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A Design presentation on

Natural Gas Processing Plant


Presented by :
Abdulla-Al-mamun
St. ID: 0802021
Dept: Ch.E.
BUET

Objectives
By using Aspen hysis simulation
Ensuring more efficient and profitability design.
Improving plant control, operability.
Eliminating process bottle necks and minimizing process network.
Reducing human error and time requirement.

Definition of the project


Location- Kailashtilla, Sylhet
Capacity-550 MMSCFD
Raw materials-Raw Natural Gas From 3 Producing Gas Wells
DEAmine Solution, TEG.
Utility- Electricity(2 MW Capacity), Natural Gas.

Available Process
Gas Sweetening
Solid Bed Sweetening Process:
Molucular Sieves
Aquasorption Process (Wash Water
Process)
Selexol Process
Chemical Absorption
Process(MEA,DEA,TEA Processes)
The Holmes-Stretford Process

Gas Dehydration
Absorption Process(Methanol,
Glycol Process)
Adsorption Process (Solid
Dessicants, Alumina, Silica Gel,
Molecular Sieves)

Design Basis
Climate ConditionAmbient Temperature- Max- 35OC
Min-12OC
Design max temp- 40OC
min temp-5OC
Annual Avg. Atmospheric

pressure-0.11 MPa

Annual Avg. relative Humidity- 80%


Wind Velocity-52 miles/hr
Rain- Annual Avg. Rainfall- 2850 mm

Process Block Diagram

Hysis Simulation

Comparison Between Raw Natural gas & Product gas


Raw Natural Gas

Product Gas

Components

Composition

Components

Composition

Methane

0.8634

Methane

0.930973

Ethane

0.0574

Ethane

0.053632

Propane

0.0088

Propane

0.000658

i-Butane

0.0007

i-Butane

0.000022

i-Butane

0.0005

i-Butane

0.000014

n-Pentane

0.0005

n-Pentane

0.000007

n-Hexane

0.0003

n-Hexane

0.000002

H2O

0.0467

H2O

0.000101

Nitrogen

0.0018

Nitrogen

0.002029

CO2

0.0204

CO2

0.012562

List of Equipment
Designation in
Equipment Name

Quantity

the HYSYS
Simulation

Compressor

K-100

Heat Exchanger

E-100, E-102

Absorber

T-100, T-102

Separator

V-100, V-101, V-104

Pump

P-100, P-101

Storage Tank

V-106

Stripper Column

V-102, V-103

Stabilizer Column

V-105

Shell and tube heat exchanger design parameter (E-100)


Tube side (cold fluid)

Inlet fluid: Glycol to be preheated (67.59 o F)


Outlet fluid: Preheated glycol to absorber (77 0F)
Shell side (Hot fluid)
Inlet fluid: Dry gas (99.880 F)
Outlet fluid: Sales gas (94.860F)
Calculation
Q = Uassume Arequired LMTD
For light - heavy organics
Overall U = 10-40 Btu/hr ft20F
Assume, Uassume = 35 Btu/hr ft20F
Arequired = 3147.4 ft2

Calculated tube no 182


Where,
1 shell pass & 6 tube pass(np).
Fixed tube plate
1.5 in. OD(d0), 16 BWG, 1.785in. square pitch, ID (di) 1.37 in,
Selected shell ID (Ds) is 35 in
Clean overall heat transfer coefficient (Uc) calculation, Uc = 42.3 Btu/hrft20F
Over design calculation:
% of over design = 20.86 % < 30 %
So, design is accepted.
Dirt factor calculation
Dirt factor, Rd = 0.00098
Because for natural gas Rd, allowable=0.001
(Ref: Mechanical Design of Process System (vol-2))
Therefore, Rd is acceptable.

Pressure drop calculation


Tube side calculation
Frictional pressure drop = 2.22 Psi
Return loss = 0.34 Psi
So, total pressure drop in tube side, 2.56 Psi < 8.7 psi which is acceptable.

Shell side calculation


Assumption:
25 % cut segmental baffles
Baffles spacing, B = 0.5 Ds = 17.5 in = 1.46 ft (half of the shell ID is selected)
Pitch, Pt = in. square pitch = 0.15625 ft
Clearance, C = Pt do = 0.03125 ft
Shell ID, Ds = 35 in = 2.92 ft
So, pressure drop = 9.38 Psi < 14.5 Psi, which is acceptable.

P & ID Diagram

Figure: 1 shell pass - 6 tube pass heat exchanger

Overall Economic Analysis


Equipment Cost at Present(2014)- $1.088 million
Total Capital Investment - $ 6.12 million
Total Annual Expenses- $ 13.24 million
Net Profit After Tax(15%)- $ 15.4 million
Pay back period 3 year 11 month
Salvage value- $ 0.532 million
Depreciation- $0.765 million/year
IRR i% = 24.58 %
ERR i% = 19.67%
Project life 20 years

The End