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LPG 11ahmad
LPG 11ahmad
LPG 11ahmad
Submitted By Ahmad, Rafiq Malla, Majed A. Osama El-Majzoub Det Hladky ,Maros Shadman Far, Amir Usman, Muhammad
Table of Contents
Abstract .......................................................................................................................................................... i 1. Introduction ...................................................................................................................................... 1 1.1 1.2 1.3 2. Properties .................................................................................................................................. 1 Uses of LPG ............................................................................................................................... 3 The future for LPG ................................................................................................................. 3
Natural Gas Liquids Processing ............................................................................................................. 5 2.1 LPG Recovery Processes ................................................................................................................ 5 Recontacting-compression ................................................................................................... 6 Refrigeration ......................................................................................................................... 6 Lean oil absorption................................................................................................................ 6 Adsorption............................................................................................................................. 6
LPG Manufacturing ....................................................................................................................... 6 Acid gas removal ................................................................................................................... 7 Extraction Unit ...................................................................................................................... 7 Fractionation Unit ................................................................................................................. 7 Deethanizer Section .......................................................................................................... 8 Depropanizer Section ........................................................................................................ 8 Debutanizer Section .......................................................................................................... 9 Product Treatment Plant ...................................................................................................... 9
Simulation ........................................................................................................................................... 12 3.1 3.2 Feed conditioning ....................................................................................................................... 12 Fractionation columns ............................................................................................................ 13 3.2.1 Deethanizer ................................................................................................................. 13 Debutanizer............................................................................................................. 14 Depropanizer .......................................................................................................... 15 Butane splitter .................................................................................................... 16
4.
LPG Transport ..................................................................................................................................... 17 4.1 4.2 Continuous flow of LPG Pipe system ....................................................................................... 17 Discrete (bulk) means of LPG transport .................................................................................. 18
Vessel tanker transport ................................................................................................... 19 Rail, truck, car transport ............................................................................................. 20 Economic analysis ....................................................................................................... 20
List of Tables
Table 1: Typical Properties of LPG ................................................................................................................ 2 Table 2:Fractionator types for LPG Production (Abdel-Aal, H. K.et al 2003) ................................................ 9 Table 3:Different Contaminants in LPG (Abdel-Aal, H. K.et al 2003) ............................................................ 9 Table 4: Specifications of feed for NGL fractionation unit (Manley ,D.B.) .................................................. 10 Table 5:Product specifications for LPG (Manley ,D.B) ................................................................................ 11 Table A1:Simulation reults ......................................................................................................................... 27
List of Figures
Figure 1:Blockdiagram for LPG Manufacturing (Parkash ,Surinder ,2009) .................................................. 7 Figure 2: Typical Fractionator train for NGL (Parkash ,Surinder 2009) ........................................................ 8 Figure3: Feed conditioning alt.1 ................................................................................................................. 12 Figure 4: Feed conditioning alt.2 ................................................................................................................ 13 Figure 5:Feed conditioning alt.3 ................................................................................................................. 13 Figure 6: Deethanizer column ..................................................................................................................... 14 Figure 7: Debutanizer column ..................................................................................................................... 15 Figure 8: Depropanizer column................................................................................................................... 15 Figure 9: Butane splitter ............................................................................................................................. 16 Figure A1: Process Flow Sheet (Simulation sheet from Hysys) ................................................................... 26 Figure A2. Distribution Chain (World LP Gas Association 2009) ................................................................. 28 Figure A3: Mid-America Pipeline (Willbros Group, Inc. 2011) .................................................................... 29 Figure A4: Jamnanagar New Delhi ............................................................................................................. 29 Figure A5: SST,SSM ..................................................................................................................................... 30 Figure A6: amerigas Canister ...................................................................................................................... 30 Figure A7: World LPG gas consumption (Fundamentals of the World Gas Industry, 2008) ....................... 31 FigureA 8: World autogas consumption (Fundamentals of the World Gas Industry, 2008) ...................... 31
Abstract
Raw natural gas contains valuable heavier hydrocarbons such as ethane, propane, butane and fraction of higher hydrocarbons. These associated hydrocarbons, known as natural gas liquids (NGL), must be recovered from the gas in order to control the dew point of natural gas stream and to earn revenue by selling these components as products for different industries. Natural gas liquids are fractionated to produce LPG. The purpose of this report is to see the method to fractionate different NGLs to produce LPG. Different processes for LPG production and recovery from natural gas are discussed. Further, process has been described for LPG production from NGL by fractionation. Simulation for fractionation columns has been done in order to investigate the material and energy balance. An overview of LPG transportation through canisters and pipeline, which is a new thing, has been highlighted in the report. Economic analysis and future market for LPG has been highlighted to see whether this product can be an alternative to high fuel consumption and demands or not.
1.1
Properties
LPG is as twice as heavy as air and half as heavy as water and it is colorless and odorless. LPG can be compressed at a ratio of 1:250 which enables it to be marked in portable containers in liquid form as mentioned above. LPG also produces less air pollutants and carbon dioxide than most other fuels; it helps to reduce the emissions of the typical house
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Property Liquid Density Conversion(Ltr per ton) Gas Density/air Boiling Point (C) Latent Heat of Vaporization Specific Heat(as liquid) Sulfur Content Calorific Value
Propane 0.50-0.51 1968 1.40-1.55 -45 358 KJ/Kg 0.60 Btu/deg 0-0.02% 2,500 Btu/ft3
Butane 0.57-0.58 1732 1.90-2.10 -2 372 KJ/Kg 0.57 Btu/deg 0-0.02% 3,270 Btu/ft3
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LPG is used as fuel, especially for vehicles such as cars and motorcycles, also as an aerosol propellant and refrigerant to avoid damage to the ozone. It is an advantage to use LPG as a fuel for vehicles because it burns cleaner than petrol and diesel. Another use is as a refrigerant. Propane gas and butane gas are used to make hydrocarbon refrigerants. Hydrocarbons are known to be more energy efficient and cheaper than other chemicals, which is why it is suitable to be used as refrigerants. Another popular use is as a cooking fuel. LPG is very popular, especially among countries like India and other Asian countries. LPG is used as a cooking fuel for households and even businesses such as restaurants. As for propane, it is more popularly being used as fuel for barbeques and portable stoves. This is because propane has a low boiling point, so it will vaporize once it is released from the container. Butane, on the other hand, is famously bottled as fuel for lighters and deodorants. When propane and butane combine together, they become LPG. LPG can be used as a back-up or secondary fuel in generating the energy for the household. For example, in order to heat water in winter, LPG is used alongside a solar panel to provide enough energy for this purpose.
1.3
LP Gas has played a valuable role in meeting the worlds energy needs. In the future, LPG has the opportunity to enhance this role by also helping to combat climate change. By releasing fewer harmful pollutants when used as a domestic and automotive fuel source LPG is not only a cleaner alternative but also a healthy one. It seems that the portable nature of bottled LPG, combined with its clean burning characteristics, presents an immediate winning solution to rapidly expand the availability of modern energy to those that have been without it. LPG can claim to be ahead of its time, for its clean-burning, low-carbon advantage is available at once, so that even using todays technology, most industries can exceed Kyoto greenhouse gas reduction targets by switching to LPG. LPG produces lower greenhouse gas
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Our aim/objective of this report is to study the fractionation of natural gas liquids to produce LPG, (Abdel-Aal, H. K et.al 2003). We will discuss first different LPG manufacturing processes.
2.1
Natural gas mainly contains methane and smaller amounts of ethane, propane, butane and heavier hydrocarbons along with varying amount of water vapors, carbon dioxide, sulfur compounds and other non-hydrocarbons. Ethane, propane, butane and propane are known as associated gases. The removal of these gases from raw natural gas is necessary to meet the desired consumer specifications of natural gas and to extract valuable products such as LPG from natural gas. Various techniques are used to recover LPG from natural gas/oil. 1. Recontacting-compression 2. Refrigeration 3. Absorption 4. Adsorption 5. A combination of above
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2.1.3 Lean oil absorption This method employs the hydrocarbon oil to recover lighter fractions. This process is used in refineries and also in gas processing plants. LPG recovery by this process is 98%. 2.1.4 Adsorption Adsorbents are used in this process so that gas molecules are bonded to the surface. Normally silica gel, activated carbon and alumina are used as adsorbent. The LPG recovery by this process is significantly lower than other two processes.
2.2
LPG Manufacturing
LPG is produced by fractionation of natural gas liquids and from crude oil by distillation, catalytic cracking, delayed cokers and hydrocrackers. LPG manufacturing process starts with acid gas removal and extraction unit, then fractionation unit and ends with the product treatment plant. The simple process is described in the following block diagram. (Parkash ,Surinder ,2009)
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Extraction Unit
Fractionation Unit
2.2.1 Acid gas removal Raw gas from the well head is received in knock out drums to separate gas and liquid phases. The oil field gases contain corrosive acid gases like CO2 and H2S.Removal of these gases is necessary to further process the gas for LPG production or more products. These acid gases are removed by amine treatment or Benfield processes .After this, acid gases free natural gas is sent to extraction unit. 2.2.2 Extraction Unit The feed of extraction unit is the combination of associated gases and condensate. The product streams are divided into three steps .One having the liquid stream rich in propane, butane, and gasoline is sent to the fractionation tower for LPG production and other two streams to the product gas unit for further processing. 2.2.3 Fractionation Unit Liquid stream consisting of ethane, propane, butane and pentane is treated in the fractionator trains to separate them and sold as LPG. Complete process flow sheet is shown in figure 2. Fractionation tower consists of three columns: Deethanizer, Depropanizer and Debutanizer. The whole process description is as follows.
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2.2.3.1
Deethanizer Section
Raw gas containing associated gases is fed from the top of the Deethanizer. Deethanizer operated at approximately 390lb/in2. We separated out ethane from this column. The overhead product is ethane in the form of vapors, which is partially condensed in the condenser by using propane at 20oF and collected in the reflux drum. Condensed product is recycled to the Deethanizer tower and non-condensed vapors (mainly ethane) are sent to the fuel gas system. Temperature inside tower is maintained by supplying heat from reboiler. The bottom product from Deethanizer enters into the next columns, depropanizer. 2.2.3.2 Depropanizer Section
The pressure of Deethanizer bottom product is reduced to 290 lb/in2 and then entered into the depropanizer. The overhead product of this column is propane rich and is condensed in the condenser by using cooling water. The condensed product is collected in the reflux drum. Some amount of this is refluxed back to the column. Heat is supplied through direct fired heater.
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Bottom product Ethane Propane plus Butanes plus Natural gasoline(pentanes plus) Normal butane
2.2.4 Product Treatment Plant Propane and butane products separated from the fractionation plant contain some impurities as residual water, H2S, Carbon disulfide and sulfur compounds. These impurities should be removed in order to meet the desired product specifications. The contaminants and their reasons for removal have been listed in the table below.
Table 3:Different Contaminants in LPG (Abdel-Aal, H. K.et al 2003)
Contaminants Hydrogen sulfide Carbon dioxide Carbonyl sulfide Carbon disulfide Mercaptans Organic sulfides Nitrogen Water
Reasons for Removal Safety and Environmental Corrosion control Product specification Prevention of freeze out at low temperatures Prevention of catalyst poisoning in downstream facilities
Numerous processes are available to remove contaminants but two of them are the most important and commonly used.
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2.3
Feed for NGL (Natural gas liquid) fractionation plants comes from upstream processing plants, which receives feed directly from gas reservoirs. Feed composition is different from different reservoirs. Feed composition is important for design considerations. The feed for NGL fractionation trains contain methane, ethane, propane, butane and heavier ones. The feed composition for NGL fractionation column is shown in the table below.
Table 4: Specifications of feed for NGL fractionation unit (Manley ,D.B.)
Liquid volume%
Methane,C1 Ethane,C2 Propane,C3 Isobutane,iC4 N-Butane,C4 Butanes, Iso-pentane,iC5 Pentanes N-pentane,NC5 N-hexane,NC6 N-heptane,NC7
Feed
Ethane
Propane
Iso-Butane
N-Butane
Gasoline
1.36 95.14 3.50 7.32 90.18 2.0 96.0 2.0 2.50 4.50 95.0 3.0 33.13 0.50 23.52
5.0 3.5
4.0 2.0
26.90 13.45
2.4
Product Specifications
The product specification for LPG plant is shown in the following table. This data has been provided by the US Gas Processors Association. The products specifications must be met to sale the qualitative gas. Vapor pressure and temperature are the most important parameters which should be controlled during operation.
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and propene
and butene
volatile residue: F b Butane and heavier, vol% Pentane heavier, vol% Residual matter, , mL Oil stain observation Volatile sulfur,grains/100 cu ft Moisture content Free water content pass d none none pass d pass c 15 15 15 pass c 10 0.05 0.05 and 2.0 2.0 2.5 2.5
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3.1
Feed conditioning
The feed streams are NGL and their compositions are given in appendix. The first feed stream is coming from separation unit from well stream and the second feed from dehydration unit. The temperature and pressure of the feeds are given to be 25C and 30 bar but they have different flow rates. These feeds are to be processed in order to extract LPG products that are propane, isobutane and n-butane. The products were selected based on demand in LPG market. Before the Deethanizer column the feeds are to be conditioned. There are three alternatives for conditioning. First alternative is to mix both feeds before Deethanizer column and then expand the mixed feed. A separator is used to remove the lighter hydrocarbons that are methane and ethane. An illustration of this alternative is shown in figure (3)
The second alternative is to expansion and separation of methane in each stream. The bottom stream from the separators in each stream are mixed in mixer and then sent to deethanizer as shown in figure (4).
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The third alternative is to mix both feeds, expand the mixed feed and let it into the Deethanizer column as shown in figure (5). In this project the third alternative was considered to be the best choice.
3.2
Fractionation columns
3.2.1 Deethanizer
In this project no refrigeration is used in order to minimize the cost. The first column is deethanizer where no condenser is used and the top product gases (methane and ethane) are withdrawn from top if gas phase. The feed is fed to the column from top. See Figure (6).
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3.2.2 Debutanizer Here the debutanizer was used before depropanizer for economic reason so that the next separation will be easier and the depropanizer will be smaller. In debutanizer the butane and lighter hydrocarbons are withdrawn as top products and condensed in condenser while heavier hydrocarbons are withdrawn from bottom as bottom products. A debutanizer model is shown in figure (7). In modelling the debutanizer two specifications are required in order to converge the column since both condenser and reboiler are present. In this case both distillate rate and component recovery of both propane and butane in top are selected. In modelling the
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3.2.3 Depropanizer
Depropanizer separates propane from butane with a similar modelling to debutanizer. Propane is withdrawn from top as top product after condensing and butane as bottom product. Figure (8) shows depropanizer column. Since there are only butane and propane in the feed, the modelling is easier. Both component recovery and component ratio are selected as specification. With thses specifications over 99.8% of propane was recovered in the top product. The condition inside the column is as follow: 15 stages, top and bottom pressure 9 and 10bar respectively.
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Demand for LPG is growing constantly. It is used in all energy requiring areas, particularly residential and commercial sectors of developed or developing countries. It is expected, that with population growth bonded with energy demand, the use of clean liquid and gaseous fuels will continue to increase. At the same time, the historic levels of oil prices are pushing the transportation demands of LPG. New transportation projects are expected to come, alongside with many already in planning stage. With increasing access to LPG and many new market possibilities, complex and innovative solutions for transport problems will play important role in those projects. The LPG distribution chain can be seen in fig 2A in appendix. Due to the fact, that LPG in normal conditions (1 bar, 20C) has gaseous form, unequal distribution in area, seasonal consumption and static, highly localized production, many problems had to be overcome and wide network of transport systems was developed. To fulfill certain pressure and market requirements, two main types of LPG distribution was introduced: Continuous flow of gas characterized by all types of pipe technologies, providing cheap, constant and simple access to LPG at the expense of high preliminary investments, localized storage terminals and additional extended network of delivery. Discrete (bulk) means of transport characterized by moving certain amount of LPG in pressurized canisters carried by cars, trains, ships. Each of those two branches contains special types of transport and is described by different safety measures and precautions. Due to their complexity its necessary to describe that in few paragraphs bellow.
4.1
LPG flow in certain time of its migration to consumers through pipelines. Although the initial construction expanses ale high, the result if are build and correctly maintained is significant. This way of LPG transport is most economic and safe, and moreover, has some other advantages such as : Better availability of LPG in hardly accessible areas Significant LPG transport reduction costs
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4.2
The discrete transport system is completely opposite than Continuous system. Where pipe system was rigid in delivery, the discrete system is flexible, in the terms of place, amount and time. The same works for price, initial investments are lover in comparison, but overall expenses are higher in order. As a result, other than pipeline systems are used whenever the pipes would be economically unjustifiable. Detailed view to each type can be read below.
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4.3
Economic analysis
Supplies of LPG are continually rising, closely followed by prices. And, the estimations show, that it will have positive future. The demand for LPG on market over years is stable, that in combination with rising supply would for commonly thinking mind signalize, easing of prices. However, the situations on markets looks different. For illustration, the price of propane rose during last few years from 500 dollars/tone to 900 d/t in late 2007 and 1500 d/t in 2011. This increase is however inevitable. It is caused by many factors, one of the biggest, is close link to price of crude oil and constantly weakening dollar. Quick rise of prices choke the demand for LPG few times in
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Main sources of LPG Refinery production increasing Crude oil associated gases processing moderate increase Non-associated natural gas processing significant increase due to new started up discoveries and large volumes originated from Qatar, Iran, UAE and Nigeria. In the past was estimated, that petrochemical industry will not be able to consume these increasing amounts, resulting in LPG price moderation. Unfortunately, as actual prices show, it didnt happen. Future estimations in this direction are unwise.
Demand Petrochemical industry in western Europe and Middle East - rising Middle East, Asia and Africa domestic sector rising Transport sector (autogas) in Europe and Asia Pacific rising North America - falling around 2,3m t/year
The increase in demand is highly fractionated, by timescale, geographically or by sector. See Fig.A7 in appendix. In domestic sector, the increase is stable thanks to easy access to LPG cylinders, growing infrastructure, substitution of other types of fuel by LPG etc. Also, domestic market in Asia shows positive numbers. Population and income are rising quicker than grid based energy sources, resulting in higher demand for flexible LPG. Similarity with natural gas is next key reason for rising LPG demand. For industry, possibility to relative easy switch from natural gas to LPG means high valued advantage, mainly in long term NG prices predictions. LPG is used also as a backup plan for NG using industry, and not surprisingly, for large-scale capital investors. Autogas sector was rising in last years probably in highest pace from all sectors. Over year growth in consumption is app. 6%. Two thirds of this consumption is located in only 7
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[1] Abdel-Aal, H. K. , Aggour ,Mohamed, Fahim, M. Al. (2003) Petroleum and Gas Field Processing, Marcel Dekker INC, New York Basel, pp- 317-329
[2] Asian development bank PROJECT COMPLETION REPORT ON THE LPG PIPELINE PROJECT (Loan 1591-IND) IN INDIA ;(2003)
[3] Bahnassi ,Essam , Khouri,Abdul Rahman , Alderton,Peter , Fleshman ,James Achieving product specifications for ethane through to pentane plus from NGL fractionation plants, (AIChE Fall Conference, Foster Wheeler); 2005
[4] Elvers ,Barbara (2008) Handbook of fuels: energy sources for transportation, WileyVCH-Verlag GmbH & Co, pp-142-149
[5] Fundamentals of the World Gas Industry, 2008, http://91.121.21.64/page_attachments/0000/0330/Petroleum_Economist.pdf [6] Gail India Limited, 2011, http://gail.nic.in/gailnewsite/businesses/lpgpipeline.html
[7] Manley.D.B. Thermodynamically efficient distillation: NGL fractionation; Department of chemical engineering, university of missouri rolla, Rolla, Missouri
[8] Naturalgas.org 2011, http://naturalgas.org/naturalgas/transport.asp [9] Parkash ,Surinder (2009) Petroleum Fuels Manufacturing Handbook: including Specialty Products and Sustainable Manufacturing Techniques McGraw-Hill Professional Publishing, pp-4-10 [10] Ren Raaijmakers, Offshore terminals for the transportation of Liquefied Petroleum Gas, Bluewater Offshore Production Systems (USA), Inc., http://www.bluewateroffshore.com/downloads/PT26_LPG%20SPM_bluewater.pdf
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Appendix
Figure A1: Process Flow Sheet (Simulation sheet from Hysys)
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Feed2 0.0000
Feed 0.0000
Feed in 0.0000
C1.C2 0.9985
C3+ 0.0000
C3+ in 0.3064
C5+ 0.0000
0.0000
C KPa
25.0 3000
25.0 3000
24.87 3000
25.06 2600
37.54 1800
246.7 2600
235.2 1700
251.7 1700
225.9
122.2
348.1
348.1
62.09
286.0
286.0
242.0
8000
3.300e+ 004
1487.0
3.151e+ 004
13.38
49.39
4.119
45.27
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FigureA 8: World autogas consumption (Fundamentals of the World Gas Industry, 2008)
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