Beruflich Dokumente
Kultur Dokumente
(222357-P)
SHORT ASSIGNMENT:
CHEMICAL ENGINEERING
NOV 2010
ii
Table of Contents
ii
TABLE OF CONTENTS
iii
LIST OF TABLES
iv
LIST OF FIGURES
SECTION 1: INTRODUCTION
1.1 Objective 1
1.2 Study Period 1
1.3 Structure of Tower 1
SECTION 3: RESULTS
SECTION 4: DISCUSSIONS 14
SECTION 5: CONCLUSION 16
iii
LIST OF TABLES
LIST OF FIGURES
LP depropanizer is a distillation column in cracker plant which separate C3 and C4. Therefore,
the incoming feed will be separated as a top vapor which is rich in C3, and a bottom liquid of
essentially C4 and heavier components. Partial reflux system where portion of C3 reflux back to
the tower to increase C3 composition in the top stream. The bottom stream is sent to debutanizer
to recover C4 from heavier components.
1.1 Objective
To compare the flow, reflux ratio and the performance of the LP depropanizer before and after
the turnaround project on October 2010.
1.3 Structure
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SECTION 2: TOWER DETAIL
1. Main liquid feed from the bottom of the HP depropanizer (2T-365) is cooled by cooling water
in LP depropanizer feed cooler (2E-368) and then enter the LP depropanizer at tray 21.
2. Another feed from the bottom of the propylene stripper (2T-530) enters the column at tray 10.
4. The condensing duty for the column is provided by the LP depropanizer condenser (2E-359)
using 7°C propylene refrigerant, which totally condenses the overhead vapor into liquid.
5. The liquid is collected in the reflux drum (2V-366). Part of the liquid is pumped back the top
of the LP depropanizer as reflux, through the pumps (2P-360A/S) to reduce the C4 amount in
the top stream.
6. The remaining liquid is pumped forward to the C3 hydrogenation system via the C3
hydrogenation feed pumps (2P-361A/S). This liquid consists of mainly C3.
7. The reboil duty for the column is provided by the LP depropanizer reboiler (2E-360) using
133°C quench oil, which heat up part of the bottom stream into vapor and send back to the
bottom of the LP depropanizer.
8. The bottom liquid product is essentially C4 and heavier components. This stream is then
transferred to the debutanizer (2T-560).
2
BTM from C3R
2E-359
2T-530 To C3
2V-366
C3 Vapor Hydrogenation
CW
BTM from
2T-365 2P-360A/S
HP DeC3 2E-368
2T-360
LP DeC3 QO
2E-360A/S
C4+ Liquid
To 2T-560
Debutanizer
3
2.2 Flow Controller and Analyzer
1. Flow controller (2FC-3701) regulates the flow of quench oil to the reboiler (2E-
360), reset by the temperature controller (2TC-3704), which used to maintain the
cut point temperature on tray 50.
2. Flow controller (2FC-5303) measures the flow rate of the reflux at the top.
3. Flow controller (2FC-3702) regulates the bottom flow from the LP depropanizer,
which is reset by the column bottom level controller (2LC-3702), to maintain
certain liquid level in the column.
4. Flow controller (2FC-3703) regulates the flow of reflux back to the top of the
column.
5. Flow controller (2FC-3704) regulates the flow to top C3 liquid flow to the C3
hydrogenation system, reset by the reflux drum level controller (LC-3705).
2.2.2 Analyzer
1. Analyzer (2AI-36021) checks on the composition of the main feed from 2T-365.
This is the mole balance calculated based on case 1 (fully naphtha feed) used to compare the
actual flow, reflux ratio and performance of the tower.
4
2FC-
2AI-
5303
36012
C3R
BTM from
2E-359
2T-530 To C3
2V-366
C3 Vapor Hydrogenation
CW 2FC-
BTM from 3704
2T-365 2P-360A/S
HP DeC3 2E-368
2FC-
2T-360 3703
2FC- LP DeC3
3604 QO
2AI-
36021 2E-360A/S
C4+ Liquid
2FC-
3702 To 2T-560
2AI- Debutanizer
36022
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Total: 3154.27 kg/h Total: 25990 kg/h Total: 8416.37 kg/h
≤C3: 2264.39 kg/h ≤C3: 8305.36 kg/h
BTM from C4+: 889.89 kg/h C3R C4+: 111.01 kg/h
2T-530 2E-359 To C3
2V-366 Hydrogenation
CW
BTM from
2T-365 2P-360A/S
HP DeC3 Total: 17573.63 kg/h
2E-368
2E-360A/S
To 2T-560
Debutanizer
Total: 22335.54 kg/h
≤C3: 15.63 kg/h
C4+: 22319.92 kg/h
Reflux Ratio = = 2.088
Legends:
Yield (C3) = = 99.81% Total – Total molar flow rate
≤C3 – C3 and lighter components
Yield (C4) = = 99.51% molar flow rate
C4+ – C4 and heavier components
molar flow rate
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SECTION 3: RESULTS
Plant loads is the percentage of naphtha feed into the furnace decided by maximum naphtha feed based on 100% naphtha feed design.
Percentage %
60 60
50 plantload2 50 plantload2
40 40
30 30
20 20
10 10
0 0
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0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 0 0:00:00 0 12:00:00 0 0:00:00 0 12:00:00 0 0:00:00 0 12:00:00 0 0:00:00
Time Time
Fig 3.1.1: Graph of plant load before TA Fig 3.1.2: Graph of plant load after TA
By comparing the two graphs above, obviously the plant load after the turnaround was much higher. This may be due to the change in
feed where feedstock used was naphtha and LPG before turnaround, and fully naphtha after turnaround.
The plant load is higher after turnaround because of 100% naphtha feed.
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3.2 Total Feed In
Total feed in is the summation of the flows of main feed from the bottom of 2T-365, and from the bottom of 2T-530
50000 50000
45000 45000
40000 40000
35000 35000
Flow Rate (kg/hr)
Fig 3.2.1: Graph of Total feed in before TA Fig 3.2.2: Graph of Total feed in after TA
By comparing the two graphs above, although the total amount of feed flow after the turnaround was fluctuating due to instability, but
the value is almost the same to the feed flow before turnaround.
The feed flow rate has not much different before and after turnaround.
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3.3 Total Flow Out
Total flow out is the summation of the top product that is going to C3 hydrogenation and the bottom liquid flow.
50000 50000
45000 45000
40000 40000
35000 35000
Flow Rate (kg/hr)
5000 5000
0 0
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0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 0 0:00:00 0 12:00:00 0 0:00:00 0 12:00:00 0 0:00:00 0 12:00:00 0 0:00:00
Time Time
Fig 3.3.1: Graph of Total flow out before TA Fig 3.3.2: Graph of Total flow out after TA
By comparing the two graphs above, although the total amount flow out from the tower after the turnaround was fluctuating due to
instability, but the value is almost the same to the total flow out before turnaround.
The amount of flow out from tower has not much different before and after turnaround.
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3.4 Deviation
25000 25000
20000 20000
Flow Rate (kg/hr)
10000 10000
Actual Actual
5000 5000
0 0
-5000 -5000
-10000 -10000
-15000 -15000
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0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 0 0:00:00 0 12:00:00 0 0:00:00 0 12:00:00 0 0:00:00 0 12:00:00 0 0:00:00
Time Time
Fig 3.4.1: Graph of Deviation before TA Fig 3.4.2: Graph of Deviation after TA
By comparing the two graphs above, although the amount of deviation after the turnaround was fluctuating due to instability, but the
value is almost the same to the amount of deviation before turnaround.
From the comparison, the amount of deviation has not much different before and after turnaround.
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3.5 Reflux Ratio
Reflux ratio is a ratio that the amount of top product reflux back to tower divided by the amount of top product sent to the next stage.
5.00 5.00
4.00 4.00
Reflux Ratio
Reflux Ratio
3.00 3.00
Actual Actual
Design Design
2.00 2.00
1.00 1.00
0.00 0.00
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0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00
Time Time
Fig 3.5.1: Graph of Reflux Ratio before TA Fig 3.5.2: Graph of Reflux Ratio after TA
By comparing the two graphs above, obviously the reflux ratio after the turnaround is lower than that before turnaround. This reflux
ratio can be controlled by the Boardman by controlling the amount of top product flowing to the C3 hydrogenation, higher reflux ratio
helps to get higher purity product.
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3.6 Top ≤ C3 composition
Top ≤ C3 composition is the molar percentage of C3 and lighter components in the top stream
100.00 100.00
90.00 90.00
80.00 80.00
70.00 70.00
60.00 60.00
mol%
mol%
50.00 Actual 50.00 Actual
Design Design
40.00 40.00
30.00 30.00
20.00 20.00
10.00 10.00
0.00 0.00
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0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 0 0:00:00 0 12:00:00 0 0:00:00 0 12:00:00 0 0:00:00 0 12:00:00 0 0:00:00
Time Time
Fig 3.6.1: Graph of Top ≤C3% before TA Fig 3.6.2: Graph of Top ≤C3% after TA
By comparing the two graphs above, obviously the percentage of ≤ C3 in top stream became lower after turnaround. Besides, the C3
composition before turnaround not so fluctuate compares to after turnaround which is fluctuate within 70% to 90%.
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3.7 Top C4+ Composition
Top C4+ composition is the molar percentage of C4 and heavier components in the top stream
6 6
5 5
4 4
mol%
mol%
3 Actual 3 Actual
Design Design
2 2
1 1
0 0
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0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00 12:00:00 0:00:00
Time Time
Fig 3.7.1: Graph of Top C4+% before TA Fig 3.7.2: Graph of Top C4+% after TA
By comparing the two graphs above, although the top C4+ molar percentage after the turnaround was fluctuating due to instability, but
the average value is almost the same to the top C4+ molar percentage before turnaround. Besides, the C3 composition before
turnaround not so fluctuate compares to after turnaround which is fluctuate within 70% to 90%.
The average top C4 + molar percentage has not much different before and after turnaround.
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SECTION 4: DISCUSSION
By comparing the actual flows to the design flows, most of the actual flows are closed to
the design flow, except for the Total In Flow. The Total In is about 3500 kg/h higher than the
design feed flow, due to the high flow of main feed from the bottom of HP depropanizer (2T-
365). For the reflux ratio, the actual reflux ratio is closed to the design one before turnaround but
lower to the design after turnaround. For the analyzer part, both the C3≤ and C4+ percentage in
the top stream showing under performance of tower if compared to the design.
From the comparison of Total In and Total Out flows, deviation keeps happening for the
tower no matter before or after turnaround which does not happen in the design condition. This
shows that certain amount of stream has been “missing” from the tower. This may be due to the
following reasons:
1. Sent for flaring or blowdown. However, this reason is not appropriate since the flaring
amount is only little when the plant is running in normal condition.
2. Inaccuracy of the flow indicator. This is reasonable to explain the missing of the flow.
Example like the inaccuracy of flow indicator for the main feed from 2T-365, this could
explain the increase of about 3500kg/h flow compared to the design value.
3. Accumulation in the tower. The product is kept in the tower to maintain the operation
parameter, causes the deviation to occur.
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Besides that, there are a few parameters founded that change after the turnaround:
1. The plant load has been increased. Plant load is the percentage of naphtha feed into the
plant compared to the amount of naphtha feed in the design (100%). This may be due to
the change in feed condition whereby naphtha was mixed with certain amount of LPG as
feed before turnaround, but used fully naphtha after turnaround. Therefore the plant load
used has been increased after turnaround.
2. The reflux ratio has been reduced. Reflux ratio is a ratio that the amount of top product
reflux back to tower divided by the amount of top product sent to the next stage. This
reflux ratio can be controlled by the Boardman by controlling the amount of top product
flowing to the C3 hydrogenation, higher reflux ratio helps to get higher purity product.
3. The percentage of C3 in top stream has been reduced. This shows that the under
performance of the tower after the turnaround. This might be due to the decrease of reflux
ratio, or the change on the plant load.
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SECTION 5: CONCLUSION
In a conclusion, LP depropanizer (2T-360is under performance compare to the design value after
the turnaround. However, the cracker plant is not so stable at the investigation period. Therefore,
a further study should be performed once the cracker plant becomes more stable.
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