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Randall Gas Technologies

ABB Lummus Global, Inc.ABB Lummus Global, Inc.Lummus Process TechnologyLummus Process Technology

Randall Gas TechnologiesRandall Gas Technologies 8282stst AnnualAnnualGPA ConventionGPA Convention

San Antonio, TexasSan Antonio, Texas

1212--MarchMarch--20032003

A Review of the Basics for Superior DesignA Review of the Basics for Superior DesignHazemHazem Haddad, Ph.D., PEHaddad, Ph.D., PE

Jorge Jorge FogliettaFoglietta, PE, PE

ABB ABB Lummus Lummus Global IncGlobal IncLummus Process Technology Lummus Process Technology -- Randall Gas TechnologiesRandall Gas Technologies

Houston, TexasHouston, Texas

IntroductionIntroduction

Why Thermodynamic Analysis?

Minimum/Ideal WorkWith Actual Work known, it gives the process efficiency.Identifies areas in the process with large lost work or Operations that are “Highly Irreversible”

What is a reversible process?

A reversible process is a process that undergoes a change in infinitesimally small steps such that, at all times, the system remains at equilibrium or infinitesimally away from equilibrium.

All heat transfer is to or from the environment via a Carnot engine.

A reversible process must produce useful work.

Introduction (…cont.)Introduction (…cont.)

For a plant to be reversible

Every operation in the process has to be reversible

One Block Movie

Two Block Movie

Four Block Movie

Types of Lost Work

Chemical Lost Work: Irreversible chemical reactions.

Heat Transfer Lost Work: Temperature gradient.

Mass Transfer Lost Work: Mixing of streams with different composition.

Momentum Lost Work: Pressure drop or irreversible change in pressure.

Ideal Work

For a work requiring process, this is the minimum work required to accomplish the process.

Shaft WorkThis is the work of rotating shafts like compressors, expanders and pumps etc.

Lost WorkThe difference between the Ideal and shaft work.

DefinitionsDefinitions

Thermodynamic CalculationsThermodynamic Calculations

The Entire ProcessThe Entire Process

WWidealideal =T=Tee∆∆SS--∆∆HH

WWshaftshaft = = ΣΣ WWii

WWlostlost == WWidealideal -- WWshaftshaft

Thermodynamic Calculations, Cont.Thermodynamic Calculations, Cont.

Heat ExchangersHeat Exchangers

WWidealideal=T=Tee∆∆SS--∆∆HH

∆∆H=0H=0

WWshaftshaft = 0= 0

WWlostlost == WWidealideal = T= Tee∆∆SS

Non Adiabatic Heat Exchangers and simplifying assumptionsNon Adiabatic Heat Exchangers and simplifying assumptions

Air CoolersAir Coolers

WWshaftshaft = 0= 0

WWlostlost = = WWidealideal

ValvesValves

∆∆H=0H=0

WWshaftshaft = 0= 0

WWlostlost = = WWidealideal = T= Tee∆∆SS

Compressors, pumps, expandersCompressors, pumps, expanders

WWshaftshaft = = WWactualactual

WWlostlost = = WWidealideal -- WWshaftshaft

Distillation ColumnsDistillation Columns

Isolate the column from the heat exchangers!Isolate the column from the heat exchangers!

∆∆H=0, H=0, WWshaftshaft = 0= 0

WWidealideal = T= Tee∆∆S= S= WWlostlost

Conventional Propane RecoveryConventional Propane Recovery

T-100Deethanizer

X-101/C-101Expander/

Recompressor

PF1Condenser

NGL ProductFigure 1

Feed Chiller

Hot Oil

1290 psia68°F

1290 psia100°F

T-101Absorber

-9.5°F

Air Cooler

Flow=0

Applications to Gas Plants Applications to Gas Plants –– CC33 RecoveryRecovery

Calculate the ideal and lost work for the entire process.

Disconnect the process into individual adiabatic processes.

Calculate the ideal and lost work for each individual operation.

Add up the total and lost work as a check.

Application to Gas Plants Application to Gas Plants –– CC33 RecoveryRecovery

T-100Deethanizer

Recompressor

PF1Condenser

NGL ProductFigure 2

Feed Chiller

Hot Oil

1290 psia68°F

1290 psia100°F

T-101Absorber

-9.5°F

Air Cooler

Recommended ApproachRecommended Approach

Simulation tools and SpreadsheetsSimulation tools and Spreadsheets

Thermodynamic Analysis of Conventional Propane RecoveryThermodynamic Analysis of Conventional Propane Recovery

11.85,01405,014Air Cooler

100.042,352-48,333-5,981Total

00-4,034-4,034Reboiler

44.018,647-42,299-25,652Rotating Equipment

16.26,84206,842Columns

0.143043Valves

27.911,805011,805Exchangers

% of lostWlostWshaftWidealEquipment

T-100Deethanizer

Recompressor

PF1Condenser

NGL ProductFigure 1

Feed Chiller

Hot Oil

1290 psia68°F

1290 psia100°F

T-101Absorber

-9.5°F

Air Cooler

Flow=0

Applications to Gas Plants Applications to Gas Plants –– CC33 RecoveryRecovery

New Concept DevelopmentNew Concept Development

The High Pressure Absorber The High Pressure Absorber -- HPAHPA

Operate the absorber at high pressure (500 to 700 psia). This pressure is limited by the approach to critical conditions and the amount of refrigeration needed from the expander to keep the process self refrigerated.

Install a compressor to compress the net deethanizer overhead.

Eliminate the pump at the bottom of the absorber.

T-100Deethanizer

Recompressor

PF1Condenser

NGL Product

Figure 3

Feed Chiller

Hot Oil

1290 psia68°F

1290 psia100°F

T-101Absorber

-27.6°F

Air Cooler

HPA for Propane Recovery HPA for Propane Recovery

Thermodynamic Analysis of the HPA Process for Propane RecoveryThermodynamic Analysis of the HPA Process for Propane Recovery

9.30-3,226-3,226Reboiler100.028,264-34,140-5,876Total

10.52,63602,636Air Cooler

38.410,843-30,914-20,071Rotating Equipment21.46,05106,051Columns

3.91,09701,097Valves

27.07,63407,634Exchangers

Comparison to Conventional TwoComparison to Conventional Two--Tower SchemeTower Scheme

HPA SchemeConventional Scheme

10.52,63611.85,014Air Cooler38.410,84344.018,647Rotating Equipment21.46,05116.26,842Columns3.91,0970.143Valves27.07,63427.911,805Exchangers

PercentLost WorkPercentLost Work

30,91444,299Total Actual Work

28,26442,352Total Lost Work

HPA HPA –– CC33 Recovery Recovery

The High Pressure Absorber The High Pressure Absorber -- HPAHPA

With reasonable heat integration, if the temperature of the residue gas stream entering the recompressor is significantly colder than the temperature of the feed then the expander is generating excessive refrigeration and the absorber can be operated at higher pressure.

Factors favoring the HPA Process for CFactors favoring the HPA Process for C33 recoveryrecovery

T-100Deethanizer

Recompressor

PF1Condenser

NGL Product

Figure 3

Feed Chiller

Hot Oil

1290 psia68°F

1290 psia100°F

T-101Absorber

-27.6°F

Air Cooler

HPA for Propane Recovery HPA for Propane Recovery

-40.00 10.00 60.00 110.00 160.00 210.00

Stage Temperature (F)

r)Deethanizer CGCC – Conventional C3 Recovery

Column Grand Composite Curve

-70.00 -20.00 30.00 80.00 130.00 180.00

r)Deethanizer CGCC – HPA C3 Recovery

T-101Demethanizer

Recompressor

PF1Gas Subcooler

NGL ProductFigure 4

Feed Chiller/Side reboiler

1290 psia68°F

1290 psia100°F

Air Cooler

Application to Ethane RecoveryApplication to Ethane RecoveryConventional Ethane RecoveryConventional Ethane Recovery

Thermodynamic Analysis of a Conventional Ethane Recovery ProcessThermodynamic Analysis of a Conventional Ethane Recovery Process

100.038,035-47,348-9,313Total

12.04,57304,573Air Cooler

17.26,53906,539Columns

11.04,18404,184Valves

T-101Demethanizer

Recompressor

Gas Gas Exchanger Gas Subcooler

NGL ProductFigure 5

Feed Chiller & Reboilers

1290 psia68°F

1290 psia100°F

-22°F

Air Cooler

Application to Gas Plants Application to Gas Plants –– CC22 RecoveryRecoveryNew ConceptNew Concept

Patent Pending

ABB Lummus Global

Thermodynamic Analysis of HPA for Ethane RecoveryThermodynamic Analysis of HPA for Ethane Recovery

100.032,572-42,501-9,929Total

12.54,05804,058Air Cooler

21.46,97606,976Columns

10.73,49803,498Valves

Comparison to Conventional GSP SchemeComparison to Conventional GSP Scheme

HPA SchemeConventional Scheme

12.54,05812.04,573Air Cooler42.313,79244.616,965Rotating Equipment21.46,97617.26,539Columns10.73,49811.04,184Valves13.04,24815.25,773Exchangers

PercentLost WorkPercentLost Work

Comparison for the CComparison for the C22 Recovery ProcessRecovery Process

42,50147,348Total Actual Work

32,57238,035Total Lost Work

-150 -125 -100 -75 -50 -25 0 25 50

Stage Temperature (°F)

r)Demethanizer CGCC – No Side Reboilers

-150 -125 -100 -75 -50 -25 0 25 50

Stage Temperaure (°F)

r)Demethanizer CGCC – 1 Side Reboiler

-150 -125 -100 -75 -50 -25 0 25 50

Stage Temperature (°F)

r)Demethanizer CGCC – 2 Side Reboilers

T-101Demethanizer

Recompressor

PF1Gas Subcooler

NGL ProductFigure 4

Feed Chiller/Side reboiler

1290 psia68°F

1290 psia100°F

Air Cooler

Application to Ethane RecoveryApplication to Ethane RecoveryConventional Ethane RecoveryConventional Ethane Recovery

More on Column TargetingMore on Column Targeting

30 50 70 90 110 130 150 170 190

More on Column TargetingMore on Column Targeting

Minimum Condenser/reboiler duties.

Percent above minimum reflux/stripping.

Maximum amount of heat that can be added/removed by a side exchanger.

A measure of reversibility.

Column TargetingColumn Targeting

LminX*

VminY*

D, XDHD

F, XF HF

(a) (b)

Let’s consider a simple distillation column with a condenser and a reboiler.By definition, the streams exiting the ideal stage are at equilibrium.

Column TargetingColumn Targeting

An overall material balance yields

A light key component material balance yields

LXDX=VY D**

minmin +

Solve for Lmin and Vmin

LD=V minmin +

DH-LH-VH=H DLVdeficit minmin

Conclusions & RecommendationsConclusions & Recommendations

The statue was already in the rock…All I had to do was take it out… Michel Angelo

With current computer technology, thermodynamic analysis of a process is no longer a tedious process.

Thank You!

Comparison to Traditional Two-Tower Scheme

Absorber Pressure,psig 440 700Two-Tower Scheme High Pressure Absorber

Cooling/Heating, mmbtu/hr 177 126

Major Equipment Count 12 12

Residue Comp. HP 44,242 30,913

Overhead Compression --- 3,770

Plate-Fin UA / 106 5.1 19.3

High Pressure Absorber Process – C3 Recovery(Pat. Pending)

Comparison to Traditional Two-Tower Scheme

Absorber Pressure,psig --- 580Two-Tower Scheme High Pressure Absorber

CO2 Freezing Margin,°F

Cooling/Heating, mmbtu/hr 108 100

Major Equipment Count 12 14

Residue Comp. HP 47,348 42,498

Overhead Compression --- 5,210

Plate-Fin UA / 106 20.6 47.7

High Pressure Absorber Process – C2 Recovery

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