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2019 Facilities Tips of The Month Ebook PDF
2019 Facilities Tips of The Month Ebook PDF
FACILI TIE S
Tips of the Month
Table of Contents
4
Optimizing Performance of a
Refrigeration System with an
External Sub-Cool Economizer
10
Impact of Heavy End on the
Performance of a Mechanical
Refrigeration Plant with MEG
Injection
26
Design and Operation of
Unconventional Surface Facilities:
Process Safety Tips
Table of Contents
39
Impact of Liquid Carryover on
the Performance of a Mechanical
Refrigeration Plant with MEG
Injection
50
A Short Cut Method for
Evaluating Molecular Sieve
Performance
60
Impact of Temperature Approach
of the Heat Exchangers on the
CAPEX and OPEX of a
Mechanical Refrigeration
Plant with MEG Injection
4
OPTIMIZING PERFORMANCE OF A
R E F R I G E R AT I O N S YS T E M W I T H A N
EXTERNAL SUB-COOL ECONOMIZER
Continuing the January 2008 [1], May Also, view the May 2008 [2] and May
2008 [2], May 2014 [3], and December 2014 [3] TOTM.
2017 [4] Tips of The Month (TOTM),
Figure 1 presents the process flow
this tip demonstrates the application
diagrams for a simple system and the
of an external sub-cooler to optimize
the performance of a mechanical system with a sub-cool heat exchange
economizer.
refrigeration system. Specifically, by
utilizing a cold process stream we will As part of a hydrocarbon dew point
minimize the compressor power and control plant, this tip will evaluate
condenser duty. The details of three and compare these two refrigeration
typical refrigeration systems are given systems.
in Chapter 15 of Gas Conditioning and
Processing, Volume 2 [5]. They are Let’s consider cooling the process gas
referred to as follows: to -20°C [-4°F] by removing 2733 kW
(9.325 MMBtu/hr) in a propane chiller
1. A simple refrigeration system (Fig and rejecting it to the environment by a
15.1). propane condenser at 37.8°C [100°F].
2. A refrigeration system employing one Pure propane is used as the working
flash tank economizer and two stages of fluid in the simulation. In this tip, all
compression (Fig 15.7). Also, view the simulations were performed with UniSim
May 2014 [3] and December 2017 [4] Design software [6] using the Peng-
TOTM. Robinson equation of state.
Fig 1. Process flow diagrams for a simple refrigeration system and with a sub-cool
economizer
5
Assuming an approach temperature condensed propane (refrigerant stream
of5°C [9°F] and a 6.9 kPa (1 psi) R4) from 37.8°C (100 °F) at 1303 kPa
pressure drop in the propane chiller, (189 psia) to a cooler temperature at
the pressure of saturated propane 1269 kPa (184 psia), depending upon
vapor leaving the chiller is 203.3 kPa the specified propane refrigerant flow
(29.5 psia), and at a temperature of rate (stream R5). The pressure drops in
-25°C [-13°F]. Assuming no frictional HEX E-102 and HEX E-104 are 35 kPa
losses in the suction line to the propane (5 psi) respectively. The heat removed
compressor, the resulting suction by the sub-cool economizer is fixed by
pressure is 203.3 kPa (29.5 psia). the process duty required to heat the
NGL process stream 9A.
The condensing propane pressure at
the specified condenser temperature of
37.8 °C (100 °F) is 1303 kPa (189 psi).
The condenser frictional losses, plus the Determination of Refrigerant
frictional losses in the piping from the Circulation Rate of Sub-Cool
compressor discharge to the condenser Economizer System:
was assumed to be 34.5 kPa (5 psi); The refrigerant circulation rate has a
therefore, the compressor discharge considerable impact on the compressor
pressure is 1338 kPa (194 psia). The power and consequently on the
propane compressor adiabatic efficiency condenser duty. Figure 2 presents the
was assumed to be 75%. variation of compressor power as a
function of the refrigerant circulation
rate. This figure indicates that the power
External Sub-Cool, Economizer: is minimum at 995.5 kW (1335 hp) for
a circulation rate of 690 kmol/h (1521.5
The process streams 9A and 9B are part lbmol/hr), with fixed propane chiller and
of a hydrocarbon dew point control plant sub-cool exchanger duties.
and are shown on the top of Figure 2.
This stream is the extracted NGL stream
from the refrigeration plant, combined
with the plant inlet condensate. The Summary:
stream properties are shown in Table 1. For the same chiller duty, chiller and
To prepare the liquids to be fed to the condenser temperatures, adiabatic
deethanizer, the process specification compression efficiency, and pressure
is to raise the temperature of the NGL drops, the results of the sub-cool
product stream 9A from -3.9°C (25°F) to exchange economizer system are
20°C (68°F) in HEX E-102. The resulting compared with the results of a simple
duty is 713.6 kW (2.435 MMBtu/hr). This refrigeration system in Table 2. This
heat will be supplied from a propane table indicates that by utilizing an
refrigerant sub-cool economizer heat external sub-cool exchange economizer
exchanger. The process duty and for this case study with optimized
the temperature of the NGL product propane circulation rate, the compressor
stream are set by the stabilization power and condenser duty are reduced
process requirements, thus the sub-cool by 25 % and 25.4%, respectively.
economizer duty is fixed.
The sub-cool economizer cools the
6
Fig 2. Cold process stream 9A part of the hydrocarbon dew point control plant is utilized
to sub-cool refrigerant stream R5.
7
Fig 3. Impact of refrigerant circulation rate on the compressor power
8
To learn more about similar cases
and how to minimize operational
problems, we suggest attending our
G4 (Gas Conditioning and Process-
ing), G5 (Practical Computer Simu-
lation Applications in Gas Process-
ing) and G6 (Gas Treating and
Sulfur Recovery) courses.
References:
1. Moshfeghian, M., http://www.
jmcampbell.com/tip-of-the-
month/2008/01/refrigeration-with-flash-
economizer-vs-simple-refrigeration-
system/, John M. Campbell Tip of the
Month, January 2008.
2. Moshfeghian, M., http://www.
jmcampbell.com/tip-of-the-
month/2008/05/flash-tank-vs-hex-
economizer-refrigeration-system/, John
M. Campbell Tip of the Month, May 2008.
3. Moshfeghian, M., http://www.
jmcampbell.com/tip-of-the-
month/2014/05/refrigeration-with-heat-
exchanger-economizer-vs-simple-
refrigeration-system/, PetroSkills Tip of
the Month, May 2014.
4. Moshfeghian, M., http://www.
jmcampbell.com/tip-of-the-
month/2017/12/optimizing-performance-
of-refrigeration-system-with-flash-tank-
economizer/, PetroSkills Tip of the Month,
December 2017.
5. Campbell, J.M., “Gas Conditioning
and Processing, Volume 2: The
Equipment Modules,” 9th Edition, 3rd
Printing, Editors Hubbard, R. and Snow–
McGregor, K., Campbell Petroleum
Series, Norman, Oklahoma, PetroSkills
2018.
6. UniSim Design R443, Build 19153,
Honeywell International Inc., 2017.
9
I M PAC T O F H E AV Y E N D O N T H E
PERFORMANCE OF A MECHANICAL
R E F R I G E R AT I O N P L A N T W I T H M E G
INJECTION
10
Fig 1. Process flow diagrams for a mechanical refrigeration plant using a sub-cool
economizer and MEG Injection system
Continuing the January 2019 [1] Figure 1 presents the process flow
Tip of The Month (TOTM), this diagrams for a typical mechanical
tip investigates the impact the refrigeration plant with MEG injection
heavy end characterizations on system. In this tip, all simulations
the performance of a mechanical were performed with UniSim Design
refrigeration plant with mono- R443 software [4] using the Peng-
ethylene glycol (EG or MEG) Robinson equation of state.
injection for hydrocarbon dew point
(HCDP) control. Specifically, the
impact of heavy end characterization
on the gas-gas heat exchanger
and chiller duties, the mechanical Case Study:
refrigeration system, and the liquid Let’s consider a rich gas with
propane recovery will be investigated the compositions and conditions
and reported. The details of a presented in Table 1. Based on
mechanical refrigeration plant with the reported molecular weight and
MEG injection and regeneration relative density for the C7+ fraction,
system are given in Chapters 6 and Table 2 presents the estimated
15 of the Gas Conditioning and normal boiling point (NBP), critical
Processing, Volumes 1 and 2 [2, 3], properties and acentric factor which
respectively. are needed by the equation of state.
11
The objective is to meet a Table 3 presents the estimated
hydrocarbon dew point specification of hydrate inhibition injection rates.
-20 °C [-4°F] at about 4000 kPa (580
psia) for the sales gas by removing Assuming an approach temperature
heat in the “Gas/Gas” heat exchanger of 5°C (9°F) and a 6.9 kPa (1 psi)
(HX) with a hot end approach pressure drop in the propane chiller
temperature of 5°C [9°F] and in a (“RefChiller”) shell side, the pressure
propane chiller and rejecting it to the of saturated propane vapor leaving
environment by a propane condenser the chiller is 203.3 kPa (29.5 psia),
(“E-103”) at 37.8°C [100°F]. Pure and at a temperature of -25°C
propane is used as the working fluid (-13°F). Assuming no frictional losses
in the simulation. The pressure drops in the suction line to the propane
in the “Gas/Gas” HX and the propane compressor “K-101”, the resulting
chiller are assumed to be 34.5 kPa (5 suction pressure is 203.3 kPa (29.5
psi). psia).
The feed gas is flashed in the “Inlet The condensing propane pressure at
Separator” at 30 °C (86 °F) and the specified condenser temperature
4000 kPa (580 psia) to remove any of 37.8 °C (100 °F) is 1303 kPa (189
condensate. The “Inlet Separator” psi). The condenser “E-103” frictional
vapor (stream “2”) is saturated with losses, plus the frictional losses in the
water by the “Saturate -100” to form piping from the compressor discharge
stream “2 Wet” upstream of mixing to the condenser was assumed to
with MEG hydrate inhibitor, stream be 34.5 kPa (5 psi); therefore, the
“EG1” and the recycle stream “18A” compressor discharge pressure is
from the deethanizer overhead vapor 1338 kPa (194 psia). The propane
(located at the right hand side of Fig. compressor adiabatic efficiency was
1). The estimated hydrate formation assumed to be 75%.
temperature of streams “2 Wet” is 14.7
°C (58.4 °F). The hydrate inhibitor is
injected at the inlet of “Gas/Gas” HX
by stream “EG1” and at the inlet of
the “Chiller” by stream “EG2”. Stream
“5” cools to about -8 °C (17.6 °F) and
stream “7” cools down to the specified
temperature of -20 °C (-4 °F) which
are below the hydrate formation
temperature (HFT) of 14.7 °C (58.4
°F). The injection rates of streams
“EG1” and “EG2” for 80 weight % lean
MEG and water solution are estimated
by the Adjust tool of UniSim. A design
margin of 1.1 °C (2 °F) HFT below the
cold temperature for streams “5” and
“7” were assumed.
12
Table 1. Rich feed gas compositions
and conditions
13
External Sub-Cool Economizer: Deethanizer Specifications and
Performance:
The cold Stream 7 is flashed in the
3-phase separator “V-102” at -20 °C The deethanizer column specifications
(-°4F) and 3931 kPa (570 psia). The are:
vapor stream “4” from this cold separator
is used to cool down the incoming
warm feed gas in the “Gas/Gas” HX. ►To recover 90 mole percent of propane
The heavy liquid stream “8B” (rich of the feed in the bottom product and
MEG solution) from the cold separator
is regenerated in the regeneration unit
(not shown in Fig. 1) and the lean 80 ►Ethane to propane mole ratio equal to
weight % MEG is recycled and used in 5 % in the bottoms product
streams “EG1” and “EG2”. The cold NGL
stream “8” (light liquid phase) from the
cold separator, “V-102”, is combined with ►Top and bottom pressures are 1450
the plant “Inlet Separator” condensate and 1500 kPa (210.3 and 217.6 psia);
(stream “3”) in the mixer “Mix-101” to respectively
form stream “9” at about 5 °C (41 °F)
and 3945 kPa (572.2 psia). To prepare
the liquid to be fed to the deethanizer, ►Number of theoretical stages 12 plus
the process specification is to raise the the condenser and reboiler (determined
temperature of the NGL product stream by the material balance and column
“9A” from about -4°C (25°F) and 1535 shortcut calculations)
kPa (222.6 psia) to 20 °C (68 °F) and
1500 kPa (217.6 psia) in “E-102” HX.
The required heat duty will be supplied The deethanizer simulation results are
from a propane refrigerant sub-cool summarized in Table 4.
economizer “E-104” HX. The process
duty and the temperature of the NGL
product stream is set by the deethanizer
process requirements, thus the sub-cool
economizer duty is fixed. Impact of Heavy End
Characterization:
The sub-cool economizer cools the
condensed propane (refrigerant stream Figure 2 presents the phase envelopes
“R4”) from 37.8°C (100 °F) at 1303 kPa for the key streams of feed (“Dry Feed”),
(189 psia) to a cooler temperature at inlet separator vapor (stream “2”)
1269 kPa (184 psia), depending upon and sales gas (stream “4”). All phase
the specified propane refrigerant flow envelopes are generated on the dry
rate (stream “R5”). The pressure drops basis. As expected the bubble point
in “E-102” and “E-104” HXs are 35 kPa curves are very close to each other but
(5 psi); respectively. The heat removed large deviations are observed for the
by the sub-cool economizer is fixed by dewpoint curves. Similar diagrams for
the process duty required to heat the the nC7 and nC8 as the heavy end are
NGL process stream “9A”. presented in the Appendix in Figures 1A
and 2A; respectively.
14
Table 4. Summary of
deethanizer key design
parameters for C7+
Fig 2. Phase diagrams for the key streams for the case of C7+ as the heavy end 15
Figures 3, 4, and 5 present the
impact of heavy ends on the phase
envelope of the key streams of
feed, inlet separator vapor (stream
“2”) and the sales gas (stream “4”),
respectively. These figures indicate
that as the heavy components are
removed in the “Inlet Separator” and
cold separator (“V-102”) from the
process streams, the impact of heavy
end characterization on the phase
envelope reduces and vanishes
almost completely for sales gas
(stream “4”) in Figure 5.
Fig 3. The impact of heavy end on the phase envelope of the feed stream
16
Fig 4. The impact of heavy end on the phase envelope of the inlet separator vapor stream
Fig 5. The impact of heavy end on the phase envelope of the sales gas (Stream 4)
17
Table 5. Impact of heavy end on the Gas/Gas HX and Chiller duties
Fig 6. Simplified schematic of the front end segment of the process flow diagram
19
Table 6. Impact of heavy end on the refrigeration systems key parameters
20
Fig 7. Simplified schematic of the back end of the process flow diagram
Table 7. Impact of the heavy end on streams “3” and “8” and the combined NGL stream
“9” rates and molecular weight
21
Using “VLV-100” stream 9 pressure is reduced from 3945
kPa (572.2 psia) to 1535 kPa (222.6 psia) in stream “9A”.
Table 8 presents the combined NGL streams “9A” and “9B”
(see Figure 7) properties. This table indicates that as heavy
end becomes heavier, the “E-102” HX duty decreases
because combined NGL stream rate decreases. The
required heat for this HX is supplied by the sub-cool HX
(“E-104”) of the refrigeration system.
Table 8. Impact of the heavy end on the combined NGL streams “9A” and “9B” properties
22
Table 9 presents the impact of heavy ►the overhead vapor temperature
end on the plant overall material from the deethanizer top remains
balance. This table indicates that as almost constant because the
the heavy end becomes heavier, overhead composition does not
significantly change
23
The overhead vapor of deethanizer
is compressed from 1450 kPa (210.3
psia) to the feed gas inlet pressure of
4000 kPa (580 psia) by the recycle
compressor (“K-100”) and cooled
down to the inlet feed gas temperature
of 30 °C (86 °F) in the “E-101” HX.
The liquid from compressor suction
scrubber is recycled and combined
with deethanizer feed by the recycle
pump. Table 10 presents the
compressor and pump power and
the “E-101” HX duty requirements.
Table 10 indicates that as the heavy
end becomes heavier, the recycle
compressor and pump power and the
cooler duty decrease because the
recycle stream rates decrease.
Table 10. Impact of the heavy end on the recycle compressor, pump, and cooler
Summary:
The feed analysis and /or heavy end As demonstrated in this tip, it would
characterization in natural gas play be a good practice to size the
an important role in the equipment equipment with a design margin of
sizing and process design. Feed 1.2 to 1.3 to take into account the
analysis may change when different changes in feed gas heavy end
wells of slightly different composition composition and characterizations.
are brought to the production facility.
This tip demonstrated the impact of
heavy end characterization in the feed To learn more about similar cases
gas on the process streams rates, and how to minimize operational
phase behavior, the equipment sizes problems, we suggest attending
and the refrigeration requirement by our G4 (Gas Conditioning and
replacing, the C7+ with n-heptane Processing), G5 (Practical Computer
(nC7) and n-octane (nC8). All Simulation Applications in Gas
other specifications and operating Processing) and G6 (Gas Treating
conditions were kept the same. and Sulfur Recovery) courses.
24
References
1. Moshfeghian, M., http://
www.jmcampbell.com/
tip-of-the-month/2019/01/
optimizing-performance-of-
refrigeration-system-with-an-
external-sub-cool-economizer/,
PetroSkills -John M. Campbell Tip
of the Month, January 2019.
2. Campbell, J.M., “Gas
Conditioning and Processing,
Volume 1: The Fundamentals,”
9th Edition, 3rd Printing, Editors
Hubbard, R. and Snow–McGregor,
K., Campbell Petroleum
3. Campbell, J.M., “Gas
Conditioning and Processing,
Volume 2: The Equipment
Modules,” 9th Edition, 3rd Printing,
Editors Hubbard, R. and Snow–
McGregor, K., Campbell Petroleum
Series, Norman, Oklahoma,
PetroSkills 2018.
4. UniSim Design R443, Build
19153, Honeywell International
Inc., 2017.
25
D E S I G N A N D O P E R AT I O N O F
U N C O N V E N T I O N A L S U R FAC E
FAC I L I T I E S: P RO C E S S
SAFETY TIPS
27
Process Safety Case Study 1: Direct a. This solves the salt build
Fired Heater Treater Burn Through up failure mode, but not the flame
Failures impingement failure.
Direct fired burners are failing due to b. Some operators use glycol as
internal flame impingement directly a heat transfer fluid. This is a cheaper
on the steel, and salt build up on the alternative to expensive heat transfer
outside of the firetube in the process fluids, but glycols degrade to acetic
fluids. The salts build up, act as an acid if the skin temperatures of the fire
insulator, and then steel temperature tubes exceed 350 °F (177 °C). These
increases until a burn through occurs. same operators rarely check the pH
Since the process side of the burner of their heat transfer fluid until leaks
operates at a higher pressure than the and severe corrosion are found. Heat
natural draft burner, the process fluids transfer oils are a better choice.
enter the burner and ignite. In many
instances, this has resulted in massive
damage to the entire battery. (2) Direct fired heater with a ceramic
sleeve to take the higher temperature
Figure 1 illustrates the location of burn
shock of direct flame impingement.
through failure that occurs in the 12
Heaters normally have ceramic
o’clock portion of the burner firetube
refractory castables and bricks to
(combustion leg).
prevent direct flame impingement. As
Solutions to this issue are to use: shown in Figures 2 and 3 Bartz et al.
[2] recommends inserting a ceramic
(1) Indirect fired heater where the tube to spread the heat flux of the
process fluid flows through coils in flame and avoid burn through.
a larger shell surrounded by a heat
transfer fluid. The firetube burner is
immersed in the heat transfer fluid
within the same shell.
28
Fig 1. Heater Treater Firetube Failure
29
(3) Best Solution: consider a separate
furnace and heat exchanger using
heat transfer oils. This solves
both issues. The heat transfer oils
are designed to operate without
degradation at process temperatures
required, and the metal temperatures
in the heat exchanger will not cause
metal failure if there are no salt
deposits on the heat exchanger. This
may require periodic hydro-blasting,
but you will not have to rebuild the
battery.
Fig 3. ALZETA general arrangement of distributed flux burner and blower [2]
30
(4) Think Reliability has a free
excellent Root Cause Analysis Excel
tool (Figure 4).
31
Process Safety Case Study 2: Tank temperature indicators and an
Blanket Gas / Flame Arrestors [3] effective isolation / shutdown system,
and tank blanket gas (BPCS-Basic
Flame arrestors and tank blanket Process Control System) has a PFD
gas provide independent layers of of 1x10-1 [3]. The designer can use
protection between the ignition source both or either to provide independent
- flare or thermal oxidizer - and the
layers of safety protection. Flame
vapor space in the water and oil arrestors are subject to plugging from
tanks. When evaluating what to use
ice, corrosion, fouling, improper or lack
in a design consider using a layer of
of maintenance. Blanket gas works
protection analysis or LOPA [3]. This well in this situation due to the narrow
tool is discussed in the PetroSkills- range of flammability of methane in
John M Campbell PS4-Process Safety
the air (5-15% fuel to air). The majority
Course. It provides a semi-quantitative
of stock tank incidents occur during
solution to design decisions that are
maintenance activities with small
based of failure frequencies and amounts of gas and large volumes of
not just personal preferences or gut air.
feels. The more independent layers of
protection the lower the frequency of During the high volume of production
the consequence occurring. timeframe for unconventional tank
batteries the stock tanks degas and
have “auto-blanketing” of the active
f = (IEF) x PFD1 x PFD2…. tank vapor space. But what happens
in the future when rates are very low?
What happens in water tanks that are
Where: not provided with gas blanketing? This
also explains why water production
f = Frequency of the consequence tanks / injection batteries experience
occurring for the scenario tank fires/explosions. In general,
methane has a very low solubility in
water - approximately 2 SCF/STB
IEF = Frequency of the initiating event (0.36 Sm3/STm3) of water going from
250 psi (1724 kPa) to atmospheric
pressure. This small volume often
PFD = Probability of the failure on results in flammable mixtures in the
demand for an independent layer of vapor space of the tank.
protection.
It is a good practice to select tank
For example, the probability that blanketing as your first line of defense
a relief valve will not operate as to prevent internal tank corrosion and
intended. gas plant amines and TEG process
corrosion/solution degradation by
keeping oxygen out of the system, and
Flame arrestors have a Probability internal explosions from flash back
of Failure on Demand (PFD) with a from flares and thermal oxidizers.
range of 1x10-1 for arrestors without
32
Process Safety Case Study 3:
Pocketing Vent / Relief Piping
Many unconventional tank batteries
run their vent / flare / thermal oxidizer
piping at grade on sleepers with
zero slope, then jump vertically into
a flare knockout (see Figure 5). This
pocketed piping is a liquid trap for
water and heavier hydrocarbons.
Once a liquid pocket forms, the tanks
overpressure, and then vent locally
through their pressure/vacuum reliefs
and thief hatches. In the winter this
pocket can freeze and block the flare
(see Figure 6). This can also cause
a loss of containment when a PSV
Fig 5. Pocketed piping causes an
activates and cannot depressure
overpressure in the tanks and results in
to the flare. This causes a loss of
venting
revenue, as well as an environmental
and safety issue. These vapors are
extremely rich and normally are
much heavier than air. This creates
the potential for an unconfined vapor
cloud explosion or flash fire locally.
Fig 6. This flare knock out has a 5 ft (1.5 m) pocket - tanks vent, and the
potential for ice blockage in the winter 33
Fig 7. Flare header design into knockout – sloped / no pockets
35
Process Safety Case Study 4: Hot
Oiling Oil Storage Tanks
►Does the lease operator visit the site
As illustrated in Figure 9, some with the contractor to issue a Hot Work
operators use hot oil trucks during Permit and JSA?
winter months to heat the crude oil
in the tanks to flash light ends off
the crude to meet vapor pressure ►Do you have operating guidelines or
specifications for crude sales. The checklists for Hot Oil Operations?
solution to this issue is not to use hot
oil trucks but is to stabilize the crude
or use a design using Vapor Recovery ►Do they include monitoring of
Towers (VRT) as discussed in the weather conditions? Wind Speed?
August 2018 Tip of the Month- Design
and Operation of Unconventional - Shutdown for low or no wind
Surface Facilities Issues-Stabilization conditions?
[1].
Many operators are faced with large ►Do they include stopping of other
numbers of tank batteries in the operations such as oil / water truck
hundreds or thousands spread over a loading?
large geographic area. Many rely on
unsupervised contractors to conduct
►Are parts of the lease blocked off
hot oiling operations, oil & water to prevent other vehicles entering as
loading and unloading, and other
ignition sources?
maintenance operations.
►Do you have an operator present at ►Are the hot oil trucks placed upwind
the location to help with hot oiling? of the tanks?
36
►Are the hot oil trucks 100 ft Read: January 25, 2019 Officials
or 50 ft from the tanks? What’s identify victims of fire on FM 1788
your company’s design spacing South
requirements for ignition sources /
direct fired equipment and oil storage Read: January 2, 2019 Noble Energy
tanks? oil tanks in West Texas catch fire
38
I M PAC T O F L I Q U I D C A R RYOV E R O N
THE PERFORMANCE OF A
M E C H A N I C A L R E F R I G E R AT I O N
PLANT WITH MEG INJECTION
39
Problems in meeting sales-gas dew investigates the impact of the liquid
point specifications are not unusual carryover (LCO) on the performance
in plants. A facility engineer often of a mechanical refrigeration plant
suspects separator carryover when with mono-ethylene glycol (EG or
troubleshooting such a plant. Proper MEG) injection for hydrocarbon dew
sizing of equipment for gas-liquid point (HCDP) control. Specifically,
separation is essential to almost all the impact of LCO on the gas-gas
processes. Many facility operating heat exchanger and chiller duties, the
problems are related to improperly mechanical refrigeration system, and
designed or under-sized gas-liquid the liquid propane recovery will be
separators. The following list presents investigated and reported.
items that can contribute to too much
liquid (carryover) in the gas stream. The details of a mechanical
refrigeration plant with MEG injection
►The mist extractor operating Ks and regeneration system are given
value is greater than the design value. in Chapters 6, 15 and 18 of the Gas
Conditioning and Processing, Volumes
1 and 2 [4, 5], respectively. In addition,
►The velocity profile through the mist how to minimize the liquid carry in
extractor is poor, resulting in localized separation equipment are discussed in
high velocities/flooding. PetroSkills-John M. Campbell course
titled, “PF42 - Separation Equipment -
Sizing and Selection”.
►The droplet sizes reaching the mist Figure 1 presents the process flow
extractor are too small. diagrams for a typical HCDP control
plant using mechanical refrigeration
with MEG injection system. This
►The entrained liquid load reaching figure is similar to the February 2019
the mist extractor is too high. TOTM [3] with the exception that the
refrigeration system utilizes a flash
tank economizer with two stages of
►The mist extractor is damaged or compression. In this tip, all simulations
plugged. were performed with UniSim Design
R443 software [6] using the Peng-
Robinson equation of state.
►Level control and instrumentation
malfunction or failure
Case Study:
►Foaming Let’s consider the same case
presented in February 2019 TOTM [3]
for a rich gas with the compositions
Continuing the December 2005, and conditions presented in Table 1
January and February 2019 [1, 2, 3] [3].
Tips of The Month (TOTM), this tip
40
Fig 1. Process flow diagrams for a HCDP plant using mechanical refrigeration with a flash
tank economizer and MEG Injection system
Based on the reported molecular Table 1. Rich feed gas compositions and conditions
weight and relative density for the
C7+ fraction, Table 2 presents the
estimated normal boiling point (NBP),
critical properties and acentric factor
which are needed by the equation
of state. The objective is to meet a
hydrocarbon dew point specification of
-20 °C (-4 °F) at about 4000 kPa (580
psia) for the sales gas by removing
heat in the “Gas/Gas” heat exchanger
(HX) with a hot end approach
temperature of 5°C (9°F) and in a
propane chiller, 5 °C (-4 °F) approach
temperature, and rejecting it to the
environment by a propane condenser
(AC-100) at 37.8°C (100°F). Pure
propane is used as the working fluid
in the simulation. The pressure drops
in the “Gas/Gas” HX and the propane
chiller are assumed to be 34.5 kPa (5
psi).
41
The feed gas is flashed in the “Inlet the specified condenser temperature
Separator” at 30 °C (86 °F) and of 37.8 °C (100 °F) is 1303 kPa (189
4000 kPa (580 psia) to remove any psi). The condenser “AC-100” frictional
condensate. The “Inlet Separator” losses, plus the frictional losses in the
vapor (stream 2) is saturated with piping from the compressor discharge
water by the “Saturate -100” to form to the condenser were assumed to
stream “2 Wet” upstream of mixing be 34.5 kPa (5 psi); therefore, the
with MEG hydrate inhibitor, stream discharge pressure of compressor
“EG1” and the recycle stream “18A” “K-102” is 1338 kPa (194 psia). The
from the deethanizer overhead vapor compressors inter stage pressure
(located at the right-hand side of Fig. was determined by equalizing the
1). power for “K-101” and “K-102”. The
compressors adiabatic efficiency was
The estimated hydrate formation assumed to be 75%.
temperature of streams “2 Wet” is 14.7
°C (58.4 °F). The hydrate inhibitor is The cold Stream 7 is flashed in the
injected at the inlet of “Gas/Gas” HX 3-phase separator “V-102” at -20
by stream “EG1” and at the inlet of °C (-°4F) and 3931 kPa (570 psia).
the “Chiller” by stream “EG2”. Stream The vapor stream “4” from this cold
“5” cools to about -8 °C (17.6 °F) and separator is used to cool down the
stream “7” cools down to the specified incoming warm feed gas in the “Gas/
temperature of -20 °C (-4 °F) which Gas” HX. The heavy liquid stream
are below the hydrate formation “8B” (rich MEG solution) from the
temperature (HFT) of 14.7 °C (58.4 cold separator is regenerated in the
°F). The injection rates of streams regeneration unit (not shown in Fig.
“EG1” and “EG2” for 80 weight % lean 1) and the lean 80 weight % MEG is
MEG and water solution are estimated recycled and used in streams “EG1”
by the Adjust tool of UniSim. A design and “EG2”. The cold NGL stream
margin of 1 °C (1.8 °F) HFT below the “8” (light liquid phase) from the cold
cold temperature for streams “5” and separator, “V-102”, is combined with
“7” were assumed. the plant “Inlet Separator” condensate
(stream “3”) in the mixer “Mix-101” to
Assuming an approach temperature form stream “9” at about 5 °C (41 °F)
of 5°C (9°F) and a 6.9 kPa (1 psi) and 3945 kPa (572.2 psia). To prepare
pressure drop in the propane chiller the liquid to be fed to the deethanizer,
(“Chiller”) shell side, the pressure of the process specification is to raise
saturated propane vapor leaving the the temperature of the NGL product
chiller is 203.3 kPa (29.5 psia), and stream “9A” from about -4°C (25°F)
at a temperature of -25°C (-13°F). and 1535 kPa (222.6 psia) to 20 °C
Assuming no frictional losses in
(68 °F) and 1500 kPa (217.6 psia) in
the suction line to the propane “E-102” HX. The process duty and
compressors “K-101” and “K-102”, the the temperature of the NGL product
resulting suction pressure is 203.3 kPa stream is set by the deethanizer
(29.5 psia). process requirements. The pressure
The condensing propane pressure at drops in “E-102” HX is 35 kPa (5 psi).
42
Deethanizer Specifications and
Performance:
Like the February 2019 TOTM [3], the
deethanizer column specifications are:
A. To recover 90 mole percent
of propane of the feed in the bottom
product and
B. Ethane to propane mole ratio
equal to 5 % in the bottoms product
C. Top and bottom pressures are
1450 and 1500 kPa (210.3 and 217.6
psia); respectively
D. Number of theoretical stages
12 plus the condenser and reboiler
(determined by the material balance
and column shortcut calculations)
The deethanizer simulation results are
summarized in Table 3.
Table 3.
Summary of deethanizer
key design parameters
43
Impact of Liquid Hydrocarbon stream 4 and sales gas to go up and
Carryover: make it off spec. To offset the effect
of LCO and bring back the sales gas
Separator “V-102” is a three-phase dewpoint temperature to spec, the
separator. Under ideal condition the
operators typically lower the chilling
vapor (stream 4) leaving the separator
temperature of feed (stream 7) to
has no LCO and its dewpoint separator (“V-102”). This is possible if
temperature is the same as the feed
the mechanical refrigeration system is
(stream 7) temperature. Typical range capable of handling a higher chilling
of liquid carry over is 0.013–0.27 m3 load.
liquid/106 std m3 of gas (0.1–2 gallon
of liquid/MMscf) [5]. In practice due Figure 2 presents the hydrocarbon
to the reasons listed in the preceding dewpoint curves as a function of the
section the LCO can be even higher. liquid hydrocarbon carryover (CO). the
In this tip, the impact of LCO was cricondentherm points shift to the right
investigated for a range of 0 to 3 as LCO increases. The bubble point
mole % of liquid in light liquid phase curves are not presented because
(liquid hydrocarbon phase) entrained the LCO has negligible effect on the
into the gas phase. The entrained bubble curves. All phase envelopes
liquid consists of heavier molecules are generated on the dry basis
causing the dewpoint temperature of
Fig 2. Impact liquid carryover on the sales gas hydrocarbon dewpoint temperature
44
Figure 3 presents the impact of
LCO on the sales gas dewpoint
temperature and the required cold
separator feed (chilling) temperature
to offset the LCO. As the LCO
increases the chiller temperature
should be decreased to meet the
sales gas dewpoint spec of -20 °C
(-4 °F). For 3 mole % LCO, the sales
gas dewpoint temperature is -14.4 °C
(6.1 °F). To bring back the sales gas
dewpoint temperature, the process
gas (stream 7) should be cooled to
-28.6 °C (-19.5 °F).
Fig 3. Impact of liquid carryover on the sales gas dewpoint temperature (solid line) and the
required cold separator feed temperature (dashed line) to offset liquid carryover
45
As the chiller temperature decreases, a likelihood of carryover of the
to counter the effect of the LCO, glycol phase. This can result in
the hydrate formation temperature problems meeting the water dewpoint
depression of streams 5 and 7 specification and also introduces a
increases, which requires a higher deleterious substance into the sales
MEG injection rate. Figure 4 presents gas (MEG) which may also not be
the impact of LCO on the rate of allowed in the sales gas contract.
streams EG1 and EG2 upstream
Lowering the chiller temperature
of Gas/Gas HX and the chiller,
to counter the effect of LCO also
respectively. Note the required
cause an increase in the compressor
inhibitor injection rate for stream EG2
power, Gas/Gas-gas HX, chiller and
upstream of the chiller increases
condenser duties. Figures 5 A and
considerably with the increase in
B illustrate the impact of LCO on the
LCO.
compressor power and Gas-Gas HX,
If there is carryover of the Chiller, and condenser duty in SI and
hydrocarbon phase, there is also FPS system of units, respectively.
Fig 4. Impact of liquid carryover on the MEG injection rate upstream of Gas/Gas HX (EG1)
and chiller (EG2)
46
Fig 5A. Impact of liquid carryover on the compressor power, Gas-Gas HX, chiller, and
condenser duty
Fig 5B. Impact of liquid carryover on the compressor power, Gas/Gas HX, chiller, and
condenser duty
47
Figure 6 presents the impact of LCO liquids from the inlet separator are
on the liquid propane and sales gas introduced lower in the column. V-100
recoveries. This figure indicates that is not required then. E-102 is usually
as the LCO increases from 0 to 3 a feed/bottoms heat exchanger.
mole %, the liquid propane recoveries Overhead of the deethanizer can
increase from about 17% to 27% on likely go to the sales gas and may not
mole basis but the sales gas recovery have to be recycled. It really should
decreases slightly from about 97 % not contain anything heavier than
to 96 % on mole basis. The extra propane, heavy key (HK).
propane liquid recovery is achieved
Table 4 presents the impact of LCO
by operating the chiller at a lower
on the key equipment incremental
temperature which requires higher
capacity requirement to meet the
OPEX and CAPEX.
sales gas hydrocarbon dewpoint
As the chiller temperature is reduced, temperature by lowering the chiller
more ethane and methane end up in temperature. Assume the system
the low temperature separator (LTS), was built with a design margin factor
V-102, liquids. These need to get of 1.25. Table 4 indicates that this
boiled out in the deethanizer, so the system can handle up to one mole
duty of E-102 increases, reboiler and % LCO with higher OPEX. However,
condenser duty of the deethanizer for more than one mole % LCO,
increase, and the recompression the system cannot lower chiller
power in K-100 also increases. It temperature enough to meet the sales
may also be possible to flood the gas dewpoint temperature. As shown
deethanizer. in Table 4, the compressor power,
hydrate inhibition rate, condenser and
The cold condenser on the chiller duties are the limiting factors.
deethanizer requires propane for Under such condition it may require
cooling. These units are also designed plant shutdown for trouble shooting to
with no condenser. The cold LTS (V- reduce the LCO.
102) liquid is used as reflux, and the
48
Summary: References:
The common practice to meet 1. Moshfeghian, M., http://www.jmcampbell.
sales gas hydrocarbon dewpoint com/tip-of-the-month/2005/12/impact-of-
temperature under the condition of liquid-carry-over-on-sales-gas-dew-point/,
liquid carry is to operate the chiller at PetroSkills -John M. Campbell Tip of the
a temperature below the sales gas Month, December 2005.
hydrocarbon dewpoint spec. This is
2. Moshfeghian, M., https://www.petroskills.
only possible if the key equipment
com/blog/entry/00_totm/jan19-fac-
can handle the extra load with higher
optimizing-performance-of-refrigeration-
OPEX. This tip demonstrated the
systems-with-an-external-sub-cool-
impact of varying the LCO from 0 to
economizer, PetroSkills -John M. Campbell
3 % on a mole basis on the process
Tip of the Month, January 2019.
stream rates, phase behavior, the
equipment sizes and the refrigeration 3. Moshfeghian, M., https://www.petroskills.
requirement. com/blog/entry/00_totm/feb19-fac-impact-
of-heavy-end-on-the-performance-of-a-
As demonstrated in this tip, it would
mechanical-refrigeration-plant-with-meg-
be a good practice to size the
injection, PetroSkills -John M. Campbell Tip
equipment with a design margin of
of the Month, February 2019.
1.2 to 1.3 to consider the changes
in operation conditions and the 4. Campbell, J.M., “Gas Conditioning and
liquid carryover. Most important to Processing, Volume 1: The Fundamentals,”
minimize LCO is to have a properly 9th Edition, 3rd Printing, Editors Hubbard,
designed separator with good feed R. and Snow–McGregor, K., Campbell
pipe, inlet device, mist extractor, gas Petroleum
gravity separation and liquid gravity
5. Campbell, J.M., “Gas Conditioning and
separation sections.
Processing, Volume 2: The Equipment
To learn more about similar cases and Modules,” 9th Edition, 3rd Printing, Editors
how to minimize operational problems, Hubbard, R. and Snow–McGregor, K.,
we suggest attending our G4 (Gas Campbell Petroleum Series, Norman,
Conditioning and Processing), G5 Oklahoma, PetroSkills 2018.
(Practical Computer Simulation
6. UniSim Design R443, Build 19153,
Applications in Gas Processing), and
PF42 (Separation Equipment - Sizing Honeywell International Inc., 2017.
and Selection) courses.
A SHORT CUT METHOD FOR
E VA LUAT I N G M O L E C U L A R S I E V E
PERFORMANCE
50
This Tip of the Month shows how a The above results were calculated
Short Cut Method (SCM), after one used the concepts outlined in
Performance Test Run (PTR), may be Chapter 18 of Gas Conditioning
used to estimate the life of a Type 4A and Processing, Volume 2: The
molecular sieve dehydrating a water- Equipment Modules (9th Edition)
saturated feed of natural gas. [2]. Due to the non-linearity of the
modeling techniques, the manual
The May 2015 Tip of the Month [1] calculations are tedious. The June
discussed the benefits of standby 2016 Tip of the Month [3] showed how
time. In that Tip (which the reader a computer module developed for the
is urged to revisit), a case study was PetroSkills-John M. Campbell GCAP
presented for a 3-tower dehydration (Gas Conditioning and Processing
system. The system was designed Software) [4] could be used to perform
to meet a three-year life; however, the same calculations. Among other
a PTR after one year of service things, the GCAP module directly
predicted the total life of the molecular calculates the life factor, FL, which
sieve would only be about two years. generates more consistent results
Using the available stand-by time, the compared to visually reading the
molecular sieve life was extended to Generic Molecular Sieve Decline
about 3.7 years. Curves (Figure 1).
FL = BTL/18 (1)
2. The feed conditions remain
relatively constant throughout the life where:
of the molecular sieve system
FL = Life factor
53
Table 3. Results of Performance Test Run (PTR) after 12 months of operation
55
Because the unit has a regeneration calculations (June 2016 Tip of the
circuit that can handle an additional Month).
15% of flow, the complete
The difference between the predicted
regeneration cycle (heating, cooling,
life using standby time shown by
de- and re- pressurization) can be
the Computer Model and the two
reduced to 7.0 hours. This allows
manual methods is primarily due
the beds to turn around faster. Using
to the inherent inaccuracy of trying
the reduced cycle time (the complete
to interpolate and extrapolate data
cycle time is now 21 hours vs the
plotted on Figures 3 and 4. The
original 24 hours) and the original
computer model will produce the
design basis conditions with the SCM
same result every time. This cannot
recipe:
be said when visually reading Figures
1. Calculate End of Life BTL = 9.3 wt 3 and 4. Figure 5 shows the output
% (from Equation 2). from the GCAP Computer Model [3].
Note that when working on one curve,
►BTL =100 (14 h)(163 kg water the higher the calculated EOL FL, the
removed/h)/(24630 kg mol sieve) fewer the Number of Cycles (NOC)
=9.3% remaining until the beds need to be
►BTL =100 (14 hr)(360 lbm water replaced.
removed/hr)/(54300 lbm mol sieve) The PTR in the above Case Study
=9.3% was run after 365 cycles. The slope
of the curve is fairly steep in this
region and small changes in data
2. Calculate End of Life FL = 9.3/18 can have a significant impact on the
= 0.52 (from Equation 1). This is life predictions. While the user can
because less water is being adsorbed get a good indication of the state
per cycle. of decline of their molecular sieve
unit, scheduling additional PTR’s is
highly recommended. Finally, generic
3. Interpolating and extrapolating curves are used in these Figures. The
from the PTR FL Point, we find the shape of your specific molecular sieve
End of Life FL of 0.52 occurs around capacity decline curve may differ from
1400 cycles (see Figure 4). Since these generic curves. Despite these
365 cycles have already occurred and caveats, the SCM offers the user a
going forward a reduced cycle time quick and easy way to assess the
will be used, the molecular sieves are capacity decline of their molecular
forecast to last a total of 3.5 years. sieve unit.
57
Fig 5. Projected life factor (LF = 54.3% and NOC = 1251.4) if standby time is used
59
60
60
I M PAC T O F T E M P E R AT U R E
A P P ROAC H O F T H E H E AT E XC H A N G E R S
ON THE CAPEX AND OPEX OF A
M E C H A N I C A L R E F R I G E R AT I O N P L A N T
WITH MEG INJECTION
61
Fig 1. Process flow diagrams for an HCDP plant using mechanical refrigeration with a
flash tank economizer and MEG Injection system
62
Fig 2. Effective Temperature Difference Schematics [2]
63
specific process application (gas- C7+ fraction, Table 3 presents the
gas exchanger) both effects should estimated normal boiling point (NBP),
be considered in heat exchanger critical properties and acentric factor
specifications. which, are needed by the equation
of state. The objective is to meet a
Note that the minimum approach may hydrocarbon dew point specification of
occur at the “hot” end or “cold” end -20 °C (-4 °F) at about 4000 kPa (580
of the exchanger depending on the psia) for the sales gas by removing
application. The minimum approach heat in the “Gas/Gas” heat exchanger
may also occur internally inside (HX) with a hot end TA of 5°C (9°F)
the exchanger. Typical economic and in a propane chiller, 5 °C (-4 °F)
minimum approaches for various TA, and rejecting it to the environment
heat exchangers and applications are by a propane condenser (AC-100) at
presented in Table 1. 37.8°C (100°F). Pure propane is used
For compact exchangers, smaller as the working fluid in the simulation.
minimum approaches are usually The pressure drops in the “Gas/
economically justifiable. Compact heat Gas” HX and the propane chiller are
exchangers have a greater surface assumed to be 34.5 kPa (5 psi).
area per volume than shell and tube
heat exchangers. In addition, they
have higher fluid velocities, which Table 2. Rich feed gas compositions and
result in greater overall heat transfer conditions
coefficients.
Case Study:
Let’s consider the same case
presented in Apr 2019 TOTM [1] for
a rich gas with the compositions and
conditions presented in Table 2 [1].
Based on the reported molecular
weight and relative density for the
64
Table 3. Estimated C7+ properties [4]
The feed gas is flashed in the “Inlet compressors “K-101” and “K-102”, the
Separator” at 30 °C (86 °F) and resulting suction pressure is 203.3
4000 kPa (580 psia) to remove any kPa (29.5 psia).
condensate. The “Inlet Separator” The condensing propane pressure at
vapor (stream 2) is saturated with the specified condenser temperature
water by the “Saturate -100” to form of 37.8 °C (100 °F) is 1303 kPa
stream “2 Wet” upstream of mixing (189 psi). The condenser “AC-
with MEG hydrate inhibitor, stream 100” frictional losses, plus the
“EG1” and the recycle stream “18A” frictional losses in the piping from
from the deethanizer overhead vapor the compressor discharge to the
(located at the right-hand side of Fig. condenser were assumed to be
1). 34.5 kPa (5 psi); therefore, the
The estimated hydrate formation discharge pressure of compressor
temperature (HFT) of streams 5 and “K-102” is 1338 kPa (194 psia). The
7 is 14.7 °C (58.4 °F). The hydrate compressors interstage pressure
inhibitor is injected at the inlet of was determined by equalizing the
“Gas/Gas” HX by stream “EG1” and power for “K-101” and “K-102”. The
at the inlet of the “Chiller” by stream compressors adiabatic efficiency was
“EG2”. Stream “5” cools to about -8 °C assumed to be 75%.
(17.6 °F) and stream “7” cools down The cold Stream 7 is flashed in the
to the specified temperature of -20 3-phase separator “V-102” at -20
°C (-4 °F), which is below the HFT °C (-°4F) and 3931 kPa (570 psia).
of 14.7 °C (58.4 °F). The injection The vapor stream “4” from this cold
rates of streams “EG1” and “EG2” separator is used to cool down the
for 80-weight % lean MEG and water incoming warm feed gas in the “Gas/
solution are estimated manually or by Gas” HX. The heavy liquid stream
the Adjust tool of UniSim. A design “8B” (rich MEG solution) from the
margin of 1 °C (1.8 °F) HFT below the cold separator is regenerated in the
cold temperature for streams “5” and regeneration unit (not shown in Fig.
“7” were assumed. 1) and the lean 80 weight % MEG is
Assuming a temperature approach recycled and used in streams “EG1”
of 5°C (9°F) and a 6.9 kPa (1 psi) and “EG2”. The cold NGL stream
pressure drop in the propane chiller “8” (light liquid phase) from the cold
“Chiller” shell side, the pressure of separator, “V-102”, is combined with
saturated propane vapor leaving the the plant “Inlet Separator” condensate
chiller is 203.3 kPa (29.5 psia), and (stream “3”) in the mixer “Mix-101” to
at a temperature of -25°C (-13°F). form stream “9” at about 5 °C (41 °F)
Assuming no frictional losses in and 3945 kPa (572.2 psia). To prepare
the suction line to the propane the liquid to be fed to the deethanizer,
65
the process specification is to raise Table 4. Summary of deethanizer key
the temperature of the NGL product design parameters
stream “9A” from about -4°C (25°F)
and 1535 kPa (222.6 psia) to 20 °C
(68 °F) and 1500 kPa (217.6 psia) in
“E-102” HX. The process duty and
the temperature of the NGL product
stream is set by the deethanizer
process requirements. The pressure
drops in “E-102” HX is 35 kPa (5 psi).
Fig 3. Impact of the temperature approach on the MEG injection rate upstream of Gas/
Gas HX (EG1) and chiller (EG2)
67
Increasing TA causes a decrease Figure 5 presents the impact of TA on
in the Gas/Gas-gas HX duty, which the required surface area of the Gas/
results in an increase in the chiller Gas HX, chiller and the refrigerant
duty because the total cooling condenser. This figure indicates that
duty is constant. As the chiller duty the Gas/Gas HX required area is
decreases, the compressor power much greater than the chiller and
and condenser duty decreases, too. condenser area because it has
Figures 4 A and B illustrate the impact greater heat duty. Note for TA cases
of TA on the compressor power, Gas/ of 1 and 2 °C (1.8 and 3.6 °F) the
Gas HX, Chiller, and condenser required surface areas of Gas/Gas
duty in SI and FPS system of units, HX are greater than 6000 m2 (64,590
respectively. ft2); therefore, two HXs of 50% of the
required area should be used [5].
In order to calculate the required
surface area of the heat exchangers a
design factor of 1.25 and the following
overall heat transfer coefficients in W/
m2-°C (Btu/hr-ft2-°F) were assumed:
Gas/Gas HX = 283 (50), Chiller = 444
(78), and Condenser = 460 (81).
Fig 4A. Impact of the temperature approach on the Gas/Gas HX, chiller and condenser
duty, and compressor power
68
Fig 4B. Impact of the temperature approach on the Gas/Gas HX, chiller and condenser
duty, and compressor power
Fig 5. Impact of the temperature approach on the Gas/Gas HX, chiller and condenser
surface area 69
The procedure suggested by Hubbard CAPEX cost was estimated based
[5] was used to perform the cost on 5 years recovery. The annual
analysis. The CAPEX is the sum of OPEX (energy cost) was estimated
the HXs and compressor costs. The based on the compressor power
HXs cost was estimated based on requirement. The total cost is the
the size and surface area for the shell sum of the annualized CAPEX and
and tube types HXs. It is assumed annual OPEX (energy cost). These
that the maximum shell diameter is costs are based on a design factor
1.97 m (6 ft) and the L/D was 10. of 1.25. Because total MEG injection
For these dimensions, the maximum rate and deethanizer performance
surface area per shell is about 6000 are independent of TA, they were
m2 (64,590 ft2). For TA cases of 1 excluded in the cost analysis.
and 2 oC (1.8 and 3.6 oF), the Gas/
Figure 6 presents the impact of TA
Gas HX with an area greater than
on the estimated annualized CAPEX,
6000 m2 (64,590 ft2) two HXs with
annual OPEX (energy cost), and the
50% required area were used. The
total annual cost. This figure indicates
compressor CAPEX was estimated
that the optimum TA for the Gas/Gas
based on the required power with
HX occurs at 3 °C (5.4 °F).
a design factor of 1.25. Annualized
72