DSc PRO/II? APPLICATION BRIEFS * GAS PROCESSING © REFINING * PETROCHEMICAL © CHEMICAL * SOLIDS Technical ‘Additional manuals are available upon request from Simulation Sciences Inc. Assistance ‘The PROMI! Program is technically supported and serviced by SimSci®™ and is agents and representatives around the word. you have any questions regarding the use ofthe program or the interpretation of the output, please contact SimiSci ot its agents or representatives for free advice and consultation ‘Support Center Telephone Facsimile USA and Canada ‘Simulation Sciences Inc. (800) siMscit_ (714) 579-0354 601 S. Valencia Ave (714) 579.0412 Brea, Calfornia 92621 Pacific Rim ‘Simulation Sciences Inc. (714)579.0412, (714) 879-7468 601 S Valencia Ave Brea, Calfornia 92621 Japan SSIMSCI Japan K.K. 81-3.3432-4631 ‘Towa Hamamatsucho Building #203 2.6-2 Hamamatsucho Minato-ku, Tokyo 105, Japan Europe/india ‘SIMSCI International 44-161-429-6744 44.161-480-9063, High Bank House, Exchange Street Stockport, Cheshire United Kingdom SK3 OET South America ‘SIMSCI Latinoamerica C.A. 58-2.959-803358-2.993-2717 Centro Banaven (Cubo Negro) Torre "A, PHA-2 Ay, La Estancia, Chuao Caracas, 1060, Venezuela PROIll APPLICATION BRIEFS August 1995 E> oS SOLID CONVERTER POF > satin seeee = SOLID CONVERTER PDF > omc tinesin pa teTable of Contents PROIII APPLICATION BRIEFS. INTRODUCTION ii INDEX OF FEATURES FA GAS PROCESSING PHASE ENVELOPE om DEETHANIZER oot REFRIGERATION LOOP ost COMPRESSOR TRAIN out EXPANDER PLANT os ‘THREE STAGE LETDOWN cet GAS DEHYDRATION USING TEG. or AMINE SWEETENING PLANT cat REFINING (CRUDE HEATING CURVE Rit DE-IC4 TOWER Rot (CRUDE OIL DISTILLATION Rat VACUUM COLUMN, Rat FCC MAIN FRACTIONATOR: RS SOUR WATER STRIPPER Ret STABILIZER Rr NAPHTHA SPLITTER Ret PETROCHEMICAL, (C3 SPLITTER Pit AROMATICS SEPARATION Pot ETHYLENE FRACTIONATOR Pat (CYCLOHEXANE PLANT Pat NAPHTHALENE RECOVERY Pst MTBE SEPARATION Pet PROPYLENE CHLORINATION Prt PROIll APPLICATION BRIEFS ‘TABLE OF CONTENTS -i August 1995 DSc E> oS SOLID CONVERTER POF > satin seeCHEMICAL DRYER COLUMN, ort AMMONIA-ACETONE-WATER SEPARATION 21 MEK-WATER-TOLUENE ost AZEOTROPIC SEPARATION cat PHENOL EXTRACTION 51 DECANT COLUMN cet ‘SHIFT AND METHANATOR REACTORS orm ADVANCED CASCADE REFRIGERATION Att PHENOL DISTILLATION Aaa HDS REACTOR SECTION Ast ‘TURBO-EXPANDER GAS PLANT OPTIMIZATION Aa ‘SULFURIC ACID ALKYLATION A541 AMMONIA SYNTHESIS 6-1 ‘SOLIDS P-XYLENE CRYSTALLIZATION sit ji- TABLE OF CONTENTS. PROIII APPLICATION BRIEFS. August 1995 DSc E> oS SOLID CONVERTER POF > satin seeINTRODUCTION ‘Tris manual contains Application Briefs illustrating the use of the PROIlI Simulation Program to solve a wide range of typical industrial mass and energy balance problems. Its intended as a complement to the PROM Keyword Input Manual, providing a reference source for detailed examples of PROIII features and input and ‘output options. For convenience, the Application Briefs are dvided into six sections: Gas Process- ing, Refining, Petrochemical, Chemical, Advanced, and Solids. The Table of Con- tents lists the applications in each section. The Index of Features gives @ cross-reference of PROIll features ilustrated by each application Each application includes: a process description and flowsheet, a discussion of the simulation model, and comments on results. The complete PROIII input and selected outputs are shown for each application. Readers are reminded thatthe Application Briefs are only examples and should not bbe used for other purposes. The user is urged to read and become familiar withthe PROV Keyword Input Manual available upon request from SimSci before attempt- ing to use the program. Finally, while the applications contained herein are based (on actual cases, they may nat always be typical, nor are the data used always the ‘most accurate, ‘These input files are available on a floppy disk which may be requested from your ‘SimSci representative. PROIll APPLICATION BRIEFS August 1995 DSc E> oS SOLID CONVERTER POF > satin seeee = SOLID CONVERTER PDF > omc tinesin pa teINDEX OF FEATURES Application Brief ASSAY ANALYSIS ‘API GRAVITY 1, R3, RS 1160 DISTILLATION DATA, Ra 1086 DISTILLATION DATA, Rt, RS LIGHTENDS Rt, R3 ‘SPECIFIC GRAVITY Rt, R4 ‘TBP DISTILLATION DATA R3,R5 CALCULATOR 4, C5, GB CASESTUDY AB, RE COLUMN ‘ALGORITHMS CHEMDIST ‘2, C2, €3, C6 ELDIST 6 10 Ad, C1, C4, C5, G2, G5, G8, PI, P2, 3, PS, PG, R2, R4, RS, R6, RT, RB wex cs SURE AS, P3 CONDENSERS Bubble point condenser ‘A2, AS, C1, C2, C3, C4, C6, P1, PS, R7. RB Fixed temperature cs Mixed phase condenser RS No condenser G5, G7, G8, R4, RE Partial with vapor product A2, A4, 62,68, PS ‘Suboooled total condenser P2, R3 DAMPING AS, C3, G8, R3, R4, RS FEED FLASH 2, P6 FEED HEATER ON FEED TRAY 3, R4, RS INITIAL ESTIMATE MODEL. Chemical 03,06 Conventional 2, A4, AS, C1, C2, C4, G2, G5, G7, G8, P1, P6, RE, R7, RB PROIll APPLICATION BRIEFS INDEX OF FEATURES IF-1 August 1995 ee = SOLID CONVERTER PDF > omc tinesin pa teApplication Brief Refinery 3, R4, RS Simple 2, PS LIQUID SIDE DRAW 62, R3, R4, RS, RB MULTLFEED A4, C4, R3, R4, RS, RB NO REBOILER G7, G8, P3, RB, R4, RS PSEUDO STREAMS Ra PUMPAROUNDS P3, RB, R4, RS SIDE HEATERS/COOLERS 3, R3, R4, RS SIDE STRIPPERS 3, RS, RB Steam stripped 3, R3, RS, RS Reboiled Re SPECIFICATIONS ‘Component purityitecovery 2, C1, C3, C5, G2, G8, PI, P2, PS, 6, RE, RB ‘Component ratio 6, 65, Distilation point R3,R5 ‘Overfiashirunback to feed zone R3,R4 Product molal rate Ad, C2, RT Product volume rate 3, R4, RS Product weight rate 2, C4 Reflux (external) A2, C2, C3, C4, C5, C8, GB, PS Reflux (internal) Ra RP RT ‘Tray temperatures AS, G7, P3, Ra SPECIFICATION VARIABLES Feed 8, P3, R3, R4, RS, RE, RB Heater/cooler 2, A5, C1, C2, C3, C4, C5, C8, G2, G5, G7, G8, P1, P2, P5, Pé, RB, R5, R7, RB Side draw rate 2, R4 ‘THERMOSIPHON REBOILER G2,R5 TRAY SIZINGIRATING 1, C4, G2, RS VAPOR SIDE DRAW P2 WATER DECANTING 3, R3, RS |F-2 INDEX OF FEATURES PROIII APPLICATION BRIEFS. August 1995 ee = SOLID CONVERTER PDF > omc tinesin pa teApplication Brief COMPONENT PROPERTIES INPUT CRITICAL PROPERTIES. LATENT HEAT LIQUID ENTHALPY LIQUID DENSITY MOLECULAR WEIGHT NORMAL BOILING POINT ‘SPECIFIC GRAVITY VAPOR PRESSURE COMPRESSORS AFTERCOOLER. GENERAL, LINKED TO EXPANDER MANUFACTURER'S PERFORMANCE CURVES CONTROLLERS DIMENSIONAL UNITS ENGLISH METRIC sl ENTHALPY OPTIONS LEE-KESLER IDEAL EXPANDER FLASHES ADIABATIC DECANTWATER ISOTHERMAL, DEFINED SPECIFICATION PROIll APPLICATION BRIEFS August 1995 2 BRERRERERE ca A1, 3, AS, AB, G8, PA, PT 4,65 os A1,A3, AS, AG, G3, G6, P3, P4, St 1, A3, Ad, AS, AB, C3, C4, C5, C8, C7, G1, G2, G3, G5, G6, G7,G8, PS, PA, P6, R3, RS, R6, R7, RB ‘A2, C1, P5, R& ©2, 64, P2 Ps 2, C1,C2, C4 4,65 AI, A4, AB, G3, G4, G5, G6, G7, P4 cs A1, A2, AS, AS, A, G6, G7, RS 8, R3, R4 INDEX OF FEATURES IF-3 ee = SOLID CONVERTER PDF > omc tinesin pa teApplication Briot FUGACITY OPTIONS IDEAL 2,01 SOAVE-REDLICH-KWONG P6 HEAT EXCHANGER ‘ATTACHED a CONFIGURATION Pa PROCESSIPROCESS AI, A3, Ad, AS, AB, G5, G7, GB, P4, S1 PROCESSIUTILITY 4, A5, C5, GB, G8, P4, St SINGLE SIDED AS, G3, G5, G7, P7 ‘SPECIFICATION ‘Approach AM, A5, G5 Duty co Liquid fraction AM,A5, G3 Temperature A3, AS, AS, AB, G3, G5, G5, GB, PA, P7 HEATING/COOLING CURVES FEED VAPORIZATION RI INTERACTIVE G3, P2 K-VALUES ‘ALCOHOL, 3,08 AMINE 8 BRAUN K10 3, Ra, RS CHAO-SEADERIGRAYSON-STREED 3, P2, PA, PS, RT ctycoL, or NRTL 2,01, 62, C5 PENG-ROBINSON A, G3, G5, P1, P3 Interaction parameter Pt POYNTING 2,1, PS SOAVE-REDLICH-KWONG AS, AB, C7, G1, G2, G4, G6, RB UNIFAC 5, P6 VAN LAAR ca SOUR Re IF-4 INDEX OF FEATURES PROIII APPLICATION BRIEFS. August 1995 DSc E> oS SOLID CONVERTER POF > satin seeApplication Brief LIQUID DENSITY OPTIONS APL IDEAL LEE-KESLER COsTALD MIXER OPTIMIZER OUTPUT OPTIONS ASTMITBP CURVES LIQUID VOLUME MULTIPLE OUTPUTS: PARTIAL ‘STREAM COMPONENT FRACTION/PERCENT ‘STREAM SUMMARY PETROLEUM FRACTION INPUT PHASE ENVELOPE PUMP REACTORS ‘CONVERSION csTR EQUILIBRIUM METHANATOR SHIFT RECYCLE ‘ACCELERATION CLOSED LooP GENERAL PROIll APPLICATION BRIEFS August 1995 A1,C7 ‘A2, C6, G7 63, G2, G4, G5, PS P3, P7 At, A3, G3, G8, PA, P7, RA 4, RT P3, RI, RS, R4, RS 5,65 7,65 G4, RB ‘A2, A3, C1, C2, C3, C4, P1, P2, P6, RB, St 3, R4, RS, RS AS, G4, G6, P3, PS a ‘Ad, C5, G7, G8, P4, St 3,5, PA P7 or or AS, AB, G8, PA, P7, St At, A5, G3 2, A4, G4, GB INDEX OF FEATURES IF-5 ee = SOLID CONVERTER PDF > omc tinesin pa teApplication Briot PURGED 3, Pa THERMAL AI, G5 TOLERANCE Pa REFERENCE STREAMS AM, G5, G8, P4 SEQUENCING 4,5, P4 SHORTCUT DISTILLATION FENSKE MULTIPRODUCT RS ONE FEED, TWO PRODUCT 1, P5, P7 SOLIDS CENTRIFUGE st CRYSTALLIZER st DISSOLVER, st MELTER, st SPLITTER Al, A3, A4, AB, C5, G8, G8, P4, P7 STREAM CALCULATOR A3, AG, C7, G7, G8, P4, P7 STREAM INPUT "ASTM CURVE Rt, R4, RS LIGHTENDS RI,R3 LIQUID FRACTION 2 ‘TBP CURVE R3, RS THERMODYNAMIC PROPERTIES INPUT a6 ‘SOAVE-REDLICH-KWONG TRANSPORT PROPERTIES ’APILIQUID VISCOSITY Fa, RS PETROLEUM 4, RI, R, Ra, RS PUREILIBRARY ©2.65.¢7,62 SIMSCILIQUIO VISCOSITY Ra IF-6 INDEX OF FEATURES PROM APPLICATION BRIEFS August 1995 ee = SOLID CONVERTER PDF > omc tinesin pa teApplication Brief VALVE VAPOR PRESSURE SPECIFICATIONS RVP A2, A4, AS, C5, G3, G5 R7 We 6 VLE REGRESSION c1,Pt VLLE 3,06 WATER DECANTATION IN COLUMN CONDENSER 3,5 WATER TRAP TRAYS. P3 PROIll APPLICATION BRIEFS INDEX OF FEATURES IF-7 August 1995 ete = SOLID CONVERTER PDF > omnes pues e‘This page intentionally lft blank. |F-8 INDEX OF FEATURES PROIII APPLICATION BRIEFS. ‘August 1995 ee = SOLID CONVERTER PDF > omc tinesin pa tePhase Envelope [ef] Amine Sweetening Plant Kid Deethanizer IZ Refrigeration Loop Ki Compressor Train Expander Plant Three Stage Letdown Gas Dehydration using TEG [ey PROIll KEYWORD MANUAL February 1992 ete = SOLID CONVERTER PDF > omnes pues ePHASE ENVELOPE ‘A high pressure natural gas stream is being transported through a pipeline. You ‘need to establish whether liquid will dropout during a cold winter, and, if so, what you must do to prevent it err Er) ‘The first step is to determine the conditions under which liquid will appear. The easiest way to do this is to produce a phase envelope for the gas mixture and ‘examine the boundary of the two phase region. Process Data Table G1.1 shows the composition of the gas stream. No addtional data are required to solve this problem. Table 61.1 GAS STREAM COMPOSITION Component mole % Component mole % Nitrogen 1.40 Nebutane | 0.44 Methane 94.30 Nepentane 0.37 Ethane 2.60 Nehexane 021 Propane 0.68 Methods ‘The phase envelope will solve using ether Soave-Redlich-Kwong (SRK) or Peng- and Data Robinson (PR) for the equilibrium and enthalpy calculations. This example uses SRK Simulation _ Phase envelopes may be generated for any flow sheet stream whetheritisadefined Model feed stream or the product from a unit operation. The phase envelope isa function only of the stream composition, ‘All you need to specify to generate the complete envelope is the stream label. No initial estimates are required. The critical point, cricondentherm and cricondenbar, will all be calculated, Input Data The phase envelope is generated by the fist EVALUATE statement. The other statements produce lines of constant liquid fraction which are superimposed on the envelope. The temperature and pressure of the stream must be entered on the PROP statement, but they are not used in the calculation. PROIll APPLICATION BRIEFS PHASE ENVELOPE G1-1 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teInput Data File: i Results “The maximum dew point temperature occurs at the cricondentherm which is 28.2 F at a pressure of 600 psia > Figure G11 Phase Envelope Plot G1-2 PHASE ENVELOPE PROIll APPLICATION BRIEFS February 1991 ete = SOLID CONVERTER PDF > omnes pues eConclusions If temperatures below 28 F are possible, condensation could occur in parts of the pipeline which are exposed to the atmosphere. ‘You will need to study the specific pipeline further to establish whether heaters are: required orifinsulation will be sufficient. Altematively, you might consider removing ‘more of the heavier components in the gas treatment before the gas enters the pipeline. err Er) Output ‘The phase envelope information is most easily interpreted when presented in graphical form. The phase envelope plot shows the type of output produced from the PC graphics option. ‘The plot shows the envelope with the lines of constant liquid fraction at 19% and 5% superimposed ont. If you could accept up to 1% liquid in yourline, there would be ‘no problem unless the temperature fll below -19 F. ‘The tabular temperature and pressure points for the phase envelope are printed, ‘and the critical points identifed. Similar tables are available forthe lines of constant liquid fraction. PROIll APPLICATION BRIEFS PHASE ENVELOPE G1.3 February 1991 DSc E> oS SOLID CONVERTER POF > satin seePHASE ENVELOPE TABULAR OUTPUT G1-4 PHASE ENVELOPE PROIII APPLICATION BRIEFS. February 1991 &SouID CONVERTER POF > satin neau reeDEETHANIZER ‘You have to design a deethanizer to remove C2 and lighter components from a ight hydrocarbon gas stream. 99% of the propane in the feed must be recovered in the bottom product. The bottoms purty is defined by an ethane to propane ratio of 0.025. ‘There is a design trade-off between capital and operating costs. Capital cost {depends on the number of stages, which determines the height, and on the diameter, of the column. Operating costs depend on condenser and reboiler loadings. In order to develop a relationship between capital and operating costs, a number of ‘uns wit different column heights (stages) is required. This example calculates the diameter of a 20 theoretical tray column operating at 82% of flood, with an 18-inch sieve tray spacing. The diameters of the sections above and below the feed are determined separately Peery Process Data The flow sheetis shown in Figure G2.1 1,10 Figure G2.1 Deethanizer Column PROIll APPLICATION BRIEFS DEETHANIZER G2-1 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teTable G2.1 shows the composition ofthe feed stream, Table G2.1 GAS STREAM COMPOSITION Component mole % Component, mole % if Nitrogen’ 0.03 N-butane 4.60 Fa Methane 44.59 pentane 1.68 Fy Etane 19.83 Nepentane 1.16 8 Propane 19.09 N-hexane 2.96 Ey butane 4.16 N-heptane 1.90 Total flow (Ib moles/hr) 900.00 The known process conditions are shown in Table G2.2. Table G2.2 Process Conditions: Stream Prossure ‘Thermal (psig) Conditions 1 (feed) 440 '30 mole % vaporized 2 (condenser) 425 dew point 3 (bottoms) 440 bubble point Methods Soave-Redlich-Kwong has been chosen to calculate equlbrium, enthalpy, and and Data vapor density. Lee-Kesler is used for quid density. The tray sizing calcuation requires transport properties which are generated by component blending. Simulation —_Thedeethanizeris modeled as a conventional distillation columa with 20 theoretical Model stages including the condenser. A thermosiphon reboiler is required; this is simu- latedby a pump-around heater on the bottom tray, with aretum stream vapor fraction 0f 0.35. The feed is flashed at the feed tray pressure, the vapor rising under tray 9 and the liquid dropping onto tray 10. 62.2 DEETHANIZER PROIll APPLICATION BRIEFS February 1991 ete = SOLID CONVERTER PDF > omnes pues eInput Data Standard English units have been chosen except thatthe pressure units have been changed to psig and liquid volume units to US gallons. “The liquid fraction ofthe feed is entered, and the temperature at the feed pressure willbe calculated, ‘The SEPARATE keyword on the FEED statement sends the vapor tothe tray above. Without it, the vapor portion of a mixed phase feed would enter below the feed tray. ‘The tray sizing calculations are invoked by the TSIZE statements. The size of each tray is determined, and each section is then rated at its largest tray diameter “The propane recovery is defined by a 1% molar loss inthe overhead. The ethane/pro- pane ratio in the bottoms, 0.025, is the rato ofthe component molar flow rates, The ‘condenser and reboller duties are varied in order to meet the specications, Input Data File: ry DIMENSION PRES=PSIG, LIQVOLAGAL :D 1112/2, 1/3,€2/4,03/5, METHOD SYSTEMASRK, DENSITY (L) «LK, TRANSPORT-PURE, (COMP=0.03/44.59/19.83/29.09/4.16/6 4-60/1.68/1.16/2.96/1.90 PROIll APPLICATION BRIEFS DEETHANIZER G23, February 1991 ™ SOLID CONVERTER POF > satin nea. reeResults ‘The capital cost ofthe column depends on its height and diameter. The heights a function of the number of trays. The diameters for 20 theoretical stages are 30, inches above the feed and 54 inches below it Conclusions This simulation shows the diameter and duties for one specific column height. The column costs obtained from the height and diameter. The column duties determine ‘the capital costs of the condenser and reboiler, as well as representing the major ‘operating costs. You will need to run cases at other column heights to determine the capitaloperating cost relationship. Output ‘The column summary output shows the details of the temperatures, pressures, duties and flow rates inthe column, ‘The tray sizing results show the calculated diameter for each tray. Where the calculated diameter is not sufficient to accomodate the tray free area plus the downcomer area, a warning is printed and the diameter is increased until the restriction has been overcome. Casi) ‘The largest ray diameterin each section is used to rate the whole section, 30 inches in the top and 54 inches in the bottom of the column. The flooding factor and downcomer backup are printed for each tray. Finally, part of the stream printout is presented with a summary of the feed and product streams. 62-4 DEETHANIZER PROIII APPLICATION BRIEFS. February 1991 DSc E> oS SOLID CONVERTER POF > satin seeDEETHANIZER COLUMN OUTPUT mey Te PRESSURE “LIQUID VAPOR Pua -PROOUCT. OATES bec F PSIG 1-woL i vos Tue TPE STREAN FHRGE FROM 7D LIQUID you exras HEAT BATES TRAY TRAY FRACTION —1B-MOL/HR tee BIU/R ProucT 3 © LIQUID 20, 322.49 ease OvmpaLe, oss BALIWCE, (FEEDS - PROGUCTS) 3.00368-04 OWBRALE MENT BALIWCE, (HLIN) HIT) } -1.19368-04 ey mm, bas F LIQUID FaRcTION ates PROIll APPLICATION BRIEFS DEETHANIZER G25, February 1991 &SouID CONVERTER POF > satin neau reeTRAY SIZING CALCULATION OUTPUT . ey varOR LIQUID via —nesr@t — Mex? swueR MENT LaRGER MP 62.6 DEETHANIZER PROIII APPLICATION BRIEFS. February 1991 &SouID CONVERTER POF > satin neau reeTRAY RATING CALCULATION OUTPUT 2 02. Aaa w/a 2 SA 5202 aa AY VAEOR LIQUID viGRD DIAM FF NP DROP EREESSRREEER ERE? PROIll APPLICATION BRIEFS DEETHANIZER G27 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teSTREAM COMPONENT FLOW RATE OUTPUT Biase vax ware LIQUID Casi) 62-8 DEETHANIZER PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teREFRIGERATION LOOP ‘A refrigeration loop was orginally designed to take advantage ofa low temperature stream from another process, to help condense the refrigerant. Now itis proposed that some or all of this stream will be used elsewhere in the plant. You must determine the effect on the refrigeration loop of losing this auxiliary cooling duty Process Data The process flow sheetis shown in Figure G3.1. The loop is closed and operates with a fixed quantity of refrigerant. The liquid refrigerant flashes through the valve, V1, and some of the vapor produced is condensed in the cooler H2. The proposed ‘modifications will reduce or eliminate this duty ‘The two phases in the stream leaving the cooler are separated in the flash, F1, and the liquid portions vaporized to provide the required refrigerant duly. The two vapor streams are then combined, recompressed, and condensed. PCC Pre Figure G3.1 Refrigeration Loop Flow Sh ‘The refrigerant composition is shown in Table G3.1 Table 63.1 REFRIGERANT COMPOSITION Component | tb molesihr | Component _| tb molesihr Ethane 1.04) ‘Butane 1.68 Propane 96.94 Butane 0.34 PROMI APPLICATION BRIEFS REFRIGERATION LOOP G3-1 February 1991 ete = SOLID CONVERTER PDF > omnes pues eBecause the process changes will change the flow rate through the existing compressor, performance curves supplied by the manufacturer are used in the caloulations. The curves are shown in Figure G3.2. & eo] Fi g Figure G32 Compressor Performance Curves Methods “The Peng-Robinson equation of state has been selected for calculating equitrium and Data values, enthalpies, and entropies. Liquid densities are calculated using the Lee-Kesler correlation. This combination gives accurate results for this type of ight hydrocarbon system, Simulation The independent variable inthis simulation is the flow rate of the refrigerant. This Model flow rate is estimated in the Stream Data Catagory based on the latent heat of propane, and a feedback controller is used to calculate it as shown in Figure G33. ‘The vaporizer exit streams set to its dew point, and the controller varies the rate of stream 1 in order to meet the required refigerant duty. 63.2 REFRIGERATION LOOP PROIII APPLICATION BRIEFS. February 1991 DSc E> oS SOLID CONVERTER POF > satin seePCC Pre Figure G33 ‘Simulation Flow She We want to study the effect of reducing the duty of H2. Although multiple cases ‘could be executed, in this example, the interactive facility is used to change the duty and observe its effect on the other important parameters. This facility uses a {question and answer procedure, and allows any specification in the flow sheat to bbe changed and any parameter to be inspected during the program execution. The interactive facilty may be invoked via the Graphics User Interface on the PC, or via the PROIII driver on mainframe computers. ‘The existing base case is simulated. Then the duty of H2 is reduced in steps until the program indicates that the combination of required process conditions is impossible. The refrigerant flow rate, the compressor work, and the cooling in Ht are inspected at each step. Input Data English units default, and U.S. gallons are specified for liquid volume on the DIMENSION statement. ‘The defined stream 1 flow rate of 20,000 molesihris an estimate, and this is varied by the contol to meet the duty specication on exchanger, H3. An absolute tolerance of 0.5 MM BTU is specified on this duty. ‘The H3 specification of a zero liquid fraction sets the outlet condition to its dew point. ‘The compressor performance curves for actual head and adiabatic efficiency are input as tabular values against actual inlet flow rate. PROIll APPLICATION BRIEFS REFRIGERATION LOOP G3-3. February 1991 DSc E> oS SOLID CONVERTER POF > satin seeInput Data File: DIMEN LIQV=GAL METHODS SYSTEMAPR, DENSITY (L) =LiC coupat,1-04/2,96.94/3,1-68/4, 0.34 {UTANE/4, BUTANE HEAD ACTUAL4912000, 38000/2016000,37000/1237000,35300/ 1356000, 33100/2427000,27250 1386000,73 /2427000,71 63-4 REFRIGERATION LOOP PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teInteractive The interactive procedure pauses for commands after the input check. The RUN ‘command is entered to execute the program and solve the low sheet. The relevant portions ofthe output are then examined using the VIEW command. This is shown below forthe ial case. The user entries are undertined. An entry of HELP to any question gives a lst of the possible replies. The HELP facility may be turned on ppermenantly with the SET MENU command. ‘The command parts may be entered singularly, as when requesting the stream ‘output, or they may be entered together, as shown for the compressor and cooler output Itis not necessary to wait fr the execution to finish to inspect or change data, The ‘execution may be interrupted at any time by pressing the interrupt’ key ('Esc’ on IBM PC’s and compatibles, ‘Break’ on Prime, "*C’ on VAX). Items may then be ‘examined or altered, and the execution continued. ENTER COMMAND (HELP) } aa PCC Pre [STREAM OR UNIT (/ TO ABORT COMMAND) vr} srazay ENTER STREAM ID OR ANUMBER (HELP - / TO ABORT coMMAND) vr st ja PROIll APPLICATION BRIEFS REFRIGERATION LOOP G35, February 1991 E> oS SOLID CONVERTER POF > satin see) vnew ) vnew ower a M04 BTU/aR bu, Bru/uR-rr2-F 63-6 REFRIGERATION LOOP PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa te‘After the results have been inspected, the CHANGE command is entered to reduce the duty of H2 as shown below. ) cuanee ort 2 ca ux a2 ) bury cH uw 2 DUTY Jas ‘After PROII's internal pointer is reset to the beginning of the calculation sequence with GOTO UNIT #1, the RUN command re-solves the flow sheet, and the results, are inspected as before. PCC Pre Results ‘The base case flow sheet converges in only two recycle tials. The flow sheet is solved with the existing duly of cooler, H2, and then with 15 and 12.5 MM Btu. However, when the duty below 12.2 MM Btulh, the refigerant flow rate increases «dramatically beyond the range of the compressor performance curves. ‘The main flow sheet parameters are listed in Table G3.2 forthe frst three cases. Exchanger H2 condenses some of the refrigerant, and therefore, if the duty is reduced, lass condensation occurs. This is reflected in the lower liquid fraction at the separator. Higher retigerant flow rates are therefore required to maintain the ‘same liquid flow through the vaporizer. ‘The performance curves in Figure G3.2 show that the compressor head falls with increasing flow rate. At the flow rates in these simulations, the efficiency increases: with flow rate, and so the compressor outlet pressure increases. Table 63.2 RESULTS 2 duty (MM Btu/hr) 17.34 15.0 12.5 ‘Stream 1 (Ib moleihr) 16688 17280 1714 Separator UF o7it2 0.6873 0.6651 Compressor work (HP) | 13122 13683, 13790 Compressor Temp (F) 1836 186.16 1829 Compressor Pres (psia) | 321.9 333.15 3222 Ht duty (MM Bturhr) 98.78 102.68 105.27 PROIll APPLICATION BRIEFS REFRIGERATION LOOP G3-7 February 1991 DSc E> oS SOLID CONVERTER POF > satin see‘When the refrigerant flow rate exceeds 18000 Ib molefhr, both the efficiency and head fall wth increasing flow rate. When this happens, the feed pressure to the valve, V1, is reduced, and so the expansion produces less cooling. This, in tur, leads to less liquid for the vaporizer. The controller then increases the refrigerant flow rate, which again reduces the amount of liquid, andit is not possible to supply the specified refrigeration duty Conclusions The refrigerant loop can only operate as currently configured ifthe cooling duty in exchanger H2 exceeds 12.2 MM Blulhr. Ifthe duty isto be reduced farther, the low sheet will require other modifications. “The interactive feature is extremely useful inthis type of study, as the user can intervene when impossible process conditions occur. When low H2 duties are entered, the compressor calculation fails, and the execution i interrupted. The duty is then changed and the calculation continues until a solution is possible. ‘This simulation shows the importance of considering the real performance charac teristics of process equipment. Ifthe compressor were specified with only a defined ey exit pressure, the problem with increased flow rate might nat have been detected a Unila later, and more cost, stage. 3 ‘The stream outputs shown for the case with the cooler duty at 12.5 MM Bult. 63-8 REFRIGERATION LOOP PROIll APPLICATION BRIEFS February 1991 DSc E> oS SOLID CONVERTER POF > satin seeSTREAM OUTPUT SE gu woe so vance MOLE FRAC LIQUID 2.0000 0.5743 0.6624 ‘0.0000 SE ugu vneor varoa vance Nou FRAC LIQUID xoce 0.00000 0000 «00000 PROIll APPLICATION BRIEFS REFRIGERATION LOOP G3.9 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa te‘This page intentionally lft blank. Cet boy 63-10 REFRIGERATION LOOP PROIll APPLICATION BRIEFS February 1991 ete = SOLID CONVERTER PDF > omnes pues eCOMPRESSOR TRAIN ‘A plant has been designed to compress a gas stream from 450 kPa to 6200 kPa, in three stages, for transportation by a pipeline. To select the compressors, you have to calculate the required work for each stage. You also need the cooler duties, ‘and recycle rates in each stage for utlity calculations. ‘The compressed gas is to be cooled to 60 C after each stage, to condense the heavier components. In order to maximize the gas product rate, the quid from each stage is recycled back to the previous stage. Process Data The flow sheet is shown in Figure G4.1. Each stage consists of a compressor, aftercooler, and separator drum. Table 4.1 ists the specified operating conditions for the compressors. Figure G4.1 Compressor Train Flow Sheet Table 4.1 COMPRESSOR DATA ‘Compressor Pressure (kPa) | Adiabatic Efficiency (%) Stage 1 1100 78 Stage 2 2600 75 Stage 3 6200 2 PROIll APPLICATION BRIEFS COMPRESSOR TRAIN G4-1, February 1991 ete = SOLID CONVERTER PDF > omnes pues eThe feed details are shown in Table G4.2 Table G42 FEED STREAM INFORMATION Component | kgmolesime | Component | kg molesihr Nitrogen 181 pentane 953 co. 1920 Nepentane 1633, Methane 14515 Hexane 1542 Etane 072 BP 135 11975 Propane 7260 BP 260 072 butane 770 ap 500 072 N-butane 2at0 Prossure (kPa) 450 ‘Temperature (C) 48 Methods ‘The Soave-Redich-Kwong (SRK) equation of state is used to calculate equibum and Data values, enthalpies, and vapor densities. Binary interaction parameters ae bull into the program in order to model accurately the non-ideal behavior of Nz and COz with the hydrocarbons. The SRK method has been found to predict liquid densities which may be 10-20% low. Forthis reason, the LK method has been selected as the mast suitable for ight hydrocarbon, high methane mixtures. The heavy end ofthe gas streamis characterized as three petroleum fractions. The properties ofthe fractions are listed in Table G43. Table G4.3 PETROLEUM FRACTION PROPERTIES Fraction Molecular wt._| Sp. Grav. NBP (c) BP 135 120 757 135 BP 260 200 0.836 260 BP 500 500 0.950 500 64.2 COMPRESSOR TRAIN PROIll APPLICATION BRIEFS February 1991 ete = SOLID CONVERTER PDF > omnes pues eSimulation —_The compressors are modeled with fixed outlet pressures and efficiencies. The Model PROIII compressor model has a built-in aftercooler and flash separator drum. ‘The separators for stages 1 and 2 are modeled as separate adiabatic flash drums, in order to mix the compressor product with the recycled liquid, [No estimates are required forthe ate and composition of the three recycle streams. Input Data Stunts are used inthis simulation withthe temperatures in Celsius rather than the default of Kelvin. The three petroleum fractions are characterized by molecular weight, specifc gravity, and boiling point. XDEN=SPGR indicates that specific gravity is entered rather than density, the default fr SI unis PROIll APPLICATION BRIEFS COMPRESSOR TRAIN G4.3 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teInput Data File: METHODS SYSTEM-GRK,ORNSTTY (2) =U coupe2, 181/2,1920/3,14535/4, 9072/5, 7260/6,770/7,2820/e (LET GAS/10,COMPR VAPOR /11, CONDENSATE G44 COMPRESSOR TRAIN PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teResults ‘The recycles converged after & iterations. The work, duty, and recycle rates are summarized in Table G4.4 Table G4.4 COMPRESSOR RESULTS Compressor_| Work (kW) Duty (Guihe) [Recycle (kmotine) Stage 7 27801 B19) 1118 Stage 2 28048 120.1 5180 Stage 3 27782 164.8 9730 Conclusions The work requited for all the compressors is similar, and it may be possible to use identical machines for each, The duty required to cool the vapor and the amaunt of liquid to be recycled increase as the pressure difference increases across each stage. The total cooling requirement is 366.8 Gr. Output ‘The flash summary shows the details ofthe feed flash and fist two letdown stages. Details ofthe third stage are shown on the output from compressor C3. ‘The PRINT statement specifies that only part ofthe stream printouts required. This, prints the component flow rates, temperatures, and pressures, but omits the property output. The final output ists the details ofthe feed and product streams. PROIll APPLICATION BRIEFS COMPRESSOR TRAIN G4-5 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teFLASH SUMMARY G4-6 COMPRESSOR TRAIN PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teOUTPUT FOR STAGE 3 COMPRESSOR Prooucrs LigurD ° CALCULATED FROM HERD EQUATION PROIll APPLICATION BRIEFS COMPRESSOR TRAIN G4-7 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teFEED AND PRODUCT STREAM OUTPUT Paase wee LIQUID MoD Moe FRAC LIQUID 0.0000 1.0000 G4-8 COMPRESSOR TRAIN PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teEXPANDER PLANT ‘The demethanizer in an expander plant removes methane from a production gas stream, to maintain a methane/ethane Volumetric ratio of 0.015 in the colurmn liquid product. A new feed gas stream with a different composition is being brought on stream, and you must ensure that the same purity specification can be maintained, and that the new reboiler duty does not exceed the capacity ofthe unit. ‘You also need to know what pressure recovery is possible on the methane stream leaving the plant. Process Data The flow sheet is shown in Figure G5.1 and the new feed composition is in Table 5.1 Peony Figure G5.1 Expander Plant Flow Sheet PROIll APPLICATION BRIEFS EXPANDER PLANT GS-1 February 1991 ete = SOLID CONVERTER PDF > omnes pues eTable G5.1 FEED STREAM INFORMATION ‘Component mole % ‘Component mole % Nitrogen 7st Nbutane 244 Methane 73.08 bpentane 089 Etane 798 Nepentane oaz Propane 569 Hexane 042 butane 0.99 Hepiane ost Flow rate (seta) 24.4410 Temperature (F) 1200 Pressure (psig) 5860 “The expander lets the pressure down to 125 psig, which isthe working pressure of the demethanizer column. 90% of the expander work is utlized by the compressor. “The expander efficiency is 80% and the compressor efficiency is 75%, Methods Peng-Robinson is chosen for K-value and enthalpy calculations. It is applicable to and Data light hydrocarbon systems, and PROMI includes binary interaction constants to predict accurate Ne/hydrocarbon equilibria. The Lee-Kesler method, specified for liquid density. works well for hydrocarbon components lighter than about Co. Simulation —_The flow sheet shown in Figure G5.1 is thermally coupled in the gas-gas exchanger Model 1. However, you can often eliminate thermal couples and significantly reduce the computation time, simply by re-ordering the calculation. “The purpose of the chiller is to ensure that the temperature of the flash separator D1 is constant, and so you know all the process conditions of stream 3. If you start the calculation at D1, then E1 and E2 can be calculated after the column, and no iteration is required. “The procedure for this is simple: 1) reference stream 3 to feed stream 100 in the STREAM data section 2) use a SEQUENCE statement to start the calculations with unit Dt 3) give the product stream from unit E2 a dummy stream label 3X. Streams 3 and ‘3X are identical “The demethanizer is modeled as a conventional distillation column with 10 theoreti- calstages, including the reboiler. The reboiler duty is varied to achieve the specified ‘methanelethane ratio in the bottom product. 65.2 EXPANDER PLANT PROIll APPLICATION BRIEFS February 1991 DSc E> oS SOLID CONVERTER POF > satin seeInput Data The problem input data are supplied in standard English units, except that the pressures are in psig rather than psia. The resuits, however, are required in Sl units ‘soan OUTDIMENSION statementis used to obtain both English and Sl output. The stream output is requested in both molar and liquid volume unis. ‘The SEQUENCE statement ists the UIDs ofthe units, inthe order in which they will be calculated. Any units which are not specified on ths statement are not calcu- lated No solution method is defined for the demethanizer column, and so the default, Inside-Out (10) method willbe used. The column has no condenser and stream 7 is fed to tay 1 ‘Tho DEFINE statementin the compressor species that 90% ofthe work produced by the expander is used Input Data File: seu DL, vi x1,71,21,22,C2 PROP STREAM=100, TENP=120, PRES=508, PHASE-V, RATE (G MAME 100, INLET GAS/11,GRS PRODUCT/9, LIQUID PROD Peroni PROIll APPLICATION BRIEFS EXPANDER PLANT G5-3 February 1991 ™ SOLID CONVERTER POF > satin nea. reeVALVE UIDAVL,NAMBALIO VALVE Results ‘The demethanizer column solves with a reboiler duty of 25 Gh. The expander produces 287 kW of work, and 258 kW are used by the compressor. The compres- sor feed is at 9.29 bar, and the outlet pressure is 12.07 bar. The expander drops the pressure from 40.5 bar to 9.6 bar. Conclusions —Thedemethanizercolumn can meet the purty specification with the new feed stream as long as the required 2.5 GJihr is available for the reboller. The compressor recovers 2.78 bar from the expansion of the column feed vapor stream through 30.9 bar. Output ‘The demethanizer outputs in SI units and shows the required duty as well as the column temperatures and intemal flow rates. The expander and compressor outputs show the isentropic and theoretical calculation results, as well as the actual performance. ‘The heat exchanger results are shown in the input (English) units. ‘The stream component flow rates showing the feed and product streams are presented in both the molar and quid volume unit. 65-4 EXPANDER PLANT PROIII APPLICATION BRIEFS. February 1991 DSc E> oS SOLID CONVERTER POF > satin seeDEMETHANIZER COLUMN OUTPUT TRAY TH PRESSURE LIQUID VAPOR FEED PROUUCT. DUTIES TPE STREAN PHNGE FROM TD LIQUID Fou exras EAT BATES OMmpALL MENT BALANCE, (LIN) HIG) } ~6.50578-04 PROIll APPLICATION BRIEFS EXPANDER PLANT G5-5 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teEXPANDER AND COMPRESSOR OUTPUT MOLE PERCENT LIQUI 6170 6.2012 ce) (ce-R) ce/c Nous PERCENT LIQUID 65.6 EXPANDER PLANT PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teHEAT EXCHANGER OUTPUT PROIll APPLICATION BRIEFS EXPANDER PLANT G5-7 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teFEED AND PRODUCT STREAM OUTPUT (Molar) BYRALEY, WeEG/IR 1.9606 Nou FRAC LIQUID 65-8 EXPANDER PLANT PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teFEED AND PRODUCT STREAM OUTPUT (Volume) moe ago rea as meouct me GAs pose EQ varaR VABOR abo MOLE FRAC LIQUID 10000 PROIll APPLICATION BRIEFS EXPANDER PLANT G5-9 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa te‘This page intentionally lft blank. 65-10 EXPANDER PLANT PROIll APPLICATION BRIEFS February 1991 ete = SOLID CONVERTER PDF > omnes pues eTHREE STAGE LETDOWN ‘The dissolved gases in crude oil from a well are released as the pressure drops and must be removed in order to avoid storage and transportation difficulties. To ‘minimize oil loss tis removed in several stages, recompressing vapor and recyciing liquid which drops out. ‘You must simulate the three-stage letdown process to determine how much gas will 'be produced and calculate the crude oil flow rate for transportation. The true vapor pressure (TVP) ofthe oil product must not exceed 14.7 psia, to ensure that no vapor, flashes off. Cooling water for the compressor aftercoolers is avalable at 70 F ands alowed to rise 30 F. You must determine how much cooling water is required. Process Data The flow sheet for the three stage process is shown in Figure G6.1. The foed consists of water, pure hydrocarbons, and petroleum fractions as shown in Table 6.1 PROIll APPLICATION BRIEFS February 1991 EE S115 De PE). Te Figure G6.1 Three Stage Letdown Flow Sheet ‘THREE STAGE LETDOWN G6-1 CONVERTER PDF > tims esis rheTable G6.1 FEED STREAM INFORMATION ‘Component _| _tbmolesir | Component _| th molesihr Water 3000 Gut 11 165 02 35 cutt2 303 Ne 30 cutt3 560 ct 290 outta 230 c2 300 outs: 300 o3 520 cut t6 300 ica 105 outt7 300 nea 283 cut 18 280 ics 100 cut19 260 nes 133 Temperature (F) 150 Pressure (psia) 1000 “The first stage flash is at 300 psia and 200 F. The second stage is adiabatic at 200, psia. The third stage is also adiabatic, but the pressure is calculated in order to ‘meet the TVP specification, 660% ofthe free water in stage 1 is removed from the process. The remainder is removed from the following flashes. The compressor outlets are cooled to 120 F, and the liquid portions are recycled to the third stage lash, “The vapor from stages 2 and 3 are recompressed to 97 and 297 psia respectively. ‘The final product gas is produced at 297 psia. Methods “The crude oil has been characterized inthe laboratory into rine petroleum fractions, and Data with the properties listed in Table G6.2. The data are entered with the PETRO statement, and all other properties are are estimated from the given data, using standard petroleum correations. Equilibrium K-values, enthalpies, and vapor densities are calculated using the ‘Soave-Redlich-Kwong (SRK) equation of state. This method is applicable over a wide range of temperature, pressure, and composition. The API Data Book method is automaticaly selected for quid densities with the SRK system. This method gives good results for hydrocarbon liquid streams which do not contain large amounts of methane or ethane. 66.2 THREE STAGE LETDOWN PROIll APPLICATION BRIEFS February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teTable G62 PETROLEUM FRACTION PROPERTIES Fraction | Molecular Wt | API Grav. NBP (F) curt 31 4 780 cure 4100 a 210 cuts 120 56 220 cuts 150 48 370 cuts 200 40 495 cuts 245 35 590 cuz 300 20 ear cute 360 6 770 cut 430 2 265 Simulation —_ Tne TVP specifcationis the vapor pressure of the liquid at a defined temperature. Model “The most widely used temperatures 100F andthisis he defaultin PROMI. Different temperatures may be defined with the TVPBASIS entry on the CALC statement in General Data ‘The pressure of the final letdown stage (VAL2) is varied using a controller to meet, the TVP specication on the liquid product. The intial pressure defined for VAL2 is, a first estimate. ‘The calculation requires recycle and controller loops. Computation time is reduced bby modeling the compressors as isothermal lashes within the loops. After the recycle and controller have solved, the compressors and aftercoolers are rigorously ‘modeled to determine horsepowers and duties. No inital estimates are required for the recycles. In order to calculate the cooling water requirements, separate heat exchanger ‘models are used instead of the built-in compressor aftercooler. Input Data No dimensional units are defined for this simulation, so they default tothe standard set of English units. “The free water is decanted from the frst stage flash, and 60% is removed by the spliter unit. The remainder ofthe waters fed tothe second stage. ‘The controller specifies that the TVP of the oil must be 147 with an absolute tolerance of 0.1. The variable is defined as the pressure of unit VAL2. The convergence of the controllers handled automatically. Te ‘The flashes C1+ and C2+ replace the compressors and aftercoolers during recycle trials. A stream may feed more than one unit operation, and so the feeds to C1+ and C2* are also fed to the rigorous compressor models. The products from the aftercoolers do not feed other units ,and so the program only calculates the ‘compressors and aftercoolers after the recycle has converged, PROIll APPLICATION BRIEFS ‘THREE STAGE LETDOWN G6-3 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa te‘The cooling water required in the aftercoolers is calculated when WATER is specified with the UTILITY statement. The inlet and outlet water temperatures are supplied, and the quantity is calculated from the heat balance. Input Data File: ‘DIME LIQVOL-BEL — LIBID. —1,yatmR/2, c02/3,N2/4,C1/5,C2/6,C3/& ‘conP=1, 3000/2, 35/3, 30/4,890/S, 300/6,520/7, 105/8,263/e '9,100/20, 133/12, 165/22, 303/13, 860/14, 930/15, 300/e 16,200/17, 300/28, 260/19,260 66-4 THREE STAGE LETDOWN PROIII APPLICATION BRIEFS. February 1991 ™ SOLID CONVERTER POF > satin nea. reeResults “The gas product dry fow rates 715,789 ff, and the ol production is 2496 boi. ‘The final stage pressure which gives the required oil TVP is 35.7 psia, ‘The cooling water required by stages 1 and 2 is 83,124 and 112,554 lbh respec- tively (simulation output not shown here). Conclusions This simulation has provided all the necessary information. The model could now bbe used to investigate if different letdown andior compressor conditions could improve the oil product rate, Output ‘The flash drum summary shows the conditions in each letdown and compression stage. The full details ofthe second stage compressor and aftercooler appear on the compressor and heat exchanger output. The aftercooler details show the cooling water requirement ‘A portion of the stream property output showing the feed and product streams is presented. PROIll APPLICATION BRIEFS ‘THREE STAGE LETDOWN G6-5 February 1991 E> oS SOLID CONVERTER POF > satin seeFLASH SUMMARY Lagu 2 a 105 10 MOLE FRAC TOTAL LIQUID 0.87253, 0.89920 0.97532 0110698, Moe FRAC H/C LIQUID o'sans 0.72095 o.a7siz_—— oo oan Ors, et BTU/AR 2sla76ss 0.00000 0.00000 _-2.52528 uigup 8 Moe FRAC TOTRL LIguID o:oanse MOLE FRAC H/C LIQUID 0.05622 DOTY, Mat BU/ER -3.47833 66.6 THREE STAGE LETDOWN PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teSTAGE 2 COMPRESSOR CALCULATED FROM HEAD BOUTIN. PROIll APPLICATION BRIEFS ‘THREE STAGE LETDOWN G6-7 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teSTAGE 2 AFTERCOOLER rguID poner on VAPOR, 18-NOL/aR 2065.39 196.986 Nw eso2 58.289 QUID, 1-yoL/ 220.207 Nw 7aae wom, 12-90L/aR 40163 N/m 0.868 TOTAL, L2-MDL/HR 2065.396 © 2065.396 swam 66.502 66-502 conpmIsaTION, 1-N0L ae0.a10 66-8 THREE STAGE LETDOWN PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teSTREAM PROPERTIES OUTPUT PIRSE Mer VAPOR WET LIQUID. WET LIQUID WET vAEOR PATE, 1B-¥0L HR ou4.44209793.999 932.193 1096.906 MOLE FRACTION LIQUID 0.00000 1.00000 «1.00000 0.00000 PATE, 1B-¥01 HR ous 442 wa N/A 1996.966 M FTS/aR 20.872 1A aya 35.127 ‘sm VAP RRTE(L), M FTG/iR 3591397 am NA 19.670, DENSITY, Le/M FT a4 528 aa N/A 1662-237 — rom ug — PATE, 1B-¥0L HR WA 673.999 3932.19 na x ia WA e303 748.323 N/a BL WA 72821665 2607.934 N/a capa WA 22771858 2053.48 N/A smo 119 RXTE, BL/R WA 430x767 2496.61 na MouncuLAR WE: WA 94.398 162.677 NA BMnALeY, BTU/LB WA 35.964 a0.730 N/a ce, BrU/ia-F wa 05a o.sz2 N/A Dawsrry, 12/aat WA 260.630 272.277 Na PROIll APPLICATION BRIEFS ‘THREE STAGE LETDOWN G6-9 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teSTREAM PROPERTIES OUTPUT (Cont) Pare, La-wou aR er ay urge Pare, La-Wou/AR Nay sm 10 ARTE, aL/am Nia Na Na Na Na Na Na Na Mer LIQUID WET LIQUID wer vAROR na w/a 1006.222 Na NA 50196 na NA 34 902 na NA 30.853, Na NA 06934 na MA 0505 Na NA 1667-376 (2) Sm vapor VOUNE 15 379.49 FTD/LB-MOLE (60 F AND 14.696 SIA) 66-10 THREE STAGE LETDOWN PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teGAS DEHYDRATION USING TEG Gas dehydration is being performed by an existing TEG plant currently in operation. ‘You wish to model the operation ofthis plant based on recent plant test data in order to estimate annual TEG vaporization losses. Process Data _Theprocess fowsheet fr the TEG dehydration system s shown in Figure G7.1. The feed to this system is 39 MMSCFD of wet gas (21.5 pounds of water per MMSCF of wet gas) at 80 F and 720 psig. This feed streamis synthesized by mixing the hydrocarbon gas on adry basis (stream 1G") with water (stream “1W') to yield the actual wet gas feed (stream "t"). The ‘Stream Data specifications consist of the composition and thermal condition of the ‘wo feed streams (streams "1G" and "1W) and the recycle stream (stream °3") Table 67.1 Feed Stream Information ‘Stream ID 16 Ww 3. Stream Name_| Gas Mix Water Mix. Lean TEG ‘Stream Mole Weight Components Percent tay Percent 1 co2 1.385 0.00 0.000) 2 Ws 4.700 0.00 0.000 3 ct 88.140 0.00 0.000 4c 6410 0.00 0.000 5 cs 1.710 0.00 0.000 5 Ica 0.181 0.00 0.000 7 Nea 0.239 0.00 0.000 8 ics 0.069 0.00 0.000 9 Nos oor 0.00 0.000 10 Nos 0.054 0.00 0.000 11 Nor 0.081 0.00 0.000 12 H20 0.000 838.50 1.400 13 Tes 0.000 0.00 98.600 Input Unis 'SCFD Tbiday galhe stream Rate an0E+6 838.50 600,000 Temperature (F) 80 30 120 Pressure (psig) 720 720 20 PROIIl APPLICATION BRIEFS. February 1992 GAS DEHYDRATION USING TEG G7-1 eee = SOLID CONVERTER PDF To remove tis message, purchase the ‘product at www.SolidDocu ws.comto eomacron eae} | ase mn . Figure G7.1 TEG Plant Flowsheet Methods and Data ‘The system keyword GLYCOL is used to select equlbrium and enthalpy data for the dehydration calculations. This is a special data package provided in PROIII specif. cally for glycol dehydration systems. The data inthis package have been fitted over 2 range of typical temperatures and pressures for TEG dehydration systems. ‘The GLYCOL package is based on TEG solutions which are typically used in dehydration operations (98+ percent TEG by weight). Note that ideal flowing densities are selected for the TEG solutions, Simulation —_The TEG plant process flowsheetis shown in Figure G7.1. The corresponding PROMI Model simulation flow diagram is shown in Figure G72. Figure G7.2 ‘Simulation Flowsheet for TEG Process Petes 3 G7-2 GAS DEHYDRATION USING TEG PROMI APPLICATION BRIEFS. February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa te‘The standard convergence criteria have been modified to ensure that the trace recycle component (water) will be tested for closure. Convergence of the recycle stream (lean TEG, stream "3" is enhanced by specifying the recycle stream tem- perature (see "Cooler" heat exchanger specification). This is good simulation prac- fice and also corresponds wel to actual operations. ‘The actual feed stream is synthesized as mentioned above by isothermal mixing of the water and natural gas portions of the feed stream in a flash module. ‘The Stream Data Category also includes specifications to: ‘+ Speed convergence by utilizing the reference stream feature to relate heat ‘exchanger inlet and outlet streams. ‘+ Establish a user-defined output format ‘+ Name the principal process streams. ‘A contactor model using three theoretical trays or equlbrium stages is used tomatch ‘actual plant data accurately. ‘The regeneratoris modeled by feeding the warm, rich glycolto tray one. Ifitis desired to furnish a condenser, the reflux rate should be specified and the condenser duty calculated. The reboiler temperature is specified, which sets the lean TEG concen tration. ‘The Inside/Out (VO) method is used for both the contactor and the regenerator. Regenerators in which stripping gas is injected may also be modeled. External stripping columns may be modeled with two or three equilibrium stages. ‘A*Stream Calculator utility module is used to create the make-up TEG stream. TEG losses in the plant outlet streams treated gas—stream '2", flash gas—stream "7", ‘and water vapor—stream "1 1") are summed to determine the required TEG make-up. Input Data The standard stream summary is suppressed (Note 1) and a user-defined output format is used to generate special reports instead (Note 2). Note the tightening of the trace component tolerance for the recycle streams (Note 3) and the use of the “Stream Calculator’ utlty module (Note 4) as discussed above PROIIl APPLICATION BRIEFS. GAS DEHYDRATION USING TEG G7-3 February 1992 DSc E> oS SOLID CONVERTER POF > satin seePetes 3 Ue) gC SOLID Input Data File ‘TITLE PROJECT=APPERIEF PROBLEM=G7, & USER=SIMSCI,OATE=01/20192 DESC. GAS DEHYDRATION USING TES DIMEN ENGLISH PRINT STREAM=-COMP INPUT=NONE SNOTE1 DBASE DATA=PC1,IDATA=3.SDATA=G7AMC TOLER STREAM=0.01,0.0005, SNOTES COMPONENT DATA IBID 1,C02/2,HYSULFIO/2.METHANEM4 ETHANE! & ‘PROPANE |BUTANEI7,BUTANEIS,/PENTANE! & S.PENTANEN0, HEXANE! 3, HEPTANE/!2,H201 & 137s. ‘THERMODYNAMIC DATA METHOD. KVALUE(VLE)=SRKM,ENTH(V)=SRKM,ENTH(L}=SRKM, & EENTRIV)=SRKM,ENTR(L)PSRKM.DENS(V}=SRKM, & DENS(L)HIDEA SET=SETO!,DEFAULT KVALUE(VLE) BANK=GLYCOL SIMSCI STREAM DATA ‘PROP STREAM=1G, TEMP=E0,PRES=720,PHASE? RATE(GV,FTSIDAY)=39.06+006, & COMP(M)=1,1.96912,1713,88.14i4 6.411 & 9,1.71116,0.18117 0.2398,0.000/ & 910.071/10.0.054/11,0.061 NORMALIZE PROP STREAM=1W,TEMP=80, PRES=720,PHAS ‘COMP(WTLBIDAY) PROP STREAN-3,TEMP=130 PRES RATE(LV}=600, & 2,1.4113.98.6. NORMALIZE ‘TEMP> PROP STREAM=10,REFS=8,TEMP=240,PRES=40 NAME 16,GAS MIX/1W.WATER MDCS LEAN TEG! & 6 FLASH FEED/I0,RICH TO REGIS FLASH LIQUID! & 1LOFF GAS/15 MAKEUP TEGI2 DRY GAS! 4 RICH TEGIT FLASH GAS/I2HOT LEAN’ & S.WET GAS (OUTPUT FORMAT=1,STRM=1.3.24, 8 SNOTE2 SONTACTOR STREAMS FORMAT IDNO=1,NAME, PHASE. TEMP PRES CRATE, & RATE LINE,CRATE(WT) RATE(WT)LINE VAPOR, & RATE(GY,FTSIDAYMW DENSITY(LBIFTS), & LIQUID RATE(LV. GALMIN) SPGR, & DENSITY(LBIFT3) G7-4 GAS DEHYDRATION USING TEG PROMI APPLICATION BRIEFS. February 1992 CONVERTER PDF > mas tisnesin putas teUNIT OPERATIONS. FLASH UID=1.NAME=FEED MIX FEED 1G.1W PROD_V ISO TEMP=a0,PRE 10=30 PROD GVHD=2.4400.8TMS=4 PRINT PROP=PART ITER=PART.XYDATA EST! MODEL-CONVENTIONAL COLUMN _UID=4,NAME=REGENERATOR PARAM TRAY=3,0=30 FEED 10.1. NOTSEP PROD OVHD=11,10.8TMS=12 4.0PCOL: PRINT PROP=PART,ITER=PART.XYDATA ESTI_ MODEL-CONVENTIONAL SPEC 'COLUMN=4,TRAY=3,TEMP,* ‘VALUE=400 VARY DUTY= Hx. HOT FEED=191.=14,0P=0.1 COLD FEED=51.=0.0P=10 OPER CTEMP=170. CONFIG TPASS=1.SPASS- STCALC UID=8NAME-MAKEUPTEG — SNOTE4 FEED. 2,.0000/7, 1.000011, 1.0000 PROD. L=15PRES=1,TEMP=80 FPROD 1,120.0/18.15,10 PROIIl APPLICATION BRIEFS. GAS DEHYDRATION USING TEG G7-5 February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa tePUMP. UID=9,NAME=GLYCOL PUMP FEED 14,15 PROD L=16 (OPER PRESS=720 HX UID=10.NAME=COOLER HOT FEED=16=3,0P=10 OPER HTEMP=120 CONFIG TPASS=1,SPASS=1 END Results “The recycle loop converged in three iterations. The regenerator duty is 0.63 MM Btu/hr, the glycol pump hydraulic horsepower is 4.6 hp and the duties for the “Lean‘Rich 1", "Lean-Rich 2", and "Cooler" heat exchangers are 0.25 MM Btulhr, 0.32 MM Btufhr, and 0.38 MM Btulhr respectively. The make-up TEG flowrate is 0.014 Lomolat. Conclusions The natural gas stream is dehydrated from a water content of 21.5 pounds of water er MMSCF of gas to 2.8 pounds of water per MMSCF of gas with a 10 gpm lean ‘TEG flowrate tothe contactor. Annual TEG vaporization losses willbe approximately 1900 gallons per year based on a 97% operating factor (excluding losses due to entrainment or upsets in column operation). Output Partial results are shown below forthe simulation input given above. Note the stream data output printed in the user-defined format for the contactor streams, regenerator streams, and flash tank streams. The standard component flow report was also requested, but is not shown. G7-6 GAS DEHYDRATION USING TEG PROMI APPLICATION BRIEFS. February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teFLASH ID NAME FeeDs PRODUCTS VAPOR Liguio TEMPERATURE, F PRESSURE, PSIG PRESSURE DROP, PSI MOLE FRAC VAPOR MOLE FRAC LIQUID DUTY, MM BTURR FLASH TYPE PROIIl APPLICATION BRIEFS. February 1992 Flash Summary FEED MIX FLASH TANK 170.000 0,000, 0.000 o.04ass 0.95946 .00000 ISOTHERMAL ADIABATIC.P GAS DEHYDRATION USING TEG G7-7 ete = SOLID CONVERTER PDF > omnes pues eLean TEG Trim Cooler UNIT 10, 10, "COOLER (OPERATING CONDITIONS DUTY, MM TUR oz HOT SIDE CONDITIONS INLET OUTLET FEED 16 Liguio PRooUCT 3 LIQUID, LB-MOLR aa7s1_ 40.751 MiBmR se28 5.028 cp, BTULEF 0623 0.562 TOTAL, LB-MOLMR 40751 40.751 MiBmR se28 5.028 CONDENSATION, LE-MOLIHR 0.000 TEMPERATURE, F 256.552 120.000 PRESSURE, PSIG 730.000 720.000 G7-8 GAS DEHYDRATION USING TEG PROMI APPLICATION BRIEFS. February 1992 ete = SOLID CONVERTER PDF > omnes pues eRegenerator Feed/Bottoms Exchanger UNITS, 8, LEAN-RICH 1 OPERATING CONDITIONS DUTY, MM BTUR. 0.242 Lar, 162.588, F FACTOR (FT) "000 MD.F 162.558, U'A, BTU 1486.067 HOT SIDE CONDITIONS: ImeTouTLET FEED 12 Ligup pRopucT 13 LQUID, Le-MOLINR: 40739 40.730 MLBIHR 5626.” 5.626, cp, BTULEF 0.662 0.602 TOTAL, LB-MOLHR 40739 40.739 MLBIR 5626" 5626, CONDENSATION, LE-MOLIHR 0.000 ‘TEMPERATURE, F 400.000 936.143, PRESSURE, PSIG ‘100° 1.000 COLD SIDE CONDITIONS IMT OUTLET FEED 8 MIXED PRODUCT 10 ‘VAPOR, LB-MOLMR 0.166 MILER 5.6196-03 cp, BTULEF 0.358 QUID, LE-MOLMR: 49789 43.022 MLaMR e710. 8.704 cp, BTULEF 0586 "0.620 TOTAL, LB-MOLHR 4a7e9 42,780 MLamR smo 8710 VAPORIZATION, LB-MOLIHR 0.106 TEMPERATURE, F 170.009 240,000 PRESSURE, PSIG 50.000 40,000 PROIIl APPLICATION BRIEFS. GAS DEHYDRATION USING TEG G7-9 February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teRich/Lean TEG Exchanger UNIT, "7, LEAN-RICH 2 (OPERATING CONDITIONS DUTY, MM TUR 0.288 uwTo. 169.061 F FACTOR (FT) 1.000 AD, F 169.081 UA STUHR 1683.016 HOT SIDE CONDITIONS INLET OUTLET FEED 13 Liguio PRODUCT “ LIQUID, LB-MOLHR ao7s9 40.739 MiBmR 5626. 5.028, cp, BTULEF 0662 0.625 TOTAL, LB-MOLMR 40739 40.730 MiBmR 5026 5.028 CONDENSATION, LE-MOLIHR 0.000 TEMPERATURE, F 335.143 250.651 PRESSURE, PSIG ‘000 d.900, COLD SIDE CONDITIONS. INLET OUTLET FEED 5 MIXED PRODUCT 6 ‘VAPOR, LB-MOUHR 1201 “1850 MLBMR 0.032 ~ 0.052 cp BTULEF 0421 0298 UQUID, LB-MOLR “44.08 43,709 MiBmR 5729 5710 cP. BTULEF see “sa6 TOTAL, LB-MOLMR 45699 45.030 MiBMR 5761 5.761 VAPORIZATION, L8-MOLHR. o.s20 TEMPERATURE, F ea6t1 170.000 PRESSURE, PSIG 60000 50.600 3 G7-10 GAS DEHYDRATION USING TEG. PROMI APPLICATION BRIEFS. February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teStream Calculator Summary UNIT 8,8. MAKEUP TES FEEDS STREAMID FACTOR 2 1.000 TOTALRATE LEMOUMR _ 4279.185 TEMPERATURE, F 94228 PRESSURE, PSIG 720,000 MOLECULAR WEIGHT "18.4446 MOL FRAC VAPOR 1.00000) MOL FRAC TOTAL LIQUID. 0.00000 MOLFRAC MW SOLID 0.00000, ENTHALPY,MMBTUR = 3.19901 7 1.000 TOTALRATE, LEMOUHR 1.850 ‘TEMPERATURE, F 170.000 PRESSURE, PSIG 50.000 MOLECULAR WEIGHT 27.9638 MOL FRAC VAPOR 1.00000 MOL FRAC TOTAL LIQUID. "0.00000, MOLFRACMW SOLID 0.00000, ENTHALPY, MMBTUIKR 0.00974 " 4.000 TOTALRATE LEMOUMR 2050 TEMPERATURE, F anisor PRESSURE, PSIG ‘0100 MOLECULAR WEIGHT 27.4296 MOL FRAC VAPOR 1.00600" MOL FRAC TOTAL LIQUID. 0.00000 MOLFRAC MW SOLID 0.00000, ENTHALPY, MMBTUIR 0.04996 PRODUCTS OVERHEAD BOTTOMS ALTERNATE PRODUCT 15 au TOTALRATE LEMOUNR = NANA 1.2056-02 TEMPERATURE, F NA’ NIA 80.000 PRESSURE, PSIG NA NIA 1.000 PRESSURE DROP. PS! NA NA -0.900 ENTHALPY, MM STUHR PROIIl APPLICATION BRIEFS. February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa te NA 'NIA 2.178326-05 GAS DEHYDRATION USING TEG G7-11Contactor Column Output UNIT2, 2, CONTACTOR’ ‘TOTAL NUMBER OF ITERATIONS IOUT METHOD 11 ‘COLUMN SUMMARY NET FLOWRATES————_ HEATER TRAY TEMP PRESSURE LIQUID VAPOR FEED PRODUCT DUTIES DEGF PSIG LE-MOUHR MM BTURR. 1 842 72000 438 40aL 4279.2 2 B10 72000 440 42822 3 807 72000 42824 4284.1V 45.6L FEED AND PRODUCT STREAMS TYPE STREAM PHASE FROM TO LIQUID FLOWRATES HEAT RATES "TRAY TRAY FRAC LE-MOUMR MM ETUHR FEED3 © LIQUID. 11.0000 ©4075 0212 FEED! © VAPOR 90.0000 4264.07 2.9832 PROD 2 VAPOR + 427918 3.1339 PROD 4 — LIQUID 3 4864 0.0805 OVERALL MOLE BALANCE, (FEEDS-PRODUCTS) 8,500.05 (OVERALL HEAT BALANCE, (H(N)-H(OUT) ) 1 9861E-05 3 G7-12 GAS DEHYDRATION USING TEG PROMI APPLICATION BRIEFS. February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teRegenerator Column Output UNIT 4, REGENERATOR TOTAL NUMBER OF ITERATIONS IWOUT METHOD 36 COLUMN SUMMARY ner Ftowrates ——___ eater TRAY TEMP PRESSURE LIQUID VAPOR FEED PRODUCT DUTIES DEGF PSIG LB-MOUHR, MM BTUR. 1 2715 010 495 43am gov 2 2005 060 540 28 3 4000 1.10 133 4o7L 06207 FEED AND PRODUCT STREAMS TYPE STREAM PHASE FROM TO LIQUID FLOW RATES HEATRATES TRAY TRAY FRAC LE-MOLIMR™ MM BTUHR FEED 10 MIXED «109747 43.79 0.5069, PROD 11 VAPOR 1 305" 0.0800 PROD 12 LIQUID a 4074 1.1676 OVERALL MOLE BALANCE, (FEEDS -PRODUCTS) 6 69866-06 OVERALL HEAT BALANCE, (H(IN)- H(QUT) ) “1 32856-06 SPECIFICATIONS PARAMETER TRAY COMP SPECIFICATION SPECIFIED CALCULATED TYPE NO NO TYPE. VALUE VALUE TRAYLIQ.3.——«‘TEMPERATURE 4000602 40006402 PROIIl APPLICATION BRIEFS. GAS DEHYDRATION USING TEG G7-13, February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teUser-Defined Stream Output CONTACTOR STREAMS FEBRUARY 1992 STREAMID 1 3 2 4 NANE WETGAS LEANTEG ORVGAS cH TEG PRASE Waron igUD'” vaPoR uGUuD NAME WETGAS LEANTEG DRYAS RICH TEG PHASE VAPOR LIQUID.” VAPOR LIQUID TEMPERATURE, F 2000" 13000 ees 8D Pressune-rsig 720o0 720000 720000 “720.000 COMP. MOLE RATES, TBMOLER 1002 504506 19167E-07 se2se7 _o.tet8 2AvSULeID ‘tees 2usiee-o4 71z5e4 1 5364 S METHANE Sr1423t6 2 70056-09 S773.0418 0.8827 “ETHANE ziasea0. 22500608 2742640" 02374 S PROPANE Tzoee Sazaseos “Toasts Oai6! b ieUTANE 77600 10052608, 77088" 00u8 BUTANE fogse s7oweo Tatete “coeze éiPenTaNe Doses 27e00E08 ‘2eleo seteuets SPENTANE Solos «ereseos 30202 ort IOMEXANE 25123 ‘teorneoe | 2oeso 0.0000 Ht MEPTANE Zot2t Sere7eos 26650 00ee2 i2Heo. 1930 stats 0.242 caret totes diseco 7.0286 1.25486-03 "7.0083 RATE LeMoLMR “izeaor28407ett #2781846 45.6382 CCoMP. wr. RATES, La 002 25724062. 8AS1TE-0G 256.9660 8.4420 2veuurm "Figo roee‘esscoe-03 ae. sara SMETMANe ——Gosso.ouso aa7ereos coeds 227 14.220 oetuae cosserse erase? excesiso, 7.1310 S PROPANE 32308880. 230126-06 82087600 67S bieuTaNe asoois eorese-0s 447502 2sae BUTANE Soaesoe 27sose 06 sovoen Aye? éirentane 713 004 T9565e-06 zizsssi oan SPENTANE Hasees Sseove 00 aiessr? sore IOHEXANE fosarie teosceoe ta6.o1 28018 TMePTANE BEi7ss0 ‘Ses0ee'03 ‘2/104 4.6802 iano sagore e7ose0 42067" s7s7e0 lates 0000. sscosve0 ‘.teb4, seco,cobe maTetsme —“pooreote "sen7.0272Tebz50s0t 57614522 “= vaPOR PHASE Ps RAYEMTTDAYs00176581_ NA aeg7a.eis NA 3 Mouecutawetcwr taasaa “wa rmeats NA Ea DENSITY-LSMETS, —zseaisésr” Ni “2geh aoe” Wa Fd LeU PHASE a rave GRLMIN NA 99762 NA. t0s961 HY Sto. SPOR (H2O60F).SFGR NIA 1.4278 Nia 1.1079 Ee DENSITY, LTS wa “eeeted NA “eeozoe 67-14 GAS DEHYDRATION USING TES PROMI APPLICATION BRIEFS February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teUser-Defined Stream Output, cont'd. REGENERATOR STREAMS FEBRUARY 1992 STREAM ID ow on 2 NAME RICHTOREG OFFGAS HOT LEAN PHASE MIXED” VAPOR” LIQUID NAME RICHTOREG OFFGAS HOT LEAN PHASE MIXED VAPOR” LIQUID TEMPERATURE, F 24000 271.81 400.00 PRESSURE, PSIG 40.000 0.100 1.100 COMP. MOLE RATES, LE-MOUHR 1002 0.0561 0.0561 1.91576-07 2HYSULFID 1.0500 1.0888 2.4518E-04 METHANE 0.0862 6.0462 2.7908¢-09 4 ETHANE, 00346 0.0346 2.20606-08 ‘S PROPANE 0.0268 0.0268 §.42256-08 GIBUTANE 0229 0.0229" 1.03626-08, BUTANE 0.9500 0.0500 _4.70096-05 SIPENTANE 32508603 “3.25056-03 2.76996-08 9 PENTANE 4459506.03 4.59596-03 4.97636.08 10 HEXANE 00197 0.0197 1.86776-06, 11 HEPTANE 0.0376 0.0376 i.9187E-05 1220 5200816785 3.7213 i3Tes. srozs Go19 37.0179 RATE, LB-MOUMR, 437887 30499 40.7380 COMP. WT. RATES, LMR. C02 24686 24686 0.49116-06 2HYSULFID "36.0903 26.0821 8.3550E-03 ‘3 METHANE 0.7407 07407 44767E-08 4 ETHANE: 1.0394 1.0304. 6,72366-07 ‘PROPANE 41e2e 4.1828 290126.06 GIBUTANE vai 1.3321 eo1e86-05 BUTANE 29062 29060 2.73236-04 SIPENTANE 02343 02345 1.9085E-08 9 PENTANE: 03316 03316 3.50046-05, 10 HEXANE 116957 1.6955. 1.6096E-04 11 HEPTANE 37675 37636 3.92686-03 12420 972769, 20.2486 67.0384 13 Tes 500.0802 1.6413 5959,0966 RATE, LAUR ‘709.7471 89.6568 5626.0879 "VAPOR PHASE" RATE, M FTSIDAY 19158277771 NIA MOLECULAR WEIGHT 337676 | 27.4206 NIA DENSITY, LEMFTS 248.7423" 51.9605 NIA LIQUID PHASE“ RATE, GALIMIN 10.1630 NIA 9.9729 STO.SPGR,(HZ060F),SPGR 1.12200, -NA 1.1278 PROIIl APPLICATION BRIEFS. GAS DEHYDRATION USING TEG G7-15 February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teDENSITY, LEVFTS 646805 NA 60.8464 Petes 3 G7-16 GAS DEHYDRATION USING TEG. PROMI APPLICATION BRIEFS. February 1992 ete = SOLID CONVERTER PDF > omnes pues eUser-Defined Stream Output, cont'd. FLASH TANK STREAMS FEBRUARY 1992 STREAM ID 6 7 38 NAME FLASH FEED FLASH GAS FLASH LIQUID PHASE MIXED VAPOR LIQUID NAME FLASH FEED FLASH GAS FLASH LIQUID PHASE MIXED VAPOR LIQUID TEMPERATURE, F 170.00 170.00 170.00 PRESSURE, PSIG 50.000 50.000 50.000 COMP. MOLE RATES, LE-MOLHR 1002 0.1918 0.1357 _ 0.0861 2HYSULFID 15364” 04779 1.0590 ‘3 METHANE 0.927 08466 0.0462 4 ETHANE: 02371 02028 0.0346 S PROPANE 01151 00883 “0.0268 GIBUTANE 0.0438 00209 0.0229 BUTANE 0.082¢ 0.0324 0.0500 SIPENTANE, a.6060E-09 “§.41646-03 3.25056.03 9 PENTANE 00111 @5175E-03 4.59506.03 10 HEXANE 0290 935606-03 0.0197 11 HEPTANE 0.0862 @.60866-03 0.0376 12420 sai6a 00167 5.2908 13 TES 37.0283 6.4024E-05 37.0282 RATE, LB-MOUMR, 48630218504 43.7887 COMP. WT. RATES, LMR. C02 24420 9734 2.4006 2HYSULFID 523574” 16.2671 36.0003 3 METHANE 14.3220 135813 0.7407 SETHANE, T1310 60s16 1.0304 ‘S PROPANE 50765 38037 | 1.1828 GIBUTANE 2sue 12177 13921 7 BUTANE S701 Yaass 29062 SIPENTANE 06253 03908 0205 9 PENTANE: baore 4702 03906 10 HEXANE 25019 0.8063 1.6957 11 HEPTANE “46202 0.026 4.7675 1220 975769 0000 97.2769 iBT 15500.6904 9.6147E-03 S560.6902 RATE, LAUR '9761.4922 51.7449 §709.7471 "VAPOR PHASE" RATE, M FTSDAY 16.2529 168529 NA MOLECULAR WEIGHT 27.9698 27.9638 NIA DENSITY,LaMFTS 270.9962 270.9962 NIA LIQUID PHASE“ RATE, GALIMIN 10.1815 NA 10.1815 STD.SPGR,(HZ060F),SPGR 1.1211 NA 1.1211 DENSITY, LBVFTS 669289 NA 66.9283, PROIIl APPLICATION BRIEFS. GAS DEHYDRATION USING TEG G7-17 February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa tePetes 3 G7-18 GAS DEHYDRATION USING TEG. PROMI APPLICATION BRIEFS. February 1992 ete = SOLID CONVERTER PDF > omnes pues eg 4 GAS SWEETENING USING AMINES ‘A sour natural gas feed containing 1.37 and 1.70 mole percent COp and H2S respectively is to be sweetened. Your job is to design an amine treating facility to bring the concentration ofthe acid gases in 100 MMSCFD of natural gas down to less than 5 PPM, Process ‘The flowsheet for this problem is shown in Figure G8.1. The natural gas feed stream Data information is given in Table G8.1, and the process information in Table G8.21 Figure G8.1 Natural Gas Sweetening 4. Ball, T., and R. Veldman, “Improve Gas Treating’, Chem. Ena. Proa., vol. 87, pg 67-72 (1991). PROIII APPLICATION BRIEFS. GAS SWEETENING USING AMINES G8-1 December 1992 ete = SOLID CONVERTER PDF > omnes pues eFa Table 8.1 iq Feed Stream Information Py Component Ibmoteihe Ps coz 149.9254 _ Hes 186.7203, CH 9680.8887 Cate 704.0451 Cae 187.9284 iCeHio 19.8801 Cato 26.2507 Ista 7.8787 Geta 7.7983 Cette 5.9310 Cite 6.7000 1:0 4.9745 Rate (MMSCFi) 417 Temperature (F) 100 Pressure (psia) 200 Table 68.2 Process Information Absorber Pressure 250 psia Absorber Pressure Drop 1.0 psia Absorber Amine Feed 15 wt% MEA Concentration Regenerator Pressure 155 psia Regenerator Column 2psia Pressure Drop 68-2 GAS SWEETENING USING AMINES PROIll APPLICATION BRIEFS Decmber 1992 ete = SOLID CONVERTER PDF > omnes pues eMethods “The K-values forthe system are computed using a special AMINE thermodynamic and Data data package. This package contains K-values for CO, H:S, H20 and MEA compo- i ‘nents, while SRKM is used for the remaining gas components. Liquid enthalpies and F344 densities are calculated using brary values. Vapor phase properties are calculated {Bf from SRKM. 3 Simulation 4 15 weight percent MEA in water solution is used to treat the sour gas. The gas is Ki Model first contacted with the amine solution in a6 tray absorber at 250 psig and about 110 F, where virtually all the HS and CO> are removed. After passing through the absotber, the amine solution, now rich in acid gases, is flashed to near atmospheric pressure by passing through a pressure-reducing valve where the hydrocarbons are removed. The resulting rich-amine then enters the regenerator, a 12.tray distillation column, where itis reboiled to release the acid gases, which exit at the top of the column. The lean-amine solution leaving the bottom of the regenerator is heat ‘exchanged with the rich-amine solution from the contactor before being sent to a ‘surge tank, Here, make-up MEA is added, The resulting lean-amine solution is luted to 15% MEA by adding make-up water, and is then air-cooled before being recycled to the absorber. Input Data English units are used forthe simulation. The regenerator condenser duty is varied in order to meet a specication on the temperature of the top tray, while the reboler duty is varied to meet a specication onthe vapor rate fr the bottom tray (Note 1). ‘k STREAM CALCULATOR and a SPLITTER unit are used to model the plant make-up MEA needed, while a CALCULATOR unit and a specication on the ‘make-up water spiter unit are utized to obtain a plant water balance (Note 2). An inal estimate forthe lean-amine recyete rat fs given based on an MEA loading of about 0.5 mole of aid gas per mole of amine. The Wegstein acceleration method is Used with default parameter in order o speed up convergence ofthe recycle loops. Input Data File TETLE PROJECT-APPBRIEF, PROBLEM=C8, & USER=SIMSCI, DATE=12/22/92 DESC AMINE SWEETENING PLANT DIMEN ENGLISH, LIQV=GAL PRINT RATE=M, STREAMALL, INPU! TOLER STREAM=0.01,,5.08-05,DUTY=0.01 CALCULATION TRIALS@15 COMPONENT DATA LrBID 1, C02/2, HYSULPID/3 , METHANE /4,ETHANE/ & 5, PROPANE/6, IBUTANE/7, BUTANE/, IPENTANE/ & 9, PENTANE/10, HEXANE/11,HEPTANE/12,H20/ & a3 Mea, PROIII APPLICATION BRIEFS. GAS SWEETENING USING AMINES 8-3 December 1992 erp &} SOLID CONVERTER PDF > ome rteTHERMODYNAMIC DATA FH METHODS SYSTEN-AMINE, SET-SE701, DEFAULT fy STREAM DATA = PROP STREAM=1,TENP=100, PRES=255,PHASE=M, & RATE(G)=4.172+06, & COMP (M)=1,58.481/2,72.7961/3,3774.26/4,274.484/ & 5,73.2671/6,7.7506/7,10.2343/8,2.9547/ & 9,3.0403/10,2.3123/11,2.6121/12,1.9394, & NORMALIZE PROP STREAM=3,TEMP=115, PRES=250, PHAS! RATE(M) =16000, & COMP (W) =1, 0.003 /2,0.003/12,0.85/13, 0.18, NORMALIZE PROP STREAM=19, TEMP=90, PRES=15.5, PHAS! COMP (My) =13, 2000 PROP STREAM=10B, TEMP=90, PRES-15.5,PHASE=L, & COMP (MH) =13, 10 PROP STREAM=10, REPS-9, TEMP(P) =170 PROP STREAM-WAT, TEMP=200, PRES=14.7,COMP=12, 2000, PHAS! NAME 1,G? WET GAS/2, TREATED GAS/WAT,WATER/3,AMINEH20/ & 4, BOTTOMS/S,#20 FLASH/8, ACID GAS/10B,MEA MAKEUP/ & 419, MER/W1, WATER MAKEUP UNIT OPERATIONS COLUMG —UID=CN-1,,NAME=CONTACTOR PARAM TRAY=6,10=50,DAMP=0.4, ERRINC=2.0 FEED 3,1/1,6 PROD OVHD=2, 10700, BTM: PSPEC TOP=250, DP= PRINT PROP=PART, ITER=PART, XYDATA, ESTI MODEL=CONVENTIONAL, TTEMP=100, & BTEMP=110, RTEMP=110 VALVE UID. FEED 4 PROD Ls6,V=5 OPER PRES=16.1 <1, NAME=PRESS VALVE ax UID=HX-1, NAME-AMINE 1X1 HoT PEED=9,1"10,DP=0 coLDFEED=6,L=7,D! OPER HTEMP=170 conrie coum PARAM FEED 7,5, SEPARATE PROD OVHD=8, 400, BIW: G8-4 GAS SWEETENING USING AMINES PROIII APPLICATION BRIEFS. Decmber 1992 ™ SOLID CONVERTER POF > satin nea. reeCOND TYPE-PART, PRES=13.5 PSPEC TOP=15.5,DPCOL-2 BEAT 1,12/2,1 PRINT | PROP=PART, ITER=PART, XYDATA SPEC TRAY=1, TEMP, VALUE=120 snore 2 SPEC TRAY=12, PHASE=V, PATE, RATIO, STREAM=9, RATE, VALUE=0.5 VARY DUTY=1,2 STCALC UID=SC-1,NAME-MEA MAKEUP FEED 2,1.0/5,1-0/8,1.0 PROD L-20, TEMP-90, PRES PROD 1,12,0.0/13,13,1.0 5.5 CALCULATOR UID=CL-1,NAME-H20 CALC SEQUENCE STREAM=2,5,8,1 RESULT 1,1 PROCEDURE R(1) = SCMR(12,2) +ScMR(12,5) +ScMR (12, 8) -SCMR (22,1) RETURN SPLITTER UID=SL-1,NAMB=SPLITTER FEED 19 PROD SPEC STREAM RATIO, STRE= MIXER UID=MX-1, NAME. FEED 108,10 PROD OPER BX UIDSHXA HOT FEED=11,L-11¢ OPER HTEMP=150 SPLITTER UI L-2, NAMB=SPLITTER FEED WAT PROD L-Wi, LeXWAT SPEC STREAN-W21,COMP=12,RATE(M), & snore 2 DIVIDE, CALCULATOR=CL-1, (2) , VALUE=2 MIXER UID=HX-2,NAME=H20 MAKE-UP FEED 1,110 PROD M=3C OPER DI PUMP UID=PU-1,NAME=AMINE PUMP PROIII APPLICATION BRIEFS. GAS SWEETENING USING AMINES G85 December 1992 ™ SOLID CONVERTER POF > satin nea. reeFEED 3¢ PROD L=38 OPER PRESS=250,BFF-70 = ax Hor OPER CONFIG TPA: UTIL AIR, TH IR COOLER & EI RECYCLE DATA ACCEL TYPE: Results “The flowsheet converged in 4 recycle iterations. The concentrations ofthe acid gases COz and H2S were reduced from 1.37 and 1.7 mole percent in the sour gas feed to less than 1 PPM in the treated effluent gas. Output: ‘The following data were extracted from the PROIII output 1) Absorber Column summary 2) Regenerator Summary 3). Stream Output G8-6 GAS SWEETENING USING AMINES PROIII APPLICATION BRIEFS. Decmber 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teAbsorber Column Summary Foe To LIQUID Flow exTES WERT RATES OVERALL HET BALANCE, (HIN) - IOUT) } 3.02238-04 PROIII APPLICATION BRIEFS. GAS SWEETENING USING AMINES G87 December 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teRegenerator Column Summary (PE STEM FIRE FROM TO LIQUID Fou wares HEAD BATES Pao 9 nig a2 asese.si 55.5034 OvmpALL MEAT BALANCE, (HLIN) ~ MCGUT } 0.0250 aw La 2 al2oomoa 1,2008¢02 G8-8 GAS SWEETENING USING AMINES PROIII APPLICATION BRIEFS. Decmber 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teStream Component Summary MOLE FRAC LIQUID 10000 30000 PROIII APPLICATION BRIEFS. GAS SWEETENING USING AMINES G89 December 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teStream Component Summary, cont’d ase vapor ve LIQUID. LIQUID BURRLEY, oC BTO/iR ya.2707 13.6936 33.7370 MOLE FRAC LIGUID 0000 0.0000, 1/0000 668-10 GAS SWEETENING USING AMINES PROIlI APPLICATION BRIEFS Decmber 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teStream Component Summary, cont’d PHASE gup ‘LIQUID ‘varoR nigup MOLE FRAC LIQUID 10000 10000 0000 20000 PROIII APPLICATION BRIEFS. GAS SWEETENING USING AMINES G8-11 December 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teStream Component Summary, cont’d Base vex om LID BITEALPY, MM BTU/ER 38.5342 3.3980 55.5034 39.1471 Nou Frac LIQUID 0.9997 0.0000 1.0000 1.0000, 68-12 GAS SWEETENING USING AMINES PROIII APPLICATION BRIEFS. Decmber 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teStream Component Summary, cont’d nse mop gD agp aqui PROIII APPLICATION BRIEFS. GAS SWEETENING USING AMINES G8-13 December 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teSteam Power Generation Loop In many applications today, steam is used as a major source of ower. In one form of a heat engine model, the working fluid is com pletely enclosed and goes through a cyclical process, accomplished by vaporization and condensation. There are several ways to model the conversion of heat into work by such power cycles. The Rank- ine cycle is used to describe power plants that generate saturated ‘steam. The turbines in such plants are designed so thatthe mois- ture formed is removed at various stages of the process. ‘This gas processing application involves a Rankine cycle steam power generation loop. You are given the assignment to perform the calculations to predict the performance of the steam powered en- gine. ‘After inital pressurization, water is boiled and superheated, passed through an expander (producing the shaft work output), and con- oS SOLID CONVERTER POF > satin seeTable 69.1: Initial Charge Information Stream CONDENSED Value Rate 100 Lb-molt Pressure 15 Psia Temperature Bubble Point A Pet) Unit Parameter Value Pressure (Pressurizer Pump) 1750 Psia Degrees of Superheat (Supetheater HX) Calculated Shaft Work (Turbine Expander) 300 Hp minimum Outlet Pressure (Turbine Expander) 15 Psia Cold Side niet Temperature (Condenser HX) 120F Cold Side Outlet Temperature (Condenser Hx) | 200F Outlet Steam Quality (Turbine Expander) 99.59% minimum Methods ‘The only component present is water. The SRK system is chosen and Data as ithas direct access to the steam tables ifthe user activates the \water options, decants the water, and sets the decanted water prop- fetes to steam. This sets up an unusual situation. The user has re- {quested that water be decanted as a separate phase leaving nothing clse available fora “dry” basis report. Unusual, but the simulator wil hhandleit perfectly well by reporting "not available” for the “dry’ stream report. Simulation the charge (given as an initial estimate in the loop) is fed into a Model pump. The pressurized output enters a heat exchanger (modeling both the boi and superheater) in which the hot side is given as a generated heat source (no process streams given). The super- heated steam enters an isentropic expander which takes the steam down oa lower pressure while extracting shat work ‘Afiash drum follows the expander. This is not a physical fash, rather itis a mathematical construct used to determine how much heat must be added or removed to meet the minimum 99.5% quality ‘expander exhaust steam constraint. When the feedback control loop converges, the duty will be zero. In effect, nothing happens as the feeds flow through the unit. ‘G7 Steam Power Generation Loop PROM APPLICATION BRIEFS January 1995 ete = SOLID CONVERTER PDF > omnes pues e‘A condenser completes the closed loop. It too is modeled as a heat ‘exchanger except a specific air cooling medium is chosen to turn the vapor back into a liquid. The cycle repeats itself at this point. ‘Outside the loop are two other units. One is a calculator “utlity” type Unit operation. The other is a feedback controller model ‘The calculator takes several work and duty values and uses them to produce results. The overall efficiency, n, of a heat engine is given’ {as the amount of shaft work produced minus shaft work performed divided by the duty ofthe superheater. The second calculation is an intemal cross check of the loop’s energy balance. ifthe energy bal ‘ance is correct, then the ratio ofthe shaft work to the heat duty ‘should be unity ‘The feedback controller manipulates the number of degrees of su- perheat in the superheater so that the amount of heat needed in the seudoflash mathematical construct is zero. Ifthe specification is met, then the exhaust stream from the expander has achieved the uaity specification ‘The questions arise "Why use a pseudofiash at all? Why not just ‘specify the expander exhaust conditions directly?” The answer lies in a char of exhaust steam quality versus number of degrees of su- perheat as shown in Figure G9.2. Figure G9.2: Exhaust Steam Quality vs. Number of Degrees of Superheat (not to scale) 500 4000 1500 Number of Degrees of Superheat Notice the lat portion of the graph. If the initial estimate for the num- ber of degrees of supetheat is to high, the controller moves in both directions along the fat portion and determines that the manipulated variable has no effect in achieving the specification Input heat to the pseudoflash versus number of degrees of super- heat looks quite different as shown in Figure G3.3. PROM APPLICATION BRIEFS ‘Steam Power Generation Loop G3 January 1995 DSc E> oS SOLID CONVERTER POF > satin seeFigure G9.3: Flash Duty vs. Number of Degrees of Superheat (not to scale) A This function has a monotonic behavior, and the controler can lo- cate the point at which the needed heat is zero regardless of the starting point. This approach adds convergence robustness in many feedback controller problems where the specified variable, ois fst derivative is subject to discontinuities while crossing phase bounda- Input Data Engish units are used troughout the simulation. The keyword input data fis shown below ‘GS-7 Steam Power Generation Loop PROM APPLICATION BRIEFS January 1995 ete = SOLID CONVERTER PDF > omnes pues eKeyword Input Data File DESC BASIS IS A 100 LB-WOL/H CHRRGE AROUND THE LOOP : 5 ’ WOUE CONDISED, Saturated Liquid/PRESSURIZED, igh Presmure Liquid & SUPERUENTED, Superheated Vapor/EXPAIOED, Low Pressure Mix) & PIAGIED,Poetdoflaah Output Mie 5 ‘PIMP CID-ERESGURIZER, NHME-Shatt Work Input § INITIAL BSTIWATE DOREES OF SUPERIEAT 5 THIS WILL BE MANIPULATED BY THE CONTROLLER EXEANDER UID-EXPANDER, SOMEAShaft Work Output f SUAPP WoRK OUTPUT MUST BE AT LEAST 249 HP § REAL WORK OUTPUT WONDATED AS AT LEAST 300 HP § FoR THIS CARRE OF FLOW : . {5 THE PSGUDOPLAGH 1S BEING USED TO PERFORM A NiGAT IF?" $ CALORATION Git THE EXPANDED STREAM. IT SHOULD REQUIRE {5 NO DUTY To OBTADN A PRODUCT WICK TS 99.5% vAEOR PROM APPLICATION BRIEFS ‘Sieam Pawar Generation Loop GOS January 1995 ee = SOLID CONVERTER PDF > omc tinesin pa teKeyword Input Data File (continued) 4 SEARGH FOR THE MOGGR OF DEGREES OP SUPERMEAT REQUIRED 3 IP SO, Wo DUTY SHOULD Bs REQUIRED IN THE PSELDOFLAGH CONTROLLAR UIDKCOMTROLLER, NAME-Superheat Manipulator 3 MEAT BALANCE 15 BOUL TO SHRPT WORK OUT MINUS SHAFT WORK IN § SHOULD BE BOUNL TO 1 WITHIN ROUNDOFF TOLERANCES RESULT 1,Overall Bta/2,Work to Heat 3 WORK, NORMALLY TW HP, 18 CONVERTED 70 BIU/IR BEPINE'P(1) AS EXPRNDERACEMNDER, WORK (BTU/E) DEFINE (2) AS PUMPAPRESSURIZER, WORK (STU/3) {5 DUTIES MILTIPLIED BY 186 BECAUSE THEY APPEAR AS HO BTU/HR DEFINE P(3) AS HOASUPGRAEATER, DUTY, TIMES, 186 DEFINE (4) AS JOCCONDENSER, COTY, TIMES, 18s = (Pa) - PI) / PO) 2 Pa) =P] / CPA) - Pm? ‘Ge Steam Power Generation Loop PROM APPLICATION BRIEFS January 1995 ee = SOLID CONVERTER PDF > omc tinesin pa teResults ‘The results show that the turbine expander operating at 99.5% effi- ciency produces 307.7 HP of work with a cold side outlet tempera- ture of 1161 F and an estimated efficiency af 30.7%. a E eRe ‘Shaft Work (Turbine Expander) 307-7 Hp (actual) Outet Steam Quality (Turbine Expander) 995% Cold Side Outlet Temperature (Superheater HX) | 1161 F Ea Efficiency (Eficlency and Balance Caleulator)] 30.7% Heat Balance (Eficiency and Balance Calculator) | 1 (ross check matches) Duty (Pseudoflash Fash) ° Conclusions in conciusion, the results show that the plant will generate an accept- ble amount of power while maintaining good overall thermodynamic heat engine efficiency. Furthermore, these conditions will not pro- omnes pues eOutput Data Files Flash Drum Summary Output Bepander Summary ‘Ga Steam Power Generation Loop ee = SOLID CONVERTER PDF > omc tinesin pa te PROM APPLICATION BRIEFS January 1995Pump Summary Output Calculator Summary Output PROM APPLICATION BRIEFS ‘Sigam Power Generation Loop 63-5 January 1995 ee = SOLID CONVERTER PDF > omc tinesin pa teHeat Exchanger Output HoT LIQUID FRACTION coup Ligon FRactroN HoT LIQUID FRACTION (COLD LIQUID FRACTION ‘G10 Steam Power Generation Loop PROM APPLICATION BRIEFS January 1995 ee = SOLID CONVERTER PDF > omc tinesin pa te‘Stream Molar Composition Rate Output (PRO/II) me Saturated Low Preamire Peeudotlash High Superheated Liquid Mie Output Mix Pressure Vapor FLUID RATES, LB-"OL/AR Tom, PATE, Le-MoLy HR 100.0000, NoUE FRAC H/C LIQUID PROM APPLICATION BRIEFS ‘Steam Power Generation Loop GS-11 January 1995 ee = SOLID CONVERTER PDF > omc tinesin pa teStream Summary Output (PRO/II) me Saturated Lov Pressure Peeudotleah High Superhested By Liquid Mie Output Mix Pressure ‘epor Ly _ hgus Bg ce, tenon 100.000 200.000 «200.000 100.000 100.000 ba Nay 201 2.601 1eo1 ta08 1808 BILPY, ot BTU/HR 327 2065 29 2848 Brut e568 audezal—aaalas2—aseo aie wou ACTION LIGETD 4.00000 0s00 1.00000, ‘00000 PATE, LNOL AR N/A 99.500 99.500, W/m 100.000 er N/a 2.782 1792 am 102 MFT /am NA a7 se a7 a6 4A ee sro VAP RATB(R), M PT2/R, NA 37759 37.759, WA aria MOLECULAR WEIGHT NA wos was WA aw. ons BOALPY, BTU/IE N/A 12521068 1251069, WA aseolale ce, Bru/ia-P N/a a6 ae WA 00 DENSITY, L2/M Fra NA woz waz W/m 19091083 2 (ROW oaNSTTY) Na 982 uaz A 5493 s--- Tom LaguD ----- PAR, LB-WOL AR 200.000 500 soo 100.000 wa en 2.801 9.0078-02 9.007R-03 Fars wa sm 110 akTE, 773/am 28.099 144 ve 28.899 wa Bry, BTU/a asris6a—281s6a aa 6a 10 452 wa ce, BTu/ia-P 2.007 2.007 1.007 1002 WA DaIsITY, 19/Fr3 59.790 59.790 59.790 60.064 WA 2 (ROW oanstTy) 6.25726-06 6.25718-04 6.25718-04 om WA (2) smumnan vaFOR YOURE IS 279.49 £73/LB-OLE (60 F AND 14.696 PSIA} ‘GT Steam Power Generation Loop PROM APPLICATION BRIEFS January 1995 ee = SOLID CONVERTER PDF > omc tinesin pa teStream Summary Table (PROVISION) PROM APPLICATION BRIEFS ‘Seam Power Generation Loop 5-13 January 1995 ee = SOLID CONVERTER PDF > omc tinesin pa teCRUDE HEATING CURVE ‘A flash vaporization curve is to be generated for a crude oil mixture as the fist step inthe design of a crude unit. The design flow rate of crude is 75,000 BBLiday. Process Data The ight ends, API gravity, 02887 simulated distillation, and molecular weight data are given in Tables R1.1-R1.4, Table R11 Light ends Component | LV Percent on Crude. Ethane o4 Propane 14 Butane ons N-Butane 31s N-Pentane 54 Table R12 API Gravity Mid Wt Percent APL 8.33 8001 16.89 6290 34.80 506 5847 382 80.10 28 PROIII APPLICATION BRIEFS, CRUDE HEATING CURVE R1-1 February 1992 ete = SOLID CONVERTER PDF > omnes pues eTable R13. ‘Simulated Distillation (ASTM 02887) Mid Wt Percent _| Temperature (F) 5.74 135 19.55 210 35.89 370 60.04 585 69.82 685 73.38 800 e794 990 Table R14 Molecular Weight Data Mid Wt Percent Mw 18.92 995 33.39 135 48.41 1847 69.80 3348 100 789 Average 1629 Methods ‘The simulated cistilation at 760 mmbg is represented by the ASTM D2887 option. and Data ATEPCUTS statement is used to reduce the number of pseudo components, wrile allowing enough pseudo components to represent the fractionation, The BK10 thermodynamic system is selected forthe calculations. This system is fast and easy and provides good results for low pressure crude systems. The Grayson-Streed system may also be used and typically predicts slightly more vaporization. The transport properties are predicted using the PETRO method, Simulation —_The HCURVE unit is used to compute 20 points at even enthalpy increments over Model the range of temperature and pressure conditions given in Table R1.5 1-2 CRUDE HEATING CURVE. PROIll APPLICATION BRIEFS February 1992 ete = SOLID CONVERTER PDF > omnes pues eTable R15 Process Conditions ‘Temperature (F) | Pressure (psia) 375 300 690 50 Input Data —_Engiish units are used forthe simulation with standard liquid volumes set as barrels. [Note how the optional molecular weight and API gravity data are provided (only the average gravity is required) (Note 1) and how the adiabatic lash vaporization curve for the crude feed is given in the HCURVE statement (Note 2). The TBP option on the PRINT statement requests the printing ofthe TBP/ASTM distllations ofthe crude. Input Data File DEM MNGLISH,LIgv=BBL ‘PROP STRENM2,TEMP=275,PRESA200, PHAGEAM, BATE V)=3125, & LEGIT STRENHeL, PERCENT) “10.4, & PROIll APPLICATION BRIEFS CRUDE HEATING CURVE R1-3 February 1992 DSc E> oS SOLID CONVERTER POF > satin seeOutput ‘The following data were extracted from the PROIIl output for the crude feed: 1) Adiabatic Flash Curve 2). Petroleum Properties 3) Transport Property Curves, 4) Stream Component Flow Rates 5) Stream TBPIASTM Distillation Curves 1-4 CRUDE HEATING CURVE. PROIII APPLICATION BRIEFS. February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teAdiabatic Flash Curve ADDANTIC FLASH CURVE FOR STREAM 1, TOTAL DUTY = 2.50374H+02 MM BTU/AR cme Paes VAPOR LIQUID WATER VAPOR LIQUID. ATER TOD, Derr PSIA 1H LB-WOL AR rot T/A PROIll APPLICATION BRIEFS CRUDE HEATING CURVE R1-5 February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teAdiabatic Flash Curve, cont’d. ome PRES “VAPOR LIQUID. WATER VAPOR LIQUID VAPOR LIQUID BEG FBSA x BAR (are.0) 1-6 CRUDE HEATING CURVE. PROIII APPLICATION BRIEFS. February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teAdiabatic Flash Curve, cont’d. varor LIQUID VAPOR LIQMID VAPOR LIQUID PROIll APPLICATION BRIEFS CRUDE HEATING CURVE R1-7 February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa tePetroleum Properties ‘PEIROLEIM PROPERTIES (ORY BASIS) FOR STREAK 1 ho. Tm pres VAPOR LIQUID. VAROR vneor aqui 1-8 CRUDE HEATING CURVE. PROIII APPLICATION BRIEFS. February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teTransport Properties No. TIN PRES VAROR LIQUID.» VAROR LIQUID. TENSION 1 375.00 300.00 N/m 5.3554B-02 104988402, 2 397185 2a6_a¢ Nm 5 9.45098+00 PROIll APPLICATION BRIEFS CRUDE HEATING CURVE R1-9 February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teStream Component Flow Rates PaAsE ror Tom RATE, LB-¥OL/ER Nou FRAC LIQUID 1-10 CRUDE HEATING CURVE PROIII APPLICATION BRIEFS. February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teTBP/ASTM Distillation Curves PROIll APPLICATION BRIEFS (CRUDE HEATING CURVE R1-11 February 1992 ee = SOLID CONVERTER PDF > omc tinesin pa teTBP/ASTM Distillation Curves, cont’d. 1-12 CRUDE HEATING CURVE PROIll APPLICATION BRIEFS February 1992 ete = SOLID CONVERTER PDF > omnes pues eDE-IC4 TOWER Deisobutanizer You have to design a deisobutanizer to separate isobutane and lighter from butane ‘and heavier, using distillation with a volumetric reflux ratio of 4.5 with respect to the feed, and 25 percent by volume of the feed recovered as overhead product. ae Process The flow sheet is shown in Figure R2-1 Data fete Oo ‘SUBCOCLED CONDENSER 7 149 pia 1555 pole C6 Figure R2.1 Deisobutanizer Column PROIll APPLICATION BRIEFS DE4C4 TOWER R2-1 February 199 ete = SOLID CONVERTER PDF > omnes pues eTable R2.1 shows the composition ofthe feed stream. Table R2.1 Feed Stream Composition ‘Component Feed v%) o 14 ica 338 nes 648 ics. 02 ‘The known process conditions are shown in Table R2.2. Table R22 Process Conditions Pressure [Temperature] Rate (sia) (dog) | (bir) Feed 200 630 Condenser 140 Column Top 145 Column Bottom 1835 Methods and The Grayson-Streed method has been chosen to calculate K-values. Most hydro- Data carbon refinery simulations with components ranging from propane through gas oils are handled wall with the Grayson-Streed method. Lee-Kesler enthalpies are used since these are in good agreement with API data book enthalpy procedures. Lee-Kesler densities are quite satistactory for hydrocarbon systems up to about C10 ‘carbon number. The column is modeled as an ordinary disillaion column with 66 theoretical stages Model including the condenser and reboiler. The feed is introduced on tray 35. The condenser is modeled as a total condenser at a temperature 10 F below the calculated bubble point. The reboiler and condenser duties are varied to meet the specifications. R22 DE-IC4 TOWER PROIll APPLICATION BRIEFS February 1991 ete = SOLID CONVERTER PDF > omnes pues e‘The simulation uses the inital estimate generator model CONVENTIONAL to gen- crate temperature and flow profiles. This model is recommended for conventional ‘columns with reboiler and condensers, TITLE PROBLEM-R2, PROJECT-APPERIEFS, + USER-SIMECI, DATE-SEPTEMRER 90 DINE ENGLISH, LIQV-BBL PRINT MBAL COMPONENT DATA LIBI 1, PROPANE/2, IBUTANE/3, BUTANE/4, IPENTANE ‘THERMODYNANEC DATA METHOD SYSTEM-GS, ENTHALEY=LK STREAM DATA PROP STREAM=1,TEMP=140,PRES=200, RATE (V)=630,* COMP(V) =1.4/33.8/64.6/0.2 NAME 1, PEED/2, OVERHEAD/3, BOTTOMS UNIT OPERATIONS DATA ‘COLUMN PARA FEED PROD conD PSPE HEAT 1,1/2,66 SPEC STREAN=2, RATE (V), RATION, STREAN=1, VALUE=0.25 SPEC |, BATE (V) , RATION, STREAM=1, VALUB=4..5 VARY ESTL PRIN HCURVE ve 180 COLWAI=T-1, HEAT=1 END Input Data standard English units have been chosen and LIQ) default iqud volume units of FT3 fo BBL (artes), BL in order to change the Output ‘The folowing data were extracted from the PROIIl output 41) Column summary 2) Condenser HCURVE 3) Stream molar flow rates PROII APPLICATION BRIEFS DEIC4 TOWER R23 February 199 erp &} SOLID CONVERTER PDF > ome rteDEISOBUTANIZER COLUMN SUMMARY snjour mean 3 Tey TEMP PRESSE LIQUID FEED vortes 1B-WOL i ec BO 2-4 DE-IC4 TOWER PROIll APPLICATION BRIEFS February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teDEISOBUTANIZER COLUMN SUMMARY (CONT) TPE SRE PINSE FROM TO LIQUID Flow pares EAT BATES mp 1 Lagu 352.0000 2ise.se 0.2157 owt 2 gD a 529.87 ez out 3 LiguD 66 654.67 8.5729 OVERALL HEAT BALANCE, (H(ZN) - H(QUT) ) ~ 0.0200 mar ug 1 You RATIO. 4_500E¥00 44998100 PROIll APPLICATION BRIEFS DE4C4 TOWER R2-5 February 199 ee = SOLID CONVERTER PDF > omc tinesin pa teCONDENSER COOLING CURVE ‘TOTAL DUTY = ~7.56941E+01 Me BTU/ER Tome PRES VAPOR LIGUID WATER VAPOR LIQUID. WATER TOTAL pes PSIA M 1B-WOL eR Me BTU WATER VAPOR LIQUID VAPOR LIQUID aiRt.0} 2-6 DE-IC4 TOWER PROIll APPLICATION BRIEFS February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teCONDENSER COOLING CurRVE (ConT) Doc F PSIA VAPOR LIQUID. VAROR LIQUID VAPOR LIQUID FLUID exes, 12-MOL/ HR ‘TOD, RATE, 1B-NoL/i 539.0667 MOLE FRAC LIQUID 10000 PROIll APPLICATION BRIEFS DE4C4 TOWER R2-7 February 199 ee = SOLID CONVERTER PDF > omc tinesin pa teCRUDE OIL DISTILLATION ‘The feed to a refinery often changes every few days. An existing refinery has received an Indonesian crude oil nd you must simulate the atmospheric cistilation column to establish the correct operating conditions for a throughput of 120,000 barrels(day. The crude unit configuration and typical operating data are shown in Figure R3.1. The products must meet the speciied D86 and TBP points in Table R3.1, and the yields are to be calculated. Crary See ae Figure R31 Crude Distillation Column PROIll APPLICATION BRIEFS (CRUDE OIL DISTILLATION R3-1 February 1991 ete = SOLID CONVERTER PDF > omnes pues eTable R31 ASTM 086 (F) Lv% | Naphtha | Kerosene | Diese! | Gas oi crude 0 330 60 555) 5 - 380 530 635 (625) os | 340 520 665 (285) 100 | 370 550 705 (955), Process Data _ Forthis simulation, the stipping stream and pumparound cooling shown on Figure R3.1 are used, The crude oilhas been analysed as an atmospheric TSP curve and defined ightend components as shown in Table R3.2. Table R32 (CRUDE OIL DATA TSP @ 760mm Hg Lightends tv | Temp iF) | _Lv% | Temp (F) [component] Lv% 5 149 50 690 | Ethane 4 10 | 208 60 770 | Propane | 02 20 | 330 70 ass | iButane | 03 so | 459 80 30 | neButane| 07 40 | 890 100 1600 | iPentane| 05 nPentan 12 ‘Average API gravity 292 Total 30 The laboratory data for the TBP curve are supplied only up to the 80% point. A typical value is assumed for the 100% point to assist the extrapolation of the curve. Methods The GS thermodynamic system is recommended for calculating K-values and and Data enthalpies in crude and vacuum systems. The BK10 system may also be used, but ittends to predict slightly less vaporization. Column temperatures can generally be ‘matched with either system. If not, the column pressure data are probably in error. ‘Accurate characterization of the crude oil is vital for good simulation results. The greatest errors often appear in the residue stream and can lead to poor results when Simulating the downstream vacuum column. The characterization may be improved by supplying gravity and molecular weight data if they are availabe. 3-2 CRUDE OIL DISTILLATION PROIll APPLICATION BRIEFS February 1991 ete = SOLID CONVERTER PDF > omnes pues e‘The program automaticaly generates a number of petroleum fractions and calcu- lates the molecular weight, gravity, and boling point for each. These are then used in standard petroleum correlations to generate all the other required properties. ‘The TBP curve must be matched to the lightends data to produce a smooth curve. To assist this, the boiling point (97 F) of the n-pentane is input as an adaitional 3.0% point atthe front ofthe curve. Viscosity and thermal conductivity data are generated for the streams for use in cther calculations. The API data book method is selected for the quid viscosities. For crude ol streams, these data are more accurate than the 'PETRO option used for the other transport properties. Simulation The frststepin he simulation iso ensure tha tis possible to produce the specied Model products from the cride ol feed and establish the material balance. The mutidraw (Shortcut) Shortcut istilation mode! (MODEL = REFINE) isa quick and easy tool for these calculations. This model uses the Fenske calculation method and considers the column to be a series of two-product columns as shown in Figure R3.2. The ‘condenser is simulated with an external lash drum, ‘The specifications chosen for the shortcut model define the separation in each section. For this simulation, the 95% cistilation points and 5.95% gaps are used. ‘The data are taken from Table R3.1 2 3 ‘5% and 95% points should always be used instead of intial and end points, as they {are generally more accurate. The simulated end points are affected by the number (of petroleum cuts, the parameter TBPEP (on the ASSAY statement in Component Data) which defaults to 98%, and the Fenske model itself, which tends to overtrac- tionate on the product tals." In addition, the shortcut simulation ignores the side- strippers which also affect the ends ofthe curves. arvana A-we Figure R3.2 ‘Shortcut Crude Unit Model PROIll APPLICATION BRIEFS (CRUDE OIL DISTILLATION R33. February 1991 DSc E> oS SOLID CONVERTER POF > satin seeInthe shortcut model, allthe stripping steams added with he feed. The main effect, ofthis on the simulation results is that the influence of the steam on the product ‘temperatures is not modeled, and the calculated temperatures will be high Input Data ‘The simulation units are defined as English but with pressure as psig and liquid (Shortcut) volumes in barals. As crude oil has no defined components, the component flow rate outputis suppressed, and only the stream summary sprinted. The PRINT TEP. option gives the TBP and ASTM curves for all hydrocarbon streams. Itis not known whether or not there will be any vapor product from the column. As there may be vapor, the condenser is defined as mixed phase at the defined temperature. ‘The MODEL=REFINE option specifies no reflux between sections in the column, ‘The default would assume total reflux between the sections. The product rate estimates are supplied as volume percent cutpoints on the crude oil feed, Input Data File: DIMEN PRESS-PSIG, LIQV-BBL LIBID —1,820/2,C2 /3,C3 /4,1c4/5,wc4/¢,105/7, 115 METHODS SYSTEMAGS, COND-PETR, VISC(V) satin nea. reesection are shown in Table R3.3. Output ‘The shortcut column results are shown on the next page. The shortcut model [ey (Shortcut) predicts the minimum numberof trays, calculated a otal reflux, needed to meet the feb Specified separalons. Typical values for crude oll separations for each col i 3 Table R33. TYPICAL SHORTCUT TRAYS Column Section Minimum Trays. Naphtha - Kerosene 35-50 Kerosene - Diese! 25-35 Diesel - Gas oil 20-30 Gas oil Topped crude 13-18 ‘As long as the shortcut model reports figures within these ranges, the separations will be feasible. Significant departures from these values mean a dificult, f not impossible, separation ‘The simulation predicted no overhead vapor at the desired condenser conditions. Tris is not unusual for crude unit simulations because some lightends may have been lost in sampling the crude oil, or because lightends produced by cracking in the furnace are not included in the simulation model. ‘Once the shortcut model is solved, the material balance is defined. 1 difficulties ‘occur solving the rigorous model, then the heat balance is likely to be at faut. PROIll APPLICATION BRIEFS CRUDE OIL DISTILLATION R35 February 1991 DSc E> oS SOLID CONVERTER POF > satin seeSHORTCUT COLUMN OUTPUT x Lrg 6479642 a trom 144506 42 2 com 2eei8 47 20 rou 695517 88 3-6 CRUDE OIL DISTILLATION PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teSimulation The numberof theoretical trays must be established fr the rigorous dstilaion Model ‘This may be obtained by: (Rigorous) applying typical overall ray efcencies tothe number of actual rays using values from previous simulations ofthe column assuming that the number of theoretical trays is about twice the minimum number Inthis example, typical efficiencies were used to get the configuration ofthe model shown in Figure R33. 2 mews iS y “Te. Figure R33 Rigorous Crude Unit Mode PROM APPLICATION BRIEFS cRuine On. HSMLLATION 2-7 February 1991 ete = SOLID CONVERTER PDF > omnes pues e‘Virtually all the heat in the distillation enters withthe crude oil feed, and so itis vital that the feed temperature is correct. For this reason, the furnace and flash zone are included inthe simulation asa heat source on the feedtray. The feedis specified 23 liquid at the lash zone pressure to ensure that no flash is performed and all the {feed's placed on this tray. The furnace duty is then calculated to match the specified liquid runback into the fash zone. Only one other specification can be made on the main column, together with one ‘on each sidestripper, and so not all the distillation specifications on the shortcut can be used. The best strategy sto specify one distllaion point or gap for each product, except for the topped crude. The topped crude is not usually specified since this has the greatest uncertainty. Specifying the 95% points generally gives good results. Iflarge differences appear at the top ofthe curves, then the simulation may be improved by specifying some 5% points. The specication variables are the condenser duty and the side product draw rates. ‘As forthe shortcut simulation, 5% and 95% points are used in preference to initial and end points. ‘The circulation rates for the pumparound cooler circuits are calculated to meet the desired cooling duties and return temperatures. ‘When specifying sidecooler duties, be wary of duties which are based on measured pumparound rates. These are notoriously inaccurate, and too much cooling wil dry Up the liquid leaving the tray above the cooler. The subsequent calculation failure reflects the operational failure of the actual column when drying up occurs. If pumparound duties are uncertain, they may be calculated to meet specified liquid runbacks. ‘The shortcut model showed that there is no overhead vapor. Therefore, the condenser is defined as TYPE = TFIX, which is total at a fixed temperature. Solution of the main column is enhanced by using the molal product flows deter- ‘mined in the shortcut simulation as inal estimates. The REFINERY model is used to generate the intial solution profiles ‘The temperature of the oil leaving the furnace is not the same as the flash zone ‘temperature. In order to calculate the furnace temperature, a fash is used to add the calculated furnace duty to the feed stream. Input Data The dimensional units and printout options forthe rigorous simulation are the same (Rigorous) as were used inthe shortcut model. The steam feeds are now fed tothe bottom of the main colurmn and to the sidestrippers. “The column is defined as arefinery unit, and a damping factor of 0.8 is automatically appliadto the IO solution method. This damping assists in the convergence ofthis type of column “The sidestippers are entered as separate unis, but PROII solves them simultane- ously with the main column, ‘The column feed temperature is not calculated until after the column has been converged R3-8 CRUDE OIL DISTILLATION PROIII APPLICATION BRIEFS. February 1991 erp &} SOLID CONVERTER PDF > ome rteInput Data File: 5 LIQV=BBL LIBID —1,820/2,C2/3,c3/4,10a/5,Nc4/6,105/7,NCS METHODS SYSTEMAGS, COND-PETR, VISC(V) omc tinesin pa teSPEC STREAN-10,D86(95) , VALUE. 1,86 (95) , VALUE~66s d SPEC STREAN-12, TRP(95) ,VALUEA085 3-10 CRUDE OIL DISTILLATION PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teCOMPARISON OF SHORTCUT AND RIGOROUS RESULTS: ‘The product qualities are compared below: ‘ASTM D86 (F) Naphtha Kerosene Diesel Gas Oil ive | sic | rig | sic | rig | sic | rig | sic | rig | o | 52] 52] 358) 304] s10| 450) 506] 490 5 | 73 | 78 | 380) 374] sao] sis] 635] 613 to | 130] 130] saa} 390] s37| 528) 648 | 639 so | 28] 218) 433) 431] sas] sas] 715] 717 a0 | sta] 31s] 500) 499] 646] 64s] ais] a17 as | 340] 340] 520] sao] o65| 665] a2] 42 soo | 376 | 363 a2 | oo | 696 | son | ape Bbthr| 1090) 1083) 642) 612] 477] 525) 798] 699 2 api | ts] 615] 406] 407] 316] sta] 251] 252 3 ‘TBP @ 760 mm Hg (F) Gas ot _| Topped Crude wv% | sic | rig | sic | Rig | o | 520] 422] 463] 54a 5 | et] 503] 695] 605 to | 637] 630] 747] 743 so | 727| 728] 972] 968 a0 | aso] ast | 1447] 1445} a5 | aas| sas| 1523) 1520] soo | o4o | 942 | saa! 1548] Bbuhr| 748) 699] 2043) 2071 api | 251) 252) 141] 144 PROIll APPLICATION BRIEFS CRUDE OIL DISTILLATION R3-11 February 1991 ete = SOLID CONVERTER PDF > omnes pues e“There is good agreement between the 5% and 95% points, especially towards the top of the column. The fractionation on the product front ends (0-5%) is sharper with the shortcut model, while the rigorous simulation predicts better fractionation con the tail ends (95-10%). This is largely due tothe simplifying assumptions ofthe shortcut medel and the presence ofthe sidestrippers in the rigorous simulation. Because of the simplification in the way the steam feeds are handledin the shortcut ‘model the product temperatures willnat match. The rigorous values should always be used Results ‘The simulation shows that the column can be operated to produce the required products. The yield of each products shown in the output. The pumparound rates, furnace and condenser duties have also been calculated along with the actual ‘temperature of the oil leaving the furnace, ‘The flash output below shows that the furnace outlet temperature is 694.5 F, while the column output shows that the fash zone is at 692.9 F. Output ‘The column summaries show the output for the main column and the sidestrippers. (Rigorous) Tables may also be produced with vapor and liquid rates, densities and transport properties, but these are not presented here “The stream component output was suppressed and only the stream summaries are printed. A sample of the stream summary is show for both wet and dry basis properties. Part of the disilation curve output is shown for the feed and some product streams. All pure water streams are omitted from this output Finally, a comparison is presented of the analyses of the shortcut and rigorous products. FEED TEMPERATURE FLASH ne w/e Lr 3-12 CRUDE OIL DISTILLATION PROIII APPLICATION BRIEFS. February 1991 DSc E> oS SOLID CONVERTER POF > satin seeCRUDE COLUMN SUMMARY PROIll APPLICATION BRIEFS CRUDE OIL DISTILLATION R3-13 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teCRUDE COLUMN SUMMARY (Cont) TE STREAM HINGE ROK TO LIQUID Flow wares NEXT RATES TRAY TARY FRACTION = LB.ML/HR MY BTUAR prooucr 20 © LIgUD 20, 1360.87 2a a29, mp as LUD 21 1.0000 19.19 35.8340, prooucr 10 LIQUID rid 26.6130, mm 7 LD 23 1.0000 e29.36 49.0366 pRooucT 1 LIguD 24 Sar9e 36.4206 me 9 LUD 25 1.0000 m.so 78.2636 pRooucT 12 LigD 26 sage. 70.2986 OVERALL YASS BALANCE, (FEEDS - PRODUCTS) 2.64058-03 (OVERALL HEAT BALANCE, GHCEN) = (GUD) -8.60108-03 amy TEN, eG P—LgUID Racin ———___ oe vce TO FROM FROM IBNOL/R Me 1B/HR STD BBL a 3-14 CRUDE OIL DISTILLATION PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teCRUDE COLUMN SUMMARY (Cont) PROIll APPLICATION BRIEFS CRUDE OIL DISTILLATION R3-15 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa tePRODUCT STREAM SUMMARY ase Wer LEGS NED LIQUID Wer LIGDED wer vason sas, wast toiz.40a—ett.ss¢ = eae 457.823 wisi isso: Sse.eso—aae.tae “aon SSL, wr BTU/eR gees seen volgen a saa vue Fancrze LEGER Yecee0 320000 i.a0000 0.00000 ef PATE, UB-WoL AR Na na NA 457.923, - wisi wa wn wm “ap.007 EA neta wa wn Wn 130337 38 sop wa? FACE{a), M FTS/im wa wn wa ans 2 YeEsevian went wn wn wm “as.a0e = (BVIALPY, BTU/LB N/A N/A WA 372.817, ce, wis. wa wn wa o.sar SeiSEY u8/m ¥ra wn wn Wa 252.40 SNE COND, BTG/IR-ET- va wa Wa boeiese visastey, eb va wn WR bleioae —— reo ergo — as, wae oiz.402—ett.356 © eaa.914 wn wisi isis Sse_ei0 aaa. 796 wm mp ug RATS, BBL jie Saves nue wa Sacer, e90/ie iia en hale” wa 5 COND, SOU/RRFT roses G.ouase © O.0a833, wa (2) Sm vapor VOUNE 15 379.49 FTD/LB-MOLE (60 F AND 14.696 SIA) 3-16 CRUDE OIL DISTILLATION PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa tePRODUCT STREAM SUMMARY (Cont) Pans Wer LIQUID Wer LIQUID Wer LIQUID wer vnFoR * MwaR 275.754 ase _519 224.19 sm 10 aATE, naj sinosz 522.755 Tho.ass 125.822 MOLE FRACTION LIQUID 1.0000 2.6000 ©——2.0000 «0.0000 PRES (KAYS ROLE) 9.0807 0.2096 0.1439 0.0704 , 13/BBL 2e7-626 303.238 «= 316.124.279.277 “aR Na MA WA 35 296 NPT/aR Na A NA B0l5a5 sm va aATE(L}, M FTIR Na Wa WA 91.983 SPECIFIC GRAVITY (AIR-1.0) na Na Na 5003 ey Licup "Mw paR 275.754 as8_519 224.19 wR aL ae maais2 — Gta938 516.999 Wr 1D LIQ PATE, BaL/oR 611.052 522.755 710.856 WA SPECIFIC GRAVITY ‘(H20-2.0) o.sz1e 0.8660 0.9028 Ma Derry, 12/am zazisa 245.790 245-061 an (0) STD vapoR VOUNE 15 379.48 FTB/LB-WOLE (60 F AND 14.696 SIA) PROIll APPLICATION BRIEFS CRUDE OIL DISTILLATION R3-17 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa tePRODUCT DISTILLATION CURVES 3-18 CRUDE OIL DISTILLATION PROIII APPLICATION BRIEFS. February 1991 &SouID CONVERTER POF > satin neau reeVACUUM COLUMN You have been asked to prepare a base case simulation model for an existing vacuum column by matching measured test run data. This model will hen be used for further studies of the column performance as part of a revamp excercise. Process Data The flow sheet forthe column is given in Figure R41. The column's in two sections, each with a total draw and 2 pumparound returning cooled liquid to the top of the section. The slop wax is part ofthe heavy gas oil draw which is mixed with the feed before it enters the furnace. Table R4.1 shows the analysis ofthe topped crude feed to the unit. The steam feed is at 355 C and 8500 mm Hg, “The product balance forthe testrun is shown in Table R4.2, Measured temperatures ‘and pressures for the column are listed in Table R43. TOPPED CRUDE « DISSOLVED STEAV PROIll APPLICATION BRIEFS February 1991 ect &SoLiDb J veto GAOL NSHEANY stopwac [> GASOL FURNACE URIACE | SEAT va L___ vasthune RESID. Figure Rat ‘Vacuum Column Flow Sheet VACUUM COLUMN Ré-1 CONVERTER PDF > tims esis rheTablo Ré.t FEED ASSAY (ASTM D1160 @ 2mm Hg) Lv Tomp (C) wv Tomp (C) ° 8 40 252 5 145 50 295 10 190 J 326 20 206 70 375 30 236 75 409 Specific Gravity 0.9883 ‘Temperature (C) 330 Prossure (mm Hg) 8000 Table R42 PRODUCT BALANCE Stream mathe git Topped crude (ry) 99.37 97,508 Dissolved Water - 318 Bottom Steam - 08 Overhead Gas - 1246 Light Gas ©il LvGO) 7.10 6.430 Heavy Gas OilHVGO) 4134 38.997 Vacuum Resid 50.82 52,062 Table R43 COLUMN DATA TRAY Prossure(mmHg) [Temperature (C) Top 74 66 LVGO draw - 196 HVGO draw - 282 Flash zone 98 amt Bottom 115 366 R42 VACUUM COLUMN PROIlI APPLICATION BRIEFS. February 1991 ete = SOLID CONVERTER PDF > omnes pues e“The pumparound flow rates are uncertain, but the measured retum temperatures are 49 Cathe top and 166 C forthe lower pumparound, The slop wax rate is 3.50 mI. Methods ‘The BK 10 thermodynamic system is recommended for K-value, enthalpy and density and Data calculations for refinery vacuum units. The PETRO option is selected to calculate thermal conductivity and liquid viscosity. The API method generally gives the best prediction of liquid viscosity for heavy hydrocarbon systems. ‘The ASTM D1 160 distilation data at 2mm Hg are used directly by specifying the ‘measurement pressure on the D1160 statement. The data are only available up to the 75% point on the curve. Measured data rarely go beyond this and the program ‘extrapolates tothe 100% point. The extrapolated portion of he curve makes upmost ofthe bottom product, and any inaccuracies will mainly affect the bottoms tempera- ture. This example uses the minimum assay data which are the distilation curve and average gravity. Results may be improved by entering gravity and/or molecular weight curves if available, Simulation The column is modeled as 2 refinery column with 7 theoretical trays as shown in Model Figure R4.2. Each packed section is assumed to be 2 theoretical trays. The number of trays may also be obtained from a previous shortcut simulation. Tray 6 represents the fumace and flash zone where the slop wax and fresh feed are mixed and heated. “The furnace is included in the column model to calculate the duty and ensure that a heat balance is obtained. The slop wax stream is the liquid runback from the tray above the flash zone. ‘The temperature of the feed from the furnace will not be the same as the flash zone temperature. Itis calculated in a separate flash drum by adding the furnace duty to the feed and the slop wax streams. ‘Thermal cracking usually ocours in the fumace, producing some light gases. The only effect of these is on the temperature at the top of the column, and it can be ignored unless this temperature is important. For this simulation, we will match the top temperature by adding a small quantity of ethane and propane to the feed to represent the cracked gases. A shortcut model may be used to adjust the amount Of light gases to match the conditions at the top of the column, Trays 2 and 5 are total draws with all the liquid (except forthe slop wax from tray 5) {going to the purparounds and products. These are modeled by specifying the liquid from tray 2 at a very small value and that from tray 5 as the actual slop wax rate into the flash zone. \When modeling an existing column, the most reliable measured data should be used forthe specifications. Less reliable data can be compared with the calculated results. ‘The reliability of the measured pumparound rates is suspect, but the return tempera- tures are thought to be reasonably accurate. Therefore, the pumparound return temperatures are entered and the corresponding rates calculated. ‘The other specifications in this simulation are the volumetric rates of the HVGO and RESID and the top tray temperature. The variables are the three duties and the side raw molar rates. PROIll APPLICATION BRIEFS VACUUM COLUMN R4-3 February 1991 erp &} SOLID CONVERTER PDF > ome rteInput Data Meticunits are specitied for this simulation with mmHg forthe pressure. The default component fow rate output is suppressed, asthe oil does not have defined compo- nents. The TBP option is used to request printout ofthe dstilation curves for ll he streams. “The damping parameter value DAMP=0.6 is recommended for vacuum columns, as itassists the convergence. “The feed temperature calculations separate fromthe column model andis calculated afterthe column has converged. In order to feed the slop wax tothe flash calculation, the TFLOW statement is used to create the stream SLOP, which is identical to the liquid from tray 5. The flash unit simply adds the flash zone duty tothe feed and slop ‘wax streams, and the resultant temperature is the fumace outlet temperature. OvERWEAD ve > so Hvao, TOPPED CRUDE UGHT ENDS ‘stray ——>L STEAK vewwresio Figure R42 ‘Simulation Model for Vacuum Unit 4-4 VACUUM COLUMN PROIII APPLICATION BRIEFS. February 1991 DSc E> oS SOLID CONVERTER POF > satin seeInput Data File: ‘TITLE PROBLEN-R4 , PROJECT-APPERIEFS, USER-SINSCI, DATE-SEPT 90 DIMEN METRIC, PRES=NMHG PRINT STREAN-SUNMARY, TAP COMPONENT DATA LIBID — 1,H20/2,C2/3,C3 ‘THERMODYNAMIC DATA METHODS SYSTEM=BK10, COND=PETR, VISC (V) STREAM DATA PROP STREAM-R1A, TEMP=330, PRES=8000, RATE(V) =99.37, ASSAY=LV DIIGO STREAM=RIA, PRES (MMHG) =2, & DATA=0, 93/5, 145/10, 190/20,206/30,236/40,252/a 50,295/60, 326/70, 375/75, 409 SPGR -«STREAM-R1A,AVG-0..9833, othBRf-nis, remp=330, PRES=8000, RATE (V) =3, COMP=2,75/3,25 PROP STREAM=-R1C, TEMP=330, PRES=8000, RATE (W) =318,,COMP=1, 100 PROP STREAM-W2, TEMP=355, PRES=8500, RATE (W) =908 , COMP=1, 100 NAME RIA, TOPPED CRUDE/R1B,LIGHT ENDS/RIC,DIS.. STW/e RL, VAC FEED/R2, FURNACE PROD/Vi, OVERHEAD/V2,LVGO/& V3, HVGO/V4,VAC RESID "BTR, VISC(L) =APT unr opgeAtioNs ie MIXER UIDetL, NAMBSFEED MIX 35 PEED RIA,RIB, gE PROD Mem Es COLUM UID=C1,NAME=VAC COLUMN PARAM TRAY-7,DAMP=0..6 FEED 1, 6/W PROD OVHD=Vi, BIMS=V4, 80, LDRAW=V2,2,25/V3,4,120 PA FROM=2, TO“ PA FROM PRESS 1,74/6,98/7,125, ESTI — MODEL-REFINERY SPEC RATE(V) , DRY, VALUB=41.34 SPEC RATE (V) , DRY, VALUE=50.88 SPEC TRAY=S, PHASE=L, RATS (V) , VALUB=3.5 SPEC TRAY=2, PHASE=L., RATE, VALUE=0.2 SPEC TRAY=1, TEND, VALUE=67 VARY HEAT=1,2,3,DRAN=V2,V3 FLASH UID=PL1,NAME=FEED TEMP FEED R1,SLOP PROD 2 DEFINE PRES AS COLUNN=C1,TRAY=6, PRES DEFINE DUTY AS COLUMN=C1, DUTY (1) END PROIll APPLICATION BRIEFS VACUUM COLUMN R4-5 February 1991 Mt ™ SOLID CONVERTER POF > satin nea. reeResults “The calculated results should be compared with all the available measured data. If the match is not considered good enough, then it may be necessary to try diferent specifications or ater the number of theoretical trays. Only when the base case is, satisfactory should it be used to investigate changes in the column operation In this example, the calculated tray temperatures show good agreement with the measured values shown in Table Ra.3. Output ‘The result of the feed temperature calculation is shown on the flash output below. ‘The temperature of the feed stream is 371.3 C compared with the flash zone ‘temperature of 368.7 C shown on the column summary. ‘The column summary output shows the pumparound duties and rates as well as al the tray flowrates, temperatures and pressures. A range of other tray properties is available, ‘The extract from the stream summary output shows the properties for the product streams. Part ofthe distillation curve outputs also shown, FEED TEMPERATURE FLASH MOLE FRAC H/C LIgUID 4-6 VACUUM COLUMN PROIII APPLICATION BRIEFS. February 1991 DSc E> oS SOLID CONVERTER POF > satin seeVACUUM COLUMN SUMMARY my TEMP PRESSURE LIQUID. «VAPOR FEED PRODUCT. DUTIES pase tm AG HG-MOL MORAL (PE SIREN PHASE FROM TO LIQUID Flow ATES EXT RATES TRAY TRAY FRACTION KG-MOL/HR_—MOKCAL/HR Mer slop LDS 130 0.7800 OVERALL YASS BALANCE, (BEDS - PRODUCTS) 3.02758-05 OVERALL HEAT BALANCE, (HCN) — (OUT) ) 4.00438-05 cy 7m, oes C LIQUID FRACTION ares —— row To FRM TRC i KHOR STD U3 /R PROIll APPLICATION BRIEFS VACUUM COLUMN R4-7 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa tePRODUCT STREAM SUMMARY ase Mer VAPOR WET LIQUID. WET LIQUID Wer LIgHD [ENTWALEY, MeKCAL/HR 1913 0.700 7.409 12.247 noua ssis72 1101387 as0.e10 233-615, ous FRACTION LIgUID 0.00000 1.00000 «1.00000 1.00000, 1 VAP EATE(L), KO AR 25315 aa am Na BOALEY, OAL 3751372 a wa na ‘TERR COND, HEAL/IR-M-C 0.02029 M/A aa N/A — tom uo wR N/a 49.500 52.059 cara A aire 273.237 sm 19 RATE, 16, Wa ao S0.8a1 BOALeY, eae WA aos 73.615, (2) sm vigor vou 15 22.014 Ma/x-wouE (0 ¢ AND 1 ATM) 4-8 VACUUM COLUMN PROIII APPLICATION BRIEFS. February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa tePRODUCT STREAM SUMMARY (Cont) va pare 2), 0 — va trou PATE, HONOUR Kena/ie sm 10 ARTE, wo/HR Na ver urguD na Na na Na Na na Na na wer wiqurD wer LiguID (a) 9m VAPOR VOUNE 18 22.414 12/KG-HOLE (0 C RID 2 AM) PROIll APPLICATION BRIEFS February 1991 VACUUM COLUMN R4-9 ee = SOLID CONVERTER PDF > omc tinesin pa tePRODUCT DISTILLATION CURVES 4-10 VACUUM COLUMN PROIII APPLICATION BRIEFS. February 1991 &SouID CONVERTER POF > satin neau reeFCC MAIN FRACTIONATOR ‘A fluidized catalytic cracker (FCC) operation is being expanded and modified to increase gasoline production and eliminate production of heavy cycle oil You have to adapt an existing main fractionator column for this new service. The flow sheet, for the column is shown in Figure R51. Process Data The new operation product slate for the 15,000 barrelsiday design basis charge is shown in Tables R5.1 and R5.2. The column feeds the FCC reactor effluent which is synthesized by blending these product streams together with the 3000 lbfhr of, reactor stripping steam. > ah. CME Ey 3 ee ra Figure R51 Fractionator Column PROIll APPLICATION BRIEFS FCC MAIN FRACTIONATOR R5-1 February 1991 ete = SOLID CONVERTER PDF > omnes pues eTable R51 - GAS PLANT PRODUCTS ({bihr) Component | _ Off Gas. 3's a's Gasoline He 120 - - - Hes 246 . coz 317 . Ne 545 - . 3935 - - 4218 - - 3290 - - 2879 6335 29 1047 2887 208 lesz 161 - 2358 324 463 - 6658 560 586 - 7191 34 Nos 168 - 2521 451 - . 1793 les 260 - 194 8755 Nos 104 - 25 1668 Total 18,336 8892 19,184 13,585 Table R52 - PRODUCT ASSAYS (F) Lv% C6 plus (086)_| Gasoline (086) _|Light Cycle (TBP) ° 175 370 483, 5 7 470 705 10 179 512 m7 30 215 567 a7 50 266 601 976 70 22 637 1080 20 4a 604 1250 95 492 73 1391 100 537. 745: 1439 Barrels/hour 258.13 6267 53.54 API Gravity 470 184 aa 5-2 FCC MAIN FRACTIONATOR PROIll APPLICATION BRIEFS February 1991 ete = SOLID CONVERTER PDF > omnes pues e‘The fractionation has to meet the specifications shown in Tables R5.3 and RS.4 Tablo R53 FRACTIONATION SPECIFICATIONS ‘Univstream Property Value Gasoine eG End Point 450 Light Cycle Oi 86 Ena Point 740 F Condenser Temperature ra0F Pressure drop Spsi Main Column Top pressure 20 p89 Pressure Oop psi Botioms temperature 680 F Steam feed 500 for Sidestipper steam feed 500 lone steam Saturotes) | Pressure 150 psig Tablo R54 PUMPAROUND INFORMATION Pumparound | Duty (MMBtu/hr) | Rate (bbi/day) | Return Temp (F) es Top 20 - 25 Fa Wide 10 - 450 8 ston 12,000 Bs ‘The main fractionator is sized for single pass valve trays on 24-inch spacings at 75% of flood. The actual column contains 24 trays, not counting the baffes in the {quench zone. ‘The sidestripper has eight actual trays and is represented by two trays for the simulation. Methods ‘The BK10 thermodynamic system is used for the K-values, enthalpies and vapor and Data densities. This system works well for main fracionators. The API correlation is used for the quid viscosity predictions. In this simulation, we have a complete distilation profile for the slurry oil. An ‘accurate characterization ofthe slury is important because its bubble point (column bottom temperature) is normally used as a control parameter. In operating units, slurry data are often incomplete, and a shortcut model of the bottom section ofthe, ‘column may be used to develop the slury oil data PROIll APPLICATION BRIEFS FCC MAIN FRACTIONATOR R5-3 February 1991 ee = SOLID CONVERTER PDF > omc tinesin pa teSimulation —_The details of the simulation model are shown in Figure 5.2. Typical tray efficiencies Model are used to obtain the number of theoretical rays from the actual rays. The number of trays used does not have a critical effect on the simulation results. The quench zone is represented by a single tray with a pumparound through a cooler. 'AMIXED condenser is used, and the desired condensing temperature is set as a performance specification. The condenser duty is varied to meet this specification. “The gasoline draw rate is varied to meet the D86 end point specification. Similan, in the sidestripper, the cycle oll rate is varied to meet the specified end point. “The quench zone cooler duty is calculated to meet the slury cil rate specication “The return temperature for this pumparound is computed from the desired circula- tion rate. The pumparound side coolers have cooling duties set with the HEAT statement. The return temperatures are given and the corresponding circulation rates calculated. Figure R52 Simulation Model of Fractionator Column 5.4 FCC MAIN FRACTIONATOR PROIll APPLICATION BRIEFS February 1991 DSc E> oS SOLID CONVERTER POF > satin see