UAE University

College of Engineering
Training and Graduation Project Unit

Group Members
Group Supervisor Dr. Samir Abu-Eisha
Manal Ali 200104884
Shamma Saeed 200104967
Ahoud Ibrahim 200104837
May Matar 200105183

















Problem Definition
A vapor recovery unit is a device that captures or recovers
valuable volatile organic component and other rich gas streams
that may otherwise be a significant environmental pollutant or
hazardous air pollutant.
Design and Application
Hydrocarbons VRU

















Objective
Design and Application
Hydrocarbons VRU

















Flaring Gas Without Recovery
Design and Application
Hydrocarbons VRU

















Flaring Gas With Recovery
Design and Application
Hydrocarbons VRU

















Section1(Sweetening Process)

Updating MB & EB

Optimization

Simulation

Equipment Design

Material Selection

Cost Estimation

Hzop Study



OUTLINE
Conclusion


Introduction

Section2(Dehydration Process)

Updating MB & EB

Optimization

Simulation

Equipment Design

Material Selection

Cost Estimation

Hzop Study



Section1:
Sweetening Process
Sweetening Background
Sweetening process describe the removal of hydrogen sulphide
(H2S), Carbon Dioxide (CO2), and possibly other sulphur
component.

Why Sweetening?
Safety and Environmental Protection.

Gas Sweetening Process:
Gas Sweetening process includes absorber, stripper (Regenerator) and
common accessories
Updating MB & EB

















Sweetening Process

















Up dating material balance

















Up dating material balance
Importance of updating material balance

Updating material balance on absorption column

Updating material balance on flash column



















Updating material balance on absorption column
100 % Recovery
0.999 Recovery
100 Feed In (tons/day )
153.2 Gin Feed In (Kmol/hr )
142.4 Gout (Kmole/hr)of dry gas
0.06 Yico2
0.0071 Yi
H2S
0.0001 Youtco2
1.151 E-05 Yout
H2S
0.00 Xico2
0 Xi
H2S
0.1913 Xoutco2
0.0165 Xout
H2S
80 Lin
100 Lout
105.2 DGA (MW )
Table1: Results of updating material balance
Figure1: Absorption column

















Updating material balance on flash column
Table2: Results of updating material balance
Figure2: Flash column
0.01655 Xin H2S
0.19138 Xin CO2
0.79206 XDGA
0.01653 Xout H2S
0.15145 Xout CO2
0.79135 XoutDGA
Optimization Part

















Optimization of the operation conditions
Optimization
Derivation of a set of model parameters
that produces the:best results when
compared to observed data

Searching for the best solution among alternatives

Seeking the most favorable condition



















Optimization of the operation conditions
Pressure
Temperature
Flow rate
Absorber type
Fluid package type

Distillation
Flash
Absorption
Pump
Distillation
Flash
Absorption
Heat Exchanger
All Process
Absorption
Absorption

















Pressure Optimization
P Vs Purety CO2
0
0.05
0.1
0.15
0.2
0.25
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Pressure(Kpa)
P
u
r
e
t
y

(
%
)
P Vs Purety of H2S
0
0.2
0.4
0.6
0.8
1
1.2
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Pressure
P
u
r
e
t
y
3700
Kpa
in
out in
Purity

=
Temperature Optimization
Temp Vs Purity
0
0.2
0.4
0.6
0.8
1
1.2
0 10 20 30 40 50 60 70 80
Temp(c)
P
u
r
i
t
y
(
%
)

















Flow Rate
4000 p(kpa) 560 DEA(kmol/hr)
4000 p(kpa) 145.16 Flare Gas(Kmol/hr)
30 Column Temp 3700 Column Pressure(Kpa)
DEA Vs Purity
0
0.2
0.4
0.6
0.8
1
1.2
0 100 200 300 400 500 600 700 800 900
DEA flow rate
P
u
r
i
t
y
(
%
)
H2S Purity
CO2 Purity
600

















Optimization of the operation conditions
Summery
Pressure
Temperature
Flow rate
Absorber type
Fluid package type

3700 Kpa
30 C
600 Kmol/hr
Diethyl Amine
General NRTL
Simulation Part

















Importance of HYSYS
1. HYSYS Program definition:

HYSYS is a process simulation environment designed to
serve many processing industries especially Oil &
Gas and Refining.

2. Important of HYSYS:

o You can create accurate steady state and
dynamic models for plant design, performance
monitoring, troubleshooting, operational
improvement, and business planning and asset
management.

o You can easily manipulate process variables

















Complete Process

















Bases Information
The base information's for the inlet stream
DGA (in) Flare gas The parameters
4000 4000 Pressure(Kpa)
45 40 Temperature(
o
C)
20 148.16 Molar flow rate(kmole/hr)
Methane = 0.0
Ethane = 0.0
Propane = 0.0
i-Butane = 0.0
n-Butane = 0.0
i-Pentane = 0.0
n-Pentane = 0.0
n-Hexane = 0.0
n-Heptane = 0.0
H
2
O = 0.6667
H
2
S = 0.0
CO
2
= 0.0
DGAmine = 0.3333
Methane = 0.60773
Ethane = 0.10207
Propane = 0.07262
i-Butane = 0.01342
n-Butane = 0.03015
i-Pentane = 0.00821
n-Pentane = 0.00781
n-Hexane = 0.00451
n-Heptane = 0.00881
H
2
O = 0.00
H
2
S = 0.01152
CO
2
= 0.13313
DGAmine = 0.0
Feed composition = Mole flow rate%
General NRTL- Ideal General NRTL- Ideal Fluid Packages
Separation Separation Reaction Type

















Hysys Result Summary
Equipment Design Part

















Equipment Design

Design is one of the most important stages in
the project development process and it can be
applied for many applications such as:

Modification and additions to an existing
plant.
New production capacity to meet growing
sales demand.
New process that developed from experiment
Design and Application
Hydrocarbons VRU

















Design

The main pieces of equipment in this process were
designed. The proposed process consists of 6 main
units. These include: absorption column, flash
column, distillation column, two heat exchangers and
pump.
Design and Application
Hydrocarbons VRU

















Design
Flash Column
By using the heuristics for phase separator
Rule 3: Vertical vessel
Rule 4: L/D between 2.5 and 5 with optimum at 3
Rule 5: liquid hold-up time is 5 min based on 1/2
volume of vessel
Rule 9: Gas velocity u is given by { u=k[(
l
/
v
)-1]
0.5
}
K= 0.0305
Rule 12: good performance obtained at 30-100% of u
from rule9, typical value is 75%

















Flash Design summary
Unit Gas-liquid separator
m 1.26 Height
m 0.5060 Diameters

















Design
Heat Exc-101
By using the heuristics for Heat Exchanger
0.9 Rule 1: set F=
850 Rule 8: U= W/m
2o
C
From Hysys program
6962000 Q = (KJ/h(
1933.89 Q = (KJ/s(
( )
( ) ( ) | | 2 / 1 ln
) 2 ( 1
T T T T
T T T T
TLm


= A

















Design
Heat Exc-102
By using the heuristics for Heat Exchanger
0.9 Rule 1: set F=
850 Rule 8: U= W/m
2o
C
From Hysys program
10350000 Q = (KJ/h(
2875 Q = (KJ/s(
( )
( ) ( ) | | 2 / 1 ln
) 2 ( 1
T T T T
T T T T
TLm


= A

















Heat-Ex Design summary
Heat Exchanger1
m
2
65.6 Area
- 704.99 Number of tubes
Heat Exchanger2
m
2
185.15 Area
- 1988 Number of tubes

















Design
Pump-101
By using the heuristics for Pump
From Hysys program
Rule 1: Power (kw) = (1.67) x Flow (m3/min( x P (bar( /
Rule 4-7: Type of pump based on head

















Design
Distillation column-101
By using the heuristics for Distillation
Rule 5: Optimum reflux ratio in the range of 1.2-1.5 Rmin
Rule 6: Optimum number of stages approximately 2Nmin
Rule 7: Nmin =
Rule 8: Rmin = { F/D}/(-1)
Rule 9: Use a safety factor of 10% on number of trays
Rule 14: Lmax = 53 m and L/D <30

| | | | { } o ln / ) 1 /( / ) 1 /( ln min bot x x ovhd x x N =
Rule 2: Fs= u *
v
0.5
= 1.2 to 1.5 m/s(kg/m
3
(
0.5

Rule 3: P
tray
0.007 = bar = 0.1 psi
Rule 4:
tray
60 - 90 = %

















Design
Distillation column-101
L-component n-Pentane
H-component n-Hexane
Dx R Qc ) 1 ( + =
Condenser Duty
Re-boiler Duty
F D W C B
H H H Q Q + + =

















Distillation Design summary
Units Distillation Parameters
1.88 Optimum reflux
23 Actual Number of Plates
m 18.4 Height
m 0.714 Diameter
kW 1565.0 Condenser duty
kW 1510.6 Reboiler duty
Material Selection Part
Material selection

Corrosion Resistance
Cost
Availability
Safety
Mechanical Property
Material selection

CO2 = Carbonic Acid

13 CR

With H2S

316 at 60 C

Duplex 22 Cr at limit partial pressure = 3 psia
Partial pressure of H2S = 100 psia

NI is the best choice
Cost Estimation Part
Cost Estimation
CAPCOST Program
CAPCOST Program Results
CAPCOST Program
Equipment CP($) CBM($)
Pump 1 19864 330861
Heat-Exchanger 1 7392 30514
Heat Exchanger 2 20880 86190
Flash Vessel 7757 121193
Distillation 30671 1493240
CAPCOST Program Results
C
GR
=C
TM
+0.35C
BM
Effect of time of purchased Equipment Cost
) (
1996
2007
1996 2007
I
I
Cp Cp =
Manufacturing Cost
Manufacturing Cost
It is the cost of producing the products.
It is needed to judge the viability of the project
and select between alternative processing method.
Factors affecting the cost of manufacturing
(COM) can be divided in to:

Direct Manufacturing Costs
Fixed manufacturing Costs
General Expenses

Direct Manufacturing Costs

Its represent operating expenses that
vary with production rate.

In general the direct manufacturing costs
include the cost of:

Raw Materials.
Operating Labor
Utilities.
Maintenance and repair



Fixed Manufacturing Costs

Theses cost do not vary with production rate.

They includes:


Property taxes

Insurance

Depreciation




General Expenses


Cost associated with management level
and administrative activities.

They include:

Administration Costs.
Distribution and selling costs.
Research and development.





The equation used to evaluate the COM
) ( ) (
) ( ) (
GE Expenses General FMC Costs ing Manufactur fixed
DMC Cost ing Manufactur Direct COM e Manufactur of Cost
+ +
=
COM FCI C GE
FCI C FMC
COM FCI C C C C DMC
OL
OL
OL UT WT RM
16 . 0 009 . 0 177 . 0
168 . 0 708 . 0
03 . 0 069 . 0 33 . 1
+ + =
+ =
+ + + + + =
) ( 23 . 1 73 . 2 304 . 0
RM WT UT OL
C C C C FCI COM + + + + =
COM Estimation
The total manufacturing cost can be obtained by
adding three cost categories together and solving
for the total manufacturing cost (COM).


The cost of manufacturing (COM) can be
determined when the following costs are known
or can be or can be estimated:

Fixed Capital Investment (FCI): C
TM
or C
GR
.
Cost of Operating Labor (COL).
Cost of Utilities (CUT).
Cost of Waste Treatment (CWT)
Cost of Raw Materials (CRM).



COM Estimation

Cost of operating labor
The following calculations were applied to get the average yearly
wage of operators.

year
operators of wage yearly avg
operators
year operator
shif ts
year
shif t operating
needed operator each f or hired operators of
year per shif ts operating
day
shif ts
year
days
year per shif ts operating
week
shif ts
year
weeks
year per operator per shif ts
aweek shif ts hrs f ive
weeks year per weeks operating
800 , 46 $
5 . 4
.
245
1095
#
1095 3 365
245 5 49
8
49
=
= =
= =
= =
=
Labor Costs Results
Process Equipment Number of Equipments
Operators per Equipment
per shift Operators per shift
Heat-Ex 2.00 0.10 0.20
Pumps 1.00 0.00 0.00
Towers 3.00 0.35 0.70
Vessels 0.00 0.00 0.00
TOTAL 1.05
Operating Labor 4.725
Operating Labor (rounded) 5.0
Labor Cost $/yr 234000
Utility Costs

Utility Cost $/Common Unit
Units
($/common unit)
Electrical Substation 0.06 $/kWh
Cooling Water 6.7 $/1000m3
LPS(75 psig) 6.62 $/1000m3
Pump-101

Shaft Power (kW) 82.19
Cost of Electric Substation 0.06
Yearly Cost ($/yr) 54718.81
- Costs of Raw Materials:
Fixed Capital Investment (FCI), C
GR

C
GR
=722000.0 $/yr

75 Raw Material(DGA)($/ton)
497.8 DGA required in the sweetening process (kg/h)
4099.084 DGA required in the sweetening process (ton/yr)
307431.3 cost of DGA ($/yr)
Manufacturing Costs Results 1996
Yearly Costs and Stream Factors:
365
) (
year per Operates Plant Days of Number
SF Factor Stream =
299856.
5 Total utilities
0 water treatment=
307431.
3 Raw Material(DGA)($/ton)
234000 C
OL
=
7848000 FCI= total grass root
Effect of time of purchased Equipment Cost
) (
1996
2007
1996 2007
I
I
Cp Cp =
$/yr 5035350 2006 at Cost ing Manufactur Total =
382 Index 1996=
510 Index 2006=
Project Feasibility
15645.36 Dry Gas produced(ton/yr)
55 Dry gas cost(/ton) [14]
103.8538 Dry gas cost($/ton) (1.00 = 1.88825$)
1624829 Dry Gas($/yr)
The economic feasibility = Market value of products- COM
The economic feasibility was calculated to be -3410521$/yr.
Hazop Study Part
Define the Purpose, Objectives, and Scope of the Study
1. Check the safety of a design
2. Decide whether and where to build
3. Develop a list of questions to ask a supplier
4. Check operating/safety procedures
5. Improve the safety of an existing facility
6. Verify that safety instrumentation is reacting to best parameters
It is also important to define what specific consequences are to be considered :
Employee safety (in plant or neighboring research center)
Loss of plant or equipment
Loss of production (lose competitive edge in market)
Liability
Insurability
Public safety
Environmental impacts.
Area of Applying HAZOP study
HazOp depends on several factors
The completeness and accuracy of drawings
Data used as a basis for the study
%100
%30
Process after Hazop Study
Section2:
Dehydration Process
Dehydrations Background
A prevention of the problems associated with water presence.
Hydrates exclusion and less corrosion.

Ease of operations and economics enhanced a TEG use.

TEG absorption system:
Absorption process includes absorber, stripper (Regenerator) and
common accessories.
Updated Material Balance
T 101 Illustration
Given H
2
O molar composition:
y
2
= 0.051487
y
3
= 0.091050
y
4
= 0.000130
y
5
= 0.541348
m
2
+ m
3
= m
4
+ m
5

165.11 kmol/hr = m
4
+ m
5
(1)

x
2
*m
2
+ y
2
*m
3
= y
4
*m
4
+ x
5
*m
5


14.748 kmol/hr = 0.00013*m
4
+ 0.541348*m
5

(2)

Substituting equation 1 in 2 leads to:

m
4
= 137.9 kmol/hr

m
5
= 27.71 Kmol/hr
Material Balance Summary
Updated Energy Balance

Two main equipments
were considered:

Condenser
Reboiler

T
ref
= 0
o
C = 327.15 K
Condenser Example
- Main Equations -
R = 1.1


Heat capacity of each component was figured using the following equation:



The final value of the enthalpy (kJ) is computed by:

Dx R Qc ) 1 ( + =
3 2
dT cT bT a C
p
+ + + =
}
A =
T
T
p
ref
dt T C H .
Results
H
v
= 39764.24 KJ/Kmol

D = 20 Kmol/hr

Q
c
= 463.9 Kw

Q
c
(HYSYS) = 379 Kw

Error % = 22%

Reboiler Example
- Data Given & Results -
The main energy balance was:


Data given based on HYSYS:




Qr = 513.01 Kw
Qr (HYSYS) = 428 Kw
Error % = 20

F D W C B
H H H Q Q + + =
Feed
(F)
Res.
(W)
Dist.
(D
2
)
Dist.
(D
1
)
Absorbers Optimized operating conditions
Pressure:
Temperature was set to 40
o
C, pressure values were changed between1000 to
9000 kpa.
Optimum pressure was equal to 4000 kpa.
Pressure Attitude (Kpa)
98.9
99
99.1
99.2
99.3
99.4
99.5
99.6
99.7
99.8
0 2000 4000 6000 8000 10000
Pressure Kpa
H
2
O

R
e
m
o
v
e
d

p
e
r
c
e
n
t
a
g
e
Absorbers Optimized operating conditions
Temperature:
Optimum pressure was set to 4000 kpa.
Temperature values of the column changed between 30 80
o
C.
The obtained trend was decreasing but the percentage remained as 99%, thus
there would be no difference if 40
o
C was selected.
Temperature variations
99.52
99.54
99.56
99.58
99.6
99.62
99.64
99.66
99.68
0 20 40 60 80 100
T (
o
C)
H
2
O

R
e
m
o
v
e
d

p
e
r
c
e
n
t
Regenerators Optimized operating
conditions
Pressure:
Temperature of the column was fixed at 105
o
C, pressure values of the column
varied between 60 to 120 kpa.
Optimum pressure was equal to almost atmospheric.
Pressure Trend at Constant Temp
79.516
79.5165
79.517
79.5175
79.518
79.5185
79.519
60 70 80 90 100 110 120 130
Pressure (Kpa)
H
2
O

R
e
m
o
v
e
d

p
e
r
c
e
n
t
Regenerators Optimized operating
conditions
Temperature:
Optimum pressure was set to 105 Kpa.
Temperature values of the column changed between 80 110
o
C.
Optimum temperature selected = 100
o
C.
TemperatureVariation
79.5164
79.5166
79.5168
79.517
79.5172
79.5174
79.5176
79.5178
79.518
79.5182
80 85 90 95 100 105 110 115
T (
o
C)
H
2
O

R
e
m
o
v
e
d

p
e
r
c
e
n
t
HYSYS Final
HYSYS Results
Final
Design Example
T 101
Absorber T 101:

( )
( )
2 / 1
2
047 . 0 27 . 0 171 . 0
(

+ =
v
v L
t t v
l t u

v v
c
u
V
D
t
4
=
LK
b
LK
HK
d
HK
LK
m
X
X
X
X
N
o log
log
(

=
( )
( )
b r i
d r i
LK
x x
x x
/
/
= o
1 . 1 x
N
N
thr
act
q
=
Design Summary
Sieve trays were assumed with
18 spacing.

Length of the column was
calculated as:


L = N.Trays* Tray Spacing + (20% Lorg)

Minimum reflux:

) 1 /(
min
= o
D
F
R
Heater & Cooler Design
Heat transfer can be equated to both equations:
) (
1 2
T T UA Q =
) (
1 2
T T mC Q
p
=
Reciprocating Pump Design
P (Kw) = 1.67FP/
F = 0.01561 m
3
/min
P = 38.8 bar
= 0.75
P (Kw) = 1.35
Material Selection
Stainless Steel:
Resistant to acids, reducing discoloration.
Available with variety of alloys.
Less abraison.
Expensive as a disadvantage.
Difficult in fabrication.
Alloy materials may have catalytic effects.
Carbon Steel:
Low cost and available.
Resist abrasion and easy fabricated.
Resist alkali.
Poor resistant to acids and strong alkali.
Often causes contamination.

A - Capital cost estimation
The cost associated with each
equipment:



Direct and Indirect costs of the unit:





Total module cost:









) (
2 1 p M p
BM
o
p
BM
o
F F B B C F C C + = =
2
3 2 1
) (log log log A K A K K C
p
+ + =
2
3 2 1
) (log log log P C P C C F
p
+ + =

+ =
BM TM GR
C o C C 325 .
The total purchased cost= $79,772
The bare module cost = $519570.
B
2
B
1
C
3
C
2
C
1
K
3
K
2
K
1
Equipment
1.72 2.5 -- -- -- 0.2146 0.5262 3.6237 T 101
1.72 2.5 -- -- -- 0.2053 0.5893 3.4746 T 102
1.21 0.74 0 0 0 0 0.9658 2.1138 E 101
1.5 1.8 0 0 0 0 0.9658 2.1138 E 102
1.5 1.8 0 0 0 0.07961 0.2688 3.2138 Condenser
1.5 1.8 0 0 0 0.07961 0.2688 3.2138 Reboiler
1.8 1.8 0.056 0.632 0.312 0.09141 0.417 3.9412 P 101
Values of constants used
Cost Summary
Fixed capital cost = 710,283$

Fixed cost = 810,692$

Variable costs = 67,338$

Direct production cost = 878,030$

Annual production cost = 1,404,847$
Cost Summary
Over- pressure:
Failure of a vessel can cause sequences of events that culminate in a
disaster.

Excessively high temperature:
Causes structural failure and initiate a disaster. High temperatures can
raise form loss of control of reactors and heaters.

Flow affect

Level affect
Illustration: (T 101)
PID after HazOp
Conclusion
The goal of our project was achieved