Design of Akib Vai

Table of Contents
List of Tables ................................................................................................................................................. 6

1. Introduction ............................................................................................................................................ 14
1.1. Standard of NG................................................................................................................................. 14
1.2. Objective of NG processing .............................................................................................................. 15
2. Definition of the project.......................................................................................................................... 17
2.1. Definition of Project ......................................................................................................................... 17
2.2. Composition of Natural Gas ............................................................................................................. 17
2.3. Products ........................................................................................................................................... 18
3. Selection of process ................................................................................................................................ 20
3.1 Natural Gas Processing ..................................................................................................................... 20
3.2 Oil and Condensate Removal ............................................................................................................ 21
3.4 Glycol Dehydration ........................................................................................................................... 22
3.4.1. Glycols Used in Dehydration ..................................................................................................... 26
3.4.2. Selection Criteria of the Glycols: ............................................................................................... 26
3.5. Alternatives for dehydration of Natural Gas.................................................................................... 27
3.5.1. Advantage of glycol dehydration process ................................................................................. 28
3.5.2. Disadvantage of glycol dehydration process ............................................................................ 28
3.6 Reasons for selection of TEG............................................................................................................. 28
3.7 Amine Sweetening Process ............................................................................................................... 29
4. Design basis ............................................................................................................................................. 32
4.1 Design Basis....................................................................................................................................... 32
4.2. Meteorological Condition and Soil Properties of the Plant Site ...................................................... 33
4.3. Climate Condition ............................................................................................................................ 34
5. Process Block Diagram ............................................................................................................................ 38
5.1. Description of Process Block Diagram ............................................................................................. 39
6. Process Flow Diagram Figure 6.1: Process Flow Diagram of natural gas processing plant ................... 41
7 Material Balance ...................................................................................................................................... 43
7.1 Three phase separator (first) ............................................................................................................ 43
7.2 Flash Separator ................................................................................................................................. 45
7.3 Glycol Dehydration unit .................................................................................................................... 46
1|Page
7.4 Amine Sweetening Unit .................................................................................................................... 49
7.4.1 Absorber..................................................................................................................................... 49
7.5 Flash Separator ................................................................................................................................. 52
7.6 Second Three Phase Separator ......................................................................................................... 55
7.7 De-ethanizer...................................................................................................................................... 60
7.8 Mixer ................................................................................................................................................. 62
8 Energy Balance ......................................................................................................................................... 64
8.1 Glycol absorption unit ....................................................................................................................... 64
8.2 Energy balance around Pump ........................................................................................................... 67
8.3 Energy balance on Glycol Reboiler.................................................................................................... 68
8.4 Amine Absorption Unit Energey balance around Absorber ............................................................. 69
8.4.1 Reboiler Unit .............................................................................................................................. 70
8.5 Energy balance around Amine Absorption Pump ............................................................................. 70
8.6 Energy Balance around De-Ethanizer column .................................................................................. 71
9. Equipment design ................................................................................................................................... 74
9.1 Three phase Separator (1) ................................................................................................................ 74
9.2 Three phase Separator (2) ................................................................................................................ 76
9.3 Glycol Absorption tower ................................................................................................................... 78
9.4 Heat Exchanger (Glycol Unit) ............................................................................................................ 80
9.5 Reboiler for Glycol ............................................................................................................................ 82
9.6 Glycol Surge tank .............................................................................................................................. 83
9.7 Glycol pump ...................................................................................................................................... 84
9.8 Amine absorption unit ...................................................................................................................... 84
9.9 Heat Exchanger (Amine Unit) .......................................................................................................... 86
9.10 Flash Separator Sizing ..................................................................................................................... 88
9.11 Amine Surge Tank ........................................................................................................................... 92
9.12 Amine pump.................................................................................................................................... 93
9.13 Sizing of De-ethanizer ..................................................................................................................... 94
10 Detailed Individual Equipment Sizing .................................................................................................. 101
10.1.1. Sizing and Calculation for Horizontal Separator ................................................................... 102
10.1.2. Determination of Allowable design velocity from vertical terminal velocity ....................... 102
10.1.4. Determination of Volumetric Flow Rates ............................................................................. 102
10.1.5. Determination of residence time for heavy and light liquid ................................................. 103
2|Page
10.1.6. Determination of Diameter of Vessel ................................................................................... 103
10.1.7. Determination of vertical vessel cross sectional area on the vapor Disengagement space 104
10.1.8. The level of low liquid in the light liquid compartment:....................................................... 104
10.1.9. Determination of vertical vessel cross sectional area on the light liquid compartment: ..... 104
10.1.10 Liquid Settling Compartment: .............................................................................................. 105
10.1.11. Design of mist eliminator .................................................................................................... 109
10.1.12. Sizing of Nozzle ................................................................................................................... 109
10.1.13. Material of Construction ..................................................................................................... 111
10.1.14 Mechanical Drawing ............................................................................................................ 113
10.1.15: P&ID of Three Phase Separator .......................................................................................... 117
10.1.16. Specification Sheet of Three Phase Separator .................................................................... 118
10.2. 1. Liquid density calculation..................................................................................................... 121
10.2.2. Vapor density calculation: .................................................................................................... 121
10.2.3. Kdrum calculation: ................................................................................................................... 122
10.2.4. Uperm calculation: ................................................................................................................... 123
10.2.5. Ac calculation:........................................................................................................................ 123
10.2.6. Diameter calculation: ............................................................................................................ 124
10.2.7. Height of a vertical Vessel: .................................................................................................... 124
10.2.8. Surge Volume ........................................................................................................................ 126
10.2.9. Demister Sizing for Mist Elimination:.................................................................................... 126
10.2.10. Selected Wire mesh form ................................................................................................... 128
10.2.11. Mesh Pad Installation: ........................................................................................................ 128
10.2.12. Nozzle Sizing & Inlet Device: ............................................................................................... 129
10.2.13. Determination of Wall Thickness: ....................................................................................... 131
10.2.14. Skirt Support: ...................................................................................................................... 133
10.2.15. Material of Construction ..................................................................................................... 136
10.2.16. Design Specification: ........................................................................................................... 137
10.2.17. Detailed Flash Separator ..................................................................................................... 138
10.2.18. Mechanical Drawing of Flash Separator ............................................................................. 139
10.2.19. P&ID of Flash Separator ...................................................................................................... 142
10.2.20. Specification Sheet of Flash Separator ............................................................................... 143
10.3 TEG absorber................................................................................................................................. 145
10.3.1 Tower diameter...................................................................................................................... 146
3|Page
10.3.2 Material of construction ........................................................................................................ 151
10.3.3 Support system evaluation .................................................................................................... 153
10.3.4 Feed nozzle calculation .......................................................................................................... 156
10.3.5 Flow pattern selection: .......................................................................................................... 158
10.3.6 Downcomer design: ............................................................................................................... 159
10.3.7 Weir design: ........................................................................................................................... 160
10.3.8 Liquid entrainment checking: ................................................................................................ 161
10.3.9 Tray Specification: .................................................................................................................. 162
10.3.10 Hole specification:................................................................................................................ 163
10.3.11 Pressure drop: ...................................................................................................................... 164
10.3.12 Piping and instrumentation diagram of TEG absorption unit .............................................. 174
10.4. Glycol/Glycol Heat Exchanger ...................................................................................................... 178
10.4.1. Stream Flow Rates ................................................................................................................ 178
10.4.2. LMTD Calculation .................................................................................................................. 180
10.4.3. Viscosity of the streams ........................................................................................................ 182
10.4.4. Thermal conductivity of the streams .................................................................................... 184
10.4.5. Specific Heat.......................................................................................................................... 186
10.4.6. Specific Gravity...................................................................................................................... 188
10.4.7. Heat Balance ......................................................................................................................... 190
10.4.8. Shell side of the heat exchanger ........................................................................................... 190
10.4.9. Hot fluid, 100% TEG in shell side........................................................................................... 192
10.4.10. Cold fluid, 98.85% TEG in shell side .................................................................................... 194
10.4.11. Checking Dirt Factor, Rd ...................................................................................................... 197
10.4.12 Pressure Drop....................................................................................................................... 197
10.4.13. Mechanical Design .............................................................................................................. 199
10.4.14 Head Thickness .................................................................................................................... 202
10.4.15 Channel Thickness ................................................................................................................ 202
10.4.16. Bundle Diameter ................................................................................................................. 202
10.4.17. Baffles ................................................................................................................................. 203
10.4.18. Supports .............................................................................................................................. 203
10.4.19 Material of Construction ...................................................................................................... 204
10.4.20. Design Summary ................................................................................................................. 206
10.4.21. Mechanical Drawing ........................................................................................................... 208
4|Page
10.4.22. Piping and Instrumentation Diagram.................................................................................. 215
10.4.23. Heat Exchanger Specification Sheet ................................................................................... 216
11. Process Licensor .................................................................................................................................. 219
11.1 Dehydrogenation .......................................................................................................................... 219
11.2. Drying ........................................................................................................................................... 219
11.3. Effluent Clean Up ......................................................................................................................... 219
11.4. Flue gas treatment ....................................................................................................................... 220
11.5 Hydrogen Production .................................................................................................................... 220
11.6 Liquid Training............................................................................................................................... 220
11.7 Liquid Training............................................................................................................................... 221
12 List of Vendors ..................................................................................................................................... 223
13 Codes & Standard ................................................................................................................................ 225
13.1. Codes and Standards of Major Equipment .................................................................................. 225
14 List of Equipment ................................................................................................................................. 229
15 Plot Plan ............................................................................................................................................... 231
16. Economic Analysis ............................................................................................................................... 233
16.1 Purchased equipment cost ........................................................................................................... 233
16.2 Total capital investment ............................................................................................................... 234
16.3 Rate of Return ............................................................................................................................... 237
16.4 Feasibility Analysis ........................................................................................................................ 237
16.4.1 IRR Method ............................................................................................................................ 237
16.4.2 ERR Method ........................................................................................................................... 237
16.4.3 Payback period ....................................................................................................................... 238
17.Conclusion ............................................................................................................................................ 240
Reference .................................................................................................................................................. 242
Appendix ................................................................................................................................................... 244
5|Page
List of Tables
Table number Name of Table Page number
Table 3.4.1. Different hydrate control methods, their 24
main features and major applications
Table 10.1.1 Chemical Composition of Stainless Steel 111
- Grade 316 (UNS S31600)
Table 10.1.2. Mechanical properties of 316 grade 112

stainless steels.
Table 10.1.3. Typical physical properties for 316 112

grade stainless steels
Table 10.2.1: Chemical Composition of SA-106 B 136
Carbon Steel
Table 10.2.2: Mechanical Property of SA-106 B 205

Carbon Steel
Table: 10.4.1 Heat Exchanger Specification 205
Table 13.1: Organizations issuing codes and 206

standards
6|Page
List of Figures
Table number Name of Table Page number
. 38
Figure: 5.1 Description of Process
Block
Figure 6.1 Process Flow Diagram of 41

natural gas processing
plant
Figure 10.1.2 .: Mechanical Drawing of 1131

a three phase Separato
Figure 10.1.3 Mesh separaotr pad 114
Figure 10.1.4 : Specifications of Mesh 115
Figure 10.1.5 .: Saddle type of support `115

and its Specifications
Figure 10.1.6. Piping and 116

Instrumentation Diagram
7|Page
128
Figure 10.2.1 Download type of
demister pad.
Figure 10.2.2. Guideline for inlet and 130

outlet nozzle sizing
Figure 10.2.3 Mechanical design of 138

flash separator
Figure 10.2.4 Mechanical Drawing of 139

Flash Separator
Figure 10.2.5 . Vessel Head 140

Specification and Top
View
Figure 10.2.6 . Mist Eliminator and 141

Mesh Specification
Figure 10.2.7 Piping and 142

of Flash Separator
Figure 10.3.1 Single pass cross flow 158

pattern
8|Page
Figure10.3.2 Selection guide for sieve 158
trays.
Figure 10.3.3 Segmental downcomer 159

design chart (LUDWIG
,1964)
Figure10.3.4 Envelop type weir 160

downcomer structure
Figure 10.3.5 Entrainment correlation 161

from Fair (1963).
Figure 10.3.6 : Equilateral triangular 163

pitch geometry
Figure 10.3.7 Pressure heads on sieve 169

trays
Figure 10.3.7 Schematic diagram of 170

TEG absorber
Figure 10.3.8 Front view of TEG 171

absorber
9|Page
Figure 10.3.9 Front view of Head and 172
bottom section

bottom section

bottom section
Figure 10.3.12 : piping and 174

instrumentation diagram
Figure 10.4.1 Viscosity of TEG in 182

different temperatures
Figure 10.4.2: Viscosity of TEG in 183

Figure 10.4.3 Thermal conductivity of 184

TEG in different
temperature

TEG in different
temperatures
10 | P a g e
Figure 10.5.5 Specific heat of TEG at 186
Figure 10.4.6 Specific Heat of TEG in 187

Figure 10.4.7 Specific Gravity of TEG 188

in different temperatures

TEG in different
temperatures
Figure 10.4.9 Cross sectional view of 1- 208

2 shell and tube heat
exchanger
Figure 10.4.10 Dimensional cross section 209

of 1-2 shell and tube heat
exchanger
Figure 10.4.11 Side view of heat 210

exchanger
Figure 10.4.12 Top view of heat 210

exchanger
11 | P a g e
Figure 10.4.14 .: Front view of heat 211
exchanger
Figure 10.4.15 saddle support 212
Figure 10.4.16 Segmental transverse 213

baffle
Figure 10.4.17 Baffle arrangement with 214

pitch diameter and
clearance
Figure 10.4.18 Piping and 215

of heat exchanger
12 | P a g e
Chapter-1
Introduction
13 | P a g e
1. Introduction
Natural gas produced from either an oil or gas reservoir is a complex mixture with different
compounds of hydrocarbons (primarily methane and varying amounts of ethane, propane, butane,
and even higher molecular weight hydrocarbons), an amount of water vapor, small amounts of
nonhydrocarbon gases (hydrogen sulfide, carbon dioxide, and mercaptans such as methanethiol
and ethanethiol).
Water is almost always present at wellhead conditions but is typically not shown in the analysis.
Some gas fields, however, contain no water. Unless the gas has been dehydrated before it reaches
the gas processing plant, the common practice is to assume the entering gas is saturated with water
at the plant inlet conditions.
1.1. Standard of NG
According to EIA, 2006 commercially acceptable natural gas must fulfill following criteria:
It must be within a specific Btu content range. For example, in the United States, it should be about
1,035 ±50 Btu per standard cubic foot (at 1 atmosphere and 60°F).
It should be delivered at a specified hydrocarbon dew point temperature level. This would prevent
liquids to condense and form liquid slugs which could be very damaging to the pipeline.
The gas should not contain more than trace amounts of compounds or elements such as hydrogen
sulfide, carbon dioxide, mercaptans, nitrogen, water vapor, and oxygen.
The water vapor must be removed (i.e., dehydrate the gas) sufficiently to prevent corrosion and
the formation of gas hydrates in the processing plant or the pipelines.
All particulates must be removed.
14 | P a g e
1.2. Objective of NG processing
The three basic reasons for processing raw natural gas are the following:
• Purification- Removal of materials, valuable or not, that inhibit the use of the gas as an industrial
or residential fuel.
•Separation- Splitting out of components that have greater value as petrochemical feedstock, stand-
alone fuels (e.g., propane), or industrial gases (e.g., ethane, helium).
•Liquefaction- Increase of the energy density of the gas for storage or transportation.
The whole process of removing water from the gas consists of few distinguishing steps as- heating,
separation in a three-phase separator, treating in an absorption column, and regeneration of the
absorber.
15 | P a g e
Chapter-2
Definition of the project
16 | P a g e
2. Definition of the project
2.1. Definition of Project

A natural gas treatment plant is to be set up at Bahubal, PO: Bahubal, in the district of Habiganj,
Sylhet in Bangladesh having a capacity of 100 MMSCFD including all off sites, auxiliaries,
utilities and supporting facilities using raw gas from well as feedstock.
2.2. Composition of Natural Gas

Methane (90%)
Ethane (3.8%)
Propane (0.08%)
Butane (0.04%)
Higher Hydrocarbon (0.71%)
Water (0.93%)
Nitrogen (0.3%)
H2S (1.5%)
CO2 (0.0208%)
Oxygen (1.5%)
17 | P a g e
2.3. Products
92.22% methane
4.9 % ethane
1.1% propane
0.00225% butane
1.38% O2
0.0277% N2
0.000126 % water
LPG (72.1% propane, 27.9% butane)
This plant can be justified as estimated gas reserve is 1335.6 bcf (recoverable). By modeling with
composition and flow rate of raw material a significant amount of sales gas, LPG and NGL is
obtained.
Furthermore, increasing demand for natural gas can’t be met with existing gas infrastructure. So,
this project can be helpful to meet increasing demand. All components of this project is in
consistent with government rules and regulations. In addition natural gas supply, transmission and
distribution can be enhanced by means of this project.
Without this project, Bangladesh would need to import petroleum products at world prices, use
more coal, and increase the burning of wood. The increased availability of gas has encouraged
energy consumers from all categories to switch to the generally cheaper, cleaner and more
convenient gas. The project will contribute indirectly to poverty reduction in surrounding areas
by supporting economic growth and spreading of wealth.
18 | P a g e
Chapter-3
Selection of the process
19 | P a g e
3. Selection of process
3.1 Natural Gas Processing
Natural-gas processing is a complex industrial process designed to clean raw natural gas by
separating impurities and various non-methane hydrocarbons and fluids to produce what is known
as pipeline quality dry natural gas. The natural gas used by consumers is composed almost entirely
of methane. Natural-gas processing begins at the well head.
Natural gas processing consists of separating all of the various hydrocarbons and fluids from the
pure natural gas, to produce what is known as ‘pipeline quality’ dry natural gas. Before the natural
gas can be transported it must be purified. While the ethane, propane, butane, and pentanes must
be removed from natural gas, this does not mean that they are all ‘waste products’ .In fact,
associated hydrocarbons, known as ‘natural gas liquids’ (NGLs) can be very valuable by-products
of natural gas processing. NGLs include ethane, propane, butane, iso-butane, and natural gasoline.
The actual practice of processing natural gas to pipeline dry gas quality levels can be quite
complex, but usually involves four main processes to remove the various impurities:
In addition to the four processes above, heaters and scrubbers are installed, usually at or near the
wellhead. The scrubbers serve primarily to remove sand and other large-particle impurities. The
heaters ensure that the temperature of the gas does not drop too low.
20 | P a g e
3.2 Oil and Condensate Removal
In order to process and transport associated dissolved natural gas, it must be separated from the oil
in which it is dissolved. This separation of natural gas from oil is most often done using equipment
installed at or near the wellhead. The most basic type of separator is known as a conventional.
3.3 Water Removal or Dehydration

CaCl2 for water removal
CaCl2 as a solid spontaneously absorbs water. Also the concentrated solution of it absorbs water
and these solutions normally have lower vapor pressure of water than hat it prevailing in the
atmosphere at the same time.
Operational Problems
-need considerable recharging
Solid Desiccant Dehydration
Solid desiccant dehydration systems work on the principle of adsorption. Adsorption involves a
form of adhesion between the surface of the solid desiccant and the water vapor in the gas. The
water forms an extremely thin film that is held to the desiccant surface by forces of attraction, but
there is no chemical reaction.
21 | P a g e
Operational Problem
1. Bed Contamination
The most frequent cause is incomplete removal of contaminants in the inlet gas separator. Also, if
the regeneration gas leaving the separator is commingled with the feed gas to the dehydrators, then
a separator malfunction can dump liquid hydrocarbons and water onto the desiccant.
2. High Dew Point

High dew point is one of the two common problems that can cause operating trouble.
3. Premature Breakthrough
Satisfactory dew points are observed at the beginning but not for the entire duration of the drying cycle.
Desiccant capacity should decrease with use but should stabilize at 55–70% of the initial capacity.
However, premature symptoms of “old age” are caused by an unrecognized increase in inlet water
loading, an increase in heavy hydrocarbons (C4+) in feed gas, methanol vapor in feed, desiccant
contamination, or incomplete regeneration.
3.4 Glycol Dehydration

Among the different gas drying processes, absorption is the most common technique, where the
water vapor in the gas stream becomes absorbed in a liquid solvent stream. Glycols are the most
widely used absorption liquids as they approximate the properties that meet commercial
application criteria. Several glycols have been found suitable for commercial application.
The commonly available glycols and their uses are described as follows-
1. Monoethylene glycol (MEG); high vapor equilibrium with gas so tend to lose to gas phase in
contactor. Use as hydrate inhibitor where it can be recovered from gas by separation at
temperatures below 50◦F.
22 | P a g e
2. Diethylene glycol (DEG); high vapor pressure leads to high losses in contactor. Low
decomposition temperature requires low reconcentrator temperature (315 to 340◦F) and thus
cannot get pure enough for most applications.
3. Triethylene glycol (TEG); Reconcentrate at 340–400◦F for high purity. At contactor
temperatures in excess of 120◦F, there is a tendency to high vapor losses. Dew point depressions
up to 15 °F are possible with stripping gas.
4. Tetraethylene glycol (TREG); more expensive than TEG but less loss at high gas contact
temperatures. Reconcentrate at 400 to 430◦F.
TEG is by far the most common liquid desiccant used in natural gas dehydration. It exhibits most
of the desirable criteria of commercial suitability listed here (Manning and Thompson, 1991;
Hubbard, 1993).
TEG is regenerated more easily to a concentration of 98–99% in an atmospheric stripper because

of its high boiling point and decomposition temperature.
TEG has an initial theoretical decomposition temperature of 404◦F, whereas that of diethylene
glycol is only 328◦F (Ballard, 1966).
Vaporization losses are lower than monoethylene glycol or diethylene glycol. Therefore, the TEG
can be regenerated easily to the high concentrations needed to meet pipeline water dew point
specifications.
Capital and operating costs are lower
Dehydration of natural gas by TEG is first outlined by summarizing the flow paths of natural gas
and glycol. Then the individual components of a typical TEG unit are described in detail. As shown
in Figure, wet natural gas first typically enters an inlet separator to remove all liquid hydrocarbons
from the gas stream. Then the gas flows to an absorber (contactor) where it is contacted counter
currently and dried by the lean TEG.
23 | P a g e
TEG also absorbs volatile organic compounds (VOCs) that vaporize with the water in the reboiler.
Dry natural gas exiting the absorber passes through a gas/glycol heat exchanger and then into the
sales line. The wet or “rich” glycol exiting the absorber flows through a coil in the accumulator
where it is preheated by hot lean glycol. After the glycol– heat exchanger, the rich glycol enters
the stripping column and flows down the packed bed section into the reboiler. Steam generated in
the reboiler strips absorbed water and VOCs out of the glycol as it rises up the packed bed. The
water vapor and desorbed natural gas are vented from the top of the stripper. The hot regenerated
lean glycol flows out of the reboiler into the accumulator (surge tank) where it is cooled via cross
exchange with returning rich glycol; it is pumped to a glycol/gas heat exchanger and back to the
top of the absorber.
Various hydrate control methods along with their features and major applications are listed below:
Table 3.4.1: different hydrate control methods, their main features and major applications
Method Variation Positive features Negative features Major Applications

Chemical Methanol 1.Inexpensive 1.High methanol losses 1. Seasonal control in
inhibition equipment 2. Introduction of a gathering systems.
2. Easy to handle potential containment 2. Temporary control in
cryogenic plants
Glycol Inexpensive Difficult to handle in 1. Gathering systems
equipment. very low temperature where regeneration
High recovery and conditions. equipment is unavailable
reuse rate. May reduce efficiency or undesirable.
of downstream heat 2. Low temperature
exchangers. plants for localized
control.
Thermal - Steam or 1. Ease of control none None
inhibition electric 2. Good for sour
(heat) tracing of gas wells.
pipes - Gas
heaters in
field
Liquid(Glycol) none 1.relatively 1. Limited dew-point 1. Gathering systems,

inexpensive depression. wellheads.
equipment 2. Subject to foaming in 2. Feed to transmission
some gas systems. lines.
24 | P a g e
2. easy to operate 3. Feed to moderately
and maintain low temperature
3.energy processes.
consumption
fairly low in
proportion to the
water load
Dehydration Dry bed 1. Equipment 1. Equipment cost is 1. Feed to cryogenic
(e.g., reliable for higher than other kinds plants.
activated unattended of dehydrators. 2. Liquid HC drying
alumina, operation 2. Energy requirements 3. Combination systems
silica gel, 2. Very low dew is relatively high. 4. Hydrocarbon (HC)
molecular points are possible. dew point control
sieves) 3. Can be designed
to dry and sweeten
simultaneously, or
to control HC dew
points.
Dehydration of sales gas is also an essential part of gas processing plant. Sales gas is preferred to
be dry for increased heat content in comparison to wet gas.
Water can be removed by absorption or adsorption process. In dehydration by absorption, a liquid

is chosen that has the following qualities:
High affinity for water, and a low affinity for hydrocarbons.

The absorbent must also be of lower volatility to reduce losses due to vaporization.
Non-corrosive and non-toxic.
No contamination by acid gases.
Besides it must be of low viscosity making it easier to pump and ensuring good contact between
gas and liquid phase.
Most importantly it must be easy to regenerate without causing any decomposition.
Glycols (such as Ethylene glycol [EG], Di ethylene Glycol [DEG], Triethylene Glycol [TEG] and
Tetraethylene glycol [TRG] etc.) are most commonly used as absorbent. Some of the glycols used
along with their properties are as follows:
25 | P a g e
3.4.1. Glycols Used in Dehydration
In a glycol absorption unit, the wet gas passes through an inlet scrubber to remove solids and free
liquids, and then enters the bottom of the glycol contactor. The gas flows upward while the lean
glycol solution flows downward over the trays. The rich glycol after it has absorbed the water
leaves at the bottom of the column while the dried leaves through the top. The gas leaving from
the dehydration unit in a gas processing plant is usually the sales gas.
3.4.2. Selection Criteria of the Glycols:

Tri-ethylene glycol (TEG) is the most commonly used dehydration liquid and is the assumed type
in this process description.
Di-ethylene glycol (DEG) is sometimes used for dehydration for uniformity when hydrate
inhibition is required upstream of dehydration.
Tetra-ethylene glycol (TREG) is more viscous and more expensive than the other glycols. The
only real advantage is its lower vapor pressure which reduces absorber vapor loss. It should only
be considered for rare cases where glycol dehydration will be employed in a gas whose temperature
exceeds about 50o C, such as when extreme ambient conditions prevent cooling to a lower
temperature.
26 | P a g e
3.5. Alternatives for dehydration of Natural Gas
Solid desiccant dehydration
Solid desiccant dehydration systems work on the principle of adsorption. Adsorption involves a
form of adhesion between the surface of the solid desiccant and the water vapor in the gas. The
water forms an extremely thin film that is held to the desiccant surface by forces of attraction, but
there is no chemical reaction. Solid desiccant dehydrators are typically more effective than glycol
dehydrators, as they can dry a gas to less than 0.1 ppmV (0.05 lb/MMcf). However, in order to
reduce the size of the solid desiccant dehydrator, a glycol dehydration unit is often used for bulk
water removal. The glycol unit would reduce the water content to around 60 ppmV, which would
help reduce the mass of solid desiccant necessary for final drying. Using desiccant dehydrators as
alternatives to glycol dehydrators can yield significant economic and environmental benefits,
including reduced capital cost, reduced operation and maintenance cost, and minimal VOC and
hazardous air pollutants (BTEX).
A variety of solid desiccants are available in the market for specific applications. Some are good
only for dehydrating the gas, whereas others are capable of performing both dehydration and
removal of heavy hydrocarbon components. Desiccant should be chosen based on its properties
like selectivity, regeneration etc.
Silica gel
The most common commercial desiccants used in dry bed dehydrators are silica gel (i.e., Sorbead),
molecular sieves, and activated alumina. Silica gel (a generic name for a gel manufactured from
sulfuric acid and sodium silicate) is a widely used desiccant, which can be used for gas and liquid
dehydration and hydrocarbon recovery from natural gas. It is characterized by the following.
Best suited for normal dehydration of natural gas.

Easily regenerated than molecular sieves.
Has high water capacity, where it can adsorb up to 45% of its own weight in water.
Costs less than molecular sieve.
Capable of dew points to −140◦F.
27 | P a g e
Molecular sieve
A molecular sieve is the most versatile adsorbent because it can be manufactured for a specific
pore size, depending on the application. It is:
Capable of dehydration to less than 0.1 ppm water content.

The overwhelming choice for dehydration prior to cryogenic processes (especially true for LNG).
Excellent for H2S removal, CO2, dehydration, high temperature dehydration, heavy hydrocarbon
liquids, and highly selective removal.
More expensive than silica gel, but offers greater dehydration.
Requires higher temperatures for regeneration, thus has a higher operating cost.
3.5.1. Advantage of glycol dehydration process

1. Lower initial capital investment required
2. Glycol regeneration is easy and straight forward
3. Glycol dehydration is a continuous process
3.5.2. Disadvantage of glycol dehydration process

1. Cannot achieve dew point low enough for cryogenic applications
2. Glycol can get easily contaminated and become corrosive.
3.6 Reasons for selection of TEG

TEG is by far the most common liquid desiccant used in natural gas dehydration. It exhibits most
of the desirable criteria of commercial desirability which are listed below:
TEG is regenerated more easily to to a concentration of 98-99% in an atmospheric stripper because

of its high boiling point and decomposition temperature.
TEG has an initial theoretical decomposition temperature of 404o F, whereas that of diethylene
glycol is only 328o F.
Vaporization losses are lower than monoethylene glycol or diethylene glycol. Therefore, TEG can
be regenerated easily to the high concentrations needed to meet the pipeline water dew point
specifications.
Capital and operating costs are lower.
28 | P a g e
3.7 Amine Sweetening Process
Amine sweetening process basically removes CO2 and H2S from natural gas. Amine has a natural
affinity for both CO2 and H2S which makes it a very efficient and effective removal procedure.
Amine gas sweetening process removes H2S and CO2 from natural gas and liquid hydrocarbon
streams through absorption and chemical reaction.
Amine gas treating process includes an absorber unit and regenerator unit as well as accessory
equipment. In the absorber the down-flowing amine solution absorbs H2S and CO2 from the up-
flowing sour gas to produce a sweetened gas streams and an amine solution rich in the free
hydrogen sulfide and carbon dioxide as a product and an amine solution rich in the absorbed acid
gases. The ‘rich’ amine is the routed into the regenerator to produce regenerated or ‘lean’ amine
that is recycled for reuse.
Each of amine offers distinctive features but comparing with previous data and literature
suggestion we have chosen MEA (Monoethanol amine) as it can be used for natural gases at low
pressure.
Selective amines absorb H2S preferentially to CO2. Many authors have concluded that this
preference results from differences in solubility, rates of reaction, or a combination of the two.
Although all amines show some degree of selectivity based on kinetic effects the rate of reaction
for CO2 decreases with the substitution on the nitrogen group such that primary amines react faster
than secondary and tertiary amines. The rate of reaction for H2S is so fast that equilibrium is
effectively reached for all of the amines. Designing a selective commercial sweetening unit with
primary amines is thus not feasible since the CO2-amine reaction rate is so fast; however, selective
units incorporating secondary and tertiary amines are routinely designed to exploit this capability.
The development of selective amine treating units has resulted in an increase in plant efficiency.
The industry has been quick to embrace this new technology because of its economic advantages.
The primary aminemethanolamine (MEA) and diglycolamine, (DGA) offer no selectivity in
normal operating units, absorbing CO2 as completely as H2S. The secondary and tertiary amines
diethanolamine (DEA), diisopropanolamine, (DIPA), and methyldiethanolamine (MDEA) are
selective amines and are most effective for high pressure applications (> 300 psi, 20 KPa). Trying
29 | P a g e
to improve the efficiency with selective amines, researchers have studied some low molecular
weight sterically hindered amines with advantages similar to MDEA regarding selectivity.
30 | P a g e
Chapter-4
Design basis
31 | P a g e
4. Design basis
4.1 Design Basis
This plant can be modeled with composition and flow rate of raw material a significant amount of
sales gas, LPG and NGL is obtained.
Furthermore, increasing demand for natural gas can’t be met with existing gas infrastructure. So,
this project can be helpful to meet increasing demand. All components of this project is in
consistent with government rules and regulations. In addition natural gas supply, transmission and
distribution can be enhanced by means of this project.
Without this project, Bangladesh would need to import petroleum products at world prices, use
more coal, and increase the burning of wood. The increased availability of gas has encouraged
energy consumers from all categories to switch to the generally cheaper, cleaner and more
convenient gas. The project will contribute indirectly to poverty reduction in surrounding areas
by supporting economic growth and spreading of wealth.
Design basis includes site conditions, utilities and climate conditions which influence the design
of individual unit, equipment or facility of the overall project.
Soil type
The area of interest are formed by the deposition of three different materials, e.g. Piedmont
Alluvium, Tista Alluvium and Barind Tract. Clay layer is either exposed at the surface or
concealed under a thin soil layer less than one m thick, formed from the weathering of the red clay.
Due to the removal of the clayey materials, the soil has become sandier than the parent rock.
Surface area of standing water bodies, excluding ponds and tanks was surveyed. In the study area,
total surface area of standing water bodies are 254 km
32 | P a g e
Seismic condition
Moderate to large earthquake magnitudes are common in this region and recently there has been
frequent moderate to less type of earthquakes are occurring there and will continue to occur as
long as the tectonic deformation continues. From recent statistics there are four events located with
earthquake magnitude between 4.8 to 6.5 occurring frequently.
4.2. Meteorological Condition and Soil Properties of

the Plant Site
Ambient Temperature:
Absolute max. Temperature: 38 oC

Absolute min. temperature: 12oC
Designed max .temperature: 38oC
Designed min. temperature: 5oC
Atmospheric Pressure:
Annual average atm. Pressure: 0.11 MPa
Max. Average atm. Pressure: 0.15 MPa
Min. average atm. Pressure: 0.09 MPa
Designed average atm. Pressure: 0.2 MPa
Humidity:
Annual average relative humidity: 80 %
Max. Monthly average relative humidity: 87 %
Min. monthly average relative humidity: 65 %
Designed relative humidity: 90 %
Wind:
Wind direction: Generally wind flows from the north to the south in the winter season and from the
south to north in the summer in our country.
33 | P a g e
Wind Velocity: 50 knot (50 nautical miles per hour or 58 miles/hr)
Rain:
Annual avg. rainfall: 2850mm
Max. Monthly rainfall: 235mm
Earth Bearing Capacity:

Load bearing capacity: The soil has a bearing capacity of 0.5 kg/cm2. Required piling is used.
Corrosive tendency: Non Corrosive.
4.3. Climate Condition

Summer:
Wet bulb Temperature (max) 30.5C

Dry bulb Temperature (max) 36C
Relative humidity 84%
Wet bulb temperature (min) 22C

Dry bulb Temperature (min) 25C
Dew point 21C
Winter:
Wet bulb Temperature (max) 21C
Dry bulb Temperature (max) 26C
Dew point 20C
Wet bulb temperature (min) 100C

Dry bulb Temperature (min) 8C
Dew point 8C
34 | P a g e
Electric power
440 V – 3 phase, 50 Hz for motors in the range of:
230V-1 phase 50 Hz for motors 0.5 KW and below.
120V-1 phase 50 Hz for instruments and control.
Normal lighting:220 V-1 phase,50 Hz
Air
Instrument air
Pressure: 800 KPa
Temperature: 25o C
Plant effluents and other waste disposal must meet the environmental regulations of
the government.
Hot air Temperature: 170 oC
Steam
180 oC saturated steam at 8 bar
119 oC saturated steam at 2 bar
Raw Materials
Natural Gas obtained from wells.
35 | P a g e
Solvent for extraction
Triethylene glycol and Monoethanolamine
Other Information
Natural catastrophe: A possibility of storm in the months of April-May.
36 | P a g e
Chapter-5
Process Block Diagram
37 | P a g e
5. Process Block Diagram
Figure 5.1: Process Block Diagram
38 | P a g e
5.1. Description of Process Block Diagram
Raw natural gas is withdrawn from well. Valve is used for choking effect to reduce its pressure
below hydrate formation pressure as huge amount of water remains in the raw gas. In this project
one well is considered to be used for withdrawal of gas. Then gas from the well is undergone
through the pigging operation to remove the solid residue that the raw natural gas is containing at
a temperature of 37 oC and at a pressure of 1400 psi .After pigging operation the raw gas entered
into 3-phase separator where it splits into vapor, light liquid and heavy liquid portion. Vapor
produced due to flash in the vessel which contains mainly methane, ethane and light hydrocarbons
is sent to the dehydration unit for further process. In light liquid, small amount of methane along
with higher hydrocarbons are present which is sent to the flash separator and NGL (C5-C14) is
obtained from processing through flash separator. In heavy liquid a huge amount of water is
removed. The wet gas from the top enters in to glycol absorber where it comes in contact with
MEG. MEG absorbs water and then rich glycol is heated by a heat exchanger before it enters into
stripper. Stripper provides a certain height with random packing where vapor emits out and glycol
is being regenerated. Regenerated glycol along with makeup glycol enters into absorber. Before
that it was cooled by glycol-glycol heat exchanger. The treated outlet from dehydration unit is sent
to the amine sweetening unit to remove CO2 and H2S from natural gas. These two pollutant is
removed from NG to a great extent and water free hydrocarbon gas is passed through a heat
exchanger in to 3 phase separator where remaining amount of water is separated as heavy liquid.
Vapor outlet of this separator is known as sales gas. Light liquid from this separator is sent into
de-ethanizer which makes gas free from propane and butane and joined with upper stream of 3
phase separator as sales gas. Bottom product of de-ethanizer is known as LPG. Light liquid stream
from the first 3 phase separator is sent to stabilizer where it gives out the methane percentage as
upper stream. The last obtained treated gas is containing 92.22% methane.
39 | P a g e
Chapter-6
Process Flow Diagram
40 | P a g e
6. Process Flow Diagram
Figure 6.1: Process Flow Diagram of natural gas processing plant
41 | P a g e
Chapter-7
Material Balance
42 | P a g e
7 Material Balance
7.1 Three phase separator (first)
Gas
Inlet natural gas stream
Light Liquid
Heavy Liquid
Inlet Stream: 5498300 mol/hr
For operating temperature and pressure of 400C and 1100 psia respectively, using depriester chart,
Molar Composition:
CO2: 0.000208 mol/mol
Methane: 0.90 mol/mol
Ethane: 0.308 mol/mol
Propane: 0.008 mol/mol
Butane: 0.004 mol/mol
Higher hydrocarbon (C5 –C18): 0.0071 mol/mol
Water: 0.0093 mol/mol
43 | P a g e
N2: 0.003 mol/mol
H2S: 0.015 mol/mol
O2: 0.015 mol/mol
Outlet:Gas Stream: 4948470 mol/hr
CO2: 0.000231 mol/mol
N2: 0.0033 mol/mol
H2S: 0.0166 mol/mol
O2: 0.0166 mol/mol
Light Liquid: 505844 mol/hr
Heavy Liquid: 43986 mol/hr liquid water
44 | P a g e
7.2 Flash Separator
Gas
Light Liquid
Liquid
For operating temperature and pressure of 370C and 1000 psia respectively, using depriester chart,
Inlet: 505844 mol/hr
Outlet: Gas Stream: 465000 mol/hr
Water: 0.005 mol/mol,
Liquid Stream: 40852 mol/hr higher Hydrocarbon (C5-C18)
45 | P a g e
7.3 Glycol Dehydration unit
Absorber
Balance around “Dehydration unit”
Input streams,
Wet Gas
Wet Gas = 5413.468 kgmole/hr
XCH4 = 0.92
XC2H6 = 0.038
XC3H8 = 0.0078
XC4H10 = 0.00433
XCO2 = 0.000193
XN2 = 0.00277
XH2O = 0.001343
XH2S = 0.0139
XO2 = 0.0139
46 | P a g e
Molar flow rates of inlet gas
NCH4 = 5413.468 kgmole/hr x 0.92 = 5070.96 kgmole/h
NC2H6 = 5413.468 kgmole/hr x 0.038 = 209.45 kgmole/h
NCO2 = 5413.468 kgmole/hr x 0.0001935 = 1.06 kgmole/h
NN2 = 5413.468 kgmole/hr x 0.00277 = 15.26 kgmole/h
NH2O = 5413.468 kgmole/hr x 0.001342 = 7.25 kgmole/h
NH2S = 5413.468 kgmole/hr x 0.0139 =76.61 kgmole/h
NO2 = 5413.468 kgmole/hr x 0.0139 = 76.61 kgmole/h
INLET LEAN TEG
TEG = 551.179 kgmole/h
Output streams from “Dehydration unit”,
Rich TEG and Dry Gas
Rich TEG
In Rich TEG, there will be water and TEG
So, Rich TEG = TEG + Water
= (551.179 +6.498) kgmole/h
= 557.677 kgmole/h
551.179
XTEG =
557.677
47 | P a g e
= 0.9885
6.498
XH2O =
557.677
= 0.115
Dry gas
Dry gas = Wet gas + TEG - Rich TEG
= (5413.46+ 551.179 – 557.677) kgmole/hr
= 5406.97 kgmole/hr
Molar flow rates of outlet gas
NC4H10 = 5406.97 kgmole/hr x 0.00409 =23.86 kgmole/h
NH2S = 5406.97 kgmole/hr x 0.01517= 76.61 kgmole/h
48 | P a g e
7.4 Amine Sweetening Unit
7.4.1 Absorber
Balance around “Absorber of Amine Sweetening Unit”
For amine separation 15 wt% MEA was chosen and an absorber unit of 20 equilibrium stages were
operated at 100 °F in order to achievce a 90% removal of sour gases i.e. hydrogen sulfide and
carbon dioxide.
Input streams,
Sour Gas
Sour gas = 5505.42 kgmole/hr
XCH4 = 0.9178
XC2H6 = 0.0387
XC3H8 = 0.00814
XC4H10 = 0.00409
XCO2 = 0.00021
XN2 = 0.00302
XH2O = 0.001343
XH2S = 0.01517
XO2 = 0.0152
49 | P a g e
Molar flow rate of inlet gas
NC4H10 = 5505.42 kgmole/hr x 0.00409 =23.86 kgmole/h
NH2S = 5505.42 kgmole/hr x 0.01517= 76.61 kgmole/h
Inlet Lean Amine
Lean Amine = 135.887 kgmole/h (15 wt%)
Xamine= 0.0687
XH2O= 0.931
Molar flow rate of inlet amine
Namine = 135.887 kgmole/h x 0.0687 = 9.335 kgmole/h
NH2O = 135.887 kgmole/h x 0.931= 126.606 kgmole/h
Output stream from Absorber of Amine Sweetening Unit,
Rich Amine with Gas
The gas liquid mixture which will come out will have rich amine containing acidic gases with
product gas which will be separated in a subsequent flash separator.
50 | P a g e
Rich Amine and Natural Gas
In Rich Amine and Natural Gas Mixture there will be Rich MEA containing CO2+ H2S and Natural
Gas.
So, Rich MEA and Natural Gas mixture = (Rich Amine) + Natural Gas
= (135.887+5360.891 ) kgmole/h
= 5641.307 kgmole/h
Molar flow rate of outlet gas
NC2H6 = 5641.307 kgmole /hr x 0.0371 = 209.29 kgmole/h
NC4H10 = 5641.307 kgmole /hr x 0.0039 =22.0011 kgmole/h
NCO2 = 5641.307 kgmole /hr x 0.000183 = 1.0324 kgmole/h
NN2 = 5641.307 kgmole /hr x 0.0029 = 16.36 kgmole/h
NH2S = 5641.307 kgmole /hr x 0.0133= 75.029 kgmole/h
NO2 = 5641.307 kgmole /hr x 0.01458 = 82.250 kgmole/h
NH2O(g) = 5641.307 kgmole /hr x 0.00013 = 0.7503 kgmole/h
NH2O(l) = 5641.307 kgmole /hr x 0.034 = 191.8044 kgmole/h
NMEA = 5641.307 kgmole /hr x 0.002506 = 14.137 kgmole/h
51 | P a g e
7.5 Flash Separator
Balance around “Flash Separator of Amine separation unit”
Input streams,
Sweet Gas with Rich Amine mixture = 5641.3071 kgmole/h
XCH4 = 0.8805
XC2H6 = 0.0371
XC3H8 = 0.0078
XC4H10 = 0.0039
XO2 = 0.01458
XN2 = 0.0029
XH2O(g) = 0.00133
XH2S = 0.0133
XCO2 = 0.000183
XH2O(l) = 0.034
XMEA= 0.002506
52 | P a g e
Inlet Gas
NC4H10 = 5641.307 kgmole /hr x 0.0039 =22.0011 kgmole/h
NCO2 = 5641.307 kgmole /hr x 0.000183 = 1.0324 kgmole/h
NN2 = 5641.307 kgmole /hr x 0.0029 = 16.36 kgmole/h
NH2S = 5641.307 kgmole /hr x 0.0133= 75.029 kgmole/h
NO2 = 5641.307 kgmole /hr x 0.01458 = 82.250 kgmole/h
NH2O(g) = 5641.307 kgmole /hr x 0.00013 = 0.7503 kgmole/h
NH2O(l) = 5641.307 kgmole /hr x 0.034 = 191.8044 kgmole/h
NMEA = 5641.307 kgmole /hr x 0.002506 = 14.137 kgmole/h
Output Sweet Gas stream from Flash Separator of Amine Sweetening Unit,
Sweet Gas= 5360.89 kgmole/h
XCH4 = 0.9266
XC2H6 = 0.0389
XC3H8 = 0.00819
XC4H10 = 0.00399
XO2 = 0.01458
XN2 = 0.00299
53 | P a g e
XH2O(g) = 0.000136
XH2S = 0.00023
XCO2 = 0.0000032
Molar flow rate of outlet sweet gas
NCH4 = 5360.89 kgmole/h x 0.9266= 4967.4007 kgmole/h
NC2H6 = 5360.89 kgmole/h x 0.0389= 208.538 kgmole/h
NH2O= 5360.89 kgmole/h x 0.000136 = 0.7291 kgmole/h
NO2 = 5360.89 kgmole/h x 0.01528= 81.9144 kgmole/h
NN2 = 5360.89 kgmole/h x 0.00299= 16.029 kgmole/h
NH2S = 5360.89 kgmole/h x 0.00023 = 1.233 kgmole/h
NCO2 = 5360.89 kgmole/h x 0.0000032= 0.01715 kgmole/h
54 | P a g e
7.6 Second Three Phase Separator
F17
4.88×106 moles/hr
X17C1
X17C2
X17C3
X17C4
X17N2
X17O2
F12
5.36×106 moles/hr F18
4.77×105 moles/hr
3-Phase Separator
X12C1 0.928 mol/mol X18C1
X12C2 .039 mol/mol X18C2
X12N2 .003 mol/mol
X12O2 .0153 mol/mol F19
X12H2O .000137mol/mol
734 moles/hr H2O
55 | P a g e
Material Balance around the 3-phase Separator
F17= 88.823×54983 moles/hr
=4.88×106 moles/hr
F19= .000137×54983 moles/hr
=734.32 moles/hr
F18 = F12-F17-F19
= (97.5-88.823-.0117)× 54983 moles/hr
= 8.667× 54983 moles/hr
= 4.76×105 moles/hr
Here,
At 3-phase separator temperature T= 30o C
Pressure P = 400 KPa
For the lower hydrocarbon the value of constant k from De-Priester Chart,
Methane, k1 =38
Ethane, k2 = 7.5
Propane,k3 =2.6
n-Butane, k4 = 0.65
From Rachford-Rice equation
( 𝑘𝑖 −1)×𝑧𝑖
f(V/F) =∑ 𝑉
1+(𝑘𝑖 −1)×(𝐹)
For (V/F)= 0.2

(38−1)×0.928 (7.5−1)×0.039 (2.6−1).0082 (0.65−1).004
f(0.2)= 1+(38−1)×0.2 + 1+(7.5−1)×0.2+1+(2.6−1)×0.2+1+(0.65−1)×0.2
56 | P a g e
=4.087+0.11+.00993-.00151
=4.440
The function is positive so (V/F) will be higher.
Derivative of Rachford-Rice equation
𝑑𝑓 (𝑘1 −1)2 ×𝑧1 (𝑘2 −1)2 ×𝑧2 (𝑘3 −1)2 ×𝑧3

( 𝑉 )1 = -[ 𝑉 + 𝑉 + 𝑉 +
𝑑( ) {1+(𝑘1 −1)×( )}2 {1+(𝑘2 −1)×( )}2 {1+(𝑘3 −1)×( )}2
𝐹 𝐹 𝐹 𝐹
(𝑘4 −1)2 ×𝑧4
𝑉 ]
{1+ (𝑘4 −1)×( )}2
𝐹
(38−1)2 ×0.928 (7.5−1)2 ×0.039 (2.6−1)2 ×0.0082 (0.65−1)2 ×0.004

=-[ 𝑉 + 𝑉 + 𝑉 + 𝑉 ]
{1+(38−1)×(𝐹)}2 {1+(7.5−1)×(𝐹)}2 {1+(2.6−1)×(𝐹)}2 {1+(0.65−1)×(𝐹)}2
With (V/F)=0.2
𝑑𝑓
( 𝑉 )1 = - [18+0.311+0.00746+.00046]
𝑑(𝐹)
= -18.318
So,
4.44
(V/F)2 =0.2+
18.318
=0.44
Again from Rachford-Rice equation,
(38−1)×0.928 (7.5−1)×0.039 (2.6−1).0082 (0.65−1).004

f(0.2) = 1+(38−1)×0.44 + 1+(7.5−1)×0.44+1+(2.6−1)×0.44+1+(0.65−1)×0.44
=1.987+.0656+.00769-.00165
=2.058
57 | P a g e
This is still positive.
𝑑𝑓
( 𝑉 )2 = 4.253+0.11+.00447+.000558
𝑑(𝐹)
= 4.368
2.058
So, (V/F)3 =0.44+
4.368
=0.911
By doing trial and error the value of (V/F)= 0.911
Calculation of x
𝑧1
𝑥1 = 𝑉
1+(𝑘1 −1)×(𝐹)
0.928
= =0.0267
1+(38−1)×0.911
𝑧2
𝑥2 = 𝑉
1+(𝑘2 −1)×(𝐹)
0.039
=
1+(7.5−1)×0.911
=0.00563
𝑧3
𝑥3 = 𝑉
1+(𝑘3 −1)×(𝐹)
0.0082
=
1+(2.6−1)×0.911
=0.00333
𝑧4
𝑥4 = 𝑉
1+(𝑘4 −1)×(𝐹)
0.004
=
1+(.65−1)×0.911
58 | P a g e
=0.00587
Using the equation y=kx
Composition of output stream F17 are-
𝑥17𝐶𝐻4 = 0.9320 mol/mol
𝑥17𝐶2𝐻6 =0.0387 mol/mol
𝑥17𝐶3𝐻8 = 0.0079 mol/mol
𝑥17𝐶4𝐻10 =0.0034 mol/mol
𝑥17𝑁2 =0.00293 mol/mol
𝑥17𝑂2 =0.0153 mol/mol
Composition of output stream F18 are-
𝑥18𝐶1 =0.643 mol/mol
𝑥18𝐶2 =0.1355 mol/mol
𝑥18𝐶3 = 0.0794 mol/mol
59 | P a g e
7.7 De-ethanizer
F20 moles/hr
𝑥20𝐶1
𝑥20𝐶2
F18 moles/hr De-Ethanizer
𝑥18𝐶1
𝑥18𝐶2
𝑥18𝐶3
𝑥18𝐶4 F22 moles/hr
𝑥22𝐶1
𝑥22𝐶2
𝑥22𝐶3
𝑥22𝐶4
Material balance for methane around the De-Ethanizer,
F20 = 8.667×54983× (0.643+0.1355)
=3.70×105 moles/hr
F22 = F18-F20 =1.05×105 moles/hr
Composition of the upper stream:
𝑥20𝐶1 = 0.826 mol/mol
𝑥20𝐶2 = 0.174 mol/mol
60 | P a g e
Composition of the downstream:
𝑥22𝐶1 =0.0043 mol/mol
𝑥22𝐶2 =0.0012 mol/mol
61 | P a g e
7.8 Mixer
F20 moles/hr
𝑥20𝐶1
𝑥20𝐶2
F21 moles/hr
Mixer
F17 moles/hr X21C1

X21C2
X17C1 X21C3
X17C2 X21C4
X17C3 X21N2
X17C4 X21O2
X17N2 X21H2O
X17O2
Here, F21= F17+F20

=(88.823+6.747)×54983 moles/hr
=5.254×106 moles/hr
Composition of F21 stream:

x21C1=0.922 mol/mol
x21C2= 0.049 mol/mol

x21C3= 0.011 mol/mol
x21C4=0.000225 mol/mol
x21N2= 0.00277 mol/mol
x21O2=0.0138 mol/mol
x21H2O=0.0000126 mol/mol
62 | P a g e
Chapter-8
Energy Balance
63 | P a g e
8 Energy Balance
8.1 Glycol absorption unit
Energy balance around Absorber
Inlet Outlet
Lean TEG Wet gas Dry gas Rich TEG
Temperature (oC) 40.00 37.78 39.80 38.00
Pressure (Psi) 1000 1000 1000 1000
Energy balance table
Basis: N2, H2, O2, at 25oC and 1 atm
Component nin (kmol/h) Hin (kJ/kmol) nout (kmol/h) Hout(kJ/kmol)
TEG 551.179 H1 557.677 H7
C1 5070.96 H2 5070.96 H8
C2 209.45 H3 209.45 H9
CO2 1.06 H4 1.06 H10
N2 15.26 H5 15.26 H11
H2O 7.39 H6 0.892 H12
H2S 76.61 H13 76.61 H15
O2 76.61 H14 76.61 H16
C3 42.99 H17 42.99 H19
C4 23.86 H18 23.86 H20
64 | P a g e
Hi = Formation enthalpy + Cp∫ 𝑑𝑇
H1= -8.31x105 + 359.2 (40-25)
= -8.3x102 kJ/mol
(37.78−25)2
H2= -74.85 + 32.31x10-3x(37.78-25) + 5.47x10-5 2
= -74.43 kJ/mol
(37.78−25)2
H3=-84.67+49.3x10-3x(37.78-25)+13.92x10-5 2
= -82.9 kJ/mol
(37.78−25)2
H4=-393.5+36.11x10-3x(37.78-25)+4.233x10-5 2
=-392.2 kJ/mol
(37.78−25)2
H5= 29x10-3(37.78-25)+0.22x10-5 2
= 1.047 kJ/mol
(37.78−25)2
H6= -241.83+33.46x10-3 x(37.78-25)+0.688x10-5 2
= -245.5 kJ/mol
H7= -8.31x105 + 359.2x(40-25)
= -825.61 kJ/mol
(39.8−25)2
H8=-74.85+34.31x10-3x(39.8-25)+5.465x10-5x 2
= -73.9 kJ/mol
(39.8−25)2
H9=-84.67+49.3x10-3x(39.8-25)+13.92x10-5
2
= -83.93 kJ/mol
(39.8−25)2
H10=393.5+36.11x10-3x(39.8-25)+4.233x10-5 2
=-392.8 kJ/mol
(39.8−25)2
H11= 29x10-3(39.8-25) + 0.22x10-5 =0.55 kJ/mol
2
65 | P a g e
H12= -285.84+75.4x10-3x(38-25)
= -282.88 kJ/mol
(39.8−25)2
H13=-84.67+49.3x10-3x(39.8-25)+13.92x10-5 2
= -282.8 kJ/mol
(37.78−25)2
H14=-29x10-3(37.78-25)+0.22x10-5 2
= -282.88 kJ/mol
(39.8−25)2
H15= 29x10-3(39.8-25) + 0.22x10-5 =0.55 kJ/mol
2
H16= -285.84+75.4x10-3x(38-25)
= -282.88 kJ/mol
(39.8−25)2
H17= -85.67+ 64.3x10-3x (39.8-25) +0.1892x10-5 2
= -84.4 kJ/mol
(39.8−25)2
H18=-91.4+76.3x10-3x (39.8-25) +1.92x10-5 2
= -91.2 kJ/mol
(37.78−25)2
H19= -85.67-64.3x10-3 (37.78-25) +0.1892x 10-5 2
= -282.88 kJ/mol
(37.78−25)2
H20=-91.4+76.3x10-3x (37.78-25) +1.92x10-5 2
= -91.14 kJ/mol
𝐻 = ∑ 𝑛𝑖𝑛 𝐻𝑖𝑛 -∑ 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡
= -3469 kJ/h
66 | P a g e
8.2 Energy balance around Pump
Inlet Outlet
TEG TEG
Temperature (oC) 40.00 39.80
Pressure (Psi) 14.7 1000
Basis: N2, H2, O2, at 25oC and 1 atm
TEG 551.179 H1 557.677 H2
H1= -8.31x105 + 359.2 (40-25)
= -7.771x105 kJ/kmol
H2= -8.31x105 + 359.2 (39.8-25)
= -7.771x105 kJ/kmol
=-551.179x(-7.711x105) + 557.677x(7.72x105)
= 5.05x106 kJ/h
67 | P a g e
8.3 Energy balance on Glycol Reboiler
Q = Energy required for pre-heating (Glycol+Water ) + Energy required for heating
(Glycol+Water) at heat exchanger
= Q1+ Q2
i) Q1 = (Cp× nTEG× ∆T)+ (nwater× ∆H)
= 0.6×4200 J/kg. °C× 552850 mol ×(195-25) °C ×(150×10-3) kg/mol + ( 13.92×103)KJ
= (3.55×106) kJ+ (13.92×103) kJ
=3.56×106 kJ/hr
ii) Q2= Q2Water+ Q2gycol
Q2TEG = 0.72×4200 J/kg. °C+552850 mol ×(198-195) °C × 552850 mol ×(195-25) °C
= 0.75×106 kJ
Q2Water= Q2 Vaporization
= (60.984×106) kJ+ (5.78+0.13) kJ
= (60.984×106) kJ
So,Q2= Q2Water+ Q2gycol
= 0.75×106 kJ + (60.984×106) kJ
= 0.813 kJ/hr
Total Heat Load = 3.56×106 kJ/hr+0.813 kJ/hr
Qr = 4.373×106 kJ/hr
68 | P a g e
8.4 Amine Absorption Unit
Energey balance around Absorber
Inlet(℉) Outlet ℉)
Inlet gas Lean amine Outlet gas Rich amine
Temperature 104℉ 122 136 136

(oC)
Pressure (Psi) 14.7 14.7 84.67 84.67
Basis: N2, H2, O2, at 0oC ,waterand 1 atm
Component nin (mol/h) Hin (kJ/mol) nout (mol/h) Hout(kJ/mol)
MEA 15698.29835 0.218745 14020.7925 0.216686
C1 49676452.5 1.41622 4967401.832 H13
C2 2094659.742 2.0849 208538.6696 H14
CO2 11366.3707 1.47765 17.154 2.15488
N2(g) 163296.859 1.16188 16029.06484 1.67936
H2O 77252.827 44.27622 729.08121 44.8771
H2S 821084.9688 1.352838 1233.004988 1.96187
O2 821084.9688 1.17313 81914.4183 1.7
C3 440582.1784 2.89922 43905.6993 4.298833
C4 221373.6007 3.91176 21389.95609 3.91176
H20(l) 212906.5997 1.885 191524 2.470858
CO2(flue gas) -- -- 1015.10537 2.15488
H2S(flue gas) -- -- 73749.36855 1.96187
69 | P a g e
= 9254.273-1613.9798
= -6885.5248 kJ/h
8.4.1 Reboiler Unit
0.12 kg/l amine is required for amine sweetening process of sour gas Fitzgerald & Richardson
For regenerator stripping column operating at 2.1-2.2 bar grom graphical representation 2.3 MW
heat load is observed.
Flow rate of rich amine ids 3213.6007 L/h MEA
3213.6007 L rich MEA needs 26780.00583 kg/steam
8.5 Energy balance around Amine Absorption Pump

H1= -8.31x105 + 359.2 (40-25)
= -7.771x105 kJ/kmol
H2= -8.31x105 + 359.2 (39.8-25)
= -7.771x105 kJ/kmol
=-551.179x(-7.711x105) + 557.677x(7.72x105)
= 5.05x106 kJ/h
70 | P a g e
8.6 Energy Balance around De-Ethanizer column
H1
Qc
0
1320 F hF L D ,hD -15 F
De- 3.70×105 moles/hr
4.76×105 moles/hr
Ethanizer
column X20C1=0.826
X18C1=0.643
X20C2=0.174
X18C2=0.135
X18C3=.0794
X18C4=0.141
B ,hB 1100 F
1.05×105 moles/hr
X20C1=0.0043
X22C2=0.0012
X22C3=0.360
X22C4=0.630
71 | P a g e
Assumption:
𝐿
Recycle ratio, =3
𝐷
Condenser energy (Qc) calculation
Qc = (L+D) ×(hD- H1)
𝐿
=D(1+ ) ×[(0.826CC1+0.174CC2) ×( 247-298)- (0.826CC1+0.174CC2) ×( 325-298)]
𝐷
=3.70×105(1+3)×[(0.826×34+0.174×45.7)×(247-298)-(0.826×37.32+0.174×56.85)×
(325-298)]
= - 4.347× 109 J/hr
= -1.20× 106 W
72 | P a g e
Chapter-9
Sizing
73 | P a g e
9. Equipment design
9.1 Three phase Separator (1)
Sizing and Calculation for Horizontal Separator
Outlet Mass flow rate (lb/h) density (lb/ft3) viscosity Temperature
Streams (cp) (oC)
Gas 192232 3 0.00126 37
light liquid 27615.55 44 0.52 37
heavy liquid 1745.54 62.4 1 37
Determination of Allowable design velocity from vertical terminal velocity
Vertical Terminal Velocity, 𝑉𝑡 = 𝐾𝑠𝑏 √(𝜌𝐿 − 𝜌𝑣 )/𝜌𝑣
According to Gas Process supplier’s Association, Ksb=0.43-0.023 ln(P)=0.269
And for the three phase separator, P=1100 psia
Therefore, Vt= 1 ft/s
And Allowable design velocity, Vv=0.75×VT= 0.75 ft/s
Determination of Volumetric Flow Rates
Vapor volumetric flow rate,
𝑚
𝑣
𝑄𝑣 = 3600×𝜌 = 17.8 ft3/s
𝑣
74 | P a g e
Light and Heavy Liquid Volumetric Flow Rates,
𝑚
𝑙𝑙
𝑄𝐿𝐿 = 60×𝜌 = 10.46 ft3/min
𝑙𝑙
𝑚
ℎ𝑙
𝑄𝐻𝐿 = 60×𝜌 = 0.466 ft3/min
ℎ𝑙
Determination of residence time for heavy and light liquid

The residence time for the heavy phase,
𝜃𝐻𝐿 = 6 𝑚𝑖𝑛
The residence time for the light phase,
𝜃𝐿𝐿 = 6 𝑚𝑖𝑛
Determination of Diameter of Vessel
Assuming L/D Ratio from Table:
L/D Ratio Guidelines
Vessel Operating Pressure(psig) L/D
0<P≤250 1.5-3.0
250<P≤500 3.0-4.0
P>500 4.0-6.0
For P=1100 psig, let L/D= 4
1
3
16(𝑄𝐿𝐿 𝜃𝐿𝐿 + 𝑄𝐻𝐿 𝜃𝐻𝐿 )
𝐷=( ) = 4.92 𝑓𝑡
𝐿
0.7 × 𝜋 × 𝐷
However, Vapor Space height must be 0.2D or 2 ft.
75 | P a g e
Thus Diameter should be greater than 2 ft to accommodate the vapor space height. Let D=5 ft
And the Area of cross section for the vessel in radial direction,
AT=19.63 ft2
Detailed calculation is showed in the detailed equipment design.
Finally, Total Length of the three phase separator, L=11 ft
9.2 Three phase Separator (2)

Sizing and Calculation for Horizontal Separator

Streams
(cp) (oC)
Gas 184933 3 0.00126 40
light liquid 27367 44 0.52 40
heavy 29.13 62.4 1 40

liquid
Determination of Allowable design velocity from vertical terminal velocity
Vertical Terminal Velocity,
And for the three phase separator, P= 400 kPa or 60 psia

Therefore, Vt= 1.24 ft/s
76 | P a g e
And Allowable design velocity,
Vv=0.75 VT= 0.93 ft/s
Determination of Volumetric Flow Rates
𝑣 𝑚
𝑄𝑣 = 3600×𝜌 =17.12 ft3/s
𝑣
𝑚
𝑙𝑙
𝑄𝐿𝐿 = 60×𝜌 = 10.366 ft3/min
𝑙𝑙
𝑚
ℎ𝑙
𝑄𝐻𝐿 = 60×𝜌 = 0.0078 ft3/min
ℎ𝑙
Determination of residence time for heavy and light liquid
The residence time for the heavy phase, 𝐻𝐿 = 5 𝑚𝑖𝑛
The residence time for the light phase, 𝐿𝐿 = 5 𝑚𝑖𝑛
Determination of Diameter of Vessel
Assuming L/D Ratio from Table:

0<P≤250 1.5-3.0
250<P≤500 3.0-4.0
P>500 4.0-6.0
1
3
16(𝑄𝐿𝐿 𝜃𝐿𝐿 +𝑄𝐻𝐿 𝜃𝐻𝐿 )
Let L/D = 4 SO, 𝐷 = ( 𝐿 ) = 4.45 𝑓𝑡
0.7×𝜋×
𝐷
77 | P a g e
Thus Diameter should be greater than 2 ft to accommodate the vapor space height
Let D=4.5 ft
And the Area of cross section for the vessel in radial direction, AT= 15.904 ft2
L/D =4
And, Length, L=4×4.5 =18 ft
9.3 Glycol Absorption tower

Diameter:
Liquid rate, FL = 1293.05 lbmole/hr
Vapor Rate, FG = 11840.5 lbmole/hr
Vapor molecular weight =17.49
Vapor density, ρG = 0.007g/ml
Liquid density, ρL = 0.4256g/ml
𝑊 𝜌 183203 0.007
The factor Flv = 𝑊𝐿 √ 𝜌𝑉 = √
𝑉 𝐿 208715 0.426
= 0.1125
For 24-inch tray spacing, log Csb = -0.94506 - 0.73234 (log Flv) -.202618 (log Flv)2
= -0.94 - 0.73 (log 0.1125) -0.202 (log 0.1125)2
= -0.40
So, Csb = 0.40
78 | P a g e
σ 0.2
The factor Kv can be found from kv = Csb ( )
20
81.8 0.2
σ = 81.8 dyne/cm, now kv =0.40× ( )
20
kv = 0.53
ρL -ρG
The flooding velocity based on net area for vapor flow, Vm = Kv √
ρG
0.426 −0.007
= 0.54× √
0.007
= 4.10 ft/s
V×454 g/lb×𝑀𝑊
The area can be calculated as, A = 𝑈 × 3600×ρ ×28316.85𝑉 𝑚𝑙/𝑓𝑡2
𝑜𝑝 V
11326×454 𝑔/𝑙𝑏×17.6
= 𝑚𝑙
4.18× 3600×0.007×28316.85𝑓𝑡2
= 25.91 ft2
π 2
The diameter can be calculated using Area = ×Dia
4
So, Diameter of the column dia, = 5.75 ft

Height:
The height of tower, H = h1 + h2 + h3
5.75
Where, H1 = space above the residue = 1 ft + 2 ft
= (1+2.875) ft
= 3.875 ft
H2 = height of the absorption section
= number of absorption stage × tray thickness × (number of absorption stage-1) × tray spacing
= (12× 0.078) + {(12-1) × 2} ft
79 | P a g e
= 22.936 ft
H3 = skirt height = 4.0 ft (assumed)
So, total height, H= (3.875+ 22.936 +6.0) ft
= 32.82 ft
9.4 Heat Exchanger (Glycol Unit)

Hot Fluid Cold Fluid
196 °C 128 °C 68 °C
125 °C 40 °C 85 °C
71 °C 88 °C -17 °C
T1-T2 t2-t1 ∆tc-∆th
For 100% TEG, Q = mhotCphot∆Thot
=52245.733×0.4986× (196-125)
= 1.85 ×106 Btu/hr
For 98.85% TEG, Q = mcoldCpcold∆Tcold
= 35273.049×0.606× (128-40)
= 1.85 ×106 Btu/hr
(T2 −t1 )−(T1 −t2 )

LMTD = (T −t )
ln 2 1
(T1 −t2 )
(125−40)−(196−128)
= (125−40)
ln
(196−128)
80 | P a g e
= 76.2697 ˚C
T1 −T2 196−125 159.8

R= = = =0.8068
t2 −t1 128−40 190.4
t2 −t1 88
S= = = 0.05641
T1 −t1 196−40
By using the values of R and S from “Process Heat Transfer” Tata McGraw Hill edition
1997 by Kern page -828, figure-18 for 1-2 heat exchanger, we have the LMTD correction
factor,
FT =0.821 which is greater than 0.75
LMTD=76.2697 °C
FT = 0.821
Corrected LMTD, ∆t= 76.2697 °C × 0.821= 62.617 °C
=52245.733×0.4986× (196-125)
= 1.85 ×106 Btu/hr
= 35273.049×0.606× (128-40)
= 1.85 ×106 Btu/hr
For medium organics, UD is 20-60 range
Let, UD=50
81 | P a g e
Q 1850000
Area, A= UD×∆t = 50×62.617 ft2
= 591 ft2= 54.9057 m2
9.5 Reboiler for Glycol

Q = Energy required for pre-heating (Glycol+Water) + Energy required for heating
(Glycol+Water) at heat exchanger
= Q1+ Q2
i) Q1 = (Cp× nTEG× ∆T)+ (nwater× ∆H)
= 0.6×4200 J/kg. °C× 552850 mol ×(195-25) °C ×(150×10-3) kg/mol + ( 13.92×103)KJ
= (3.55×106) kJ+ (13.92×103) kJ
=3.56×106 kJ/hr
ii) Q2= Q2Water+ Q2gycol
Q2TEG = 0.72×4200 J/kg. °C+552850 mol ×(198-195) °C × 552850 mol ×(195-25) °C
= 0.75×106 kJ
Q2Water= Q2 Vaporization
= (60.984×106) kJ+ (5.78+0.13) kJ = (60.984×106) kJ
So,Q2= Q2Water+ Q2gycol
= 0.75×106 kJ + (60.984×106) kJ
= 0.813 kJ/hr
Total Heat Load = 3.56×106 kJ/hr+0.813 kJ/hr So, Qr = 4.373×106 kJ/hr
Qr
Reboiler Area, A=
U ×∆T
82 | P a g e
4.373×106 kJ/hr
=
0.454 ×(195−37)×3600s
=25.95 m2 So, The reboiler area is 25.95 m2
9.6 Glycol Surge tank

Inlet Outlet
Temperature 40.00 39.80

(oC)
Pressure (Psi) 14.7 14.7
TEG 551.179 H1 551.179 H2
ntotal ×MWavg
Volumetric flow rate = ρavg
551179
mol ×150×10−3 kg
ℎ𝑟 𝑚𝑜𝑙
= kg
1125
𝑚3
𝑚3 𝑚3
=74.5 = 1788
ℎ𝑟 𝑑𝑎𝑦
Retention time (assumed) = 30 min = 0.5 h

=0.0208 day
𝑚3
Volume of the tank = 1788 ×0.0208 day
𝑑𝑎𝑦
= 37.19 m3
83 | P a g e
9.7 Glycol pump
Assuming the efficiency of the pump is 70%
Pump inlet Pressure, P1 =14.7 psi = 101325 N/m2
Pump outlet Pressure, P2 = 1000 psi =6892857 N/m2
Density, ρ = 426 kg/m3
Volumetric flow rate, = 73.40 m3/hr = 0.0204 m3/s
Required head (neglecting minor loss)
𝑃2−𝑃1
h=
𝜌×𝑔
6892857−101325
=
426×9.8
= 1626 m
ℎ×𝑚𝑣1 ×𝜌 ×𝑔
So, required power = η×746
1626 × 0.0204× 426 × 9.8

= 0.7×746
= 265 hp
9.8 Amine absorption unit

Absorption tower: Diameter
Vapor Rate, FG = 11840.5 lbmole/hr
84 | P a g e
𝑊 𝜌 183203 0.007
𝑉 𝐿 208715 1.085
= 0.07
= -0.94 - 0.73 (log 0.1125) -0.202 (log 0.1125)2
= -0.37
So, Csb = 0.425
σ 0.2
20
47.2 0.2
σ = 81.8 dyne/cm, now kv =0.40× ( )
20
kv = 0.504
ρL -ρG
ρG
1.825 −0.007
= 0.54× √
0.007
= 8.12 ft/s
𝑜𝑝 V
85 | P a g e
11826×454 𝑔/𝑙𝑏×17.89
= 𝑚𝑙
4.18× 3600×0.007×28316.85𝑓𝑡2
= 16.68 ft2
π 2
4
Height:
4.60
Where, H1 = space above the residue = 1 ft + ft
2
= (1+2.3) ft
= 3.3 ft
= (8× 0.078) + {(8-1) × 2} ft
= 14.624 ft
= 21.924 ft
9.9 Heat Exchanger (Amine Unit)

Qhot= mhotCphotΔThot
= 4.847 lb/hr× 0.75236 Btu/lb.⁰C ×(127-61.11)⁰C
= 240.289 Btu/h
86 | P a g e
Qcold = mcoldCpcoldΔTcold
= 7.6067 m3/hr×3.085 kg/m3× 2.2046 lb/kg ×CpcoldΔTcold
From the law of conservation,
51.735 lb/hr × 0.4729 Btu/lb. ⁰C × ΔTcold = 240.289 Btu/h
⟹(Tout-Tin) cold =9.822 ⁰C
⇒Tout -Tin= 9.822 ⁰C
⇒Tout = 9.822+ 57.578 ⁰C
=67.4 ⁰C
(𝐓𝟐 −𝐭 𝟏 )−(𝐓𝟏 −𝐭 𝟐 )
LMTD = (𝐓 −𝐭 )
𝐥𝐧(𝐓𝟐−𝐭 𝟏 )
𝟏 𝟐
(𝟔𝟏.𝟏𝟏−𝟓𝟕.𝟓𝟕𝟖)−(𝟏𝟐𝟕−𝟔𝟕.𝟒)
= (𝟔𝟏.𝟏𝟏−𝟓𝟕.𝟓𝟕𝟖)
𝐥𝐧 (𝟏𝟐𝟕−𝟔𝟕.𝟒)
= 19.8415⁰C
𝑇1−𝑇2 127−61.11
R= = = 6.708
𝑡2−𝑡1 67.4−57.578
𝒕𝟐− 𝒕𝟏 𝟔𝟕.𝟒−𝟓𝟕.𝟓𝟕𝟖
S= = = 0.1415
𝑻𝟏− 𝒕𝟏 𝟏𝟐𝟕−𝟓𝟕.𝟓𝟕𝟖
87 | P a g e
By using the values of R and S, we have the LMTD correction factor FT =0.773 which is greater
than 0.75. For medium organics UD is between 20-60.
So, ∆t= 67.7147×0.773= 52.343 ℉
240.289 Btu/hr
Heat transfer area, A = = 2295 cm2
52.343×20
9.10 Flash Separator Sizing

1. Liquid density calculation
The average molecular weight of liquid is

61.08+18+34+44
̅̅̅̅̅
MWL = 4
= 39.27 g/g-mol
Then
MWL
ρL = ̅L
V
39.27
= 45.40
= 0.865 g/ml
2. Vapor density calculation:

P ̅̅̅̅̅̅
MWV
ρV = RT
The average molecular weight of vapor is
88 | P a g e
̅̅̅̅̅V = y1MWC1 + y2MWC2 + y3MWC3 + y4MWC4+ y5MWO2+ y6MWN2+ y7MWH2O+
MW
y8MWH2S+ y9MWCO2
= 0.9266×16 + .0389×30+.00819×44+.00399×58+.01458×32+.0029×28+.000136×18
+.00023×34+.0000032×44
= 17.142 g/g-mole
𝑃
ρV = RT
g
(5.736 atm)(17.142 )
g−mol
= ml atm
(82.0575 )(330 K)
mole k
= 0.00363 g/ml
3. Kdrum calculation:
Calculation of flow parameter Flv
L = 2.80×105 moles/hr
V = 5.36×106 moles/hr
̅̅̅̅̅V
WV =V×MW
= 5.36×106 ×17.142 g/hr
= 9.188×107 g/hr
̅̅̅̅̅L
WL= L×MW
=2.80×105×39.27 g/hr
=10.99×106 g/hr
𝑊𝐿 𝜌𝑉
Flv =
𝑊𝑉
√𝜌
𝐿
10.99×106 0.00363
= √
9.188×107 0.865
89 | P a g e
= 0.0078
From, Backwell (1984) fit Watkins' correlation
(ln Flv)2 + D (ln Flv)3 + E (ln Flv)4 ]

Kdrum = 𝑒 [A + B ln Flv + C
A = -1.877478097
B = -0.8145804597
C = -0.1870744085
D = -0.0145228667
E = -0.0010148518
From the above equation

2 + D (ln Flv)3 + E (ln Flv)4 ]
Kdrum = 𝑒 [A + B ln Flv + C (ln Flv)
(ln 0.0078)2 + D (ln 0.0078)3 + E (ln0.0078)4 ]
= 𝑒 [A + B ln(0.0078) + C
= 𝑒 (−1.233)
= 0.29
It agrees with the Kdrum value from Watkin’s (1967) Chart.
4. Uperm calculation:
Permissible vapor velocity is
ρL −ρV
Uperm = Kdrum√
ρV
0.00589−.00363
= 0.29√ .00363
= 4.48 ft/s
90 | P a g e
5. Ac calculation:
Cross sectional area is
𝑉× MW𝑉
Ac =
𝑈𝑝𝑒𝑟𝑚 ×3600 ×𝜌𝑉
g−mol g
(5.36×106 )×(17.142 )
h g−mol
= ft g ml
(0.40 )(3600)(0.00363 )(28316.85 2 )
s ml ft
= 50.29 ft2
= 4.674 m2
6. Diameter calculation:
4 Ac
D =√ π
4× 4.674
=√
π
= 2.43 m
7. Height of a vertical Vessel:
If use,
𝐿
=3
𝐷
Then
L = 2.43×3
= 7.31 m
91 | P a g e
9.11 Amine Surge Tank
Component nin (kmol/h) nout (kmol/h)
Mono Ethanol Amine 229.28 229.28

(MEA)
Inlet Outlet
Temperature (℃) 40 39.26
Pressure (psi) 14.7 14.7
ntotal×MW
Volumetric Flow Rate, Ṽ =
ρ
mol
229281.2 ×0.6108 kg/mol
h
= kg
1085
m3
= 12.907 m3/hr
=309.777 m3/day
Retention time (assumed) = 30 min = 0.5 h

=0.0208 day
Volume of the tank = 309.777 m3/day×0.0208 day
= 6.443 m3
92 | P a g e
9.12 Amine pump
Assuming the efficiency of the pump is 70%
Pump inlet Pressure, P1 =34 psi = 234422 N/m2
Pump outlet Pressure, P2 = 1000 psi =6892857 N/m2
Density, ρ = 1085 kg/m3
Volumetric flow rate, = 27.53 m3/hr =0.0076 m3/s
Required head (neglecting minor loss)
𝑃2−𝑃1
h= 𝜌×𝑔
6892857−234422
= 1085×9.8
= 626 m
ℎ×𝑚𝑣1 ×𝜌 ×𝑔
So, required power = η×746
626 × 0.0076× 1085 × 9.8

= 0.7×746
= 96.87 hp
93 | P a g e
9.13 Sizing of De-ethanizer
1. Diameter (from Peters & Timmerhaus)
Here,
𝐋
R=𝐃=3
𝐋 𝐋
So, 𝐕 = 𝐋+𝐃
𝐋
𝐃
= 𝐋
+𝟏
𝐃
𝟑
= 𝟑+𝟏
= 0.75
94 | P a g e
For the above graph, the X-axis,
𝑳 𝝆
= (𝑽) ( 𝝆𝒗 )𝟎.𝟓
𝒍
𝟐.𝟔𝟖
= (𝟎. 𝟕𝟓)( 𝟕𝟓𝟎 )𝟎.𝟓
= 0.044
Tray spacing = 0.5 m
So, the Souders Brown co-efficient, CSB = 0.08 m/s.
Now, the surface tension, S.T = 12.2 dyne/cm.
So, net vapor velocity at flood condition,
𝑺.𝑻 𝝆𝒍 −𝝆𝒗 𝟎.𝟓

Vnf = CSB × ( 𝟐𝟎 )𝟎.𝟐 × ( )
𝝆𝒗
𝟏𝟐.𝟐 𝟕𝟓𝟎−𝟐.𝟔𝟖 𝟎.𝟓

= 0.08 × ( 𝟐𝟎 )𝟎.𝟐 ×( )
𝟐.𝟔𝟖
= 1.21 m/s
Assuming 80% of flooding,
Actual vapor velocity, Vn = 0.8×Vnf
= 0.8 × 1.21
= 0.968 m/s
Mass flow rate of vapor, V =18.436×3.70×105 g/hr
= 1.895 kg/s
𝐕
Volumetric flow rate of vapor, mv = 𝛒
𝟏.𝟖𝟗𝟓
= m3/s
𝟐.𝟔𝟖
= 0.71 m3/s
95 | P a g e
Net column area, An= mv /Vn
0.710
= .968
= 0.734 m2
Assume the down comer occupies 15 percent of the cross sectional area of the column,
𝐴𝑛
The cross sectional area of the column, Ac = 0.85
0.734
= 0.85
= 0.87 m2
The column diameter, D = √(4Ac /π)
= 1.05 m.
=3.43 ft ~ 4ft (considering safety)
2. Stage calculation
The relative volatility, α = 4.83
𝒙 𝒙
𝐥𝐧( 𝑳𝑲 / 𝑯𝑲 )
𝒙𝑯𝑲 𝑫 𝒙𝑳𝑲 𝑩
Nmin =
𝒍𝒏𝜶
𝟎.𝟗𝟗𝟕 ×𝟎.𝟗𝟗
𝐥𝐧
𝟎.𝟎𝟎𝟑 ×𝟎.𝟎𝟏
=
𝒍𝒏𝟒.𝟖𝟑
= 6.60 stages
R = 1.2Rmin
Rmin = 3/1.2
= 2.5
𝑵−𝑵𝒎𝒊𝒏 𝑹−𝑹𝒎𝒊𝒏 𝟎.𝟓𝟔𝟔

Now, = 0.75× (𝟏 − )
𝑵+𝟏 𝑹+𝟏
96 | P a g e
Therefore, N = 24 stages
Now,
𝑵 𝑩 𝒙 (𝒙 )
log𝑵𝑫 = 0.206 log [ (𝑫)( 𝒙𝑯𝑲 )𝑭 ((𝒙 𝑳𝑲 )𝑩 )𝟐 ]
𝑩 𝑳𝑲 𝑯𝑲 𝑫
𝑵𝑫
So, = 0.976 ………….. i
𝑵𝑩
ND + NB = N = 24 …………ii
Solving i & ii
NB =13
ND = 11
Thus, the feed enters the column 13 theoretical stages above bottom stage.
3. Height Calculation
From Peters & Timmerhaus,
Actual column height, Hc = (the actual no. of trays, N – 1) × the plate spacing,Hs + ∆H
Here, N = 24
Hs = 0.5 m
∆H = the height required for phase disengagement + liquid holdup needed for surge capacity +
liquid height in the base of the column.
According to “Distillation Design and control – William L. Luyben, p-82”
An additional 20% more height than that required should be added for the requirements of ∆H.
So the actual height of the column, Hc = 1.2 × (24-1) × 0.5
= 13.8 m
97 | P a g e
4. Downcomer area
Downcomer area, Ad = Ac - An
= (0.870 – 0.734) m2
= 0.136 m2
0.136
Down comer area as a percentage of tower area = × 100 %
0.87
= 15.63 %
5. Tray specification
The type of tray used is sieve tray.
Tray spacing = 0.5 m = 19.69 inch

Hole diameter, d = 0.45 inch (range of hole diameter here is assumed for natural gas processing)
Assume, pitch is of equilateral triangular form (most preferable) 60o
Pitch size, PT = 3.8d = 1.71 inch
[Ludwig, Earnest E., Applied Process Design, volume 2, 3rd ed., Page-178]
Tray thickness to diameter= 0.4 (range is 0.1-0.7)
So, Tray thickness, Tt = 0.4d = 0.4×0.45
= 0.18 inch
[Peters, M.S. & Timmerhaus, K.D., Plant Design and Economics for Chemical Engineering, 4th
ed. Page-681]
Total hole area

Ah/Ap =
perforated area
1 𝜋
× ×𝑑 2
2 4
= √3
𝑃
4 𝑇2
= 0.063
98 | P a g e
Active area, Aa = Ac -2Ad
= (0.87 - 2×0.136) m2
= 0.598 m2
The area available for perforation is reduced by the obstruction caused by structural members (the
support rings and beams etc ) .
Assuming perforated area is 85% of active area.
Perforated area, Ap = 0.5083 m2
Total hole area, Ah = 0.5083 × 0.063 m2
= 0.032 m2
Single hole area = 7.9 × 10-5 m2
𝟎.𝟎𝟕
Number of holes = 𝟕.𝟗 × 𝟏𝟎−𝟓
= 406
99 | P a g e
Chapter-10
Detailed Individual Equipment Sizing
100 | P a g e
10 Detailed Individual Equipment Sizing
Detailed Design of a
Three Phase Separator
Prepared By
Mesbah Ahmad
Student ID: 1202001
101 | P a g e
10.1 Three Phase Separator (Interface control with
weir)
10.1.1. Sizing and Calculation for Horizontal Separator
Streams (cp) (oC)
Gas 192232 3 0.00126 37
light liquid 27615.55 44 0.52 37
heavy liquid 1745.54 62.4 1 37
10.1.2. Determination of Allowable design velocity from vertical terminal velocity

Vertical Terminal Velocity, 𝑉𝑡 = 𝐾𝑠𝑏 √(𝜌𝐿 − 𝜌𝑣 )/𝜌𝑣
And for the three phase separator, P=1100 psia
Therefore, Vt= 1 ft/s
And Allowable design velocity,
Vv=0.75×VT= 0.75 ft/s
10.1.4. Determination of Volumetric Flow Rates

𝑚𝑣
𝑄𝑣 = = 17.8 ft3/s
3600×𝜌𝑣
102 | P a g e
𝑚𝑙𝑙
𝑄𝐿𝐿 = = 10.46 ft3/min
60×𝜌𝑙𝑙
𝑚ℎ𝑙
𝑄𝐻𝐿 = = 0.466 ft3/min
60×𝜌ℎ𝑙
10.1.5. Determination of residence time for heavy and light liquid

The residence time for the heavy phase,
𝜃𝐻𝐿 = 6 𝑚𝑖𝑛
The residence time for the light phase,
𝜃𝐿𝐿 = 6 𝑚𝑖𝑛
10.1.6. Determination of Diameter of Vessel

Assuming L/D Ratio From Table:
0<P≤250 1.5-3.0
250<P≤500 3.0-4.0
P>500 4.0-6.0
For P=1100 psig, let L/D= 4
1
3
16(𝑄𝐿𝐿 𝜃𝐿𝐿 + 𝑄𝐻𝐿 𝜃𝐻𝐿 )
𝐷=( ) = 4.92 𝑓𝑡
𝐿
0.7 × 𝜋 × 𝐷
Thus Diameter should be greater than 2 ft to accommodate the vapor space height
Let D= 5 ft
103 | P a g e
And the Area of cross section for the vessel in radial direction,
AT=19.63 ft2
10.1.7. Determination of vertical vessel cross sectional area on the vapor

Disengagement space
𝐴𝑢𝑛𝑘𝑛𝑜𝑤𝑛 −5
𝑊𝐷 𝑊𝐷 2 𝑊𝐷 3
= {−4.755930 × 10 + 0.174875 ( ) + 5.668973 ( ) − 4.916411 ( )
𝐴𝑇 𝑊 𝑊 𝑊
𝑊𝐷 4 𝑊𝐷 𝑊𝐷 2
− 0.145348 ( ) } ÷ {1 + 3.924091 ( ) − 6.358805 ( )
𝑊 𝑊 𝑊
𝑊𝐷 3 𝑊𝐷 4
+ 4.018448 ( ) − 1.801705 ( ) } … … … … … … … … … … … (1)
𝑊 𝑊
For Vapor Disengagement Height, Hv= 2 ft and replacing the term (WD/W) by Hv/D in above
equation (1),
The vessel cross sectional area on the vapor Disengagement space, Av= 7.33 ft2
10.1.8. The level of low liquid in the light liquid compartment:

HLLL = 0.5D + 7
=0.5×5 + 7
= 9.5 inch
Where, D is in ft and HLLL is in inch.
10.1.9. Determination of vertical vessel cross sectional area on the light liquid
compartment:
𝐴𝑢𝑛𝑘𝑛𝑜𝑤𝑛 𝑊𝐷 𝑊𝐷 2 𝑊𝐷 3
= {−4.755930 × 10−5 + 0.174875 ( ) + 5.668973 ( ) − 4.916411 ( )
− 0.145348 ( ) } ÷ {1 + 3.924091 ( ) − 6.358805 ( )
𝑊 𝑊 𝑊
+ 4.018448 ( ) − 1.801705 ( ) }
𝑊 𝑊
104 | P a g e
For level of low liquid, HLLL= 9.5 inch and replacing the term (WD/W) by HLLL/D in above equation
(1),
The vessel cross sectional area on the light liquid compartment: ALLL= 2 ft2
Weir height, Hw = D - Hv
=5-2 = 3 ft
The minimum length of the light liquid compartment to accommodate holdup/surge,
𝑄𝐿𝐿 𝜃𝐿𝐿+𝑄𝐻𝐿 𝜃𝐻𝐿

L2 =
𝐴𝑇 −𝐴𝑉 −𝐴𝐿𝐿𝐿
=6.36 ft
1
Rounding to the nearest 2 ft, L2= 6.50 ft
𝐻𝑤
Setting the interface at the height ,
2
Height of heavy liquid, HHL = Height of light liquid, HLL = 1.5 ft
10.1.10 Liquid Settling Compartment:

For height of heavy liquid, HHL= 1.5 ft and replacing the term (WD/W) by HHL/D in above equation
(1),
The cross sectional area of the heavy liquid: AHL= 4.954 ft2
The cross sectional area of the light liquid: ALL= AT – AV - AHL
= 19.63 - 7.33 – 4.954
= 7.346 ft2
Settling velocity of heavy liquid out of light liquid phase,
𝜌𝐻 −𝜌𝐿
UHL = 𝐾𝑠 ( )
µ𝐿
105 | P a g e
62.4−44
= 0.163×
0.52
= 5.77 inch/min
Settling velocity of light liquid out of heavy liquid phase,
𝜌𝐻 −𝜌𝐿
ULH = 𝐾𝑠 ( )
µ𝐻
62.4−44
= 0.163×
1
= 3 inch/min
Settling time of heavy liquid out of light liquid phase,
tHL = 12HLL/ UHL
= 3.12 min
Settling time of light liquid out of heavy liquid phase,
tLH = 12HHL/ ULH
= 6 min
Minimum length to facilitate liquid-liquid separation:
𝒕𝑳𝑯 ×𝑸𝑯𝑳 𝒕𝑯𝑳 ×𝑸𝑳𝑳

L1 = max ( , )
𝐴𝐻𝐿 𝐴𝐿𝐿
= 4.44 ft ≈ 4.5 ft
L=L1 + L2
= 4.5 + 6.5 ft
=11 ft
106 | P a g e
Liquid Dropout Time,
𝑣𝑎𝑝𝑜𝑟 𝑑𝑖𝑠𝑒𝑛𝑔𝑎𝑔𝑒𝑚𝑒𝑛𝑡 𝑠𝑝𝑎𝑐𝑒 𝑖𝑛 𝑣𝑒𝑠𝑠𝑒𝑙 𝐻𝑉

∅= = = 2.67 𝑠𝑒𝑐
𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑉𝑉
Actual Vapor Velocity,
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑄𝑉

𝑉𝐴𝑉 = = = 2.43 𝑓𝑡/𝑠
𝐶𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑑𝑖𝑠𝑒𝑛𝑔𝑎𝑔𝑒𝑚𝑒𝑛𝑡 𝑠𝑝𝑎𝑐𝑒 𝐴𝑉
Therefore, the Minimum Length required for separation,
𝐿𝑚𝑖𝑛 = 𝑉𝐴𝑉 × ∅ = 6.50 𝑓𝑡
Since L>Lmin, L will be the acceptable length for the separator.
L=11 ft
And L/D ratio,
𝐿 11 𝑓𝑡
= = 2.2 > 1.5
𝐷 5 𝑓𝑡
So, this length is acceptable.
Determination of Wall Thickness, Surface Area and Approximate Vessel Height

Wall Thickness for Shell,
𝑃𝐷
𝑇ℎ𝑠ℎ𝑒𝑙𝑙 = + 𝜎𝑐
2𝑆𝐸 − 1.2𝑃
Here, design pressure, P= operating pressure + (10% of operating pressure) = 1210 psia
Allowable stress (for SA 516-Grade 70), S=17500 psi
Joint efficiency E is within range 0.6-1.0. Here E is assumed to be 0.7.
Corrosion allowance, 𝜎𝑐 = 0.125 𝑖𝑛𝑐ℎ
Therefore for 5 ft diameter,
107 | P a g e
𝑇ℎ𝑠ℎ𝑒𝑙𝑙 = 0.3875 𝑖𝑛𝑐ℎ
Surface area of shell,
𝐴𝑠ℎ𝑒𝑙𝑙 = 𝜋𝐷𝐿 = 172.79 𝑓𝑡 2
For elliptical head,
𝑃𝐷
𝑇ℎℎ𝑒𝑎𝑑 = + 𝜎𝑐 = 0.3744 𝑖𝑛
2𝑆𝐸 − 0.2𝑃
And surface area,
𝐴ℎ𝑒𝑎𝑑 = 1.09𝐷2 = 27.25 𝑓𝑡 2
Therefore, weight of vessel,
490𝑙𝑏 𝜎
𝑊=( ) ( ) (𝐴𝑠ℎ𝑒𝑙𝑙 + 2𝐴ℎ𝑒𝑎𝑑 )
𝑓𝑡 3 12
Here, Thickness from above calculation,
𝜎 = 0.3875 𝑖𝑛𝑐ℎ
Therefore, weight of vessel approximately, W=3596.39 lb
Normal and High Liquid Levels:

HHLL= 𝐷 − 𝐻𝑉
= 5-2 = 3 ft
ANLL = ALLL + VH/L2
2
=2+ = 2.31 ft2
6.5
108 | P a g e
𝐴𝑢𝑛𝑘𝑛𝑜𝑤𝑛 −5
𝑊𝐷 𝑊𝐷 2 𝑊𝐷 3
= {−4.755930 × 10 + 0.174875 ( ) + 5.668973 ( ) − 4.916411 ( )
− 0.145348 ( ) } ÷ {1 + 3.924091 ( ) − 6.358805 ( )
𝑊 𝑊 𝑊
+ 4.018448 ( ) − 1.801705 ( ) }
𝑊 𝑊
Using this equation for ANLL/AT =2.31/19.63 = 0.118 and replacing the term (WD/W) by HNL/D,
HNL is obtained.
HNL= 0.91 ft
10.1.11. Design of mist eliminator

Here, vertical terminal velocity for outlet vapor phase as calculated initially,
𝑉𝑡 = 1 𝑓𝑡/𝑠
Area of mesh demister,
𝑣𝑎𝑝𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑄𝑣

𝐴𝑀𝐸 = = = 17.8 𝑓𝑡 2
𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑡𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑉𝑇
Therefore, for rectangular mist eliminator,
Let, Length = 6.5 ft
17.8
So, Width= =2.73 ft
6.5
Rounding to nearest value = 2.75 ft
10.1.12. Sizing of Nozzle

Diameter of nozzle,
0.5
4𝑄𝑚𝑖𝑛
𝑑𝑁 = ( )
60𝜋
⁄√𝜌
𝑚
Where, 𝜌𝑚 = 𝜌𝐿 𝜔 + 𝜌𝑉 (1 − 𝜔) = 3.41
109 | P a g e
And,
𝑄𝐿
𝜔= = 0.010
𝑄𝐿 + 𝑄𝑣
𝑄𝑚𝑖𝑛 = 𝑄𝐿 + 𝑄𝑉 = 17.98 𝑓𝑡 3 /𝑠
Therefore, dN = 0.84 ft = 10 inch
Support: Saddle type

𝑃𝑑 1210×5
Longitudinal Stress = = = 46838.7 psi
4𝑡 4×.3875/12
𝑃𝑑𝑚 1210×5.02
Circumferential Stress = = = 94052 psi
2𝑡 2×.3875/12
Allowable Longitudinal Stress limit = ES = 0.7×46838.7 = 32786.6 psi
Allowable Circumferential Stress limit = 0.5S = 0.5×94052 = 47026 psi
𝐴 𝑅2 −𝐻2
1− +
𝑄𝐴 (1− 𝐿 4𝐻 2𝐴𝐿 )
1+
3𝐿
Maximum Longitudinal Stress on each Saddle= 2 = 24.33 psi
𝐾1 𝑅 𝑡𝑠
𝑊
Where, Q= 2 =1798 lb
A= 1.5 ft, 𝐾1 = 0.335 for angle Ɵ=120°
H= 1 ft, L=11 ft, R=2.5 ft, 𝑡𝑠 =0.3875 in
Maximum Circumferential Stress on each saddle =

𝑄
+ 3𝐾62𝑄
4𝑡𝑠(𝑏+1.56√𝑅𝑡𝑠) 2𝑡𝑠
=375.94 psi
Where, b= 4 in, Q=1798 lb

𝐴
𝑡𝑠 =0.3875 in, 𝐾6 = 0.014 𝑓𝑜𝑟 𝑅 = 0.6
Since, Maximum stress in both cases are lower than allowable limit, the design is acceptable.
110 | P a g e
10.1.13. Material of Construction
The Material selected for constructing the three phase separator is Stainless Steel - Grade 316
(UNS S31600). It is an austenitic chromium-nickel stainless steel containing molybdenum. This
addition increases corrosion resistance, improves resistance to pitting chloride ion solutions and
provide increased strength at elevated temperatures. Corrosion resistance is improved,
particularly against sulfuric, hydrochloric, acetic, formic and tartaric acids, acid sulfates and
alkaline chlorides.
Table 10.1.1: Chemical Composition of Stainless Steel - Grade 316 (UNS S31600)
Grade CC Mn Si P SS Cr Mo Ni N
Min - - - 0 - 16.0 2.00 10.0 -

316
Max 0.08 2.0 0.75 0.045 0.03 18.0 3.00 14.0 0.10
Min - - - - - 16.0 2.00 10.0 -

316L
Max 0.03 2.0 0.75 0.045 0.03 18.0 3.00 14.0 0.10
Min 0.04 0.04 0 - - 16.0 2.00 10.0 -

316H
max 0.10 0.10 0.75 0.045 0.03 18.0 3.00 14.0 -
111 | P a g e
Mechanical Properties:
Table 10.1.2. Mechanical properties of 316 grade stainless steels.
Grade Tensile Yield Strength Elong Hardness

Strength 0.2% Proof (% in 50
(MPa) min (MPa) min mm) min Rockwell B Brinell (HB)
(HR B) max max
316 515 205 40 95 217
316L 485 170 40 95 217
316H 515 205 40 95 217
Note: 316H also has a requirement for a grain size of ASTM no. 7 or coarser.
Physical Properties
Table 10.1.3. Typical physical properties for 316 grade stainless steels.
Grade Density Elastic Mean Co-efficient of Thermal Specific Electric

(kg/m3) Modulus Thermal Expansion Conductivity Heat 0- Resistivity
(GPa) (µm/m/°C) (W/m.K) 100°C (nΩ.m)
(J/kg.K)
0- 0- 0- At At
100°C 315°C 538°C 100°C 500°C
316/L/H 8000 193 15.9 16.2 17.5 16.3 21.5 500 740
112 | P a g e
10.1.14 Mechanical Drawing
Figure 10.1.1.: Schematic Diagram of a Three Phase Separator
113 | P a g e
Figure 10.1.2.: Mechanical Drawing of a three phase Separator
114 | P a g e
Figure 10.1.3.: Mesh Separaotr Pad
Figure 10.1.4: Specifications of Mesh
115 | P a g e
Figure 10.1.5.: Saddle type of support and its Specifications
116 | P a g e
10.1.15: P&ID of Three Phase Separator
Figure 10.1.6.: Piping and Instrumentation Diagram
117 | P a g e
10.1.16. Specification Sheet of Three Phase Separator
Identification:
Item : Three Phase Separator Date:
Item no: V-101 Name of Client:
No. required: 1
Function:
Separation of heavy and Light Liuids from Natural Gas
Operation:
Continuous
Natural Gas from Well Head after
Materials handled reducing pressure
Quantity (lb/h) 221593

Temperature ( ) 37
Design data:
Material of Construction: Stainless Steel - Grade 316 (UNS S31600)
Functional Length: 11 ft
Diameter: 5 ft
Maximum allowable vapor velocity (superficial): 0.75 fps
Design Pressure: 1100 psig
Corrosion allowance: 0.125 inch
Gas Data:
Gas Flow Rate: 192232 lb/h
Density of Gas: 3 lb/ft3
Viscosity of Gas: 0.00126 cP
Specific Gravity: 0.048
Liquid Data
Light Liquid Heavy Liquid
Light Liquid Flow Rate: 27615 lb/h Heavy Liquid Flow Rate: 1745 lb/h
Density: 44 lb/ft3 Density: 62.4 lb/ft3
Viscosity: 0.52 cP Viscosity: 1 cP
Specific Gravity: 0.704 Specific Gravity: 1
Supporting: Yes. Saddle type
Controls: To maintain interface, Liquid Level controls are used. A pressure controller is used
to maintain uniform pressure.
Comments and drawings: Location and sizes of inlets and outlets are shown on drawing
118 | P a g e
Detailed Design of
FLASH SEPARATOR
Prepared By
Fahmida Akter
Student ID: 1202044
119 | P a g e
Vapor, F4
4.649×105 moles/hr
x4c1 =0.946 mol/mol

x4c2 =.0360 mol/mol
x4c3=.0044 mol/mol
x4c4=.0066 mol/mol
x4cHC=.0808 mol/mol
x4cH2O=.0046 mol/mol
Feed, F2
5.058×105 moles/hr
T = 40°C
P = 1000 Psi
x2c1 =0.8700 mol/mol
x2c2 =.0330 mol/mol
x2c3=.0040 mol/mol
x2c4=.0066 mol/mol
x2cHC=.0808 mol/mol
x2cH2O=.0046 mol/mol
Liquid (recovery),F5
4.085×104 moles/hr
x5cHC=1.0
120 | P a g e
10.2. 1. Liquid density calculation
The average molecular weight of liquid is

72+86+100+114+128+142+156+170
̅̅̅̅̅
MWL = 8
= 121 g/g-mol
̅L =139.88 mL
Specific volume for light liquid V
Then
MWL
ρL = ̅L
V
121
= 139.88
= 0.865 g/ml
10.2.2. Vapor density calculation:

̅̅̅̅̅̅V
P MW
ρV = RT
The average molecular weight of vapor is

̅̅̅̅̅
MWV = y1MWC1 + y2MWC2 + y3MWC3 + y4MWC4+ y5MWH2O
= 0.946×16 + .036×30+ .0044×44+ .005×18
= 18.242 g/g-mole
𝑃
ρV = RT
g
(68.0272 atm)(18.242 )
g−mol
= ml atm
(82.0575 )(313 K)
mole k
= 0.018 g/ml
121 | P a g e
10.2.3. Kdrum calculation:
Calculation of flow parameter Flv

V = 8.457×54983 moles/hr
=4.649×105 moles/hr
L = 0.743 ×54983 moles/hr

= 4.085×104 moles/hr
̅̅̅̅̅V
WV =V×MW
= 4.649×105 ×18.242 g-moles/hr
= 8.480×106 g/hr
̅̅̅̅̅L
WL= L×MW
=4.085×104×121 moles/hr
=4.942×106 g/hr
𝑊𝐿 𝜌𝑉
Flv =
𝑊𝑉
√𝜌
𝐿
4.942×106 0.0483
= √
8.480×106 0.865
= 0.1377
From, Backwell (1984) fit Watkins' correlation

(ln Flv)2 + D (ln Flv)3 + E (ln Flv)4 ]
Kdrum = 𝑒 [A + B ln Flv + C
A = -1.877478097
B = -0.8145804597
C = -0.1870744085
D = -0.0145228667
E = -0.0010148518
122 | P a g e
From the above equation
2 + D (ln Flv)3 + E (ln Flv)4 ]
Kdrum = 𝑒 [A + B ln Flv + C (ln Flv)
(ln 0.1377)2 + D (ln 0.1377)3 + E (ln0.1377)4 ]
= 𝑒 [A + B ln(0.1377) + C
= 𝑒 (−0.90038)
= 0.40
It agrees with the Kdrum value from Watkin’s (1967) Chart.
10.2.4. Uperm calculation:
Permissible vapor velocity is
ρL −ρV
Uperm = Kdrum√
ρV
0.865−.0483
= 0.406√ .0483
= 1.70 ft/s
10.2.5. Ac calculation:
Cross sectional area is

𝑉× MW𝑉
Ac =
𝑈𝑝𝑒𝑟𝑚 ×3600 ×𝜌𝑉
g−mol g
(4.649 ×105 )×(18.242 )
h g−mol
= ft g ml
(1.70 )(3600)(0.00483 )(28316.85 2 )
s ml ft
= 1.013 ft2
123 | P a g e
10.2.6. Diameter calculation:
4 Ac
D =√ π
4× 1.013
=√
π
= 1.136 ft
For safety, use a flash separator having diameter of 2 ft
10.2.7. Height of a vertical Vessel:

Assumption:
𝐿
=4
𝐷
Then
L = 4×2
= 8 ft
The height required for the Low Liquid Level (LLL):

The level instrument determines the LLL. For mechanical reasons, the nozzle of this instrument
should be at least 150 mm above the bottom tangent line. The level instrument requires an
additional 50 mm. Therefore, the LLL is about 200 mm or 0.2m above the bottom TL of a vessel.
Clearance between the inlet device and the top TL:

Here, The height of the drum above the centre line of the feed nozzle,
hv = 0.9144 + 0.5 × D
= 0.9144+0.5×0.6096 m
=1.2192 m
=3.998 ft
= 47.986 inch
Without safety consideration,
hv = 0.9144 + 0.5 × D
124 | P a g e
= 0.9144+0.5×0.346 m
=1.0875 m
= 42.814 inch
The minimum distance from the center line of the feed nozzle should be 48 inch.
So, safety consideration needs to be included.
Clearance between the High Liquid Level and the inlet nozzle:
The height of the center of the feed line above the maximum level of liquid pool,
hf = 0.3048 + 0.5 × D
=0.3048+0.5×0.6096 m
=.6096 m
=1.991 ft
=23.998 inch
The minimum distance from the center of the feed line above the maximum level of liquid pool
should be 18 inch. Considering safety the minimum distance will be appropriate.
The height required for the liquid hold-up

Depth of the liquid pool, hL = L- hv- hf
= (2.438 – 1.2192 – 0.6096) m
= 0.6092 m
=1.998 ft
Geometry Checking
Hence, the geometry can be checked
ℎ𝑡𝑜𝑡𝑎𝑙 ℎ𝑉+ ℎ𝐹 +ℎ𝐿
=
𝐷 𝐷
125 | P a g e
ℎ𝑉+ ℎ𝐹 +ℎ𝐿 1.2192+0.6096+0.6092
=
𝐷 0.6096
=3.999~ 4.0
The ratio should be between 3 to 5.So, this is in the acceptable range.
10.2.8. Surge Volume
𝜋𝐷2
Surge volume, Vsurge = hL × 4
Where, depth of the liquid pool, hL = L- hv- hf
𝜋𝐷2
So, surge volume, Vsurge = hL × 4
𝜋𝐷2
= (L- hv- hf) × 4
𝜋×.60962
= (2.438 – 1.2192 – 0.6096) × 4
= 0.1778 m3
10.2.9. Demister Sizing for Mist Elimination:
Demisters are limited by a maximum velocity given by
Where,
Kd = demister capacity factor, ft/sec and depends upon the demister type
Vm = maximum velocity, ft/sec
ρL = liquid density, lbm/ft3
ρg = gas density, lbm/ft3
T = operating temperature, °R
126 | P a g e
Qg = gas flow rate, MMscf/D
P = operating pressure, psia
Z = gas compressibility
For vertical vessels, the required demister area (Ad) is given by
𝟎.𝟑𝟐𝟕×𝟓𝟔𝟑.𝟔𝟕×𝟎.𝟖𝟒×𝟕.𝟎𝟗𝟐
=
𝟏.𝟕𝟎×𝟏𝟎𝟎𝟎
=0.645 ft2
So,
t =0.906 ft
= 10.88 inch
127 | P a g e
10.2.10. Selected Wire mesh form
Standard Type Demister Pad STWM-02 is used for this flash separator.
Specifications of standard type demister pad
Item Wire type Wire size Wire width Bulk Specific surface porosity
(mm) tolerance density area
(mm) (kg/m3) (m2/m3)
STWM-01 Flat wire 0.1 × 0.4 +10/-0 150 475 0.981
STWM-02 Round 0.23 320

wire
Note: every 100 mm thick mat has 25 layers wire mesh.
10.2.11. Mesh Pad Installation:
There are two kinds of wire mesh demister pad, which are disk shaped demister pad and bar type
demister pad. According to different using condition, it can be divided into upload type and
download type.
As the opening is considered to be in the below of the demister pad, download type demister pad
is chosen.
Figure 10.2.1: Download type of demister pad.
128 | P a g e
10.2.12. Nozzle Sizing & Inlet Device:
For Feed inlet diameter of nozzle,

0.5
4𝑄𝑚𝑖𝑛
𝑑𝑁 = ( )
60𝜋
⁄√𝜌
𝑚
Where, 𝜌𝑚 = 𝜌𝐿 𝜔 + 𝜌𝑉 (1 − 𝜔)
3847 𝑙𝑏/ℎ𝑟
𝑄𝑣 =3.015 𝑙𝑏/𝑓𝑡 3 ×60 = 21.26 ft3/min
2242 𝑙𝑏/ℎ𝑟
𝑄𝐿 =54 𝑙𝑏/𝑓𝑡 3 ×60 = 0.6919 ft3/min
𝑄𝑚𝑖𝑛 = 𝑄𝐿 + 𝑄𝑉
=21.95 ft3/min
=0.366 ft3/sec
And,
𝑄𝐿
𝜔=
𝑄𝐿 + 𝑄𝑣
0.6919
=
21.95
=0.032
𝜌𝑚 = 𝜌𝐿 𝜔 + 𝜌𝑉 (1 − 𝜔)
=21.350 lb/ft3
0.5
4 × 0.366
𝑑𝑁 = ( )
60𝜋⁄
√21.350
=0.241 ft
=2.90 inch ~ 3 𝑖𝑛𝑐ℎ
129 | P a g e
For vapor outlet nozzle,
0.5
4𝑄𝑣𝑎𝑝
𝑑𝑁 = (60𝜋 )
⁄√𝜌
𝑣
0.5
4 × 1.722
=( )
60𝜋⁄
√3.015
=0.2518 ft
= 3.03 inch
For feed inlet nozzle, 𝜌𝑚 𝑉 2 =21.350×7.342 lbm/ft.sec2

=1185.746 lbm/ft.sec2
For vapor outlet nozzle, 𝜌𝑣 𝑉 2 = 3.015×1.702 lbm/ft.sec2
=3.452 lbm/ft.sec2
For liquid outlet nozzle, 𝜌𝑙 𝑉 2 = 54×.2342 lbm/ft.sec2
=2.979 lbm/ft.sec2
Figure 10.2.2.: Guideline for inlet and outlet nozzle sizing
So, half-open pipe inlet is needed for the feed inlet nozzle.
And, for vapor & liquid outlet nozzle no inlet device is needed.
130 | P a g e
10.2.13. Determination of Wall Thickness:
Wall Thickness for Shell,
𝑃𝐷
𝑇ℎ𝑠ℎ𝑒𝑙𝑙 = + 𝜎𝑐
2𝑆𝐸 − 1.2𝑃
Here,
Design pressure, P= operating pressure + (10% of operating pressure)
= 1000+100 psia
=1100 psia
Allowable stress (for SA 106-B Carbon Steel), S=20000 psi
Joint efficiency E is within range 0.6-1.0.
In this case, ASME Code Standard Efficiency E = 0.74
Corrosion allowance, 𝜎𝑐 = 4 𝑚𝑚 = 0.156 𝑖𝑛𝑐ℎ
Therefore for 2 ft diameter,
Thshell = 0.2338 𝑖𝑛𝑐ℎ
131 | P a g e
Vessel Head:
This flash separator have 2:1 elliptical heads as the diameter of the flash separator 24 inch is less
than 30inch and the vessel heads are welded to the shell of the vessel. However, in some cases
other types of heads are used.
Technical explanations
D0 = external head diameter

Di = internal head diameter
CR = crown radius
KR = knuckle radius
SF = straight flange height
DH = depth of dishing
THi = total internal head height
t = wall thickness
Technical Data for 2:1 elliptical head:
CR = 0.8Do
=1.6 ft
KR = 0.154Do
=0.308 ft
SF = 3t =.0584 ft
DH = 0.255Do – 0.635t
=0.565 ft
132 | P a g e
10.2.14. Skirt Support:
Skirt support is used to support the flash separator
Inner diameter of the vessel = 1.98 ft
Outer diameter of the vessel = 2 ft
Here,
Ws = Shell Weight.
𝜋
Volume of the Shell = × (242 – 23.762) × 8 × 12
4
= 864.246 𝑖𝑛3
= 0.0142 m3
So,
Ws = 0.0142 × 7870 = 112.544 kg.
WT = Weight of Shell during Water Test.
𝜋
Volume of empty space inside the shell = × 𝐷2ℎ
4
= 24.63 𝑓𝑡3
= 0.699 𝑚3
Density of water is 1000 kg/m3.
So the weight of water if the shell is poured with water, WT = 0.699 𝑚3 × 1000 kg/m3
= 699 kg
Volume demister = Surface Area × Height
= 2.617 ft3
= 0.074 m3
Weight = 7870 × 0.074 m3 = 583.645 kg
For elliptical head,
133 | P a g e
𝑃𝐷
Thhead = + 𝜎𝑐
2𝑆𝐸 − 0.2𝑃
= 0.2308 𝑖𝑛
Surface area, Ahead = 1.09𝐷2
= 4.36 𝑓𝑡 2
Therefore, weight of elliptical head
WE= 25.195 kg
Wmax , Wa = (112.544 +699 + 583.645+25.95) kg

Total weight = 1420.38 kg
Wind Load of the Tower, Pw = 0.5ρaCpVa2
Cp = Wind Pressure Co-efficient = 1.05 (For Cylindrical Vessel)
ρa = Air Density = 1.225 kg/m3
Va = Air Velocity = 30 m/s (At the worst situation during Cyclones)
Thus, Pw per unit surface area= 578.8125 Pa = 0.0059 kg/cm2
Outside surface area of the tower = 3.1416 × 2 × 8 𝑓𝑡 2
= 50.2656 𝑓𝑡 2
= 46698 𝑐𝑚2
So, Pw = 46698 × 0.0059 = 275.519 kg
Using the chart from Process Equipment Design by Joshi, 386 pp. it’s been assumed that,
The height of skirt from base, L = 2.5 ft
The height of vessel bottom from base, F = 1.3 ft
134 | P a g e
Thus, the height of the tower from ground, H = 8+1.3 = 9.3 ft
Diameter of the bolt circle, Db = 0.0328 ft
135 | P a g e
10.2.15. Material of Construction
The Material selected for constructing the flash separator is SA 106-B Carbon Steel (ASME standard
and specification). Carbon steel is a steel with carbon content up to 2.1% by weight, no minimum
content is specified or required for chromium, cobalt, molybdenum, nickel, niobium, titanium,
tungsten, vanadium or zirconium, or any other element to be added to obtain a desired alloying
effect. The specified minimum for copper does not exceed 0.40 percent or the maximum content
specified for any of the following elements does not exceed the percentages noted: manganese
1.65, silicon 0.60, copper 0.60. Carbon steel has a relatively low tensile strength, but it is cheap
and easy to form; surface hardness can be increased through carburizing.
Application:
Carbon steel is used for low and medium pressure boiler, high pressure boiler, ship-building, liquid
service, petroleum cracking, chemical fertilizer equipment, Drawing-oil-equipment and structure
purposes.
Packing: Bundles, seaworthy packing.
Table 10.2.1: Chemical Composition of SA-106 B Carbon Steel
Standard Trade Chemical components

mark
C Si Mn P S Cu Ni Mo Cr V
B ≤.30 ≥ .10 0.29~ ≤ .035 ≤ .035 ≤ 0.40 ≤ 0.40 ≤ .15 ≤ .40 ≤ .08
1.06
ASTM
C ≤ .35 ≥ .10 0.29~ ≤ .035 ≤ .035 ≤ 0.40 ≤ 0.40 ≤ .15 ≤ .40 ≤ .08
A106
1.06
136 | P a g e
Table 10.2.2: Mechanical Property of SA-106 B Carbon Steel
Mechanical property
Tensile Yield Strength Elongation

Standard Trade mark
Strength(Mpa) (Mpa) (%)
ASTM B ≥ 415 ≥ 240 ≥ 30

A106
C ≥ 485 ≥ 275 ≥ 30
10.2.16. Design Specification:
DESIGN STANDARDS ASME B16.5
ASME SECTION VIII, DIV, 1(NOTE 1)

DESIGN CODE
WELDING QUALIFICATIONS ASME SECTION IX
137 | P a g e
10.2.17. Detailed Flash Separator
Figure 10.2.3. Mechanical design of flash separator
138 | P a g e
10.2.18. Mechanical Drawing of Flash Separator
Figure 10.2.4: Mechanical Drawing of Flash Separator
139 | P a g e
Figure 10.2.5. Vessel Head Specification and Top View
140 | P a g e
Figure 10.2.6. Mist Eliminator and Mesh Specification
141 | P a g e
10.2.19. P&ID of Flash Separator
Figure 10.2.7 Piping and Instrumentation Diagram of Flash Separator
142 | P a g e
10.2.20. Specification Sheet of Flash Separator
FLASH SEPARATOR
Identification: Item: Flash Separator Date: 09/07/2017
Item No.: F-102
No required : 01
Function: Separation of heavy hydrocarbon as liquid (NGL) from natural gas
Operation: Continuous
Materials Handled Feed Liquid Outlet Vapor Outlet
Quantity (moles/hr) 5.058×105 4.085×104 4.649×105
Pressure (psi) 1400 1000 1000
Composition 87.6% CH4 NGL 97.4% CH4
Design Data:
Materials of Construction: SA-106B Carbon Steel
Temperature: 40oC
Functional Diameter: 2 ft
Functional Height: 8 ft
Maximum permissible velocity: 1.71 ft/sec
Demister Thickness: 0.833 ft
Feed Nozzle: 0.26 ft
Demister pad : Downcomer type
Demister wire mesh : STWM-02
Controls: Pressure is controlled by manipulating feed flowrate, Liquid level is controlled by

an outlet control valve.
Support: Skirt Support
Tolerances: TEMA standards

Comments and drawings: Location and sizes of inlets and outlets are shown on drawing
143 | P a g e
Detailed Design of
GLYCOL ABSROBTION TOWER
Prepared by
SUMAN NANDY
Student ID: 1202006
144 | P a g e
10.3 TEG absorber
Lean TEG Dry Gas
Wet Gas
Rich TEG
Inlet Outlet
Lean TEG Wet gas Dry gas Rich TEG
Temperature 40.00 37.78 39.80 38.00

(oC)
Pressure (Psi) 1000 1000 1000 1000
Flowrate 551.179 5413.468 5406.79 557.677

(kgmole/hr)
145 | P a g e
10.3.1 Tower diameter
At the bottom of the tower:
Vapor: Wet gas
Liquid: Rich TEG
Vapor Rate, FG = 12151.7.5 lbmole/hr
The flooding velocity based on net area for vapor flow is determined from
ρL -ρG
Vm = Kv √
ρG
[Separation Process Engineering, Third Edition, Phillip C. Wankat, Chapter 10: Staged and
Packed Column Design , Eqn : 10.8]
Vm = Maximum allowable superficial vapor velocity, ft/s
Kv = an empirical constant
The factor Kv can be found from

σ 0.2
kv = Csb ( )
20
Where σ is the surface tension in dynes/cm and Csb,f is the capacity factor. Csb,f is a function of
the flow parameter.
146 | P a g e
For 24-inch tray spacing,
log Csb = -0.94506 - 0.70234 (log Flv) -.22618 (log Flv)2
Packed Column Design , Eqn : 10.10.e]
𝑊 𝜌
now the factor Flv can be calculated as, Flv = 𝑊𝐿 √ 𝜌𝑉
𝑉 𝐿
where WL and Wv are the mass flow rates of liquid and vapor.
The operating vapor velocity is determined as Uop = (fraction) × U flood
where the fraction can range from 0.65 to 0.9.
Jones and Mellbom (1982) suggest using a value of 0.75 for the fraction for all cases.
Packed Column Design]
The operating velocity Uop can be related to the molar vapor flow rate.
𝑜𝑝 V
Packed Column Design, Eqn : 10.14]
π 2
4
Where MWv = Molecular weight of vapor.
147 | P a g e
Calculation: At the bottom of the tower:
kgmol kg kg
Flow rate of liquid, 𝑊𝐿 = 557.677 × 150 = 83651hr
hr kmol
kgmol kg kg
Flow rate of vapor, 𝑊𝑣 = 5413.468 × 17.60 = 95300hr
hr kmol
𝑊 𝜌 83651 0.007
𝑉 𝐿 95300 0.426
= 0.1125
= -0.94 - 0.73 (log 0.1125) -0.202 (log 0.1125)2
= -0.40
So, Csb = 0.40
σ 0.2
20
81.8 0.2
σ = 81.8 dyne/cm, now kv =0.40× ( ) So, kv = 0.53
20
ρL -ρG
ρG
0.426 −0.007
= 0.54× √
0.007
= 4.18 ft/s
𝑜𝑝 V
11326×454 𝑔/𝑙𝑏×17.6
= 𝑚𝑙
4.18× 3600×0.007×28316.85𝑓𝑡2
= 25.91 ft2
148 | P a g e
π 2
4
Calculation: At the top of the tower:
kgmol kg kg
Flow rate of liquid, 𝑊𝐿 = 551.18 × 150 = 82677hr
hr kmol
kgmol kg kg
Flow rate of vapor, 𝑊𝑣 = 5406.79 × 17.60 = 95188hr
hr kmol
𝑊𝐿 𝜌
The factor Flv can be found =
𝑊𝑉 √ 𝜌𝑉
𝐿
82677 0.007
= √
95188 0.426
= 0.11
= -0.94 - 0.73 (log 0.11) -0.202 (log 0.11)2
= -0.42
So, Csb = 0.39
σ 0.2
20
81.8 0.2
σ = 81.8 dyne/cm, now kv =0.39× ( )
20
kv = 0.52
ρL -ρG
ρG
0.426 −0.007
= 0.52× √
0.007
= 4.02 ft/s
149 | P a g e
𝑜𝑝 V
11221×454 𝑔/𝑙𝑏×17.6
= 𝑚𝑙
4.02× 3600×0.007×28316.85𝑓𝑡2
= 25.61 ft2
π 2
4
The diameter of the column to be selected is based on the load on the bottom part of the
absorber.
So, the selected diameter of the column = 5.75 ft
Column Height based on top portion

Where,
5.75
H1 = space above the residue = 1 ft + 2 ft
= (1+2.875) ft
= 3.875 ft
= (12× 0.078) + {(12-1) × 2} ft
= 22.936 ft
= 32.82 ft
150 | P a g e
10.3.2 Material of construction
The dehydrated and purified gas-condensate is almost entirely hydrocarbon. These hydrocarbons
are non-corrosive. So any metal can be used to construct the distillation column. Moreover, the
gas streams from the gas fields in Bangladesh are free from any type of corrosive compounds as-
hydrogen sulfide (H2S), sulfur di oxide (SO2) etc.
Since carbon steel is the cheapest, it is used as the material of construction.
For the distillation the following data are available:
Design pressure = 110 % of maximum pressure
= 1.1 × 1000 Psi
= 1100 Psi
[Using the chart from Applied Process Design for Chemical and Petrochemical Plants, Volume
1,
409 pp. design pressure is taken 121% of the operating pressure]
Corrosion allowance = 3 mm= 0.11811 in
Joint efficiency or welded joint for double welded butt joints = 0.85
Shell thickness calculation
The equation used for minimum shell thickness required, exclusive of corrosion allowance is:
𝑃× 𝐼𝐷
t= (Brownell E. L., 1959)
2×𝑆𝐸−0.6 𝑃
Where,
t = minimum shell thickness required exclusive of corrosion allowance, inch
P = design pressure at pound per square inch
E= welded joint efficiency
SE= maximum allowable stress, pounds per square inch
151 | P a g e
ID = inside radius of the shell, inches
In this case,
ASME Code Standard Joint Efficiency, E = 0.95
S= 19800 psi for carbon steel in the temperature range of -29o C to 343o C, which is the desired
range
ID = (12×5.75) inch
1100×5.75 × 12
So, t =
(19800×0.95)−(0.6×1100)
= 3.789 inch
Now, minimum shell thickness = (3.789+0.11811) inch
= 3.90711 inch
So, outer radius = (69+3.907) inch
= 72.907 inch
= 6.075 ft
152 | P a g e
10.3.3 Support system evaluation
[Process Equipment Design by Joshi, 380 pp.]
Skirt support is used to support the absorber column
Material to be used: structural steel
Inner diameter of the vessel = 5.75 ft
Outer diameter of the vessel = 6.075 ft
Maximum Weight of the Tower

Calculation
Here, Ws = Shell Weight.
Weight of attachments = weight of load + weight of loader + weight of overhead vapor line +
weight of pipe insulation
𝜋
Volume of the Shell = × (72.9032 − 692) × 32.82 × 12 = 171300 𝑖𝑛3
4
= 94.05 𝑓𝑡3
= 2.663 m3
So, Ws = 2.663 × 7870 = 20957.81 kg.
Again, WT = Weight of Shell during Water Test.
𝜋
Volume of empty space inside the shell = × 𝐷2ℎ = 800 𝑓𝑡3 = 22.65 𝑚3
4
Density of water is taken 1000 kg/m3.
So the weight of water if the shell is poured with water, WT = 22.65 𝑚3 × 1000 kg/m3
= 22650 kg
Volume of tray =No. of tray × Surface Area × Height
= 1.75 ft3 = 0.05 m3
So, Weight = 7870 × 0.05 m3 = 393.5 kg
So, Wmax , Wa = 22650 kg + 393.5 kg + 20957.58 kg.

Total weight = 44001 kg
153 | P a g e
Using the equation from Process Equipment Design by Joshi, 381 pp. it’s possible to deduce the
maximum total compressive load at the most remote corner of the column from support.
4𝑃𝑤 (𝐻 − 𝐿) 𝑊𝑚𝑎𝑥
𝑃= +
𝑛𝐷𝑏 𝑛
Wind Load of the Tower, Pw = 0.5ρaCpVa2
Cp = Wind Pressure Co-efficient = 1.05 (For Cylindrical Vessel)
ρa = Air Density = 1.225 kg/m3
Va = Air Velocity = 30 m/s (At the worst situation during Cyclones)
Thus, Pw per unit surface area= 578.8125 Pa = 0.0059 kg/cm2
𝜋
Outside surface area of the tower = 4 × 6.0752 × 30.82 = 892.88 𝑓𝑡 2 = 828695 𝑐𝑚2
So, Pw = 828965 × 0.0059 = 4889.3 kg
Using the chart from Process Equipment Design by Joshi, 386 pp. it’s been assumed that,
The height of skirt from base, L = 4 ft = 1.524 m
Diameter of the bolt circle, Db = 0.01 m
Now putting the values it can be obtained that, P = 956978 kg
𝑘𝑔
Circumferential Stress: 𝑓𝑎𝑐 = 2𝑓𝑎𝑝 = 774.8 𝑐𝑚2
𝑘𝑔
=20029.9 𝑐𝑚2
123𝑥
Stress induced due to bending moment= 𝜋 2 2
× (72.903 − 69 ) × 30.82 × 12
4
𝑘𝑔
= 3137.26 x2
𝑐𝑚2
154 | P a g e
𝑘𝑔
Compressive Stress due to weight up to a distance x meter 𝑓𝑑𝑠 = 𝜌𝑠 𝑥 = 25416.98 𝑥 𝑐𝑚2
Combined stress under operating condition on upward side gives:
Ftensile = Fwx +Fa press – Fd x = 3137.26 x2 + 375×104 - 25416.98 X - 20029.9
= 3137.26 x2 - 25416.98 x – 3729970.1
As per the condition stress should be less than the permissible stress of the metal
3137.26 x2 - 25416.98 x + 3729970.1 = 780 × 104 × 0.85
 3137.26 x2 – 25416.98x -2900029.9 = 0
 x2 – 8.1016x – 924.38 = 0
 x = 34.72 m.
which is larger than the height of the column. 34.72 > 32.82 m.
So, skirt support system is selected for the vessel because the permissible height that would be
allowed by the moment generated from the tower is greater than the assumed height.
so the skirt height is 4ft.
155 | P a g e
10.3.4 Feed nozzle calculation
Dry gas
0.5
4𝑄
Diameter of nozzle, 𝑑𝑁 = (60𝜋 𝑚𝑖𝑛 )
⁄√𝜌
𝑚
𝑄𝐿
now, fraction liquid = 𝑄 = 0.15
𝐿 +𝑄𝑣
𝜌𝑚 = 𝜌𝐿 × fraction liquid + 𝜌𝑉 (1 − fraction liquid) = 0.74
Volumetric flow rate of the feed, 𝑄𝑚𝑖𝑛 = 76 𝑓𝑡 3 /𝑠
0.5
4𝑄
⁄√𝜌
𝑚
0.5
4 ×76
= (60𝜋 )
⁄
√0.74
= 1.15 ft
So,15 inch nozzle will be used.
Lean TEG
0.5
4𝑄
⁄√𝜌
𝑚
𝑄𝐿
𝐿 +𝑄𝑣
Volumetric flow rate of the feed, 𝑄𝑚𝑖𝑛 = 0.7175 𝑓𝑡 3 /𝑠
0.5
4𝑄
⁄√𝜌
𝑚
0.5
4× .71715
= (60𝜋 )
⁄
√62.07
= 0.36 ft So, 6 inch nozzle will be used.
156 | P a g e
Wet gas
0.5
4𝑄
⁄√𝜌
𝑚
𝑄𝐿 5 𝑚3/ℎ𝑟
now, fraction liquid = = = 0.16
𝑄𝐿 +𝑄𝑣 32 𝑚3/ℎ𝑟
0.5
4𝑄
⁄√𝜌
𝑚
0.5
4×76.01
= (60𝜋 )
⁄
√0.74
= 1.16 ft
So, 15 inch nozzle will be used.
Rich TEG
0.5
4𝑄
⁄√𝜌
𝑚
𝑄𝐿
𝐿 +𝑄𝑣
0.5
4𝑄
⁄√𝜌
𝑚
0.5
4×0.72
= (60𝜋 )
⁄
√62.07
= 0.36 ft So, 6 inch nozzle will be used
157 | P a g e
10.3.5 Flow pattern selection:
Standard volumetric liquid flow rate = 31.97 m3/hr
= 0.0089 m3/s
= 140.75 gal/min
Initial flow pattern selection can be made using Figure 1, which has been adapted from a similar
ﬁgure given by Huang and Hodson (1958).
Packed Column Design , 10.1.1]
The plate diameter is 5.75m. So, It can be decided that a single pass cross flow should be used.
Figure10.3.2 : Selection guide for sieve trays. Huang and Hodson, Petroleum Refiner (1958).
Figure 10.3.1: Single pass cross flow
pattern
158 | P a g e
10.3.6 Downcomer design:
Downcomer segment is 12.4% of the tower area.
π×dia2
Cross sectional area of tower, At =
4
π×5.752 2
= ft
4
= 29.95 ft2
Downcomer area, Ad = (12.4 % of tower area)
= 0.124 ×29.95 ft2
= 3.2178 ft2
active area = tower cross section – (2 ×downcomer area)
= 29.95 – (2× 3.2178) ft2
= 19.5144 ft2
Figure 10.3.3: Segmental downcomer design chart (LUDWIG ,1964)
159 | P a g e
10.3.7 Weir design:
From Figure for segmental downcomers which is 12.4% of column cross-sectional area, the weir
length id 75% of tower diameter.
75×5.75
Wire length = ft
100
= 4.37 ft
Packed Column Design , 10.1.1]
Downcomer width
To prevent the liquid coming off the bubbling area from splashing against the column wall
minimum downcomer width = 5 in
Figure10.3.4: Envelop type weir downcomer structure
160 | P a g e
10.3.8 Liquid entrainment checking:
The fractional entrainment predicted using Fair’s correlation in terms of the flow
parameter
𝑊 𝜌
Flv = 𝑊𝐿 √ 𝜌𝑉
𝑉 𝐿
Figure 10.3.5: Entrainment correlation from Fair (1963).

75% of flooding gives fractional entrainment, ψ = 0.045
Packed Column Design , 10.5]
ψ × liquid flow rate

So entrainment, e =
1- ψ
0.045 × 1293.05
=
1- 0.045
= 60.92 lb/hr
This amount of entrainment is quite reasonable.
161 | P a g e
10.3.9 Tray Specification:
The Sieve trays are easy to manufacture and are inexpensive. The holes are punched or drilled in
the metal plate. The efficiency is good at design conditions. However, turndown is relatively poor.
For sieve plates, efficiency drops markedly for gas flow rates that are less than about 60% of the
design value. Thus, these trays are not extremely flexible. Since sieve trays are easy to clean, they
are very good in fouling applications and are the normal choice when solids are present. Because
of above characteristics sieve trays were selected.
Packed Column Design , 10.1.1,tray, weir, downcomer]
Tray spacing = 24 inch
Hole diameter= 3/16 inch
Hole area/tower area= 0.2
14 US Std. Gauge SS tray material
Weir height = 5 inch

Thickness of tray = 0.078 inch
162 | P a g e
10.3.10 Hole specification:
Hole diameter, do = 3/16 inch
Pitch size, Pt = 3.8 do = 0.711 in
Tray thickness, Tt = 0.4 do = 0.075 in
No. of holes/sq. inch of plate area = 8
active area = tower cross section – (2 ×downcomer area)
= 29.95 – (2× 3.2178) ft2
= 19.5144 ft2
So, total no. of holes per tray = 8 × 19.5144 ×12×12
= 22500
Tray geometry = Equilateral triangular pitch
Figure 10.3.6 : Equilateral triangular pitch geometry
163 | P a g e
Packed Column Design , 10.5, tray geometry]
10.3.11 Pressure drop:
Figure: Pressure heads on sieve trays
The head of clear liquid in the downcomer, hdc, can be determined from the sum of heads that
must be overcome,
hdc= hp,dry + hgrad+hcrest+hdu

Packed Column Design , Eqn:10.23]
hp,dry calculation:
𝜌 1- 0.22
hp,dry = 0.003× V2 × 𝑊 × 𝜌𝑉 ×
𝜌𝐿 𝑐2
The orifice coefficient, Co, can be determined from the correlation of Hughmark and O’Connell
(1957). This correlation can be fit by the following equation (Kessler and Wankat, 1987).
164 | P a g e
hole dia hole dia 2
Co = 0.85 - { 0.04321×( )} + 0.0017854× ( )
tray thickness tray thickness
hole dia 0.1875

= = 2.4
tray thickness 0.078
0.1875 0.1875 2
So, the orifice coefficient Co = 0.85 - { 0.04321×( )} + 0.0017854× ( )
0.078 0.078
= 0.759
𝑉×𝑀𝑊𝑉
Hole velocity, V =
𝜌𝑉 ×𝐴ℎ𝑜𝑙𝑒 × 3600
11940×17.49
=
0.46×3.9 × 3600
=32 ft/s
Packed Column Design , Eqn: 10.24] the dry tay pressure drop can be calculated,
165 | P a g e
𝜌𝑊 1- 0.22
The dry tray preesure drop, hp,dry = 0.003× V2 × × 𝜌𝑉 ×
𝜌𝐿 𝑐2
55.5 1- 0.22
= 0.003× 322 × 26.56 × 0.46 × 0.7592
= 4.92 inch
hcrest:
𝐿𝑔
hcrest = 0.092×Fw × ( )2
𝑙𝑤𝑒𝑖𝑟
Packed Column Design , Eqn: 10.27]
𝑞
the factor is calculated, = 15.43
𝑙𝑤 2.5
From the figure, the weir correction factor, Fw = 1.08
The liquid flow rate in gallon per minute , LG = 615.91 gpm
𝐿𝑔 615.91
So, h crest= 0.092×Fw × ( 𝑙𝑤𝑒𝑖𝑟 )2 = 0.092 ×1.08× ( 4.37 )2
=2.69 inch
166 | P a g e
hdu
𝐿𝑔
hdu = 0.56 ×( )2
449× 𝐴𝑑𝑜𝑤𝑛
2
Area of the downcomer, Adown = × 4.37 ft2
12
= 0.728 ft2
615.91
So, the preesure drop, hdu = 0.56 ×( )2
449×0.728
=1.98 inch
The total pressure drop = (4.92 + 2.69 + 1.98 + 1) inch
= 10.59 inch
Since this is much less than the 24-inch tray spacing, there should be no problem.
𝑉×𝑀𝑊𝑉
Hole velocity , V =
𝜌𝑉 ×𝐴ℎ𝑜𝑙𝑒 × 3600
11940×17.49
=
0.46×3.9 × 3600
=32 ft/s
167 | P a g e
As the hole vapor velocity is well above the minimum vapor velocity, weeping is not considered
as a problem.
168 | P a g e
Figure 10.3.7: Schematic diagram of TEG absorber
169 | P a g e
Figure 10.3.8 : front view of TEG absorber
170 | P a g e
Figure 10.3.9 :Front view of Head and bottom section
171 | P a g e
Figure 10.3.10 :Front view of Head and bottom section
172 | P a g e
Figure 10.3.11:Front view of Head and bottom section
173 | P a g e
10.3.12 Piping and instrumentation diagram of TEG absorption unit
Figure 10.3.12 : piping and instrumentation diagram
174 | P a g e
Specification sheet
Tower Specification
Service: To absorb water from natural gas using TEG Size
No of unit: 1 Inner Outer
Item number: A1 Diameter:5.75’ Diameter:6.0
75’
Height: 32.82’
No. of Trays :12 Type: Sieve tray
Operating and Mechanical Conditions
Operating pressure: 1000 Operating temp.: 95O F

psig
Design pressure: 1800 psig Design temp.: 100O F
Shell Materials- Carbon Steel skirt– Carbon steel
Metal Lining - None Plastic Lining - None

Code - ASME Insulation -No
Internal Corrosion Allowance – 3 mm maximum
Nozzles
Service No. Size Mark
require number
d
Wet gas feed 1 15 ″ A
Lean TEG feed 1 6″ B
Dry gas exit 1 15 ″ C
Rich TEG exit 1 6″ D
Manhole 3 12 ″ E
Safety valve 1 F
Pressure probe 1 G
Liquid drain nozzle 1 2″ H
Pressure drop
Dry tray 4.92 in
Wet tray 5.67 in
Total 10.59 in
Control system
Service No required
Level control 1
Pressure control 1
Remark
TW point : tray 2 from bottom
Liquid level sampling output point : 2 inches above the liquid
holdup plate
175 | P a g e
Tower internals specification No. of units: 1
Tray type columns Item no.
Contacting device: Sieve tray No. of trays: 12 Type: Fixed, Welded
Tray spacing: 24 inches Manhole: Yes number of manhole :3
Removable from: Top
Holes /in2 plate area: 8
Number of hole: 22500
3
size:16 inch
pitch: 0.711 inch
clearance: 0.5235 inches
Tray thickness: 0.078 inch
Type of flow: Cross
Tray geometry: equilateral triangular pitch
Inlet wires: Yes length of the wire: 4.37 ft
Height over tray floor: 5 inches
Outlet wire: yes length :5 inches

Downcomer: Yes Segmental: Tapered Downcomers orientation:Fixed
Clearance above tray: 5 inches
Materials of construction
Risers: Carbon steel Gaskets: Asbestos Bolts, nuts and washers: Carbon steel
Trays: 14 US Std Gauge SS Gaskets: Asbestos
Bolting: Carbon steel
Tray supports, down comer and seal pans: Carbon steel
Remarks
Trays to be designed by the specifications and layout given above with removable top section access
through tower from above. Sieves to assembled and mounted on trays in fabricator’s shop.
176 | P a g e
Detailed Design of
HEAT EXCHANGER
Prepared By
Tasneem Tabassum
Student ID: 1202009
177 | P a g e
10.4. Glycol/Glycol Heat Exchanger
10.4.1. Stream Flow Rates

Molar flow rate of cold glycol is 553743.864mol/hr
% Xglycol= 0.9885
% Xwater= 0.0115
Volumetric flow rate of 98.85% glycol at 40 °C and 1 atm

PV=nRT
553743.864 ×8.205746×10−5 ×313 m3
V= 1 hr
= 14222.349009 m3/hr
Density=1.125 kg/m3
Mass Flow rate of cold 98.85% glycol

= 14222.34909 m3/hr × 1.125 kg/m3 ×2.2046 lb/kg
= 35273.04885 lb/hr
178 | P a g e
Molar flow rate of hot glycol is 547365.72mol/hr
% Xglycol= 1
% Xwater= 0
Volumetric flow rate of 100% glycol at 196 °C and 1 atm

PV=nRT
547365.72 ×8.205746×10−5 ×469 m3
V= 1 hr
= 21065.34168 m3/hr
Density=1.125 kg/m3
Mass Flow rate of cold 100% glycol

= 21065.34168 m3/hr × 1.125 kg/m3 ×2.2046 lb/kg
= 52245.733 lb/hr
Molecular Weight f TEG = 150.17 g/ mol
Molecular Formula → C6H14O4

For 100% molar TEG, weight percent is 100 wt%
For 98.85% molar TEG,

98.85 mole ×150.17 g/mole= 14844.3045 g TEG
1.15 mole × 18.16 g/mole= 20.884 g H2O
100 mole of 98.85% TEG = 14865.1885 g
14844.3045
Weight Percent=14865.1885 = 99.86 % (wt)
179 | P a g e
End average molar mas is 148.65 g/mole
For Cold Fluid (98.85% Glycol)::

Molar Flow Rate:: 553743.864 mol/hr
Volumetric Flow Rate:: 14222.34909 m3/hr
Mass Flow Rate:: 35273.04885 lb/hr
Weight percent:: 99.86% (wt)
For Hot Fluid (100% Glycol)::

Molar Flow Rate:: 547365.72 mol/hr
Volumetric Flow Rate:: 21065.34168 m3/hr
Mass Flow Rate:: 52245.733 lb/hr
Weight percent:: 100% (wt)
10.4.2. LMTD Calculation
Hot Fluid Cold Fluid

196 °C 128 °C 68 °C
125 °C 40 °C 85 °C
71 °C 88 °C -17 °C
T1-T2 t2-t1 ∆tc-∆th
(T2 −t1 )−(T1 −t2 )

LMTD= (T −t )
ln 2 1
(T1 −t2 )
(125−40)−(196−128)
= (125−40)
ln
(196−128)
= 76.2697 ˚C
180 | P a g e
T1 −T2 196−125 159.8
R= = = =0.8068
t2 −t1 128−40 190.4
t2 −t1 88
S= = = 0.05641
T1 −t1 196−40
By using the values of R and S from “Process Heat Transfer” Tata McGraw Hill edition
1997 by Donald Q. Kern page -828, figure-18 for 1-2 heat exchanger, we have the LMTD
correction factor,
FT =0.821 which is greater than 0.75
LMTD=76.2697 °C
FT = 0.821
Corrected LMTD,∆t= 76.2697 °C × 0.821= 62.617 °C
∆tc=85 °C
∆th = 68 °C
85
∆tc/∆th=68= 1.25
100% TEG is Dominating

From “Process Heat Transfer” Tata McGraw Hill edition 1997 by Donald Q. Kern page -843,
Figure 17
Fc= 0.465
181 | P a g e
For 100% TEG
Tc = (125 + 0.465×71) °C = 158 °C or 316.4 °F
For 98.85% TEG

tc = (40+ 0.465×88) °C = 81 °C or 316.4 °F
And also since,

R = 0.8068
S = 0.5641
1-2 Shell and Tube heat exchanger will be satisfactory
10.4.3. Viscosity of the streams
µ= A×10Bx
Figure 10.4.1:Viscosity of TEG in different temperatures
182 | P a g e
Figure 10.4.2: Viscosity of TEG in different temperatures
µ of 100 wt% TEG at Tc=158 °C/316.4 °F
Ax= 0.12749
Bx= 7.62806×10-3
x= 100/100=1
⸫ µ = 0.12749×10(0.00762806)×1
= 0.1297 cP
µ of 99.86 wt% TEG at Tc=158 °C/316.4 °F
Ax= 0.3168
Bx= 1.562×10-2
x= 99.86/100=0.9986
⸫ µ = 0.12749×10(0.01562)×0.9986
= 3.284 cP
183 | P a g e
Viscosity, µ of 99.86 (wt%) TEG at 177.7 °F/ 81 °C is 0.3284 cP
Viscosity, µ of 100 (wt%) TEG at 316.7 °F/ 158 °C is 0.1297 cP
10.4.4. Thermal conductivity of the streams

k= Ax+BxT
Figure 10.4.3:Thermal conductivity of TEG in different temperature
184 | P a g e
Figure 10.4.4:Thermal conductivity of TEG in different temperatures
k of 99.86 wt% TEG at tc=81 °C/177.7 °F

Ax= 0.1415
Bx= -3.1620×10-4
⸫ k = 0.1415 + (-3.1620×10-4)×81
= 0.1159 Btu (ft)/ hr.(ft2).°F
k of 100 wt% TEG at Tc=158 °C/316.4 °F

Ax= 0.14133
Bx= -3.1667×10-4
⸫ k = 0.14133 + (-3.1620×10-4) ×158

= 0.0913 Btu (ft)/ hr.(ft2).°F
185 | P a g e
Thermal Conductivity, k of 99.86 (wt%) TEG at 177.7 °F/ 81 °C is 0.1159 Btu (ft)/ hr.(ft2).°F
Thermal Conductivity, k of 100 (wt%) TEG at 316.7 °F/ 158 °C is 0.0913 Btu (ft)/ hr.(ft2).°F
10.4.5. Specific Heat
Cp= Ax+BxT+CxT2
Figure 10.4.5:Specific heat of TEG at different temperatures
186 | P a g e
Figure 10.4.6: Specific Heat of TEG in different temperatures
Cp of 99.86 wt% TEG at tc=81 °C/177.7 °F

Ax= 0.486876
Bx= 1.3913×10-3
Cx= 1.314×10-7
⸫ Cp= 0.486876 + (1.3913×10-3) ×81+ (1.314×10-7) ×812

= 0.6427 Btu/ lb.°F
Cp of 100 wt% TEG at Tc=158 °C/316.4 °F
Ax= 0.48614
Bx= 1.3929×10-3
Cx= -5.714×10-8
⸫ Cp = 0.48614 + (1.3929×10-3) ×158+ (-5.714×10-8) ×1582

= 0.7048 Btu/ lb.°F
187 | P a g e
Specific Heat, Cp of 99.86 (wt%) TEG at 177.7 °F/ 81 °C is 0.6427 Btu/ lb.°F
Specific Heat, Cpof 100 (wt%) TEG at 316.7 °F/ 158 °C is 0.7048 Btu/ lb.°F
10.4.6. Specific Gravity
Cp= Ax+BxT+CxT2+ DxT3
Figure 10.4.7:Specific Gravity of TEG in different temperatures
188 | P a g e
Figure 10.4.8:Thermal conductivity of TEG in different temperatures
Sg of 99.86 wt% TEG at tc=81 °C/177.7 °F

Ax= 0.9728
Bx= 4.649×10-3
Cx= 1.037×10-5
Dx= 1.039×10-7
⸫ Sg = 0.9728+ (4.649×10-3) ×81+ (1.037×10-5) ×812 + (1.039×10-7) ×813

177.7°F
= 0.9775 × 60 °F
= 2.895
Sg of 100 wt% TEG at Tc=158 °C/316.4 °F

Ax= 0.9728
Bx= 4.649×10-3
Cx= 1.037×10-5
189 | P a g e
Dx= 1.039×10-7
⸫ Sg = 0.9728+ (4.649×10-3) ×158+ (1.037×10-5) ×1582 + (1.039×10-7) ×1582

316.4°F
= 1.02 × 60 °F
= 5.3788
Specific Gravity, Sg of 99.86 (wt%) TEG at 177.7 °F/ 81 °C is 2.895.

Specific Gravity, Sg of 100 (wt%) TEG at 316.7 °F/ 158 °C is 5.3788.
10.4.7. Heat Balance

=52245.733×0.4986× (196-125)
= 1.85 ×106 Btu/hr

= 35273.049×0.606× (128-40)
= 1.85 ×106 Btu/hr
The stream with lower mass flow rate cold stream (98.85% TEG) is put in the tube side.
1 7
∆P will be large with many tube passes. So a heat exchanger with tubes having 12 in OD and 18
in square pitch with 25% cut baffles 5in apart in 2 passes is considered.
10.4.8. Shell side of the heat exchanger

For medium organics,
UD is 20-60 range
190 | P a g e
Let, UD=50
Q 1850000
Area, A=UD×∆t = 50×62.617 ft2
= 591 ft2= 54.9057 m2
Selection of Tubes
1
Assuming 12 in OD tubes,
Length =16 ft
16 BWG
Wall thickness = 0.065 inch
ID = 1.37 inch
Flow area per tube = 0.3925 inch2
Surface area per linear feet/tube =0.3587 ft2 (outside)
Weight per linear feet = 1.09 steel
aʹʹ = 0.3925 ft2/linft
table-10
Tube arrangement
7
18 inch, square pitch
No. of Tubes
No.of tube×flow area/tube
Flow area, at =
No.of passes
191 | P a g e
table-10
16ʹʹ BWG tubes
2×591
Number of tubes =16ʹ0ʹʹ × 0.3925 = 188.21
1 7
The closest exchanger is with 196 tube in two passes with 12 in OD on 18 in square pitch with a
shell diameter35 in.
Now, corrected co-efficient,

16 × 0.3925 × 196
A= = 615.44 ft2
2
Q 1850000
UD = A×LMTD×Ft = 615.44×62.617 = 48
10.4.9. Hot fluid, 100% TEG in shell side
Inlet=196°C
Outlet=125°C
Tc = 158°C
1 cP= 2.419 lb/ft.hr
Viscosity of 100 (wt%) TEG at 316.4 °F/ 158 °C , µ = 0.1297 cP

= 0.1297×2.419 lb/ft.hr
= 0.313 lb/ft. hr
So,
192 | P a g e
Viscosity, µ = 0.313 lb/ft.hr
Thermal Conductivity, k = 0.0193 Btu(ft)/ hr. ft2.°F
Specific Heat, Cp= 0.7048 Btu/ lb.°F
Mass Flow Rate, W= 52245.733 lb/hr
Since the minimum baffle space area will provide the greatest value of h0, assuming
BD= ID/5 = 35/5 in = 7 in
ID ×CʹB 35 ×0.375 ×5.4
as= = ft2
144Pt 144 ×1.875
= 0.3403 ft2
Mass velocity,
Gs = W/ as
= 52245.733 lb/0.3403 ft2. hr
= 1.54× 105 lb/ ft2. hr
De= 1.48/12 ft = 0.12333 ft

Figure-28
Re= De Gs/µ
= (0.1233×1.54×105)/ 0.313
=60680
193 | P a g e
jH= 150
Figure-28
0.7048×0.313
Cpµ/ k = = 2.416
0.0913
1
1
Cp×µ 3
k( ) =0.0913× (2.416)3 = 0.1225 Btu(ft)/ hr. ft2.°F
k
(Cpµ/k)(1/3) = 1.342
1
k Cp×µ 3
ho= jH×De×( k ) ×Φs
ℎ𝑜 0.1225
= 150× 0.1233
Φs
ℎ𝑜
= 149.027 Btu/hr (ft2)°F
Φs
h0≈ 150 Btu/hr (ft2)°F
10.4.10. Cold fluid, 98.85% TEG in shell side
Inlet=40°C
Outlet= 88°C
tc = 81°C
Viscosity of 99.86 (wt%) TEG at 177.7 °F/ 81 °C , µ = 3.284 cP
194 | P a g e
= 3.284×2.419 lb/ft.hr
= 7.947 lb/ft. hr
So,
Viscosity, µ = 7.947 lb/ft. hr
Thermal Conductivity, k = 0.0193 Btu(ft)/ hr. ft2.°F
Specific Heat, Cp = 0.7048 Btu/ lb.°F
Mass Flow Rate, W= 52245.733 lb/hr
Flow area, atʹ= 1.47 in2
196×1.47
at = ft2
144×2
=1.00042 ft2
Mass velocity,
Gt = W/ at
= 35273.04885 lb/1.00042 ft2. hr
= 35125.522 lb/ ft2. hr
D= 1.37/12 ft = 0.1142ft
table-10
195 | P a g e
Ret= DGt/µ
= (0.1142×35125.522)× 2/ 7.947
=1009.52 ≈ 1010
jH = 25
Figure-24
0.606×7.947
Cpµ/ k = = 40.709
0.1183
1
1
Cp×µ 3
k ( k ) =0.1183× (40.709)3 = 0.4069 Btu(ft)/ hr. ft2.°F
(Cpµ/k)(1/3) = 1.342
1
k Cp×µ 3
hi= jH ×D×( k ) ×Φs
hi 0.40698
= 25× Btu/hr (ft2)°F
Φt 0.1142
hi
= Btu/hr (ft2)°F
Φt
hio hi ID
= ×
Φt Φt OD
0.1142×12
= 89.1× Btu/hr (ft2)°F
1.5
hio≈81.4Btu/hr (ft2)°F
196 | P a g e
10.4.11. Checking Dirt Factor, Rd
Using table -12 of “Process Heat Transfer” Tata McGraw Hill edition 1997 by Donald Q. Kern
appendix,
For Ethylene Glycol Solutions,
Dirt Factor, Rd required=0 .002 ft2-°F-hr/BTU
hi0 h0 150×81.4
Uc= = = 52.765.
hi0 + h0 150+81.4
1 1 1 1
Rd(calculated) = - = − = 0.001881 ft2-°F-hr/BTU <Rdreq
UD UC 40.276 52.765
Therefore, this heat exchanger can be accepted.
10.4.12 Pressure Drop
i) Pressure Drop (shell-side)

For Res= 101634
From “Process Heat Transfer” Tata McGraw Hill edition 1997 by Donald Q. Kern page – 839,
fig – 29,
f = 0.00135
2 x 16
No. of crosses, N +1 = 2L/B = = 4.57
7
Shell ID = 35/12 ft= 2.91678 ft≈ 3 ft

Tc = 158˚C
Sp. Gravity=1.02/ 60°F
Shell-side pressure drop,
fxG2s xDs x(N+1)

∆Ps =
5.22x1010 x De x s x Φs
197 | P a g e
0.00135x(1.54×100000)2 x3x4.57
=
5.22x1010 x0.1233x1
= 6.82 psi < 10 psi

So, the exchanger is accepted from the shell-side pressure drop criteria
ii) Pressure Drop (Tube-side)

For Ret = 919.506
Using figure-29 from “Process Heat Transfer” Tata McGraw Hill edition 1997 by Donald Q.
Kern page – 839
ft =0.0025
Sp. Gravity = 0.9775/60°F
fxG2t xDs x(N+1)

∆Pt =
5.22x1010 x De x s x Φs
0.0025x(35125.522)2 x16x2
=
5.22x1010 x0.1142x 0.0163
= 1.016 psi < 10 psi
iii)Pressure Drop for Bending or Return
For Gt = 35125.522 lb/ft2.hr
Using figure-27from“Process Heat Transfer” Tata McGraw Hill edition 1997 by Donald Q. Kern
appendix,
v2/2g = 1.4797
4nv2 4x2x1.4797
∆PT = = = 4.0890 psi
st x 2g 2.895
198 | P a g e
Total tube side pressure drop, ∆PT = 1.016 + 4.0890 = 4.1544 psi
<10psi
So, the exchanger is accepted.
10.4.13. Mechanical Design
i) Shell thickness
PD = Design pressure = 1.2 × (operating pressure) = 1.2 × 25 psia = 30 psia ≅ 2.109kg/cm2
IDs = shell ID = 35 inch = 68.58 cm
F= maximum allowable stress for stainless stell =950 kg/cm2
J= 0.85
Corrosion allowance = 3 mm
PD x IDs 1.406 x 68.58

ts= = + 3 = 0.0597 + 3 = 3.0597 mm
2Fj+PD 2x950+1.406
So, thickness = 4 mm
ii) Tube-side thickness
Operating temperature = 354 K
Design temperature = 450 K
Operating pressure = 2.109 kg/cm2
Design pressure, Pt = 1.2×30 psia = 2.53105 kg/cm2

ODt = 1 inch = 25.4 mm
Allowable stress = 1000 kg/cm2

J = 1, C = 1 mm
199 | P a g e
Pt x ODt 1.7576x 25.4
ts= +C= + 1= 0.0223 + 1 = 1.027
2Fj+PD 2×1000×1+1.7576
So, thickness = 2 mm
Here, Material = Stainless Steel
Tube type = horizontal U bend tube
iii) Insulation Thickness

Insulation material = Polyester and continuous roving Laminate 70% E-glass, Fiber glass.
hair= 3 W/m2K
Kglass = 0.04 W/mK at 363 k
Specific gravity = 1.9
Let us, about 5% heat is lost in θc = 0.05 Q
= 0.05 x 1850000 Btu/h
= 92500 Btu/h
Outer diameter, OD =ID + Thickness
= (35 + 0.157) in
= 35.157 in
= 2.9298 ft
L (Including allowance) = 16.5 ft
∆T (Temperature diff) = (200-40) = 160 ºC
Area of heat transfer = πDl
= π x 2.9298 x 16.5
= 151.87 ft2
∆T
We know, Q = KA ∆x
200 | P a g e
160
⇒ 92500 = 0.287 x151.87 x
∆x
Critical radius of insulation = 0.075393 ft = 23 mm
So insulation thickness should be 1.96 inches
M)Nozzle diameter and thickness
i) Nozzle diameter
Let, nozzle diameter = DN
D
Then, D < 4
N
DN>6.79 inch
Using table-11 from “Process Heat Transfer” Tata McGraw Hill edition 1997 by Donald Q. Kern
page – 844,
Taking nearest nominal pipe size 8.625 inch and schedule no. 40
Nozzle diameter= 8 inch
ii) Nozzle thickness

PDn 2.109×8×2.54
tN= 2Fj-P =
2×950×0.85−2.109
or, tN= 0.0266 cm=0.266 mm

with corrosion allowance, nozzle thickness= 3mm +0.266 mm= 3.266 mm
201 | P a g e
10.4.14 Head Thickness
pRcW
tH=
2fJ
Here, P= design pressure= 1.7576 kg/cm2
RC= crown radius= 286.65 mm
R1= knuckle radius= 6% of inside diameter= 0.06x286.65 mm
1 Rc
Therefore, w = x(3+√ )
4 R1
2.109x 286.65 x 1.38

So, head thickness = = 0.516 mm
2 x 950 x 0.85
With corrosion allowance, tH= 3+0.431= 3.516 mm
10.4.15 Channel Thickness

pDN
tc =
2 f J−p
Where, P= design pressure= 2.109 kg/cm2
D= shell inside diameter= 88.9 cm
f= permissible stress= 950 kg/cm2
J= joint efficiency= 0.85
2.109 x 88.9
Channel thickness, tc = = 0.1162 cm = 1.162 mm
2x950x0.85−2.109
Corrosion allowance = 3mm
Channel thickness including corrosion allowance=3+ 1.162= 4.162mm
10.4.16. Bundle Diameter

N
Db = Do (K t )1/n1
1
Here, Db= bundle diameter
202 | P a g e
Nt= no. of tubes= 196
1
Do=tube OD= 12inch
7
For 18inch square pitch, 2 pass
Using table 12.4, Coulson et. Al, Chemical Engineering Design, volume-6, page-649
Kt=0.156 and n1= 2.291
Therefore, bundle diameter, Db= 33.79349 inch
10.4.17. Baffles
Baffle shape = segmental
Cut= 25%
Length of tubes= 16 ft
Baffle spacing = 0.5833 ft
No. of baffles = 16/0.5833 = 27.42 = 28 (almost)
10.4.18. Supports
Horizontal shells supported on saddle supports. One end is fixed and other is placed on rollers.
Support: Saddle type
𝑃𝑑 30×2.91678
Longitudinal Stress = = = 1682.7577 psi
4𝑡 4×0.013
𝑃𝑑𝑚 30×2.929
Circumferential Stress = = = 3379.615 psi
2𝑡 2×0.013
Allowable Longitudinal Stress limit = ES = 0.7×46838.7 = 1177.9304 psi
Allowable Circumferential Stress limit = 0.5S = 0.5×94052 = 1689.808 psi
203 | P a g e
A R2 −H2
1− +
QA (1− L 4H 2AL )
1+
3L
Maximum Longitudinal Stress on each Saddle= = 65.7 psi
K1 R2 ts
𝑊
Where, Q= 2
W= 490lb/ft3×ts×(Ashell+2× Ahead)=490×0.013(591+2×9.2733)
=3882.8118 lb
Thus, Q=1941.406 lb
A= 1.5 ft, 𝐾1 = 0.335 for angle Ɵ=120°
H= 1 ft, L=64.499 ft, R=1.4584 ft, 𝑡𝑠 =0.158 in
Maximum Circumferential Stress on saddle =

𝑄
+ 3𝐾62𝑄
4𝑡𝑠(𝑏+1.56√𝑅𝑡𝑠) 2𝑡𝑠
=69.4 psi
Where, b= 4 in, Q=1941.406 lb
𝑡𝑠 =0.3875 in, 𝐾6 = 0.014
Since, Maximum stress in both cases are lower than allowable limit, the design is acceptable.
10.4.19 Material of Construction

A variety of materials are used in the design of shell and tube heat exchangers, including carbon
steel, stainless steel, copper, bronze, brass, titanium and various alloys. Generally, the outer shell
is made of a durable, high strength metal, such as carbon steel or stainless steel. Inner tubes require
an effective combination of durability, corrosion resistance and thermal conductivity. Regular
materials used in their construction are copper, stainless steel, and copper/nickel alloy. Other
metals are used in device fittings, end bonnets and heads. The Material selected for constructing
the shell and tube of the heat exchanger is Stainless Steel - Grade 309S. It is basically the low
carbon version of Stainless Steel - Grade 309. It is a highly alloyed austenitic stainless steel used
204 | P a g e
for its excellent oxidation resistance, high temperature strength and creep resistance. The lower
nickel content of this improves resistance to sulphur attack at high temperatures. It is tough and
ductile, and can be readily fabricated and machined. CS 309 / 309S is used exclusively for its high
temperature oxidation resistance.
Table 10.4.1:Chemical Composition of Stainless Steel - Grade 309/309S
Mechanical Properties
Table 10.4.2.Mechanical properties of 309/309S Grade Stainless Steels.
205 | P a g e
Properties of Stainless Steel- Grade 309S at elevated Temperature
Table 10.4.3.Properties of Stainless Steel- Grade 309S at elevated Temperature
10.4.20. Design Summary

Table: Heat Exchanger Specification
Shell ID 35 inch = 0.889 m
Tube OD 1.5 inch = 0.0381 m
No of Tubes 196
Tube Length 16 ft = 4.8768 m
Pass 2
Baffle Space 0.5833ft = 0.178 m
Baffle Number 28
Pitch 1.875 inch square
BWG 16
h0 3067.50 W/m2K
hi0 851.79W/m2K
Uc 299.631W/m2K
UD 228.711W/m2K
Rd 0.001881
∆Ps 6.82 psi
∆Pt 1.016psi
Shell thickness 4 mm
206 | P a g e
Tube thickness 2 mm
Insulation thickness 23 mm
Nozzle diameter 8 inch
Nozzle thickness 3.266 mm
Head thickness 3.5165 mm
Channel thickness 3.639mm
Bundle diameter 33.7935 inch
207 | P a g e
10.4.21. Mechanical Drawing
Figure 10.4.9: Cross sectional view of 1-2 shell and tube heat exchanger
208 | P a g e
Figure 10.4.10: Dimensional cross section of 1-2 shell and tube heat exchanger
209 | P a g e
Figure 10.4.11: Side view of heat exchanger
Figure 10.2.12: Top view of heat exchanger
210 | P a g e
Figure 10.4.14.: Front view of heat exchanger
211 | P a g e
Figure 10.4.15.: Saddle Support
212 | P a g e
Figure 10.4.16: Segmental transverse baffle
213 | P a g e
Figure 10.4.17: Baffle arrangement with pitch diameter and clearance
214 | P a g e
10.4.22. Piping and Instrumentation Diagram
Figure 10.4.18. Piping and Instrumentation Diagram of heat exchanger
215 | P a g e
10.4.23. Heat Exchanger Specification Sheet
Company:
Service Of Unit: Our Reference:
Item No.: Your Reference:
Date: Rev No.: Job No.:
Size / in Type AEU horizontal Connected in Parallel Series
Surf/unit(eff.) ft2 Shells/unit 1 Surf/shell(eff.) ft 2

PERFORMANCE OF ONE UNIT
Fluid allocation Shell Side Tube Side

Fluid name 98.85% TEG 100% TEG
Fluid quantity, Total lb/h 35273.04885 52245.733
Vapor(In/Out) lb/h
Liquid lb/h
Noncondensable
Temperature (In/Out)ºF 104 262.4 384.8 257
Densitylb/ft3 0.06882 0.0843 0.139 0.0802
Dew / Bubble point ºF -0.202 115.85 187.74 97.94

Specific Gravity 1.18 1.956 3.065 1.919
ViscosityccP 0.61 0.1918 0.1397 0.188
Molecular wt, g/mol 150.17 150.17

Specific Heat BTU/lb.F 0.54 0.667 0.767 0.659
Thermal conductivityBtu (ft)/ hr.(ft2).°F 0.12886 0.101 0.079 0.102

Latent HeatBTU/lb
Pressurepsia 558.4 551.1 29.01 21.76

Velocityft/s
Pressure Drop, allow./calc. psi 10/6.82 10/1.016
Fouling resist. (min) ft2 h F/BTU 0.0002 0.0002
Heat Exchanged LMTD corrected 62.617˚C

Transfer Rate, Service Dirty 48 Clean 52.765 BTU/ft 2 h F
216 | P a g e
CONSTRUCTION OF ONE SHELL Sketch
Shell Side Tube Side
Design/Test Pressure psi 30/25 35/30

Design TemperatureºF 360 450
Number passes per shell 1 2
Corrosion allowance in 0.118 0.118
Connections In / /
Size/rating
in Out / /
Intermediate / /
Tube no OD 1.5in Tks-avg 0.078 in Length 16 ft Pitch 1.875 in
Tube Type Plain Material Tube Pattern U

Stainless Steel
Shell ID 35 in OD 35.158 in Shell cover Removable
Channel or bonnet Channel Cover
Tube sheet Floating
Floating head cover Impingement protection
Baffle Type segmental Cui (%d) 25 spacing: c/c
Baffle long Seal Type Inlet in

Support tube Fixed end Type tie rod
Bypass seal tube sheet joint expand
Expansion joint Tube
RhoV2- inlet nozzle Bundle entrance Bundle exit lb/ft. s 2
Gaskets- shell side Tube side
Floating head
Code requirements TEMA class B Chemical service
Weight/Shell Filled with water Bundle lb
Remarks
217 | P a g e
Chapter-11
Process licensor
218 | P a g e
11. Process Licensor
11.1 Dehydrogenation
Uhde GmbH, Dortmund, Germany
11.2. Drying
Advantica Ltd.
SIIRTEC NIGI
Prosernat IFP Group Technologies And Titan SNC Lavlin
11.3. Effluent Clean Up

SIIRTEC NIGI and HERA LLC
Parsons Energy & Chemicals Group Inc. and UOP LLC.
Prosernat IFP Group Technologies
CB&I, TPA
Shell Global Solutions Global B. V.
Lurgi Oel-Gas-Chemie GmbH
219 | P a g e
11.4. Flue gas treatment
SIIRTEC NIGI, Milan-Italy
Shell Paques: PAques B.V.
UOP LLC, Monsanto Environchem System Inc. and Paques B.V.
11.5 Hydrogen Production

Foster Wheeler
Technip
UOP LLC
CB&I Howe Baker
Haldar Topsoe A/S
Aor Products And Chemicals, Inc.
Air Liqude S.A (MEDAL, L.P.)
11.6 Liquid Training

Merichem Chemicals & Refinery Services LLC
220 | P a g e
11.7 Liquid Training
Flour Enterprises, Inc.
Prosernat IFP Group Technologies
BASF AG
UOP LLC
Randall Gas Technologies, ABB Lumus Global Inc.
Engelhard Corp.
NATCO Group Inc.
Axens
Connelly GPM Inc.
Advantica Ltd.
Jhonson Matthey Catalyst
Linde AG
Alocoa Inc., Alocoa World Chemicals
Jacobs Netherlands B.V.
Engelhard Process Chemicals GmbH
Sulfatreat, A business Unit of M-I, LLC.
Thio Solv LLC
Twister B.V.
221 | P a g e
Chapter-12
List of Vendors
222 | P a g e
12 List of Vendors
Nuevo Pignone
AEG
Borsig
MHI
THI
KTI
Larson
Uhde
Linde
Foster Wheeler AG
CIE_Krebs
Babcock & Wilcox
Uhde
223 | P a g e
Chapter-13
Codes and Standards
224 | P a g e
13 Codes & Standard
13.1. Codes and Standards of Major Equipment
Codes and Standards deal with the minimum acceptable requirements for design, fabrication,
assembling, inspection and test of the materials and equipment. These will produce safe and
reliable equipment and materials. Code encompasses regulatory matters highlighting
safety issues and considerations.
Standards represent agreement to adopt common rule for dealing with routinely recurring items. It
specifies objects like threads, pipe, fitting, valves, flanges, electric motors, control instruments,
test methods etc.
A code or standard always define its scope and areas of application. Certain standards and codes
contain data or specification sheet appropriate for relevant equipment and this is to be filled in by
the purchaser and the vendor as instructed to make it complete.
Different codes and standards developed by different countries or companies are used for different
types of work and project design. Institutions and organizations widely acknowledged are ASME,
ASTM, API, ANSI and TEMA etc.
225 | P a g e
Table 13.1: Organizations issuing codes and standards
Areas of Application Organization issuing codes and standards
a) American Society for testing and

Materials (ASTM)
1. Materials
b) American Society of Mechanical
Engineers (ASME)
2. Pressure vessels ASME
a) ASME
3. Welding materials
b) American Welding Society (AWS)
4. Welders and welding Procedure a) ASME

Qualification b) AWS
a) TEMA
5. Shell and Tube Heat Exchanger
b) American Petroleum Institute (API)
6. Centrifugal Pump API
a) ANSI
7. Pressure piping
b) National Plumbing Code
8. Pressure Relieving Systems API
a) ANSI
9. Steel Structures b) American Institute of Steel
Construction (AISC)
10. Safety OSHA
ASTM: American Society for Testing and Materials
ASME: American Society of Mechanical Engineers
API: American Petroleum Institute
TEMA: Tubular Exchanger Manufacturers Association
ANSI: American National Standard Institute
226 | P a g e
AWS: American Welding Society
OSHA: Occupational Safety and Health Administration
NFPA: National Fire Protection Association
ACI: American Concrete Institute
227 | P a g e
Chapter-14
List of Equipment
228 | P a g e
14 List of Equipment
TABLE 14.1: LIST OF MAJOR EQUIPMENT AND VENDORS
Serial
List of major equipment Quantity
number
1 3 Phase Separator 2
2 Flash Separator 2
3 Pipeline pigging dust separator 1
4 Steam Heater 1
5 Mixer 2
6 Centrifugal Pump 2
7 Surge Drum 2
8 Absorption column 2
9 De-ethanizer 1
10 Heat exchanger 2
229 | P a g e
Chapter 15
Plot Plan
230 | P a g e
15 Plot Plan
Figure15.1: Plot Plan
231 | P a g e
Chapter 16
Economic Analysis
232 | P a g e
16. Economic Analysis
16.1 Purchased equipment cost

Unit No. Description Cost in US dollar
1 Pipeline pigging dust separator
45000
2 Steam heater
156000
3 Three phase separator (inlet)
180000
4 Three phase separator (sales unit)
180000
5 Flash separator (sales unit)
30000
6 Flash separator
24000
7 Mixer (glycol inlet)
87000
8 Mixer
87000
9 Centrifugal Pump (glycol unit)
13110
10 Centrifugal Pump (amine unit)
14700
11 Heat exchanger (glycol unit)
82800
12 Heat exchanger (amine unit)
81000
13 Surge drum (Glycol unit)
127800
14 Surge drum (Amine unit)
127800
15 Glycol absorber
630000
16 Amine absorber
285000
17 Reboiler (Glycol absorber)
120000
18 Reboiler (Amine absorber)
138000
19 De-ethanizer
120000
20 Condenser (De-ethanizer)
105000
233 | P a g e
16.2 Total capital investment
Percent of delivered Cost in US dollar

equipment Cost
Direct Cost
Purchased equipment cost 100
2184750
Purchased equipment installation Cost 39
1026834
Instrumentation and Control 26
786510
Piping 31
1485630
Electrical system 10
240321
Building 29
393255
Yard improvement 12
218475
Service facility 55
1529325
Total direct plant cost 302
7865289
Land 5
109237
Indirect Cost
Engineering and Supervision 32
720966
Construction expense 34
895749
Legal expense 4
87390
Contractors fee 19
480645
Contingency 37
961290
Total indirect plant cost 126
3146040
Fixed capital investment 420
11011329
Working capital 75
1944429
Total capital investment 503
16101795
So, Total Capital Investment, TCI = 16.2 million USD = 1296 million BDT
234 | P a g e
Determination of manufacturing cost based on total product cost
Manufacturing cost includes:
A. Direct Production cost

B. Fixed Charges
C. Plant Overhead costs
The direct production cost includes:
I. Cost of Raw Materials

II. Operating Labor
III. Direct supervisory and Clerical labor
IV. Utilities
V. Maintenance and repairs
VI. Operating supplies
VII. Laboratory Charges
VIII. Patents and Royalties
Let, the total product cost is C.
From Peters, Timmerhaus and West’s ‘Plant Design and Economics for Chemical Engineers’,
Direct Production cost is assumed to be within 66% of total product cost.
Let, direct fixed production cost is 59.28% of total product cost.
Fixed Charges include: Depreciation, Local Taxes, Insurance, Rent and Financing.
Let, fixed charges are 15% of total product cost.
The Plant overhead cost includes general plant upkeep and overhead, payroll overhead, packaging,
medical services, safety and protection, storage facilities etc.
Let, the plant overhead cost is 5% of total product cost.
General expenses include: Administrative cost, distribution and marketing cost, and research and
development cost.
235 | P a g e
Let, administrative cost is 4% of total product cost, Distribution and selling cost be 10% of total
product cost, and research and development be 5% of total product cost. Utility
Table 2: Table for utility cost-
Equipment Operating Cost per Year

Reboiler 180861
Reboiler 960700
Pump 14770
Total utility cost = $ 1156331

Maintenance and repair cost (5% of Fixed Capital) = $550563
Operating Supplies (10% of Maintenance and repair) = $55056
Laboratory Charges (15% of Operating Supplies) = $447650

Total Direct product Cost = $ 2209600
The Financing of plant is assumed to be 10% of Total capital investment= $ 1620000
Now, Manufacturing cost= fixed charges + Plant overhead cost + Direct production cost
= $ 2209600+ $ 1620000+ $ 101830686
= $ 102420286/ year
Equating for total production cost,
Total Production cost= $ 102420286/ year
Selling Price of Natural Gas
Based on the price $0.11375/cubic meter natural gas, for 365 days of production annually,
Sales gas = 5.254×106 moles/hr
= 2825200 m3/day
Selling price= $321343.75 /day
Thus, the amount of return annually is $3622904/yr
236 | P a g e
16.3 Rate of Return
Assuming Tax=25%
Net profit after paying al taxes=$ 2898323
Thus
Net Profit
Percent rate of return = × 100%
Total capital investment
2898323
= × 100%
16101795
=17.98%
16.4 Feasibility Analysis

16.4.1 IRR Method
Let, MARR = 15%

PW = -Total capital investment + Annual income (P/A,i%,25) + Salvage value(P/F,i%,25)-
Or, 0 = -162000000 + 2898323 (P/A,i%,25) + 720967 (P/F,i%,25)
(1+𝑖)25 −1
Or, 0 = -162000000 + 2898323 { } + 720967 (1+i)-25
𝑖(1+𝑖)25
By trial and error, i = 16.98 %

Since i is greater than MARR, so the project is acceptable.
16.4.2 ERR Method
Let, MARR = 15%

PW = -Total capital investment
= 162000000
Total capital investment (F/P,i%,20) = Salvage value + Annual revenue (F/A,15%,20)
Or, 16200000 (F/P,i%,20) = 720967 + 29760000 (F/A,12%,20)
237 | P a g e
1.1220 −1
Or, 16200000 (1+i)20 = 720967+ 29760000 ( )
0.12
Or, i = 15.67%
Since, i is greater than MARR, so project is acceptable.
16.4.3 Payback period

Without Interest Method
FCI = $ 11011329
Net cash flow=$ 2898323
𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

 Payout Period =
𝑁𝑒𝑡 𝑐𝑎𝑠ℎ 𝐹𝑙𝑜𝑤
11011329
=
28983235
= 3.79years = 4 years
238 | P a g e
Chapter 17
Conclusion
239 | P a g e
17.Conclusion
The project topic was to design the design a natural gas processing plant with major
equipment like three phase separator, flash separator, heat exchanger, amine
sweetening unit, glycol dehydration unit etc. The main objective of this project was
to process maximum amount of natural gas. These products have greater demand and
more economic value in the as domestic and industrial fuel. The design project proved
to be profitable. The projected units produces natural gas with 92.22% methane, 4.9%
ethane and LPG (72.1% propane, 27.9% butane) with trace amount of sour gas.
 The total capital investment for designing this plant is 105.6 million US $ while annual
cash flow is 16.2 million US$. Project viability test- IRR = 16.98 % and ERR = 15.67%
 In this design project, the major equipment designed are three-phase separator, flash
separator, glycol dehydration unit, amine sweetening unit, stripper and debutanizer
column. The design results are satisfactory. Each major equipment is appropriately sized
and detailed mechanical design was also done.
 In this design project, Simulation results, Process Block Diagram (PBD), Process Flow
Diagram (PFD), Piping and Instrumentation Diagram (P&ID) for major equipment, Plot
plant have also been prepared and attached as an important part of plant design.
240 | P a g e
Reference
241 | P a g e
Reference
 Peters, M.S. & Timmerhaus, K.D., “Plant Design and Economics for Chemical
Engineering”, 5th Edition
 Henry Z kister.,David R Gill., et al,: Distillation Design
 McCabe, Warren E. : Unit Operations of chemical Engineering, 4th Edition.,McGrawhill

Book Company, 1999.
 Subramanyan, S., et al.: Heat and Mass Transfer Data Book, 4th ed.,Wiley eastern Limited,
September 1991
 Sullivan,William G.,et al.: Economy, 11th ed., PearsonEducation,2000
 Ludwig, Earnest E., “Applied Process Design for Chemical Engineering & Petrochemical
Plants”, volume 2, 3rd Edition
 Perry, Robert H., et al,: Chemical Engineering Handbook, 7th ED., Mcgrawhill-Book
Company-1997
 Foust et. al., “Principles of Unit Operations”, 2nd Edition
 Donald Q Kern, “Process Heat Transfer”, Int. Edition 1997
 M V Joshi, “Process Equipment Design”
 F L Evans, “Equipment Design Handbook”
 www.alibaba.com (accessed on September 7, 2017)
 R H Perry, “Perry’s Chemical Engineering Handbook”
242 | P a g e
Appendix
243 | P a g e
Appendix
Heat exchanger
The most important commercial application of radiant heat transfer calculation is encountered in
the design of petroleum refinery heat exchanger. Since the art of the construction of the heat
exchanger developed for the theory, empirical methods were evolved for the calculation of radiant
heat transfer in such heat exchanger. Various contributions to the literature on general and specific
radiant heat transfer problems, especially those of H.C, had made possible the more fundamental
approach to heat exchanger design. Several theoretical methods for radiant section heat transfer
calculation are now available. The precautions, which must be taken into account to avoid the
deposition problem in heat exchanger, have a pronounced effect on the actual design of refinery
heat exchanger. Heat exchanger is very important in terms of reducing or increasing heat of fluid.
Petroleum Refinery heat exchanger
Heat exchangers also are widely employed in various heating, treating and-vapor services.
Refinery heat exchanger of various types are required for handling liquid at high-temperature and
high-pressure Oil or gas fuels or combination of them are used exclusively in the shell and tube
side of heat exchanger. Refinery heat exchangers are usually containing both radiant and
convection heat transfer surfaces. High viscosity liquid or vapors are usually given in the tube side
as fouling problem can occur and low viscosity fluids are given in the shell side as if fouling occurs
then it is easy to clean tube side then shell side.
Types of Furnaces
1. Types of contact
a. Direct contact
b. Indirect contact
2. Type of Construction
a) Tubular (double pipe, shell & tube)
b) Plate
c) Extended surface
244 | P a g e
d) Regenerative
3. Type of flow arrangement
a) Single pass
b) Multi-pass
4. Type of surface compactness
a) Noncompact (area< 700 m2/m3)
b) Compact (area< 700 m2/m3)
Indirect contact heat exchangers are mostly used in the industry. Double passes heat exchangers
are mostly preferable in petroleum refinery.
Double pipe heat exchanger
 Fluid flows through tube/pipe
 Outer one acts like a Jacket of the inner one
 Hairpin construction mostly important to make practical one where one hairpin is
connected with other one.
 Opposite ends are joint by U-bends
 Bending tube thickness is comparatively larger
 For low heat duty application
245 | P a g e
Figure: Double pipe heat exchanger
Various component of shell and tube heat exchanger

Shell
 Enclosure of tube bundle and allow the passage shell side fluid
 For big size shell metal plate is rolled and welded in axial direction
 If the diameter is less than 60 cm, a pipe with suitable thickness can be used
 Material of construction: carbon-steel is very common which mainly depends on

operating conditions, i.e. temperature, pressure and type of fluid
Tube
 Tube wall separate the two fluids and acts as surface for heat transfer
 Fluid following through the tube is called as tube side fluid
 Material of construction: carbon-steel, copper, brass or stainless steel which mainly

depends on operating conditions, i.e. temperature, pressure and type of fluid
Tube size: ¾”, 1”, 1¼” and 1½”
Narrower tubes are used for smaller heat exchanger and working with clean fluid
Tube Thickness
BWG –Berminghamwire gauge It depends on
i) operating pressure,
ii) corrosiveness of fluid to be handled and
iii) thinning of tube wall during bending
Tube Length: 8’, 16’, 20’ and 24’
Tube arrangement:
1. Square pitch
2. Triangular pitch
C = Clearance
P = Pitch
246 | P a g e
Pass partition plate:
1.Tube side plate
2.Shell side plate
No of passes indicates the no of times the shell or tube side fluid traverses the length of the heat
exchanger.
1:2 1:4 2:4 2:6
M:N SHE; where M=no of shell side pass and N= no of tube side pass
Increase of the number of passes reduce the flow area for the fluid and increase
1.Turbulence
2.Flow rate
3.Heat transfer coefficient
4.Pressure drop
Baffles
A metal plate in the form of the segment of a circle with necessary holes to accommodate tubes.
Baffles also have layout like tube sheet. There should be some segmental cut.
Segmental baffles:
247 | P a g e
a) Create huge turbulence
b) Increase heat transfer coefficient
c) Act as a support
Baffles cut:
a) Vertical cut
b) Horizontal cut
Cut up to 50 percent, usually 20 percent cut baffles are used. There has grooves in the baffles.
Groove in the baffles is helpful for draining out all the liquid present in the shell side.
Licensed Gas Processing Units
Taking the typical example of the natural gas processing set-up designed to produce pipeline gas
from a sour gas feed (as shown in Figure 1), there are four main blocks, which usually means four
licensors: • Gas Sweetening Unit (GSU) • Gas Dehydration Unit (GDU) • Mercaptans Removal
Unit (MRU) • Sulfur Recovery Unit (SRU) + Tail Gas Treating Unit (TGTU)
Up to four license contracts are need for each of the above mentioned steps including the
guarantees and well defined border limits for the different interfaces. The large number of package
vendors may give good reasons why the product specifications are not met. If one specification is
not met in one unit, the other licensors cannot necessarily meet their liabilities. The other aspect is
unit optimization. As each licensor is responsible for his part, he takes a certain security margin.
The overall security margin is higher than the margin taking into account the concept as a whole
with the strength and weaknesses of every single unit.
248 | P a g e
This section discusses several integration aspects of the main gas treating processes involved. The
technical options considered may be a combination of both open art technology and licensed
processes.
249 | P a g e

Design of Akib Vai

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Design of Akib Vai

Uploaded by

Copyright:

Available Formats

Table of Contents

List of Tables ................................................................................................................................................. 6

Table 10.1.2. Mechanical properties of 316 grade 112

Table 10.1.3. Typical physical properties for 316 112

Table 10.2.2: Mechanical Property of SA-106 B 205

Table 13.1: Organizations issuing codes and 206

Figure 6.1 Process Flow Diagram of 41

Figure 10.1.2 .: Mechanical Drawing of 1131

Figure 10.1.3 Mesh separaotr pad 114

Figure 10.1.4 : Specifications of Mesh 115

Figure 10.1.5 .: Saddle type of support `115

Figure 10.1.6. Piping and 116

Figure 10.2.2. Guideline for inlet and 130

Figure 10.2.3 Mechanical design of 138

Figure 10.2.4 Mechanical Drawing of 139

Figure 10.2.5 . Vessel Head 140

Figure 10.2.6 . Mist Eliminator and 141

Figure 10.2.7 Piping and 142

Figure 10.3.1 Single pass cross flow 158

Figure 10.3.3 Segmental downcomer 159

Figure10.3.4 Envelop type weir 160

Figure 10.3.5 Entrainment correlation 161

Figure 10.3.6 : Equilateral triangular 163

Figure 10.3.7 Pressure heads on sieve 169

Figure 10.3.7 Schematic diagram of 170

Figure 10.3.8 Front view of TEG 171

Figure 10.3.10 Front view of Head and 173

Figure 10.3.11 Front view of Head and 173

Figure 10.3.12 : piping and 174

Figure 10.4.1 Viscosity of TEG in 182

Figure 10.4.2: Viscosity of TEG in 183

Figure 10.4.3 Thermal conductivity of 184

Figure 10.4.4 Thermal conductivity of 185

Figure 10.4.6 Specific Heat of TEG in 187

Figure 10.4.7 Specific Gravity of TEG 188

Figure 10.4.8 Thermal conductivity of 189

Figure 10.4.9 Cross sectional view of 1- 208

Figure 10.4.10 Dimensional cross section 209

Figure 10.4.11 Side view of heat 210

Figure 10.4.12 Top view of heat 210

Figure 10.4.15 saddle support 212

Figure 10.4.16 Segmental transverse 213

Figure 10.4.17 Baffle arrangement with 214

Figure 10.4.18 Piping and 215

All particulates must be removed.

Definition of the project

2.1. Definition of Project

2.2. Composition of Natural Gas

Higher Hydrocarbon (0.71%)

LPG (72.1% propane, 27.9% butane)

Selection of the process

3.3 Water Removal or Dehydration

-need considerable recharging

Solid Desiccant Dehydration

2. High Dew Point

3.4 Glycol Dehydration

3. Triethylene glycol (TEG); Reconcentrate at 340–400◦F for high purity. At contactor

TEG is regenerated more easily to a concentration of 98–99% in an atmospheric stripper because

Capital and operating costs are lower

Method Variation Positive features Negative features Major Applications

Liquid(Glycol) none 1.relatively 1. Limited dew-point 1. Gathering systems,

Water can be removed by absorption or adsorption process. In dehydration by absorption, a liquid

High affinity for water, and a low affinity for hydrocarbons.