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PLP E-11-2003, Lean Oil Absorbers-2nd Ed-Rosen
PLP E-11-2003, Lean Oil Absorbers-2nd Ed-Rosen
This manual is one of a series for your use In order for you to learn the contents of the
in learning more about equipment that you manual, you must dig out the pertinent facts
work with in the petroleum industry. Its pur- and relate them to the subject. Simply reading
pose is to assist in developing your knowl- the material and answering the questions is
edge and skills to the point that you can not enough. The more effort you make to
perform your work in a more professional learn the material, the more you will learn from
manner. the manual.
The manual was prepared so that you can Teaching yourself requires self-discipline
learn its contents on your own time, without and hard work. In order to prepare yourself for
the assistance of an instructor or classroom the sacrifice you will have to make, you should
discussion. Educators refer to learning by set goals for yourself. Your ultimate goal is to
self-study as Programmed Learning. It is a perform your work in a more professional
method widely used in all industries as a manner. Training is one step in reaching that
means of training employees to do their job goal. Application of what you learn is another.
properly and teach them how to perform higher Seeking answers to questions is a third.
rated jobs.
Once you have established your final goal,
You can demonstrate your desire to be a you must determine the means for reaching
professional by taking a positive attitude to- that goal. You may decide, for example, that
ward learning the contents of this manual and you must complete a series of 10 to 15 manu-
others that are applicable to your job. als to get the basic knowledge and skills you
need. After you decide which training material
The author of this manual has years of is required, you should set a time table for
experience in operating petroleum equipment. completing each section of the material.
He also has the technical knowledge of how
and why petroleum equipment functions. Achieving your final goal may take more
The text was written for use by personnel with than a year, and will require hours of hard
little or no previous experience with petro- work on your part. You will know you have
leum equipment. Consequently, some of the achieved your goal when you understand
material may be familiar to you if you have how and why to operate oilfield equipment in
experience with oilfield equipment. From such order to obtain the maximum product at the
experience, you have observed the effect of lowest cost. Your sacrifice will have been
making operating changes. The manual will worth-while from the satisfaction of knowing
help explain why the changes occurred that that you can perform your job in a methodical
you observed. It will also teach you how and professional manner, instead of a trial-and-
why equipment functions. error approach.
© 2003 Petroleum Learning Programs Ltd. No part of this manual may be reproduced in any form. Its use as a
reference in training courses is specifically reserved for Petroleum Learning Programs Ltd. All translation rights are
likewise reserved.
This your manual. You should write your 1. Turn to Page 1. Read the material until
name on the cover. Upon completion you will you come to the first problem or ques-
find it helpful to keep it in an accessible place tion.
for future reference. 2. Work the first problem or answer the
question and enter the answer in the
Problems are included throughout the text. proper space in ink. If the problem or
The solutions to the problems are given at the question is shown in both SI and En-
end of the book. glish Units of measurement, answer
only the part in units of measurement
The manual is used in training programs that you use.
all over the world. In some countries, English 3. Compare your answer with that shown
units of measurement such as feet, gallons, at the end of the book; be sure to use
pounds, etc, are used. In other countries, solutions to the problems in the units
Systems Internationale (SI) or Metric units, you are working in.
such as meters, liters, kilograms, etc., are If your answer is correct, continue read-
used. In order for the manual to be of maxi- ing until you come to the next problem
mum use, both SI and English units are shown. and work it. If not, restudy the manual
until you understand the reason for
The SI unit always appears first, and the your error. Rework the problem if
English unit follows in brackets [ ]. Example: necesary. Leave your wrong answer
the temperature is 25°C [77°F]. The English and note the correct one. This will keep
equivalent of the SI unit will be rounded off to you from making the same mistake
the nearest whole number to simplify the text later on.
and examples. A distance of 10 m may be 4. Proceed stepwise as shown above
shown as 33 ft whereas the exact equivalent until you have completed the text.
is 32.81 ft.
The above approach will require thought,
If you are working in English units, you making mistakes, and rethinking the situ-
may find it helpful to mark out the parts that ation. Concenrate on two things — the how
are in SI units and vice versa. and why. Do not cheat yourself by taking
short-cuts or looking up the answers in ad-
Some of the Figures have units of meas- vance. It saves time and errors but produces
urement. In such cases, two figures are in- no real understanding. Your future depends
cluded. The first one is in SI units, and the on how efficiently you perform your job and
second-figure will be on the next page and will not on how rapidly you proceed through this
have English units. Each figure is identified manual. Since this is your manual, any errors
with SI or English units. Be sure you use the you make are private.
figures in the units you are working in.
A validation or test covering the entire
The following procedure is recommended manual is included at the back of the book.
for using this manual: Answers will be sent to your supervisor or
training director at their request at no cost.
INTRODUCTION ...................................................................................................................... 1
I. DESCRIPTION OF ABSORBER ................................................................................... 2
II. PRINCIPLES OF ABSORPTION .................................................................................. 6
A. Flow Description ...................................................................................................... 6
B. Principles of Hydrocarbon Recovery by Absorption ................................................. 9
C. Lean Oil Loss in Absorber Outlet Gas ................................................................... 11
1. Reabsorber ....................................................................................................... 15
D. Lean Oil Composition ............................................................................................. 15
1. Lean Oil Distillation ........................................................................................... 17
E. Lean Oil/Gas Mixing Stages .................................................................................. 20
F. Heat of Vaporization of Hydrocarbons ................................................................... 23
1. Lean Oil Pre-Saturator ...................................................................................... 24
G. Absorber Capacity ................................................................................................. 27
H. Puking and Carryover ............................................................................................ 29
III. OPERATION AND CONTROL .................................................................................... 31
A. Start-Up Sequence ................................................................................................ 31
B. Shut Down ............................................................................................................. 31
C. Routine Operating Checks ..................................................................................... 31
D. Control ................................................................................................................... 32
1. Gas and Lean Oil Temperature ........................................................................ 32
2. Lean Oil Flow .................................................................................................... 32
3. Lean Oil Purity .................................................................................................. 32
E. Presaturator Control ............................................................................................... 38
F. Operation with Refrigeration System Shut Down ................................................... 38
IV. TROUBLESHOOTING ................................................................................................ 40
A. Failure to Absorb Proper Quantity of Hydrocarbons .............................................. 40
B. Foaming or Carryover ............................................................................................ 40
VALIDATION - SI UNITS ....................................................................................................... 41
SOLUTIONS TO PROBLEMS - SI UNITS ............................................................................. 42
VALIDATION - ENGLISH UNITS ........................................................................................... 43
SOLUTIONS TO PROBLEMS - ENGLISH UNITS ................................................................. 44
Absorber .................................................................................................................. 2, 7, 24
Packing in Absorber ............................................................................................................. 3, 4
Trays in Absorber ..................................................................................................................... 5
Flow on Trays ........................................................................................................................... 8
Lean Oil Loss in Absorber Outlet Gas .................................................................................... 12
Lean Oil Loss in Absorber Outlet Gas - Example .................................................................. 13
Reabsorber .......................................................................................................................... 15
Isomers of Octane .................................................................................................................. 16
Lean Oil Distillation ................................................................................................................ 18
Type of Lean Oil from 50% Boil-Off Temperature .................................................................. 19
One Mixing Stage ................................................................................................................... 20
Two Mixing Stages ................................................................................................................. 21
Example of Tray Efficiency ..................................................................................................... 22
Example of Packing Height .................................................................................................... 22
Temperature Rise in Absorber ............................................................................................... 24
Presaturator .......................................................................................................................... 25
Absorber Capacity Curves ..................................................................................................... 28
Burping or Puking ................................................................................................................... 29
Simplified Flow Diagram of Lean Oil System ......................................................................... 33
Lean Oil Distillation Curves - SI Units .................................................................................... 35
Lean Oil Distillation Curves - English Units ............................................................................ 36
A drawing of a typical Absorber is shown The vessel is a cylindrical shell with heads
below. The major components are the vessel attached to each end. Most Absorbers in the
and the trays. petroleum industry operate at fairly high pres-
sures. All metal seams are welded
OUTLET GAS
together, and the design and fabri-
cation of the vessel must be in accor-
dance with rigid specifications for
pressure vessels. The thickness of
the vessel includes a high margin of
Mist Pad
safety against rupture from internal
LEAN OIL pressure or bending from high winds.
The vessel part of almost all Ab-
sorbers is made of steel. If corrosion
is anticipated, the inside of the ves-
Trays sel can be lined with a thin layer of
corrosive resistant material such as
monel or stainless steel.
Each nozzle on the vessel is at-
Vessel tached in a specified manner so that
it will not pull out, or bend the vessel
plate when pipe is attached to the
nozzle.
Most vessels that are 1 m [36 in.]
INLET GAS in diameter or larger have a manway
at the bottom of the vessel, and often
one at the top, that a man (usually a
Level
small one) can enter and inspect and
Controller
repair the inside of the vessel.
The trays are the other major part
of an Absorber. Two types of trays
are commonly used: a valve type or
RICH OIL bubble caps. The Figure on page 5
shows examples of each. The valves
ABSORBER can be circular or rectangular, de-
STRUCTURED PACKING
Gas Out
SLOTTED RINGS
Liquid In Liquid
Distributor
Packing
Restrainer
Shell Random
Tower
Packing
RASHIG RINGS
Liquid
Redistributor
PLASTIC SADDLES
TYPES OF PACKING
BUBBLE CAP
TRAY
VALVE TRAY
Valve
Tray
Downcomer
Bubble
Cap
Tray Tray Installation
In Tower
Loose packing is often used in towers Both types of packing require a liquid dis-
having a diameter less than 600 mm [24 in.] tribution system at the top of the tower, and a
diameter. It can be made of steel, plastic or rigid support system at the bottom.
ceramic, depending upon the corrosiveness Selection of packing or trays is usually a
of the liquid in the tower. Care must be taken matter of economics. The packed towers are
in filling the vessel to assure uniform installa- usually cheaper for towers less than 60 cm [24
tion so that channeling does not occur. in.] in diameter. The tray towers are often less
expensive in larger sizes.
Problem 1
Match items in the column on the right with the equipment on the left.
Refer to the opposite Figure to follow the are removed from the gas that leaves the top
flow in the tower. tray. It may contain some entrained liquid,
Inlet gas enters the tower below the bot- which coalesces into drops in the mist pad.
tom tray and flows up the tower. It bubbles The liquid drops fall to the tray below, and gas
through the liquid on each tray, and some passes out the top tray.
heavy hydrocarbons in the gas are absorbed Lean oil enters the top tray and flows down
in the liquid. Most of the heavy hydrocarbons the vessel, absorbing hydrocarbons from the
OUTLET GAS
LEAN OIL
Flow
Indicator
INLET GAS
Level
Controller
RICH OIL
ABSORBER
Liquid flows down the downcomer from liquid level on the tray to seal the space
the tray above and flows across the tray and behind the downcomer so that vapor will not
spills over the weir into the downcomer to the flow up the downcomer and by-pass the tray.
next tray. The weir maintains a level of liquid Gas flowing up the tower flows through the
on the tray 50 to 75 mm [2 to 3 in.] deep. Note riser on the bubble cap and around the cap
that the bottom of the downcomer is below the and bubbles through the liquid on the tray. On
DOWNCOMER
RETAINING BUBBLE CAP
BOLT AND NUT LIQUID
FLOW
WEIR
RISER
VAPOR
DOWNCOMER FLOW
VALVE
VALVE RETAINING
TRAY EAR
FLOW ON TRAYS
100.0
Lean oil is a liquid hydrocarbon. We want to heavy ends than C9, and so on. Thus, in order
select a lean oil that will give the maximum to get the most absorption with the least lean
recovery at the lowest cost. To put it another oil circulation, we must use a lean oil with the
way, we want each liter [gallon] of lean oil to fewest number of carbon atoms. The ideal
absorb the maximum quantity of heavy ends. lean oil is one that has one more carbon
Let's review our hydrocarbon chemistry. atom than the heaviest component in the
You recall methane - C1 - has one carbon gas.
atom; ethane - C2 - has two carbon atoms; The gas entering most gasoline plants
propane - C3 - has three; butane - C4 - has four, contains some hydrocarbons with 8 or more
and so on. The ideal absorption oil is one that carbon atoms. It would appear that the best
has one more carbon atom than the gas it is lean oil would be one with 9 or more carbon
absorbing. For example, the ideal lean oil to atoms. In non-refrigerated gas plants, the
remove propane from gas is butane. We want lean oil is usually kerosene, which is a mixture
to absorb a number of hydrocarbons from the of hydrocarbons having properties similar to
gas; we want to get the propane, butane, and C14.
gasoline, which is a mixture of C5, C6 and C7. In refrigerated gasoline plants, almost all
In some cases we also want to remove the of the C7 and heavier hydrocarbons condense
ethane. It would appear that the best lean oil when the gas is chilled prior to its entry to the
would be a mixture of propane, butane, gaso- Absorber. Thus, the heaviest hydrocarbon
line and octane. remaining in the gas entering the Absorber is
There is a hitch to using such a mixture. usually C6. The ideal lean oil is C7, heptane,
We can't remove propane from the gas with a which has one more carbon atom than the
liquid that contains propane; and butane won't heaviest component in the gas.
be removed with a liquid that contains butane.
C. Lean Oil Loss in Absorber Outlet Gas
Consequently, the lean oil should not contain
any of the components we want to remove As the gas flowing up the Absorber reaches
from the gas. Thus, if the heaviest component the top trays, most of the heavy ends have
in the gas is C6, the ideal lean oil is C7. been removed from it. The gas at the top of the
You are probably wondering why C7 is Absorber can be visualized as a sponge that
better than C8 or some other hydrocarbon with has been squeezed to remove water from it.
more than 8 carbon atoms? The reason is that The dry sponge will absorb water that it con-
1 liter [1 gallon] of C7 will absorb about 10% tacts. In a similar manner, dry gas at the top of
more heavy ends from the gas than 1 liter [1 the Absorber will pick-up some lean oil, which
gallon] of C8; and C8 will absorb 10% more will vaporize and leave in the outlet gas.
, C6
NE
XA
HE 0
10
10 000 .=
.W
C 7 , M
N E,
PTA
HE
.= 114
, C8 M.W
OCTANE
28
M.W. = 1
N ONANE , C
9
0
-30° -20° -10° 0°
ABSORBER TOP TEMPERATURE, °C
175
ENGLISH UNITS
LEAN OIL IN ABSORBER OUTLET GAS, GAL/MMcf AT 700 psi
150
125
= 86
100
. W.
M
, C6
NE
XA
75 HE
50 00
.=1
C M.W 7
NE ,
H EPTA
25 . = 114
8 M.W
OCTANE, C .W. = 128
N O NANE , C 9 M
0
-30° -20° -10° 0° 10° 20°
ABSORBER TOP TEMPERATURE, °F
The quantity of lean oil that vaporizes approximate quantity of lean oil that vaporizes
depends upon the temperature at the top of and leaves in the outlet gas at a pressure of
the tower, and the number of carbon atoms in 4800 kPa [700 psi].
the lean oil. The opposite graphs show the
Example
The Absorber in a refrigerated gasoline plant operates at 4800 kPa [700 psi] and the top
temperature is -18°C [0°F]. Gas flow rate is 1.4 million m 3/d [50 MMcf/d]. Production of
C 3 is 150 000 L/d [40 000 gal/d]. Lean oil is a hydrocarbon having properties similar to
C 8. Determine whether or not C 7 is a more cost effective lean oil. Assume the following:
C3 production will be 10% more with C7 than with C8.
Net profit from C3 is 0.0265 US dollars per liter [$0.10/gal].
Value of lean oil is 0.2 US dollars/liter [$0.75/gal].
If we used C9 for lean oil, the lean oil loss uct recovery and low lean oil loss in the outlet
in outlet gas would be about 300 dollars per gas. Furthermore, the values of lean oil and
day less than that with C8 lean oil, but product products will vary from one plant to another,
recovery would be about $400/d less, so the and from summer to winter.
net effect would be a loss of $100/d. You may wonder why the C7 and heavier
You can see from the above that it is not an components in the inlet gas condense when
easy matter to select the lean oil that provides the gas is chilled, and the same components
the most economic combination of high prod- will be picked-up by the gas in the top of the
Absorber. At a given temperature and pres- will hold more heavier hydrocarbons. Another
sure, gas will hold so much heavy hydrocar- reason the gas will pick up lean oil is that the
bons. It will selectively hold more ethane and gas temperature at the top of the absorber is
propane than heavier hydrocarbons. How- 5 - 11°C [10 - 20°F] higher than its tempera-
ever, when the ethane and propane are re- ture out of the chiller. Warm gas will hold more
moved (as they are in the absorber) the gas heavy ends than cold gas.
Problem 2
Gas leaves an Absorber at a temperature of -10°C [14°F]. Flow rate is 2 million m3/d [70 MMcf/d]. The
volume of lean oil loss per day using C7 is _______. Loss with C8 is _______________.
1. Reabsorber
Refrigerated gasoline plants having a ca- trays, and the lean oil is a hydrocarbon with 10
pacity of 7 million m3/d [250 MMdf/d] or more - 12 carbon atoms. It is often mounted on top
often have a second Absorber to recover lean of the main Absorber. With this arrangement,
oil from the gas leaving the first one. The lean oil to the primary Absorber can be C6 or
second Absorber is often called a Reabsorber C7 which recovers the maximum heavy ends
or Sponge Oil Absorber. It usually has 2 - 6 from the gas. The lean oil that leaves the top
OUTLET GAS
of the main Absorber in the
outlet gas is absorbed in the
Reabsorber. Since the lean oil
to the Reabsorber has 10 - 12
carbon atoms, very little of it REABSORBER
LEAN OIL, C10
will vaporize and leave in resi-
due gas. REABSORBER
H C C C C C C C C H
H H H H H H H H
NORMAL OCTANE - C8
Boiling Point = 126°C [258°F] Relative Density = 0.707
H H
H C H H C H
H H H H H H H H H H
H C C C C C C C H H C C C C C H
H H H H H H H H H H H
Boiling Point = 116°C [241°F] Rel Dens = 0.7029 H C H
H C C C C C C C H H H
H H H H H H H H C H H C H
H
H C C C C C H
H H H H H H
C
H C H
H H H H H H
Boil Pt = 99°C [211°F]
H H H Rel Dens = 0.6918
C C C C C C C
H H H H H H H
H
Boil Pt = 118°C [244°F] Rel Dens = 0.7211
H C H
H H H H H H H
H C H H C H H C C C C C C H
H H H H
H H H H H
H C C C C C C H H C H
H H H H H H H
Boil Pt = 108°C [227°F] Rel Dens = 0.6985 Boil Pt = 116.5°C [242°F] Rel Dens = 0.7211
ISOMERS OF OCTANE
When we speak of octane or lean oil specific gravity will be the weighted average of
having a molecular weight of 114, we are that of each component.
actually referring to a mixture of hydrocarbons The table below indicates the properties of
that has properties similar to pure N-octane various hydrocarbons.
(see opposite drawing for atomic arrange-
1. Lean Oil Distillation
ment). Furthermore, since the mixture con-
tains hydrocarbons with different boiling The hydrocarbon used for lean oil can be
points, it will not boil at a single temperature determined from a distillation. The appratus
as a pure component does. It will start boiling and procedure for running a distillation are
at approximately the temperature of the low- shown on the next page. The type of hydrocar-
est boiling component and continue boiling bon and its molecular weight can be esti-
until the temperature of the highest boiling mated from the distillation temperature ob-
component is reached. The relative density or served at 50% boil off, and the graphs on
page 19.
Example
The temperature at 50% boil off of a lean oil sample is 135°C [275°F]. Determine the type of
hydrocarbon.
Problem 3
You want to use a lean oil having a molecular weight of 114. The name of the hydrocarbon
is _________________. Its symbol is _________. The 50% boil-off temperature should be about
_______°.
THERMOMETER
DISTILLING
FLASK
BATH COVER
ASBESTOS
BOARDS BATH
BLOTTING
SHIELD PAPER
GRADUATED
AIR VENTS CYLINDER
SUPPORT
DISTILLATION PROCEDURE
1. ADD 100 ML SAMPLE OF LEAN OIL TO DISTILLATION FLASK AND ARRANGE APPARA-
TUS AS SHOWN ABOVE.
2. LIGHT BURNER.
SI UNITS
170
C10
160
50% DISTILLATION TEMPERATURE, C
150
140
C9
130
120
110 C8
100
C7
90
100 110 120 130 140 150
LEAN OIL MOLECULAR WEIGHT
350
ENGLISH UNITS
50% DISTILLATION TEMPERATURE, F
325
C10
300
275
C9
250
225 C8
C7
200
100 110 120 130 140 150
LEAN OIL MOLECULAR WEIGHT
The absorption shown below is for a con- of holding. In an absorber tower, the gas and
stant flow of gas and lean oil. A higher lean oil liquid are in contact with one another about
flow would increase absorption, but not pro- 0.2 seconds on each tray. This is not long
portionally. enough for total mixing to occur. The net result
The mixing stages shown opposite repre- is that more than one tray is required to be
sent the absorption that occurs when the gas equivalent to one mixing stage. The term tray
and liquid thoroughly mix, and are in contact efficiency is used to define the degree of
with one another long enough for the lean oil mixing that occurs on a tray. If 50% mixing
to absorb all of the hydrocarbon it is capable occurs, the efficiency is 50%, and 2 trays are
OUTLET GAS
LEAN OIL C1 = 89.10
C2 = 6.77
C3 = 1.41
C4 = 0.17
C5 = 0.00
97.45
2 MIXING STAGES
required for each mixing stage. The number Mixing Stages x 100
No. of Trays =
of trays required equals: Tray Efficiency
Example
An Absorber requires 12 mixing stages in Mixing Stages x 100
No. of Trays =
order to obtain the desired propane recovery. % Tray Efficiency
Tray Efficiency is 40%. Determine the number 12 x 100
= = 30 Trays
of trays in the tower. 40
Problem 4
How many mixing stages are in an Absorber having 25 trays with an efficiency of 40% ____
____________________________________________.
Tray efficiency in an Absorber is usually occurs with a low viscosity liquid such as
40 - 60%. It remains fairly constant over gasoline, than with a high viscosity liquid such
changes in gas and/or lean oil flow rates of 50 as glycol.
- 125% of design. The efficiency (and recov- Clean lean oil has a low viscosity, and
ery) will drop off at high or low flow rates. good gas-liquid mixing occurs. However, if the
One of the principle factors that effects lean oil contains solid particles or heavy ends,
tray efficiency is that of the viscosity of the its viscosity can increase and significantly
liquid. More thorough mixing of gas and liquid reduce tray efficiency and recovery.
Example
An Absorber has 25 trays with an efficiency of 40%. Recovery is that shown in the table on
page 20. Determine the percent loss in propane recovery if the lean oil becomes contaminated
and results in a tray efficiency of 36%.
40 '
No. of mixing stages at 40% Efficiency = 25 x = 10 stages
100
Propane recovery with 10 stages = 82.5%
25 x 36
No. of mixing stages with 36% efficiency = = 9 stages
100
Propane recovery with 9 stages = 79.2%
Difference in propane recovery = 82.5 - 79.2 = 3.3%
3.3 '
% difference in propane recovery = x 100 = 4%
82.5
Heavy ends that can raise the viscosity of height of packing is based on the number of
lean oil are removed in the Reclaimer. It mixing stages and the height equivalent to 1
should be closely checked to see that it is stage. A height of 60 -120 cm [2 - 4 ft] is usually
operating properly. Refer to pages 33 - 37 for
equivalent to 1 mixing stage.
the procedure to determine the quantity of
Packing height = (No. Mixing Stages)
heavy ends in lean oil.
(Height per Stage)
When packing is used instead of trays, the
Problem 5
Propane production with clean lean oil in the previous example is 192 500 L/d [50 000 gal/d].
Profit from propane is 0.026 dollars/L [$0.10/gal]. Daily loss in profit with contaminated lean
oil is ___________ dollars.
Example
Determine the height of packing in an Absorber having 10 mixing stages when a
height of 120 cm [4 ft] is equivalent to 1 mixing stage.
SI UNITS ENGLISH UNITS
Packing Height = (No. Mixing Stages) x (Height per Stage)
Height = 10 x 120 = 1200 cm 10 x 4 = 40 ft
or 12 m
F. Heat of Vaporization of
Hydrocarbons
In most Absorbers, the temperature of gas are shown on the next page.
and lean oil entering the tower are about the The outlet gas and liquid temperatures are
same. It would appear that the temperature of higher than the inlet temperatures because of
outlet gas and rich oil would be the same as the heat of vaporization released when ab-
the average temperature of the inlet gas and sorbed hydrocarbons change from a gas to a
lean oil. This is not the case. The temperature liquid.
of outlet gas and rich oil is 6 - 11°C [10 - 20°F] You recall that in order to boil water, its
above the inlet temperatures. Typical operat- temperature must be raised to 100°C [212°F],
ing temperatures at a refrigerated Absorber and then 2263 kJ/kg [970 Btu/lb] of heat must
gas and rich oil will be higher than INLET GAS Level
the inlet temperatures. Controller
C 3 VAPOR
TO COMP. LEAN
OIL
TO RECOMPRESSOR
OUTLET GAS PRESATURATOR
CHILLER
C3
REFRIGERANT
TO
RECOMPRESSOR
LC
PRESATURATOR
SEPARATOR
PRESATURATED
LEAN OIL PUMP
INLET
GAS
PC
DEMETHANIZER
ABSORBER
FLASH
TANK
PRESATURATOR
The gas from the Flash Tank mixes with with gas from the Demethanizer instead of the
lean oil and the combined stream flows Flash Tank as shown on the previous page.
through the chiller, where the temperature of Regardless of the arrangement, the function
the gas-lean oil stream is lowered to approxi- is the same.
mately the same temperature as that of inlet The decision whether or not to use a
gas to the absorber. When the gas-lean oil presaturator is one of cost. We can get the
stream is cooled, most of the gas will be same absorption as that using a presaturator
absorbed in the lean oil. The heat of vaporiza- by lowering the inlet gas and lean oil tempera-
tion released when the gas is absorbed is ture, which requires more refrigeration; or by
removed in the chiller. Thus, the lean oil increasing the lean oil flow rate, which re-
leaving the presaturator chiller is saturated quires larger pumps and more refrigeration.
with methane, and it will absorb very little The cost of each method has to be determined
methane in the Absorber. before the final selection can be made.
The net effect is to lower the temperature The other factors that affect absorption are:
in the Absorber and thereby increase the
1. Pressure. Maximum absorption of heavy
recovery of propane. The presaturator facility
ends occurs at a pressure of 4000 - 5000
is usually cost effective for plants with pro-
kPa [600 - 700 psi]. Absorption will be less
pane production of at least 400 m3/d [100 000
at lower or higher pressure.
gal/day].
The purpose of the presaturator is to re- 2. Gas flow rate. Reducing the flow rate will
duce the temperature rise in the absorber so increase the percentage of absorption of
that more absorption will occur. Ethane and each component. At a high gas rate, the
propane absorption will be about 5% more volume of recovered products will increase,
with a presaturator than without one. but the percentage of ethane and propane
In some plants, lean oil is presaturated recovery will go down.
SUMMARY OF FACTORS THAT AFFECT ABSORPTION
FACTOR EFFECT ON ABSORPTION
Lean Oil Flow Rate More absorption at higher rate.
Lean Oil Composition Less absorption when light ends or heavy ends are present.
Absorber Temperature More absorption at lower temperature.
Absorber Pressure Less absorption at pressure above or below 4000 - 5000
kPa [600 - 700 psi].
Gas Flow Rate Lower percent absorption at high flow rate.
In your absorption plant, you normally sition. Other factors are limited by the size of
have operational control over only 3 factors: equipment or conditions beyond your control.
temperature, lean oil flow, and lean oil compo-
Problem 6
Match the items in the column on the right with those that most closely describe the items in
the column on the left.
_______ 1. Weir a. C4
_______ 2. Amount of absorption b. Gas changes to liquid
_______ 3. Absorption process c. Holds liquid level on tray
_______ 4. Lower Absorber temperature d. Hydrocarbon vapor pressure
_______ 5. Ideal lean oil to absorb C3 e. More absorption
G. Absorber Capacity
cate the approximate maximum gas flow rates
In order to get good mixing of gas and lean in various diameter absorbers at various oper-
oil on each tray, the velocity of gas moving up ating pressures that result in good mixing on
the absorber must be low enough that it does each tray. Gas rates above those shown on
not blow through a tray in a slug, and high the graphs may result in lean oil carryover in
enough so that it does not channel. The the outlet gas. Flow rates less than 50% of
velocity of the gas is determined from the gas those shown on the graphs will probably result
flow rate, operating pressure, and absorber in poor mixing on the trays, which will lower the
diameter. The graphs on the next page indi- absorption of propane.
Example
An absorber operating at 3500 kPa [500 psi] has a diameter of 2450 mm [96 in.]. Determine
the maximum gas rate.
SI UNITS ENGLISH UNITS
Absorber operating pressure 3500 kPa 500 psi
Absorber diameter 2450 mm 96 in.
3
Maximum gas flow rate (P-28) 7.7 million m /d 270 MMcf/d
Problem 7
The gas capacity of an absorber having a diameter of 1800 mm [72 in.] and operating at a
pressure of 5000 kPa [750 psi] is ________.
2500
00
a
10
, kP
00 URE
00 20 SS
15 00 P RE
ABSORBER DIAMETER, mm
30
0 ER
50 00 RB
2 00 40 SO
2000 35 0 00 AB
0 60
50
00
70
1500
1000
500
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
MAXIMUM GAS FLOW RATE, Million m/d
120
ABSORBER CAPACITY - ENGLISH UNITS
110
ABSORBER DIAMETER, INCHES
100 i
ps
0
10
RE,
SU
30 0
ES
20
90 PR
0
0 ER
40 00 ORB
5
A BS
80 0
75 0
0
10
70
60
50
40
30
0 50 100 150 200 250 300 350 400 450 500 550 600
MAXIMUM GAS FLOW RATE, MMcf/d
I'm getting
sick.
URP!
LIQUID
INLET
OBSTRUCTION
GAS
INLET
Liquid flow down the tower becomes Gas pressure builds up in the bottom
restricted, and liquid starts to build until it is enough to overcome the
up on the trays. Gas pressure starts liquid head on the trays. At that time,
to build up in the bottom of the tower. a slug of gas moves up the tower.
It travels at a high velocity and carries
liquid with it as it flows out the top.
PUKING
When a tower pukes, most of the liquid in Quite often, carryover occurs at the nor-
the upper part of the vessel is blown out the mal gas flow rate when the Absorber is
top of the tower. Puking usually occurs at a operating at a pressure below normal. If an
high liquid rate. It happens like this: At a high Absorber is designed to handle a certain
liquid rate, the liquid level on one or more trays gas rate at 6000 kPa [870 psi] pressure,
will rise. It will reach the point that a surge of and it is only operating at one half design
gas will suddenly move up the tower with pressure or 3000 kPa [435 psi], the allow-
enough velocity to carry the liquid with it. able gas flow rate will be only one half of
Reducing the lean oil flow rate will usually design.
eliminate puking.
Puking is not be confused with carryover. 2. Some of the bubble caps or valves have
Puking occurs intermittently; one minute you come loose from the top tray, and gas is
have a level of rich oil in the bottom of the blowing through the holes they left on the
tower, and the next minute, it is gone. Carryover tray and carrying out some lean oil with it.
is continuous. The causes for it are: Here again, the mist pad can get saturated
with lean oil, and lose its effectiveness.
1. The gas flow rate is high enough to sweep
some lean oil with it as it flows out the top Remember, Puking happens quickly, and
of the Absorber. Even though the tower is caused by a high liquid flow rate. Carryover
has a mist pad, an excessive gas flow rate is continuous and is caused by a high gas flow
will carry enough liquid to saturate the mist rate. Both give the same end result: a loss of
pad, and some liquid will carry out in the lean oil and less absorption.
gas stream.
Problem 8
Match each item on the right that is most closely associated with the item on the left.
______ 1. Dirty lean oil a. Gas velocity
______ 2. Puking b. Thoroughness of mixing
______ 3. Absorber diameter c. Liquid flow rate
______ 4. Downcomer size d. High vapor flow rate
______ 5. Tray efficiency e. High liquid flow rate
______ 6. Carryover f. Low tray efficiency
3. Slowly open the gas to the Absorber. Do 4. Check the temperature of the inlet gas.
not allow a sudden surge of gas to enter,
as it might blow liquid out the tower, or 5. Check the temperature of the lean oil.
damage the bubble caps or valves on
the tray. 6. Check the flow rate of lean oil to be sure
B. Shut Down the lean oil pump is operating at full
capacity.
Shut down sequence is the opposite of
start-up: shut in the flow of gas, and then shut
An important operating check is to look for
in the flow of lean oil.
breaks in cold insulation in refrigerated plants.
C. Routine Operation An accumulation of ice will indicate an insula-
Routine operating checks include the tion failure. The insulation should be repaired
following: at the next plant shut-down.
Problem 9
ABSORBER DEETHANIZER
and heavy ends are present. Further-
more, a change in gravity merely tells HEAT
SOURCE
you that contaminants are present, RECLAIMER
but it does not tell you how much. LEAN OIL
the operator to minimize the quantity of light data is the operator's best guide for determin-
ends and heavy ends in the lean oil in order to ing whether it contains excessive light ends or
maximize gas absorption. Lean oil distillation heavy ends.
Example
Distillation Temperatures
Oil with Oil with
Good Oil, Heavy Ends, Light Ends,
Sample #1 Sample #2 Sample #3
°C °F °C °F °C °F
Initial Boiling Temperature 80 176 80 176 70 158
5% Boiling Temperature 93 200 93 200 87 188
10% Boiling Temperature 99 211 99 211 93 200
20% Boiling Temperature 106 223 104 220 102 215
30% Boiling Temperature 110 230 108 226 107 225
40% Boiling Temperature 112 233 112 233 111 231
50% Boiling Temperature 113 236 114 238 113 236
60% Boiling Temperature 115 240 118 244 117 243
70% Boiling Temperature 118 245 121 250 121 249
80% Boiling Temperature 122 251 114 259 124 255
90% Boiling Temperature 128 262 135 275 128 263
95% Boiling Temperature 133 272 143 290 134 273
End Point Temperature 147 296 161 323 147 296
Interpretation of distillation data to detect is 80°C [176°F], which is below the ideal
light or heavy ends can be improved by plot- temperature. This indicates some light ends
ting a distillation curve. Curves for the 3 oil are present. However, a small quantity of light
samples above are shown on the following ends can depress the initial boiling tempera-
pages. After drawing the curves, a straight ture 10 - 20°C [18 - 36°F].
line is drawn (dashed lines on curves) that is The end point temperature of Sample 1 is
closest to the points in the 20% to 80% boiling 147°C [296°F] which is 19°C [33°F] higher
range. This line represents the ideal distilla- than the ideal. This indicates some heavy
tion curve. On the good oil sample - #1 - it ends are present in the lean oil. However, a
indicates the initial boiling temperature (0% small quantity of heavy ends can raise the end
boil-off) should be 100°C [212°F], and the end point 10 - 20°C [18 - 36°F], and Sample 1 is
point (100% boil-off) should be 128°C [263°F]. within this range.
The initial boiling temperature of Sample 1
150 150
140 140
130 130
120 120
Ideal Distillation Line
110 110
140
70
130
BOILING TEMPERATURE, C
130
Plot of Distillation Data
120 120
100 SAMPLE 2
Excessive
Excessive 150
Heavy
Heavy Ends
Ends
90
140
80 Effect of
Heavy Ends
130 130
110 110
Plot of Distillation Data
100
Effect of
90 Light Ends SAMPLE 1
80
0 20 40 60 80 100
% BOIL-OFF
275
250
Ideal Distillation Line
225
Plot of Distillation Data
200
175 SAMPLE 3
Excessive
ExcessiveLight
Light Ends
Ends
150
325
300
BOILING TEMPERATURE, F
275
Plot of Distillation Data
250
200 SAMPLE 2
Excessive
ExcessiveHeavy Ends
Heavy Ends
175
300
Effect of
275 Heavy Ends
200 Effect of
Light ends
SAMPLE 1
175
0 20 40 60 80 100
% BOIL-OFF
Sample 2 is lean oil with excessive heavy find the operating conditions at the Lean Oil
ends. Its boiling temperature during the last Still and Reclaimer that result in the highest
50% of boil-off is above that of the good oil quality lean oil your plant is capable of making.
sample. The distillation curve shows a large One other point: if you purchase lean oil for
area between the ideal distillation line and the make-up, its quality may not be as good as
plotted line. that in your system. It may contain more light
Heavy ends are removed from lean oil in ends and/or heavy ends. Thus its distillation
the Reclaimer. In order for it to remove more curve should not be used as a standard for
heavy ends, the temperature in the Reclaimer comparing your lean oil.
should be lowered. Solid particles often appear after a shut-
Sample 3 is lean oil with excessive light down, but they usually settle out of the lean oil
ends. Its boiling temperature during the first after a few hours. If they are continually
50% of boil-off is lower than that of the good present, a filter should be installed to
oil sample. The distillation curve shows a remove them.
large area between the ideal distillation line Water can get into lean oil in non-refriger-
and the plotted line. ated plants in which stripping steam is used in
Light ends are removed from lean oil in the the Lean Oil Stripper. The source of water
Still. In order to remove more light ends, the may be steam, or, in some cases, the Lean Oil
Still temperature should be raised, or the Cooler. The source of water entry should be
reflux rate lowered. determined and corrected. Glycol gets into
The distillation curves for lean oil in your lean oil in refrigerated plants when it fails to
plant may be above or below those shown on drop out in the Glycol Separator, and enters
pages 35 or 36. They should have the same the Absorber with inlet gas. If glycol gets in the
shape as the curves shown. It is your job to lean oil system, it will be concentrated to
Problem 10
The lean oil in the plant with distillation curves on pages 35 and 36 has a 5% boiling
temperature of 70°C [160°F] and a 95% temperature of 127°C [260°F]. What is wrong with the
lean oil and what do you do about it? ____________________________________________
_______________________________________________________________________.
almost 100% purity in the Still. Pure glycol will The temperature of the lean oil should be
freeze at a temperature of -7°C [20°F]. Thus, held as low as possible, so proper operation of
the glycol will often freeze in the Lean Oil the oil chiller and refrigeration system are
Chiller and plug it; or it may carry into the important.
Absorber and settle out on the top trays.
F. Absorber Operation when
There have been instances of glycol freeze-
Refrigeration System is Down
up in the top of Absorbers that restricted the
flow of gas through the Absorber. When this When the refrigeration unit is down, the
occurs, the tower must be warmed up by Absorber will still operate, but the quantity of
shutting down the refrigeration system. After absorption will be much less. In addition, the
the glycol melts, it should be drained from the lean oil composition must be changed to pre-
bottom of the Absorber, and other parts of the vent excessive losses.
Lean Oil System should be checked to be When the refrigeration unit is operating,
sure all of the glycol is removed. the gas stream is chilled before it enters the
It is good operating practice to frequently Absorber. Almost all of the C7 and heavier
check the bottom of the Absorber, hydrocarbons contained in the gas are con-
Demethanizer, Still and Lean Oil Surge Tank densed in the Chiller. Consequently, the gas
for the presence of glycol, and drain it from the that flows up the Absorber has very little C7
system before it has a chance to freeze-up in and heavier hydrocarbons in it. The lean oil is
the Chiller or Absorber. usually C8 or C9.
The inlet gas stream contains some C7 and
E. Control of Absorber with Presaturator
C8 and possibly some C9 and C10 in it. These
The primary control point on the components normally condense in the Chiller.
Presaturator is the level control in the separa- However, when the Chiller is not operating,
tor. The level controller regulates the flow of these heavy ends are in the gas flowing up the
lean oil to the Absorber. The controller should Absorber. Furthermore, they will not be ab-
be set with a high proportional band so that sorbed in a lean oil that is C8 or C9. In fact, at
the oil flow is fairly constant. A constant flow ambient temperature, some of the lean oil will
of lean oil to the Absorber will result in more vaporize and end up in the gas stream.
absorption than a varying flow. The level You recall we said that the ideal lean oil is
should be held as low as possible in the one that has one more carbon atom than the
presaturator separator in order to provide the heaviest component in the gas stream. When
maximum vapor disengaging space and mini- the refrigeration unit is down, the heaviest
mize lean oil carryover in the outlet gas. component in the gas may be C8 or C9. conse-
quently, the ideal lean oil will be C10. the refrigeration shut-down is only a few days,
If the refrigeration unit will be shut down for you would not want to replace it. Instead, you
an extended period, you probably want to should shut-down the reclaimer, and let the
replace the lean oil in the system with one heavy ends build up in the lean oil.
having properties similar to C12. However, if
Problem 11
Match each item on the right that is most closely associated with the item on the left.
Problem 12
The propane recovery in an Absorber has dropped from 80% to 70%. List 3 possible causes
for the drop.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________
2. Check each of the following items that will result
in an increase in absorption. LEAN OIL
_____ Raise lean oil flow rate
_____ Lower lean oil flow rate
_____ Raise temperature of gas and lean oil
_____ Lower temperature of gas and lean oil
_____ Raise the quantity of heavy ends in lean oil
_____ Lower the quantity of heavy ends in lean oil
_____ Raise quantity of light ends in lean oil
_____ Lower quantity of light ends in lean oil 4800 kPa
6. 1. c 8. 1. f
2. d 2. e
3. b 3. a
4. e 4. c
5. a 5. b
6. d
7. Gas capacity of 1800 mm dia. absorber operating at 5000 kPa pressure is 4.9 million m3/d
(graph page 28)
9. Lean oil
10. Contains too much light ends. Raise Still temperature or lower reflux.
11. 1 d
2 a
3 e
4 f
5 c
6 b
12. Three of the following:
Lean oil contains too much heavy ends.
Lean oil contains too much light ends.
Lean oil flow has decreased.
Inlet gas and/or lean oil temperature have risen.
Inlet gas rate is up.
Absorber trays are fouled
6. 1. c 8. 1. f
2. d 2. e
3. b 3. a
4. e 4. c
5. a 5. b
6. d
7. Gas capacity of 72 in. diameter absorber operating at 750 psi pressure is 185 MMcf/d
(graph page 28)
9. Lean oil
10. Contains too much light ends. Raise Still temperature or lower reflux.
11. 1 d
2 a
3 e
4 f
5 c
6 b
12. Three of the following:
Lean oil contains too much heavy ends.
Lean oil contains too much light ends.
Lean oil flow has decreased.
Inlet gas and/or lean oil temperature have risen.
Inlet gas rate is up.
Absorber trays are fouled
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