World appl. programming, Vol(5), No (2), February, 2015. pp.

31-40

TI Journals

ISSN:

World Applied Programming

2222-2510

www.tijournals.com

Copyright 2015. All rights reserved for TI Journals.

LPG Recycling Process Design in Paraxylene Production Unit

Behrouz Raei*
Department of Chemical Engineering, College of Chemical Engineering, Mahshahr Branch, Islamic Azad University, Mahshahr, Iran.

Davood Abbaspour
Persian Gulf Petrochemical Company, Mobin Petrochemical Company, Asalooyeh, Iran.

Mohammad Abdollahi
Bandar-e-imam Khomeini, Petzone, Bou AliSina Petrochemical Company, technical service department, Iran.
*Corresponding author: b.raei@mhriau.ac.ir

Keywords

Abstract

LPG
Paraxylene unit
HYSYS

Bou Ali Sina Petrochemical Company has been established as aromatic feedstock to produce a number of
petrochemical in special economic zone. Vapors from reflux drum at this company, wasted fuel gas stream, contains
amount of propane and butane which is 3921 Kg / hr that have the potential to be retrieved to LPG. For LPG recovery,
a line with a control valve designed to carry the fuel gas to LNG recovery unit. For best performance, valve opening,
line sizing and other required characteristics were simulated with HYSYS software. The results shows that no problem
had seen in normal operating conditions and the annual benefit due to this change will approximately $ 3600000.

1.

Introduction

Energy demands are constantly increase in worldwide and forecasts on average are expected to grow 2.1 per year [1]. Due to the abundance and
availability of fossil fuel resources, could estimate that they play an important role in the world energy economy. Fossil fuels currently provide about
85 percent of the world's commercial energy requirements. It is anticipated that China [2] , which supplies most than 90% of its energy requirements
with coal, its energy demand for electricity will increase by more than double in the next century, which is more than one-third of the energy demand
in the United States [ 2, 3].
Currently, automotive, is responsible for oil demand and more than half of this demand is expected to grow substantially. Demand in developed
countries is expected to rise like developing countries as economic growth and welfare which are led to a significant increase in the use of personal
vehicles. At the same time even increases efficiency and renewable energy and nuclear energy growth between 2005 and 2030, the growth of
greenhouse gas emissions is expected increase up to 30 percent [1].
Fulfill the increasing energy demand and reduce greenhouse gas emissions, the incentive to find alternative fuels [4] instead of hydrocarbons such as
gasoline and diesel, which ultimately led to collection of some of the fuel that is commercially available. Natural gas as a renewable energy resources
(through the production of biogas and bio-methane), which is available to reduce greenhouse gas emissions, offers a benchmark for comparison with
other traditional fuels and alternative. Natural gas can be used compressed natural gas (CNG), liquefied natural gas (LNG) or even mixed with
hydrogen. The use of natural gas vehicles (NGVs) also promotes energy security and energy diversity. Thus, natural gas as fuel, the property is
inherently eco-friendly; greater efficiency and cost effectiveness are the most preferred. For long-distance transport of natural gas, liquefied natural
gas (LNG) has many advantages for transportation is through pipes. Similar to all natural gas, LNG is cleaner than coal and oil that offers the
opportunity for diversification of energy sources. Natural gas is a mixture of paraffinic hydrocarbons such as Methane, Ethane, Propane, Butane, etc.
Small amounts of higher hydrocarbons other than carbon dioxide, small amounts of nitrogen, hydrogen sulfide may be present. Because, LNG is the
cleanest form of natural gas containing more than 98% methane, therefore, it is synonymous with methane [5].
Natural gas has a low density (0.789 based on air) and has lower sulfur content than gasoline, and is virtually free of carbon monoxide emissions. By
cooling natural gas to -162 C, LNG is converted [6]. This process reduces its volume by more than 600 times [7]. This processes, typically used 5.56 kWh of energy per kilo mole of LNG [8, 9]. The conversion of natural gas to LNG, Makes for ocean-going ships carry out transfer operations and
gas can be delivered to consumers worldwide [10].
Now, most of the refinery fuel gases are burned. While it is possible to produce liquefied petroleum gas (LPG) from these gases and export as LNG
in market and also the environmental problems will decreased. In the last 15 years, annual production of liquefied natural gas is growing. The amount
of pollution caused by burnt one million cubic feet of gas produced nearly 0.135 tons of H2S, 1.44 tons of SO2, 7.3 tons CO and 7.68 tons of carbon

Behrouz Raei *, Davood Abbaspour, Mohammad Abdollahi

32

World Applied Programming Vol(5), No (2), February, 2015.

dioxide. LPG applications ranging from commercial and domestic consumption, the consumption of petrochemical and polymers products (such as:
PVC, PP, PE) [11].
LPG is a cleaner fuel and as a fuel have various applications in domestic, commercial and industrial sources of carbon in metals processing,
petroleum products and petrochemical feedstock [12, 11].
The HYSYS software is used for needed changes to simulate the unit. HYSYS is planned to combine the simulation speed and accuracy to simplicity
of simulate. For new designs, HYSYS is able to quickly create models for evaluating multiple options. After selecting a preferred design, very
realistic models are considered to be created based on additional equipment and process details. HYSYS can be integrated with operations to improve
the speed and accuracy to ensure the devices function [13].

2.

Description of Process

Bou Ali Sina Petrochemical Company has been established as aromatic feedstock to produce a number of petrochemical in special economic zone.
Most of the special economic zone have integrated product line feed each other as primary or secondary, and are dependent on each other [14].
After investigation, Stripper column is tasked with maintaining the quality of pure benzene, some overhead vapors are condensed in tower AE-7002
while the final cooling is performed to 400 C in the E-7005 AB (Trim Cooler). Then the liquid are assembled with operational conditions (10 bara,
400 C) in the drum D-7003 (Reflux Dram). Vapor from D-7003 is used to control the pressure of D-7001 and additional gases are sent under pressure
controller to wasted FG (Fuel gas).
In this case, mixture of propane and butane is 3921 Kg / hr that have the potential to be retrieved to LPG.

Figure 1: Overview of T7001 and D7003 Paraxylene Tower unit in Bou Ali Sina Petrochemical Complex
Gas composition sent to the Fuel gas header based on design criteria is shown in table 1.
Table 1: Composition of gas sent from the D7003 to FG header based on design criteria

33

LPG Recycling Process Design in Paraxylene Production Unit

World Applied Programming Vol(5), No (2), February, 2015.

Composition of C3, C4 in this process is 3921 Kg / hr that a major part of it can be retrieved. Drum D4005, LPG absorber drum, does hydrocarbon
recovery C3, C4 from vent gas flow of Stabilizer Tower. In Figure 2, an overview of the process in LPG recovery is shown.

Figure 2: LPG recovery process

The feed of drum is provided from two streams. The first flow, phase effluent from the D4003 (Recontacting drum), after passing the E4006 is mixed
with the second Flow which is the vent gas of stabilizer tower and sent to D4005 (LPG absorber drum) as feed. Exhaust gases from high of drum
D4005are sent to fuel gas header and liquid effluents of drum D4005 are sent to Stabilizer for separation of LPG from aromizate. Composition of
inlet flows to the D4005 based on design conditions, are listed in Table 2.
Table 2: The composition of inflows to the D4005 based on design conditions

Behrouz Raei *, Davood Abbaspour, Mohammad Abdollahi

34

World Applied Programming Vol(5), No (2), February, 2015.

3.

Proposed process for LPG recovery

To evaluate the proposed LPG recovery from drum D7003 based on the design conditions, the process proposed in Figure 3, were taken.

Figure 3: Proposed Process for recovering LPG

Due to the figure 3 and design conditions, operating pressure of D4005is more than D7003so one of two approaches could carried on:
1.
2.

Use a compressor to deliver gas from D7003 to D4005.

Depressurize D4005 so that pressure can overcome operational pressure of D7003 and gas stream could establish from D7003 to D4005.

The first method is very time consuming and expensive so the second method reviewed and evaluated.

4.

Results

4.1 Performance of PIC-70110

The design data of PIC-70110 is shown in Figure 4.

Figure 4: Design data of control valve PIC-70110

A control valve as PIC 70110 placed in simulated environments, and then characteristic curve was defined based on the Data Sheet shown in Figure
4. Both data sheet specification and simulation graphs based on PIC 70110 are shown in figures 5 and 6.

35

LPG Recycling Process Design in Paraxylene Production Unit

World Applied Programming Vol(5), No (2), February, 2015.

Figure 5: feature graph based on data sheet PIC 70110

Figure 6: Graph characteristics defined in HYSYS

According to above, since the purge gas flow split is taken from before of PIC-70110, pressure conditions of D4005should be formulated that stream
flow be about 300 Kg / hr and PIC-70110opening remains about 20 ~ 30%. PIC70110 controlled conditions before and after the changes are shown
in Figures 7 and 8.

Figure 7: PIC70110 condition before changes

Figure 8: PIC70110 condition after changes

4.2 Sizing of new pipeline

According to proposed process in Figure 3, pipeline sizing calculations between D7003 and D4005 are as follows:
a)
b)

To calculate the maximum pressure drop for maximum flow so considered that the new pipeline passed all 4905 Kg / hr at 9.7 bara
pressure and inlet temperature of 40C and composition given in Table 1.
The initial estimate, for fitting, the equivalent required length of pipeline considered about 500 m andfor increase the accuracy of pressure
drop calculations, two Gate valve (half open) and a Check valve (swing) considered in the calculations.

The results of calculations for two 4 and 6 inch diameters are shown in Figures 9 and 10.

Behrouz Raei *, Davood Abbaspour, Mohammad Abdollahi

36

World Applied Programming Vol(5), No (2), February, 2015.

Figure 9: Results of pipeline sizing with 6 inch diameter (Design)

Figure 10: Results of pipeline sizing with 4 inch diameter (Design)

According to the results shown in Figures 9 and 10, both of 4 and 6 inch diameter pipelines are suitable for new line. However, 6 inch diameter
pipeline is more appropriate in terms of creating less pressure drop. The results of the calculations for the current operating conditions are shown in
Figures 11 and 12 for both 4 and 6 inch diameter pipeline.

Figure 12: Results of sizing pipeline with 4 inch diameter

(operational)

Figure 11: Results of sizing pipeline with 6 inch diameter (operational)

4.3. Reduction of design pressure at D4005

For LPG recovery in the D7003 operating pressure of D4005 must be reduced. Therefore, in this paper, the lowest pressure that cause worth case
studied so according to Figure 10, it was assumed that the pressure is reduced to 7 barg.
First, process based on the design conditions of D4005 simulated then two flows with the specifications given in Table 2 defined and after mixing of
two streams, sent into a flash drum as D4005.
Gas and liquid phase flows output of D4005 based on simulation and assessed minimum design pressure (7 barg) are shown in Figures 13 and 14.

Figure 13: Purge of D4005 in design conditions and 11 barg

Figure 14: Purge of D4005 in new condition and 7 barg

Simulation repeated for 9 and 8 barg pressure and results shown in Figures 15 and 16.

37

LPG Recycling Process Design in Paraxylene Production Unit

World Applied Programming Vol(5), No (2), February, 2015.

Figure 15: Purge of D4005 in new condition and 8 barg

Figure 16: Purge of D4005 in new condition and 9 barg

The mass difference between the compounds in purge gas flow of D4005 based on design conditions at different pressures are shown in Table 3.

Table 3: mass flow rate increases in Purge gas flow compounds of D4005 due to reducing the pressure

4.4. LPG Recycled in D7003

To calculate the amount of recycled LPG of D7003, 4605 kg / hr of produced FG sent to D4005 and the rest sent to the main path and into the
PIC70110. Results are shown in Figure 17.

Behrouz Raei *, Davood Abbaspour, Mohammad Abdollahi

38

World Applied Programming Vol(5), No (2), February, 2015.

Figure 17: The new LPG recycling system in D7003 at the lowest pressure (7 barg)

3.5. Performance of pumps (P4002A, B)

To evaluate the performance of pumps, first, its characteristic curve was drawn based on the data sheet. Through the curve fitting, the equations of
the characteristic curve obtained by a fourth-degree polynomial that are shown in Figure 18.

Figure 18: Pump characteristic curve and its equation in a fourth-degree polynomial
Output head and pressure of pump is shown in Figure 19.

39

LPG Recycling Process Design in Paraxylene Production Unit

World Applied Programming Vol(5), No (2), February, 2015.

Figure 19: Simulation of pump at Psuction = 8 barg

Simulation results of pump at inlet pressure 7barg are shown in Figure 20.

Figure 20: Simulation of pump at Psuction = 7barg

5.

Conclusion

The following results are concluded:

1.
2.

3.
4.

In terms of operation and the process, not problem had seen in normal operating conditions and changes in reduction of D4005 pressure in
normal operating conditions are accepted.
Total amount of FG decreases is at least 2 ton / hr but the amount of LPG production at least 2 ton / hr will increase. Assuming that 4 ton /
hr FG rises and only about 1 ton / hr LPG product added that annual benefit will approximately $ 3600000.
FG price = 4 ton/hr 7920 hr/yr 10$/ton = 316800 $/yr
FG price = 1 ton/hr 7920 hr/yr 500$/ton = 3960000 $/yr
D7003 LPG Recovery Income = 3960000 - 316800 = 3643200 $/yr
Changes do not cause any problem in normal operating conditions and only flow pass through PIC70110 and thus the FG output will be
reduced.
Use 6 inch pipe instead of 4 inch pipe is recommended because the project income is very high and the price difference between 4 and 6
inch pipe is less. In addition, the pressure drop in 6 inch line is less than 4 inch and pressure of D4005 remains upper that LPG recovery in
D7003 is increased.

Acknowledgements
This paper financed by the research department of Islamic Azad University, Mahshahr branch, Iran on research project with title design of LPG
recovery process in orthoxaylene unit

Behrouz Raei *, Davood Abbaspour, Mohammad Abdollahi

40

World Applied Programming Vol(5), No (2), February, 2015.

References
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]

The outlook for energy: A view to 2030. www.exxonmobil.com.

Lin W, Zhang Na, Gu A. LNG (liquefied natural gas): a necessary part of Chinas future energy infrastructure. Energy 2010.
Parik J, Dutta BCR, Singh C, Singh V. Natural gas requirement by fertilizer sector in India. Energy 2009.
Astbury GR. A review of the properties and hazardous of some alternative fuels. Proc Safety Environ Protect 2008.
LNG: An eco-friendly cryogenic fuel for sustainable development, Satish Kumar , Hyouk-Tae Kwon , Kwang-Ho Choi , Wonsub Lim , Jae Hyun Cho ,
KyungjaeTak ,Il Moon, Applied Energy, 2011.
Chamberlain GA. Management of large LNG hazardous, 23rd World gas conference, Amsterdam; 2006.
Shukri T. LNG technology selection. HydroEng2004.http://www.fwc.com/ publications/tech_papers/files/TariqLNG.pdf.
M. Hasan, I. Karimi, H. Alfadala, Optimizing Compressor Operations in an LNG, Plant, in: Proceedings of the 1st Annual Gas Processing Symposium, 2009.
Optimization of propane pre-cooled mixed refrigerant LNG plant, Abdullah Alabdulkarem, Amir Mortazavi, Yunho Hwang, Reinhard Radermacher, Peter
Rogers, Applied Thermal Engineering, 2011.
Active constraint regions for a natural gas liquefaction process, Magnus G. Jacobsen, Sigurd Skogestad, Journal of Natural Gas Science and Engineering, 2013.
Liquefied Petroleum Gases, A.F, Williams & W.L.Lom, second Revised Edition, Ellis HORWOOD publishing, 1982.
Encyclopedia of chemical Technology; Kirk-othmer, Volume 14, 1981.
Aspen Technology, Inc. Aspen HYSYS help
Document center of Bue Ali Sina Petrochemical Company