Di srenr onGAS CONDITIONING AND PROCESSING VOLUME 3 ADVANCED TECHNIQUES AND APPLICATIONS By ROBERT N. MADDOX Leonard F. Sheerar Professor Oklahoma State University and JOHN H. ERBAR Professor of Chemical Engineering Oklahoma State University Edited for Campbell Petroleum Series by John M. Campbell ©Copyright 1982 by Campbell Petroleum Series. This book is sold for personal or library reference use, or for regularly scheduled university classes only; use as a reference or manual for adult training program is specifically reserved for John M. Campbell and Co. No part of the text or original figures may be reproduced in any form without written permission of the publisher. All translation rights are likewise reserved. .GAS CONDITIONING AND PROCESSING Volume 3 Library of Congress Catalog Card No.: 76-157183 Printed in U.S.A., January 1982 Published By: Campbell Petroleum Series 1215 Crossroads Blvd. Norman, Oklahoma 7306910. TABLE OF CONTENTS Introduction 2. ee ee eee ew “Garbage Begats garbage" Phase Behavior of Hydrocarbon Systems... . - eee eee ot ae sree ee Pure component phase behavior, multicomponent phase behavior Thermodynamic Property Prediction Methods... 22... 2. 0 31 Basic thermodynamic property equations, equation of state solution methods, evaluation of thermodynamic property prediction procedures, selecting a thermodynamic property prediction procedure Equilibrium Calculations... 2-2... Retest ibe Hee Edd. Basic equilibrium calculations, equilibrium calculation failures Predicting the Properties of Hexanes Plus (C64) Fractions .. ~ 5-1 Cgq fraction availability Advanced Characterization Methods... -. eee ee ee eee 6-1 Data requirements, critical property estimation procedure, verification of the method, effect of proposed procedure on processing calculations Principles of Continuous Binary Distillation... 2... + 7-1 Minimum trays, minimum reflux, complex fractionators Continuous Multicomponent Distillation ©... 2... ee Bl Minimum number of trays, minimum reflux, operating reflux and plates, feed plate location, influence of feed operation Tray-By-Tray Calculations... 6... ee ceeaaenc | Lewis-Matheson method, Thiele-Geddes method, contemporary” tray-by-tray calculation procedures, thermodynamic property prediction methods and C,, characterization, reconmended procedure for distillati8a column simulation, "diagnosing" tray-by-tray output Absorption . .. Sees trees eee rec etieeea tierce eee tee teteEEdOeT Graphical calculation, how an’absorber operates, multicomponent absorption, stripping, multicomponent stripping, tray-by-tray calculations, complex absorber calculationsChapter i. 12. 13. 4. 15. 16. Column Sizing Calculations «©... ee eee ee eee Plate (tray) towers, effect of liquid hydraulics (Compressfontete susie sucaet suet etter eaeaercr decree teedgue Prediction methods, Mollier chart method, gas law methods, true polytropic method, efficiencies based on operating data, comparison of the methods, comparison of efficiencies, corrections to the predicted gas power requirements, optimum interstage pressures, thermodynamic property prediction effects on compressor evaluation, specific centrifugal compressor parameters, second level efficiency estimation Expansion Processes 6... ee ee ee ee Adiabatic expansion processes, cryogenic expander processing Natural Gas--Water System... ee ee ee ee Phase behavior, water content prediction methods, comparison of methods, hydrate prediction Dehydration et see ee csec case eee cent ee Absorber design factors, regenerator design, isotherms for molecular sieves Fluid Flw . 2-2-2222 2-0-- see eeetesee eae Gas flow equations, two phase flow calculation methods: Lockhart-Martinelli, Baker, AGA, Flanigan, Beggs and Brill ii Page 1-1 12-1 13-1 14-1 15-1 16-1ORUNnHSwe Vo oos wre & EGRES wo 4. 4 4 4 4 4 5. 5, 5, 5: 5, LIST OF FIGURES A Typical Pure Component Pressure--Temperature Design . . - A Typical Pure Component Pressure--Volume Diagram... . . Phase Envelope for a Typical Natural Gas Mixture... . . Composition--Critical Temperature Diagram for a Methane-Propane Binary... - ee ee ee ee a Composition--Critical Pressure Diagram for a Nethane-Propane Binary... eee eee ee eee Typical Pressure-Temperature Envelopes for Various Mixtures Possible Critical Point Locations Along the Pressure-Temperature Envelope... + +e ee ee eee Retrograde Behavior . . . - Bebe Ha He ae se eee Phase Envelope for Example 2.1)... . 2. rn Phase Envelope for Example 2.2... ... annie Illustration of the Path of Enthalpy Change. . . Overall Equation of State Solution Procedure . . Typical Behavior of Cubic Equations of State . . Block Diagrams for Equation of State Solution . . Typical Effect of Errors in Compressibility Factor Calculations 2. ee ee ee ee ae Block Diagram for Bubble Point Calculation .....-.- Block Diagram for Dew Point Calculation. ....- 2+. Temperature Adjustment Routines for Equilibrium Calculations . 2... ee... ee SHH une Ea Pressure Adjustment Routines for Equilibrium Calculations . . Block Diagram for a Flash Calculation. .... 2... +> Example of Difficulties in Performing Flash Calculations at Fixed Enthalpy Conditions ..... . eee Graphical Example Showing How Fixed Enthalpy/Entropy Problems Are Solved... ee eee ee ee ee Block Diagram for Enthalpy/Entropy Balancing Procedure . « Possible Trouble Points in Bubble/Dew Point Calculation Specifications ....--. ++ ee- Temperature-Pressure Diagram for Gas Shown in Table 4.1 Example of a "Needle Shaped" Phase Envelope... .. - Forbidden Regions for Bubble/Dew Point Calculations . . . Phase Diagrams for Different Hexanes Plus Characterizations Phase Envelopes Predicted by Split and Single Equation ‘of State Approaches se eee tee ee ee es Another Example of Phase Envelope Predictions by Split and Single Equation of State Approaches... .-.-.- Critical Temperature of Petroleum Fractions .. +... Critical Pressure of Petroleum Fractions ...- ++ +++ TBP Specific Gravity and Molecular Weight Data for Sample Problem Ce, Fraction... vee eee eee Effect of C., Charactérization on Predicted Liquid Formtigf... 2... se ee ee Wolecular Weight, API Gravity and Boiling Point of Petroleum Fractions... - sean wie wok BESaNNSS on Bb beeen Se f BEE SEOSample Problem Data for Converting Partial TBP Analysis to Complete TBP Analysis . . . . Relationship Between ASTM and TBP Analyses . 7 Sample ASTM Distillation Curve ....... : Plot of Calculated TSP Curve from Table 5.5... . . Empirical Correction Factor for Chromatographic TBP's Plot of a Chromatographic Based TEP Distillation . Graphical Example of Data Requirements... . . . Typical Critical Function Plots. ... 1.1... Effect of C,, Characterization on Predicted Dew Point Efvelope . . . ppaeenes Comparison of Calculated and Experimental Liquid” Formation at 70°F... 1... 2. pe tece ue Comparison of Calculated and Experimental Liquid Formation at 10°F oo. eee ee eee Comparison of Calculated and Experimental Liquid Formation at 160°F .. ee ee ee ee eee Comparison of Calculated and ‘Experimental Liquid” Formation at 220°F ...... 2... eee : Comparison of Calculated Well Bore Conditions | 2. Simplified Three Stage Separation System .. 1... Simplified Turbo-Expander Process... ae Schematic of a Continuous Distillation Colum 122111! Equi VibriuniPlabedstacsaasiasctasieiccseaeevenee ee eae Graphical Construction of Equilibrium Curve and Operating Lines... . Se oa rt Feed Plate of Distillation Colum... .. 2... tee Location of q-Line for Various Feed Conditions»... 2. Construction for Graphical Solution... .....- 7 Graphical Construction of Theoretical Plates . . McCabe-Thiele Construction for Minimum Plates... 5... McCabe-Thiele Construction for Infinite Plates»... 1. Determination of Minimum Reflux Rate on McCabe-Thiele Plot. . Distillation Colum with Side Product... ....... fe McCabe-Thiele Construction for a Column with Rectifying Section Side Draw... .. » eeesereas Schematic of a Distillation Column with Two Feeds |.) 1! NeCabe-Thiele Construction for a Column with Two Feeds . . . Construction Showing Effect of Incorrect Feed Plate location... . : Variation of Distillate Composition with Distiila Multicomponent Column at Minimum Trays... 2... 2. oe Schematic of a Complex Fractionator for Minimum Trays Calculation... 2... ee ee ee eee eto ee Colunn at Minimum Reflux 2.22 De an and Key Ratios in Feed... . eset tied Light Keys and Lighter 222. D LID DI IIIT! Light Keys and Lighter 2s. le Heavy Keys and Heavier... ee ee ee ee eee Minimum Reflux for Complex Fractionator : | eee Gilliland Graphical Correlation of Reflux and Plates |. iv Page 2 geamaqnan z 5 en RES SSURUREDe SPEEEPEe SOY wey RBESEEGNeFigure 8.11 8.12 8.13 8.14 8.15 © Reaver 10. 10. 10. 10. i il. MM. ll. il. i. DORURHOVAGS ul. 7 ll. 8 1. 9 11.10 un 11.12 11.13 11.14 11.15 42.1 12. 2 12. 3 12.4 12.5 12. 6a Martin-Brown Graphical Correlation of Reflux and Plates . . Erbar-Gray-Maddox Correlation... 2. ee ee eee Relationship Between Reflux and Trays for De-propanizer . Effect of Feed Plate Location on Required Reflux Rate ‘at Constant Separation, Feed 3% Vaporized . . . . +. + Effect of Feed Plate Location on Required Reflux Rate ‘at Constant Separation, Feed 67% Vaporized .....- Material and Energy Balance Envelopes for the Rectifying Section ..--- +--+ +. eee Logic Diagram for Rectifying Section Calculations . Overall Colum Balances... ee ee ee Material and Energy Balances for Stripping Section Logic Diagram for Stripping Section Calculations Nodels of Two Different Feed Zones... - +++ + Logic Diagram for Feed Zone Calculations ..-...- fogic Diagram... ee eee ee ee et ae Schematic Diagram of an Absorber... ssw ee ee ee Graphical Construction for Determination of Minimum Solvent Rate to Recover Specified Amount of Solute . . - Graphical Determination of Minimum Solvent Rate to Recover All of Solute... ....- Graphical Solution of Equation 10.12... ..--- 5 + Schematic of a Stripper... 1 ee ee ee ee ee ee Nomenclature Used in Tray-By-Tray Absorption Development Sketch of Absorber Process for Tray-By-Tray Calculations Typical Reboiled Absorber... +s eevee eee es Effect of Vapor and Liquid on Sieve Tray Performance Representation of Free and Active Area... - Types of Downcomers . . - + ee ee ee ee Multi Pass Trays . 0s Tray Dynamics Schematic Diagram. . 22... Correlation for Overall Efficiency of Absorbers andlieractdonacanseisteriieusioripeeeeieriarses Effect of Vapor and Liquid Load on Sieve Tray Efficiency Tower Sizing Correlation for Sieve Trays ..-- +--+ Tower Sizing Correlation for Bubble-Cap Trays... + - + Tray Sizing Correlation for Koch Flexitrays .. . Generalized Flooding Capacity for Glitsch Sailast Trays + + - Specific Surface and Voids Fraction for Tower Packings Correlation for Flooding Characteristics of Packed Towers in Gas Liquid Service «+ +s eee eee ere Nguyen Correlation for Flooding Effects... ++... Correlation to Determine Flooding Velocities in Liquid-- Liquid Contactors . . ee ee ee ee et ee Logic Diagram for Compressor Calculations»... -- ++ Compressor Calculation on Mollier Chart... 2... a+ Approximate Horsepower Requirement for Centrifugal (Compressors) ecg rer seis tint aise arrest Approximate Heat Capacity Ratios of Hydrocarbon Gases - + « Conversion of Adiabatic to Polytropic Efficiency ..-- - Logic Diagram for Compressor Horsepower Calculation . . . . . v Page 8-23 8-24 8-27 8-31 8-32 easeecaseestt caaeceeaaaaa 1l- lle i 11-10 11-12 i-14 11-15 11-16 11-18 12-4 12-5 12-7 12-9 12-10 12-12Figure 12. 12. we. 1. 6b Logic Diagram for Compressor Horsepower Calculation . 7 Figure of Turboexpander Recompression Process . . . « 8 Sketch of Reinjection Compression Process... ... 9 Sketch of Process and Process Conditions for Interstage Pressure Study... 2... - eee ee 12.10 Effect of Specific Speed and Diameter on Compressor Efficiency... . . ereedieeisedieee 12.11 Comparison of Predicted and Neasured Efficiencies . | 13, 1 Typical Expansion Processes... .... +--+ 40. 13. 2 Sketch of Process Flow Diagram»... 222.102 13. 3. Phase Envelope for the Gas... es. le 13. 4 Heavy Component K-value as Function of Separator Condi 13. § Sketch of Process Flow Diagram... 2.2... 44 13. 6 P-T Envelope for Separator Feed and Off-Gas .. . . 13. 7 Process Flow for Expansion Process... . . | a 13. 8 Bubble Point-dew Point Curve for Gas After 80% Ethane Recovery... +e eee ee ee 13. 9 Process Conditions and Pressure-Enthalpy Diagram . 13.10 Block Diagram for Compressor Calculations... . +. 13.11 Process Flow Sheets... 2.2... cscs 13.12 Turbine Outlet Temperature and Liquid Formation as Function of Turboexpander Efficiency .. . ‘i 13.13 Allowable Turbine Speed (RPM based on of1 bearings) 13.14 Specific Speed Efficiency Relationship for Turbines . 13.15 Turboexpander Efficiency as a Function of (Tip Speed/Spouting Velocity)... ......5 13.16 Balje and Scheel Correlation for Expander Efficiency 13.17 Schematics of Expansion Processes... 1... 14. 14. 14. M4. 14. 14. 14. 14. 14. 1 Phase Envelope for Wet Gas... -.. ee eee ee 2 Liquid Formed... . Beccieacnci Seatac 3. Phase Envelope for Wet Gas 11.1] lll 4 Liquid Formd. . 1.2... ee eee 5 Phase Envelope ...... eee aiaesteeeiae 6 Liquid Formed... .. 0. ‘i pecieniee 7 Water Content of Lean, Sweet Natural Gas 1... 8 | Schematic Diagram of Three-Phase Separator... . . 9 Comparison of Predicted and Experimental Phase Solubilities for Nethane-Water Systen...... 14.10 Comparison of Predicted and Experimental Phase Composition for n Butane-Water ... 1. ee es 14.11a Comparison of Predicted and Experimental Vapor Phase Composition for Methane-n Butane-Water System... . . 14.11b Comparison of Predicted and Experimental Water-Rich Liquid Compositions for Methane-n Butane-Water Systems. 14,11e Liquid Phase Composition for Methane-n Butane- Comparison of Predicted and Experimental Hydrocarbon-Rich Water Systems... 2... aire eaters aineeeE 14.12 Comparison of Predicted and Experimental Phase Composition for Carbon Dioxide-hater System. . . viFigure 14.13 14.14 14.15 14.16 44.17 14.18 15. 1 15. 15. 15. 15. 15. 15. is. 15. 15.10 15.11 15.12 15.13 15.14 15.15 15.16 15.17 15.18 15.19 15.20 15.21 15.22 16. 1 16. 16. 16. 16. 16. 16. 16. OVARY ean Aen 16. 9 16.10 16.11 16.12 Comparison of Predicted and Experimental Phase Comparison for Hydrogen Sulfide-Water System 2... + Comparison of Predicted and Experimental Bubble Point Pressures for Nethanol-Carbon Dioxide System... « Comparison of Predicted and Experimental Bubble Point Pressures for Methanol-Hydrogen Sulfide Systems . . . Process Nodel .. ett te ee Effect of Methanol on Predicted C02 Solubilities in Liquid Water oe ee et ee es Effect of Methanol on Predicted Hydrocarbon Solubility in Liquid Water se ee ee Equilibrium Water Dew Point as Function of TEG Concentration and Contactor Temperature»... + + + Activity Coefficient for Water in TEG-Water Systems . . . Another Correlation for Water Dew Point of Natural Gas . WT. % Water vs. Nol Fraction Water in TEG-Water Solutions Dew Point Depression vs. Glycol Rate . +--+ + sees Dew Point Depression vs. Glycol Rate -. +. +--+ +s Dew Point Depression vs. Glycol Rate... + eee eee Nomograph for Predicting Regenerator Performance ... ~ Mater Adsorption Isotherms for Type 4A Molecular Sieves . Schematic Representatives of the Adsorption Zone Concept Equilibrium Adsorption Loading of COz on 4A Pellets . « Equilibrium Adsorption Loading of COz on 5A Pellets . . Equilibrium Adsorption Loading of C02 on 13X Pellets Equilibrium Adsorption Loading of figs on 4& Pellets « Equilibrium Adsorption Loading of H2S on 5A Pellets . Equilibrium Adsorption Loading of H25 on 13x Pellets Equilibrium Adsorption Loading of H2S on 3A Pellets « Equilibrium Adsorption Loading of H2S on 5A Pellets . . Equilibrium Adsorption Loading of H2S on 5A Pellets « Equilibrium Adsorption Loading of H2S on 13X Pellets Friction Factor... eee et ee ee Pressure Drop Coefficient... 2-1 eee eee Friction Factor for Use in Equation 16.5 .... + Roughness of Commercial Pipe... -.. + : Equivalent Length of Valves and Fittings . . - Two-Phase Flow Regimes According to Baker . . . Panhandle Pipeline Efficiency. ...----+-- Flanigan Correlation for@ «2. +... +e eee Two-Phase Flow Friction Factors for AGA Procedure . . . Liquid Holdup Correlation for Horizontal Pipe for AGA Procedure . ee eee ee eee Influence of Heat Transfer on Line Temperature... . Horizontal Line Comparison Smooth Pipe, No Heat Transfer Horizontal Line Comparison, Roughness 0.0005 ft. No Heat Transfer... eee tee ee es Horizontal Line Temperature Comparison Smooth Pipe, No Heat Transfer oe ee ee eet et vii Page 14-23 14-26 14-27 14-29 14-32 14-33 15Figure 16.13 16.14 16.15 16.16 16.17 16.18 Horizontal Line Temperature Drop Comparison. Roughness 0.005 ft., No Heat Transfer... . . Pipeline Elevation Profile Inclined Flow Pressure Drop Comparison Smooth Pipe, No Heat Transfer Inclined Flow Pressure Drop Comparison, Roughness 0.0005 ft., No Heat Transfer : Inclined Flow Pressure Drop Comparison, Smooth Pipe, is 0.5 Btu/hr-ft2-°F Vertical Flow Pressure Drop Comparison Page 16-42 16-43 16-44 16-45, 16-46 16-47