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RESUMEN
Ul fractionation plant is located on Intercomunal Avenue, Sector La Vaca,
Simn Bolvar Municipality in Zulia State. Its function is to split the NGL coming
from Tia Juana 2 and 3 plants in propane, butanes mixture (n-butane and ibutane) and natural gasoline (C5 +).
With the commissioning of the Occidente Cryogenic Complex (OCC), the Ul
Fractionation Plant (GLP-2) will receive from the extraction train of this complex,
NGL at different conditions of composition (Lean, Average and Rich NGL),
which generates the necessity of defining the highest NGL feed flow rate that
plant can handle.
That is why, it is required a hydraulic capacity study of each column in order to
avoid operational problems such as flooding or weeping, and thereby ensure
optimal operation of fractionation columns, meet quality product requirements
demanded by the client and ensure the operational availability of fractionation
towers.
To achieve this objective, there were applied several assessments or
sensitivities at different feed rates to GLP-2 by using Aspen Hysys 2006
process simulator to find the maximum power of fractionation columns, under
different scenarios of OCC feed.
From sensitivities results, it was obtained that the maximum feed flow rates for
each of the evaluated scenarios for GLP-2 towers (under different OCC feeding
scenarios) are 27.5 MBPD of Lean NGL, 42.8 MBPD of Average NGL and
34.55 MBPD of Rich NGL, without occurring hydraulic problems in fractionating
columns.
INTRODUCCION
Ul Fractionation Plant is comprised by plants GLP-1, 2 and 3. It is currently
operating the GLP-2 plant with a capacity by design of 46.0 MBPD of NGL from
Tia Juana 2 and 3 plants, producing: propane, butanes mixture and natural
gasoline. At present, GLP-2 processes about 16.0 MBPD as average.
PROBLEM STATEMENT
On April 29, 1958, Ul Fractionation Plant started operations with Creole
Petroleum Corporation Company. After the nationalization period in 1975, Ul
became as part of the assets of the Venezuelan oil industry and began its
operations with the company LAGOVEN S.A. After the unification of the
Venezuelan oil subsidiary in 1997, the Ul Fractionation Plant is transferred to
PDVSA Gas, as part of the Western Gas Processing Management.
With the commissioning of Western Cryogenic Complex, the extraction process
will have the capacity to process 950 MMSCFD of gas which will produce 58.88
MBPD of natural gas liquids (Average NGL).
The OCC inlet gas to be processed (extraction process), comes from various
production blocks or zones in the region, resulting in different compositions,
which are mentioned hereunder:
Lean Gas (2.2 GPM).
OBJETIVES
MAIN OBJECTIVE
To evaluate the process hydraulic capacity of U Fractionation Plant under the
scenario of future feeding from Occidente Cryogenic Complex, in order to meet
the quality requirements of fractionated products and ensure operational
continuity of fractionation towers with the OCC commissioning.
SPECIFIC OBJECTIVES
To find the maximum flow feed rate to GLP-2 fractionation towers under
different OCC feeding scenarios.
The considered NGL feed flows (minimum and maximum) for GLP-2
fractionation towers hydraulic evaluation were ranged from 10.0 to 42.0
MBPD.
The different NGL compositions (Lean, Average and Rich) from OCC
Extraction Plant used for the sensitivities or hydraulic evaluations are as
follow. (Source: Doc. 8922Y-000-PP-202 Rev. 0, Bases de Diseo
Bloque I y II FEED 98% (OCC Project):
Lean NGL
Average NGL
Rich NGL
(% Molar)
(% Molar)
(% Molar)
Ethane
0.53
0.58
0.59
Propane
52.97
58.37
58.63
i-Butane
10.16
9.00
9.77
n-Butane
17.36
16.18
17.97
i-Pentane
5.69
5.40
5.18
n-Pentane
5.49
5.47
5.06
n-Hexane
4.49
3.29
2.17
n-Heptane
2.70
1.23
0.47
n-Octane
0.62
0.28
0.06
n-Nonane
0.0
0.16
0.04
n-Decane
0.0
0.03
-0.06
n-Undecane
0.0
0.0
0.06
Components
% Molar
Methane
Max. 0.5
Ethane
Max. 5.1
Propane
Min. 90.0
i-Butane
Max. 1.82
n-Butane
Max. 0.28
Table 2: Maximum and minimum quality values for Depropanizer Column Top
% Molar
Propane
Mx. 2.5
i-Pentane
Mx. 1.4
n-Pentane
Mx. 0.35
Table 3: Maximum and minimum quality values for Debutanizer Column Top
The natural gasoline must comply with a maximum Reid Vapor Pressure
(RVP) of 15.0 psia.
EXPANSION
PROJECT
ULE
FRACTIONATION
PLANT
The final dry tray pressure drop will generally fall in the range of 1 to 4 in.
(25 to 100 mm) of hot liquid, according to PDVSA Design Manual,
PDVSA MDP-04-CF-12 (Valve Tray Type).
In the next chart it can see the recommended residence time in the
downcomers, depending on the hydrocarbon molecular weight. (Applied
Process Design for Chemical and Petrochemical Plants, E.
Ludwing).
METHODOLOGY
This research was done according with the following steps:
S T AR T
S IMUL AT IO N
V AL ID AT IO N
- NGL FEED
- PROCESS DATA
- HYSYS SIMULATOR
S IMUL AT IO NO F C C O
O P E R AT IO NAL C O ND IT IO NS
L O WE R ING NG L
F L O WF E E D
R AT E
- PRESSURE DROP
- FLOODING FACTOR %
- DOWNCOMER VELOCITY
- RESIDENCE TIME
NO
C O NV E R G E ?
NO
E ND
YES
E ND
YES
- QUALITY PLAN
C O MP L Y ?
MAX IMUMF E E D
F L O WR AT E
10
1,8500
Lean NGL
Average NGL
1,8000
Rich NGL
1,7500
1,7000
1,6500
1,6000
1,5500
1,5000
0
10
15
20
25
30
35
40
Tray Number
In Figure 1, the pressure drop in the internal section of the depropanizer tower
(D8-504) is within the PDVSA established range in its standard MDP-04-CF-12
(valve trays type), from 1.0 to 4.0 inches of hot liquid. The range of pressure
drops varies from 1.5 to 1.83 inches.
For the debutanizer tower D8-506, Figure 2 shows the variation of dry tray
pressure drop for 42.0 MBPD of Lean, Average and Rich NGL.
7,0000
Lean NGL
6,0000
Average NGL
Rich NGL
5,0000
4,0000
3,0000
2,0000
1,0000
0,0000
0
10
15
20
25
30
Tray Number
11
For the debutanizer tower (D8-506), the pressure drop along the internal
section, Figure 2 shows that only the scenario with Average NGL feed is within
the limits described in the PDVSA standard, these values are in a range of 1.3
to 3.0 inches.
While the other two feeding schemes (Lean and Rich NGL) exceed the values
of pressure drop in trays sections from the top and bottom in the column, in the
case of Lean NGL for example, only the first two internal (trays) are among the
values described by the standard (3.71 - 3.94 inches of liquid) and the middle
part of trays below the feed tray (tray 19).
The top column internal values range from 4.0 to 6.0 inches of liquid. The Rich
NGL ranges between 2.5 and 4.5 inches of liquid, so it neither complies with the
PDVSA standard MDP-04-CF-12 (valve tray type).
Flooding Factor.
Figures 3 and 4 show the flooding factors of GLP-2 fractionation columns for the
different scenarios evaluated in this study.
70,00
65,00
60,00
Flooding Factor %
55,00
50,00
Lean NGL
45,00
Average NGL
Rich NGL
40,00
35,00
0
10
15
20
25
30
35
40
Tray Number
12
120,00
110,00
100,00
90,00
Flooding Factor %
80,00
70,00
60,00
Lean NGL
50,00
40,00
30,00
Average NGL
Rich NGL
0
10
15
20
25
30
On Figure 3 it is shown that the flooding factor of the depropanizer column for
the evaluated scenarios has an efficient behavior, according to the standards
PDVSA MDP-04-CF-14 (Tray Efficiency) and PDVSA MDP-04-CF-12 (Valve
Tray), which states that a flooding factor range between 40% and 90% is an
efficient behavior for a column. The reported values are between 43% and 63%
for Rich, Lean and Average NGL.
Regarding the debutanizer columns, Figure 4 shows that only the Average NGL
scenario complies with the standards having a range of 53% to 73% of flooding,
the rest of the feed scenarios show a flooding factor that exceeds the standard
all along column internals. For the Rich NGL scenario the section of the column
below the feed tray has flooding factor ranging from 80% to 74%, whereas the
section above ranges from 90% to 82%. For the Lean NGL case, the whole
column is flooded 95% to 113%.
Downcomer velocity.
Figures 5 and 6 show the downcomer velocities for the GLP-2 fractionation
columns for the different composition scenarios evaluated in this study.
13
0,8000
Lean NGL
Average NGL
0,7000
Rich NGL
0,6000
0,5000
0,4000
0,3000
0,2000
10
15
20
25
30
35
40
Tray Number
0,6500
0,6000
0,5500
0,5000
0,4500
0,4000
0,3500
Lean NGL
0,3000
Average NGL
Rich NGL
0,2500
0,2000
0
10
15
20
25
30
In figure 5, it can be seen that downcomer velocity ranges from 0.21 to 0.67 ft/s
which indicates that velocities in the bottom section would be exceeded in the
bottom section of the depropanizer (D8-504) for the three feed scenarios of the
CCO.
downcomer entrance velocity should be limited to 0.15 m/s (0.5 ft/s) maximum.
The top section of the column complies with the standard (0.41 ft/s).
14
Average NGL
3,0000
Rich NGL
2,5000
2,0000
1,5000
1,0000
0
10
15
20
25
30
35
40
Tray Number
2,7000
Lean NGL
2,5000
Average NGL
Rich NGL
2,3000
2,1000
1,9000
1,7000
0
10
15
20
25
30
Tray Number
15
16
1,8500
1,8000
1,7500
1,7000
1,6500
1,6000
1,5500
1,5000
1,4500
1,4000
10
15
20
25
30
35
40
Tray Number
On Figure 9 can be seen the pressure drop on the internals of the depropanizer
column (D8-504) for different flow rates and feed compositions, each of the
scenarios is under the ranges established on the standard PDVSA MDP-04-CF12
(Valve Trays).
Average NGL scenario since is the one with the highest feed rate. In this case,
the pressure drop is 1.68 to 1.8 in.
3,0000
2,5000
1,5000
1,0000
0
10
15
20
25
30
Tray Number
17
On Figure 10 are shown the debutanizer (D8-506) pressure drop for each of the
flow rate and composition scenarios, the highest pressure drops on the internals
of the debutanizer column were found for the Rich NGL case since it has the
greatest amount heavy ends on the feed stream. The range of the pressure
drops found was 1.79 to 3.02 in
Flooding Factor.
Figures 11 and 12 show the flooding factors of the GLP-2 columns for the
different feed scenarios evaluated in the study.
65,00
60,00
Flooding Factor
55,00
50,00
45,00
40,00
35,00
30,00
25,00
0
10
15
20
25
30
35
40
Tray Number
75,00
65,00
60,00
55,00
50,00
0
10
15
20
25
30
18
Figure 11 shows the Flooding Factors for the evaluated scenarios for the
depropanizer column. The highest flooding factor is found for the Average NGL
composition in a range of 57 to 62%, in this case the behavior is considered
efficient, according to the standards PDVSA MDP-04-CF-14 (Tray Efficiency)
and PDVSA MDP-04-CF-12 (Valve Trays), which indicates that a range form 40
to 90% of flooding factors is considered efficient for a column.
While the Lean NGL feed case shows an inefficient behavior with a range from
35.7 to 39.4% in the bottom sections and part of the top sections of the column,
due to the low contents of heavy ends in the column feed. Although other
authors recommend an efficiency range for a fractionation column between 10
to 90% (A Working Guide to Process Equipment, N. Lieberman), the
authors of this work consider that low efficiency during operation of a
fractionation column could lead to weeping and flooding.
On Figure 12, it can be seen that the scenario that presents the highest flooding
factor is the Rich NGL case, and thus having the highest efficiency value, which
were found in the range of 65.9 to 76.2%.
Downcomer Velocity.
Figures 13 and 14 show the estimated downcomer velocities for the GLP2
fractionation columns.
On Figure 13, it can be seen that downcomer velocity for the different evaluated
cases are in a range from 0.65 to 0.24 ft/s for a Average NGL feed, which
indicates that velocity values in the bottom section of the depropanizer column
(D8-504), would exceed the recommended values of the standard PDVSA
MDP-04-CF-12 (Valve Trays) which states a maximum of 0.5 ft/s.
The
19
0,8000
Lean NGL 27,5 MBPD
Average NGL 42,8 MBPD
0,7000
0,6000
0,5000
0,4000
0,3000
0,2000
0,1000
0
10
15
20
25
30
35
40
Tray Number
0,3900
0,3700
0,3500
0,3300
0,3100
Lean NGL 27,5 MBPD
0,2900
0,2700
0,2500
0,2300
0
10
15
20
25
30
20
Residence Time.
Figures 15 and 16 show the residence time for each tray on the evaluated
columns.
5,0000
4,5000
4,0000
Lean NGL 27,5 MBPD
3,5000
2,5000
2,0000
1,5000
1,0000
0
10
15
20
25
30
35
40
Tray Number
2,9000
2,8000
2,7000
2,6000
2,5000
2,4000
2,3000
2,2000
2,1000
2,0000
1,9000
0
10
15
20
25
30
Tray Number
On Figure 15 can be seen that the residence time on the internals of the
depropanizer column for the different evaluated scenarios. The residence time
ranges from 1.4 to 1.7 seconds in the bottom section, while in the top section it
ranges from 4.55 to 4.3 seconds. From the three evaluated scenarios, the
highest residence time values were found for Lean Feed case. On Figure 16, it
Gerencia de Procesamiento de Gas Occidente
21
can be seen that the debutanizer column has residence time oscillating from
bottom to top section 1.9 to 2.8 seconds for the Average NGL Feed case.
Top Product Quality of the Depropanizer Column (D8-504).
On table 4 are presented the product qualities of the column D8-504
(depropanizer) of GLP-2, for each of the cases studied (Lean, Average and
Rich NGL):
ANALYZED STREAMS
Component
Ethane (%
Molar)
Quality Plan
Lean NGL
Average NGL
Rich NGL
Mx. 5.1
0.98
0.77
0.98
Propane
(%Molar)
Min. 90
97.46
97.64
97.44
i-Butane
(%Molar)
Mx. 1.82
1.43
1.43
1.43
n-Butane
(%Molar)
Mx. 0.28
0.13
0.15
Table 4: D8-504 Propane Product Molar Porcentages
0.15
Quality Plan
Lean NGL
Average NGL
Rich NGL
Mx. 2.5
0.34
0.33
0.29
Min. 10
34.34
33.12
32.61
Min. 30
63.28
65.41
65.42
Mx. 1.4
1.9
0.99
1.53
Mx. 0.35
0.15
0.15
Table 5: D8-506 Butane Mixture Molar Percentages
0.15
22
ANALYZED STREAMS
Property
RVP (psia)
Quality Plan
Lean NGL
Average
NGL
Rich NGL
Mx. 15.0
11.72
13.32
14.8
When comparing the maximum and minimum values of the molar percentages
of the contaminant components of the top of the depropanizer (ethane, i-butane
and n-butane) and the debutanizer (propane, i-pentane and n-pentane) columns
of GLP-2 (D8-504 and D8-506) to the values found on the different CCO feed
simulations, the Propane Product Stream (top of D8-504) is within plant design
specifications
Rich NGL), ethane (0.98 0.77 0.98% molar Lean, Average and Rich NGL), ibutane (1.43% molar for the three scenarios) and n-butane (0.13 0.15
0.15% molar Lean, Average and Rich NGL).
Regarding top product quality for the debutanizer column (D8-506), the butane
mixture also complies with plant design specifications, propane (0.34 0.33
0.29% molar Lean, Average and Rich NGL), n-pentane (0.15% for the three
scenarios). It must be noted that i-pentane content in the butane mixture has a
molar concentration of 1.9 0.99 and 1.53%, that complies with quality
specifications of the Lean NGL GLP-2 feed scenario.
23
CONCLUSIONS
For the 42.0 MBPD NGL form the CCO scenario (Lean, Average and Rich),
the depropanizer column (D8-504) complies with recommendations of the
standard PDVSA MDP-04-CF-12 (Valve Trays), regarding tray pressure
drop of 1.0 to 4.0 in of liquid.
Accordingly, for the feed scenario of 42.0 MBPD of OCC NGL, the
debutanizer column (D8-506), the pressure drop along column internals are
only standard allowable values for the Average NGL case, these values
ranged from 1.3 to 3.0 in
It was observed that the flooding factors of the depropanizer column (D8504) for the evaluated scenarios display an efficient behavior according the
standards PDVSA MDP-04-CF-14 (Tray Efficiency) and PDVSA MDP-04CF-12 (Valve Trays), which indicates that a range of 40 to 90% of flooding
for a column is considered efficient column behavior (42.0 MBPD of NGL
fractionation scenario).
For the debutanizer column (D8-506), only the Average NGL scenario
complies with the standards having a flooding factor ranging from 53 to 73%
(42.0 MBPD of NGL fractionation scenario).
Downcomer velocities were found to range from 0.21 to 0.67 ft/s, this
indicates that velocities on the bottom section of the depropanizer column
(D8-504)
for
the
three
feed
scenarios
would
exceed
standards
24
bottom section of the column for the Lean NGL case (42.0 MBPD of NGL
fractionation scenario).
The maximum feed rate to the GLP-2 fractionation columns for the different
CCO feed scenarios without having column hydraulic problems were found
to be 27.5 MBPD for the Lean NGL case, 42.8 MBPD for the Average NGL
case and 34.55 MBPD for the Rich NGL Case.
Pressure drop on the internals of the depropanizer column (D8-504) for the
different feed rates and compositions evaluated comply with the standard
PDVSA MDP-04-CF-12 (Valve Trays). The highest pressure drop range
was found for the Average NGL feed scenario since it has the highest feed
rate. The values found for the pressure drop ranged from 1.68 to 1.8 in.
For the debutanizer column (D8-506), the pressure drop was evaluated for
the different scenarios of flowrate and feed composition and the highest
were found for the Rich NGL case since it has the greates amount of heavyends content on the feed. The found pressure drop ranged from 1.79 to
3.02 in.
For the debutanizer column, D8-506, the highest flooding factors were
found for the Rich NGL case. This case was the one with highest efficiency
on which the flooding factor were found to range from 65.9 to 76.2%.
Gerencia de Procesamiento de Gas Occidente
25
Downcomer velocities for the different cases evaluated ranged from 0.65 to
0.24 ft/s for an Average NGL feed composition; this indicates that
downcomer velocities on the bottom section of the depropanizer column
(D8-504) would exceed recommended values.
For the debutanizer column (D8-506) the downcomer velocities were found
to reach a maximum for the Rich NGL scenario, on which the velocities
ranged from 0.40 to 0.23 ft/s.
The debutanizer column (D8-506) has a residence time oscillating from top
to bottom section 1.9 to 2.8 seconds for the Average LGN feed.
26
REFERENCES