Area 3 Group C

Department of Chemical Engineering
CHE 4036Z – Chemical Engineering Design
Area 3 Design
August 2023
GROUP C
Area 3 Specialist
Word Count: 16 000
Total Page Count: 65

CHE4036Z Area 3 Report Group C
A3 Table of Contents
A3 Table of Contents .............................................................................................. 3-i
List of Tables ........................................................................................................ 3-iii
Table of Figures .................................................................................................... 3-iv
List of Abbreviations ..................................................... Error! Bookmark not defined.
1.1. Design Problem Definition ................................................................................ 3-1

1.1.1. Design Problem Definition ................................................ Error! Bookmark not defined.
1.1.2. Objectives of the Report ........................................................................................... 3-2
1.1.3. Scope, Limitations, and Key Issues ........................................................................ 3-2
1.2. Process Development ........................................................................................ 3-3

1.2.1. Literature Review ....................................................................................................... 3-3
1.2.2. Base Case Development ............................................................................................. 3-7
1.2.3. Identification of Equipment for Design ................................................................... 3-9
1.3. Detailed Design ................................................................................................ 3-10

1.3.1. Explanation of How the Model Works and Software Used .................................. 3- 11
1.3.2. Assumptions and Justifications for the Base Case design ................................ 3-12
1.3.3. Thermodynamic model used ................................................................................... 3-13
1.4. Sensitivity Analysis and Optimisation of Design Model................................ 3-15

1.4.1. Sensitivity Analysis ........................................................... Error! Bookmark not defined.
1.4.2. Optimisation of Equipment Size/Configuration and Operating Conditions ................ 3-19
1.4.3. Summary of Base and Optimised Case ................................................................ 3-22
1.4.4. Implications of sensitivity analysis on control .............. Error! Bookmark not defined.
1.5. Area 3 Overview .............................................................................................. 3-24

1.5.1. Process Description ................................................................................................. 3-24
1.5.2. Process Flow Diagram ............................................................................................. 3-25
1.5.3. Stream Tables ........................................................................................................... 3-26
1.5.4. Mass Balance ........................................................................................................... 3-28
4.5.4.1. Assumptions for Mass Balance .......................................................................... 3-28
1.5.5. Plan for Area Interfaces .......................................................................................... 3-28
1.6. Equipment Specifications (10 marks ) ........................................................... 3-29

1.6.1. Drawing ...................................................................................................................... 3-29
1.6.2. Data Sheet for the deethanizer ......................................... Error! Bookmark not defined.
1.6.3. Equipment List ................................................................... Error! Bookmark not defined.
1.7. Information Provided to Other Members ........................................................ 3-32
A-3-i
1.7.1. Process Control ................................................................. Error! Bookmark not defined.

4.7.1.1. Process Control Diagram ........................................ Error! Bookmark not defined.
4.7.1.2. Control Strategy .................................................................................................. 3-37
4.7.1.3. Start-up and Shut Down Strategy ....................................................................... 3-40
4.7.1.4. Individual streams/unit controls (each have own heading)..... Error! Bookmark not
defined.
1.7.2. Safety and Environment ................................................... Error! Bookmark not defined.
4.7.2.1. Hazard Inventory ..................................................... Error! Bookmark not defined.
4.7.2.2. Unwanted event(s).............................................................................................. 3-44
1.7.3. Financial Assessment .............................................................................................. 3-46
4.7.2.3. Capital expenditure on equipment’s ................................................................... 3-46
4.7.2.4. Operating expenditure (utilities/catalysts/anti-scalants/Acid to adjust pH etc.) Error!
Bookmark not defined.
1.7.4. Utilities and Heat Integration ............................................ Error! Bookmark not defined.
1.8. Conclusion ....................................................................................................... 3-53
1.9. References ........................................................................................................ 3-55
1.10. Appendices ..................................................................................................... 3-a

1.10.1. Appendix A .................................................................................................................. 3-a
1.10.2. Appendix B .................................................................................................................. 3-a
1.10.3. Appendix C ......................................................................... Error! Bookmark not defined.
1.10.4. Appendix D .................................................................................................................. 3-b
1.10.5. Appendix E .................................................................................................................. 3-h
A-3-ii
List of Tables
Table 1: Specifications to be met ........................................................................................ 3-7

Table 2: Battery limits specified acceptable conditions ....................................................... 3-8
Table 3: Summary of base case conditions ........................................................................ 3-9
Table 4: Required units and how they are modelled ........................................................... 3-9
Table 5: Area 3 SSE analysis results per column and entire system ................................ 3-10
Table 6: The area 3 SSE Analysis results per column ....... 3-1Error! Bookmark not defined.
Table 7: Comparison of base case and optimised case ....... 3-Error! Bookmark not defined.
Table 8:Stream tables for mass and mass compostion in area 33-Error! Bookmark not
defined.
Table 9: Stream tables for mole flow and mole composition 3-Error! Bookmark not defined.
Table 10: Overal mass balance for area 3 ........................... 3-Error! Bookmark not defined.
Table 11: Inter-area consistency check up .......................... 3-Error! Bookmark not defined.
Table 12: Specification sheet of deethanizer column including hydraulics3-Error! Bookmark
not defined.
Table 13: Equipment list part 1 ............................................ 3-Error! Bookmark not defined.
Table 14: Equipment listing part 2 ..................................... 3-4Error! Bookmark not defined.
Table 15: The detailed hazop inventory for area 3 ............. 3-4Error! Bookmark not defined.
Table 16: Chemical inventory and hazard form continued . 3-4Error! Bookmark not defined.
Table 17: Indirect carbon dioxide emissions from electricity production3-4Error! Bookmark
not defined.
Table 18: Indirect emissions from steam generation .......... 3-4Error! Bookmark not defined.
Table 19: Capex breakdown or coolers and heaters .......... 3-4Error! Bookmark not defined.
Table 20 The electricity breakdown cost for area 3........................................................... 3-52
Table 21:Total expenditure estimate................................................................................. 3-54
Table 22: Stream tables for mole flow and mole composition ........................................... 3-56
Table 23: Pinch analysis data sent to a specialist engineer .............................................. 3-57
Table 24 Inter-area consistency check up ........................................................................ 3-60
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Table of Figures
Figure 1: Deviation of thermodyamic model chosen from experimenta dataError! Bookmark
not defined.
Figure 2: The temperature changes in Angola across sessionsError! Bookmark not defined.
Figure 3: Temperature influence on the recovery of key componentsError! Bookmark not
defined.
Figure 4: Pressure influence on reboiler duty and recoveries . Error! Bookmark not defined.
Figure 5: Cost optimization on reflux ratio............................... Error! Bookmark not defined.
Figure 6: Feedstage with recovery for the deethanizer ........... Error! Bookmark not defined.
Figure 7: Feedstage with the reboiler duty .............................. Error! Bookmark not defined.
Figure 8: The process flow diagram........................................ Error! Bookmark not defined.
Figure 9: Mechanical drawing of the column........................... Error! Bookmark not defined.
Figure 10: Process Control Diagram sheet 1 .......................... Error! Bookmark not defined.
Figure 11: Process Control Diagram flowsheet 2 .................... Error! Bookmark not defined.
Figure 12: Prcoess control diagram flowsheet 3 ..................... Error! Bookmark not defined.
Figure 13: Plant Layout Diagram ............................................ Error! Bookmark not defined.
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Nomenclature
Item Definition
V’ Boil up rate
PEL Permissible Exposure limit
LD50 Lethal dose
UFL Upper flammability limit
Tsat Saturation temperature
L’ Liquid flowrate exiting the column’s bottoms
QR Reboiler duty
QC Condenser duty
XD Component mole based fraction in distillate
XB Mole based fraction of component in bottoms of column
Αij Relative volatility between certain components I and j
Ki K value for a certain component I involved
TWA Time-weighted average at 8 hours
LFL Lower flammability limit
Nmin Minimum number of stages
Rr Reflux ratio
Rb Boil up ratio
Hf Heat enthaphly associated with feed flow to column
hD Heat enthaphly associated with distillate flowing out the column
hB Heat based energy associated with bottoms of column flowrate
OBL Outside Battery Limits
FCC Fluid Catalytic Cracker
F Inlet flowrate to column
D Overheads of a column flowrate
B Column bottom flowrate
V Vapour flowrate from the top of a distillation column
L Reflux rate
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Design Problem Definition

The feed to area 3 comprises overheads from the depropanizer, received at 13 bar and
8 °C. The area's purpose is to recover methane-rich vapor for use as fuel gas, ethane
for fuel gas, ethylene for sale, and send C3 products to area 4 for further processing.
The conventional process involves using the demethaniser to recover methane and
light non-condensable in the overheads. The bottoms are then sent to the deethanizer,
which separates C2’s and C3’s into distillate and bottoms, respectively. The C2
components undergo additional processing in the ethylene splitter to recover ethylene
in the overheads and ethane in the bottoms. The C3 components are sent to area 4 for
further purification. Cryogenic distillation is employed in this area, with operating
conditions limited to low pressure below 15 barg.
Table 1 : Specifications to be met

Components Units Limitations to purity
Ethylene % mol 99.95 Min
Methane & Ethane ppm mol/mol 500 Max
C3+ ppm mol/mol 10 Max
Other Olefins ppm mol/mol 10 Max
Propadiene ppm mol/mol 5 Max
Hydrogen ppm mol/mol 10 Max
CO ppm mol/mol 0.2 Max
CO2 ppm mol/mol 5 Max
Oxygen ppm mol/mol 5 Max
Nitrogen ppm mol/mol 50 Max
NO ppm mol/mol 5 Max
Water ppm wt/wt 1 Max
Table 2: Battery limits specified acceptable conditions for product exiting area 3
Product Leaving area 3 Acceptable conditions
Methane rich vapor < 45 ˚C, 16 bar,vapour
Ethylene < 45 ˚C , > 3 bar, liquid
Ethane <45 ˚C, 40 bar, liquid
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Objectives of the Report

The objectives of the report are as follows:
• Review all routes and technologies used for the cryogenic fractionation train including
demethanizer, deethanizer and the ethylene splitter.
• Simulation and optimization of the area 3 using Aspen after choosing the correct
thermodynamic model to ensure specified composition limits for components is
achieved in the area and other following area dependent on this area’s outputs.
• Design thoroughly the de-ethanizer,and specification of auxiliary equipment used
within the associated columns.
• Perform costing (capital and operating costs) for all equipment’s involved.
• Provide the following information to other specialist engineers:
• PFD, Process description and stream tables to process coordinator.
• Safety, health and environmental information to the SHE engineer.
• Costing information to accountant
• Heat integration and utility information to heat integration and utilities engineer.
Scope, Limitations, and Key Issues

The project faces technical challenges due to its low-pressure operation (<15 barg) within
cryogenic columns compared to usual high pressure application in industry, necessitating
extremely low temperatures that can incur significant capital and operational costs. Achieving
high purity for ethylene proves challenging due to its close boiling point with ethane, putting
additional stress on the design. To optimize efficiency, the project integrates ethylene and
propylene refrigeration with C2 and C3 splitters, respectively, and considers using refrigerants
outside battery limits, though the most effective option can be expensive. Notably, dealing with
the coldest streams in the ethylene production plant, like methane, demands extremely low
temperatures. The design's primary focus is meeting all requirements within the specified area,
prioritizing feasible equipment sizes, cost-effectiveness, safety, and energy efficiency.
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Process Development
Literature Review
Separation techniques explored.
Cryogenic fractionation is the dominant method for separating cracker products into useful
fractions, outperforming adsorption, membrane separation, and absorption. Cryogenic
distillation offers the advantage of achieving high purity and high recovery rates in the
separation process. However, it is widely acknowledged for its drawback of being associated
with substantial operating and capital expenses.[5]
Membrane technologies offer the advantage of lower operational costs; however, they require
water input, making them unsuitable for water-scarce regions like Angola. Additionally, these
technologies are susceptible to fouling. On the other hand, adsorption processes have high
capital costs and intricate regeneration cycles. Due to project constraints, we are restricted to
employing cryogenic distillation. Thus, our primary focus will be on researching the specific
technologies utilized in the demethenizer, deethanizer, and C2 splitter.
Cryogenic fractionation is a distillation process same as other simple distillation systems which
uses differences in relative volatilities to separate components, but it is specifically utilized for
the separation of chemicals with extremely low boiling points. In this method, the distillation
column operates at elevated pressures and very low temperatures.[5] To facilitate this
operation, a refrigeration system must be integrated with the condenser, ensuring that it
maintains the lowest feasible temperature. However, this coupling results in a significant
temperature differential between the inlet and outlet of the working fluid in the refrigeration
system, leading to substantial energy consumption.[5]
To ensure effective separation within the column, it is essential to establish efficient contact
between the liquid and vapor phases. This can be accomplished by employing internal trays
or packing. In this project, trayed towers have been preferred over packed towers. Trayed
towers have been found to be more compatible and easier to apply in cryogenic distillation
processes, especially for columns with a diameter greater than 0.6 m. They are also cost-
effective even when dealing with high liquid flowrates.[4]
Packed columns offer low pressure drops and can handle corrosive liquids, but they are
susceptible to damage to the packing material under extreme temperature conditions. The
higher liquid flowrate adversely affects the contact efficiency, leading to increased costs. To
address the drawbacks associated with trayed towers, such as pressure drops and foaming
possibilities,the internal trays, including valve, sieve, or bubble caps were compared. Among
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these options, sieve and valves are the most cost-effective with high capacity and lower
pressure drop. However, bubble trays were selected due to their superior efficiency, as
indicated in table 1 of appendix A. The presence of risers allows bubble trays to maintain a
consistent liquid level on the tray at all vapor flow rates, making them the only tray type capable
of preventing liquid from weeping through the vapor passage.[4] This design results in efficient
vapor-liquid contact, prevention of vapor bypass, enhanced separation, higher turndown ratio,
and reduced entrainment, making bubble trays the preferred choice for optimal performance
in the distillation process.[4]
Demethanizer and pre-fed conditioning (cold box and hydrogen purification)
In the ethylene production process from naphtha, the overhead vapor stream from the
depropanizer requires cooling and condensation before it can enter the demethanizer column.
To achieve this, a cold box is utilized as a crucial part of the heat integration in most processes.
The cold box consists of a series of cryogenic heat exchangers as applied in the Lummus
process and improves efficiency. In the ethylene production process from naphtha,many
flowsheets uses the ethane product and ethylene overheads from the C2 splitter, along with
the demethanizer bottoms, medium duty refrigerant, and demethanizer overheads to cool the
feed, avoiding the use of utilities outside battery limits.[6]
If hydrogen separation is necessary, a flash drum separates the cooled feed into light vapor
consisting of the non-condensable to the PSA unit and liquid for the demethanizer column.[7]
The hydrogen in the feed can be used in hydrogenation units within the plant or sold for
revenue generation if recovered. If not, hydrogen is incorporated into methane fuel to increase
its energy content, improving efficiency, and reducing emissions. In this project, the lower
hydrogen content compared to methane addresses challenges related to handling and storage
of the fuel gas due to their differing physical properties and hydrogen's flammability. This
enables the use of the mixture as fuel oil without requiring expensive hydrogen purification. [7]
The methanation of CO to methane and water to minimize its content in fuel gas was not done
since content of CO was insignificant in the feed relative to methane. The nitrogen rejection
via cryogenic distillation to remove an incombustible gas N2 was not done since this is costly
even though 24 % of the fuel gas is nitrogen.[7]
The demethanizer aims to separate methane and light gases from C2's and heavy
hydrocarbon bottom components. This column incurs high capital costs and consumes
significant energy, particularly from the refrigeration system, however some flowsheets use
dephlegmators to decrease refrigeration duty requirement. Normally, the column operates in
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between 10 to 35 bar for cryogenic fractionation and the operating temperature is always
chosen between the boiling points of ethylene and methane at the specified pressure. [5] Other
flowsheets have employed there are four feeds into this column with the coldest feed being
near the top with temperature increase from as we go to the bottom. (Luyben,2013). However,
this method was not considered for our flowsheet since this is most applicable in demethanizer
front end and the use of many flash tanks and precoolers can increase initial investment. Other
flowsheets use the Joule-Thompson throttling valve which decreases temperature and
pressure leading to condensation of heavier hydrocarbons while methane and other non-
condensable gases report to vapour phase and recovered as fuel gas. This application is one
of the energy saving flowsheet due to decreased duty need in the reboiler and no need of
condenser. However, the JT inversion can occur in case of large hydrocarbon content in the
feed which leads to increase in temperature and Pressure and adversely affected efficiency of
separation. Several ethylene licensors use either a dual de-methanizer or pre-methanizer to
reduce the cryogenic duty of the de-methanizer. The trade-off is the higher capital investment
in de-methanizer service for lower investment in cryogenic refrigeration capacity, and lower
operating cost for cryogenic refrigeration.[9]
Deethanizer
The column's objective is to separate C2’s and C3’s for subsequent processing in the ethylene
and propylene splitters. A standard deethanizer operates between 15-30 bar with 25-60
stages, although variations may exist based on feedstock type, purity, and specified operating
conditions.[5] The main challenge with this column is achieving a high recovery of ethylene,
particularly in the C2’s (ethane and ethylene). To address this challenge, various flowsheets
have been developed to optimize production. The three common flowsheet configurations
eirther in low- or high-pressure operation are the single deethanizer, dual-pressure
deethanizer, and diving wall column coupling with ethylene splitter.[7]
Coupling deethanizer and ethylene fractionator into a single column divided by a vertical wall
allows lower operating pressure in the deethanizer eliminating reflux condenser and requires
a smaller reboiler thus overall capital and operational costs decreases.[7] However this
alternative has a complex design and applying process control can be difficult. Other
flowsheets uses dual pressure deethanizer which assist reducing energy consumption and
column bottoms temperature which further reduces possibility of fouling in reboilers.This also
have drawbac[[ks of high capital investments and complex unit operation design thus the
project will focus on the simple conventional single column for the deethanizer.[7]
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C2 Splitter
This column aims to separate ethylene to the overheads, and ethane to the column bottoms.
Ethane can be blended with propane and utilized as a fuel gas. Commercially, the ethylene
splitter typically operates at high pressures (17-28 bar) with 90-125 stages. However, our
scope is limited to a low-pressure system (10-15 bar). [5] Past flowsheets used heat pump
fractionation method which uses heat pump to recover and recycle some of the heat from the
overhead vapor and the bottoms liquid streams, significantly reducing reboiler and condenser
duties was not considered due to its complexity. Comparison was done for conventional and
feed splitting processes. [5]
Conventional C2 splitter distillation operates at low temperatures, leading to high energy

requirements for the reboiler and condenser. Three alternative feed splitting topologies were
considered to address this energy consumption issue. All three topologies utilize a flash tank
to separate the feed into liquid and vapor streams. [7] The flash tank liquid product is directed
to the bottom of the C2 column, and the flash vapor is cooled using the C2 column distillate.
The first alternative the vapour phase is precooled and sent to the column. This was found to
decrease condenser and reboiler duties by 14 % and 21 % respectively. [6]
The second alternate the vapour phase from the flash tank is cooled and flashed again the
second vapour and liquid products are sent to the tank, this lead to a decrease in condenser
and reboiler duties by 15 % and 22 % respectively. The last alternate involved cooling the first
flash tank vapour phase and re-cool the fraction of it before it is sent to the column, the other
fraction is directed to the column, this led to reduction of condenser and reboiler duty by 11%
and 19 % respectively. Although these alternatives showed significant energy requirement
reductions, the cost of the conventional method was 35% lower due to the absence of the flash
tank.The project thus used conventional method with the column.
Units Sequencing
The sequencing of units in a plant takes into consideration various factors, such as safety,
simplicity, possibility for expansion, and overall efficiency. This approach aims to decrease
backtracking, minimize pressure drop, and enhance the plant's performance. In the context of
ethylene production, the unit sequencing is entirely dependent on the chosen front end.
Commercially, the front end deethanizer uses the least amount of energy compared to the
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front end demethanizer and depropanizer. However, the focus here is limited to the front end
depropanizer.
Direct sequencing systematic approach was used taking votalities (boiling point) of
components to be separated in areas 3 with methane and ethane in the extremes thus are
separated first and last respectively. Multiple columns operating at different pressures were
used in an energy efficient manner [4]
Within area 3, the demethanizer is the coldest column, followed by the deethanizer and
ethylene splitter. The units are arranged based on the decreasing temperature gradient.[4] To
avoid backtracking and the introduction of unnecessary heavy hydrocarbon loads that could
alter ethylene purity or complicate optimization, the deethanizer should separate C2 and C3
first before the ethylene splitter occurs. Ethylene is the last unit to produce the required
products, ethane, and ethylene. Most flowsheets with this sequence desire a decreasing
pressure gradient. Design is not limited to that arrangement, and the final pressures used will
depend on optimization. This arrangement is desirable since it decreases the need to employ
many pressure and temperature changing units within the plant area which can be costly and
space consuming which poses threats to the plant since enough space between units to
ensure easy maintenance.
Base Case Development

Steps taken to develop the base case
• Utilize literature to explore applicable thermodynamic models in the chosen process model
simulator. Employ data analysis to identify the model with the least error compared to
experimental data predictions for selected binary pairs.
• Select the operational temperature and pressure range based on literature and design brief.
• If above is not possible due to time constraints and data limitations, assume a decreasing
pressure gradient for the columns, with each subsequent column operating at 1 barg less
pressure than the last and the demethanizer at the highest pressure within the 10-13 barg
range because high pressure decreases the duty significantly.
• Use Aspen to find saturation temperature of the demethanizer at the highest pressure of 13
barg for efficient separation which works on the model equation below.
𝐵 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 1
𝑇𝑠𝑎𝑡 = −𝐶
𝐴 − (ln(𝑃))
This saturation temperature is always in the range of light and heavy key components at a
specified pressure and composition.
• Except for the demethanizer due to noncondensible equation 1 was used to estimate
light and heavy key boiling point temperatures based on their normal boiling points at
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the chosen pressure of 13 barg. This was used as a temperature range in a slight
analysis as seen in appendix xx.
𝑃1 ∆ℎ𝑣𝑎𝑝 1 1 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 2
ln ( ) = [ − ]
𝑃2 𝑅 𝑇2 𝑇1
• A slight sensitivity analysis was conducted on the determined feed temperature range
to assess its implact on main product recovery. Engineering judgment guided the
selection of initial inlet feed temperatures for each column, aiming for minimal
condenser temperature outputs. This facilitates the use of internal refrigerants or
restricts external large refrigerant flow rates, serving the purpose of meeting column
specifications initially. Further detailed analysis is planned for later stages, focusing on
refining the process.
• These changes were done in the DSTWU which was assumed to operate at 1.3Rmin
and transferred to the Radfrac as initial estimates to allow rigorous calculations.
• Moving to the next two columns the feed was always at saturation temperature and
outlet pressure of the previous column.
• Design spec block on Aspen was used to fine tune results by changing the reflux ratio
to meet the specifications of each column in the radfrac.
Observations for the base case.

The columns were sequenced with decreasing pressure, each operating 1 bar lower than the
previous, aligning with real-world pressure drop considerations and eliminating the need for
inter-column pressure and temperature adjustments. The bottoms outlet temperature for each
column closely matched the recommended feed temperature range of the next, minimizing
heater usage. Additionally, the inlet stream consistently maintained higher pressure than the
column, reducing pressure drop effects and potentially leading to significant equipment size
reduction while enhancing overall efficiency.
Final observations
The existing base case is functional, but the column duties and number of stages could lead
to economic impracticality, as shown in Table 2. Our next design phase involves a detailed
sensitivity analysis to enhance operability. Our objective is to establish an optimized base case
considering capital, operational, and annual costs. For a concise view of base case operations,
refer to Table 2. The restricted low-pressure range and utilization of distinct feedstocks,
especially with the specific front-end depropanizer route, introduced complexities when
comparing our capacity with literature, which may follow different sequencing, could lead to
misleading conclusions.
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Table 3: Summary of base case conditions

Specification Demethanizer Deethanizer Ethylene splitter
Actual reflux ratio 0.908 0.90703 2.58277
Condenser Duty (Kw) -11930 -38 080
Reboiler Duty 28 300 37 050
Number of stages 41 91
Distillate to feed ratio 0.293 0.841233
Condenser temperature -132 -41 -46
Reboiler temperature -14.8 30 -25.95
LK recovery 1 99.99 0.00223
HK recovery 0.00026 99.99 99.98
Identification of Equipment for Design

The area requires three distillation columns because the chosen approach for all units is a
simple conventional one-column route, aiming to avoid complexity and considering area
limitations. Standard distillation columns consist of reboilers, reflux drums, reflux pumps, and
condensers. Cooling the demethanizer feed is essential, which can be achieved through a
series of heat exchangers in the cold box applying heat integration. The coldest refrigerant has
an incoming temperature of -160°C, considering the minimum return temperature of less than
30°C concept, the refrigerant cannot economically cool the demethanizer overheads alone in
the condenser since the demethanizer is usually the coldest streams in the process[]. Previous
research has highlighted the effectiveness of the Joule-Thompson expansion valve, utilizing
the coldest methane distillate stream in the area to cool the feed. After reducing its temperature
in the valve, compression of the methane gas is required to achieve the specified conditions.
Additionally, heat exchangers are necessary for the ethane and ethylene streams to reach
acceptable conditions within the battery limits. To maintain cost-effectiveness, the ethylene
needs to be pumped to 40 bar in its liquid state rather than being compressed, leading to the
decision to operate the C2 splitter as a total condenser.
Table 4: Required units and how they were modelled
Number How it is modelled on
Unit Type
Required Aspen
Heat exchangers 4 Heater
Reboilers 3 Heater
Distillation columns 3 Radfrac column
Compressors 1 Isentrophic compressor
Pumps 3 Pump
Condenser 3 Heater
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Detailed Design
Explanation of how the model works
The reason for choosing Aspen Plus is that it offers virtual exposure to physical processes and
provides quantitative measures, such as mole fraction of liquid and vapor phases, and can
simulate changes in temperature, pressure, and activity coefficients with both steady-state and
dynamic simulations, allowing full understanding of the system's behaviour in a virtual
environment, thus helps with optimizing the system's design and operation for real-time
performance. This is preferred over Aspen HYSYS software for the design modelling due to
its reliability in plant-wide simulation solutions, accuracy, and extensive database of pure
components, including the one used in this project. The software offers various thermodynamic
models, with the Peng-Robinson model being the chosen one for this application. This model
accurately predicts phase equilibrium as it is a cubic equation of state, making it
computationally efficient and better suited for critical conditions in the Aspen simulation.
The model employs simple distillation to simulate the demethanizer, deethanizer, and ethylene
splitter which utilizes differences in relative volatilities to achieve component separation. The
data in Appendix 2 and supported by literature indicates ethane and ethylene the key
components in ethylene splitter and has a normal boiling point temperature difference of 14°C
and a relative volatility of less than 1.5 at 1 bar. This means that enhanced distillation
techniques are not required for this separation since project involves cryogenic operations,
and there are no azeotropes nor boiling point isomers present. []
In this distillation model, the major units utilised to model real life columns are DSTWU, Distil,
RadFrac, and ConSep. Distil can perfom calculation using Edmister approach however this
needs the user to specify the number of stages and reflux ratio desired thus was not used.
RadFrac is the primary modeling approach used for all the distillation columns for this project
since other columns available in the software are used for complicated separation simulations.
RadFrac utilizes initial estimates from DSTWU to improve convergence during simulation.
DSTWU uses the Gilliland, Winn, and Underwood methods to determine crucial parameters
such as reflux ratio, feed stage, number of stages, and operating conditions. The system is not
having non-ideal mixture thus DSTWU being used to initial estimates is acceptable.
𝑁 − 𝑁𝑚𝑖𝑛 𝑅 − 𝑅𝑚𝑖𝑛 0.567 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 2
= [1 − ( )
𝑁+1 𝑅+1
The equation xx shows the Gilliland equation used to calculate the number of stages required
based on reflux ratio specified or the calculates specific reflux ratio based on number of stages.
A-3-10
𝑥 𝑥 𝐵 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 3
log [(𝑥𝐷 )𝐿𝐾) ∗ (𝑥𝐷 )𝐻𝐾 ∗ (𝐷 )1−𝑏
𝐵 𝐵
𝑁𝑚𝑖𝑛 =
log (𝐵𝑖𝑗 )
The Winn’s equation above determines the minimum number of stages
(𝐻𝑣 − ℎ𝑓) 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 4
𝑞=
(𝐻𝑣 − ℎ𝑙)
∝𝑖∗𝑋𝐷𝑖 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5
1−𝑞 =
∝𝑖 − 𝜃
∝𝑖∗𝑋𝐷𝑖 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 6
𝑅𝑚𝑖𝑛 + 1 =
∝𝑖 − 𝜃
The equation 4 to 6 above shows the Underwood equations used to compute the minimum
reflux ratio.
RADFRAC employs the inside-out algorithm to efficiently simulate complex separation

processes. This algorithm iteratively calculates phase equilibrium using initial estimates from
the DSTWU. The inside-out algorithm performs iteration for phase equilibrium per tray, while
the outside loop handles each stage and updates overall mass and energy balances.
Additionally, it introduces new parameters to improve convergence and accuracy during the
iterations, enabling detailed insights into process behavior. Associated MESH(material
balance, equilibrium between phases, mole fraction summation and energy balance across
trays) equations utilised for these iterations are listed below.
𝐹 =𝐵+𝐷 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 7
This is overall unit mass balance since no accumulation was assumed feed goes to distillate
and bottoms of the column.
𝐹. 𝑁𝑛𝐹 = 𝐷. 𝑋𝑛𝐷 + 𝐵. 𝑋𝑛𝐵 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 8
This equation shows the mass balance for the component at the nth stage.
𝐹ℎ𝑓 + 𝑄𝑅𝑏 = 𝐷ℎ𝐷 + 𝐵ℎ𝐵 + 𝑄𝑐 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 9
This shows the energy balance for each stage equation utilized in the model
𝐶 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 10
(𝑆𝑥 )𝑗 = ∑ 𝑥𝑖.𝑗 − 1
𝑖=1
𝐶 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 11
(𝑆𝑦 )𝑗 = ∑ 𝑦𝑖.𝑗 − 1
𝑖=1
The Summation equations above
A-3-11
𝐸𝑖.𝑗 = 𝑦𝑖,𝑗 − 𝐾𝑖.𝑗 𝑥𝑖.𝑗 = 0 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 12
The equilibrium equation

𝒗𝒂𝒑 𝒗𝒂𝒑
𝑸𝒄 = 𝑽. ∆𝒉𝒗𝒂𝒑 = 𝑫(𝑹 + 𝟏)(𝑿𝑫 . ∆𝒉𝑨 + (𝟏 − 𝑿𝑫 ). ∆𝒉𝑩 ) 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 13
𝑸𝒄 = 𝑳. ∆𝒉𝒗𝒂𝒑 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 14
The equations are used in the calculation of the condenser duty, for both total and partial are
condensers.
𝒗𝒂𝒑 𝒗𝒂𝒑
𝑸𝒄 = 𝑽′ . ∆𝒉𝒗𝒂𝒑 = 𝑩. 𝑹𝒃 (𝒚𝑵+𝟏 . ∆𝒉𝑨 + (𝟏 − 𝒚𝑵+𝟏 ). ∆𝒉𝑩 ) 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 15
The reboiler duty is given by the equation above proper explanation were done in brief for all
these equations on Appendix B
Assumptions and Justifications for the Base Case design

• All components were assumed to be stable thus no reactions occur within the
components in the system.
• The liquid and vapour flowrates are perfectly mixed upon entering each stage under
specified conditions.
• The operation was assumed to be ideal and under steady state.
• Compounds present in the concentration less than 0.0001 % on a mass basis are
considered trace components and do not significantly affect the chosen thermodynamic
model.
• The columns operate adiabatically with no heat losses.
• Streams leaving each stage were assumed to be in thermodynamic equilibrium.
• Constant tray efficiency was assumed throughout the simulation.
• Pressure drop was not considered for the initial based case.
• The compressors employed in this area were assumed to work adiabatically and with
efficiency an of 0.9.
• Partial condenser was assumed for the demethanizer since this stream is rich in light
gases and noncondensibles and total condenser for the deethanizer and ethylene
splitter because it is easier and economical to transport and pump liquid.
• Assume a saturated feed, as opposed to other types like subcooled or dew point feed,
due to its positive impact on separation efficiency..
A-3-12
Thermodynamic model used

Proper property method selection is crucial to enhance simulation accuracy, and several
factors influence the method choice, such as feed composition, equipment operating
conditions, component nature, and parameter availability. The Aspen Method Selection Assist
validates experimental data by first selecting a thermodynamic model (AC or EOS) and then
choosing a property package through the analysis of binary interactions in each unit. The
decision tree method is primarily used for qualitative selection and cross-verified with Aspen's
method assist. Units like deethanizer, demethanizer, and ethylene splitter require accurate
physical properties, and models are tailored for specific systems and operating conditions,
necessitating thorough analysis for proper property package selection in each unit.
The first criterion in the decision tree focuses on polarity, determining the types of interactions
possible between specific components within the system. The system mainly comprises non-
polar components with minimal polarity. The second branch assesses the components, each
being well-defined with real and predictable physical and chemical properties. These
properties can be derived from experimental data or thermodynamic models, avoiding any
approximations for complex structures. The suggested models for such systems are Peng-
Robinson, Redlich-Kwong-Soave, and Lee-Kesler-Plöcker which was consistent with what
literature and Aspen assist suggested.
In low-pressure applications where gas concentrations in liquids become significant due to the
presence of non-condensable gases like CO, N2, and CO2, specifying Henry's law is crucial.
It improves design, simulation, and realistic optimization. To choose the most appropriate
model, experimental data within the appropriate temperature and pressure range (low-
pressure cryogenic distillation system) from NIST is compared to model predictions for vapor-
liquid equilibrium. The binary pairs of interest were selected as heavy and light key
components for each column. Statistical analysis was conducted by comparing experimental
data for liquid and vapor mole fractions to model predictions and calculating the associated
root mean square error.
Binary pairs of interest

The deethanizer column aims to separate the C2s and C3s in the distillate and bottomes
respectively to allow for further processing and recovery of essential hydrocarbons.The binary
pairs for deethanizer were selected as ethane and propylene based on light and heavy key
looking into their boiling point relative to other components entering the column and the column
A-3-13
objective. For the demethanizer column the binary pairs of interest were methane and ethylene
since it is desirable to recovery close to perfect separation of each in the bottoms and distillate
respectively.The separation has been an issue in industry such that commonly only a 92%
recovery of ethylene occurs to the distillate and a sensitivity analysis on this would be done
since slight optimization of demethanzier would improve the deethanizer efficiency. The
molecular similarities between the ethylene and methane causes mass transfer limitations and
thus significantly impact recovery thus it is desirable to model the column based on those key
components. The ethylene splitter binary pairs selected were ethane and ethylene. The
primary goal was to achieve a high level of purity for ethylene in the last column. The presence
of impurities, such as water and light gases affects the quality of ethylene, as it may lead to
side reactions. Additionally, water plays a significant role in the freeze point depression of
ethylene. Therefore, this approach was implemented to optimize the separation process and
guarantee the production of a pure and high-quality ethylene product. To ensure accurate
comparison, the operating temperature and liquid mole fraction were controlled variables
between the experimental data and model predictions.
Results discussion.
3
Liq PR P-xy diagram for ethane
2.5 Vap PR
Exp liq
2 Exp Vap
LK-P vap
Pressure in psia
1.5 LK-P liq

LK-P vap
0.5
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Mole fraction of ethane
Figure 1: The deviation of two best models with the experimental data for deethanizer
binary pairs
The figure 1 above shows the deviations of the model predictions form the NIST data. However
nothing significant can be drawn directly from the visuals that is why the mathematical analysis
A-3-14
was conducted. Results in table xx shows that the best model for the column is xx as seen
from the smallest SSE of 0.005 followed by PR- BM with SSE of 0.115. The results of RSK
model having a significant large error (0.154) is due to assumptions it works by that might not
be valid for a non-ideal behaviour which might occur at high pressure and very low cryogenic
temperatures. The induced dipole interaction between these key elements is not accounted
for if RSK is used. The parameterization of LPK and the fact that it is an enhancement from
RSK is seen in the error shown in the table.
The analysis results show that the demethanizer column can effectively be modelled using the
PR-BM model, exhibiting the lowest error of 3.8% (table 5). The ethylene splitter can accurately
be represented by the LP-plock model, with a small error of 0.005% and PR-BM model, with a
0.017% error, was the second-best choice for this unit. The PR-BM model's average error
across all units had the lowest average error (1.301 %) which made it suitable for modelling
area 3. However, employing different thermodynamic models for specific unit operations within
area 3 to 4 could potentially give rise to inconsistencies, errors, and challenges in terms of
accuracy and the overall efficiency of the simulation. Table xx shows that across all the units
based on overall average errors peng robson has an SSE of 0.00845 % thus the area 2-4 were
all simulated on the same flowsheet. The findings on minimal error aligns with literature since
Peng-Robinson equation of state (EOS) is well-suited for hydrocarbon systems due to its
accurate prediction of phase equilibria and critical point parameters which is instrumental in
informing proper column design, operating conditions, and optimization strategies. [].
Table 5: The area 3 SSE analysis results per column and entire system
Column Binary pairs Model SSE % Best Model
LP-Plock PR-BM RKS
Demethanizer Methane and Ethylene 5.38 3.793 4.705 PR-BM
Deethanizer Ethane and propylene 0.089 0.115 0.154 LP-Plock
Ethylene LP-Plock
Splitter Ethylene and ethane 0.005 0.017 0.011
Entire area 1.825 1.308 1.623 PR-BM
Table 6: SSE analysis for the area 2 to 4

Model SSE
LK-PLOCK 0.0115
PR-BM 0.00845
RKS-BM 0.0104
Sensitivity Analysis and Optimisation of Design Model
A-3-15
To fully optimize the deethanizer a short analysis of the demethanizer column was done
specifically. The demethanizer is the coldest unit in the plant we aim to have an optimised case
that does not use the expensive refrigerant. The pressure of the vessel was varied from 10-13
bar range. The temperature was varied between -80 C to -110 C.. The column was found to
work best in high pressure and have a significantly reduced temperature however it is
impossible to operate without the need to use the expensive refrigerant. However choosing
the pressure of 13 bar and -90 C makes an improvement touching mostly on the recovery of
ethylene because in industry they have been recovering in the range of 91-93 %, however the
optimised demethanizer is able to recovery 94 % of ethylene.
Effects of feed temperature and feed pressure to the deethanizer

A sensitivity analysis was carried on a deethanizer inlet temperature with an aim to find an
optimum operating condition. The temperature was varied from xx – xx C which defines the
range of specific boiling points of light and heavy key of the deethanizer in the given pressure
range. The graph shows that the ethane recovery significantly decreases after -14 C with an
analysis being done at 13 bar. However, the recovery of propylene in the bottoms is still great
due to purity requirements of propylene the column should operate between -13.8—16 C.The
temperature could increase due to demethanizer conditions however a sensitivity analysis on
demethanizer was done to feed optimum ranges in the deethanizer. A factor to the temperature
of the feed increasing can be fixed by control since it is due to the natural positive ambient
conditions in Angola. The figure below shows the usual range during the year.
Figure 2 : Temperature ranges in Angola [xx]
A-3-16
Figure 4: Effect of temperature on deethanizer column operations
The effects of pressure of the feed.

The pressure of the feed should always be higher than the operational pressure of the column
since. The pressure was ranged from 12.5-16 bar to look into finding the optimum range. The
figure xx shows that as the pressure increases recovery of all components increases. This
graph show that ethane is the one which needs moderate pressure for a recovery higher than
95 % in the distillate.
Influence of operating pressure of the column

The base case operates at 11 bar however a sensitivity analysis based on the top and bottom
stage pressure being varied between 8-15 bar to access how the system behaves with change
in pressure. The figure below shows a sweet spot in the pressure range of cc-xx bar for overall
system efficiency.
Viable operational range and control implications
A-3-17
To properly control the operation a design specification was used in the radfrac on Aspen to
keep the recoveries the same each time while changing the operating pressure of the column
and the feed stage. The suggested ranges from prior analysis was used to determine viable
operating range taking into consideration possible control strategies in case of significant
deviation. The aim was to see exactly what happens between that range is it entirely optimum
or not.
Temperature analysis from C – xx C.
The temperature was ranged withing the suggested range of xx- xx C from the prior sensitivity
analysis done. The reflux ratio had to change each time a temperature was varied to ensure
specifications are met to have a basis of comparison. The change sequentially involves the
condenser and reboiler duties to change. It is not desirable to have large duties because it
may be noneconomical. The figure below shows for the range xx-xx C reboiler duty increases
significantly, like wise from the range xx-xx C the reflux ratio which is directly proportional to
condenser duty increase significantly. It is advisable based on energy consumption to operate
at a temperature xx-xx C while ensuring design specifications are met. However, should
temperature deviations be prevalent such that we operate in the undesired temperature range
the specifications will still be met though control on the reboiler duty and reflux ratio as depicted
in the figure xx.
Figure 3: The temperature changes and adjustment of reboiler duty and reflux ratio.
Pressure of the column with energy consumption

The same was done for the deethanizer radfrac. From the suggested range in the sensitivity
analysis of xx- xx bar the column had to change the reboiler ratio and reflux ratio
consequentially their duties to meet specifications. A plot shown on figure xx suggests that the
reflux ratio decreases with increasing in pressure and thus lower condenser duty which is of
interest in the project given the cost of refrigerants. The diagram in the context of control
implication shows how the reboiler duty and reboiler ratio will be adjusted to account for the
A-3-18
fluctuation to meet specification. The only constrain is that the analysis were done changing
one thing variable at at a time. To couple these results together it can be concluded that the
use of control loops for example which measures feed pressure and manipulate the column
pressure slightly to ensure operation still meets specification in the events of fluctuations’ next
phase is to do optimization on the basis of cost as this couples together the operation and the
equipment using total annual cost.
Figure 4: Recovery of key components and column duty with changes is column operating
pressure.
Optimisation of Equipment Size/Configuration on a cost basis

The optimization process ensures consistent operational outcomes (recovery, purity,
mass balance, composition) for column distillate and bottoms while minimizing costs.
Key variables like reflux ratio, stages, and feed stage were optimized, excluding
temperature and pressure due to prior sensitivity analysis. A detailed hydraulic design
for column internals was conducted first . The total annual cost combines capital and
operational costs for effective comparison, yielding an optimal point that balances
performance and economic viability. The reflux ratio defines the ratio of reflux flow to
the flow withdrawn from the column. The number of stages is highly influenced by the
reflux ratio, impacting capital costs. Capital costs for the columns were found using xxx.
Variations in the reflux ratio notably affect the reboiler and condenser duties,
subsequently altering operational costs. These operational costs were calculated using
the flowrate of utility used and its cost. The UH&I engineer provided the factor of costs
associated with the refrigerants utilised in the column of interest. An annualization
factor of 5 years was used in this project to determine total annual cost.
A-3-19
As the reflux ratio (R) approaches the equilibrium line the pinch between the operating and
equilibrium lines widens, necessitating an increase in the required stages. This divergence
signifies the point of minimum reflux ratio at an infinite number of stages. The DSTWU was
over specified initially to ensure when initial estimates are transferred to the Radfrac the
conditions are still met. The number of stages were varied from number of stages in minimum
number of stages of 24 suggested by aspen till 100 stages where reflux ratio is close to Rmin.
Each combination underwent profile analysis, especially regarding temperature and flow
profiles across stages, to identify and eliminate dead zones or redundant stages and ensure
mass balance is the same as the base case since within the points analysed each is a potential
optimum point. Sample profiles are available in the appendix for reference.
The provided diagram (5) illustrates the shifts in operating, capital, and total annual costs that
result from the specified variables. This diagram was generated using data from Notably, a
clear trend emerges wherein decreasing the reboiler ratio leads to an increase in capital costs,
accompanied by a decrease in operational costs. The Total Annual Cost (TAC) curve guides
the identification of the optimal operational point. Following an exhaustive analysis, the optimal
reflux ratio of corresponding to 1.42 Rmin was achievable over 54 stages at a minimal cost.
CHART TITLE
capex opex TAC
20000000
15000000
COST$)
10000000
5000000
0
0 0.5 1 1.5 2 2.5 3 3.5 4
REFLUX RATIO
Figure 5: The process cost as a function of reflux ratio
A-3-20
Recovery of key elements with change in

feedstage
1.2
1
Recovery in overheads
0.8
0.6
0.4
0.2
0
-0.2 0 10 20 30 40 50 60
Feedstage
Ethane Propylene
Figure 6:The recovery versus feedstage at optimum reflux ratio for constant number of stages
Two distinct procedures can be employed to determine the optimal feed location as it
significantly affect the operation. A primary design principle is to ensure alignment between
the feed composition and the column vapor-liquid composition. The initial approach involves
maintaining a constant number of stages and reflux ratio while shifting the feed location. The
reboiler duty is observed in this process. Alternatively, the reflux ratio can be kept at Roptimal
while identifying an optimal combination of the number of stages and feed stage to locate the
sweet spot on the basis of energy consumption and desired recovery of key components. The
results of the optimization based on the feed stage are depicted in the figure (6) above. This
figure illustrates the correlation between feed stage and the recovery observed at Ropt and
Nstages. It is evident from the data that the optimal feed stage for the column is determined to
be in range 25-35 since that is where recovery of all key components is at a desired level >
99.98 %. The figure 7 below shows the comparison of reboiler duty with feed stage
manipulated.From the figure the feed stage should always be in the range 15-35 to avoid high
energy consumption.
A-3-21
Reboiler duty versus feedstage
27800
Reboiler dutiy (kW)
27600
27400
27200
27000
26800
26600
26400
0 10 20 30 40 50 60
Feedstage
Figure 6b: The influence of feed stage to reboiler duty
How the optimum case responds to changes in the feedstock to area 3

Changes in the feedstock of the cracker
The influence of the change in propylene flowrate into the deethanizer
The propylene has a significant flowrate in relation to the other components fed to area 3. It is
important to note that the change in the feedstock may affect the operation and the catalytic
cracker performance fluctuations will significantly alter the composition of components being
feed to the fractionation train. Thus, the flowrate of propylene was varied from 80% of current
value to 120% of the current value to see the influence it will have on the separation efficiency
of the deethanizer column.
Figure 9 :The influence of the change in the ethane flowrate into the deethanizer
Ethane was used to track the implications of deviations in the optimised case more than
ethylene comparison since it was seen on earlier stages that ethylene recover is always
attainable compared to the the ethane recovery. Ethane is a light key component the sensiti
analysis shows the change of flowrate and how it affect the recovery of key elements in the
distillate and bottoms.To conclude the changes in the cracker compositions is outside the
control however should this occur to overcome the separation strain it puts on the column. It
is suggested to implement a control strategy on the distillate of the column each time to
maintain desired recovery and purity. Another possible analysis could have been the influence
of malfunctioning of the depropanizer such that recoveries of components creeps into the
overheads, how would the deethanizer behave in those conditions. Due to time this was not
done.
A-3-22
Summary of Base and Optimised Case

The feed stage, number of stages, reflux ratio was used to optimise the column on a
basis of benefit (recovery of key components), cost (operating and capital costs) and
energy consumption using the reboiler duty. Detailed hydraulic design and equipment
sizing was done on the column using a combination of heuristics from [4] and guidelines
provided by [4]. The base case was found to be 54 theoritical stages while the optimised
case has 60 stages. The capital cost of optimised case was lower than that of the base
case.
A-3-23
Area 3 Overview
Process Description
The feed to the process originates from the overheads of the depropanizer column situated in
Area 2. This feed comprises rich C3- hydrocarbon products and light non-condensable gases
including nitrogen, and carbon monoxide. This feed comes at a temperature of 8 °C and a
pressure of 14.01 bar. To achieve optimal conditions for further processing, the feed is directed
through E-301 and E-302, where cooling takes place, reducing the temperature to -35°C and
-90°C respectively. Ethylene-51 and ethylene-95 are used since this was found to be more
economical. This configuration allows proper heat integration to be done to atleast on of the
heat exchanges given the large temperature difference for cooling.The feed is directed to the
demethanizer column (T-301), which is operates at 14 bar. Within this column, a 100%
recovery of methane and light gases is achieved.
Due to the non-condensable nature of the stream, a partial condenser E-303 is employed to
produce distillates product which are further directed to an isentropic compressor (C-301),
followed by a heater(E-305) utilizing low-pressure steam. This process elevates the methane-
rich gas flowing at 48 800 kg/h to a pressure of 16 bar and a temperature of 25°C, facilitating
its proper storage at battery limits.The bottom fraction from the demethanizer column (T-302)
at -13.7 ˚C and 14 bar is sent to a deethanizer column (T-302) , operating at 13 bara. A total
condenser E-307 is utilised to enhance separation since it is convenient to pump a liquid than
compress a liquid. 99.95 % and 99.97 % of ethane and propylene was achieved in the distillate
and bottoms respectively. The content of ethane in this stream of xx kg/h was very insignificant
before being sent at 13 bar and 30.3 ˚C to area 4 for further fractionation using propylene
splitter. This liquid stream is feed in saturation conditions to the ethylene splitter (T-303) at 13
bar and -41.2 °C to separate ethane and ethylene.
T-303, operates under a pressure of 12 bar, attaining a 99.99 % and 99.8 %recovery of
ethylene and ethane in the distillate and bottoms respectively. The resultant ethylene product
with a purity of 99.95 mol.% is sent to area 4 at 12 bar and -46.18 C where refrigeration cycle
occurs to produce different levels of ethylene refrigerants as part of energy integration.
Bottoms of T-303 are mainly ethane which is intended for utilization as fuel gas. To ensure its
proper handling, the pressure reducing valve VP-301 is employed to reduce the gas pressure
to 4 bar and maintains the gas pressure above its saturation pressure of 3.55 MPa at 30 °C.
E-310 is utilized to increase the gas temperature, bringing it closer to ambient conditions
considering SHE related reasons.
A-3-24
Process Flow Diagram
Figure 7: The process diagram for area 3
A-3-25
Stream Tables
Table 8 : The stream tables for mass and mass composition in area 3
Stream numbers 301 302 303 304 305 306 307 308 309 310 311 312 313
Temperature ( ˚C) 8.017 -35 -90 -105.2 -92.92 25 -13.72 -41 -46 -26 -58 25 30
Pressure (bar) 14.01 14.01 14.01 14.01 17.01 16 14.01 13.01 13.01 12 4 4 13.01
Phase (V/L) V V/L V/L V V V L L L L V/L V L
Molar vapour fraction 1 0.488 0.1986 1 1 1- - - - 0.21 1-
Mass flow (kg/h)
Hydrogen 2479 2479 2479 2479 2479 2479 - - - - - - -
Nitrogen 9555 9555 9555 9555 9555 9555 - - - - - - -
Carbon monoxide 147 147 147 147 147 147 - - - - - - -
Carbon dioxide - - - - - - - - - - - - -
Methane 29670 29670 29670 29670 29670 29670 - - - - - - -
Ethylene 108900 108900 108900 6970 6970 6970 101900 101900 101900 9.475 9.475 9.475 0.01769
Ethane 20640 20640 20640 - - - 20640 20630 46.81 20580 20580 20580 -
Propylene 165500 165500 165500 - - - 165500 41.9 - 41.9 41.9 41.9 165500
Propane 26530 26530 26530 - - - 26530 0.03386 - 0.03386 0.03386 0.03386 26530
Water 0.3977 0.3977 0.3977 - - - 0.3977 - - - - - 0.3977
Total 363000 363000 363000 48800 48800 48800 315000 122600 101900 20630 20630 20630 192000
Mass fractions (wt.%)
Hydrogen 0.6821 0.6821 0.6821 5.077 5.077 5.077 - - - - - - -
Nitrogen 2.629 2.629 2.629 19.57 19.57 19.57 - - - - - - -
Carbon monoxide 0.04045 0.04045 0.04045 0.3011 0.3011 0.3011 - - - - - - -
Carbon dioxide - - - - - - -
Methane 8.165 8.165 8.165 60.77 60.77 60.77 - - - - - - -
Ethylene 29.96 29.96 29.96 14.28 14.28 14.28 32.39 83.14 99.95 0.04593 0.04593 0.04593 -
Ethane 5.679 5.679 5.679 0.0001112 0.0001112 0.0001112 6.56 16.83 0.04592 99.75 99.75 99.75 -
Propylene 45.54 45.54 45.54 - - - 52.61 0.03419 - 0.2031 0.2031 0.2031 86.18
Propane 7.3 7.3 7.3 - - - 8.433 - - 0.0001641 0.0001641 0.0001641 13.82
Water 0.0001095 0.0001095 0.0001095 - - - 0.0001264 - - - - - -
Total 100 100 100 100 100 100 100 100 100 100 100 100 100
A-3-26
Table 9 : Stream tables for mole flow and mole composition
Stream numbers 301 302 303 304 305 306 307 308 309 310 311 312 313
Temperature ( ˚C) 8.017 -35 -90 -105.2 -92.92 25 -13.72 -41 -46 -26 -58 25 30
Pressure (bar) 14.01 14.01 14.01 14.01 17.01 16 14.01 13.01 12.01 12 4 4 13.01
Phase (V/L) V V/L V/L V V V L L L L V/L V L
Molar vapour fraction 1 0.488 0.1986 1 1 1- - - - 0.21 1-
Molar flow (kmol/h)
Hydrogen 1230 1230 1230 1230 1230 1230 - - - - - - -
Nitrogen 341.1 341.1 341.1 341.1 341.1 341.1 - - - - - - -
Carbon monoxide 5.248 5.248 5.248 5.248 5.248 5.248 - - - - - - -
Carbon dioxide - - - - - - - - - - - - -
Methane 1850 1850 1850 1850 1850 1850 - - - - - - -
Ethylene 3881 3881 3881 248.5 248.5 248.5 3632 3632 3632 0.3377 0.3377 0.3377 0.0006305
Ethane 686.3 686.3 686.3 0.001806 0.001806 0.001806 686.3 686 1.557 684.4 684.4 684.4 0.3002
Propylene 3933 3933 3933 - - - 3933 0.9957 - 0.9957 0.9957 0.9957 3932
Propane 601.6 601.6 601.6 - - - 601.6 0.0007679 - 0.0007679 0.0007679 0.0007679 601.6
Water 0.02208 0.02208 0.02208 - - - 0.02208 - - - - - 0.02208
Total 12530 12530 12530 3674 3674 3674 8853 4318 3634 685.7 685.7 685.7 4534
Composition (mole%)
Hydrogen 9.816 9.816 9.816 33.47 33.47 33.47 - - - - - - -
Nitrogen 2.723 2.723 2.723 9.284 9.284 9.284 - - - - - - -
Carbon monoxide 0.04189 0.04189 0.04189 0.1428 0.1428 0.1428 - - - - - - -
Carbon dioxide - - - - - - - - - - - - -
Methane 14.76 14.76 14.76 50.34 50.34 50.34 - - - - - - -
Ethylene 30.98 30.98 30.98 6.763 6.763 6.763 41.03 84.095 99.96 0.04925 0.04925 0.04925 -
Ethane 5.478 5.478 5.478 - - - 7.752 15.8818967 0.0428 99.81 99.81 99.81 -
Propylene 31.4 31.4 31.4 - - - 44.42 0.02305325 - 0.1452 0.1452 0.1452 86.72
Propane 4.802 4.802 4.802 - - - 6.795 - - 0.000112 0.000112 0.000112 13.27
Water 0.0001762 0.0001762 - - - - - - - - - - -
Total 100 100 100 100 100 100 100 100 100 100 100 100 100
A-3-27
Mass Balance (0.25 page)

Table 10:The overall mass balance of the process in area 3
IN OUT
Mass flow (kg/h) 301 306 309 312 313
Hydrogen 2479 2479 - - -
Nitrogen 9555 9555 - - -
Carbon monoxide 147 147 - - -
Carbon dioxide - - - - -
Methane 29670 29670 - - -
Ethylene 108900 6970 101900 9.475 0.01769
Ethane 20640 - 46.81 20580 -
Propylene 165500 - - 41.9 165500
Propane 26530 - - 0.03386 26530
Water 0.3977 - - - 0
Total 363000 48800 101900 20630 192000
Total in 363000
Total out 363330
Difference % 0
4.5.4.1. Assumptions for Mass Balance

Steady state operation was assumed for the simulation of area 3.
Plan for Area Interfaces
Table 11: Inter-area consistency check up
Stream Area 2 Area Stream Area Area
[209] 3[301] 3[309] 4[xx]
Temperature ( 8.017 8.017 Temperature ( -46 -46
˚C) ˚C)
Pressure (bar) 14.01 14.01 Pressure (bar) 13.01 13.01
Phase (V/L) V V Phase (V/L) V V
Mass flow Mass flow
(kg/h) (kg/h)
Hydrogen 1230 1230 Hydrogen - -
Nitrogen 341.1 341.1 Nitrogen
Carbon 5.248 5.248 Carbon
monoxide monoxide
Carbon dioxide - - Carbon dioxide - -
Methane 1850 1850 Methane - -
Ethylene 3881 3881 Ethylene 101900 101900
Ethane 686.3 686.3 Ethane 46.81 46.81
Propylene 3933 3933 Propylene - -
Propane 601.6 601.6 Propane - -
Water 0.02208 0.02208 Water - -
Total 12530 12530 Total 101 900 101 900
A-3-28
The table below is used to confirm consistency within each area interface as area 2 is feeding
area 3 it was necessary to ensure the stream used for optimization is the same stream out of
area 3 after optimization. Note that the mass fractions and other parts of the stream tables
were not shown since it just to check if the streams are the same.
Equipment Specifications
Drawing
Figure 8 : The mechanical drawing of the deethanizer column
A-3-29
The equipment specification sheet

Table 12: The specification sheet of deethanzier column including hydraulics design
Deethanizer Specification Sheet
Streams 1
Feed Distillate Bottoms 2
Temperature (°C) -13.72 -41.2 30.3 3
Pressure (atm) 14.01 13.01 13.01 4
Flowrate (kg/s) 87.4 34.05 53.33 5
Ethylene mass fraction 0.323 0.831 0 6
Ethane mass fraction 0.0656 0.168 0 7
Propylene mass fraction 0.526 0.0003 0.862 8
Propane mass fraction 0.0843 0 0.138 9
Average Molecular Weight 35.5 28.38 42.4 10
(kg/kmol)
Density (kg/m3) 530 491 510 11
Column Operating Data 14
Operating Temperature (°C) 30.3 15
Design Temperature (°C) 55.3 16
Operating Pressure (bar) 13.01 17
Design Pressure (bar) 14.7 18
Pressure Drop per Tray (Pa) 706 19
Total Pressure Drop (Pa) 36712 20
Minimum Reflux Ratio, Rmin 0.633 21
Reflux Ratio 0.823 22
Boil Up Ratio 1.54 23
Light Key, LK Ethane 24
Heavy Key, HK Propylene 25
Condenser Reboiler 26
Type Total Partial 27
Heat Duty (MW) 23030 26600 28
Operating Temperature (°C) -41 30 29
Utilities Ethylene-51 Low pressure steam 30
Tower Shell 31
ID (m) 7.61 32
OD (m) 7.98 33
Height (m) 33.9 34
Material of Construction Stainless Steel 36
Corrosion Allowance (mm) 3.8 37
Shell Thickness (mm) 9 38
Insulation Thickness (mm) 25.4 39
Internals 40
Tray Type Bubble cap 41
Tray Spacing (m) 0.55 42
Number of active holes 3000 43
Hole diameter(mm) 5 44
Weir height (m): weir length(m) 0.05 : 2.92 45
Minimum Number of Stages, Nmin 24 46
Number of Trays, N 52 47
Downcomer ratio (%) 80 48
Feed Tray Location 30 49
Tray Efficiency 0.82 50
Material of Construction Stainless Steel 51
A-3-30
Table 13 : Equipment listing for area 3 part 1
Equipment Name of Specifications

Code Equipment
E-301 Type: Shell-and-tube, Passes: 1 , Heat Transfer Area: 1140 m2, DP: 17.2
Demethanizer bar, DT (Process/Utility Side): -10°C/-26°C, Duty: -31 912 kW, Utility:
Pre feed heater Ethyl-51, MoC (Process/Utility): Carbon steel (TL): 4.9 m D: 1.18 m
Demethanizer bar, DT (Process/Utility Side): -80°C/-70°C, Duty: 22 880 kW, Utility:
Feed cooler Ethyl-95, MoC (Process/Utility): Carbon steel (TL): 4.9 m D :1.83 m
Demethanizer bar, DT (Process/Utility Side): -80°C/-135°C, Duty: -11 940 kW, Utility:
Condenser RG1, MoC (Process/Utility): Carbon steel (TL): 4.9 m D: 0.78 m
Type: Shell-and-tube, Passes: 1 , Heat Transfer Area: 228 m2, DP: 17.2
Demethanizer bar, DT (Process/Utility Side): 11°C/175 °C, Duty: 28 300 kW, Utility: RG1,
E-304 Reboiler MoC (Process/Utility): Carbon steel (TL): 4.9 m D: 0.99 m
E-305 Methane product Type: Shell-and-tube, Passes: 1 , Heat Transfer Area: 407 m2, DP: 16.2
Heater bar, DT (Process/Utility Side): 50 °C/183 °C, Duty: 26 600 kW, Utility:
Ethy-51, MoC (Process/Utility): Carbon steel (TL): 4.9 m D: 1.22 m
Deethanizer Type: Shell-and-tube, Passes: 1 , Heat Transfer Area: 155 m2, DP: 16.2
Reboiler bar, DT (Process/Utility Side): 55°C/183 °C, Duty: 26 600 kW, Utility: LPS,
E-306 MoC (Process/Utility): Carbon steel (TL): 4.9 m D: 0.86 m
Type: Shell-and-tube, Passes: 1 , Heat Transfer Area: 878 m2, DP: xx bar,
Deethanizer DT (Process/Utility Side): -16°C/-26 °C, Duty:2830 kW, Utility: LPS,
E-307 Condenser MoC (Process/Utility): Carbon steel (TL): 4.9 m D: 1.62 m
Ethylene bar, DT (Process/Utility Side): -21°C/-70°C, Duty: 381 000 kW, Utility:
E-308 Splitter Ethy-95, MoC (Process/Utility): Carbon steel (TL): 4.9 m D: 0.894 m
Condenser
Ethylene bar, DT (Process/Utility Side): 0°C/50°C, Duty: 37 900 kW, Utility:
E-309 Splitter Propy20, MoC (Process/Utility): Carbon steel (TL): 4.9 m D: 1.51 m
Reboiler
E-310 Ethane product Type: Shell-and-tube, Passes: 1 , Heat Transfer Area:273 m2, DP: 15.07
Cooler bar, DT (Process/Utility Side): 50°C/50°C, Duty: 37 900 kW, Utility:
Propy20, MoC (Process/Utility): Carbon steel (TL): 4.9 m D: 1.06 m
T-301 Demethanizer Type: Trayed, Orientation: Vertical, Height: 32.2 m, Diameter: 2.5
m, DP: 17.3 bar, DT: -65 °C, Tray Type: Bubble Cap,RR= 0.907
Number of Trays: 53 , MoC:Stainless Steel, Efficiency: 80 %
A-3-31
Table 14 : Equipment listing for area 3 part 2
Equipment Code Name of Specifications

Equipment
Type: Trayed, Orientation: Vertical, Height: 71 m, Diameter: 6.3 m, DP: 14 bar, DT: -16°C,
Ethylene Tray Type: Bubble Cap, RR= 2.53
T-303 Splitter Number of Trays: 91 , MoC:Stainless Steel, Efficiency : 80%
Orientation: Horizontal, Length: 3.06 m, Diameter: 1.2m, DT : -80 °C, DP: 17.3 bar, MoC:
Carbon steel
RD-301 Demethaniser
Reflux Drum
Orientation: Horizontal, Length: 6.026 m, Diameter: 2.01m, DT : -16 °C, DP: 16.17 bar,
MoC: Carbon steel
RD-302 Deethaniser
Reflux Drum
Orientation: Horizontal, Length: 4.89 m, Diameter: 1.63 m, DT : -21 °C, DP: 15.07 bar,
MoC: Carbon steel
RD-303 Ethylene Splitter
Reflux Drum
Type: Single stage centrifugal, Capacity: 0.253 m3/min, Head: 34 m, Shaft Power: 1.7 kW,
Efficiency: 45 %, IP: 14.01 bar, OP: 15.7 bar, DT: -80 °C, Driver Type: Electric motor, MoC:
P-301 A/B Demethanizer
Reflux pump Stainless Steel
Type: Single stage centrifugal, Capacity: 3.422 m3/min, Head: 36.9 m, Shaft Power: 14.5
kW, Efficiency: 70 %, IP: 13.01 bar, OP: 14.7 bar, DT: - 16 °C, Driver Type: Electric motor,
P-302 A/B Deethaniser MoC: Stainless Steel
Reflux pump
Type: Single stage centrifugal, Capacity: 8.586 m3/min, Head: 36.2 m, Shaft Power: 36.3
kW, Efficiency: 70 %, IP: 12.01 bar, OP: 13.7 bar, DT: -21 °C, Driver Type: Electric motor,
P-303 A/B Ethylene Splitter MoC: Stainless Steel
Reflux Drum
Ethane pressure
reduction Type: Adiabatic, Capacity: 20 630 kg/hr, DT:-118 °C,
VP-301 Valve IP: 12.01 bar, OP: 4.02 bar, MoC: Carbon steel
Type: Single stage centrifugal, Capacity: 48 800 kg/h, IT:

Methane rich gas -105 °C, IP: 14.01 bar, OP: 17.01 bar, Cp/Cv: 1.40, Power: 350 kW,
C-302 Product Efficiency: 65 %, OT: -89 °C, MoC: Carbon steel, compression ratio: 1.23
Compressor
Notes Abbreviations Meaning
SS Stainless steel
OP/IP/DP Operating/Inlet/Design Pressure
IT/DT Inlet/Design Temperature

MoC /SS /CS Material of Construction/ Stainless Steel / Carbon steel
4.5.4.1. Information Provided to other area engineers.
A-3-32
A-3-33
4.7.1.1. Process Control Diagrams
ent to
gas header
Figure 9 :The control diagram for the demethanizer column
A-3-34
ent
to gas
header
Figure 10:The control diagram for the deethanizer column
A-3-35
ent
to gas
header
Figure 11: The control diagram for the ethylne splitter column
A-3-36
4.7.1.3 Control Strategy
A robust process control strategy is crucial for chemical systems prone to disturbances to
maintain process at desired operating conditions to further maintain desired component quality
and quantity and further prevent occurrence of undesired events which can affect the
equipment lifespan, economics of the plant and further affect personnel and the environment.
In area 3 monitoring ethane and ethylene recovery is essential to achieve 99.95 mol% ethylene
final product purity and ethane concentration below 30 ppm in the propylene. Three types of
process variable are useful in the process control strategy which are controlled variables
(specific parameters the system aim to achieve at setpoint), manipulated variables (MV)
(dynamic parameters adjusted to reach set points) and disturbance variables (DV) (external
factors affecting controlled variables).
Three Levels process level strategy

Basis process control strategy is employed to maintain the controlled variable at a setpoint.
This is accomplished through either feedback control, which entails measuring the output and
adjusting the input to align with the setpoint, or the feedforward strategy, where the input is
measured and adjusted to prevent disturbances and deviations from the setpoint. For each
control loop the sensors provides measurements of process variables, transmitters convert
these into signals and transmit these into relevant control systems. The second level control
includes incorporation of low and high alarm to inform operators in case of abnormal situations.
The third level of control is the SIS which serves an emergency backup to BISC in cases where
critical process variables exceed specific alarm limit which suggests operation is outside safe
operational limits. These provides automated response via interlocks and automated shutdown
and start up systems.
Heat exchangers control

Set point outlet temperature of a heat exchanger can be influenced by various disturbances,
including changes in temperature and flowrate on the process side, as well as changes in utility
flowrate. In the context of all heat exchangers within area 3, a feedback control strategy is
employed on the temperature control loop specifically manipulating the flowrate of the utility.
The heat exchanger outlet temperature is measured and monitored through a temperature
sensor (TT) which transmits an electrical signal to the temperature controller (TIC), where
comparison to the specified set point is done. Consequently, the valve (TV) on the utility line
is manipulated to modify the utility flowrate, aligning with the setpoint temperature. See control
loop 310 for sample. Specifically for condensers vapor fraction pressure is affected, that is why
A-3-37
pressure control loops are suggested to prevent vapor lock or cavitation which could affect the
overall condensation process see loop 328.
Compressor control
The compressor C-301 plays a crucial role in the process to bring methane rich vapour product
to designated battery limits at 16 bar. A pressure feedback control loop is utilised a pressure
sensor (PT) continuously gives a measurement for discharge pressure and a signal is
transmitted to the pressure controller (PIC) which further sends an instruction to an actuator
(VSD) to respond accordingly. Compressing a gas is cost intensive and is a function of
compression ratio which is industrially capped to a threshold of 4 due to economic
considerations, and its correlation with discharge temperature is pertinent. To regulate this, a
temperature feedback control loop is usually used which involves adjusting compressor speed.
These loops could be coupled if needed however for simplicity pressure loop was utilised. See
loop 319.
Valve Control
Pressure reducing valve VP-301 is utilised to bring ethane to a required gaseous stage at
pressure > 3 bar allowing it to be used as fuel gas. The product quantity and quality (physical
properties) may be affected if no pressure reduction valve control loop is used. To do this
pressure feedback closed control loop 333 is used to maintain desired pressure of ethane gas
product. The pressure transmitter (PT) consistently measures the output pressure of ethane
and transmits the signal to the pressure control unit (PIC) which provide instructions to valve
to change it orientation to adjust flowrate accordingly.
Pumps control strategy

The pumps utilized in the area are mostly reflux pumps, which serve to enhance separation
efficiency and maintain product purity. The common control strategy employed for the pumps
includes variable speed drivers which is mostly utilizing to ensure optimum operating
conditions are met for example feedstock sensitivity units may suffer reflux ratio disturbances
to control this, pressure control loop 317 was utilised, the line pressure downstream
measurement is provided by PT, and the transmitter sends an electrical signal to the pressure
control (PIC) where a comparison to the setpoint occurs. The controller further notifies the VSD
to change the pump speed in response to an error. This control strategy is useful since in case
of an emergency shutdown instruction for the VSD is sent to avoid equipment damage and
any potential negative impact on personnel eliminating the need to couple a SIS control in the
loop.
A-3-38
Distillation column control strategy including reboiler,condenser and reflux drums

The reboiler and condenser temperature are controlled in the same way as a heat exchanger
the difference is using open and closed valves for cooling and heating respectively. The high
pressure (PAH), flowrate (FAH) and temperature (TAH) alarms are continuously fitted with their
respective monitors to ensure operators are always having complete view of operation.
Regarding pressure, all distillation columns in area 3 have a pressure-relieve valve (RD) fitted.
In industry an actuator (Solenoid) activates this in the event of high-pressure occurrence. The
use of FSH may have not been a good control strategy here since they only control gradual
pressure increases in case of surges the control is inactive.
The distillates from all three columns involved in Area 3 have the desired product quality and
composition. To ensure that the desired specifications are met, the temperature of each
column needs to be controlled. This is achieved using a temperature feedback loop. See loop
334 for sample temperature sensor (TT) continuously measure the temperature of column and
transmits an electrical signal to the temperature controller (TIC) where comparison to setpoint
occurs and sends instructions to adjust the reflux flowrate accordingly through CV-XX.Degree
of freedom analysis was done with respect to the columns objective and control variable is
distillate flowrate and purity while reflux rate is manipulated, since CV> MV unnecessary loops
were eliminated since tempting with distillate flowrate is impossible to fix this an extra loop on
reflux level drum is used to manipulate the reflux flowrate while maintaining flowrate and purity
upstream.
Controlling column depends on target which might be a case of recovery and purity in the
distillate or bottoms. The distillate flowrate and purity of the column is essential in area 3 since
it affects the recovery of ethylene and furthermore the purity in the ethylene splitter. Both
columns operate at total condenser meaning the outlet product is a totally liquid. The pressure
senser (PT) on the top of column measures the pressure of the top stream inlet to the
condenser and an electrical signal is transmitted to the flow controller (FIC) to adjust the
flowrate of the column top stream this was not shown. The reflux drums have level sensors
(LT) that continuously show the level of the reflux drum since this relates to the amount leaving
the reflux drum. The reflux drum are set to operate at half full capacity each time, a signal is
transmitted to the flowrate controller (FIC) which sends an instruction to the control valve (CV-
315) to change orientation such that the distillate flow is maintained.
The level of all drums in area 3 should all have been monitors and should not drop significantly
to avoid potential flooding. A level control loop see loop includes a LSLL along with a level
sensor (LT) which continuously provide column level reading ,in events of level drop a high
A-3-39
level alarm (LAH) will be triggered to alert the operator in duty and this will be triggered first
before the LSLL.A transmitter sends a signal then to the control valved to either change
orientation or close entirely in case of LSLLA. This was not done in details due to time
constraints.
4.7.1.2. Start-up and Shut Down Strategy
Startup and shutdown stages hold significant importance due to their potential negative impact
on personnel and equipment if not executed correctly. Differentiating between reversible and
irreversible unit operations offers guidance during startup. Simultaneous inverse operations
play a key role in distinguishing these types. Reversible units can function independently
without the need for process stream adjustments due to inverse operations. For instance, in
the case of a distillation column, the presence of a condenser and reboiler indicates
reversibility. Reversible units are initiated first, based on utility source availability. Irreversible
units are introduced later. This implies that sections related to product finishing are prioritized
during startup. [8]
The pre-start up procedure employed on the distillation column is essential since it improves
the overall efficiency while ensuring safe operation. The column integrity inspection is done
which included checking structural integrity of the column, leaks inspection and ensuring all
the valves are in position required for the start-up. The column undergoes a water wash to
remove any contaminants that might impact separation. Air drying is done to eliminate any
trace of water. The feed flows into the column, the reboiler and condenser along with their
utilities are activated. The column is allowed to operate without taking any product out to reach
steady state. The top and bottom temperature are controlled manually at first to meet the
required specification after which the column is set to automatic mode.
During shutdown, units are deactivated in reverse sequence. Irreversible units are turned off
first, followed by cutting off the utility source. Subsequently, heat exchangers are shut down,
along with other auxiliary equipment. The minor units, demethanizer, deethanizer, and
ethylene splitter are then shut down in this order.
Intermediate operating states, serving as transitional phases between startup and standard
operation, establish a methodical framework for effectively managing emergency shutdown
scenarios. This structured approach permits unaffected equipment to remain at their operating
conditions while targeted issues are addressed. This method enhances safety measures,
curtails operational disruptions, and consequently diminishes downtime. By enabling operators
to concentrate on resolving specific concerns, this approach significantly contributes to a more
efficient and controlled recovery process.
A-3-40
A-3-41
1.1 Health, Safety and Environmental Impact

Table 15 : The detailed hazop inventory for area 3 of ethylene production plant
Magnitude of Release Significant Mechanisms of Chemical Release Assumptions/ Uncertainties
Process Chemicals Maximum Maximum flowrate Temperature Range Location Types of]Consequences
Pressure (kg/h) (˚C) (SHE)
(bar)
TWA: 200 ppm LD50: N/A LFL: 2.7% Dealing with mixtures, only analysing S-Flammable and explosive
the individual flammability of
Ethylene (C2H4) 14 108 900 -90 to 8 All area 3 UFL: 36% H-Respiratory irritation
components. Appreciating a significant
Except for Auto ignition T: 450 ˚C amount into the area 3 E-ground level ozone formation
deethanizer
bottoms
TWA: 500 ppm LD50: N/A Dealing with mixtures, only analysing S-Flammable, explosive with air
the individual flammability of
Propylene (C3H6) 14 165 500 -90 to 30 All area 3 LFL: 2% UFL 11.1 % Auto ignition T: H-Eye, nose and throat irritation
components. Appreciating a significant
455 ˚C amount into the area 3 E-Forms ground level ozone
All area 3 till TWA: 1000ppm LD50: N/A Dealing with mixtures, only analysing the S-Explosive
individual flammability of components.
Methane (CH4) 16 29 670 -105 to 25 demethanizer bottoms LFL: 5% v/v UFL 15% v/v Auto ignition H-asphyxiation
Appreciating a significant amount into the
T: 537.2 ˚C area 3 E-Greenhouse gas
TWA: 1000 ppm LD50: N/A Dealing with mixtures, only analysing the S-Explosive and highly flammable
Ethane (C2H6) 14 20640 -95 to 25 All area 3 LEL: 3% UEL 12.5% Auto ignition T: H-Dizziness and respiratory issue
472 ˚C area 3 E-Air pollution and smog formation
TWA: 1000ppm, PEL:1000 ppm LFL: 2.3 Dealing with mixtures, only analysing the S-Flammable, explosive with air
Propane (C3H8) 14 26 530 -90 to 30 All area 3 mole % UFL 9.5 mol % H-Eye, nose and throat irritation
Auto ignition T: 480 ˚C area 3 E-Forms ground level ozone
All area 3 TWA: 5000ppm STEL: 30000ppm LD50: Dealing with mixtures, only analysing the S-Flammable and explosive in
N/A presence of air
Hydrogen (H2) 16 2480 -105 to 25 LFL: 4% UEL 75% UEL area 3
Auto ignition T: 571 ˚C
All area 3 TWA: 5000ppm LD50: N/A LFL: N/A Dealing with mixtures, only analysing the S-asphyxiation
UFL N/A H-dizziness and loss of
Nitrogen (N2) 16 9 555 -105 to 25 Auto ignition T: N/A area 3 consciousness
E-Water pollution and disturbs
ecosystem.
A-3-42
Table 16 : The hazard inventory fomr provided to specialist engineer
Hazard Location Mechanism of Release Rank of risk Controls in Place

Control valve failure eg pressure -Proper PPE to be worn each time
distillation columns, compressor reducing valve not operational, -Installation of level alarms
Explosion ignorance by operators and fault High -Automated control within each
equipment column
Top of distillation columns, stairs Faulty due to maintenance or -Inclusion handrails to provide
Gravitational energy pull: and manholes leading to raised mistake and cultural violations. Low support in the stairways.
Falling equipment -Inclusion of handrails for all
columns
Demethanizer is the coldest stream -warning signs in all cryogenic
E-308 (Hot), distillation columns in the are with -105 C equipment
Cryogenic fluids (Cold) Medium -Proper installation and regular
maintenance
Thermal energy release All process stream heating units Faulty equipment potentially due to Medium -Proper installation by experienced
utilizing low pressure steam lack of maintenance eg leaks and personnel
faulty control valves in utility line -Warning signs on all units utilizing
steam at elevated temperatures
A-3-43
4.7.1.3. High level Risk Assessment : Unwanted event(s)

Unwanted event(s)
The demethanizer in the area operates at a high pressure of 13 barg and a highest flowrate of
. This increases the potential consequences in case of unwanted events. The column contains
a significant amount of vapor due significant number of non-condensable gases like methane.
This contributes to two potential unwanted scenarios: pressure build-up beyond the column's
design limits (vapor cloud formation) and column fouling. Vapor cloud formation could occur if
there are changes in flowrate, operating conditions and worse should there be unresponsive
high-level alarms. These situations may lead to vapor filling the limited vapor disengagement
space in the trayed column design used in the process.
What could be causing it

The column's design includes trays with bubble caps, which can only handle a certain amount
of vapor accumulation. Exceeding this capacity may cause column rupture, leaks, or even an
explosion, especially if there's an ignition source. A similar situation happened in the BP Texas
City petrochemical accident, resulting in 15 fatalities and major equipment damage due to
pressure build-up.
When is the unwanted event highly likey to happen and prevention measures
The event is likely to occur during startup or shutdown. It is recommended to ensure personnel
are evacuated during this period. The layout engineer should ensure that the control room and
storage tanks containing explosive hydrocarbons are located at a safe distance from the blast
zone. The plant should consider implementing an emergency shutdown system to respond to
abnormal situations and prevent undesired events.
The work process model should be implemented which involves hiring competent personnel
which will minimises errors and cultural violations, maintaining a safe work environment (e.g.,
keeping cars and smoking areas away from blast zones), and using equipment fit for purpose
like suitable equipment like reliable control sensors, alarms with automated responses. Proper
maintenance and continuous risk assessments should be carried out to prevent such incidents.
This approach helps mitigate potential risks and ensures safer operations. The hydraulic
design was not carried for this column thus it remains a high risk in this area.
A-3-44
4.7.1.4. Environmental Assessment

Environmental assessment for area 3 was conducted, focusing on energy demand and carbon
footprint (CO2 emissions). CO2 emissions are categorized into direct and indirect. Direct CO2
emissions in Area 3 were negligible due to prior CO2 removal in Area 1 during feed preparation.
Indirect emissions were based on electricity and steam generation for pump, heat exchanger,
and reboiler operations. Electricity generation was assumed to have an emission factor 1.06
kg e CO2 /kWh, with 45% energy generation efficiency. Results summarized in Table XX.
Sample calculation is shown below for this.
Duty utilised = 360 kW for the compressor C-301
𝐶𝑂2 𝑒𝑚𝑖𝑡𝑡𝑒𝑑 = (1.06 𝑘𝑔 𝐶𝑂2/𝑘𝑊ℎ) ∗ 360 𝑘𝑊 ∗ (8000 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 ℎ𝑟𝑠 /𝑦𝑟)
= 3050 𝑡𝑜𝑛/𝑦𝑟
Table 17 : Indirect CO2 emissions from electricity production
Equipment label Duty (Kw) CO2 (ton/yr)
C-301 360 3050
Total 360 3050
Low pressure steam used in reboilers was assumed to be from natural gas with an energy
generation efficiency and emission factor of 90% and 0.18 kg CO2, respectively. This
accommodated the presence of CH4 and NO2's .
Table 18: Indirect emissions from steam generation presented.

Equipment label Steam type Total CO2 (ton/yr)
T-301 Low Pressure 71 500
T-303 Low Pressure 95 600
E-306 Lopw Pressure 7 140
E-309 Low Pressure 10 300
Total 185 000
Total indirect CO2 emissions from Area 3 estimated at 185 000 ton/yr, assuming 8000 hours
operation annually. No emissions in Area 3 from waste creation, disposal, or liquid effluent to
the environment. See Appendix for sample calculations.
A-3-45
Financial Assessment
4.7.1.5. Capital expenditure on equipment’s
The cost analysis provided in the subsequent sections is based on the method outlined by
Chapter 22 of Seader's 3rd edition. This involves employing correlations, some of which are
shown in the appendix, utilizing equipment dimensions derived from duty, flow rate, capacity,
and area whichever applicable. Purchase costs are individually determined for each equipment
piece. The bare module costing methodology, as explained, is employed to calculate a
coherent final equipment cost. This approach accommodates considerations like material of
construction, correction factors, design elements, capacity factors, unit types, and location-
related factors where relevant. The calculations draw upon a CEPCI of 499.6, and for 2023, a
recent CEPCI value of 803 is applied due to the necessity of exporting equipment from the
United States to Angola. A location factor of 1.407 is factored in to address this export context.
Conversion to Kwacha was not done for this project since it is not significant.
For heat exchangers, including reboilers and condensers, individual costs are evaluated based
on their type, heating area required encompassing options such as shell and tube, as well as
floating head. Commonly shell and tube heaters with one pass, guided by a heuristic indicating
their preference for cases where the volume exceeds a certain threshold were employed in
area 3. Reflux pumps costs were influenced by parameters such as volumetric flow, power,
and head and motor costing was also doen where the pc of a motor was always a function of
a purchase cost of the pump. A centrifugal pump assumption is made across the board, with
each pump accompanied by a secondary backup, included in the final cost as a contingency
measure. Compressors in Area 3 costing was based on type and power utilization. Columns
and reflux drums costs depended on factors like outlet diameter, total height, and design
pressure, contingent on maximum operating pressure specifications.
To calculate operational expenses linked to temperature-changing units, utility prices are

sourced from Area 4 engineers and other provided data in the brief. In estimating operational
labour, a model of three shifts per day is employed, encompassing a varying number of
standby operators (3, 2, and 1 for each shift). Additionally, the hiring of a specialist engineer,
serving as a supervisor, and a foreman per section within the broader area is assumed.
Working capital was assumed to be 15% of the fixed capital investment. Due to time constrains
sensitivity analyses for the cost implication arising in area 3 would be done in details and
included in the finance report.
A-3-46
Table 19: CAPEX Breakdown for equipment in area 3

CAPEX breakdown:
E-301 $697 900.00
E-302 $747 400.00
E-303 $170 800.00
E-304 $233 700.00
E-305 $328 400.00
E-306 $192 700.00
E-307 $1 214 000.00
E-308 $435 400.00
E-309 $1 048 000.00
E-310 $553 600.00
P-301 A/B $1 214 000.00
P-302 A/B $15 700.00
P-303 A/B $154 000.00
T-301 $308 800.00
T-302 $1 466 000.00
T-303 $1 640 000.00
RD-301 $162 400.00
RD-302 $384 900.00
RD-303 $265 800.00
Table 20 :OPEX Breakdown for coolers and heaters

Utility Unit Absolute Duty (kW) Usage (kg/hr) $/hr Cost ($/yr)
Low pressure steam E-304 28330 48920 293.5 2348000
E-306 26570 45900 275.4 2203200
E-309 37900 65440 392.6 3140800
E-305 4068 7026 42.16 337300
E-310 2830 4887 29.32 234600
Total 99698 172173 1032.98 8264000
Ethylene -51 E-301 31910 297500 234.3 1874400

Total 31910 297500 234.3 1874400
Ethylene-95
E-302 22 880 177700 146.5 1172000
E-307 23030 178900 147.4 1179000
E-308 38080 295800 243.8 1950400
Total 83 990 652 400 538 4301000
Duty (kW) GJ/yr $/GJ $/yr

Refrigerant (-160 C) E-303 11940 343800 200 68784000
Total 11940 343800 200 68784000
A-3-47
Table 21: The electricity breakdown cost for area 3

Absolute Duty (kW) Usage (kg/hr) $/kWh Cost ($/yr)
Electricity P-301 A.B 1.7 - 0.018 244.8
P-302 A.B 14.5 - 0.018 2088
P-303 A/B 36.3 - 0.018 5227.2
C-301 2990 - 0.018 430560
Total 3042.5 - 0.072 438100
Table 22: Total expenditure estimate

Category Cost ($/year)
Raw Materials N/A
Utility cost 116 600 000
Labour 50 540
Waste disposal N/A
Total with depreciation
Total without depreciation
Pinch Technology Data : Information provided to a heat integration specialist
Table 23: The pinch analysis data sent to the specialist engineer
Stream Unit Temperature Temperature Heat Capacity Mol
Number Code in (K) out (K) of mixture Flowrate
(J/kmol.K) of mixture
(kmol/s)
301 E-301 281 238 54210 3.48
302 E-302 238 183 63640 3.48
Condenser E-303 198 168 34500 1.0205
inlet
Reboiler inlet E-304 249.3 259 63020 2.46
305 E-305 180 298 34660 1.0205
Condenser E-306 233 231 121600 1.26
inlet
Reboiler inlet E-307 303 303.3 94700 1.2
Condenser E-308 227 227 81400 1
inlet
Reboiler inlet E-309 247 247 94600 0.19
311 E-310 214.6 298 73740 0.1905
A-3-48
Table 24: The units using heating or cooling along with usage and duty for optimised case
Usage
Utility Unit Absolute Duty (kW) (kg/hr)
Low pressure steam E-304 28330 48920
E-306 26570 45900
E-309 37900 65440
E-305 4068 7026
E-310 2830 4887
Total 99698 172173
Ethylene -51 E-301 31910 297500

Total 31910 297500
Ethylene-95
E-302 22 880 177700
E-307 23030 178900
E-308 38080 295800
Total 83 990 652 400
Duty (kW) GJ/yr

Refrigerant (-160 C) E-303 11940 343800
Total 11940 343800
Total cost
heater/coolers
Possible heat integration opportunities for area 3

A pinch analysis could have been done to locate a pinch before heat integration can occur.
Ethane
The ethane leaving the column at 12 bars could have its pressure reduced close to 1
atmosphere, where it has a boiling point of significantly reduces allowing it to be utilized as a
refrigerant instead of using steam, which is an expense to the company to raise its exit
temperature. Referencing the physical property sheet of ethane , this motivated the use of a
pressure reduction valve so that ethane can be used as a refrigerant if viable if not it will be
raised to near ambient temperature to ensure proper handling.
The heater responsible for cooling the demethanizer handles a high flow rate and requires a
significant change in temperature. To overcome this, in the final process diagram, a prior
heater was implemented to initially cool the stream before it is sent to the subsequent stream.
A-3-49
This practical approach recognizes that even with comprehensive heat integration, the utility
flow rate might be a limiting factor, potentially lacking the capacity.
The use of a joule Thompson pressure reduction valve

The joule expansions valvese may be investigated as outlined before. However, this involved
a lot of pressure and temperature changing units to regulate operation once in place.
Substituting lps in some reboilers for propylene at a significant higher temperature

compared to cryogenic reboiler outputs.
Using propylene refrigerants at temperatures of 0°C and 20°C in the reboiler of a refrigeration
cycle, instead of low-pressure steam (LPS), is being explored. Observing reboiler
temperatures and the characteristics of propylene refrigerants at these temperatures has
suggested potential substitution of LPS in certain reboilers. However, simulating this in Aspen
resulted in errors. Investigating these effects is valuable due to heuristic suggestions favouring
this substitution.
Choosing which ethylene to use in the heaters

The ethylene utilized as refrigerants are coming at -51 C and -95 C, where possible substitution
of ethylene -51 with ethylene -95 C made a significant toral hourly cost difference which might
be profitable in the long run.
Using Methane rich gas straight as a fuel for area 1 may be analysed instead of sourcing
outside, however this will entirely depend on the quality needed before it can be utilised as a
fuel gas.
A-3-50
A-3-51
4.7.2.6 Project Management information for area 3 sschedule in completing the duties
27-Jul-23 28-Jul-23 31-Jul-23 01-Aug-23 02-Aug-23 03-Aug-23 04-Aug-23 05-Aug-23 07-Aug-23 08-Aug-23 09-Aug-23 10-Aug-23 11-Aug-23
Thursday Friday Monday Tuesday Wednesday Thursday Friday Sartuday Monday Tuesday Wednesday Thursday Friday
8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM
1 Problem Definition
1.1 Define the process funtionality of Area 3
1.2 Define the performance requirements/specifications for Area 3
2 Process Development
2.1 Literature review pertaining to Area 3
2.2 Work on sequencing for the unit operations in Area 3
2.3 Identify all process equipment needed for Area 6
2.4 Identify all transfer equipment needed for Area 3
3 Process Modelling
3.1 Ongoing literature review and selecting suitable thermodynamic model
3.2 Perform regression analysis and choose most appropriate thermodynamic model
3.3 Develop initial ASPEN flowsheet for Area 3
3.4 Explain how model chosen works for the simulation and list all assumptions
3.5 Meet with other group accountants to keep on track and share ideas
4 Process Optimization and specialist

4.1 Optimise the ASPEN flowsheet for Area 3
4.2 Perform sensitivity analyses and establish best operating conditions
4.3 Compare the final base and Optimised Area 3 cases
4.4 Assess the implications of the sensitivity analyses on control and operation
4.5 Specialist research and meeting with other accountants to share information
14-Aug-23 15-Aug-23 16-Aug-23 17-Aug-23 18-Aug-23 19-Aug-23 20-Aug-23 21-Aug-23 22-Aug-23 23-Aug-23 24-Aug-23
Monday Tuesday Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday
8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM8-12 AM2-5 PM 7-10 PM
5 Equipment Specification and specialist research

5.1 Create a functional accounting template and including textbook references
5.2 Provide approximate dimensions for auxillary equipment
5.3 Perfom Equipment Sizing
5.4 Perfom equipment costing
6 Information Handover
6.1 Prepare process decription for Process Coordinator
6.2 Prepare process flow diagram for Process Coordinator
6.3 Prepare stream tables for Process Coordinator
6.4 Prepare plant control diagram for Control Engineer
6.5 Prepare control strategy description for Control Engineer
6.6 Prepare Gantt Chart and critical path for Project Planning Engineer
6.7 Prepare Health, Safety and Environemntal Information for HSE Officer
6.9 Prepare heat integration and carbon footprint information
7 Report printing and handover specialist

7.1 Assess the methodologies used if an difference occurred
7.2 Preparing financial analysis section
7.3 Peforming profitability analysis
7.4 Go into detail to complete the economics section objectives
Legend
Deadline
Event : Meeting
Start
Finish
A-3-52
Conclusion
A-3-53
Recommendations
• Conduct a comprehensive optimization and hydraulic design of the demethanizer
column and the ethylene splitter, focusing on energy requirements and cost factors,
following the methodology applied to the deethanizer column.
• An in-depth and comprehensive control strategy must be implemented for this area, as
only basic control loops were employed due to time constraints. Real-life applications
often operate under dynamic conditions and are susceptible to disturbances such as
variations in feedstock quality and flowrates. Additionally, the system may exhibit
nonlinear behavior, making swift response and effective mitigation of effects
challenging. This has a detrimental impact on the quality and purity of essential
components, as well as the overall efficiency and safety of the plant.
• Low pressure cryogenic distillation may require more energy compared to high
pressure as seen from the optimization, it is recommended to operate the plant at
moderate pressure to avoid energy intensiveness which drives cost.
• The ethane product from the ethylene splitter should be used to initially cool the feed
to the demethanizer along with xx in a cascade to avoid using a larger heater for this
huge temperature difference.
• The use of the Joule Thompson valve should be considered to improve energy
utilization.
• The separation of hydrogen using crogenic distillation to eliminate it concentration on
methane rich gas while generating revenue is suggested.
• A detailed pinch analysis on the cold streams in are 3 should be done to properly
improve on the current optimization opportunities as discussed in section xx.
• Proper research on ethane refrigerant utilization is essential this will eliminate the use
of low pressure steam and further decrease in indirect carbon footprint.
• The methane can be utilised in area 1 as fuel gas this can be done following a careful
analysis of impact the concentration of gas may have on the operation in area 1.
A-3-54
References
[1]. Turton, R. et al., 2009. Analysis, Synthesis and Design of Chemical Processes. Boston:
Prentice Hall.
[2]. Aspen Technology, Inc., 2000. Aspen Plus User Guide. Cambridge: Aspen Technology,
Inc
[3]. Seider, W., Seader, J., Lewin, D. & Widagdo, S., 2009. Product and Process Design
Principles. 3rd ed. s.l.:John Wiley $ Sons.
[4]. Sinnott, R., 2005. Coulson and Richardson's Chemical Engineering Volume 6 - Chemical
Engineering Design. 4th ed. s.l.:Elsevier.
[5]. Zimmermann, H. & Walzl, R., 2012. Ethylene. In: Ullmann's Encyclopedia of Industrial
Chemistry. Pullach: Wiley
[6]. S I Consulting in ,‘’Advances in naphtha steam cracking’’, December (2005),report
number.248A.
[7]. Technip, 2015. Ethylene Production, Paris: Technip
[8] Borralho, F., 2013. Detailed Modelling and Optimisation of an Ethylene Plant, Lisbon:
Instituto Superior Tecnico
[9]. Luyben, W., 2013. NGL Demethanizer Control. Industrial & Engineering Chemistry
Research
A-3-55
Appendices
Appendix A
Literature review
Table comparing different column internal for tray towers
Comparison Sieve Valve Bubble cap
Capacity Mid High Lowest
Pressure drop Lowest Mid Highest
Turndown ratio Lowest Highest Mid
Effectiveness Mid lowest highest
Cost Cheapest 20% more than sieve Most expensive
Entrainment
Appendix B : Base case design
The tree diagram used to select the correct thermodynamic model on Aspen.
Demethanizer comparison of model with NIST Data
Mole fraction of ethane with change in pressure

model comparison
1.6
1.4
1.2 Series3
Pressure psia
1
Series4
0.8
Vap exp
0.6
0.4 Liq exp
0.2 PR liq
0 PR Vap
0 0.2 0.4 0.6 0.8 1
mole fraction of methane
Figure xx: The comparison of two best models for demethanier column versus experimental
data
A-3-a
Ethylene P-xy diagram comparing model predictions to

1.6 experimental data
1.4
1.2
Pressure psia
1
0.8
0.6
0.4
0.2
0
0 0.2 0.4 0.6 0.8 1
mole fraction of ethylene
Liq exp Vap exp LK-P vap LK-Liq PR Vap PR Liq
The comparison of two best models for ethylene splitter verus experimental daya.
Appendix C : Hydraulic Design and sizing of Deethanizer column
Deethanizer Operating and design conditions

The design temperature is 25 °C above the maximum operating temperature [xx]. The design
pressure was assumed to be 1.7 bar above the maximum operating pressure which is itself
1.7 bar from the column pressure [xx].
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = −41 ℃
𝐷𝑒𝑠𝑖𝑔𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = −41 + 25 = −16 ℃
𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 13.01 𝑏𝑎𝑟
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 13.01 + 1.7 = 14.7 𝑏𝑎𝑟
𝐷𝑒𝑠𝑖𝑔𝑛 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 14.7(1 + 10%) = 16.2 𝑏𝑎𝑟
Column Diameter
The column diameter based on the stripping section of the column depends on the vapour
flowrate flowing towards the top of the column. If the velocity is too high the column may suffer
excessive liquid entrainment and pressure drop which is not desirable. The diameter
calculations were done using the method outlined in Seader et al. (2011) for the column
operating at an optimum reflux ratio of xx and 54 stages fed at 30th tray.The profiles of Aspen
were used to calculate diameter at top and bottom stage.The largest column was then used to
calculate the final column area.
A-3-b
Calculating the FLV at for the top and the botto stages
FLV calculations
Rectifying top stream Bottoms Units
Liquid flow 0.977 3.2 kmol/s
Gas flow 2.19 1.94 kmol/s
Molecular weight
liquid 28.4 42.3 kg/kmol
Molecular weight gas 35 42.3 kg/kmol
Density liquid 19.5 1.68 kg/m3
Desity gas 490.6 510 kg/m3
FLV 0.0722 0.0947 See E-1
Determining C
Rectifying-Top Bottoms Comments/ units
CF 0.37 0.33 See E-3
Surface
tension 6 9 Dyne/cm
FST 0.786 0.852 See E-2
FF 1 1 foaming, bottom liquid*
FHA 1 1 See condition E-1
C 0.2908 0.281 Graph F-1
Table xx:
Calculating uf
Top Bottoms Comments
C 0.2908 0.2812 see above F-1
PL 490.6 510 Kg/m3
PV 19.5 1.68 Kg/m3
Uf 0.436 1.491 m/s
Ad/A 0.1 0.1 See criterion Q-1
Finding DT
Top Bottoms Comments
V 2.1891 1.94 kmol/s
Mv 35 42.3 kg/kmol
F 0.8 0.8 0.5-0.8 range given
Uf 0.436 1.491 m/s
PV 19.5 1.68 kg/m3
Ad/A 0.1 0.1 See Q1-Above
DT 3.99 7.61 E-4
DT 13.103 24.97 Ft
E-1 : Finding FLV
A-3-c
F-1 : CF Graph F-1
E-2 : Finding FSH

𝑭𝑺𝑯 = (𝑺𝒖𝒓𝒇𝒂𝒄𝒆 𝒕𝒆𝒏𝒔𝒊𝒐𝒏/𝟐𝟎)𝟎. 𝟐
E-3 Finding C
Condition E-1 for selection of FHA and FF
Q-1 : Criterion for Ad/A selection
E-4 Finding Diameter
A-3-d
Table xx: Head calculations

Vapor Pressure
drop Units Comments
Column area 45.49 m^2 See E-5
Q 31.74 m^3/s
vapour velocity 0.6978 m/s
Tops Bottom
Ad 4.55 4.549 See E-6
Aa(active area) 36.4 36.4 See E-7
Ah(hole Area) 3.64 3.64 See E-8
Uo(hole velocity) 0.272 0.188
Co 0.73 0.08 Normally 0.73 []
Hd 0.282 0.011 mm of liquid See E-9
Weir Comments
Lw(weir length) 2.915 5.56 M 0.77*Diameter
hw(weir height) 0.05 0.05 M (assumed)
Ua 0.0272 0.0188 m/s
Ks 0.00553 0.00108 m/s See E-10
QL 0.03816 0.328 m^3/s
phiL 0.895 0.975
C 937.39 937.4
Hl 50.217 140.9 mm of liquid
Dbmax 0.005 0.005 M Assumed
Hsigm 0.196 0.204 mmliquid See E-11
Ht 50.69 141.12 mm of liquid See E-13
HT 243.98 706.04 Pa
Checking weeping 50.22 140.9 mm of liquid
E-5 Cross sectional area of the column

𝐷𝑐,𝑓 2
𝐶𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 (𝐴𝑐) = 𝜋 ∗ ( )
2
E-6 Downcomer area
𝐷𝑜𝑤𝑛 𝑐𝑜𝑚𝑒𝑟 𝑎𝑟𝑒𝑎 (𝐴𝑑) = 0.12 𝐴𝑐
E-7 Active area calculations
𝐴𝑐𝑡𝑖𝑣𝑒 𝑎𝑟𝑒𝑎 (𝐴𝑎) = 𝐴𝑐 − 2𝐴𝑑
E- 8 Calculating hole area
A-3-e
𝐻𝑜𝑙𝑒 𝑎𝑟𝑒𝑎 𝐴𝑛 = 10% ∗ 𝐴𝑎
E-9 Dry pressure drop estimation
E-10 Dry pressure drop estimation
E-11 h sigma estimation
E-12 Total pressure drop
Checking if the spacing assumed is acceptable

E-13 Criterio used to check if the spacing is acceptable
As seen for the bottom stage ht of 50.69 and 141 which is greater than the hb of 0.215 [0.011+
0.204] and 0.477[0.282+0.196] respectively thus 0.55 m for tray spacing is acceptable.
Actual Column height (H)

𝐻 = (𝑁𝑎𝑐𝑡𝑢𝑎𝑙 − 1) × 𝑇𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑣𝑎𝑝𝑜𝑢𝑟 𝑑𝑖𝑠𝑎𝑛𝑔𝑎𝑔𝑒𝑚𝑒𝑛𝑡 + 𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟 𝑟𝑒𝑡𝑢𝑟𝑛
Assume tray spacing of 0.55 m [xx]. An additional height for vapour disengagement and liquid
reboiler return of 1.219 m and 1.829 m respectively is suggested
For the external diameter a heuristic for stainless steel suggested a thickness of 2.5 % from
the calculated internal column diameter
A-3-f
The final calculations

Deethanizer units
Spacing 0.55 m
Thickenss of tray 0.001 m
Number of plates 52 m
Height 28.652 m
Top height 1.219 m
Bottom Height 3.047 m
Final column height 32.918 m
L/D 4.33
Liquid Flow arrangement

The choice of plate type which can be reverse, single pass or multiple pass is dependent on
the liquid flowrate and column diameter. The figure from Huang and Hodson was used and the
liquid flow pattern for the system was determined as single pass.
The entrainment was estimated to be 0.0001 using the figure 11.29 from Coulson and
Richardson 2006 a rough guide gives the limit of 0.1 to which makes the effect on efficiency to
be very small. Thus, it is perfect to assume no entrainment at all.
The Downcomer Residence time
The sufficient residence time must be allowed in the downcomer for the entrained vapour to
disengage from the liquid steam. This time must always be greater than 3 seconds for this to
happen.
The residence time was calculated for the column using the equation below and it was above
recommended range.
𝐴𝑑 ∗ ℎ𝑏 ∗ 𝜌𝐿
𝑡𝑟 =
𝐿𝑤𝑑
This should begreater than 3 seconds
A-3-g
Appendix E : Health and safety information
Figure xx: Propylene safety data sheet
A-3-h
:Ethylene safety data sheet
Appendix D: Equipment sizing and costing using Heuristics

Equipment sizing method
Heuristics from xx[] has been used to accurately size all the equipment used in the simulation
of area .The excel sheet created by the team’s accounted was used to ensure consistent
methodology throughout.The design pressure and temperature were found by the formulas
below.
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = 183.6 ℃
𝐷𝑒𝑠𝑖𝑔𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑜𝑝𝑒𝑟𝑎𝑖𝑛𝑔 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 + 25
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 + 1.7
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒(1 + 10%) = 22.77 𝑏𝑎𝑟
Distillation column sizing approach used

To accurately size the demethanizer and ethylene splitter certain inputs from aspen were
required which are: relative volatility of the feed, feed flowrate ,vapour density inside the
volumetric flowrate into the column, operating pressure, feed temperature and compositions
of the key components in the feed,bottoms and the distillate of the column.
A-3-i
The equipment list shown in section xx of report of contains information regarding the various
sizes, duties and other information necessary to design the area. All the equipment has been
and costed using sized using the heuristics in [] and []. A breakdown of the assumptions and
tables used is given below for each unit type. A sizing template developed in excel has been
used by all area engineers to ensure consistent results.
The given number of stages from Aspen has been used as a theoretical number of stages and
a safter factor of 10% was assumed.The trays were assumed to have an efficiency of 80%.
The total height of the column was determined using the formular which accounts for vapour
disengagement and liquid level.A spacing if 0.55 m was assumed.
column sizing input parameters from Aspen

Parameter Value Unit
Number of theoretical stages 43
Operating pressure 14.01 bar
Top stage temperature -105 °C
Distillate flowrate 13.56 kg/s
Reflux ratio 0.907
Bottoms density 529.95 kg/m3
Distillate density 14.64 kg/m3
Average molecular weight 25.7 kg/kmol
Actual number of stages

Safety factor of 10% and tray efficiency of 80 % was used from xx.
𝑁𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = ( ) × (1 + 𝑠𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟)
𝑇𝑟𝑎𝑦 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
43
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = ( ) × (1 + 10%)
80%
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 53.75 ≈ 54 𝑠𝑡𝑎𝑔𝑒𝑠
Column height (H)
𝐻 = (𝑁𝑎𝑐𝑡𝑢𝑎𝑙 − 1) × 𝑇𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑣𝑎𝑝𝑜𝑢𝑟 𝑑𝑖𝑠𝑎𝑛𝑔𝑎𝑔𝑒𝑚𝑒𝑛𝑡 + 𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟 𝑟𝑒𝑡𝑢𝑟𝑛
To find the total height of the column a vapour disengagement and reboiler return of 1.219 m
and 1.829 m respectively is advisable [12]. One stage must be deducted from the total number
of stages to account for the the partial reboiler stage.
𝐻 = (54 − 1) × 0.55 + 1.219 + 1.829

𝐻 = 32.2 𝑚
Column diameter (D)
A-3-j
(25.7) × (14 × 100000) 1 𝑘𝑔

𝜌𝑣 = × = 25.8 𝑘𝑔/𝑚3
(8.314) × (−105 + 273.15) 1000 𝑔
Vapour velocity was useful in finding the columns diameter as suggested by seader seader [].
1⁄
(𝜌𝐿 − 𝜌𝑣 ) 2
𝑢𝑣̇ = (−0.171𝑙𝑡2 + 0.271𝑙𝑡 − 0.047) [ ]
𝜌𝑣
(529.95 + 25.8)
𝜌𝐿 = = 278 𝑘𝑔/𝑚3
2
1⁄
(278 − 25.8) 2
2
𝑢𝑣̇ = (−0.171 × 0.55 + 0.271 × 0.55 − 0.047) [ ]
25.8
𝑢𝑣̇ = 0.21 𝑚/𝑠
4𝑉𝑤̇
𝐷= √
𝜋𝜌𝑣 𝑢̇ 𝑣
𝟒 × 𝟐𝟓. 𝟖𝟓
𝑫= √
𝝅 × 𝟏𝟒. 𝟔𝟒 × 𝟎. 𝟐𝟗𝟖
𝑫 = 𝟐. 𝟒𝟔 𝒎
Note Vw was calculated using the reflux ratio and distillate flowrate to get the actual vapour
flowrate out of the distillation column preceding to the condenser. The vapour density was
calculated under the assumption of ideal gas law as seen earlier.The ethylne splitter was
sized using the same heuristics.
Wall thickness, corrosion allowance and outer diameter

𝑶𝒖𝒕𝒆𝒓 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓 = 𝑰𝒏𝒏𝒆𝒓 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓 + 𝟐 × (𝒘𝒂𝒍𝒍 𝒕𝒉𝒊𝒄𝒌𝒏𝒆𝒔𝒔 + 𝒄𝒐𝒓𝒓𝒐𝒔𝒊𝒐𝒏 𝒂𝒍𝒍𝒐𝒘𝒂𝒏𝒄𝒆 )
(𝟗. 𝟕 + 𝟑. 𝟖 )
𝑶𝒖𝒕𝒆𝒓 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓 = 𝟐. 𝟒𝟔 + 𝟐 × = 𝟐. 𝟒𝟗 𝒎
𝟏𝟎𝟎𝟎
MOC of Columns
The columns were assumed to be made of stainless steel because .The columns internals
were bubble cap trays as discussed in the earlier section due to their efficiency specifically in
cryogenic distillation use. The columns were assumed to work with no pressure.
Sizing of heat exchanger.
The inlet and outlet temperature of the stream undergoing temperature change were used to
find the log-mean temperature. The minimum approach temperature of the refrigerants and
fluids were assumed to be 5 C and 10 C respectively. The simulator used gave the duty related
to the unit operation, a safety factor of 10% was assumed for all the heaters and factored the
duty. A correct heat coefficient of in units W/m2.C was used thus conversion from kW to W
A-3-k
was done to get area in square meters. The F value for this two ancillary equipment was
assumed to be 1. The triangular orientation for tubes of 23.4 mm was assumed since xx and
a tube length of 4.9 m was chosen. The outlet diameter was assumed to be xx m[]
Type of heat exchanger:
Ideally shell and tube are recommended however xx. The specific type depends on the heat
transfer area. Should the estimated area be > 18.6 m2 the shell and tube should be utilised if
not a double tube heat exchanger is used []. Specific tube types are shown in the equipment
list.
MoC for the heat exchanger
Carbon steel was used for specifically for heat exchanges using low-pressure steam(xxx),it
ensure effective heat transer due its thermal conductivity. The rest of the heat exchangers
operating at cryogenic temperatures, the stainless steel is recommended because for both the
utility and process side of heat exchangers. []
In case of phase change
A difference of 1 C for the process stream was assumed between inlet and outlet temperature
to account for cases where the utility is flowing in at its saturation temperature and a phase
change occurs. This is to ensure no error when calculating the log mean temperature. This
applied the most to all refrigerant utilised in the area 3.
Sizing pumps
All pumps were assumed to be centrifugal and single staged because all were found to have
a flowrate inlet of 0.057-18.9 m3/min. The reflux pumps were assumed to pump the liquid up
to tray 1 and they all are at ground level. Motor drive efficiency of 90% was assumed for all
pumps. The shaft efficiency was 45% for xx m3/min and 70% for flow in range of 1.89 m3/min
– 37.8 m3/min
Pump sizing input parameters
Volumetric flow, Q 0.253 m3/min
Inlet pressure, P1 13.01 Barg
Outlet pressure, P2 13.01 Barg
Liquid density 529.9 kg/m3
Initial position, Z1 0 M
Liquid elevation, Z2 0 M
Gravitational acceleration 9.8 m/s2
Pump-equipment spacing 30 m
Line loss suction 0.0009 bar/m
Line loss discharge 0.0049 bar/m
A-3-l
∆P (Flow orifice) 0.1 Bar

∆P (Control valve) 0.69 Bar
∆P (Safety factor) 0.3 Bar
∆P (Heat exchanger) 0.445 Bar
∆𝑃 (𝐿𝑖𝑛𝑒 𝑠𝑢𝑐𝑡𝑖𝑜𝑛) = 𝐿𝑖𝑛𝑒 𝑙𝑜𝑠𝑠 𝑠𝑢𝑐𝑡𝑖𝑜𝑛 × 𝑃𝑢𝑚𝑝 − 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑠𝑝𝑎𝑐𝑖𝑛𝑔

∆𝑃 (𝐿𝑖𝑛𝑒 𝑠𝑢𝑐𝑡𝑖𝑜𝑛) = 0.0009 × 30
∆𝑃 (𝐿𝑖𝑛𝑒 𝑠𝑢𝑐𝑡𝑖𝑜𝑛) = 0.027 𝑏𝑎𝑟
∆𝑃 (𝐿𝑖𝑛𝑒 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒) = 𝐿𝑖𝑛𝑒 𝑙𝑜𝑠𝑠 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 × 𝑃𝑢𝑚𝑝 − 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
∆𝑃 (𝐿𝑖𝑛𝑒 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒) = 0.0049 × 30
∆𝑃 (𝐷𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 𝑠𝑢𝑐𝑡𝑖𝑜𝑛) = 0.147 bar
𝜌𝑔𝑍1
𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛 = 𝑃1 + − ∆𝑃 (𝐿𝑖𝑛𝑒 𝑠𝑢𝑐𝑡𝑖𝑜𝑛)
100000
(529.9)(9.8)(0)
𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛 = 14.01 + − 0.027
100000
𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛 = 13.98 𝑏𝑎𝑟
𝜌𝑔𝑍2
𝑃𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 = 𝑃2 + + ∆𝑃 (𝐿𝑖𝑛𝑒 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒) + ∆𝑃 (𝐻𝑋) + ∆𝑃 (𝑆𝐹) + ∆𝑃 (𝐶𝑉) + ∆𝑃 (𝐹𝑂)
100000
(529.9)(9.8)(0)
𝑃𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 = 14.01 + + 0.147 + 0.445 + 0.3 + 0.69 + 0.1
100000
𝑃𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 = 15.69 𝑏𝑎𝑟
∆𝑃 (𝑃𝑢𝑚𝑝) = 𝑃𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 − 𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛
∆𝑃 (𝑃𝑢𝑚𝑝) = 15.69 − 13.97
∆𝑃 (𝑃𝑢𝑚𝑝) = 1.7
∆𝑃 (𝑃𝑢𝑚𝑝)
𝑃𝑢𝑚𝑝 ℎ𝑒𝑎𝑑 =
𝜌𝑔
1.7 × 100000
𝑃𝑢𝑚𝑝 ℎ𝑒𝑎𝑑 =
(529.9)(9.8)
𝑃𝑢𝑚𝑝 ℎ𝑒𝑎𝑑 = 32.74 𝑚
1.67 × 𝑄 × ∆𝑃 (𝑃𝑢𝑚𝑝)
𝑆ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 =
𝑆ℎ𝑎𝑓𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
1.67 ∗ 0.253 ∗ 1.7
𝑆ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 =
0.45
𝑆ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 = 1.57 𝑘𝑊
𝑆ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟
𝐷𝑟𝑖𝑣𝑒 𝑝𝑜𝑤𝑒𝑟 =
𝑑𝑟𝑖𝑣𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
1.57
𝐷𝑟𝑖𝑣𝑒 𝑝𝑜𝑤𝑒𝑟 =
0.9
𝐷𝑟𝑖𝑣𝑒 𝑝𝑜𝑤𝑒𝑟 = 1.77 𝑘𝑊
A-3-m
𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝑠ℎ𝑎𝑓𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 × 𝑑𝑟𝑖𝑣𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 0.45 × 0.9
𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 0.405
Reflux drums
These units were sized as vessels or phase separators. A 5-minute hold up was assumed[15].
Table 22 below shows the input parameters obtained from Aspen and rules of thumb. The
incoming stream into reflux drum is made up of th reflux ratio specified using the formular.
Flowrate in= Distillate massflow*(Reflux ratio +1).

Mass flowrate of incoming 25.9 kg/s
stream to reflux drum
Density 529.8 kg/m3
Residence time 5 min
L/D ratio 3 Optimum suggested
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 =
𝐿𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
25.9
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 =
529.9
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 = 0.0488 𝑚3 /𝑠
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 = 2.93 𝑚3 /𝑚𝑖𝑛
𝐿𝑖𝑞𝑢𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 × 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒
𝐿𝑖𝑞𝑢𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = 2.93 × 5
𝐿𝑖𝑞𝑢𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = 14.663 𝑚3
Reflux drum is kept half full [] since xx .𝑇𝑎𝑛𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 = 2 × 𝐿𝑖𝑞𝑢𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒
𝑇𝑎𝑛𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 = 2 × 14.663*(1.1)
This is to include the safety factor
𝑇𝑎𝑛𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 = 29.32 𝑚3
From the range of 2.5 -6 m for L/D ratio a standard value of 3 recommended was used [xx].
Assuming a torispherocal head of 0.778 in construction.
3 4 × 𝑇𝑎𝑛𝑘 𝑣𝑜𝑙𝑢𝑚𝑒
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √
(3 ∗ 𝜋) + (8 ∗ 0.778)
3 4 × 29.32
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √
(15,64)
A-3-n
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 1.96 𝑚
𝐿𝑒𝑛𝑔𝑡ℎ = 3 × 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝐿𝑒𝑛𝑔𝑡ℎ = 3 × 1.96
= 5.87 𝑚
Sizing compressors
The compression factor Z1 was assumed to be 1 since an ideal gas behaviour was assumed.
Compressors xx utilised in the section was assumed to be made up of carbon steel since it is
cost effective. An efficiency of 90% for an adiabatic compressor was assumed. The Cp/Cv
value was assumed to be 1.4. Since the compression ratio which is Pout/Pin is below 4 a single
stage compressor is used.
Pump Costing:Centrigugal pumps

With reference to all costing using bare module a CEPCI of 499.6 for 2006 was used and a
CEPCI of 803 in 2023 was used. The location factor of 1.407 for Angola was used to find the
final costs.
A pump with a volumetric flow rate ranging from 10 gpm to 500 gpm .Size factor (S) is given
be the equation that follows Look for pump P-301
𝑆 = 𝑄(𝐻)0.5 = 15700
Q is the flowrate in gal/min, H is the pump head in ft
𝐶𝐵 = 𝑒𝑥𝑝{9.7171 − 0.6019[ln(𝑆)] + 0.0519[ln (S) ]2 } = $
The purchase cost is given by:
𝐶𝑃 = 𝐹𝑇 𝐹𝑀 𝐶𝐵 = $
Heat Exchanger Costing : choose the ethane product using lps E-309
The area is in ft2 and obtained from sizing information done earlier.The pressure used is in
psia.
Where A is Area in ft2 obtained from sizing the heat exchanger → 723 m2
𝐶𝐵 = exp{11.667 − 0.8709[ln(𝐴)] + 0.09005[ln(𝐴)]2 } = $ 65700
𝑃 𝑃 2
𝐹𝑝 = 0.9803 + 0.018 ∗ (100) + 0.0017 ∗ (100) =0.9948
For Carbon Steel a and b = 0

𝐴 𝑏
𝐹𝑀 = 𝑎 + ( ) =1
100
𝐶𝑃 = 𝐶𝐵 𝐹𝑃 𝐹𝑀 =$ 1 048 000
A-3-o

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Department of Chemical Engineering

CHE 4036Z – Chemical Engineering Design

Word Count: 16 000

Total Page Count: 65

A3 Table of Contents .............................................................................................. 3-i

List of Tables ........................................................................................................ 3-iii

Table of Figures .................................................................................................... 3-iv

List of Abbreviations ..................................................... Error! Bookmark not defined.

1.1. Design Problem Definition ................................................................................ 3-1

1.2. Process Development ........................................................................................ 3-3

1.3. Detailed Design ................................................................................................ 3-10

1.4. Sensitivity Analysis and Optimisation of Design Model................................ 3-15

1.5. Area 3 Overview .............................................................................................. 3-24

1.6. Equipment Specifications (10 marks ) ........................................................... 3-29

1.7. Information Provided to Other Members ........................................................ 3-32

1.7.1. Process Control ................................................................. Error! Bookmark not defined.

1.8. Conclusion ....................................................................................................... 3-53

1.9. References ........................................................................................................ 3-55

1.10. Appendices ..................................................................................................... 3-a

Table 1: Specifications to be met ........................................................................................ 3-7

Design Problem Definition

Table 1 : Specifications to be met

Objectives of the Report

Scope, Limitations, and Key Issues

Demethanizer and pre-fed conditioning (cold box and hydrogen purification)

Conventional C2 splitter distillation operates at low temperatures, leading to high energy

Base Case Development

Observations for the base case.

Table 3: Summary of base case conditions

Identification of Equipment for Design

Heat exchangers 4 Heater

Compressors 1 Isentrophic compressor

RADFRAC employs the inside-out algorithm to efficiently simulate complex separation

The Summation equations above

𝐸𝑖.𝑗 = 𝑦𝑖,𝑗 − 𝐾𝑖.𝑗 𝑥𝑖.𝑗 = 0 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 12

The equilibrium equation

Assumptions and Justifications for the Base Case design

Thermodynamic model used

Binary pairs of interest

1.5 LK-P liq

Table 6: SSE analysis for the area 2 to 4

Sensitivity Analysis and Optimisation of Design Model

Effects of feed temperature and feed pressure to the deethanizer

Figure 2 : Temperature ranges in Angola [xx]

Figure 4: Effect of temperature on deethanizer column operations

The effects of pressure of the feed.

Influence of operating pressure of the column

Viable operational range and control implications

Pressure of the column with energy consumption

Optimisation of Equipment Size/Configuration on a cost basis

Figure 5: The process cost as a function of reflux ratio

Recovery of key elements with change in

Reboiler duty versus feedstage

Figure 6b: The influence of feed stage to reboiler duty

How the optimum case responds to changes in the feedstock to area 3

Summary of Base and Optimised Case

Process Flow Diagram

Figure 7: The process diagram for area 3

Table 9 : Stream tables for mole flow and mole composition

Mass Balance (0.25 page)

4.5.4.1. Assumptions for Mass Balance

Figure 8 : The mechanical drawing of the deethanizer column

The equipment specification sheet

Table 13 : Equipment listing for area 3 part 1