Production of LPG From Natural Gas

CHAPTER 3

MATERIAL BALANCE (A)

3.1 Assumptions
 Complete separation takes place in separators.
 Methane is 64.64% by weight in natural gas.
 Working days of plant is taken to be 350 days.
 Less than 1ppm moisture remains in the outlet of Molecular sieve bed.
 About 20% of water is removed in Knock Out Drum.
 About 35% of water is removed in Drier.
NOTE : water removal is taken as per the ONGC Uran plant.
Plant Capacity = 2.816Lakh TPA
Here we have taken 350 days as working days.
= 2.816x106x103 kg/yeas
= 2.50x103/350x24
= 33820.82 kg/hr.

As product contains :- (by wt %)

Component Weight Flow rate (Kg/hr) Wt.fr.
Propane 58.79 19866.35 0.5879
Butane 39.57 13382.90 0.3957
Pentane 1.47 497.09 0.0147
Ethane 0.22 74.40 0.0022

Table 3.1 Composition of LPG produ

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 Production of LPG From Natural Gas

Natural Gas (feed) contains (wt %)

Component (Wt %)
Methane 64.64
Ethane 12.52
Propane 12.61
Butane 7.30
Pentane 2.16
Hexane 0.047
Nitrogen 0.54
Hydrogen 0.0013
Carbon dioxide 0.010
Water 0.17
Total 100

Table 3.2 Composition of Natural Gas

∴ feed required = 30746.20/0.180 = 1,87000 kg/hr.

Water in feed = 1,87,000x0.17/100
= 317.9kg/hr

3.2 MATERIAL BALANCE AROUND KO DRUM

Top = 186936.42 kg/hr

K
O
Feed = 1,87,000 kg/hr
D
R 34
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 Production of LPG From Natural Gas

Bottom = 63.58kg/hr

Fig.3.1 Material Balance around Knock Out Drum

In this column about 20% of water gets removed from the feed (As per the ONGC
Nomographs).
So, 187,000 x {0.17/100 }x0.20 = 63.58 kg/hr.

Outlet composition

Component Amount (Kg/hr) Wt.fr.

Methane 1,20904.32 0.646
Ethane 23185.51 0.124
Propane 23693.36 0.126
Butane 13716.25 0.073
Pentane 4058.49 0.021
Hexane 88.30 4.72x10-4
Nitrogen 1014.61 5.42x10-3
Hydrogen Sulphide 2.44 1.30x10-5
Carbon dioxide 18.78 10-4
Water 254.32 1.36x10-3
Total 1,86936.42

Table 3.3 Outlet Composition of KO Drum

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 Production of LPG From Natural Gas

3.3 MATERIAL BALANCE AROUND DRIER

Top = 100172.43kg/hr

D
Feed = 1,86682.1 kg/hr R
I
E
R

Bottom = 86509.69 kg/hr

Fig.3.2 Material Balance around Drier

Now the outlet of feed Gas knock out drum sent to dryer where about 35% of water gets
removed feed (As per the ONGC Nomographs).
Water removed = 186936.42x 0.35 = 22.25kg/hr.

Outlet composition

Component Amount (Kg/hr) Wt.fr.

Methane 1,20904.32 0.646
Ethane 23185.51 0.124
Propane 23693.36 0.126
Butane 13716.25 0.073
Pentane 4058.49 0.021
Hexane 88.30 4.72x10-4
Nitrogen 1014.61 5.42x10-3
Hydrogen Sulphide 2.44 1.3x10-5
Carbon dioxide 18.78 10-4
Water 232.06 1.24x10-3
Total 186914.16 1.0

Table 3.4 Outlet Composition of Drier

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 Production of LPG From Natural Gas

3.4 MATERIAL BALANCE AROUND MOLECULAR SIEVE BED

(MSB)

1,86914.16kg/hr. Molecular 1 76682.1Kg/hr.

Sieve Bed

Fig.3.3 Material Balance around MSB

Outlet Composition

Components Amount (Kg/hr) Wt.fr.

Methane 1,20904.32 0.647
Ethane 23185.51 0.124
Propane 23693.36 0.127
Butane 13716.25 0.073
Pentane 4058.49 0.021
Hexane 88.30 4.73x10-4
Nitrogen 1014.61 5.43x10-3
Hydrogen Sulphide 2.44 1.3x10-5
Carbon dioxide 18.78 10-4
Total 186682.1 1.00

Table 3.5 Outlet Composition of MSB

After passing through the chiller the gas mixture enters to High Pressure separator where
30% of C3 and heavy components escapes from top is the form of vapor and 70% is liquid
form from the bottom.
3.5 MATERIAL BALANCE AROUND HP SEPARATOR(HPS)
Top = 100172.43 kg/hr
H
P
Feed = 186682.1 kg/hr S
E
P
A
R
A 37
T
O
R
 Production of LPG From Natural Gas

Bottom = 86509.69 kg/hr

Fig.3.4 Material Balance around HPS

Outlet composition
Components Top (Kg/hr.) wt.fr. Bottom Wt.fr.
(Kg/hr.)
Methane 72707.59 0.725 48196.72 0.557
Ethane 14012.93 0.139 9172.58 0.106
Propane 7108.00 0.071 16585.36 0.191
Butane 4114.88 0.041 96501.37 0.111
Pentane 1,217.53 0.012 2,840.95 0.032
Hexane 26.45 2.64x10-4 61.85 7.14x10-4
Nitrogen 970.64 9.68x10-3 43.97 5.08x10-4
Hydrogen Sulphide 1.22 1.21x10-5 1.22 1.41x10-5
Carbon dioxide 13.14 1.31x10-4 5.64 6.52x10-5
Total 100172.43 1.0 86509.69 1.0

Table 3.6 Outlet Composition of HPS

Now, the vapors (top product) of High Pressure separator sent to the low pressure
separator. Where 95% of C1 & C2 are separated in a vapor form from the top of the
column and heavy components are taken from bottom side containing 70% of feed.
3.6 MATERIAL BALANCE AROUND LP SEPARATOR
Top = 85430.05kg/hr
L
P
Feed = 100172.43kg/hr S
E
P
A
R
A
T
O
R
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 Production of LPG From Natural Gas

Bottom = 14742.33 kg/hr

Fig.3.5 Material Balance around LPS

Outlet Composition
Components Top (Kg/hr) Wt.fr. Bottom (Kg/hr) Wt.fr.
Methane 69072.21 0.808 3,304.89 0.246
Ethane 13312.28 0.155 636.95 0.047
Propane 2132.40 0.025 4,523.27 0.337
Butane 244.46 2.86x10-3 3,870.41 0.262
Pentane 365.25 4.27x10-3 937.50 0.057
Hexane 7.942 9.29x10-5 20.361 1.25x10-3
Nitrogen 291.19 3.17x10-3 747.38 0.046
Hydrogen Sulphide 0.36 4.25x10-6 0.939 5.8x10-5
Carbon dioxide 3.93 4.61x10-5 10.10 6.24x10-4
Total 85430.05 1.0 14742.33 1.0

Table 3.7 Outlet Composition of LPS

Now, the top product of LP separator is sent to condenser and is used as lean gas.
The bottom of High Pressure and Low pressure sent to light end fractionation (LEF)
column where CO2, N2, H2S and CH4 is totally removed.

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 Production of LPG From Natural Gas

3.7 MATERIAL BALANCE AROUND LEF COLUMN

Condenser

Top = 62368.11kg/hr

Distillate=54233.14kg/hr
L
Feed = 101252.03 kg/hr E Reflux = Pump
F 8134.96kg/hr
C
O
L
U
M
N Reboiler

Bottom=38883.91kg/hr
Fig.3.6 Material Balance around LEF column
Total feed at LEF column is = 86509.69+14742.332
= 101252.03 Kg/hr
Feed composition

Components HP separator bottom LP separator bottom

(Kg/hr) (Kg/hr)
Methane 48196.72 3635.37
Ethane 9172.58 700.64
Propane 16585.36 4,975.59
Butane 9601.35 3,870.41
Pentane 2,840.95 852.28
Hexane 61085 18.51
Nitrogen 43.97 679.44
Hydrogen Sulphide 1.22 0.854
Carbon dioxide 5.64 9.201
Total 86509.69 14742.33

Table 3.8 Inlet Composition of LEF Column

Therefore, total feed to the (LEF column is 92047.305 Kg/hr) At CEF column, methane is
totally removed and approximately total ethane along with N2, H2S and CO2 get eliminated.
R = L / D = 0.15 D

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 Production of LPG From Natural Gas

V=L+ D
62368.119 = 0.15 D + D
D = 54233.14kg/hr
Outlet composition
Components Top product (Kg/hr) Bottom product (Kg/hr)
Methane 51832.107 -
Ethane 9795.66 77.56
Propane - 21560.95
Butane - 13471.78
Pentane - 3,693.23
Hexane - 80.371
Nitrogen 723.42 -
Hydrogen Sulphide 2.075 -
Carbon dioxide 14.83 -
Total 62368.11 38883.916

Table 3.9 Outlet Composition of LEF Column

Now doing the individual material balance as:
Vxv = LxL + Dxd

Components Distillate(kg/hr) Reflux(kg/hr)

Methane 45067.73 6,760.16
Ethane 8514.60 1,277.18
Nitrogen 596.56 89.48
H2s 1.800 0.270
Co2 12.907 1.936
Total 54233.14 8134.96
Table 3.10 Composition of LEF Distillate & Reflux
Now, here the distillate of LEF column is sent to the regenerator column so that the lean
gas can be used for heating purpose and then for the selling as a lean gas and LEF bottom
product sent as a feed to the LPG column.

3.8 MATERIAL BALANCE AROUND LPG COLUMN

Condenser
L
Top = 36,061.114kg/hr P
G
C Distillate=33,825kg/hr
O
L
U 41
M
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 Production of LPG From Natural Gas

Feed = 38,883.91kg/hr Reflux = Pump

2,236.14 kg/hr

Reboiler

Bottom=2,882.89 kg/hr

Fig.3.7 Material Balance around LPG Column

In this LPG column, pentane and Hexane removed from the bottom as a natural gas liquid
(NGL)..
Feed to LPG column = 38,883.91 Kg/hr.
R = L0/D
0.15 = L0/D

As we required the outlet rate of product = 33,825 Kg/hr.

So, 0.06611 = L0/33,825
Therefore, L0 = 2,236.14 Kg/hr.

Doing the individual material balance as:

Vxv = LxL + DxD

Outlet composition

Components Distillate(kg/hr) Reflux(kg/hr) Bottom(kg/hr)

Methane - 5.368 -
Propane 20,223.965 1,336.99 -
Butane 12,677.61 838.10 -
Pentane 835.47 55.233 2,802.52
Hexane 81.18 - 80.366
Total 33,825 2,236.14 2,882.89

Table 3.11 Outlet Composition of LPG Column

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Production of LPG From Natural Gas

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