Professional Documents
Culture Documents
Project Shihab
Project Shihab
Project definition:
A Methanol plant is to be set up at Birashar,Brahmanbaria in Bangladesh having a capacity
of 312 MT 99.49%(wt%) Methanol per day, corresponding to 112320 MT of 99.49% (wt%)
Methanol per year (360 stream day per year), and an important by product 46.872 MT/day of
96.88 % (wt%)
Methanol per year (360 stream day per year) including all offsites, auxiliaries, utilities and
supporting facilities using Natural gas (96.48% CH4) from near byTitas Gas Field as feed stock.
Composition(mol%)
96.48
1.60
0.35
0.10
0.08
0.05
0.04
0.05
0.19
0.72
0.35
100
b. Steam
Steam specification
100% pure superheated steam
Specification of product
conditions
Mass flow rate(ton/day)
312
Temperature(oC)
Pressure(kPa)
Aqueous fraction
118.3
607.9
1
Composition (Mass fraction)
CH3OH(Methanol)
H2O(Water)
0.995
.005
Properties
Mass density(Kg/m3)
Heat capacity(KJ/Kg-C)
Vapor phase fraction
Viscosity(cP)
Specific Heat(KJ/Kg-mole-C)
Surface tension(dyne/cm)
688.5
4.134
0
0.1853
126.7
19
By product
a.Specification of 96.88 % CH3OH
conditions
Mass flow rate(ton/day)
Aqueous fraction
Composition (Mass fraction)
CH3OH(Methanol)
CO2
46.87
1
0.968
0.031
6.9
0
0.137
0.020
0.008
0.011
0.009
0.025
0.021
0.090
0.688
Utilities
Electric power requirement:3.27 10
13
Plant location
Brahmanbaria/Birashar
Latitude =23.97o
Longitude =91.11o
Area
Total area required for the plant is
Design Basis
Design basis includes site conditions,utilities, raw materials etc.which influence the process
design and the design of individual unit,equipment or facility of the overall project.Design basis
in the present context is different from that one defines in stoichiometry.Design basis here is to
be considered as conditions in existence with which to design the project.
Important design basis includes :
Geological Data
Climate Conditions
Utility Conditions
Structural Design
Raw Materials
Others
Geological Data
Climate Condition
a.Design condition for equipment or facility
I. Process equipment: Summer day (dry bulb temperature =40 oC, Wet bulb
temperature =40oC, avg .relative humidity =90% ); winter day(dry bulb temperature
=12oC )
b.Design conditions for building
I. HVAC : summer day (maximum dry bulb =40oC, wet bulb =40oC)
Winter day (minimum dry bulb temperature =12oC)
II.Ventilation : summer day (maximum dry bulb =40oC)
Winter day (minimum dry bulb temperature =12oC)
c.Meteorological conditions :
I. Ambient temperature
Maximum = 40oC
Avg. daily maximum =38oC
Avg. monthly maximum =40oC
Average =28 oC
Avg. daily minimum =22 oC
Avg. monthly minimum =12 oC
Minimum =21 oC
II.Humidity
Relative humidity =80%
III.Rainfall
Avg. annual rainfall =3499.2 mm
Maximum monthly rainfall =1089.9 mm(July)
Maximum daily rainfall =405 mm
Maximum hourly rainfall =60 mm
Maximum intensity (in a 15 minute period)=108 mm/hr
Design intensity =100 mm/hr
IV. Barometric pressure (at sea level)
Minimum pressure =101253 pa
V. Wind velocity
Maximum recorded wind velocity = 199.8 km/hr
Design velocity =210 km/hr
Utility Condition
a.Raw water
I. Source:filtered water from titas river
II. Supply pressure : as per water treatment plant intake requirement
III. Supply temperature : 32oC
IV. TDS :149 ppm
V. Total hardness : 89 as gm (CaCO3)
VI. Total sulfate : 18 as gm (SO42-)
VII. PH : 7.0
Raw materials
a.Natural gas from Titas gas field
Natural gas specification on the basis of methane composition
Constituents
Composition(mol%)
Methane
96.48
Ethane
1.60
Propane
0.35
i-Butane
0.10
n-Butane
0.08
i-pentane
0.05
n-pentane
0.04
n-Hexen
0.05
n-Heptane
0.19
CO2
0.72
N2
0.35
Total
100
b. Steam
Steam specification : 100% pure superheated steam
Other Information:
Natural catastrophe: A possibility of storm in the months of April-May.
Value of by-products: No economically feasible by-products are obtained.
Process Selection
1. Natural gas Sweetening:
Amine Process: Chemical absorption processes with aqueous alkanolamine solutions are used for
treating gas streams containing hydrogen sulfide and carbon dioxide. However, depending on the
composition and operating conditions of the feed gas, different amines can be selected to meet
the product gas specification. Amines are categorized as being primary, secondary, and tertiary
depending on the degree of substitution of the central nitrogen by organic groups. Primary
amines react directly with H2S, CO2, and carbonyl sulfide (COS). Examples of primary amines
include monoethanolamine (MEA) and the proprietary diglycolamine agent (DGA). Secondry
amines react directly with H2S and CO2 and react directly with some COS. The most common
secondary amine is diethanolamine (DEA), while diisopropanolamine (DIPA) is another example
of a secondary amine, which is not as common anymore in amine-treating systems. Tertiary
amines react directly with H2S, react indirectly with CO2, and react indirectly with little COS.
The most common examples of tertiary amines are methyldiethanolamine (MDEA) and activated
methyldiethanolamine. Processes using ethanolamine and potassium phosphate are now widely
used. The ethanolamine process, known as the Girbotol process, removes acid gases (hydrogen
sulfide and carbon dioxide) from liquid hydrocarbons as well as from natural and from refinery
gases. The Girbotol treatment solution is an aqueous solution of ethanolamine, which is an
organic alkali that has the reversible property of reacting with hydrogen sulfide under cool
conditions and releasing hydrogen sulfide at high temperatures. The ethanolamine solution fills a
tower called an absorber through which the sour gas is bubbled. Purified gas leaves the top of the
tower, and the ethanolamine solution leaves the bottom of the tower with the absorbed acid
gases. The ethanolamine solution enters a reactivator tower where heat drives the acid gases from
the solution. Ethanolamine solution, restored to its original condition, leaves the bottom of the
reactivator tower to go to the top of the absorber tower, and acid gases are released from the top
of the reactivator.
2. Natural Gas Liquid recovery: Choosing a cost-effective NGL recovery technology requires
consideration of a broad range of factors (Mehra and Gaskin, 1999). The main variables that
affect the choice of the most cost-effective process for a given application include inlet
conditions (gas pressure, richness, and contaminants), downstream conditions (residue gas
pressure, liquid products desired, and liquid fractionation infrastructure), and overall conditions
(utility costs and fuel value, plant location, existing location infrastructure, and market stability).
In addition to the feed gas composition and
operation mode, the most decisive technical characteristics of any process are the feed gas
pressure and permissible unit pressure drop. The following guidelines have been suggested for
the selection of a NGL recovery process (Brands and Rajani, 2001).
1. In case of sufficiently high pressure, the self-refrigeration process requires the lowest capital
investment. However, if the pressure differential between feed gas and treated gas is insufficient,
additional compression is required.
2. When the feed gas pressure is close to the treated gas pressure, over a large pressure drop
range, it may be more economical to employ a cryogenic refrigeration process.
3. When the feed gas pressure is clearly below the required pipeline pressure, it is usually most
economical to apply mechanical refrigeration with additional compression to remove heavy
hydrocarbons instead ofcompression followed by the self-refrigeration process. This is due to the
fact that compressors are capital intensive equipments.
4. When the feed gas pressure is equal to or lower than the required pipeline pressure, solid bed
adsorption seems a good option, as it is quick to start up and is robust against changes in the feed
gas composition and flow rate. Generally the solid bed process is only practical for gas that has
small amounts of heavy hydrocarbons. Richer gases require refrigeration. It is clear that the solid
bed adsorption process will usually be competing against the self-refrigeration process.
Specially, the solid bed adsorption unit is operated at lower differential pressure compared to
selfrefrigeration and thus no additional compression is required. In fact, at low feed gas pressure
and for strict dew point specifications, economical analysis favors the solid bed adsorption
process. With reference to the membrane application to control the hydrocarbon dew point, there
is no clear judgement. Current discussions look at this on a point-by-point base and compare the
economics with other processes.The window of opportunity is still to be seen, although its use in
lean fuel gas is more common.
Catalytic Conversion
Features:
Thermal Cracking
Photo-Catalytic Conversion
Ultraviolet light breaks water into a hydrogen and hydroxyl free radical, which are highly
reactive. When a hydroxyl radical reacts with a methane molecule, a hydrogen is
displaced and methanol is produced.
With the use of tungsten oxide or a similar semiconductor, photons of lower energy than
ultraviolet (down to blue) can be used.
Using Of WO as photo-catalyst visible laser light can be used in room temperature
It is highly energy inefficient (only 2-3% efficiency)
The process is not out in commercial production yet
Biological conversion
Widely applicable to digester gas, landfill gas, peatbogs, marshes, and wastewater
treatment facilities
ICI process
Process description
1. Natural gas Sweetening:
The general process flow diagram for an amine-sweetening plant varieslittle, regardless of the
aqueous amine solution used as the sweetening agent (Figure 7-2). The sour gas containing H2S
and/or CO2 will nearly always enter the plant through an inlet separator (scrubber) to remove
any free liquids and/or entrained solids. The sour gas then enters the botto of the absorber
column and flows upward through the absorber in intimate countercurrent contact with the
aqueous amine solution, where the amine absorbs acid gas constituents from the gas stream.
Sweetened gas leaving the top of the absorber passes through an outlet separator and then flows
to a dehydration unit (and compression unit, if necessary) before being
considered ready for sale. In many units the rich amine solution is sent from the bottom of the
absorber to a flash tank to recover hydrocarbons that may have dissolved or condensed in the
amine solution in the absorber. The rich solvent is then preheated before entering the top of the
stripper column. The amineamine heat exchanger serves as a heat conservation device and
lowers total heat requirements for the process. A part of the absorbed acid gases will be flashed
from the heated rich solution on the top tray of the stripper. The remainder of the rich solution
flows downward through the stripper in countercurrent contact with vapor generated in the
reboiler. The reboiler vapor (primarily steam) strips the acid gases from the rich solution. The
acid gases and the steam leave the top of the stripper and pass overhead
through a condenser, where the major portion of the steam is condensed and cooled. The acid
gases are separated in the separator and sent to the flare or to processing. The condensed steam is
returned to the top of the stripper as reflux. The lean amine solution from the bottom of the
stripper column is pumped through an amineamine heat exchanger and then through a cooler
before being introduced to the top of the absorber column. The amine cooler serves to lower the
lean amine temperature to the 100F range. Higher temperatures of the lean amine solution will
result in excessive amine losses through vaporization and also lower acid gas-carrying capacity
in the solution because of temperature effects.
chiller. The partially condensed feed gas is sent to a separator. The liquid from the separator is
fed to the demethanizer, and the gas is cooled further in the low-temperature gasto- gas
exchanger and fed into a second cold separator. Gas from the cold separator expands through the
expansion turbine to the demethanizer pressure, which varies from 100 to 450 psia. The turbo
expander simultaneously produces cooling/condensing of the gas and useful work, which may be
used to recompress the sales gas. Typically 10 to 15% of the feed gas is condensed in the cold
separator, which is usually at 30 to 60F. The expander lowers the pressure from the inlet gas
value (600 to 900 psia) to the demethanizer pressure of 100 to 450 psia. Typical inlet gas
temperatures to the demethanizer are 130 to 150F, sufficiently
low that a great deal of the ethane is liquefied. The demethanizer is a low temperature distillation
column that makes a separation between methane and ethane. Methane and components lighter
than methane, such as nitrogen, are the principal products in the vapor near the top of the
column, whereas ethane and heavier components, such as propane, butanes, and heavier
hydrocarbons, comprise the principal components in the bottom product of the column. The
molar ratio of methane to ethane in the bottom product is typically 0.01 to 0.03. Because the
outlet of the expander is usually two-phase flow, the liquid produced in the expander serves as
reflux for the demethanizer (Elliot et al., 1996). The bottom product from the demethanizer can
be fractionated further to produce pure product streams of ethane, propane, butanes, and natural
gasolin. The bottom product temperature is often below ambient so that feed gas may be used as
the heat transfer medium for the reboiler. This provides additional refrigeration to the feed and
yields higher ethane recovery, typically 80% (Holm, 1986). The top product from the
demethanizer, after heat exchange with the inlet gas, is recompressed to pipeline pressure.
impregnated ceramic catalyst. Rows of these tubes are located inside an insulated firebox, where
they are heated by the combustion of natural gas. The natural gas and steam that are blended to
become the reformer feed enter the process at 300C and 210oC , respectively. The mixture is
preheated to 450 0C by exhaust gas from the firebox, and it is introduced to the reformer through
a header that distributes the mixture evenly among the parallel reformer tubes . Two key
reactions occur: the steam-reforming reaction itself,
CH4 + H2O
CO + 3H2
CO2 + H2
The product gas leaves the reformer at 8550C and 1.6 MPa.
Energy efficiency in the steam reforming is improved by recovering heat from the burner exhaust
gas , which leaves the firebox at 960 0C. The exhaust gas is cooled in a series of heat-exchange
operations that preheat the reformer feed streams to 4500C , produce superheated steam at 4.8
MPa and 1000C superheat from the boiler feedwater at 300C, and preheat the combustion air to
3000C. The superheated steam is used to drive turbines elsewhere in the process or it can be
exported , for example to generate electricity. The burner exhaust gas leaves the heat-recovery
units and enters a stack at 1500C for release to the atmosphere.
The product gas leaving the reformer contains water that should be removed to reduce the
amount of gas that must be compressed and to minimize the impact on subsequent conversion of
CO to methanol. Heat is removed from the gas by generating superheated steam (at 4.8MPa ,
1000C superheat), cooling the gas to 15 0C above the temperature of the generated steam. Then ,
three steps occur in recovering heat , concomitantly, reducing the water content: first, heat
recovery for use elsewhere in the process control; second, cooling by ambient air in an air cooler;
and third, use of cooling water to reduce the temperature of the synthesis gas to 350C. Condensed
water is separated from the gas in each of these steps and collected in a condensate drum. With
much of the water now removed, the product can properly be referred to as synthesis gas. The
make-up gas (MUG) compressor increases the pressure of the synthesis gas from 1.6 MPa to 7.5
MPa in two stages , so that it can be injected into the converter loop. Between compressor stages,
cooling water is used to reduce the temperature of the gas to 1000C, and any condensate formed
is removed. The compressed synthesis gas is introduced into the converter loop, where it is
combined with recycle gas.
The converter loop consists of a recycle compressor , whose primary purpose is to provide the
pressure required for the gas to flow through the system, the methanol synthesis reactor (MSR) ,
heat exchangers , a methanol condenser , and a gas-liquid separator (flash drum). The mixture
that is to become the feed to the MSR consists of recycle gas and fresh synthesis gas. After the
recycle gas and fresh synthesis gas are blended, the mixture flows through the recycle
compressor and then is heated to 130C 0C by a partially cooled product stream leaving the MSR.
The recycle compressor is sized to circulate the recycle stream at a rate that is 7.8 times the rate
at which fresh synthesis gas is fed to the converter loop. The blended recycle-fresh feed mixture
leaving the heat exchanger following the compressor is split into two streams : one, containing
30% of the mixture , is sent to another heat exchanger where its temperature is raised to 220oC
by a fraction of the product stream from the MSR and injected into the first stage of the MSR :
the remaining 70% , which is still at 1300C , is injected at various location along the MSR.
The key reactions in the MSR are :
CO2 + 3H2
CH3OH + H2O
CO + 2H2
CH3OH
The product gas leaving the MSR is partially cooled by being split into two streams each of
which passes through a heat exchanger before being recombined ; one is used to heat the feed
stream to the first stage of the MSR to 2200C , and the other passes through a waste heat
recovery unit. The recombined product stream is cooled further in an air-cooled exchanger before
being brought to 350C by cooling water. At 350C ,a liquid consisting of the condensed methanol
and dissolved gases is separated from the gas stream in a flash drum and sent to a methanol
purification column. The uncondensed gases are split , with a portion being purged from the
system and the remainder forming the recycle gas that is blended with fresh synthesis gas to form
the feed to the recycle compressor. After the condensed crude methanol is recovered in the high
pressure separator, it is sent to a methanol purification column. Typically, methanol purification
requires two columns, one to remove the light ends ( mainly by-products generated in the
methanol synthesis reactor such as dimethyl ether and dissolved gases ) and another to separate
methanol and water and any other by-products with a lower volatility than methanol.
Specification- grade methanol (99% mole fraction) is recovered as the overhead product of the
heavy ends column and sent to storage.
Reflux
Accumulato
r
Sweet
gas
Absorb
er
Regenerat
or
Lean
MEA
Recyc
le
pump
Lean-rich
Heat
Fuel Gas
MEA
Flash
Sour
gas
Separa
tor
Rich
MEA
pum
tank
Liquid
Make-up
Expander
Cold
Separat
or
Gas to Gas
heat
exchanger
Separator
Propane
chiller
Gas to
Gas
Sweet
Demethani
zer
Heat
exchange
Compressor
Processed
Secondar
y
Reformer
Primary
Reformer
Natural gas
Synthesis
gas
Preheater
WSG
Methanol
Stea
Converter
Combustion
air
m
Synthesis
Reactor
Produc
Recycle
t
Water
Gas
Shift
Convert
Condenser
Compres
DS
Gas
Distillation
sor
&
Separator
Column
Separator
PurgeMethano
Condensat
Waste
Process Flowsheet
91
89
99
88
E517
E514
86
84
VLV611
90
E515
97
64
67
98
101
D610
95
87
69
G440
76
81
82
73
E431
92
74
62
H421
59
E411
61
66
H430
78
H451
H420
71
70
58
107
H410
63
65
E516
83
G511
B11
H450
77
D620
96
93
80
79
68
100
R510
G512
E513
75
B84
72
56
60
57
E331
94
R330A
106
103
53
R330
E221
52
49
39
R320
51
G220
50
40
47
E321
G220A
VLV312
42
G216
38
45
41
32
48
46
54
E313
R310
33
E214
44
H215
55
E217
27
34
25
VLV114
D210
20
22
21
E211
24
E212
31
E218
H213
14
29
37
30
104
26
36
43
35
13
19
H122
E121
10
15
L123
4
D120
E1
E112
16
D110
E130
105
11
L124
3
7
8
Q314
18
H113
H111
17
12
102
1.
MS2
1993 kmol/h
Methane 96.65%
Ethane 1.6%
Propane 0.35%
i-Butane 0.10%
n-Butane 0.08%
i-Pentane 0.04%
n-Pentane 0.03%
n-Hexane 0.03%
n-Heptane 0.06%
CO2 0.72%
Nitrogen 0.35%
@ 25 , 7000kPa
MS1
V-100
2000 kmol/h
Methane 96.48%
Ethane 1.6%
Propane 0.35%
i-Butane 0.10%
MS3
7 kmol/h
n-Butane 0.08%
Methane 46.72%
i-Pentane 0.05%
Ethane 3.71%
n-Pentane 0.04%
Propane 1.06%
n-Hexane 0.05%
i-Butane 0.86%
n-Heptane 0.19%
n-Butane 1.07%
CO2 0.72%
i-Pentane 1.6%
Nitrogen 0.35%
n-Pentane 1.91%
@ 25 , 7000kPa
n-Hexane 5.75%
n-Heptane 36%
CO2 0.83%
Nitrogen 0.04%
@ 25 , 7000kPa
2.
MS4 ( @ 25 , 7000kPa)
7450 kmol/h
E-100
MEAmine 100%
Methane 97.35%
MS2
Ethane
0.18%
1993 kmol/h
MEAmine 0.0045
Methane 96.65%
CO2
Ethane 1.6%
Nitrogen 0.45%
0.40%
Propane 0.35%
i-Butane 0.10%
MS6
n-Butane 0.08%
7943 kmol/h
i-Pentane 0.04%
Methane 5.86%
n-Pentane 0.03%
Ethane 0.06%
n-Hexane 0.03%
Propane 0.08%
n-Heptane 0.06%
i-Butane 0.02%
CO2 0.72%
n-Butane 0.02%
Nitrogen 0.34%
i-Pentane 0.01%
@ 25 , 7000kPa
n-Pentane 0.008%
n-Hexane
0.0075%
n-Heptane 0.016%%
MEAmine 94%
CO2 0.11%%
Nitrogen 0.0007%
@ 45.5 , 7000kPa
3.
MS7
280.5 kmol/h
Methane 97.35%
Ethane 1.2%
Propane 0.25%
i-Butane 0.04%
n-Butane 0.03%
i-Pentane 0.009%
n-Pentane 0.005%
n-Hexane 0.002%
n-Heptane 0.002%
CO2 1.1%
Nitrogen 0.02%
MEAmine 0.009%
@ 44.73 , 3000kPa
MS6
7943 kmol/h
Methane 5.85%
V-101
Ethane 0.06%
MS8
Propane 0.08%
7662 kmol/h
i-Butane 0.02%
Methane 2.5%
n-Butane 0.02%
Ethane 0.02%
i-Pentane 0.01%
Propane 0.08%
n-Pentane 0.008%
i-Butane 0.02%
n-Hexane 0.0075%
n-Butane 0.02%
n-Heptane 0.015%
i-Pentane 0.01%
CO2 0.11%
n-Pentane 0.0085%
Nitrogen 0.0007%
n-Hexane 0.008%
MEAmine 94%
n-Heptane 1.6%
@ 45 , 7000kPa
CO2 0.07%
MEAmine 97.23%
@ 44.73 , 3000kPa
4.
MS 11
E-101
MS 4
7450 kmol/h
MEAmine 100%
@ 234.9 , 7000kPa
7450 kmol/h
MEAmine 100%
@ 45 , 7000kPa
5.
MS 10
MS 11
E 100
7450 kmol/h
MEAmine 100%
7450 kmol/h
MEAmine 100%
@ 263 , 7000kPa
MS 8
@ 235 , 7000kPa
MS 9
7662 kmol/h
7662 kmol/h
Methane 2.5%
Methane 2.5%
Ethane 0.02%
Ethane 0.02%
Propane 0.08%
Propane 0.08%
i-Butane 0.02%
i-Butane 0.02%
n-Butane 0.02%
n-Butane 0.02%
i-Pentane 0.01%
i-Pentane 0.01%
n-Pentane 0.0085%
n-Pentane 0.0085%
n-Hexane 0.008%
n-Hexane 0.008%
n-Heptane 1.6%
n-Heptane 1.6%
CO2 0.07%
CO2 0.07%
MEAmine 97.23%
MEAmine 97.23%
@ 44.73 , 3000kPa
@ 82.22 , 1000kPa
6.
MS 14
MIX-100
7450 kmol/h
MS 10
MEAmine 100%
7450 kmol/h
@ 263 , 7000kPa
MEAmine 100%
@ 263 , 7000kPa
MS 15
0.4275 kmol/h
MEAmine 100%
@ 25 , 7000kPa
7.
MS 9
MS 12
7662 kmol/h
420 kmol/h
Methane 2.5%
Methane 46%
Ethane 0.02%
Ethane 0.35%
Propane 0.08%
Propane 1.5%
i-Butane 0.02%
i-Butane 0.44%
n-Butane 0.02%
n-Butane 0.36%
i-Pentane 0.01%
i-Pentane 0.22%
n-Pentane 0.0085%
n-Pentane 0.17%
n-Hexane 0.008%
n-Hexane 0.17%
n-Heptane 1.6%
CO2 0.07%
T-101
n-Heptane 0.45%
CO2 1.26%
MEAmine 97.23%
MEAmine 49%
@82.22, 1000kPa
@228.3, 1000kPa
MS 20
MS 13
207 kmol/h
7450 kmol/h
Methane 0.07%
MEAmine 100%
Ethane 0.004%
@260.4, 1000kPa
Propane 0.048%
i-Butane 0.02%
n-Butane 0.03%
i-Pentane 0.03%
n-Pentane 0.03%
n-Hexane 0.065%
n-Heptane 0.32%
CO2 0.006%
MEAmine 99.37%
@ 25 .3 , 1000kPa
8.
MS 16
MS 12
420 kmol/h
212 kmol/h
Methane 46%
Ethane 0.35%
Methane 90.68%
V-102
Ethane 0.69%
Propane 1.5%
Propane 3%
i-Butane 0.44%
i-Butane 0.85%
n-Butane 0.36%
n-Butane 0.68%
i-Pentane 0.22%
i-Pentane 0.41%
n-Pentane 0.17%
n-Hexane 0.17%
n-Heptane 0.45%
n-Pentane 0.31%
n-Hexane 0.28%
n-Heptane 0.59%
CO2 1.26%
CO2 2.5%
MEAmine 49%
MEAmine 0.076%
@25, 100kPa
Nitrogen 0.0005%
@25, 90kPa
MS 18
207 kmol/h
Methane 0.07%
Ethane 0.0004%
Propane 0.05%
i-Butane 0.02%
n-Butane 0.03%
i-Pentane 0.03%
n-Pentane 0.03%
n-Hexane 0.06%
n-Heptane 0.31%
CO2 0.006%
MEAmine 99.4%
@ 25 , 90kPa
9.
MS 22
MS 23
1500 kmol/h
1499 kmol/h
Methane 97.35%
Ethane 1.8%
CO2 0.4%
MEAmine 0.0045%
Nitrogen 0.45%
Methane 97.39%
V-103
Ethane 1.8%
CO2 0.36%
Nitrogen 0.45%
@ -150, 1000kPa
@ -150, 1000kPa
MS 24
0.52 kmol/h
Methane 0.69%
Ethane 0.23%
Propane 0.007%
CO2 86%
MEAmine 13%
@ -150 , 1000kPa
10.
MS 25
MS 26
1499 kmol/h
1459 kmol/h
Methane 97.39%
Ethane 1.8%
Methane 99.5%
V-104
CO2 0.36%
Nitrogen 0.5%
@ -175, 1000kPa
Nitrogen 0.45%
@ -175, 1000kPa
MS 27
40.5 kmol/h
Methane 19.8%
Ethane 66.3%
CO2 13.65%
Nitrogen 0.11%
@ -175 , 1000kPa
11.
MS 29
MS 31
T-102
1459 kmol/h
1470 kmol/h
Methane 99.5%
Methane 99.34%
Nitrogen 0.5%
Ethane 0.20%
@ -140 , 800kPa
Nitrogen 0.46%
@ 175.5 , 689.5kPa
MS 37
MS 32
41 kmol/h
7662 kmol/h
Methane 19.65%
Ethane 65.5%
Ethane 79.8%
CO2 14.56%
CO2 19.9%
MEAmine 0.16%
Nitrogen
MEAmine 0.22%
0.11%
@ -150 , 1000kPa
@ -173.6 , 689.5kPa
12.
MS 41
MIX-102
4500 kmol/h
MS 43
H2O 100%
@ 210 , 1600kPa
5970 kmol/h
Methane 24.46%
Ethane 0.05%
H2O 75.37%
MS 94
1470 kmol/h
Nitrogen 0.11%
Methane 99.34%
Ethane 0.20%
Nitrogen 0.46%
@ 114.6 , 1600kPa
13.
MS 44
MS 45
5970 kmol/h
7408 kmol/h
Methane 24.46%
Ethane 0.05%
Methane 0.0075%
ERV-100
CO 13%
H2O 75.37%
H2O 47.69%
Nitrogen 0.11%
Hydrogen 39.15%
@ 450, 1600kPa
Nitrogen 0.09%
@ 690, 20kPa
MS 27
MS 46
496 kmol/h
Methane 99.4%
Ethane 0.6%
CO 0.007%
Hydreogen 0.0005
Nitrogen 0.0002%
@690 ,20kPa
14.
MS 45
MS 47
7408 kmol/h
25100 kmol/h
Methane 0.0075%
CO 13%
H2O 47.69%
Hydrogen 39.15% %
Ethane 0.011%
CRV-100
CO 3.85%
CO2 1.96%
H2O 18%
Nitrogen 0.09%
Nitrogen 54%
@ 690, 20kPa
Hydrogen 11.5%
Oxygen 10.5%
@ 700, 20kPa
MS 46
MS 48
496 kmol/h
Methane 99.4%
Ethane 0.6%
CO 0.007%
0 kmol/h
Hydreogen 0.0005
Nitrogen 0.0002%
@690 ,20kPa
MS 119
17200 kmol/h
Oxygen 21%
Nitrogen 79%
@ 544 , 101.3kPa
15.
MS 47
MS 51
25100 kmol/h
25110 kmol/h
Ethane 0.011%
CO 3.85%
CO 3.85%
CO2 1.96%
CO2 1.96%
CRV-102
H2O 18%
H2O 18%
Hydrogen 11.5%
Hydrogen 11.5%
Oxygen 10.5%
Oxygen 10.5%
Nitrogen 54%
Nitrogen 54%
@ 702, 20kPa
@ 700, 20kPa
MS 52
0 kmol/h
16.
MS 54
25110 kmol/h
MS 51
25110 kmol
CO 3.85%
CO 0.04%
CO 3.85%
CO2 5.8%
CO2 1.96%
ERV-101
H2O 14.22%
H2O 18%
Hydrogen 15.36%
Hydrogen 11.5%
Oxygen 10.4%
Oxygen 10.5%
Nitrogen 54%
Nitrogen 54%
@ 220, 20kPa
@ 700, 20kPa
17.
MS 54
MS 60
25110 kmol/h
25110 kmol
CO 0.0008%
CO 3.85%
CO2 1.96%
CO2 5.84%
ERV-101
H2O 14.2%
H2O 18%
Hydrogen 15.4%
Hydrogen 11.5%
Oxygen 10.4%
Oxygen 10.5%
Nitrogen 54%
Nitrogen 54%
@ 80, 20kPa
@ 200, 20kPa
18.
MS 62
25110 kmol/h
CO 0.0008%
MS 63
V-105
25110 kmol
CO 0.0008%
CO2 5.84%
CO2 5.84%
H2O 14.2%
H2O 14.2%
Hydrogen 15.4%
Hydrogen 15.4%
Oxygen 10.4%
Nitrogen 54%
Oxygen 10.4%
@ 40, 20kPa
Nitrogen 54%
@ 80, 20kPa
19.
MS 75
MS 78
32360 kmol/h
29020 kmol/h
CO 0.0008%
CO2 6%
H2O 18%
CO 0.0009%
V-108
CO2 6.73%
Hydrogen 17.8%
Hydrogen 16%
Oxygen 12%
Oxygen 11%
Nitrogen 62.5%
Nitrogen 56%
H2O 1%
@ 50, 1200kPa
@ 50, 1200kPa
MS 80
3320 kmol/h
CO2 0.03%
H2O 99.88%
Hydrogen 0.003%
Oxygen 0.02%
Nitrogen 0.06%
@ 50, 1200kPa
20.
MS 78
MS 79
29020 kmol/h
21760 kmol/h
CO 0.0009%
CO2 6.73%
H2O 1%
Hydrogen 17.8%
Oxygen 12%
Nitrogen 62.5%
@ 50, 1200kPa
CO 0.0009%
TEE-100
CO2 6.73%
Hydrogen 17.8%
Oxygen 12%
Nitrogen 62.5%
H2O 1%
@ 50, 1200kPa
MS 81
7254 kmol/h
CO 0.0009%
CO2 6.73%
H2O 1%
Hydrogen 17.8%
Oxygen 12%
Nitrogen 62.5%
@ 50, 1200kPa
21.
MS83
MS 84
MIX-104
21760 kmol/h
159900 kmol/h
CO 0.0009%
CO
CO2 6.73%
CO2 2.56%
H2O 1%
H2O 0.15%
Hydrogen 17.8%
Hydrogen 4%
Oxygen 12%
Oxygen 0.15
Nitrogen 62.5%
Methanol 0.06%
0.0003%
Nitrogen 78.5%
@20.5 ,1600 kPa a
MS 109
138100 kmol/h
CO 0.0002%
CO2 1.9%
H2O 0.008%
Hydrogen 1.8%
Oxygen 15%
Nitrogen 81%
Methanol 0.07%
@10 ,7500 kPa
22.
MS 86
MS 89
159900 kmol/h
63960 kmol/h
CO 0.0003%
CO2 2.56%
CO 0.0003%
TEE-101
CO2 2.56%
H2O 0.15%
H2O 0.15%
Hydrogen 4%
Hydrogen 4%
Oxygen 0.15%
Oxygen 0.15%
Methanol 0.06%
Nitrogen 78.5%
@ 220, 7500kPa
Methanol 0.06%
Nitrogen 78.5%
@ 220, 7500kPa
MS 90
95930 kmol/h
CO 0.0003%
CO2 2.56%
H2O 0.15%
Hydrogen 4%
Oxygen 0.15%
Methanol 0.06%
Nitrogen 78.5%
@ 220, 7500kPa
23.
MS 90
MS 95
95930 kmol/h
91170 kmol/h
CO 0.0003%
CO2 2.56%
CO 0.0003%
ERV-104
CO2 1.4%
H2O 0.15%
Hydrogen 0.34%
Hydrogen 4%
Oxygen 0.15%
Oxygen 0.15%
Nitrogen 82.5%
Methanol 0.06%
Methanol 0.15%
Nitrogen 56%
@ 50, 7500kPa
H2O 0.03%
@ 28, 7500kPa
MS 96
2398 kmol/h
CO2 0.07%
H2O 53.8%
Hydrogen 0.001%
Oxygen 0.035%
Methanol 45.96%
Nitrogen 0.06%
@ 28, 7500kPa
24.
MS 97
63850 kmol/h
CO2 2.56%
MIX-105
MS 85
155000 kmol/h
CO 0.0002
H2O 0.01%
CO2 1.88%
Hydrogen 4%
H2O 0.025%
Oxygen 0.14%
Hydrogen 1.85%
Methanol 0.03%
Oxygen 15.17%
Nitrogen 78.6%
Methanol 0.1%
@ 102.5, 7500kPa
Nitrogen 80.96%
@ 58.88, 7500kPa
MS 96
91170 kmol/h
CO 0.003%
CO2 1.4%
H2O 0.03%
Hydrogen 0.34%
Oxygen 15.48%
Methanol 0.15%
Nitrogen 82.6%
@ 28, 7500kPa
25.
MS 91
MS 92
63960 kmol/h
CO2 2.56%
63850 kmol/h
ERV-103
CO2 2.56%
H2O 0.15%
Hydrogen 4%
Hydrogen 4%
Oxygen 0.15%
Oxygen 0.15%
Nitrogen 78.6%
Methanol 0.06%
Methanol 0.03%
Nitrogen 78.5%
H2O 0.01%
@ 130, 7500kPa
@ 10, 7500kPa
MS 93
104.3 kmol/h
CO2 0.18%
H2O 81.82%
Hydrogen 0.008%
Oxygen 0.05%
Methanol 17.83%
Nitrogen 0.11%
@ 10, 7500kPa
26.
MS 104
MS 105
155000 kmol/h
155000 kmol/h
CO 0.0002%
CO2 1.88%
H2O 0.025%
CO 0.0002%
V-109
CO2 1.88%
Hydrogen 1.85%
Hydrogen 1.85%
Oxygen 15%
Oxygen 15%
Nitrogen 81%
Methanol 0.1%
Methanol 0.07%
Nitrogen 80.96%
@ 10, 7500kPa
H2O 0.008%
@ 10, 7500kPa
MS 106
74.46 kmol/h
CO 0.0002%
CO2 0.13%
H2O 35%
Hydrogen 0.01%
Oxygen 0.02%
Methanol 64.78%
Nitrogen 0.023%
@ 10, 7500kPa
27.
MS 104
MS 105
155000 kmol/h
15500 kmol/h
CO 0.0002%
CO2 1.88%
CO 0.0002%
TEE-102
CO2 1.88%
H2O 0.008%
Hydrogen 1.85%
Hydrogen 1.85%
Oxygen 15%
Oxygen 15%
Nitrogen 81%
Methanol 0.0%
Methanol 0.07%
Nitrogen 81%
@ 10, 7500kPa
H2O 0.008%
@ 10, 7500kPa
MS 108
139500 kmol/h
CO 0.0002%
CO2 1.88%
H2O 0.008%
Hydrogen 1.85%
Oxygen 0.15%
Methanol 0.07%
Nitrogen 81%
@ 10, 7500kPa
28.
MS 93
104.3 kmol/h
MIX-106
MS 110
2577 kmol/h
CO2 0.18%
CO2 0.07%
H2O 81.82%
H2O 54.46%
Hydrogen 0.008%
Hydrogen 0.002%
Oxygen 0.05%
Oxygen 0.035
Methanol 17.83%
Methanol 45.36%
Nitrogen 0.11%
@10 ,7500 kPa
,1600 kPa
MS 96
2398 kmol/h
CO2 0.07%
H2O 53.87%
Nitrogen 0.06%
@26.81
Hydrogen 0.001%
Oxygen 0.035%
Nitrogen 0.06%
Methanol 45.96%
@28 ,7500 kPa
MS 106
74.46 kmol/h
CO 0.0002%
CO2 0.13%
H2O 35%
Hydrogen 0.01%
Oxygen 0.02%
Methanol 64.78%
Nitrogen 0.023%
@ 10, 7500kPa
Absorber
Equipment
Designation
V100
V102
V103
V104
V105
V106
V107
V108
V109
T100
Distillation Colum
T101
Separator
No of equipment
8
T102
T103
T104
Reactor
Equilibri
ERV100
Capacity
1500 kmol/h
420 kmol/h
1124 kmol/h
1124 kmol/h
26700 kmol/h
26450 kmol/h
26330 kmol/h
33720 kmol/h
211400 kmol/h
1124 kmol/h gas
5970 kmol/h liquid
420 kmol/h gas &
5600 kmol/h liquid
1100 kmol/h gas &
24.24 kmol/h liquid
60.46 kmol/h gas &
1080 kmol/h liquid
407.3 kmol/h gas &
607.76 kmol/h
liquid
um
Reactor
Conversi
on
Reactor
Heat Exchanger
ERV101
ERV102
ERV103
ERV104
3
CRV100
CRV101
CRV102
18
E100
E101
E102
E103
E104
E105
E106
E107
E108
E109
E110
E111
E112
E113
E114
E115
E116
E117
4.207 10
kJ/h
6
-3.836 10
-3.754 10
-1.439 10
-6.844 10
5
4.349 10
1.185 10
5.276 10
4.457 10
kJ/h
1.664 10
kJ/h
kJ/h
kJ/h
8.770 10
kJ/h
4.086 10
kJ/h
8
-2.342 10
-2.804 10
-3.185 10
Compressor &
6000 kPa
910 kPa
-200 kPa
kJ/h
kJ/h
1.881 10
P100
P101
K100
kJ/h
kJ/h
kJ/h
kJ/h
4.876 10
Pump
kJ/h
kJ/h
kJ/h
kJ/h
Expander
K101
K102
K103
K104
K105
List of Vendors
For Heat Exchangers
-
30 kPa
1570 kPa
400 kPa
5900 kPa
880.8 kPa
For Pumps
-
Afton Pumps
AKAY Industries B.V.
AlfaLaval
Ruhrpumpen
PumpEng
PACO Pumps
Magnatex
Layne / VertiLine
For Compressor/Expander
-
a) Selection criteria
a.1) Orientation
In general, a vertical vessel is preferred for gas/liquid separation for the following
reasons:
- when the gas/liquid ratio is high;
- a smaller plan area is required (critical on offshore platforms);
- easier solids removal;
- liquid removal efficiency does not vary with liquid level;
- vessel volume is generally smaller.
However, a horizontal vessel should be chosen if:
- large volume of total fluid is available;
- large amount of dissolved gas is available;
- large liquid slugs have to be accommodated;
- there is restricted head room;
- a low downward liquid velocity is required (for degassing purposes, foam
breakdown or
in case of a difficult liquid/liquid separation).
a.2) Components
Following the gas/liquid flow path through the separator, the following parameters
should be identified:
- Feed inlet
This comprises the upstream piping, inlet nozzle, and the inlet devices (if any).
The diameter of the inlet nozzle is a function of the feed flow rate and pressure.
The criterion for the nozzle sizing is that the momentum of the feed shall not
exceed prescribed levels. The maximum allowable inlet momentum can be
increased by applying inlet devices.
The function of the inlet device is to initiate the gas/liquid separation and to
distribute the gas flow evenly in the gas compartment of the vessel.
Commonly used inlet devices are the half-open pipe and their specific proprietory
inlet devices designed for introducing gas/liquid mixtures into a vessel or column.
- Separator internals
In knock-out vessels the diameter should be selected sufficiently large to keep the
gas velocity low at which the major portion ofthe droplets could be settled by
gravity.
In all other types of gas/liquid separators, internals should be considered, for
selection the required duty, wire mesh, vane-pack (either horizontal or vertical
flow), multicyclones axial or reversed flow, filter candles, etc. should be studied.
- Gas and liquid outlets
After completion of the gas/liquid separation process the two phases will leave the
vessel via the gas and liquid outlet respectively.
- Gas handling capacity
The separator shall be large enough to handle the gas flow rate under the most
severe process conditions. The highest envisaged gas flow rate should be
determined by including a margin for surging, uncertainties in basic data. This
margin is typically between 15 and 50%, depending on the application.
- Selection strategy
1) Gas handling capacity:
- max. capacity (gas load factor);
- turndown ratio.
2) Liquid removal efficiency:
- overall;
- with respect to fine mist;
- with respect to the possible flooding above the maximal load factor (which will
affect the sharpness of the efficiency decline above the maximum capacity).
3) Liquid handling capacity:
- slugs;
- droplets.
4) Fouling tolerance:
- sand;
- sticky material.
5) Pressure drop:
unlimited turndown;
very high slug handling capacity;
liquid removal efficiency typically 80-90% (ranging from low to high liquid
load).
- Warning: Liquid removal efficiency for mist is very poor
insensitive to fouling;
very low pressure drop.
Recommended use:
vessels where internals have to be kept to a minimum and where there are height
limitations;
slug catchers;
fouling service, e.g., wax, sand, asphaltenes;
for foaming or very viscous liquids.
Non-recommended use:
where efficient demisting of gas is required.
Typical process applications:
vent and flare stack knock-out drums;
production separator-low GOR;
bulk separator;
slug catcher.
- Vertical Wire Mesh Demister
Application:
demisting of gas.
Characteristics:
high turndown ratio;
high slug handling capacity;
liquid removal efficiency > 98%;
sensitive to fouling;
low pressure drop.
Recommended use:
for demisting service with a moderate liquid load;
where slug handling capacity may be required.
Non-recommended use:
fouling service (wax, asphaltenes, sand, hydrates);
for viscous liquids where degassing requirement determines vessel diameter;
for compressor suction scrubbers unlessprecautions are taken to prevent the
possibility of loose wire cuttings entering the compressor or plugging of the
demister mat increasing suction pressure drop.
Non-recommended use:
if high pressure drop can not be tolerated.
Typical process application:
in oil refineries: Thermal Gas-Oil Unit (TGU);
Visbreaker Unit (VBU);
in chemical plants: Thermoplastic Rubber Plants.
- Vertical Multicyclone Separator
Application:
demisting and dedusting of gas in slightly fouling service and high pressure.
Characteristics:
liquid removal efficiency > 93%;
suitable for slightly fouling service (e.g., low sand loading);
high pressure drop;
compact separator;
sensitive to high liquid loading or slugs.
Recommended use:
typically for use in a slightly fouling environment where the gas pressure is
higher
than 100 bar (abs) and a compact separator is required.
Non-recommended use:
low gas pressure;
heavy fouling service (high sand loading will cause erosion);
high liquid loading;
slug;
when high liquid removal efficiency is required.
Typical process application:
wellhead separators;
primary scrubbers under slightly fouling service and when the liquid loading is
low;
compressor suction scrubbers if sand is present in the feed.
- Filter Separator
Application:
after-cleaning (liquid and solids) of already demisted gas when a very high liquid
removal efficiency is required.
Characteristics:
liquid removal efficiency > 99%;
very high pressure drop;
sensitive to high liquid loading or slugs;
1.
2.
3.
4.
5.
6.
7.
Area of application
No
.
1
Materials
2
3
4
Pressure Vessels
Fired Boiler
Process Furnace
5
6
Welding Material
Shell and Tube Heat Exchanger
7
8
9
10
Surface Condensers
Cooling Tower
Storage Tank
Rotating Equipment(Centrifugal
Compressor,Reciprocating
Compressor,Blower,Turbine)
Refrigeration and Air Conditioning
Equipment
11
12
13
14
15
16
17
18
19
Pressure piping
Pressure Relieving System
Steel Structure
Building and Concrete Structure
Material Handling Facility
Electrical
Fire Protection and Safety
Safety
20
Corrosion Protection
TECHNICAL INFORMATION
Gas/Liquid Separators
Application Data Sheet
Name: ________________________________________________ Date:
________________________________________________________
Title:
______________________________________________________________________________
___________________________________
Company:
______________________________________________________________________________
______________________________
Address:
______________________________________________________________________________
_______________________________
City: __________________________________________ State: _______ Zip:
__________________________________________________
Phone: _________________________________ Fax:
_______________________________________________________________________
E-Mail:
______________________________________________________________________________
_______
Equipment ID: H111
Product(s) of Interest
Cast ST and T Type Separators Fabricated L and T Type Separators Exhaust Heads
Cast LST Type Separators Receiver & Coalesce Type Separators Accessories
Air & Gas Drain Traps Air Vents
Application Parameters
Pipe Size: ___________ in ___________ mm
Flow Medium: Air Steam Natural Gas Other
___________________________________________________
Volumetric Flow: ___________ SCFM _______0.07____ MMSCFD ___________ NM3/hr
Weight Flow: _____________ lb/hr _____25390________ kg/hr
Average Molecular Weight:
_____________________________________19.5_____________________________________
_______
Minimum Operating Pressure: _______________ psig ___________ kg/cm2 ____70_____bar
Maximum Operating Temperature: ______________ F _____25__________ C
__Vertical Flow____
Threaded
Flanged
Socket Weld
Cast Iron
Carbon Steel
304L SS
316L SS
Other
______________________________________________________________________________
______________________