Computer-Aided Process Design Project

Development of a Saturated Gas Plant

Dr. Stephen Dufreche
Spring 2015

Contents
1

Project Description
1.1 Project Approach . . . . . . . . . .
1.2 Design Basis . . . . . . . . . . . .
1.3 Design Considerations . . . . . . .
1.4 Battery Limit Conditions . . . . . .
1.5 Electrical Data . . . . . . . . . . .
1.6 Site Data . . . . . . . . . . . . . . .
1.7 Utility Costs . . . . . . . . . . . . .
1.8 Miscellaneous Design Requirements
1.9 Economic Guidelines . . . . . . . .

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Written Report Requirements

2.1 Submission Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Section List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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List of Tables
1
2
3
4
5
6
7
8

Product Sale Prices . . . . . . . .

Product Specifications . . . . . .
Feed Specifications . . . . . . . .
Naphtha and Diesel Definitionsa .
Utilities Battery Limits Conditions
Motor Electrical Data . . . . . . .
Environmental Site Data . . . . .
Utility Cost Schedule . . . . . . .

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Based on original design by FLUOR

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7

UL Lafayette Computer-Aided Process Design

Development of a Saturated Gas Plant

Project Description

A Gulf Coast Oil Company has several gas and liquid streams that contain potentially valuable
light ends. They plan to form a joint venture with your company for processing these streams. The
terms of the joint venture are simple.
The refinery will provide the feed streams as defined.
The refinery will provide all utilities and optional feed streams at the defined tolling costs.
The refinery will purchase all fuel gas produced from the facility. Other products will be
shipped via existing pipelines or through the refinery truck loading terminal.
Your company will cover all capital and operating costs.
The open book profits will be split 50/50 between your company and the refinery.
The goal of the project team is to determine the optimum economic products that can be produced
form these streams, and design the unit that will produce these product streams. All product
specifications as presented in the design basis must be met.

1.1

Project Approach

The Project Team will approach the project in two phases.

Phase 1 A preliminary Process Flow Diagram, heat and material balance, major equipment sizing, and preliminary cost estimate will be prepared. No commercial process simulator programs
may be used for Phase 1, but spreadsheets and other computer software may be used.
Phase 2 The preliminary process scheme developed in Phase 1 will be optimized so that the
design reflects the economic optimum unit. A process simulator can be used in this Phase. The
final Process Flow Diagrams, heat and material balance, equipment sizing, utility summary, cost
estimate, and operating costs will be prepared.

1.2

Design Basis

The refinery will operate under the assumption that only products listed in Table 1 will have a viable
market. This restricts the design of your plant to only producing these streams. Any additional
waste streams may be sold back to the refinery as fuel gas with its price set by the lower heating
value. You are not required to produce all of the product streams. However, all streams must meet
the requirements listed in Table 2 to be considered for sale.
In addition to the feed streams listed in Table 3, you have the option of using up to 30,000
BPD of lean oil (diesel) from the refinery. The lean oil can be used to recover additional light
ends/naphtha within your process scheme and returned to the refinery crude unit. There is a refinery
processing fee of $5/bbl of recovered material for this service. Assume that any recovered material
comes back to your unit as additional material in the crude off gas.
2

UL Lafayette Computer-Aided Process Design

Development of a Saturated Gas Plant

Table 1: Product Sale Prices

Product

Bulk Pricing

Propane
iso-Butane
Commercial Butane
Naphtha
Fuel Gas

42.50
55.00
47.00
80.00
7.00

$/bbl
$/bbl
$/bbl
$/bbl
$/MMBTU

Table 2: Product Specifications

Product

Max P at 100 F
[psia]

Propane (HD-5)
208
iso-Butane
Commercial Butane 70
Naphtha
10
Fuel Gas
-

C3

C4

2.0
-

1.0
-

Max vol%
C4 nC+4
2.5
-

2.0
-

C+5

Max H2 S
[ppm]

- - 4
2.0 4
- - 50

The naphtha content of the rich oil returned to the refinery must be at least as high as in the
lean oil from the refinery. Lean oil has a temperature of 100 F, 75 psig, and a maximum flow rate
of 20,000 BPD. The stream contains 10% naphtha (C6 -350 F) and 90% diesel (350 F-650 F).
Specifications for these compounds can be found in Table 4.

1.3

Design Considerations

The following design considerations should be adhered to in determining the unit configuration
and specifying equipment:
All compressors must have a knockout drum preceding the compressor inlet.
All hydrocarbon pumps must be fed from a vessel.
Fractionation towers should be designed for a maximum of 80% of flood and use conventional trays.

1.4

Battery Limit Conditions

All process products should leave the unit at 60 psig and 100 F, except for propane, which will be
300 psig and 100 F. The required battery limits conditions for utilities are presented in Table 5.
Design conditions in this table refer to mechanical requirements. The operating conditions should
be used for actual process conditions.
Lean amine is available from the refinery for $4.50/1000 gal while the rich amine is returned
back to the refinery. The amine is 40 wt% MDEA, with a lean amine acid loading of 0.001-0.01
mol/mol and a maximum rich amine acid loading of 0.45 mol/mol. The refinery has agreed to
process any sour water generated by your facility at a charge of $3.80/1000 gal.
3

Vapor
105
80
7.93
0.26
93.08
106.95
108.63
104.90
153.68
90.09
73.49
46.16
18.99
10.53

Component Flow [lbmol/hr]

Water
Ammonia
H2 S
Hydrogen
Methane
Ethane
Propane
iso-Butane
n-Butane
iso-Pentane
n-Pentane
Heavy Naphtha
1.31
0.15
38.36
0.95
6.30
30.08
130.02
138.4
132.32
167.77
78.87
165.18

Liquid
105
175
1.30
0.03
6.84
229.73
53.79
22.81
9.61
3.40
2.30
1.14
0.34
0.93

Vapor
127
250

Hydrotreater Streams
Off-Gas Wild Naphtha LP Separator

Phase
Temperature [ F
Pressure [psig]

Product

Table 3: Feed Specifications

2.62
0.03
5.81
0.04
0.22
15.38
125.45
76.71
230.97
160.73
540.37
2758.20

Liquid
105
100

19.56
0.02
2.37
6.98
8.36
41.31
164.17
34.43
86.33
24.62
39.05
26.07

Vapor
105
8

Crude Streams
Wild Naphtha Off-Gas

UL Lafayette Computer-Aided Process Design

Development of a Saturated Gas Plant

UL Lafayette Computer-Aided Process Design

Development of a Saturated Gas Plant

Table 4: Naphtha and Diesel Definitionsa

Naphtha [ F]

Diesel [ F]

0
10
30
50
70
90
100

149
155
163
169
176
272
356

356
421
486
533
566
616
666

Standard Density [ API]

63.7

39.2

Liquid Volume [%]

a)

Distillation Method D-86

Table 5: Utilities Battery Limits Conditions

Utility Service

Operating
psig
[ F]

High Pressure Steam

Medium Pressure Steam
Low Pressure Steam
Low Pressure Condensate
High Pressure BFW
Cooling Water Supply
Cooling Water Return
Nitrogen
Natural Gas
Lean Amine
Rich Amine (return)
Instrument Air
Plant Air
Domestic/Potable Water
Sour Water (return)

630
441
165
25
980
65
40
350
120
250
50
90
100
140
50

Design
psig [ F]

725
675
627
500
337
190
265
30
250
1100
90
150
120 (max) 150
90
610
100
175
140
300
160 (max) 170
90
135
90
135
95
150
120 (max) 100

750
665
425
275
280
150
150
100
150
165
200
150
110
120
150

UL Lafayette Computer-Aided Process Design

Development of a Saturated Gas Plant

Table 6: Motor Electrical Data

Power

Voltage

Phase/Hertz

1
2

115
460
4000
13200

1/60
3/60
3/60
3/60

HP
HP 200
200 HP 5000
HP > 5000
3
4

Table 7: Environmental Site Data

Plant Elevation Above Sea Level

Barometric Pressure
Extreme Maximum
Extreme Minimum
Maximum Design
Minimum Design
Design for Winterization
Temperature for Air-cooler Design
Annual Average Temperature
Design Wet Bulb Temperature
Average Humidity

1.5

[ft]
[psia]
[ F]
[ F]
[ F]
[ F]
[ F]
[ F]
[ F]
[ F]
[%]

38
14.68
110
10
105
20
25
95
68.5
80
70

Electrical Data

The required voltage supply shall be based on the motor size as defined in Table 6.

1.6

Site Data

The unit design shall conform to the most stringent site data shown in Table 7.

1.7

Utility Costs

The utility cost data supplied in Table 8 shall be used for economic evaluations. Note that the
steam and condensate prices apply for either buying from or selling back to the refinery.

1.8

Miscellaneous Design Requirements

Inventory: No onsite storage is required for the primary materials, but if additional materials are
utilized in the process, sufficient storage should be provided to cater for the expected needs of 30
days of operation.
Materials of Construction (MOC) Determine acceptable MOC for this process, and clearly
state what MOC you are using in your cost basis.

UL Lafayette Computer-Aided Process Design

Development of a Saturated Gas Plant

Table 8: Utility Cost Schedule

High Pressure Steam

Medium Pressure Steam
Low Pressure Steam
Low Pressure Condensate
High Pressure BFW
Cooling Water
Electricity
Nitrogen
Natural Gas (100% methane)
a
Cost referred to LHV

$8.00
$6.00
$4.50
$0.51
$0.57
$0.08
$0.08
$1.00
$8.00

/
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/
/
/
/
/
/

1000 lb
1000 lb
1000 lb
1000 lb
1000 lb
1000 gal
kW-hr
MSCF
MMBTUa

Equipment Ratings Maximum allowable working pressure (MAWP) for pressure vessels must
be specified, including overpressure protection systems.
On-Stream Factor In order to achieve the on-stream factor, all rotating equipment required for
unit operation except for centrifugal compressors will require sparing.
Process Structure Document the overall size and cost of the process structure needed to safely
support the process, and list any applicable assumptions used (e.g., cost per square meter of structure area).
Safety and Environmental Regulations for the U.S. and State of Louisiana must be followed.
Wastes are to be handled in a manner that meets all State of Louisiana and Federal regulations.
Hydrocarbon emissions to both air and water will be closely monitored and reported to the proper
authorities after normal, day-to-day operation is attained after start-up.
HeatX Minimum Approach The Tmin is 15 F when the temperatures are in normal ranges
and 5 F when refrigerants are used.
Site Location Plant location is on the Louisiana gulf coast (barge traffic is available).

UL Lafayette Computer-Aided Process Design

1.9

Development of a Saturated Gas Plant

Economic Guidelines

Purchased Equipment Cost may be estimated by methods in the course text. Cost factors are
to be based on Louisiana Gulf Coast delivery.
Fuel, steam, cooling water, and electricity are purchased for the plant.
Capital Estimate may be made using methods from the course text.
Working Capital and other Economic Factors may be estimated using the cost factors given
in the course text.
Net present worth should be used to evaluate alternatives.
Depreciation should be based on 10 years straight line for In-Site Boundary Limits (ISBL)
and 15 years straight line for off-sites.
Off-sites capital cost are assumed to be 30% of ISBL.
Discounted Cash Flow Analysis should assume:
1. 4Q 2012 startup
2. Ten year project life
3. Tax rates of 34% Federal and 6% State.
Interest rate on capital is 9%.
Maintenance, insurance, and plant overheads are estimated to be 4.0% of fixed investment.
Use a contingency of 20%.

2
2.1

Written Report Requirements

Submission Guidelines

A written report is required as the final deliverable in CHEE408. The report will be submitted in
both paper and electronic formats. A PDF of the entire document, including appendixes, references, and ASPEN printouts must be uploaded to Moodle on April 27th . A 30-minute presentation
will also be given by each group an May 1st . A panel of judges from industry and academia will
be present to grade each group on their presentation style and technical content.
The written report must be bound with a two-piece report cover having a minimum capacity
of 3 inches. Pages larger than standard letter size such as the 11"x17" PFD drawings should be
fastened in a landscape orientation and folded to fit within the cover. Fonts should be no smaller
than 12 pt double-spaced with the exception of figures and tables which may use 10 pt. Margins
for single-sided documents should be 1" on top and bottom, 1.5" on the left, and 0.5" on the right.
Documents which are printed on both sides of the paper should be 1" on top and bottom, 1.5" on
the spine edge, and 0.5" on the opposite side.
8

UL Lafayette Computer-Aided Process Design

2.2

Development of a Saturated Gas Plant

Section List

The following is a list of required sections in the final written report. Follow the order listed below
when assembling the document.
1. Letter of Transmittal
To include plant capacity, construction cost, materials cost, yearly profit, and RoI
2. Title Page
3. Table of Contents
4. Abstract
5. Introduction and Customer Requirements
6. Conceptual Design
(a) Preliminary Process Synthesis
A listing of previous attempts at flow sheet synthesis. This includes the various iterations of design from throughout the semester. Describe why a design was tried and why
it was discarded.
(b) Assembly of Data Values
A listing of primary physical property information as well as costs and specifications
of products.
7. Feasibility and Development
(a) PFD and Material Balances
A PFD in Dia or another computer-aided design package. Stream tables should be
included with pressure, temperature, phase, and mass flow rate of each compound.
(b) Process Description
This section walks a reader through the flow sheet. Detailed information is covered
in the section on Equipment Design, but should be referenced here. Alternatives from
previously-discarded designs can also be mentioned here with the reason for omission.
(c) Energy Balance and Utility Requirement
Each equipment which uses a heating, cooling, electrical, or other utility should be
listed here. It should include the magnitude of energy required and how the need was
met (type of utility, how much, etc.).
(d) Equipment List and Unit Descriptions
Every piece of equipment on the PFD is listed here. The methods of design and calculation should be listed for each one along with basis for calculation, difficulties encountered, limitations in design, etc.
(e) Specification Sheets
In the manner of Figure 26.1 of your textbook, one per page
(f) Equipment Cost Summary
9

UL Lafayette Computer-Aided Process Design

Development of a Saturated Gas Plant

(g) Fixed-Capital Investment Summary

(h) Operating Cost and Economic Analysis
8. Safety and Environmental
(a) HAZOP Analysis
Standard HAZOP analysis on your final flowsheet
(b) Environmental Regulations and Permitting
A list of regulations applicable to the given plant site under which your design may be
covered. Detail methods for remaining in compliance with the listed regulations.
9. Conclusions and Recommendations
10. Acknowledgments
11. Bibliography
A: Raw calculations for M&E Balances, Sizing, and Costing
B: Computer programs developed during project (Excel, Polymath, MATLAB)
Excel sheets with formulas displayed, Polymath or MATLAB code, etc.
C: Complete Aspen report generated from final design
The full report option in Aspen can be used to generate this appendix. Make sure that the
text is formatted in monospace font and easily readable when printed.
D: Extra printed material not included in the other sections

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