Process Simulation Of A Back-up Condensate Stabilization Unit

Process Simulation of a Back-up Condensate Stabilization UnitbyIlmi Bin Ilias11943Dissertation submitted in partial fulfillment ofthe requirements for theBachelor of Engineering (Hons)(Chemical Engineering)SEPTEMBER 2012Universiti Teknologi PETRONASBandar Seri Iskandar31750 TronohPerak Darul Ridzuan

CERTIFICATION OF APPROVALProcess Simulation of a Back-upCondensate Stabilization UnitByIlmi Bin IliasDissertation submitted in partial fulfillment ofthe requirements for theBachelor of Engineering (Hons)(Chemical Engineering)Approved by,(DR Nejat Rahmanian)UNIVERSITI TEKNOLOGI PETRONASTRONOH, PERAKSEPTEMBER 2012i

CERTIFICATION OF ORIGINALITYThis is to certify that I am responsible for the work submitted in this project, that theoriginal work is my own except as specified in the references and acknowledgements,and that the original work contained herein have not been undertaken or done byunspecified sources or persons.ILMI BIN ILIASii

ABSTRACTHydrocarbon condensate recovered from natural gas may be shipped without furtherprocessing but is stabilized often for blending into the crude oil stream and thereby soldas crude oil. In the case of raw condensate, there are no particular specifications for theproduct other than the process requirements. The process of increasing the amount ofintermediates (C3 to C5) and heavy (C 6) components in the condensate is called“condensate stabilization”. The purpose of this work aims to investigate Reid VaporPressures (RVP) values in a back-up condensate stabilization unit with a given feed ofcondensate and obtaining the best actual operating parameter for each of equipment. Onthe basis specified target for stabilized in this unit, two properties of product shouldstabilize before storing in storage tanks and export which for RVP of maximum 10 psiafor summer season and 12 psia for winter season. Based on the research, it is foundsome techniques of condensate stabilization which are flash vaporization andfractionation. The separation of the feed is using flash vaporization in back-up unitwhich does not have any distillation column and just uses heating and flashing processesas we want to have simple process in case of plant shut down. In back-up CSU, salt andsulfur content are not affect the process as there are no any distillation in column and itoperate only for shut-down plant as well as not a continuous process. Results show thatCSU’s RVP and sulfur content is 7.932 psai and 2408.52 ppm which is the optimumcondition for the process.iii

ACKNOWLEDGEMENTSA tremendous amount of cooperation accompanied the completion of this Final YearProject (FYP), and the author is extremely grateful to the many dedicated peopleespecially Chemical Engineering Department of University Teknologi PETRONAS(UTP) who had contributed their time, talents and resources for the project.Special acknowledgment to all persons and parties who has given the author a lot of helpand contribution throughout the project, specifically to:1. FYP Supervisor: Dr Nejat RahmanianHe had given the author a whole lot of opportunity, guide, advice and also spent hisprecious time to ensure the author is always on the right track to complete the project aswell as capacity to learn and experience simultaneously. The author deeply appreciatesand grateful for the efforts and contributions during this whole time.2. Chemical Engineering Department Lecturers of UTPThe department had supported the author well not only during the course of the project,but throughout his undergraduate period. Solid basic knowledge from the start had madethe project possible. The department also had direct influence on the project as thementor, evaluator and examiner. The insightful idea and comment from them hadchanged the author view in several aspect of the project and eventually improve andexpand the project potential. The author sincerely thanks the department for beingsupportive and helpful.3. Industry PractitionerThe author recognizes the contribution of industry practitioner especially in allowing theauthor to use several data to ensure the project is very relevant to industrial work.The author recognizes and appreciates by the opportunity and chance experiencedthroughout the project. It had certainly developed the author a lot, probably more thaninitial target. The author also thanks to all of personnel who had been involved directlyor indirectly with him throughout completing the FYP project.iv

TABLE OF .11.1.Project Background.11.2.Problem Statements .11.3.Objectives.21.4.Scope of Study.21.5.Relevancy of Project .31.6.Feasibility of Project .3LITERATURE REVIEW.42.1.Natural Gas Processing.42.2.Condensate Stabilization.6.ACKNOWLEDGEMENTSCHAPTER 1:CHAPTER 2:CHAPTER 3:2.2.1. Flash Vaporization.62.2.2. Fractionation .72.33-Phase Separator.92.4Impact of Salt and Water on Back-up CSU .2.5Impact of Sulfur Concentration on10Final Product .132.6Flare System .142.7Malaysian Hydrocarbon Condensate.16METHODOLOGY/PROJECT WORK.183.1.Project Work3.1.1Overview3.1.2.18.18Plant Simulation.193.1.3Mapping the Result.203.2Methodology .213.2.1Project Methodology .21.

CHAPTER 4:3.2.2Research Methodology.223.2.3Project Simulation.223.2.4Project Design .233.4Gantt Chart.26RESULTS AND DISCUSSIONS.294.1Feed for the Process .284.2Process Description.294.3Comparison of Actual Plant Data, Pro II.Software and HYSYS Software ofCondensate Composition of Final Productat Normal ConditionCHAPTER 5:.304.4Adjusting Operating Parameter.344.4.1Effect of Steam Temperature.354.4.2Effect of Steam Pressure.374.4.3Effect of Feed Flow Rate.394.4.4Effect of Feed Temperature .414.4.5Effect of Feed Pressure.43.CONCLUSION AND RECOMMENDATION 455.1Conclusion5.2.45Recommendation.46REFERENCES .47APPENDICES.49.

LIST OF TABLESTable 1: Advantage and Disadvantage of Type 3-Phase Separator9Table 2: Product Yield of Bintulu Condensate (Based on Total Boiling PointCut points)16Table 3: Condensate Specification of PPM17Table 4: Gantt chart FYP I26Table 5: Gantt chart FYP II27Table 6: Total Properties of Feed28Table 7: Total Properties in Vapor Phase of Feed29Table 8: Total Properties in Liquid Phase of Feed29Table 9: Feed Composition49Table 10: Environmental Quality (Clean Air Regulation) 197850

LIST OF FIGUREFigure 1: Flow Diagram of Condensate Stabilization5Figure 2: Flash Vaporization Method7Figure 3: Fractionation Method8Figure 4: Salt deposits in the de-ethanizer reboiler top tube sheet before cleaning 11Figure 5: Salt deposits in the de-ethanizer reboiler top tube sheet after cleaning11Figure 6: Deposits collected from reboiler tubes at Middle East Plant11Figure 7 : Desalter13Figure 8: New Technology of Desalter13Figure 9: Process Flow of Flaring System15Figure 10: Detailed Drawing of Flare Tip15Figure 11: HYSYS Simulation Model19Figure 12: Process Parameter Input and Result Mapping20Figure 13: Project Activities Flow21Figure 14: HYSYS fluid package window23Figure 15: Components Selection Window23Figure 16: 3-Phase Separator Data Input Window24Figure 17: Heat Exchanger Data Input Window24Figure 18: Heater Data Input Window25Figure 19: Simple Solid Filter Data Input Window

as crude oil. In the case of raw condensate, there are no particular specifications for the product other than the process requirements. The process of increasing the amount of intermediates (C3 to C5) and heavy (C 6) components in the condensate is called “condensate stabilization”. The purpose of this work aims to investigate Reid Vapor