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Fractionation of Natural Gas Liquids To Produce LPG
Fractionation of Natural Gas Liquids To Produce LPG
Fractionation of Natural Gas Liquids To Produce LPG
Submitted To
Prof. Jon Steinar Gudmundsson
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
Properties .................................................................................................................................. 1
1.2
1.3
2.
2.1.1
Recontacting-compression ................................................................................................... 6
2.1.2
Refrigeration ......................................................................................................................... 6
2.1.3
2.1.4
Adsorption............................................................................................................................. 6
2.2
2.2.1
2.2.2
2.2.3
2.2.3.1
2.2.3.2
2.2.3.3
2.2.4
3.
2.3
2.4
Product Specifications................................................................................................................. 10
Simulation ........................................................................................................................................... 12
3.1
3.2
Deethanizer ................................................................................................................. 13
3.2.2
Debutanizer............................................................................................................. 14
3.2.3
Depropanizer .......................................................................................................... 15
3.2.4
4.
4.2.1
4.2.2
4.3
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
1|Page
GrossHeatValue
) of 73.5-87.5 MJ/Sm3 which is a
SpecificGravity
Property
Propane
Butane
Liquid Density
0.50-0.51
0.57-0.58
1968
1732
Gas Density/air
1.40-1.55
1.90-2.10
-45
-2
358 KJ/Kg
372 KJ/Kg
0.60 Btu/deg
0.57 Btu/deg
Sulfur Content
0-0.02%
0-0.02%
Calorific Value
2,500 Btu/ft3
3,270 Btu/ft3
2|Page
Uses of LPG
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
3|Page
4|Page
Water Removal
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
5|Page
Expander Plants
Combined 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)
6|Page
Extraction Unit
Fractionation Unit
Product
Treatment Unit
Finished Product
LPG
7|Page
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.
8|Page
Type of fractionator
Feed
Top product
Bottom product
Demethanizer
C1/C2
Methane
Ethane
Deethanizer
LPG
Ethane
Propane plus
Depropanizer
Deethanizer bottoms
Debutanizer
Deisobutanizer
Debutanizer top
Propane
Butanes plus
Natural gasoline(pentanes plus)
Isobutane
Normal butane
Contaminants
Hydrogen sulfide
Carbon dioxide
Corrosion control
Carbonyl sulfide
Product specification
Carbon disulfide
Mercaptans
Organic sulfides
Prevention of catalyst
Nitrogen
Water
at low temperatures
Numerous processes are available to remove contaminants but two of them are the most
important and commonly used.
9|Page
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
Feed
Ethane
Propane
Iso-Butane
N-Butane
Methane,C1
0.5
1.36
Ethane,C2
37.0
95.14
7.32
Propane,C3
26.0
3.50
90.18
Isobutane,iC4
7.2
96.0
4.50
N-Butane,C4
14.8
2.0
95.0
Gasoline
volume%
Butanes,
2.0
2.50
Iso-pentane,iC5
5.0
Pentanes
3.5
3.0
33.13
0.50
23.52
N-pentane,NC5
N-hexane,NC6
4.0
26.90
N-heptane,NC7
2.0
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.
10 | P a g e
Commercial
Commercial
Commercial propane
Propane
characteristics
propane
butane
butane mix
5a
Composition
mainly
propane
and propene
mainly
butane
and butene
mainly
mixes
HD-
of
90 % propane;
butane butene
Vapor
(max.)
pressure
at
208
70
208
208
37
36
36
37
100F,
psig b
Temperature
of
volatile residue: F b
Butane and heavier,
2.5
2.5
vol%
Pentane
and
2.0
2.0
heavier, vol%
Residual matter, ,
0.05
0.05
pass c
pass c
Volatile
15
mL
15
15
10
sulfur,grains/100 cu
ft
Moisture content
Free water content
pass d
pass d
none
none
11 | P a g e
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).
12 | P a g e
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).
13 | P a g e
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
14 | P a g e
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.
15 | P a g e
16 | P a g e
LPG Transport
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.
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 :
LPG pipeline system is not as wide as NG and oil pipeline system, however, it still follows all
LP gas production consumer steps. Also, it is not evenly spread over the globe and
differs by continents and final usage.
Most widespread network is in Europe, where LPG is mainly used in residential areas for
water heating. The pipes are mostly made from carbon steel and are 1 to 6 wide.
Different situation occurs on USA, where LPG is used for distributed power generation. As a
result, pipe network is not so wide, but the existing pipes are larger, and generate higher gas
flow to Gas plants. One example is double pipeline from New Mexico to Minnesota and
Wisconsin Mid-America Pipeline. First system devoted only for LPG. It is 3540 km ANSI900
system of 4to 10 pipeline, was constructed in 1960, and includes 6 delivery, 2 operating
terminals, 14 pumping stations and underground storage. The pipeline map is shown in fig.
A3 in appendix .
Similar example with different goal was established in India, where 33.6 million Indian
households in 2001 were using LPG for cooking. Primary cooking usage, lack of developed
infrastructure, and vast unsupplied areas had lead to building 1900 km LPG mostly 12 to
16 pipeline network. 1300 km branch connects Jamnagar on the west with New Delhi area
on the north. And 600 km of network is connecting Vizag on the east coast with midlands
Secenderabad. The LPG transmission system has a capacity 3.8 MMTPA LPG. The Jamnagar
New Delhi branch can be seen on figure A4 in appendix.
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.
18 | P a g e
Pressurized tankers (18 bar, ambient temperatures) used in short to medium haul
trades. Carrying capacity differs from 3 000 10 000 m3.
Semi-pressurized tankers (5-8 bar, -15 5C) for medium haul trades, with capacity 10
000 30 000 m3.
Fully refrigerated vessels (ambient pressure, -43C for pure propane) are used for long
haul trades, with high LPG demand, e.g. Japan. Those carrying capacity varies from 30
000 to 100 000 m3.
There is also considerable fleet of very small vessels used mainly for coastal, short sea and
inland-river trades.
Because the LPG vapors are highly flammable, without scent and unrecognizable by naked
eye, some safety precautions was introduced to avoid leakage or any disaster. The
containers for LPG have usually strong walls, and are shielded from outside area by innerwall layer of inert gas, mostly nitrogen. Also, because of possibility to carry other gases,
before loading are cleaned by CNG vapors blow.
Vessel transport itself can be considered as simple and safe in comparison to on-loading and
offloading. There are two main systems of transfer nowadays, static shore terminal (SST),
and single point mooring system (SPM).
SPM consist of onshore LPG storage facility and LPG offshore buoy, connected by flexible
pipelines. Thanks to the pipeline connection, SPM can be considered as middle-step
between pipe and vessel transport. Floating buoy allows connection of all types of tankers,
360 movement grants tanker possibility to moor from all sides depending on bathymetry
19 | P a g e
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
20 | P a g e
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
22 | P a g e
LPG can be an alternative fuel for vehicles as it burns cleaner and greenhouse gas
emissions can be controlled. So, it can help us to combat climate change.
LPG can be recovered from natural gas liquids by different methods. Refrigeration
method is more common of all because recovery from this process is 98%.
There are three alternatives to condition the feed stream for fractionation unit. It
has been found to be the best choice to mix the two feed streams from the wells
having different compositions and feeding it to deethanizer first.
The separation of iso and n-butane is more difficult and more number of stages are
required in order to do the separation which in turn increases the overall cost.
23 | P a g e
[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)
[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
24 | P a g e
25 | P a g e
Appendix
Figure A1: Process Flow Sheet (Simulation sheet from Hysys)
26 | P a g e
Vapor
Feed1
Feed2
Feed
Feed in
C1.C2
C3+
C3+ in
C5+
0.0000
0.0000
0.0000
0.0000
0.9985
0.0000
0.3064
0.0000
Fraction
Temp.
25.0
25.0
24.87
25.06
37.54
246.7
235.2
251.7
Pressur
KPa
3000
3000
3000
2600
1800
2600
1700
1700
Molar
Kgm
225.9
122.2
348.1
348.1
62.09
286.0
286.0
242.0
Flow
ol/hr
Mass
Kg/h
2.500e+
8000
3.300e+
3.300e+
1487.0
3.151e+
3.151e+
2.916e+
Flow
004
004
004
004
004
004
Liquid
M /h
Volume
36.00
13.38
49.39
49.39
4.119
45.27
45.27
41.02
5.499e+
1.986e+
7.485e+
7.485e+
5.203e+
5.016e+
5.016e+
4.524e+
007
007
007
007
007
007
007
007
flow
Heat
kJ/hr
Flow
Vapor
C3.C4
C3.C4 in
C4
C3
C4 in
iC4
nC4
0.0000
0.2062
0.0000
0.0000
0.2392
0.0000
0.0000
Fraction
Temperature
76.67
56.50
74.71
22.82
46.17
5.095
50.93
Pressure
KPa
1600
1000
1000
900
500
190
500
Molar Flow
Kg
44
44
29.19
14.81
29.19
10.07
19.12
2356
2356
1702
653.1
1702
583.2
1119
4.243
4.243
2.954
1.289
2.954
1.038
1.916
kJ/
hr
5.499e+00
1.986e+0
7.485e+0
7.485e+0
5.203e+0
5.016e+0
5.016e+0
07
07
07
07
07
07
mol
/hr
Mass Flow
Kg/
hr
Liquid flow
M3
/hr
Heat Flow
27 | P a g e
28 | P a g e
29 | P a g e
30 | P a g e
FigureA 8: World autogas consumption (Fundamentals of the World Gas Industry, 2008)
31 | P a g e