wettest Month
(mm)
Altitude, ft (above mean sea level)
Dry Bulb Temperature (max.),
F
Dry Bulb Temperature (min.),
F
Average Barometric Pressure
Ice/Snow
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122
38
35%
81%
251
286
--121
36
14.7psi
a
None
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2.3.7.3
SEISMIC DESIGN
DATA
Zone 2B, Upper Moderate with ground acceleration of 0.2.
AREA
4.0
CLASSIFICATION
Area with the package battery limit in Class I, Div. 2, Group D as defined by
API RP-500. Remaining area with the package limit is also Class I, Div. 2,
Group D.
Conclusion
Keeping in view the above factors the plant should be located in interior Sindh.
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CHAPTER 3
PROCESS SELECTION
3 CHEMICAL PROCESS
Most of the chemical processes are Alkanolamines.
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Acid gas loading 0.3-0.35 mole/mole for carbon steel equipment and 0.70-0.90 mole/mole
for stainless steel
Heat of reaction with CO2 825 BTU/LB and with H2S 550 BTU/LB.
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Acid gas loading 0.7-0.8 mole /mole for carbon steel equipment
Heat of reaction with CO2 600 BTU/LB and H2S 522 BTU/LB.
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[2][4]
In physical solvent processes the component being absorbed is more soluble in the liquid
absorbent than other components of the gas stream, but dose not react chemically with the
absorbent.
In early efforts, water was used as the physical solvent but the solubility of CO2 and H2S in
water were too low, due to this reason it was not commercialized. So in order to be practical, the
solvents must have simultaneously the tendency to remove acid gases several times than that of
water, also have low capacity for primary constituents of the gas stream, e.g., hydrocarbons and
hydrogen.
Physical absorption processes use an organic solvent to absorb the acid gases from the raw gas
streams without chemical reaction. Each component in the raw gas stream is absorbed in
proportion to its concentration and solubility of acid gases in the organic solvent.in most cases,
the solubility of acid gases increases with increase in the pressure and decrease in temperature.
thus physical absorption process is most efficient and economical when operated at the highest
pressure and lowest temperature possible.
Advantages
A physical solvent has three advantages compare to chemical solvent.
Selective H2S removal can be achieved with physical absorption processes since H2S has a
higher solubility than CO2 in most organic solvents.
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Disadvantages
Although the advantages of physical solvents are there, but may be offset by several of their
disadvantages since the loading capacity of physical solvent increases with the higher acid gas
partial pressure and lower working temperatures. As a result, the capital and operating costs of
the physical absorption processes are generally higher compared to those of chemical absorption
processes. Another drawback of physical solvent is that it has solubility towards hydrocarbons
and its solubility increases with increase in carbon number. Once heavier H.C(hydrocarbons)
such as pentane plus and aromatics once attached to the solvent can not be removed easily.
There are various physical solvent processes are used some of which are as follows;
2.2.1
2.2.2
Selexol process
2.2.3
Purisol process
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Selexol Process use a homologous mixture of the dimethyl ether of propylene glycol. The
process can be used to selectively or simultaneously removed sulfur compounds (such as RSH,
CS2, H2S, etc.), carbon dioxide, water, as well as paraffinic, olefin, aromatics, and chlorinated
hydrocarbons from a gas or air stream.
The solvent used in this process has low vapour pressure, which minimizes solvent loses, and is
chemically and thermally stable, which eliminates the need for reclaiming or purging. Due to the
solvents inert chemical characteristics, the Selexol process uses carbon steel as the standard
material of construction, except for areas that are exposed to CO2/H2S evolution where stainless
steel is used.
Applications and Uses:
Selexol solvent was originally used for the removal of CO2from Ammonia plant.
It is also used in desulfurization and CO2 removal in the synthesis gas obtained from the partial
oxidation of heavy petroleum stocks and from coal gasification.
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some cases , from poor separation efficiency due to close permeation rates for various
constituents of natural gas. For instance methane and some heavier hydrocarbon constituents of
natural gas have very close permeation rates with those of acid gases and water for common
polymeric membranes, therefore a significant amount of methane and heavier hydrocarbons
may be lost when this technology is used for acid gas and water removal from natural gas
streams.
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related
to
the
pressure
of
the
inlet
gas
and
permeates
streams.
The separation is actually driven by the component partial pressure differences across the
polymer membrane. Given a feed stream of CO2 and CH4 at a given pressure, CO2 being the
more permeable component will pass through the membrane to the low pressure side and exit as
the permeate stream. CH4 remains on the high pressure side and exits as the residue stream with
essentially no pressure loss. Both CH4 and CO2 permeate through the membrane, resulting in
the residue stream being more concentrated with CH4 and the permeate stream
being more concentrated with CO2.
For a given temperature, pressure, and feed composition, the permeability of an individual
component through a polymer membrane is constant. This permeability is expressed in units of
component gas flow rate per unit membrane surface area per component partial pressure
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The degree of separation of gas components is defined by the selectivity of the membrane (ratio
of component permeabilitys) and by the conditions of the separation (pressure, temperature,
flowrate).
The membrane elements are formed as fl at sheets and packed into spiral wound modules which
are then inserted into steel pressure containing tubes. A spiral wound module consists of a series
of membrane envelopes that are constructed of two sheets of membrane glued back to back
along three edges with the membrane facing outward. A spacer is inserted into the center of this
envelope to keep the membranes separated so that a channel is formed for the permeate gas. The
open end of the membrane envelope is attached to a stainless steel tube that has been
drilled with holes (Figure 2).
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on
hydrocarbon
losses.
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(See
Figure-3.5)
Our case the wellhead composition and other parameters are given below
Our Wellhead Composition
Table-3.1
Parameters
Normal Range
Well Head
Membrane separation
Temperature
10 C to 60 C
49 oC
Conditions
Match
850 psi
Not Match
Pressure Differential
Table-3.2
Components
Mol%
CO2
H2S
4
0.1
Sweet Gases
Mol Fraction Partial Pressure
Psig
0.04
34
0.001
0.85
Pi=34.85
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Temperature
o
F
120
Heating Value
BTU/SCF
950
[2]
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COS
and CS2 form degradation products with MEA and DEA. However our natural gas stream from
well head contains no mercaptants (COS and CS2). It means that this factor in our case has no
significantly important.
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[4]
Table-3.3
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Tables-3. 4
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Table 3-5
Tables 3-6
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[2]
CONCLUSION
From the above factors and using our gas stream data it is clear that there is not much high acid
gas partial pressure in the feed gas (41.6021 psia) so physical solvents are rejected secondly the
CO2 is only 4 mole % so there is no need of using membrane permeation process. Now between
chemical solvents due to selectivity required for our case for H2S we will not use primary and
secondary amines so remaining MDEA (tertiary amine) is the best choice for gas sweetening in
our case.
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Figure-4.2
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Figure-5.2 Fluid Package Basis (Amine fluid PackageNext step: inlet stream specification
as shown in Figure-4.3
After selecting the component of the fluid, the simulation environment c a n enter where the
process flow diagram is built Amine p ro ce s s f l o w diagram simulation.
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Other streams specifications made are DEA to Contactor temperature pressure and flow
rate, make up water temperature and DEA to recycle temperature, the regenerated feed out
of the amine-amine heat exchanger. One of the rigorous tasks is the convergence of the
absorber and the regenerator, to converge the absorber top and bottom temperature and
pressure was specified and run, as in Fig. 4.
The regenerator is converged by specifying the condenser and re-boiler pressure, the reflux
ratio and the vent rate, the column is then run, as in Figure-4.5.
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With the convergence of the absorber and the regenerator units a complete amine simulation
for the base case was established as shown in Figure-5.7
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CHAPTER 6
EQUIPMENT DESIGN
6.1 SEPARATOR
Separator is a kind of vessel in which fluid get separate due to the difference in density and by
the action of gravitational force. They are classified as two phase if it separate gas from the
total liquid stream and three phase if they separate liquid stream into its crude oil and water
components. Gas-Liquid separation is done to separate the liquid droplets which carried by the
high velocity gas or the bubbles of gas carried by the liquid. They are sometime called gas
scrubber when the ratio of the gas and liquid is very high.
[4]
Separator are called by different name as they are used for different fluid in between (solid,
Liquid & gas).Commonly Decanter or settler for Liquid-Liquid separation. Centrifugal separator
(Sedimentation centrifuge, Hydro cyclone) is used for solid-liquid separation.
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[4]
Example 6.1
Horizontal Separator Design Calculation
Given
Flow rate
:Qr
(bpd)
= 7200
Specific gravity:S
= 1.7
Pressure : P (psig)
= 62.4
Temperature : T (R)
= 614.9
Molecular weight : M
= 119.16
Density of gas
: g
(lb/ft^3)
Density of liquid
= 4.287
: L
(lb/ft^3)
= 55
Compressibility factor : Z
= 0.85
= 100
Viscosity : (cp)
=3
Solution:
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[4]
(t r )(QL )
0.7
d 2 Leff =
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tr
) minutes 3
(3)(7200)
=30857.14286
0.7
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Lss =
4d
3
STEP NO.3
Slenderness ratio
Slenderness ratio (12 Lss /d)
Table 5.1 Diameter VS Length for Liquid Capacity Constant
d (inch)
Leff (ft)
Lss (ft )
24
53.57142858
71.42857
35.71428572
30
34.28571429
45.71429
18.28571429
36
23.80952381
31.74603
10.58201058
42
17.49271137
23.32362
6.663890046
46
14.58277073
19.44369
5.072268079
52
11.41166526
15.21555
3.511281618
54
10.58201058
14.10935
3.135410543
56
9.839650147
13.11953
2.811328613
RESULT:
Dimension of Separator 54 inch 14.11 ft4 6 14 2
Where,
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g =density of gas
L=density of liquid
t r=retention time(min)
Q r=flow rate(barrel per day)
Lss seam seamlength (ft )
6.1.2 Vertical Separator
It vertical separator the inlet flow enters the vessel through the side.as the horizontal separator
the diverter does the initial separation. The liquid flow down the liquid collection section of the
vessel. Liquid continues to flow downward through this section to liquid outlet. As the liquid
reaches the equilibrium, gas bubbles floe counter to the direction of the liquid and liquid pump
vale operate which is regulate by a level controller. The gas also carry some small drops of liquid
which get removed when gas passes through mist eliminator or extractor same as horizontal
separator. [4][9]
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[4]
Given:
Flow Rate = 50 MMSCFD
Specific gravity = 0.756
Molecular weight = 21.91
L=61.63 Lb/ ft
Density of liquid =
Density of gas =
g =4.287 Lb /ft
CD
from Graph
C D=0.34
STEP NO. 2
V t =0.0119
V t =0.0119
L g
Micron C D
g
4.287
0.34
V t =0.746639( ft /sec)
STEP NO.3
Reynolds number
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0049
Vt
( g Micron
)
STEP NO. 4
Calculated CD
[(
CD=
Calculated
24
3
+
( )
CD
+ (Assume
STEP NO. 5
Recalculate
Vt
(ft/sec)
L g
Micron C D
g
V t =0.0119
Vt
CD
(ft/sec)
(ft./sec)
CD
88.75782
81.21732
79.54115
79.1450
79.0501
7
0.98102
4
0.439411
0.34
0.74639
134.238
7
0.77771
0.928832
0.968391
0.97810
9
0.98045
6
0.49351
0.451588
0.442268
7
0.44006
7
0.43953
STEP NO. 6
Calculate K
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Vt
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g
Calculated C D =0.27082
L g
STEP NO. 7
Gas Capacity
Gas Capacity
GasCapacity : GC = 504 x
504
( flow rate T Z K )
P
R 0.825 0.270817
( 50 MMSCFD 584.7
)
1015 psig
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STEP NO. 9
Seam-to-Seam Length (ft)
Seam-to-Seam Length (ft)
GC constant
( 12dLss )
12
STEP NO. 10
Liquid volume height (inches)
Liquid volume height (inches) (12 Seam-to-Seam Length (ft))
(40)
Liquid volume height (inches) 73.90137 or 74-ft
RESULT
Dimensions 4-ft 10-in x 14-ft 3-in. x 74 ft
Where,
d=diameter(inch )
g =density of gas
L=density of liquid
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(Gc)
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[21][25][27]
[1]
Page 68 of 200
[9]
We have used fixed valve trays. The pressure drop in the fixed valve trays is low as
compared to movable valve trays and bubble cap trays.
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[9]
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Page 70 of 200
Figure 6.3
Plates are pressed form of stainless steel, titanium, Hestelloy C, Incoloy 825, nickel 200, Monel
400, aluminium brass tantalum, etc. The thickness of plate ranges from 0.5 to 3 mm. the gas
between plates is ranging from 1.5 to 5 mm. this gap is maintained by gasket, which is
sandwiched between two metal surfaces. Plates are having corrugated surfaces. Corrugated
surface design strengthens the plates, increases the effective heat transfer area and produces
turbulence in the fluids flowing through gaps. Plates are easily cleaned and replaced. The heat
transfer area can be readily increased or decreased by adding or removing plates, respectively.
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2
from 2 to 3. The upper limit of standard gasket PHE is reported as 650 m of heat transfer
surface. Total number of plates of this PHE is 400. Variety of gasket materials (table 6.12) is used
in plate size of this PHE having 2.8 m height and 1.1 m width.
Table-6.3
Gasket Material
Styrene butadiene rubber
Medium nitrile rubber
Butyl rubber
Fluorocarbon rubber
Compressed asbestos fiber
Temperature limit, C
85
135
150
175
260
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[8]
Table-6.4
IN
GIVEN DATA
RICH AMINE TEMPERATURE (F)
(t 1)
OUT (t 2)
154.63
215.06
LEAN AMINE TEMPERATURE (F)
(T
)
1
IN
OUT (T 2)
255.74
195.60
MEAN PRPERTIES
RICH AMINE
Density (Lb/cu.ft)
64.54
Heat capacity (Btu/Lb.F)
0.84
Volume flow (cu. ft/sec)
0.517
Mass flow (Lb/sec)
33.35
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LEAN AMINE
61.31
0.90
0.518
31.75
3.49
0.221
*(From Hysys)
STEP NO. 1
Heat Duty Q
Q = m Cp (T hT c )
Q = 31.75 0.90 (255.74 195.60)
Q = 6182037(Btu/hr)
STEP NO. 2
Log Mean Temperature Difference
Let no. of passes = 1
LMTD
(T 1 t 2) (T 2 t 1)
(T t )
ln 1 2
(T 2 t 1 )
LMTD = 40.82
NTU (no. of transfer units) = (T1 T2) / LMTD
NTU = 1.473
From figure 6.36 (Ft = 0.97)
Corrected LMTD = LMTD * Ft 39.60
STEP NO. 3
Overall Heat Transfer Coefficient U (Btu/sq.ft.hr)
U = 176 (assumed)
STEP NO. 4
Area Provided For Heat Transfer A (sq. ft)
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2.23
0.227
Q
=887 sq . ft
U x T
STEP NO. 5
Plate Layout
Selecting the plate having width of 2.82 f t
Height to width ratio 2 to 3
Height 5.64 f t
Effective area of one plate 15. 92sq. f t
STEP NO. 6
First trial calculation
No. of plates =
Ap
STEP NO. 7
QL
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/sec
[Type text]
Pr
Page 76 of 200
0.65
0.4
0.26
hi=
STEP NO. 8
/sec
F)
Constants equal to
a 0.65
b 0.4
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ho =
c 0.26
(k / de) x (c) x (Re^a) x (Pr^b)
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tp
/K+ 1/
hid
+ 1/
hod
Where
hi=
F/Btu)
ho =
F/Btu)
hid
hod =
tp
F/Btu)
F/Btu)
F)
STEP NO. 10
Required heat transfer area (
Ar
Ar
= Q / U x T = 896.06 sq. f t
Since, required area is just 1.07% in excess of area provided so we can proceed to next step
otherwise change no. of passes and gap between plates and plate dimensions.
STEP NO. 11
Pressure Drop Calculations for Lean Amine
0.3
Friction factor J f =0.6 =0.069
Path length
[Type text]
LP
Page 79 of 200
de
Ve
) ((density
0.001 3.87
QL
ft
/sec
V h
Port pressure drop (1.3) (density
^2)//2 0.003281 0.16 Lb/sq.in
Total Lean Amine Side Pressure Drop Plate pressure drop + port pressure drop 3.87+
0.16 4.03 (Lb/sq.in)
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J f =
LP
plate length
J
Plate pressure drop (Lb/sq.in) (8) ( f ) (Lp/de) ((density Ve^2)/2)
0.003281 4.58
0.39 f t
/4)
(density
QL
V ho
^2) / 2
ft
/sec
0.003281 0.017
(Lb/sq.in)
Total Lean Amine Side Pressure Drop Plate pressure drop + port pressure drop
4.58+0.017=4.58+0.017=4.593 Lb/( sq . ft)
6.4 KETTLE TYPE REBOILER
The choice of the best type of reboiler or vaporizer for a given duty will
depend on the following factors:
a. The nature of the process fluid, particularly its viscosity and propensity to
fouling.
b. The operating pressure: vaccum or pressure.
c. The equipment layout, particularly the headroom available.
6.4.1 Criteria of Selection between Kettle Type Reboiler and Thermosyphon Reboiler.
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Page 82 of 200
P
q
( c)0.69
hcb =0.104
Where
hcb
. (12.63)
Operating pressure,
Pc =
q
Heat flux,
Note:
q hcb (T w T s)
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Page 83 of 200
For Mixtures
The equation (12.63) can be used for close boiling mixtures, say
less than 5C or F, but cannot be used for mixtures of wide boiling range.
Palen and Small (1964) give an empirical correction factor for mixtures which
can be used to estimate the heat transfer coefficient in the absence of
experimental data:
h
h
( cb)single component
( cb)mixture=f m
Where
f m=exp [0.0083 ( T boT bi ) ]
And
T bo=
T bi=
reboiler,
6. The maximum heat flux for stable nucleate boiling wall, however, is less
for a tube bundle than for a single tube. Palen and Small (1964) suggest
modifying the Zuber equation for single tubes with a tube density factor.
This approach was supported by Palen et al. (1972).The modified Zuber
equation can be written as:
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Pt
d0
0.25
[g ( l v ) v 2 ]
Nt
( ) ( )
.. (12.74)
Where
q cb=
Maximum (critical) heat flux for the tube bundle,
K b=
Pt =
Tube pitch,
d 0=
N t =
Nt
U-tubes.
Palen and Small suggest that a factor of 0.7 is applied to the maximum flux
estimated from equation 12.74.
6.4.4 General Design Consideration
1. The tube arrangement, triangular or square pitch, will not have a
significant effect on the heat-transfer coefficient. A tube pitch of between
1.5 to 2.0 times the tubes outside diameter should be used to avoid vapor
blanketing. Long thin bundles will be more efficient than short thick
bundles.
2. Tube bundle diameter should be greater than 1 ft and less than 4 ft.
3. The shell should be sized to give adequate space for the disengagement
of the vapor and liquid. The shell typically should be about 40% greater
than that required for tube bundle only. This allows the disengaging
action. The shell diameter required will depend on the heat flux. The
following values can be used as a guide:
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4. The freeboard between the liquid level and shell should be at least 0.25 m
or 0.8208 ft. to avoid excessive entrainment, the maximum vapor velocity
at the liquid surface should be less than that given by the expression:
<0.2 l v
v
1 /2
5. When the fluid being vaporized is a single component and the heating
medium is steam (or another condensing vapor), both shell and tube side
process will be isothermal and the mean temperature difference will be
simply the difference between the saturation temperatures. If one side is
not isothermal than the logarithmic mean temperature difference should
be used. If the temperature varies on both sides, the logarithmic
temperature difference must be corrected for cross or counter flow. etc.
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STEP NO. 2
Assumption of Overall Heat Transfer Coefficient U
Assumed U=105.6 Btu/hr. ft F (or 600 W/m C)
STEP NO. 3
Log Mean Temperature Difference (LMTD)
( T 1t 2 )(T 2t1 )
Tm
ln
T 1t 2
T 2t 1
Here,
T 1 =
T 2 =
t 1 =
t 1 =
i-e
Tm
( 399.92255.56 )(356248.9)
=
399.92255.56
ln
356248.9
STEP NO. 4
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Q=U A T m
i-e
A=
Q
9577049
=
=
U T m 105.6 124.8
[Type text]
726.697 ft 2 ( 67.47 m 2)
Page 89 of 200
Select
An even number of tube passes is usually the preferred arrangement, as these positions the inlet
and outlet nozzles at the same end of the exchanger, which simplifies the pipework.
N P =
STEP NO. 6
Number of Tubes
Nt
Nt=
Nt
A
A surface
A
726.697
=
=184.5 wetake 185 tubes
dL 0.063 6
N t 2=370
STEP NO. 7
Heat Transfer Coefficient at Shell Side (
hcb
P
q
( c)0.69
hcb =0.104
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Pc =470318.4 Lb /ft 2
41.60
Q
9577049
Heat flux: q= =
=13173.98 Btu/hr . ft W/m)
A 726.697
i-e
6055
hcb =1065.68( Btu/ ft 2 F hr ) W/m C)
h
h
( cb)single component
( cb)mixture=f m
Where,
f m=exp [0.0083 ( T boT bi ) ]
Here,
T bo=
T bi=
i-e
Correction factor (
Corrected
hcb
f m =0.95
And, Hence
5752.25
(mixture) 0.95 1065.68=1012.4 (Btu/ ft 2 . F . hr ) W/m C)
STEP NO. 8
For Tube Side Calculation
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A (cross-sectional)
velocity=
i-e
2
2
2
2
d i = (0.052) =0.00212 ft ( 0.00189 m )
4
4
d i2 t
4
NP
Reynoldsnumber : =
116.025
370
55.69 0.00212
2
DV
Where,
[Type text]
20
( 0.052
)=387
Page 92 of 200
Prandl Number (
Pr
cp
) K
Where,
C p =
K=
0.9546
=2.31 Lb /ft . hr ( 0.0009546 Kg/m. sec)
Viscosity 0.9546 Cp=
0.41338
I-e
P r=
0.5 2.31
= 13
0.086
0.33
0.33
=221
I-e
Heat transfer coefficient at tube side (hi)
N u K 221 0.086
=
=367.5 Btu/hr . sq . ft . F ( 2135 W /m2 C)
di
0.052
STEP NO. 9
For Overall Heat-Transfer Coefficient
U=
1
1
+
+
h cb hcbd
hcb =
d0
di
( )
d 0 ln
2Kw
d0
1 1
+
di
hi hid
(U )
) Here,
2
Heat transfer coefficient at shell side 1012.4 Btu /hr . sq . ft . F ( 2135 W /m C)
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Page 93 of 200
d 0=
d i=
i-e
613.5
The overall heat transfer coefficient U=107.1 Btu/hr sq . ft F W/m C)
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Page 94 of 200
( Ar )
Q
9577049
=
=716.1 ft 2 ( 65.98 m2)
U T m 107.1 124.8
Since the area required is less than area provided and % excess area should be within 20 %
Calculating %excess area
1 =
( ArA 1) 100=( 726.6
716.1 )
1.41
STEP NO. 11
q
Calculating Critical Heat Flux ( cb )
q cb=K b
Pt
d0
0.25
[g ( l v ) v 2 ]
Nt
( ) ( )
Here,
K b=
d 0=
Kg
)
m3
3
3
Density of Vapor in shell 0.07 Lb/ft (1.18 Kg /m )
i-e
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Page 95 of 200
q cb=0.44
0.102
0.051
) (
0.25
1673000
[ 0.041189.8 ( 962.101.18 ) 1.182 ]
53
Nt
d
0
Bundle diameter
K1
( )
1
n1
Here,
For 2 passes and square pitch
K 1=0.156
n1=2.291
d 0=
Number of tubes:
N t =370
i-e
D b=0.063
370
0.156
1
2.291
= 1.86 ft ( 0.567 m)
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Page 96 of 200
Ds
Db
i-e
D s=1.7 1.86
STEP NO. 13
:V max
l v
v
1/ 2
=0.2
60.230.07
0.07
(ft/sec)
1/ 2
STEP NO. 14
Actual vapor velocity
mv
3
Density of Vapor in shell 1.18 Kg /m
i-e
Actual vapor velocity
[Type text]
2.6145
=0.56 ft /sec ( 0.232 m/sec)
1.18 20 3.159
Page 97 of 200
Figure 5.5
Page 98 of 200
II.
The only common thread among these users is the need to reject heat from a source into the air.
Some of these applications also use the discharge air from the air cooler to help heat buildings or
other equipment.
The advantages and disadvantages of forced and induced draft fan operation on the performance
of the unit is described below
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Page 99 of 200
[Type text]
Figure 6.6
[Type text]
Figure 6.7
[8]
[Type text]
FIGURE 5.8
The filtration system is typically installed on the cool lean amine stream (absorber feed).
Recirculation of a slipstream from the discharge side of the charge pump to the filtration system
with a return to the suction side of the pump is a common arrangement. If they used combined in
series, the particulate filter should be installed upstream of the carbon filter to protect the carbon
filter. A second post-filter or screen should be installed downstream of the carbon filter to keep
[Type text]
[8][4]
FIGURE 5.9
6.6.3 CONCLUSIONS
Activated carbon filters may be used in lieu of all other types of filters to completely remove all
contaminants, both solid and liquid (either dissolved or entrained) from amine systems. These
activated carbon filters, when properly designed and installed will result in the system being
cleaner than will be possible with almost all other purification processes for amine and glycol
[Type text]
[Type text]
Figure 6.10
[Type text]
Figure 6.11
[Type text]
[18]
Figure 6.12
[Type text]
[Type text]
[Type text]
1. JM Motor
7. Hex nut
2. Key shaft
8. Mechanical seal
3. Slinger
9. Stud
4. Shaft sleeve
16. Plug
17. Impeller
[Type text]
5. Motor adaptor
6. Hex bolt
An external relief valve installed in the discharge line which is used for return back to
the fluid to the suction line or supply tank is recommended
[Type text]
[Type text]
[Type text]
Horse
Power
Ranger
Pump Type
Flow Rate
Ranges
Axial Flow
Pump
5,000 -200,000
gpm
10 30
ft
10 1,500
hp
5 10,000
gpm
200 7,500
ft
1 5,000
hp
5 750
gpm
20 180
ft
1 50
hp
10 200
ft
0.25 250
hp
25 15,000
psi
0.5
2,000
hp
0.25 10
hp
Booster
Pump
Circulator
Pump
10 60
psi
10 2,500
psi
50 450
psi
0.5
2,000
hp
1 500
hp
10 200
psi
0.125 5
hp
30 250
ft
50 - 5,000
psi
1 2000
hp
1 - 500
hp
.
Figure 6.15 Typical system and pump performance curves
[Type text]
[Type text]
[Type text]
[Type text]
[Type text]
[Type text]
[4]
In a non-vented bonnet type conventional relief valve, the back-pressure acts downward on the
entire disc area and upward on only a portion of the disc area. In this case, increasing backpressure increases the set point of the valve.
It should be clear from this discussion that conventional relief valves should only be used where
the discharge is routed independently to atmosphere. If installed in a header system. The backpressure build-up when the device is relieving will affect the set point of every other device in
the header system.
[Type text]
[Type text]
[4]
[Type text]
Re =
DV
Where
Re = Reynolds number
= Density, lb/ft
D = Pipe ID, ft
V = Flow velocity, ft/sec
= Viscosity, ib/ft-sec
The Reynolds number can be expressed in more convenient terms. For
liquids, the equation becomes:
Re 7738
( S .G ) d V
(7-1)
Re = 92.1
(S .G)Q l
d
(7-2)
Where
[Type text]
= Reynolds number
= Viscosity, lb/ft-sec
Ql
FLOW REGIMES
Flow regimes describe the nature of the flow. There are two basic flow
regimes for flow of a single-phase fluid: laminar flow and turbulent flow.
Laminar flow is characterized by little mixing of the flowing fluid and a
parabolic velocity profile. Turbulent flow involves complete mixing of the fluid
and a more uniform velocity profile. Laminar flow has been shown by
experiment to exist at Re < 2,000 and turbulent flow at Re > 4,000. Reynolds
numbers between 2,000 and 4,000 are in a transition zone, and thus the flow
may be either laminar or turbulent.
BERNOULLI`S THEOREM
It is a customary express the energy content in a fluid in terms of the
potential energy contained in an equivalent height or head of a column of
the fluid. using the convention, Bernoulli`s theorem breaks down the total
energy at a point in terms of:
1. The head due to its elevation above an arbitrary datum of zero
potential energy.
2. A pressure head due to the potential energy contained it the pressure
in the fluid at that point.
[Type text]
P2
= P=
H
144 l
(7-3)
Where
P = Loss in pressure between points 1 and 2, psi
0.0013 flp v
=
2d
(7-4)
Moody friction factor
The factor of proportionality in the previous equations is called the moody fiction factor and is
determined from the moody resistance diagram shown in figure 7-1(see Appendix A). The
friction is sometimes expressed in terms of the fanning friction factor, which th of the moody
friction factor. In some references the moody friction factor is used, in others, the fanning friction
is used. This must be exercised to avoid inadvertent use of the wrong friction factor. The friction
[Type text]
/ D.
Table 8-1 shows the roughness for various types of new, clean pipe. These
values should be increased by a factor of 2-4 to allow for age and use. (see
Appendix A)
6
= 11.5 10
P
(7-5)
Where
P
[Type text]
fL Q l (S . G)
d
Hl
= 0.00208
Hl
= 0.015
100
C
1.85
gpm
d 4.87
1.85
( ) ( )
Ql1.852 L
d 4.87 C 1.85
Where
H l=Head loss due friction , ft
d = Pipe ID, inch
Ql
L = length, ft.
C = Friction factor constant, dimensionless
= 140 for new steel pipe
= 130 for new cast iron pipe
[Type text]
EXAMPLE 7.1
PRESSURE DROP IN LIQUID LINE
Given
Flow rate (bpd)
= 7251.52
= 1.024
Viscosity (cp)
= 2.8
Length (ft.)
= 42
= 1015.79
Temperature (R)
= 594.6
Assumed Velocity
(ft. /sec) = 7
Absolute Roughness ()
= 0.0018
0.012 Ql
v
0. 012 7251.52
7
= 3.5257
Available diameter = 4
Re = 92.1
(S .G)Q l
d
(1.024) 7251.52
Re = 92.1
4 2.8
= 60995.64251
/ d =
Relative roughness =
At Re =60995.64251 and
0.0018
= 0.00045
4
P = 11.5 106
fL Q l (S . G)
d
= .55876 psi
T
SP
d=
60 Qg T Z
V P
Re =
20,100 Qg S
dU
U = viscosity, cp
p2 2
2
= (25.2 S Qg Z T1 f L)
5
( d )
The general gas flow equation is recommended for most general usage.
2. Weymouth Equation
This equation is based on measurements of compressed air flowing in pipes ranging from 0.8 in.
to 11.8 in. in the range of Moody diagram where the E/d curves are horizontal (i.e. ,high
[Type text]
f=
Use Weymouth equation only for small-diameter, short-run pipe within the production facility
where the Reynolds number is expected to be high.
1
p1
p2
Qg 2 L S T f
2
7.1289
1.11 d
In our case Weymouth equation is valid on line number 1, 2, 4, and 6 because Reynolds number
is very high so Moody friction factor is independent of Reynolds number and depends upon
relative roughness.
3. Panhandle Equation
Panhandle equation only use for large-diameter long-run pipelines where the Reynolds number is
expected to be moderate.
1
p1
p2
Qg 2 Z T f L S
d 5 0.1992
4. Spitzglass equation
Use the Spitzglass equation for low pressure vent lines less than 12 inches in diameter. This
equation is used for near-atmospheric pressure lines.
In our case Spitzglass equation can be useful in regenerator acid gas flare lines 14, 15, and 16.
Condition in Spitzglass equation is pressure drop is less 10 % of initial pressure.
f = (1 +
3.6
d
[Type text]
+ 0.03 d ) (0.01)
Page 140 of 200
[4]
12.6 S Qg 2 Z T f L
p1 d 5
[Type text]
= 585
Pressure (psi)
= 1015
= 49.88
Viscosity (cp)
= 0.013
Specific gravity
= 0.76
= 52.34
= 45
= 0.0018
Length (ft.)
= 42
= 0.83
Solution
Ve = 0.60 C
T
SP
Ve = 0.60 100
585
0.76 1015
[Type text]
60 Qg T Z
V P
d=
= 5.74 inches
Re =
20,100 Qg S
dU
Re =
= 9804378
Since Reynolds number is very high so we use Weymouth Equation. This is used for short-run
pipelines within the production facility.
But first we have to calculate friction factor
0.013
f = d 1 /3
0.013
6 1/ 3
f=
= 0.018
p1
1015
p2
p2
[Type text]
Qg 2 L S T f
1.11 2 d 7.1289
= 1014 psia
P = 1.08 psia.
as
20%. Nevertheless, as
gas exploration and production have moved into remote off-shore, artic, and
desert areas, the number of two-phase pipelines has increased.
In most production situation the fluid coming out of the well bore will be in
two-phase flow. Once an initial separation is made, the gas coming off the
separator can be considered to be single-phase liquid flow even though it will
contain some gas after it has taken a pressure drop through a liquid control
valve.
Other than well flow lines, the most common two-phase pipelines exist in
remote location, especially offshore, where gas and oil that have been
separated and metered are combined for flow in a common line to a central
separation facility.
In a two-phase line equation:
P
0.42 ( S .G ) Z n
States the pressure lost in each uphill segment, but this is not balanced by a
pressure gain in each downhill segment. Thus, the pressure lost due to
elevation changes is the sum of the pressure lost in each uphill segment. It is
possible in hilly terrain to have a line that flow from a high point to a lower
elevation, but which, because it crosses a valley, will still have a loss in
pressure due to elevation changes.
[Type text]
[4]
(7-5)
Where
L = length, ft.
d = pipe ID, inch
W= rate of flow of liquid and vapor, lb/hr
m
The rate of flow of the mixture to use in this equation can be calculated as
follows:
W = 3180
Qg
S + 14.6
Ql
(S.G.)
Where
Qg
Ql
12,409 ( S .G . ) P+2.7 R S P
198.7 P+ R T Z
Where
P = Operating pressure, pisa
R = Gas/liquid ratio, ft3/bbl.
T= Operating temperature, degree R
Z = Gas compressibility factor.
[Type text]
[Type text]
[Type text]
[Type text]
[3]
2.
3.
Final Control Element - It is a piece of equipment to perform the control action or to exert
direct influence on the process. This element receives signals from the controller and
performs some type of operation on the process. Generally the final control element is
simply a control valve.
[Type text]
[Type text]
[11]
Figure-8.1.1
[11]
Figure-8.1.2
3. Proportional Plus Integral Plus Derivative Control (PID)
Figure-8.1.3
ADVANTAGES
1. Does not require identification and measurement of any disturbance for corrective action.
2. Does not require an explicit process model.
3. Is possible to design controller to be robust to process/ model errors.
DISADVANTAGES
[Type text]
[3]
[Type text]
[11]
Manipulated variable
Control variable
[Type text]
[3]
Neglects process dynamics (i.e. how fast the control variable responds to changes in the
load and manipulated variables).
Acts before the effect of disturbance has been felt by the system.
[3]
DISADVANTAGES
Feed Forward Control Loop is used only at one place i-e Lean Amine Inlet to Contactor
(C-101).
CASCADE CONTROL
Cascade control system is an automatic control system in which various control units are linked
in sequence, each control unit regulating the operation of the next control unit in line. The
primary objective in cascade control is to divide an otherwise difficult to control process into two
portion, whereby a secondary control loop is formed around a major disturbances thus leaving
only minor disturbances to be controlled by the primary controller.
[Type text]
Figure-8.3
ADVANTAGES
Large improvement in performance when the secondary is much faster than primary.
Use of feedback at all levels. Primary has zero offset for step-like disturbances.
[26]
[Type text]
[Type text]
It is used to control the state variables like P, T, F, C, etc. by using electric control system.
e.g. Petrol flow with respect to rupees in Petrol pump.
2. Pneumatic Manipulation
It is used to control one thing by using Air/Pressure signals.
e.g. when applying car brakes, Brake oil pressure controls the motion of working wheel.
[Type text]
Thermocouples
Resistance Temperature Device
Radiation Pyrometer
Bimetal thermometers
[Type text]
Float Switch
Liquid Head Pressure Device
Conductivity Measurement
Visual Method
Dip-Stick Method
For the measurement of level in our case we have selected Float switch and Liquid head pressure
device because it is simple to handle at maintenance point of view.
1. Float switch
A float switch is a device used to detect the level of liquid within a vessel. Float switch signals
when certain level of liquid in vessel is achieved.
1. Liquid head pressure device
It work in such a way that it measures the difference in static pressure between two fixed
elevations, one in the vapor above the liquid and the other under the liquid surface. The
differential pressure between the two level taps is directly related to the liquid level in the vessel.
Level measuring instruments used in Knock-Out Drum (V-100) are both Liquid Head
Pressure Device and Float Switch.
Level measuring instruments used in Contactor (C-100)are both Liquid Head Pressure
Device and Float Switch.
Level measuring instruments used in Sweet-Gas Separator (V-101) are both Liquid
Head Pressure Device and Float Switch.
Level measuring instruments used in Rich Amine Flash Drum (V-102) are both Liquid
Head Pressure Device and Float Switch.
Level measuring instrument used in Reflux Drum (V-103)is Float Switch.
Level measuring instruments used in Regenerator Reboiler (EX-101) are both Liquid
Head Pressure Device and Float Switch.
ADVANTAGES
[Type text]
Bourdon Gauge
Bellows
Diaphragm
Capsules
We have used only bourdon gauge because it can work in robust environments and less
expensive as compare to bellows and diaphragm.
1. Bourdon Gauge
Bourdon gauge are circular-shaped tubes with oval cross-section. The pressure of the medium
acts on inside of the tube. The outward pressure on the oval cross-section forces it to become
rounded. Because of the curvature of the tube ring, the bourdon tube then bends as indicated in
the direction of the arrow. Due to their robust construction, Bourdon are often used in harsh
environments and high pressures, but can also be used for very low pressure; the response time
[23]
however, is slower than the bellows or diaphragm.
[Type text]
Figure 8.4
Pressure measuring instrument used in Acid-Gases Outlet from Reflux Drum (V-103)
is Bourdon Gauge.
Pressure measuring instrument used in Inlet and Outlet of Pumps (P-100, P-101, and P-102)
are Bourdon Gauge.
Pressure measuring instrument used in Flue-Gases Outlet from Column (C-101) is Bourdon
Gauge.
Pressure measuring instrument used in Sour-Gas Inlet to Contactor (C-101) is Bourdon Gauge.
[Type text]
Any organization has a legal and moral obligation to safe guard the health and welfare of its
employees and the general public. Safety is also good business. The management practices
needed to ensure safe operation will ensure efficient operation.
All manufacturing process is to some extent hazardous, but in chemical processes there are
additional, special, hazards associated with the chemicals used and the process conditions. The
designer must be aware of these hazards, and ensure to the application of sound engineering
practice, that the risk is reduced to acceptable levels.
Safety and loss prevention in process design can be considered under the following broad
headings:
1. Identification and assessment of the hazards.
2. Control of the hazards: for example, by containment of flammable and toxic materials.
3. Control of the process. Prevention of hazardous deviation in process variables (pressure,
trips; together with good operating practices and management.
4. Limitation of the loss. The damage and injury caused if an incident occurs; pressure
relief, plant layout, and provision of firefighting equipment.
The safe operation of such processes on the design and provision of engineered safety devices
and on good operating practices, to prevent a dangerous situation developing and to minimize the
consequences of any incident that arises from the failure of these safeguards. The term
"engineered safety" covers the provision in the design of control systems, alarms, nips, pressure
relieve devices, automatic shutdown systems duplication of key equipment services; and
firefighting equipment, sprinkle systems and blast valves, to contain any fire or explosion.
[Type text]
[Type text]
Score a gas test certification showing the gas conditions of the atmosphere (vessel).
2.
Avoid standing on the side of an opening where escaping gas will be blown towards
him.
3.
Provide ventilation.
4.
[Type text]
Water
2.
Carbon Oxide
3.
Foam
4.
Dry Powder.
[Type text]
[30]
A well designed machine must be equipped with safety guards. Visual warnings of danger such
as signs and color schemes should be provided. Other may include;
Non substitution of one tool for mother when each has a definite specified function.
The term "fire prevention" applies to that phase of process design which minimizes fire hazards
inherent in the process. Fire control refers to control and production against fire which have
already been started. Minimum safe practices prescribed by nationally recognized fire protection
association, engineering authorities me to be exercised.
9.9 VENTILATION
One of the major functions in most plant surveys is a study of ventilating systems, which we
used to control the health hazards. By local exhaust ventilation the air containment is removed at
the place of generation, before it comes into the workers breathing zone. Often, incorrect types of
ventilating systems are employed.
9.10 LABOR
Labor should be paid special attention i.e. Their health, welfare, recreation, etc. Such types of
facility would encourage their performance and they will concentrate on their work more.
Special programs and conferences should be held to impart plant and safety knowledge to them
and to exercise this knowledge.
Guard on window glasses as well as special protection equipment should be provided to the labor
to save them from unforeseen climates.
[Type text]
Initiating
Event
ACCIDENT
Hazard
Hazard
[Type text]
9. 13 ENVIRONMENTAL ASPECTS
9.13.1 Air Pollution
The disturbance in the natural composition of air that is 79 % N2, 21 % O2, is called air pollution
and the disturbance creating components are called air pollutants.
[Type text]
Because natural gas is the cleanest burning fossil fuel, it can help to improve quality of air and
water, especially when used in place of other, more polluting energy sources. Natural gas
combustion results in virtually an atmospheric emissions of sulphur dioxide (SO 2) or small
particular matter, and far lower emissions of carbon monoxide (CO), reactive hydrocarbons,
Nitrogen Oxides (nox) and carbon dioxide than combustion of other fossil fuels.
Natural gas is more environmentally attractive than other fossil fuels because it is composed
chiefly of methane, a molecule made up of one carbon atom and four hydrogen atoms. When
methane is burned completely, the principal products of combustion are carbon dioxide and
water vapor.
CH4 + 2O2
CO 2 + H2O
In comparison, oil and coal compounds have much more complicated molecular structures. They
include a higher ratio of carbon, as well as various sulfur and nitrogen compounds. They do not
burn as clearly. Coal and industrial fuel oil combustion also produces ash particles, which do not
burn at all however; they can be carried into the atmosphere. Because natural gas burns cleanly,
its
use
can
be
effective
means
of
controlling
pollution.
208,000
208
457
2,591
2,744
0.016
natural. Hydrogen sulfide is released into the air as a product of the decomposition of dead
plant and animal material, especially when this occurs in wet conditions with limited oxygen,
such as in swamps. Hot springs, volcanoes, and other geothermal sources also emit H2S.
Anthropogenic releases of H2S into the air result from industrial processes, primarily from
the extraction and refining of oil and natural gas and from paper and pulp manufacturing, but
the gas is also present at sewage treatment plants, manure-handling plants, tanneries, and
Coke oven plants.
sedimentary
natural
gas,
comprising 70% to 90%, while other gaseous hydrocarbons, butane (C4H10), propane (C3H8), and
ethane (C2H6), account for up to 20 percent. Contaminants present in
sand,
dioxide, nitrogen, rare gases such as helium and neon, and hydrogen
[Type text]
oxygen,
carbon
Protection
Agency
(EPA)
3
normal cubic meters (mg/Nm ) (0.25 grains per 100 standard
sweetened at processing facilities called desulfurization plants. 95% of the gas sweetening process
involves removing the H2S by absorption in an amine
carbonate processes, solid bed absorbents and
Around 30 percent
physical absorption.
Hydrogen sulfide emissions from gas development may pose a significant human health risk,
as the studies discussed below reveal. Workers in the oil and gas industry are trained to
recognize and respond to high-concentration accidental releases of H2S.
[24]
50 100
Length
of
exposure
Community
10 minutes
Prolonged
Source
EPA Report 1993, p. III32.
New
York
Department of
Rt
Snyder, p.200
State
Prolonged
25
0
Prolonged
50
0
30 minutes
Immediate
[Type text]
Effect
30]
EPA
Immediate
Stimulation
of
respiratory
system, leading to hyperpnoea
(rapid breathing); followed by
Fuller, p.940
Unconsciousness, death
100
0
Immediate
750 1000
500
0
Immediate
Immediate
Milby, p.192
Death
Fuller, p.940
EPA
43 Italics signify concentrations and health effects in studies that rely on self-reporting of
symptoms, usually in questionnaires.
[Type text]
Acid Rain
Acid rain occurs as a result of NO x and SOx emissions that are transformed in the earths
atmosphere and return to the surface as dry deposits or in rain, snow or fog. Acid rain is not a
localized problem, these pollutants travel hundreds of miles in the atmosphere, and the acid
deposits often fall far from their sources. The debates on acid rain have focused on reducing the
emissions of Sulphur dioxide (SO2) and NOx.
[Type text]
Nox
Dust
When background levels of dust are high, dust emission from the stack should not
be greater than 100 mg/ m3.
Water
[Type text]
Temperature
40oc (max)
pH
6.0 to 9.0
Free Oil
10 mg/liter (max).
[35]
[8]
Length = 14 ft.
Diameter = 5ft.
Base cost = 22000 $ (See Figure 8.1 in Appendix D1)
Pressure factor at 1000 psi = 4.2
Vessel cost = 92400 $
For two vessels = 184800 $
[8]
Length = 14 ft.
Diameter = 5 ft.
Base cost = 12000 $
[10]
Length = 34 ft.
Diameter = 5 ft.
Base cost without trays = 60,000 $
Pressure factor at 1000 psi is 4.2 plus stainless steel 304 SS is 3.5 = 462000 $
Tray cost = 6,500
Stainless steel tray factor is 1.5 = 9750 $
[Type text]
[10]
Length = 42 ft.
Diameter = 5 ft.
Base cost without trays = 73,000 $
[37]
BOOSTER PUMP
Flow = 218 gpm
Differential pressure (psi) = 98.70
Base cost = 7000 $
Stainless steel factor is 2.45 = 17150 $
CIRCULATION PUMP
Flow = 218 gpm
Differential pressure (psi) = 98.70
Base cost = 30,000 $
Stainless steel factor is 2.45 = 73,500 $
REFLUX PUMP
Flow = 207.4 gpm
Differential pressure (psi) = 466
Base cost = 2500 $
Stainless steel factor is 2.45 = 3436 $
[Type text]
[8]
Area of heat transfer 882 sq. ft. (See Figure 8.4in Appendix D4)
Cost from figure 14-25 (plant design and economics for chemical engineers) is 2000 $
FIN FAN COOLER
(AC-100)
Cost = 125500 $ [27]
(AC-101)
Cost = 278400 $ [27]
diameter inches
2
4
4
4
4
2
10
4
4
LIQUID LINE
dollar/ft.
5
6
64
6
64
5
244
6
6
[8]
4
4
2
6
12
6
15
5
20
TOTAL COST OF LQUID LINES
72
90
100
8142
($)
Table-10.2 Gas line Cost
line number
1
2
4
6
14
16
[8]
GAS LINE
dollar/ft.
total length (ft.)
4
50
9
12
9
10
9
20
64
42
5
42
TOTAL COST OF GAS LINES
diameter inches
2
4
4
4
4
2
($)
*
[15]
[10]
[Type text]
Fraction of Purchased
Calculated value $
Purchased equipment
Equipment
0.47
1494519
installation
Instrumentation and controls
Piping (installed)
Electrical system (installed)
Buildings (including service)
Yard improvements
Service facilities (installed)
TOTAL DIRECT COST $
0.36
0.68
0.11
0.18
0.10
0.70
1144739
2162284
349781
572369
317983
2225880
8267555 $
Fraction of purchased
equipment
0.33
0.41
0.04
0.22
0.44
Calculated value $
1049344
1303730
127193
699562
1399125
4578954 $
LABOUR CHARGES
1. Plant capacity = 1309680 kg/sec for gas
2. Using figure 6.9 page 265 peter
[10]
Table-10.5
Maintenance cost
10 % of fixed capital
1284651
Operating supplies
Supervisory and clerical labor
Laboratory charges
Local taxes
investment
10 % of maintenance cost
20 % of operating labor
10 % of operating labor
4 % of fixed capital
128565
34559
17280
565246
insurance
investment
1 % of fixed capital
141312
Financing (interest)
Plant overhead cost
Administrative cost
Research and development
investment
10%of total capital investment
60 % of OP, SV, and MM
20 % cost of OP, SV and MM
2 % of every sell dollar
1413116
895203
298401
388539
[Type text]
PAYBACK PERIOD
[Type text]
RETURN ON INVESTMENT
1. ROI = (annual profit / total capital investment) x 100
2. Annual profit = 13816678 $
3. Total capital investment = 14131160 $
4. ROI = 97.77 % per year
RESULTS
TOTAL CAPITAL INVESTMENT
TOTAL MANUFACTURING COST
ANNUAL REVENUE
ANNUAL NET PROFIT
PAY BACK PERIOD
RETURN ON INVESTMENT
[Type text]
14131160 $
5610290 $ per year
19426968 $ per year
13816678 $ per year
1.08 year
97.77 % per year
J.M.
and
Richardson
J.F.,
Chemical
Engineering
Design
Elsevier,
[Type text]
[Type text]