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Basic Training
SAJJAD KHUDHUR ABBAS
Training Modules
22 October 2013
Slides presentation
1. Compressor Train
2. Demethanizer Column
3. Fractionation Train
4. Propane Loop
5. Steam Reformer
23 October 2013
1. Oil Characterization
2. Refinery Separation
3. Amine System
24 October 2013
1.
2.
3.
4.
2013 PETROLIAM
2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
(PETRONAS)
Outline
2013 PETROLIAM
2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
(PETRONAS)
Introduction
Process simulation is the representation/replication of the real world
process behavior through mathematical models.
Process Simulator is a software that predicts the condition, composition
and properties of a particular point (stream) from an initial condition through
mass and energy balances and thermodynamic principles.
iCON is based squarely on fundamental thermodynamic principles
(equation based).
These principles are used in two main features of the process simulator:
The thermodynamic calculation engine
The simulation solver for unit operation and flowsheet.
Introduction
Dynamic
Always balance
Time
dependence
No
Yes
Accumulation
i.e. level
simulation
No
Yes
Not required
Required
No impact
Impacts flow
Equipment
dimension
Pressure profile
Typical
applications
Process Design
Equipment Rating &
Monitoring
Utility Balance
Process Control
Optimization
Plant Startup & Shutdown
Operator Training Simulator
What is iCON?
iCON is an innovative
steady-state & dynamic
simulation software
modeling tool for oil, gas,
petrochemical, utilities and
power generation
industries.
iCON is capable of solving a
wide range of engineering
problems and is industry
driven. It has been proven in
reliability in oil gas
production, oil refinery,
petrochemicals, utility &
power generation
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Property Package
A property package is a collections of equations that define (given set of
physical conditions) :
1. State of matter i.e vapor/mix/liquid phase
2. Physical properties.
Derived by fitting experimental data.
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2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
2013 PETROLIAM
Activity Coefficient
Model
Special Packages
Good to represent
non-ideal liquid due
to presence of polar
components, but
cannot predict
critical point
Customized to
represent specific
process which may
include kinetics
data in addition to
equilibrium data
Urea, Amine,
Steam97
Chemicals with
high polarity i.e.
water, alcohol
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Example
Objective:
To give an indication of NH3 purity, an online calculation can be implemented as part of
ELMS, to enable operators to take necessary action to drain any contaminants i.e.
compressor oil from NH3.
Actual saturation Pressure
& Temperature
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Example
Pure Ammonia Temp VS Pressure
1700
Lee
Kesler
Plocker
Thermo
1650
1600
NGL-PR
Pressure (kPaA)
Thermo
1550
1500
Actual
DCS
data
1450
1400
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Temp (deg C)
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40
APR
APR-NG
Refinery SRK
APR-LK
NGL-PR
API SOUR
CHAO SEADER
GRAYSON
STREED
MAXWELL
BONELL
LKP
UNIQUAC
wilson
TK-WILSON
NRTL
VAN LAAR
MARGULES
MARGULES 4
UNIFAC
IDEALgas
PHYSICAL
SOLVENT
REFINERY APR
EXTRACTION
GASIFICATION
The figure above shows multiple plots of pure NH3 using 21 different
thermodynamic packages and a plot of actual DCS data.
Lee-Kesler-Plcker (LKP) is found to be the best suited thermo-package.
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Modeling Approach
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Unit Operation in
iCON
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2013 PETROLIAM
2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
(PETRONAS)
Typical Specification
Stream
Separator
Cooler/Heater
Heat
Exchanger
Compressor/Pu
mp/Expander
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2013 PETROLIAM
2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
(PETRONAS)
Hands-on
Training..
21
Desktop
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New file..
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Water
Nitrogen
Carbon
Dioxide;
Methane
Ethane
Propane
IsoButane
n-Butane
isoPentane
10
n-Pentane
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Water
Nitrogen
Carbon
Dioxide;
Methane
Ethane
Propane
IsoButane
n-Butane
isoPentane
10
n-Pentane
25
Deg C
30
Pressure
Kpa
1000
Mass Flow
Kg/h
125
Water
Mol %
1
Nitrogen
Mol %
0.5
Carbon
Dioxide;
Mol %
Methane
Mol %
Ethane
Mol %
Propane
Mol %
Iso-Butane
Mol %
45
n-Butane
Mol %
40
isoPentane
Mol %
n-Pentane
Mol %
n-Hexane
Mol %
0.5
2
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# 4 Flash options
P-T Flash
P-H Flash
Vapor Fraction
(VF) Flash
Calculation
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Getting started
Starting iCON from
desktop.
Selecting thermo.
Selecting components.
Converging a stream.
Units.
Bubble / dew points.
Phase diagram.
Special properties.
Making a copy
Spec from
Clone
Copy stream
Show datasheet
Table
Writing
Controller
Temperature control
Process Calculator
Totalizer
Pseudo component
Ammonia ref choosing
thermo
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Therefore, the:
Mole Flow
Mass Flow
of In and Out port must
be IDENTICAL
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2013 PETROLIAM
2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
(PETRONAS)
31
2013 PETROLIAM
2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
(PETRONAS)
32
2013 PETROLIAM
2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
(PETRONAS)
33
2013 PETROLIAM
2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
(PETRONAS)
Flash
Calculations
P-T Flash
P-H Flash
Vapor Fraction
(VF) Flash
Calculation
34
2013 PETROLIAM
2012 NASIONAL
PETROLIAM BERHAD
NASIONAL BERHAD (PETRONAS)
(PETRONAS)
35