A study report on the recovery of LPG from GAS CONDENSATE.doc

8/11/2019 A study report on the recovery of LPG from GAS CONDENSATE.doc

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A study report on the 246376677.doc

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A study report on the 246376677.doc

PREAMBLE

In the name of ALLAH ,the compassionate the

Merciful Read the name of your lord, who creates

man from the clot of blood, read, your Lord is most

Gracious who teaches you by mean of -Pen,

teaches man -what he does not now!"

A STUDY REPORT ON

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A STUDY REPORT ON

Reco3er4 o& LPG &ro$ t'e GAS CONDENSATE

SESSION *++, - *++

T'i5 "ro6ect i5 7ei%) 587$itte9 to c'e$ic#( e%)i%eeri%) 9e"#rt$e%t!

NFC i%5tit8te o& e%)i%eeri%) #%9 &erti(i:er re5e#rc'! F#i5#(#7#9 i%

t'e "#rti#( &8(;(($e%t o& 7#c'e(or


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DEDICATED

To

M4 ##7(e F#t'er

A symbol of success for me+ Always behae lie a friend hose

mature, aluable .uidance, /inancial assistance, %nabled me to

perceie and pursue Hi.her ideals in life"

M4 #9or#7(e Mot'er

A mine rate of loe, a0ection and indness ho enli.htened me A

learnin. spirit I am learnin. much /rom her leap till now"

1

Brot'er5 Si5ter5


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All of us solemnly acnowled.e that all thans, .ratitude and

obli.ations are only for the almi.htyALLAHwho bestowed

upon the coura.e and nowled.e and enabled us to wor out this

pro2ect report" e o0er our humblest and sincerest words of

thans to !Holy Prophet!HARAT MUHAMMAD ?PBUH@

who is torchof .uidance and nowled.e"

e own no words to pay our most respectful adisors D r . JAVAID

RABBANI KHAN! $irector

NFC_IEFR D r . SHAHID RAA MALIK, Head of department,

department of chemical %n.ineerin. for his deoted, sincere and

ind .uidance throu.h out the pro2ect" He encircled us with the

nowled.e for the hole session" He did not sta..er at hard

times by eepin. our morale up aboe the sy and by

continuously encoura.in."

e also feel hi.hly priile.ed here to hae the honor of our

family to whom a lot more than 2ust thans for there endless

support and encoura.ement" e could not .et this sta.e with out

their help and .uidance"

%specially we hae no words for the special prayers of our

b l d P t


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their perfect .uidance in all respects" All they were the pillars of

coura.e and a constant source of inspiration without whose

cooperation this entire world has been impossible"

A8t'or

5

USMAN ALI RANA

M. ASIF HAYAT MALIK

HASSAN RIA

MUHAMMAD /ASIM

MUHAMMAD UBAIR


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5) Properties of LPG 21

6) Natural Gas condensate 23

7) Composition of natural gas condensate 24

8) Separating the condensate from the raw natural

gas 25

Process

1) Membrane process 28

2) Catalytic hydro cracking process 31

3) Dehydration process 32

4) Catalytic process 32

I.Objective of the catalytic process 32

II.Detailed description 37

III.Synthesis gas production process 41

IV.Industrial applicability 46

Process equipment

1) Gas-gas exchanger 49

I.Introduction 49

II.Conventional gas-gas heat exchanger 49III.Radial floe heat exchanger 50

IV.Plate type heat exchanger 51

V.Hot exchanger 52

VI.Cold exchanger 52

2) Turbo expander 53

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I.Applications 53

a)Extracting hydrocarbon liquids from

natural gas 54

b)Power generation 55

c)Refrigeration system 573) Slug catcher 58

I.Basic operation 59

II.Slugs 61

III.Purpose of slug catcher 62

IV.Slug catcher design 62

4) Molecular sieves 63

I.Types of molecular sieve beds 64II.Regeneration 68

III.Applications 69

5) De-ethanizer 70

6) De-butanizer 74

Plant location

1) Plant location & selection 78

2) Sitting factors 78

3) Environmental consideration 78

4) Labor availability & productivity 785) Living condition 79

6) Raw material availability 79

7) Accessibility to transportation 79

8) Property cost 79

9) Tax 79

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10)Specific plant site consideration 79

11)Conclusion 80

Cost estimation

1)Cost estimation 82

2)Investment & fixed capital investment 82

I.Working capital investment 82

II.Fixed capital investment

III.Direct cost 82

IV.Indirect cost 83

3)Factors effecting investment

& production cost 83

4)Types of capital cost estimate 84

5)Cost indexes 85

6)Method for estimating capital investment 85

7)Delivered equipment cost 86

8)Cost estimation (mathematically) 879)Indirect cost ( mathematically) 88

10)Direct cost (mathematically) 89

11)Processing cost 90

12)Fixed charges 90

13)General expenses 91

Instrumentation & control process

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1)Instrumentation & process control 94

2)Feed back control 94

I.Negative feed back control 94

II.Positive feed back control 94

3)Components of the control system 94I.Process 94

II.Measuring elements 95

4)Analysis of the measurement variables to be

measured 95

5)Variable to be recorded 95

I.Controller 95

II.Final control element 956)Characteristics of the controller 96

7)Modes of the controller 96

8)Flow controller 97

9)Temperature controller 97

10)Pressure controller 97

11)Level controller 97

12)Transmitters 97

13)Control valves 98

14)Instrumentation & control objectives 98

15)Programmable logic control 98

16)Integral control system 99

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Advantages, disadvantages, transportation,

application,Storage sales & uses

1)Advantages of the LPG include 1012)Draw backs of LPG include 102

3)Transportation 103

4)Application areas 104

5)Storage 105

6)Sales & uses 106

108

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C'#"ter

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Hi5tor4 o& LPG

)he birth of Li;ue9ed petroleum .as industry in 7863 was toosi.ni9cant historically to be recorded on the passin. record oftime, but in half century that followed it had such phenomenal.rowth and brou.ht so many economic and personal bene9 tsto the people in the rurall areas of the world" It is truly maybe said a destiny awaited it from the ery be.innin. and that alar.er measure of such destiny has been attained by the yearof 785B" (ottle .as is now 34 years old almost half a century"Its history be.an in 7863 in Germany with the deelopment of!(lau.as! by Herman (lau amon. German chemist" LPG was ami:ture of permanent .ases, li;uid .as, and li.ht fractions of.asoline, all synthetically produced by a modi9cation of theprealent practice of manufacturin. illuminatin. .as from oil"(lau.as was e:pensie to produce and een more e:pensie tohandle It was stored in cylinders in which the pressure ran.edfrom C56 to 7566 psi" )he cost of manufacture was rou.hly76D per lb and the users had to pay two-way frei.ht on Clbs ofsteel to .et 7 lb of fuel"

)he utiliation system consisted of a .as 9 red aporier, aseries of li;uid and apor re.ulator to reduce tan pressure to4 o and a small stora.e tan to the prepared apor" )he samee;uipment introduced into America carried installation char.esof D


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publication of this report, $r" alter @" &nellin., an e:plosiesspecialist for the (ureau of &tanfards, was worin. on theproduction

and utiliation of these same .aseous components" As early asMay 787


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foresi.ht, the list of uses included in the patent applicationincluded illumination, fuel for operatin. .as en.ines, weldin.,brain., cuttin. metals and in sur.ery as an anesthetic" (eforeMr" Peerson had been issued his patent he had an e:perimenta lautomobile operatin. on the streets of #ew *or city which useda mi:ture of (utane and Propane for the fuel"

Reasonable producer price for their product and a retail pricerespectiely" After promul.ation of the oil and .as re.ulatoryauthority F@GRA

@rdinance


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#atural Resources FMP#R prior to dere.ulation were .ien protection tothe e:tent of terms of e:istin. a.reements between the maretin.companies and producers" )hese Rules also empower the producers andmaretin. companies to 9: a reasonable producer price for theirproduct and a retail price respectiely" After promul.ation of the oiland .as re.ulatory authority F@GRA

@rdinance


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$urin. the last ten years F788>-8C to , the consumption ofpetroleum products has decreased by an aera.e rate of 6"3 percent perannum" )he consumption of .as, electricity and coal on the other hand,

has increased at an aera.e rate of C"4 percent, 5"7 percent and 4"4percent per annum, respectiely" )he annual trend of ener.yconsumption for the period 788>-8C to is .ien in )able "It isimportant to note that a structural chan.e is tain. place in ener.yconsumption pattern in Paistan since


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C'#"ter *

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boils at - 3< 6E (oth products are li;uids at atmospheric pressure whencooled to temperatures lower than their boilin. points" aporiation israpid at temperatures aboe the boilin. points" )he calori9c Fheat

alues of both are almost e;ual" (oth are thus mi:ed to.ether to attain

the apor pressure that is re;uired by the end user and dependin. onthe ambient conditions" If the ambient temperature is ery low propaneis preferred to achiee hi.her apor pressure at the .ien temperature"

Pro"ertie5 o& LPG>

LPG isN

Eolourless" @dourless" FIt=s normal to odorise LPG by addin. an odorant prior to

supply to the user, to aid the detection of any leas" /lammable" Heaier than air" Appro:imately half the wei.ht of water" #on to:ic but can cause asphy:iation" LPG e:pands upon release and 7 litre of li;uid will form appro:imately

respectiely"

apour pressure of the propane and butane at -766

Eare and 3pa respectiely and at 66E are B44 and 36pa respectiely F.au.e"

/ire point of propane and butane are 5766E in air and 3866E in airrespectiely"

(urnin. elocity of both propane and butane in air is B< cmKs"

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Eharacteristic 'nits Propane n-(utane

Ehemical formula EBH4 E3H76

Modular wei.ht 33,683 33,683

/reein. Point of li;uid at C>6 mm H. FOE -74C,C -7B4,B

(oilin. Point of li;uid at C>6 mm H. FOE -3


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N#t8r#( G#5 Co%9e%5#te>

#atural .as condensate is a low-density mi:ture of hydrocarbonli;uidsthat are present as .aseous components in the raw natural .asproduced from many natural .as 9elds"

It condensesout of the raw .as if the temperature is reduced to belowthe hydrocarbon dew pointtemperature of the raw .as"

)he natural .as condensate is also referred to as simply condensate, or.as condensate, or sometimes natural .asolinebecause it contains

hydrocarbons within the .asoline boilin. ran.e" Raw natural .as maycome from any one of three types of .as wellsN

Cr89e oi( e((5Q Raw natural .as that comes from crude oilwells is called associated .as" )his .as can e:ist separate fromthe crude oil in the under.round formation, or dissoled in thecrude oil"

Dr4 )#5 e((5Q )hese wells typically produce only raw natural.as that does not contain any hydrocarbon li;uids" &uch .as iscalled non-associated .as"

Co%9e%5#te e((5Q )hese wells produce raw natural .as

alon. with natural .as li;uid" &uch .as is also non-associated.as and often referred to as wet .as"

A low-9e%5it4, hi.h-API)r#3it4li;uid '49roc#r7o%phase that.enerally occurs in association with natural .as" Its presence as ali;uid phase depends on temperature and "re558reconditions inthe re5er3oirallowin. condensation of li;uid from apor" )he"ro98ctio%of condensate reseroirs can be complicated becauseof the pressure 5e%5iti3it4of some condensatesN $urin.production, there is a ris of the condensate chan.in. from .as toli;uid if the reseroir pressure drops below the dew point durin.production" Reseroir pressure can be maintained by Tuid in2ectionif .as production is preferable to li;uid production" Gas produced inassociation with condensate is called wet .as" )he API )r#3it4ofcondensate is typically 56 de.rees to 7


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depleted .as condensate 9elds is followed by reseroir pressuredepletion and retro.rade condensation of hi.her boilin. hydrocarbonsFcondensate with some dropped out in li;uid phase and lost toformations due to the fact that this condensate becomes immobilere.ardless of further Tuid Tow" As a result, up to B6->6? of initialcondensate reseres can remain in the formation" &o far, only onestimulation techni;ue is used for

condensate recoery enhancement and that is cyclin.-process, which isa rein2ection of dry .as into the formation" Howeer, in many cases theapplication of cyclin.-process is not applied due to economic and otherreasons" )hus, the .as industry is in desperate need for updatin.e:istin. stimulation techni;ues applied in .as condensate 9elds and is insearch of new technolo.ies to enhance condensate recoery by both,maintainin. the reseroir pressure thereby preentin. condensate lossto formation, and by e:tractin. retro.rade condensate already dropped

out in formation"

Co$"o5itio% o& %#t8r#( )#5 co%9e%5#te>

)here are hundreds of wet .as 9elds worldwide and each has its ownuni;ue .as condensate composition" Howeer, in .eneral, .ascondensate has a speci9c .raityran.in. from 6"5 to 6"4 and maycontainN

Hydro.en sul9deFH


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Se"#r#ti%) t'e co%9e%5#te &ro$ t'e r# %#t8r#()#5>

&chematic Tow dia.ram of the separation of condensate from raw natural .as

)here are ;uite literally hundreds of di0erent e;uipment con9.urationsfor the processin. re;uired to separate natural .as condensate from araw natural .as" )he schematic Tow dia.ramto the ri.ht depicts 2ust oneof the possible con9.urations"

)he raw natural .as feedstoc from a .as well or a .roup of wells iscooled to lower the .as temperature to below its hydrocarbon dew pointat the feedstoc pressure and that condenses a .ood part of the .ascondensate hydrocarbons" )he feedstoc mi:ture of .as, li;uidcondensate and water is then routed to a hi.h pressure separator esselwhere the water and the raw natural .as are separated and remoed")he raw natural .as from the hi.h pressure separator is sent to the main.as compressor"

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http://en.wikipedia.org/wiki/Process_flow_diagramhttp://en.wikipedia.org/wiki/Hydrocarbon_dew_pointhttp://en.wikipedia.org/wiki/Gas_compressorhttp://en.wikipedia.org/wiki/Image:NaturalGasCondensate.pnghttp://en.wikipedia.org/wiki/Process_flow_diagramhttp://en.wikipedia.org/wiki/Hydrocarbon_dew_pointhttp://en.wikipedia.org/wiki/Gas_compressor


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)he .as condensate from the hi.h pressure separator Tows throu.h athrottlin. control aleto a low pressure separator" )he reduction inpressure across the control ale causes the condensate to under.o apartial aporiation referred to as a Tash aporiation" )he raw natural.as from the low pressure separator is sent to a !booster! compressorwhich raises the .as pressure and sends it throu.h a cooler and on tothe main .as compressor" )he main .as compressor raises the pressure

of the .ases from the hi.h and low pressure separators to whateerpressure is re;uired for the pipeline transportationof the .as to the rawnatural .as processin.plant" )he main .as compressor dischar.epressure will depend upon the distance to the raw natural .asprocessin. plant and it may re;uire that a multi-sta.e compressor beused"

At the raw natural .as processin. plant, the .as will be dehydratedandacid .asesand other impurities will be remoed from the .as" )hen theethaneFE


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C'#"ter

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/ollowin. are the some important processes for the recoery of LPG

Membrane process

Eatalytic hydro-cracin. process

$ehydration process

Eatalytic process

Me$7r#%e Proce55

)he present inention is a process for recoerin. hi.h purity LPG from a.as condensate stream, from any source such as re9nery .ases,especially .as condensate wells which contain hydro.en, methane,ethaneKethylene, li.ht .ases containin. heteroatoms Fsulfur, o:y.en,nitro.en, e".", mercaptans as well as the EB

Vfraction alued as LPG and

simultaneously recoerin. a hi.h purity hydro.en rich stream by the useof two membranes separation units" In the present inention, the 9rstmembrane separation unit is located before a 9rst optional compressorand a nocout drum and the second membrane separation unit islocated after the nocout drum with recycle of the EBVrich stream fromthe second membrane unit for combination with the crude LPG feed forrepassa.e throu.h the nocout drum" )he current inention results inthe production and recoery of hi.h purity LPG from the nocout drumand the production and recoery of hi.h purity hydro.en retentate fromthe 9rst membrane" )his hi.h purity hydro.en obtained from the 9rstmembrane unit is of suJcient purity to be utilied as a hydro.en stream

component for a re9nery hydroprocessin. process" )he retentate of thesecond membrane unit contains mainly other li.hter hydrocarbons suchas Ei and E


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stream is diided into a Hbe utilied than if the hydro.en was not remoed prior to thecompression step upstream of the noc-out drum" )his results is bothlower inestment costs and lower ener.y consumption"

In one embodiment of the process of the present inention as presentedraw LPG feed from whateer source is fed at whateer pressure it isreceied from its source, typically 56 to 7666 psi, ia line into a 9rstmembrane unit wherein it is contacted with a rubbery polymermembrane " )he raw LPG feed is separated by the membrane into aretentate product stream enriched in hydro.en, and into a lowerKreducedpressure permeate stream enriched in LPG hydrocarbons and a reducedconcentration of hydro.en as compared to the feed stream" )he lowerpressure permeate stream enriched in EBVLPG concentration but stillcontainin. some hydro.en albeit at a reduced concentration is passedia line thou.h optional ale to optional compressor wherein itspressure can be increased at least bac up to the pressure of the of thecrude LPG, e".", 56 to 7666 psi and then throu.h line to nocout drumwherein hi.h purity EBVLPG is li;ui9ed and recoered as product ia lineand a aporous phase is recoered as oerheads ia line and sent to asecond membrane unit where it is contacted with a rubbery polymermembrane In the second membrane unit the aporous oerheadsstream from nocout drum is separated into a retentate stream rich inE7and E


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hile compressors and are identi9ed as optional, one or the other isre;uired to repressurie the streamFs recoered at reduced pressure aspermeate either from the 9rst membrane separation unit stream or fromthe second membrane separation unit stream so as to facilitate theprocessin. andKor recyclin. of these streams in the processin. circuit"Passa.e throu.h each membrane unit results in a permeate recoered ata pressure lower than that of the feed to the membrane unit"

Eompressor can be omitted if the pressure of the reduced pressurepermeate in line is still hi.h enou.h to permit e0ectie separation in thenocout drum membrane unit circuit" If not, then recompression in acompressor is necessary" If the pressure in line is suJcient withoutrecompression in compressor for passa.e to nocout drum andmembrane unit the permeate recoered from membrane unit in line willbe at yet a still lower pressure so recycle of this permeate for recycle tothe nocout drum would re;uire depressuriation by compressor "

In the membrane separations units, .as molecules sorb Fi"e", eitherabsorb or adsorb onto the polymer 9lm used as the membrane on thefeed side of the membrane, usually under pressure Fusually an appliedpressure" )his sorption creates a concentration .radient of moleculesfrom the feed side to the permeate side of the membrane 9lm" Gasmolecules di0use throu.h the membrane 9lm from the feed side to thepermeate side under the inTuence of the concentration di0erence withthe sorbed materials desorbin. from the permeate face of themembrane 9lm into the lower pressure permeate side of the membraneseparation unit" )his pressure di0erential may be the result of a hi.heror applied pressure on the feed side of the membrane than the pressureon the permeate side of the membrane andKor the permeate side can beunder a partial or full acuum to create the necessary pressuredi0erential"

In .as separation most of the membranes used are .lassy polymers suchas cellulose acetate, polysulfone, polyamide, polyimide, etc", andcombination of such polymers" In .lassy polymers the polymer moleculeis ri.idly paced in the membrane 9lm, therefore di0usion in restrictedand the di0usion rate controls the separation" Lar.er molecules hae

slower di0usion rates" )hus, .lassy polymer membranes can be used toseparate small molecules such as hydro.en Finetic diameter


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hi.h Te:ibility of the rubbery polymer 9lm and Te:ibility between thedi0erent polymer strands that comprise the membrane" )hus, di0usionrate di0erences between smaller molecules and lar.er molecules areinsi.ni9cant" Herein, the selectie separation is primarily drien not bydi0erentiation in molecular sie but instead by aJnity of the membranefor certain constituents in the feed" )he sorption on the feed side in LPGrecoery usin. these rubbery polymer membranes faors lar.e EB

molecules rather than the smaller hydro.en, E7or E


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which are rubbery at room temperature or hi.her Fabout


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In the LPG unit condensate from the slu. catcher re9ned after passin.throu.h condensate chiller, condensate coalaser 9lter, deeathanier,debutanier"

C#t#(4tic Proce55

)his inention relates to a catalyst for producin.a li;ue9ed petroleum .as containin. propane or butane as a maincomponent by reactin. carbon mono:ide with hydro.en"

)his inention alsorelates to a process for producin. a li;ue9ed petroleum .as containin.propane or butane as a main component from a synthesis .as usin. thecatalyst" )his inention also relates to a process for producin. a li;ue9ed

petroleum .as containin. propane or butane as a main component froma carbon-containin. startin. material such as a natural .as usin. thecatalyst"

O76ecti3e o& T'e C#t#(4tic Proce55

An ob2ectie of this inention isto proide a less deterioratie catalyst for producin. a li;ue9edpetroleum .as with a lon.er catalyst life, which can produce ahydrocarbon containin. propane or butane as a main component, i"e", ali;ue9ed petroleum .as FLPG, by reactin. carbon mono:ide and

hydro.en, with hi.h actiity, hi.h selectiity and hi.h yield"

Another ob2ectie of this inention is to proide a process for stablyproducin. LPG with a hi.h concentration of propane andKor butane froma synthesis .as in a hi.h yield for a lon. period, usin. the catalyst" Afurther ob2ectie of this inention is to proide a process for stablyproducin. LPG with a hi.h concentration of propane andKor butane froma carbon-containin. startin. material such as a natural .as in a hi.hyield for a lon. period"

)he present inentionproides a catalyst for producin. a li;ue9ed petroleum .as, which isused for producin. a li;ue9ed petroleum .as containin. propane orbutane as a main component by reactin. carbon mono:ide andhydro.en, comprisin. a Pd-based methanol synthesis catalystcomponent" Moreoer, the present inention proides a process forproducin. a li;ue9ed petroleum .as, comprisin. the step ofN

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Reactin. carbon mono:ide and hydro.en in the presence of the catalystfor producin. a li;ue9ed petroleum .as as described aboe to produce ali;ue9ed petroleum .as containin. propane or butane as a maincomponent"

Moreoer, the

present inention proides a process for producin. a li;ue9ed petroleum.as, comprisin. the steps ofN

F7 "ro98ci%) # 54%t'e5i5 )#5from a carbon-containin. startin.material and at least one selected from the .roup consistin. of H


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sub2ected to polymeriation to .ie a lower ole9n" )he lower ole9n thus.enerated is released from the pore in the eolite catalyst componentand is rapidly hydro.enated on the methanol synthesis catalyst to .ie aparaJn comprisin. propane or butane as a main component, i"e", LPG"

Herein, a methanol synthesis catalyst componentW means a compound

which can act as a catalyst in the reaction of E@V


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methanol synthesis catalyst can be used preferably at


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)he amount of supported Pd in a Pd-based methanol synthesis catalystcomponent is preferably 6"7 wt ? or more, more preferably 6"5 wt ? ormore, particularly preferably 7 wt ? or more" In the li.ht ofdispensability and economical eJciency, the amount of supported Pd ina Pd-based methanol synthesis catalyst component is preferably 76 wt? or less, more preferably 4 wt ? or less, particularly preferably > wt ?or less" (y ad2ustin. the amount of supported Pd in a Pd-based methanol

synthesis catalyst component within the aboe ran.e, propane andKorbutane can be produced with a hi.her conersion, a hi.her selectiityand a hi.her yield"

(y ad2ustin. the amount ofsupported Pd to be 6"7 wt ? or more, more preferably 6"5 wt ? or more,particularly preferably 7 wt ? or more, carbon mono:ide and hydro.encan be conerted into methanol with a hi.her conersion, and methanolproduced can be conerted into a li;ue9ed petroleum .as comprisin.propane or butane as a main component with a hi.her selectiity" @n theother hand, by ad2ustin. the amount of supported Pd to be 76 wt ? orless, more preferably 4 wt ? or less, particularly preferably > wt ? orless, methanol produced can be conerted into a li;ue9ed petroleum .ascomprisin. propane or butane as a main component with a hi.herconersion"

A support for Pd may be selected from nown supportswithout limitation" %:amples of a support include silica Fsilicon dio:ide,alumina, silica-alumina, carbon Factiated charcoal and o:ides ofirconium, titanium, cerium, lanthanum, iron or the lie, and compositeo:ides containin. two or more types of these metals, and compositeo:ides containin. one or more types of these metals and one or moretypes of other metals" &uch supports may be used alone or incombination of two or more"

A support is preferably neutral tobasic" (y usin. a neutral to basic support, hi.her actiity and selectiitycan be achieed in methanol synthesis"

Amon. others, a preferable support for Pd issilica" (y usin. silica as a support, methanol can be produced with ahi.her selectiity and a hi.her yield without producin. a hydrocarbon

and carbon dio:ide as a by-product"

A silica support preferably has a speci9c surface area of 3


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be achieed and propane andKor butane can be produced with a hi.herconersion and a hi.her yield"

)he upper limit of a speci9c surface area of a silicasupport is not particularly restricted, but is .enerally about B66 m


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of supported basic metals within the aboe ran.e, dispensability of Pdcan be improed, and thus hi.her catalytic actiity can be achieed andpropane andKor butane can be produced with a hi.her conersion and ahi.her yield"

In this inention, a Pd-based methanol synthesis catalyst component

may be a silica support on which other components, in addition to Pdand a basic metal, are supported as lon. as the desired e0ects of thecatalyst are maintained"

A Pd-based methanol synthesis catalyst component in which Pd, a basicmetal or the lie are supported on silica, may be prepared by a nownmethod such as an impre.nation method and a precipitation method"#e:t, there will be described a process for producin. a li;ue9edpetroleum .as comprisin. propane or butane, preferably propane, as amain component by reactin. carbon mono:ide and hydro.en usin. acatalyst for producin. a li;ue9ed petroleum .as accordin. to thisinention as described aboe"

A reaction temperature is preferablyB66O E" or hi.her, more preferably B


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component and a \-eolite catalyst component may .ie a contact timeachiein. a further suJcient conersion" A

concentration of carbon mono:ide in a .as fed into a reactor ispreferably


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Process for Producin. a Li;ue9ed Petroleum Gas from a Earbon-Eontainin. &tartin. Material"In this inention, a synthesis .as can beused as a startin. .as for producin. a li;ue9ed petroleum .as FLPG"

#e:t, there will be described an embodiment of a process for producin.LPG accordin. to this inention, comprisin. the steps of producin. asynthesis .as from a carbon-containin. startin. material Fsynthesis .asproduction process and then producin. LPG from the obtained synthesis.as usin. a catalyst of this inention Fli;ue9ed petroleum .as productionprocess"

S4%t'e5i5 G#5 Pro98ctio% Proce55

In a synthesis .as production process, a synthesis .as is produced froma carbon-containin. startin. material and at least one selected from the.roup consistin. of H


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necessary" hen a coal is used as a startin. material, a synthesis .ascan be produced usin. an aeratin. .asi9cation furnace"

/or e:ample, a shift reactor may be placed downstream of a reformer,which is a reactor for producin. a synthesis .as from the aboe startin.materials, so that a synthesis .as composition can be ad2usted by a shiftreaction FE@VH


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.as space elocity FGH& of


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mono:ide by-products, carbon dio:ide, ethane, ethylene and methaneand so on and a hi.h-boilin. component hain. a hi.her boilin. pointthan the boilin. point of butane Fby-products, hi.h-boilin. paraJn.ases are, if necessary, separated from the lower-paraJn-containin..as, so as to obtain a li;ue9ed petroleum .as FLPG comprisin. propaneor butane as a main component" If necessary, the .as may bepressuried andKor cooled so as to obtain a li;ue9ed petroleum .as"

In a li;ue9ed petroleum .as production process, carbon mono:ide andhydro.en are reacted in the presence of the aboe catalyst for producin.a li;ue9ed petroleum .as of this inention, to produce a paraJncomprisin. propane or butane as a main component, preferably aparaJn comprisin. propane as a main component"In this case, a .as fedinto a reactor is the synthesis .as produced in the aboe synthesis .asproduction process" )he .as fed into a reactor may contain, in

addition to carbon mono:ide and hydro.en, other components such ascarbon dio:ide, water, methane, ethane, ethylene and an inert .as" )he.as fed into a reactor may be a .as obtained by addin. carbonmono:ide, hydro.en or other components, if necessary, to the synthesis.as produced in the aboe synthesis .as production process" And the.as fed into a reactor may be a .as obtained by separatin. a certaincomponent, as necessary, from the synthesis .as produced in the aboesynthesis .as production process"

A .as fedinto a reactor may comprise carbon dio:ide, in addition to carbonmono:ide and hydro.en, which are startin. materials for producin. alower paraJn" As the carbon dio:ide, by recyclin. carbon dio:idedischar.ed from the reactor, or by usin. the correspondin. amount ofcarbon dio:ide, formation of carbon dio:ide from carbon mono:ide by ashift reaction in the reactor can be substantially reduced or beeliminated"

A .as fed into a reactor may comprise water apor"

A reaction temperature is preferably B66O E" or hi.her, more preferably

B


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A .as space elocity ispreferably 566 hr[7 or more, more preferably 7566 hr[7 or more" @n theother hand, as described aboe, a .as space elocity is preferably 76666hr[7 or less, more preferably 5666 hr[7 or less"

A .as fed into a reactor can be diidedly fed to the reactor soas to control a reaction temperature" )he reaction can be conducted in a

9:ed bed, a Tuid bed, a moin. bed or the lie, and can be preferablyselected, tain. both of control of a reaction temperature and are.eneration method of the catalyst into account" /or e:ample, a 9:edbed may include a ;uench type reactor such as an internal multista.e;uench type, a multi tubular type reactor, a multista.e type reactorhain. a plurality of internal heat e:chan.ers or the lie, a multista.ecoolin. radial Tow type, a double pipe heat e:chan.e type, an internalcoolin. coil type, a mi:ed Tow type, and other types of reactors"

hen used, a catalystfor producin. a li;ue9ed petroleum .as accordin. to the presentinention can be diluted with

silica, alumina or an inert and stable heat conductor for controllin. atemperature" In addition, when used, a catalyst for producin. a li;ue9edpetroleum .as accordin. to the present inention can be applied to thesurface of a heat e:chan.er for controllin. a temperature"

A lower-paraJn-containin. .as produced in the li;ue9ed petroleum .as productionprocess comprises a hydrocarbon containin. propane or butane as amain component" In the li.ht of li;uefaction properties, it is preferablethat the total content of propane and butane is hi.her in a lower-paraJn-containin. .as" Accordin. to this inention, there can beobtained a lower-paraJn-containin. .as hain. a content of propaneand butane of 56 mol ? or more, preferably >6 mol ? or more, morepreferably C6 mol ? or more Fincludin. 766 mol ? to the hydrocarboncontained therein, in total" /urthermore, a lower-paraJn-containin. .asproduced in the li;ue9ed petroleum .as production process preferablycontains more propane in comparison with butane, in the li.ht of

inTammability and apor pressure properties"

)hus, water, a low-boilin. component and a hi.h-boilin.component are, as necessary, separated from a lower-paraJn-containin. .as produced, so as to obtain a li;ue9ed petroleum .as FLPGcomprisin. propane or butane as a main component" &eparation ofwater, a low-boilin. component or a hi.h-boilin. component can beconducted in accordance with a nown method"

ater can be separated by, for e:ample, li;uid-li;uid separation"

47


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A low-boilin. component can be separated by, for e:ample, .as-li;uidseparation, absorption separation or distillation more speci9cally, .as-li;uid separation at an ambient temperature under increased pressure,absorption separation at an ambient temperature under increasedpressure, .as-li;uid separation with coolin., absorption separation withcoolin., or combination thereof" Alternatiely, for this purpose,membrane separation or adsorption separation can be conducted, or

these in combination with .as-li;uid separation, absorption separation ordistillation can be conducted" A .as recoery process commonlyemployed in an oil factory Fdescribed in @il Re9nin. ProcessesW, appliedto separation of a low-boilin. component"A preferable method ofseparation of a low-boilin. component is an absorption process where ali;ue9ed petroleum .as comprisin. propane or butane as a maincomponent is absorbed into an absorbent li;uid such as a hi.h-boilin.paraJn .as hain. a hi.her boilin. point than butane, and a .asoline"Ahi.h-boilin. component can be separated by, for e:ample, .as-li;uidseparation, absorption separation or distillation"

/or consumer use, it is preferable that a content of a low-boilin.component in the LPG is reduced to 5 mol ? or less Fincludin. 6 mol ?by separation, for e:ample, in the li.ht of safety in use")he total contentof propane and butane in the LPG

thus produced may be 86 mol ? or more, more preferably 85 mol ? ormore Fincludin. 766 mol ?" And a content of propane in the LPGproduced may be 56 mol ? or more, more preferably >6 mol ? or moreFincludin. 766 mol ?" )hus, accordin. to this inention, LPG hain. acomposition suitable for a propane .as, which is widely used as a fuel forhousehold and business use, can be produced"

In this inention, a low-boilin. component separated from the lower-paraJn-containin. .as can be recycled as a startin. material for thesynthesis .as production process"A low-boilin. component separatedfrom the lower-paraJn-containin. .as includes substances which can berecycled as startin. materials for a synthesis .as production process fore:ample, methane, ethane, ethylene and so on" And carbon dio:ide inthe low-boilin. component can be bac to a synthesis .as by a E@O E" F7BBO /" and C7O E" F7>6O /"" )herefore, thereis no foulin. in either tower or their respectie reboilers"

)he acetylene hydro.enation unit is hi.hly eJcient and selectie" )heacetylene remoal easily results in acetylene concentrations of less than7 ppm in the 9nal ethylene product while the ethylene .ain amounts to

56? or more of the acetylene" $ue to the hi.h hydro.en content of thefeed .as, no carbonaceous material is deposited on the catalyst" )hecatalyst needs no re.eneration and thus the reactors need no spares"Green oil formation is miniscule"

In the acetylene hydro.enation reactor about 46? of the methyl-acetylene and


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)he inte.rated column can hae a deethanier section comprisin. from6 trays" )he upper and lower portions of the inte.rated columnpreferably hae the same cross-sectional diameter" )he inte.ratedcolumn can also include a reboiler for the deethanier section heatedwith hi.h pressure depropanier .ross oerhead or some other suitableheatin. medium" )he inte.rated column can also include a reboiler forthe ethylene stripper section, heated by ethylene condensed at a

relatiely hi.her pressure than the inte.rated column" )he inte.ratedcolumn preferably includes a line for reTu:in. the upper portion of thecolumn with the ethylene condensed in the ethylene stripper sectionreboiler" )he inte.rated column can include a compressor forcompressin. oerhead apor from the upper portion of the column tothe pressure of the ethylene stripper section reboiler" )he inte.ratedcolumn preferably comprises respectie li;uid lines from the distributionpan to the tops of the dethanier section and the ethylene strippersection" )he line from the distribution pan to the top of the deethaniersection can include a ale for controllin. the amount of li;uid suppliedto the deethanier section" )he inte.rated column preferably has anoperatin. pressure of from < to


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Proce55 De5cri"tio%

)he debutanier column considered in this study "the LPG can beproduced with hi.h LPGalues Fup to 75oE and sent to the /EE unit tobe reprocessed" $ependin. on the adopted operatin. strate.y,

completely di0erent process conditions are obtained and conse;uentlythe system follows di0erent models" )hen, a robustness problem iscreated and the control system must deal with it" )he schematicrepresentation of the debutanier is shown in /i."B" )he feed streamcomes from the top of the crude pre-Tash column at a temperature of36oE and pressure of 4 .fKcmoE and it is >?aporied" )he feed is introduced in the debutanier column F)-67 atsta.e 7C" )he column has B6 sta.es with a Murphree eJciency of

appro:imately C5?" Measured points of the temperature pro9le are thetop Fabout 53oE, bottom Fabout 7>BoE and sta.e 5 Fabout >CoE" )hetop condenser has a heat duty of appro:imately 7"6 MMcalKh thatcorresponds to a distillate Tow of about 764 mBKd and a reTu: Tow ofabout 366 mBKd" A small Tow of fuel .as is also produced"

78
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In the control scheme adopted in this study the manipulatedariables are the reboiler heat duty FjR%( and the reTu: Towrate FR) which operatin. window is represented in /i."3" )hisoperatin. window results from seeral process constraints thatare de9ned in)able 7"

79
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80


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C'#"ter ,

PLANT LOCATION SELECTION

&electin. a plant side is critical to 9nancial success of a plant" &eeral

81


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factors must be considered in selectin. a .eneral plant location"

SITTING FACTORS

)he primary sittin. factors, which inTuence the selection of a plant

location, are as follows"

%nironmental consideration

Labor aailability and productiity

Raw material aailability

Pro:imity to maret

Property cost

)a: incenties

%lectric power aailability and cost"

%#IR@#M%#)AL E@#&I$%RA)I@#

%nironmental consideration is the most important factor in selectionof location"

LABOR AVAILABILITY AND PRODUCTIVITY

It is prefer to hae access to a wor force with deeloped sills that -canbe readily conerted to suit the special re;uirement of a new business"

LIVING CONDITION

Liin. conditions such as house aailability, cost, safety, school, healthcare, ma2or

82


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hospitals and local doctors, musical place, are considered ery importantfor ;uality of life"

RA/ MATERIAL AVAILABILITY

/or many industries such as the petroleum and petrochemical industries,aailability of raw materials is most important factor in selectin. a plantsite"

ACCESSIBILITY TO TRANSPORTATION

)he cost of transportation is important factor in plant side selection" )heplant needs to be located close to the maret the cost of shippin. bytaner is lowest"

PROPERTY COST

Land cost is the most important factor in side selection" Plants tend tolocate away from areas where residential homes drie up the propertycost"

TA

hen considerin. ta:es, all types needed to be considered, initial fees,capital alue, corporate rate, personal income ta:, sales ta:, propertyta: and unemployment, insurance"

SPECIFIC PLANT SITE CONSIDERATION

@nce a .eneral plant location has been established, a speci9c plant sitelocation to be determined" @ne approach is to use the kcorn 9eldmethod of plant site assessment, the purpose of which is to deelop anideal list of speci9cation that de9ne what would be re;uired to put the

plant in any corn 9eld"

CONCLUSION

83


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eepin. in iew the aboe factors and on the assumption, we haedecided to construct the GA& PR@E%&&I#G PLA#) in the rural areas ofSINDH"

84


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C'#"ter 1

Eost estimation

An acceptable plant desi.n must present a process that is capable of

operatin. under conditions, which will yield a pro9t" It is necessary the

85


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chemical en.ineer be aware of many di0erent types of costs inole in

the manufacturin. process" Eapital must be allocated for direct plant

e:penses, such as those for raw material, labor and e;uipment" (esides

direct plant e:penses, many other indirect e:penses are included if a

complete analysis of the total cost is to be obtained" )he total capitalinestment for any process consists of /Ig%$ EAPI)AL I#%&)M%#) for

physical e;uipment and facilities in the plant plus @RI#G EAPI)AL"

I#%&)M%#) 1 /Ig%$ EAPI)AL I#%&)M%#)

/ori%) C#"it#( I%3e5t$e%t

)he capital, which is necessary for the operation of the plant, is called

worin. capital inestment"

Fi=e9 C#"it#( I%3e5t$e%t

)he capital needed to supply the necessary manufacturin. and

production is called worin. 9:ed inestment" It is diided in to two-sub

diision"

Direct Co5t

)he direct cost items are incurred in the construction of the plant in

addition to the cost of e;uipment"

Purchased %;uipment"

Purchased %;uipment Installation"

Instrumentation and Eontrol"

Pipin."

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%lectrical %;uipment and Materials"

(uilidin.

*ard Improement

serice /acilities

Land

I%9irect Co5t

$esi.n 1 %n.ineerin."

Eontractor=s %:penses"

Eontractor=s /ee"

Eontin.ency"

/AE)@R& A//%E)I#G I#%&)M%#) A#$ PR@$'E)I@# E@&)&

hen a chemical en.ineer determines costs for any type o commercial

process, these costs should be of suJcient accuracy to proide reliable

decisions" )o accomplish this" )he en.ineer must hae complete

understandin. of the factors that can a0ect cost" &ome important factors

are"

&ources of %;uipment"

87


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Price /luctuations"

Eompany Policies"

@peratin. )ime 1 Rate of Production"

Goernment Policies"

TYPES OF CAPITAL COST ESTIMATE

An estimate of capital inestment for a process may ary from pre-

desi.ned estimate based on little information e:cept the sie of the

proposed pro2ect to a detailed estimate prepared from complete

drawin.s and speci9cation" (etween these two e:tremes of capital

inestment estimates, which ary in accuracy dependin. upon the sta.e

of deelopment of pro2ect"

/ollowin. 9e cate.ories are used for desi.n purpose"

@rder of Ma.nitude %stimateN (ased on similar-preious cost data

probable accuracy of estimate oer V B6?"

&tudy %stimateN (ased on nowled.e of ma2or items of e;uipment,

probable accuracy of estimate up to VB6?"

Preliminary %stimateN (ased on suJcient data to permit the estimate to

be bud.eted" probable accuracy of estimate with in V


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speci9cation and side surey probable accuracy of estimate with in

V5?"

E@&) I#$%g%&

A cost inde: in merrily an inde: alue for a .ien point in time showin.

the cost at that time relatie to a certain base time if the cost at same

tie in the past is nown the e;uipment and the present time can be

determine by multiplyin. the ori.inal cost by the ratio of the present

Inde: alue to the inde: alue when the ori.inal cost was obtained"

)hese inde:es show accurate estimates if the time period inoled is

less than 76 years" )he most common inde:es areN

Marshall and &wift All Industry 1 Process Industry e;uipment

inde:es"

%n.ineerin. #ews Record Eonstruction Inde:"

#elson-/arrar Re9ner Eonstruction Inde:"

Ehemical %n.ineerin. Plant Eost Inde:"

M%)H@$ /@R %&)IMA)I#G EAPI)AL I#%&)M%#)

arious methods can be employed for estimatin. capital inestment the

choice of any method depends upon the amount of the detailed

information aailable and the accuracy desired"

$etailed Item %stimate"

89


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'nit Eost %stimate"

Percenta.e of $eliered %;uipment Eost"

Land factor for Appro:imation of Eapital Inestment"

Power /actor Applied to Plant Eapacity Ratio"

Inestment Eost per 'nit of Eapacity"

)urn @er Ratios"

e hae estimated the total inestment for our pro2ect by usin.

percenta.e of deliered cost"

$%L%I%R%$ %j'IPM%#) E@&)

Inde: 'sedN Marshall and &wift Installed %;uipment Inde: Ffor process

industry Inde: alue in 78868


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COST ESTIMATION

Eost of slu. catcher 7,66,66

Eost of /in /an Eooler 3B666D

86,666D

46,666D

7>,7,8>


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>6C566D

92


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Eost of H>7C76"C88

)otal indirect Eost D


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/i:ed Eapital Inestment /$V:VC4768858"


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PR@E%&&I#G E@&)

Processin. Eost $irect Production wst V 9:ed char.es V plantoerhead cost

/Ig%$ EHARG%&

Patent 1"

royalties

$uplication

Local )a:es

Insurance

/i:ed Ehar.es

Plant oer head

cost

Processin. Eost

6"6B:

) 6"7

:/

6"658C55"CB

Rs"

738B4"8B

Rs"

B36>743


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)urn oer ratio is .ien byN

Gross annual sales K/EI

B:768K34>5C55"B

>"7C


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C'#"ter 2

I%5tr8$e%t#tio% #%9 co%tro( "roce55

)he important common to all processes is that a process is neer ina state of static e;uilibrium e:cept for a ery short period of time


100/114

and process is a dynamicentity sub2ect to continual upsets ordisturbances which tend to drie it away from the desired state ofe;uilibrium" If a process is to operate eJciency, disturbances andthe process must be controlled" A process desi.ned for a particular

ob2ect and is then found" &ome time by trial and error and sometime by re0erin. from the preious e:perience that control of aparticular ariable associated with some sta.es of the process arenecessary to achiee the desired eJciency" Process may becontrolled more precisely to .ie more uniform and hi.h ;ualityproducts by the application of automatic control, often leadin. tohi.h pro9ts" Additionally, process which response too rapidly to becontrolled by human operator can be controlled automatically"Automatic control is also bene9cial in certain remote, haards orroutine operations" After a period e:perimentation, computer arebein. used to operate automatically control" Processin. systems,

which may too lar.e and too comple: for e0ectie direct humancontrol"

Fee9 7#c co%tro(

hen a controller corrects a ariable, it does so in response to asi.nal send from the measurin. deice" )his si.nal deice is calledcalled feedbac"

N#)#ti3e &ee9 7#c co%tro(

#e.atie feed bac ensures that the di0erence between )r Fsetpoint and )m Fmeasured alue is used to ad2ust the controlelement in order to reduce the error"

Po5iti3e &ee9 7#c co%tro(

If the si.nal to the comparator will be obtained by addin. )r and )m,we would hae a positie feed bac system, which is unstable" %rrorsi.nal F% is obtained as,

% )r V )m

Co$"o%e%t5 o& t'e co%tro( 545te$

Proce55Any operation or series of operation that produces desired 9nalresults is a process" In this discussion the process is the puri9cationof natural .as"


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Me#58ri%) e(e$e%t5

As all he parts of the control system, measurin. elements isperhaps the most important" If the measurements are not madeproperly the remainder of the system can not operate satisfactorily"

)he measured ariable is chosen to represent the desired conditionsin the process"

A%#(45i5 o& t'e $e#58re$e%t 3#ri#7(e5 to 7e$e#58re9

ariables to be measured

Pressure measurement

)emperature measurement

/low rate measurement

Leel measurement

V#ri#7(e5 to 7e recor9e9

Indicated temperature, composition , pressure ,etc"

Co%tro((er

)he controller is the mechanism that responds to any errorindicated by the error deductin. mechanism,"@utput of the controller is the some predetermined function of theerror " )here are three types of the controller" Proportional action ,which moes the control ale indirect proportion to the ma.nitudeof the error "

Inte.ral action which moes the control ale based on the timeinte.ral of the error and the purpose of the inte.ral action is to driethe process that to its set point when it has been disturbed"

Ideal deriatie action Fpre acts and its purpose is to anticipatewhere the process is headin. by cooin. at the time a rate ofchan.e of error"

Fi%#( co%tro( e(e$e%t

)he 9nal control element receies the si.nal from the


102/114

controller and by some pre determined relationship chan.es theener.y input to the process"

C'#r#cteri5tic5 o& t'e co%tro((er

In .eneral the process controller can be classi9ed as

Pneumatic controllers

%lectronic controllers

Hydraulic controllers

In the puri9cations of .as condensate the controller and 9nal controlelement may be pneumatically operated due to the followin.reasons"")he pneumatic controller is ery ru..ed and almost free ofmaintenance ")he maintenance men need no suJcient trainin."Pneumatic control appears to be safer in a potentially e:plosiesatmosphere which is often present in the petrochemical industry"

Mo9e5 o& t'e co%tro(

)he arious types of controls are called =modes= and then determinethe type response obtained" In other words these describe theaction if controller that is the relationship of output si.nal to theinput or error si.nal"

It must be noted that it is error that actiates the controller" )hefour basic mode of control areN

@0-on control"

Inte.ral control"

Proportional control"

Rate of deriatie control"

In industry purely inte.ral, proportional or deriatie modes seldomoccur alone in the control system"

)he o0-on control, with the ery hi.h .ain" In this case the errorsi.nal at once o0 the ale or any other parameter upon which itsits or completely sets the systems"


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F(o co%tro((er

)hese are used to control the feed rate into a process unit" @ri9ceplates are the most used as the Tow rate sensor" #ormally ori9ce

plates are desi.ned to .ie a pressure drop in the ran.e of


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Co%tro( 3#(3e5

)he interface in the process are the other end of the control loop ismade by the 9nal control element in an automatic control ales"

)he Tow of steam that open or closes ori9ce openin. as the steamis raised or lowered" )he steam is attached to the diaphra.m that isdrien by chan.in. air pressure aboe the diaphra.ms" )he fore forthe air pressure is opposed by a sprin."

I%5tr8$e%t#tio% #%9 co%tro( o76ecti3e5

)he main ob2ecties are as followsN

&afe plant operation"

)o eep the process ariable within nown safe operatin.limit"

)o detect dan.erous situations as they deelop and to proide

an alarm and automatic shut down systems"

Pro98ctio% R#te>)o achiee the desi.n product output"Pro98ct 8#(it4>)o maintained the product composition with inthe speci9c ;uality standards"

Co5t>)o operate at the lowest production cost"

In a typical chemical processin. plant these ob2ecties are achieedby combination of automatic control, manual monitorin. andlaboratory analysis"

Pro)r#$$#7(e (o)ic co%tro( ?PLCS@

)hese were deeloped in the early 78C6s and represent the earliestand most successful application of computers in process control"

)oday, PLE& are one of the most hi.hly deeloped and one of themost rapidly eolin. e:amples of computers in the process control"

)he term pro.rammable means that e;uipments behaiour isde9ned by instructions Fsoftware, not by its manufacturin.speci9cation" PLE was the name .ien to the ori.inal e;uipment,which performed only Lo.ic operations" )oday=s units are calledsimply pro.rammable controllers FPEs and many be part of


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inte.rated control"

)he 9rst PLE was small computers desi.ned primarily to sere aspilot relay replacements"

PLE=s are widely used today as inputKoutput FIK@ counts of B666 ormore are common" )he IK@ modules are sericed oer a networ bya separate processor unit located for the conenience of the user")he lar.e IK@ counts also made the PLE a rich source of data"

I%te)r#te9 co%tro( 545te$

Many deelopment are occurrin. simultaneously" PLE=s haeac;uired loop control capabilities in addition, the lo.ic capabilities ofcontrol systen are bein. enhanced, and $E& is enterin. thetraditionally discrete control 9eld of the PLE=s"


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C'#"ter 0

T'e #93#%t#)e5 o& LPG i%c(89e

/ollowin. are the ma2or adanta.es

(ecause LPG apories when released from the tan and is notwater soluble, LPG does not pollute under.round water sources"

Propane has a hi.h octane ratin. of 763, in-between Eompressed#atural Gas FE#G F7B6 and re.ular unleaded .asoline F4C"

Refuelin. a propane ehicle is similar to 9llin. a .as .rill tanthe time it taes is comparable with that needed to 9ll a E#G,.asoline or diesel fuel tan"

Its hi.h octane ratin. enables it to mi: better with air and to burnmore completely than does .asoline, .eneratin. less carbon"


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ith less carbon buildup, spar plu.s often last lon.er and oilchan.es are needed less fre;uently"

(ecause it burns in the en.ine in the .aseous phase, propaneresults in less corrosion and en.ine wear than does .asoline"

(oth Propane and (utane are easily li;ue9ed and stored in

pressure containers" )hese properties mae the fuel hi.hlyportable, and hence, can be easily transported in cylinders ortans to end-users"

LPG is a .ood substitute for petrol in spar i.nition en.ines" Itsclean burnin. properties, in a properly tuned en.ine, .iereduced e:haust emissions, and e:tended lubricant and sparplu. life"

As a replacement for aerosol propellants and refri.erants, LPGproides alternaties to Tuorocarbons which are nown to causedeterioration of the earth=s oone layer"

)he clean burnin. properties and portability of LPG proide a

substitute for indi.enous fuels such as wood, coal, and otheror.anic matter" )his proides a solution to de-forestation and thereduction of particulate matter in the atmosphere Fhae, causedby burnin. the indi.enous fuels"

)his is called =sweatin.=, and is caused by the process of LPGchan.in. from its li;uid state to a apour state" LPG in a stablestate consists of both li;uid and apour" hen apour is drawnfrom the cylinder the apour pressure in the cylinder is reducedand alters this stability between the apour pressure and thepressure re;uired maintainin. the LPG as a li;uid" In thiscondition, the li;uid LPG boils releasin. apour which stabilies

the pressure within the cylinder" In order for LPG to boil, it mustdraw in heat throu.h the cylinder wall" As this happens the wallof the cylinder is cooled and moisture in the air condenses on thewall of the cylinder" In e:treme cases, the cylinder may hae iceformin. on the surface of the cylinder" Interestin.ly, the top ed.eof the sweatin. or ice, reeals the leel of the LPG remainin. inthe cylinder"

Li;ue9ed petroleum .as FLPG is a fully-Ted.ed fuel for internalcombustion en.ines" Gas has been uniersally reco.nied as acheap, ecolo.ical fuel, which is superior to petrol in seeralaspects" It is also important to now that there is no need to

redesi.n a ehicle in order to use LPG, which results in theopportunity to use both petrol and LPG as a fuel"

(ecause of its relatiely fewer components, it is easy to achieethe correct fuel to air mi: ratio that allows the completecombustion of the product" )his .ies LPG its clean burnin.characteristics"

%Jcient and economical hydrocarbon recoeryN typically >6? to86? recoery of feed LPG


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LPG recoery as an easy to handle li;uid Reduces Tarin. and corrects re9nery fuel balance Recoery of puri9ed hydro.en can be an added bene9t Proen performanceN doens of references for both hydrocarbon

and hydro.en membranes"

Lon. membrane lifeN typical membrane lifetime is 3 to 5 years ormore" &imple, reliable, Te:ible unit easy to install and operate @perates at moderate temperatures and pressures &imple installation and operation with compact sid-mounted

construction Re;uires no additional chemicals produces no wastes

T'e 9r#7#c5 o& LPG i%c(89e

/ollowin.s are the ma2or disadanta.es

In cold conditions, below B< de.rees /ahrenheit, startin. couldbe a problem because of the low apor pressure of propane atlow temperatures"

@ne .allon of LPG contains less ener.y than a .allon of .asoline")he driin. ran.e of a propane ehicle is about 73 percent lowerthan a comparable .asoline-powered ehicle"

LPG is .enerally hi.her priced than other fuel alternaties suchas E#G and .asoline"

)here are oer 3,666 LPG refuelin. sites in the '&, more than allof the other alternatie fuels combined" Most of these stations,howeer, are not readily aailable to consumers on a


109/114

/irstly, a cylinder can be wei.hed to chec how much product isleft in the cylinder" )he wei.ht of the LPG remainin. in thecylinder is total wei.ht of the cylinder plus the LPG, less theempty wei.ht or tare wei.ht, of the cylinder" F)he re.ulator andany other 9ttin.s should be remoed prior to wei.hin. the

cylinder" &econdly, some cylinders hae .au.es which show the amount

of LPG contained within the cylinder" )hirdly, li;uid crystal .au.es, which stic to the outer surface of

the LPG cylinder, are aailable, and these show the leel of theli;uid LPG within the cylinder by indicatin. a colour chan.e atthe interface between the li;uid and apour leels caused by thetemperature ariation"

/ourthly, if the cylinder is bein. used, then it may be possible tosee the leel of the LPG in the cylinder by obserin. the leel ofthe sweatin. on the cylinder wall"

Lastly, it is possible to see the leel of the LPG li;uid within acylinder by pourin. boilin. water down the side of the LPGcylinder" )he li;uid leel is reealed where a condensate or frostline occurs"

Recent deelopments and trends in transportation of LP .as areN

'se of lar.e multipurpose FLP .as and ammonia railroad tancars" )an cars with a >6,666 .al capacity hae been introduced"

$eelopment of lar.e refri.erated ocean taners capable of

transportin. millions of .allons of LP .as at atmosphericpressure"

A""(ic#tio% Are#5

Re9nery fuelKTare .as

Eatalytic reformer net .as Pressure swin. adsorption FP&A tail .as /luidied catalytically craced F/EE main column oerhead .as Aromatics plant pur.e and ent .ases &team methane reformer feed .as


110/114


111/114

)he capacity of the stora.e units aries from a one-;uart pressurecylinder to a 56-million .al under.round stora.e caern"%conomic factors determine the proper stora.e for any .ienre;uirementN Aboe-.round hi.h-pressure stora.e tans are usually desi.ned

for a


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lon. distances, low pressure, refri.erated transportation is often moreeconomical than hi.h-pressure pipelines howeer, for small ;uantitiesof ethane, multi tube truc trailers are often used"

SALES AND USES

)he sales of LP .as due to e:clusie of LP .as used in theproduction of .asoline hae increased from 366,666 .al to 7Bbillion"

)he yearly increase in sales oer the past ten years was about4? a year" )he oerall supply and demand for LP .as has beenessentially in balance the past one or two years"

Althou.h the total olumes of both butane propane in Lp .assales hae continued to increase oer this period, propane saleshae increased more rapidly than butane sales" As a result, thetrend shows a lar.er percenta.e of sales represented by propaneand a correspondin. decrease for butane, partially a result of theincreased re9nery demand for butane in motor fuel" /urthermore,the supplies of LP .as propane hae increased more rapidly thanthose of butane" )he older natural .as processin. plantsrecoered only nominal ;uantities of propane" the processimproements in e:traction of LP .as hae increased therecoery of propane up to about 86?"

As propane recoeries are increased, ethane recoeries are alsosubstantially increased" In the future, process reisions toincrease recoery are liely to proide .reater increase inproduction for ethane than for propane" %thane is used lar.elyfor the production of ethylene" )hermal cracin. of ethaneproides hi.h yields of ethylene because fewer by-products areproduced than with other feed stocs such as propane, butane,or heaier hydrocarbons" )he demand for ethane as a raw forpetrochemical manufacture should continue to e:pand rapidly"

Residential and commercial demands represent nearly half of theLP .as sales, Home heatin. is the leader in this demand" @therdomestic uses also represent si.ni9cant olumes of LP .as" )hesecond lar.est use of LP .as is in the manufacture of

petrochemical and polymer intermediates" Plastic polymers arethe lar.est consumer of intermediates deried from LP .as" )hemanufacture of polyethylene, polypropylene, and polyinylchloride, three lar.e olume and rapidly .rowin. plastic resinproducts, re;uires lar.e olumes of ethylene and propylenewhich are produced by thermal cracin. of propane, butane, andethane"

)he use of propylene for the manufacture of synthetic deter.ents


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will be substantially reduced because in the new biode.radabledeter.ents a normal in main. the alylate" )he e:pected .ainsfor propylene in polypropylene plastic and ethylene-propylenerubbers will tend to o0set the decrease in propylene"


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References

1.International Energy Glossary(a page from the website of the

Energy Information Administration)

2.Natural gas processing(a page from the website of theEnergy

Information Administration)

3.Natural Gas CondensateMarathon Oil CompanyMSDS

4.Natural Gas CondensatePhillips Petroleum CompanyMSDS

5.Condensate (Alaska)ConocoPhillipsof Alaska MSDS

6.Natural Gas CondensateAmerada Hess CorporationMSDS

7.Chemical process control George stephenpolous

8.Encyclopedia for the chemical technology. Kirk Orthomer, 4th

edition

9.Natural gas engineering, Donald. E. Katz

10. Chemical engineering handbook Robert H. Perry & DonGreen, 8thedition
http://www.eia.doe.gov/emeu/iea/glossary.html#Lhttp://en.wikipedia.org/wiki/Energy_Information_Administrationhttp://www.eia.doe.gov/pub/oil_gas/natural_gas/feature_articles/2006/ngprocess/ngprocess.pdfhttp://en.wikipedia.org/wiki/Energy_Information_Administrationhttp://en.wikipedia.org/wiki/Energy_Information_Administrationhttp://www.marathonpetroleum.com/msds/0245MAR001.pdfhttp://en.wikipedia.org/wiki/Marathon_Oil_Companyhttp://en.wikipedia.org/wiki/MSDShttp://seweb1.phillips66.com/hes/msds.nsf/5bbae21d3705607e86256bd5006a8bc9/bdb184e665400a87862565e5004b85a2?OpenDocumenthttp://en.wikipedia.org/wiki/Phillips_Petroleum_Companyhttp://seweb1.phillips66.com/hes/msds.nsf/MSDSID/US741060/$file/30017244.pdfhttp://en.wikipedia.org/wiki/ConocoPhillipshttp://www.hess.com/ehs/msds/Nat_Gas_Cond_Sweet_15017_clr.pdfhttp://en.wikipedia.org/wiki/Amerada_Hess_Corporationhttp://www.eia.doe.gov/emeu/iea/glossary.html#Lhttp://en.wikipedia.org/wiki/Energy_Information_Administrationhttp://www.eia.doe.gov/pub/oil_gas/natural_gas/feature_articles/2006/ngprocess/ngprocess.pdfhttp://en.wikipedia.org/wiki/Energy_Information_Administrationhttp://en.wikipedia.org/wiki/Energy_Information_Administrationhttp://www.marathonpetroleum.com/msds/0245MAR001.pdfhttp://en.wikipedia.org/wiki/Marathon_Oil_Companyhttp://en.wikipedia.org/wiki/MSDShttp://seweb1.phillips66.com/hes/msds.nsf/5bbae21d3705607e86256bd5006a8bc9/bdb184e665400a87862565e5004b85a2?OpenDocumenthttp://en.wikipedia.org/wiki/Phillips_Petroleum_Companyhttp://seweb1.phillips66.com/hes/msds.nsf/MSDSID/US741060/$file/30017244.pdfhttp://en.wikipedia.org/wiki/ConocoPhillipshttp://www.hess.com/ehs/msds/Nat_Gas_Cond_Sweet_15017_clr.pdfhttp://en.wikipedia.org/wiki/Amerada_Hess_Corporation

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A study report on the recovery of LPG from GAS CONDENSATE.doc

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