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SAJJAD KHUDHUR ABBASChemical Engineering , Al-Muthanna University, IraqOil & Gas Safety and Health Professional – OSHACADEMYTrainer of Trainers (TOT) - Canadian Center of Human Development
Episode 7 : iCON
Basic Training
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
SKG 16 - iCON Basic Training – Itinerary
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Day Training Modules
22 October 2013 Slides presentation1. Compressor Train2. Demethanizer Column3. Fractionation Train4. Propane Loop5. Steam Reformer
23 October 2013 1. Oil Characterization2. Refinery Separation3. Amine System
24 October 2013 1. Utility Optimizer Module 12. Utility Optimizer Module 23. Column Optimization4. Property Regression
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Outline
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• Introduction to Process Simulation
• iCON Software
• Thermodynamic Property Package
• Modeling Approach
• Hands On Training
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
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Introduction to Process Simulation
Introduction
Process simulation is the representation/replication of the real world
process behavior through mathematical models.
Process Simulator is a software that predicts the condition, composition
and properties of a particular point (stream) from an initial condition through
mass and energy balances and thermodynamic principles.
iCON is based squarely on fundamental thermodynamic principles
(equation based).
These principles are used in two main features of the process simulator:
The thermodynamic calculation engine
The simulation solver for unit operation and flowsheet.
Introduction
The thermodynamic engine provides:
Rigorous thermodynamic equilibrium and physical property estimation
for industrially important systems
The simulation solver continually monitors:
The degrees of freedom of the flow sheet,
Immediately invokes the necessary calculations when the degrees of
freedom are complete,
Solved the system of equations describing the flow sheet.
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Steady State Vs Dynamics
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Steady State Dynamic
Mass & Energy Balance
Always balance Not always balance
Time dependence No Yes
Accumulation i.e. level simulation
No Yes
Equipment dimension
Not required Required
Pressure profile No impact Impacts flow
Typical applications • Process Design•Equipment Rating & Monitoring• Utility Balance
• Process Control Optimization• Plant Startup & Shutdown•Operator Training Simulator
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS) 8
Process Simulation & Optimization Cycle
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2
3
45
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PETRONAS Official Process Simulation Software
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
What is iCON?
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iCON is an innovative steady-state & dynamic simulation software modeling tool for oil, gas, petrochemical, utilities
and power generation industries.
iCON is capable of solving a wide range of engineering problems and is
industry driven. It has been proven in reliability in oil gas production, oil refinery, petrochemicals, utility &
power generation
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Thermodynamic Property Package
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS) 12
Property Package
A property package is a collections of equations that define (given set of
physical conditions) :
1. State of matter i.e vapor/mix/liquid phase
2. Physical properties.
Derived by fitting experimental data.
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Why proper property selection is crucial?
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• To calculate the component properties at certain T&P (e.g. density, heat capacity etc.)
• To determine the phase of the component at certain T&P (e.g. V/L/V+L)
• To determine the in what proportion the component would exist in each phase (equilibrium)
• The accuracy of the calculated/simulated results will greatly depend on the accuracy of the thermodynamic package prediction.
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS) 14
Types of Property Package
Equation of State Model
• Good for non polar liquid and gas phase since can calculate critical point.
• Covers a wide temperature & pressure range
• Advance Peng-Robinson, Soave-Redlich-Kwong
• Hydrocarbon application
Activity Coefficient Model
• Good to represent non-ideal liquid due to presence of polar components, but cannot predict critical point
• Limited T & P range
• Non Random Two Liquids (NRTL), UNIFAC, UNIQUAC, Wilson
• Chemicals with high polarity i.e. water, alcohol
Special Packages
• Customized to represent specific process which may include kinetics data in addition to equilibrium data
• Limited T & P range
• Urea, Amine, Steam97
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Property Package Selection Guideline
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PETRONAS Technical Standards : Property Package Selection
(PTS 20.00.10.37 ) is available in AXIS
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS) 16
Example
Objective:
To give an indication of NH3 purity, an online calculation can be implemented as part of
ELMS, to enable operators to take necessary action to drain any contaminants i.e.
compressor oil from NH3.
Actual saturation Pressure & Temperature
Actual saturation Pressure & Temperature
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS) 17
Example
• The figure above shows multiple plots of pure NH3 using 21 different thermodynamic packages and a plot of actual DCS data.
• Lee-Kesler-Plöcker (LKP) is found to be the best suited thermo-package.
1400
1450
1500
1550
1600
1650
1700
33 34 35 36 37 38 39 40
Pre
ss
ure
(k
Pa
A)
Temp (deg C)
Pure Ammonia Temp VS PressureAPR
APR-NG
Refinery SRK
APR-LK
NGL-PR
API SOUR
CHAO SEADER
GRAYSONSTREEDMAXWELLBONELLLKP
UNIQUAC
wilson
TK-WILSON
NRTL
VAN LAAR
Actual DCS data
NGL-PR Thermo
Lee KeslerPlockerThermo
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Modeling Approach
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Modeling Approach – Degree of Freedom
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Unit Operation in iCON
Degree of Freedom • No. of specification required for the calculation to complete• Inadequate specification calculation will not progress• Overspecified inconsistency error will created
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Modeling Approach – Degree of Freedom
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Unit Operation Typical Specification
Stream Pressure, Temperature, Flow, Composition
Separator With feed stream, separator will converged without having to specify anything
Cooler/Heater With feed stream, user needs to specify either:1. Temperature outlet, Delta P2. Temperature outlet, Pressure outlet
Heat Exchanger User needs to have both fluids properties (2 streams; shell and tube)Other specifications are similar to cooler/heater
Compressor/Pump/Expander
With feed stream, user needs to specify either:1. Pressure outlet, Efficiency2. Pressure outlet, Temperature outletIf with compressor curve, speed is required as specification
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
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Hands-on Training..
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Desktop
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New file..
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#1 Property package: Advance Peng Robinson
#2 Add components:Water; Nitrogen; Carbon Dioxide; Methane; Ethane; Propane; iso-Butane; n-Butane; iso-Pentane; n-Pentane; n-Hexane;
h2o;n2;co2;c1;c2;c3;ic4;nc4;ic5;nc5;nc6;
1 Water
2 Nitrogen
3 Carbon Dioxide;
4 Methane
5 Ethane
6 Propane
7 Iso-Butane
8 n-Butane
9 iso-Pentane
10 n-Pentane
11 n-Hexane
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#1 Property package: Advance Peng Robinson
#2 Add components:Water; Nitrogen; Carbon Dioxide; Methane; Ethane; Propane; iso-Butane; n-Butane; iso-Pentane; n-Pentane; n-Hexane;
h2o;n2;co2;c1;c2;c3;ic4;nc4;ic5;nc5;nc6;
1 Water
2 Nitrogen
3 Carbon Dioxide;
4 Methane
5 Ethane
6 Propane
7 Iso-Butane
8 n-Butane
9 iso-Pentane
10 n-Pentane
11 n-Hexane
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#3 Flash a material streamUnit
Temperature Deg C 30
Pressure Kpa 1000
Mass Flow Kg/h 125
Water Mol %
1
Nitrogen Mol %
0.5
Carbon Dioxide;
Mol %
0.5
Methane Mol %1
Ethane Mol %1
Propane Mol %5
Iso-Butane Mol %45
n-Butane Mol %40
iso-Pentane Mol %2
n-Pentane Mol %2
n-Hexane Mol %2
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# 4 Flash options
P-T Flash
Vapor Fraction (VF) Flash Calculation
P-H Flash
Temperature , Pressure , Flow ,Composition
Enthalpy, Pressure , Flow ,Composition
Vapor Fraction, Pressure , Flow ,Composition
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# 5 Pseudo component: Min data: Normal Boiling Point or Molecular Weight + Liquid Density
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Getting startedStarting iCON from desktop.Selecting thermo.Selecting components.Converging a stream.Units.Bubble / dew points.Phase diagram.Special properties.
Making a copy• Spec from•Clone•Copy stream
•Show datasheet•Table•Writing
Controller• Temperature control
Process Calculator•Totalizer
Pseudo component
Ammonia ref – choosing thermo
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Modeling Approach – Data Propagation
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• In port has a mass flow of 200 kg/hr (mole flow = 4.84 kg-mole/hr)• Since the cooler has a single In and a single Out material port:
No accumulation of matter No chemical reactions
•Therefore, the:
Mole Flow Mass Flow
of In and Out port must be IDENTICAL
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Modeling Approach – Data Propagation
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• Note that even though the mole and mass flows are NOT known, the thermodynamic state of the In port IS known.
• Click on thenode and inspect the physical properties of the In port.
• Now click on the (Mass Flow, In) cell and press the <Delete> key.
• You will notice that the since the mass flow is not specified, the mole flow is automatically forgotten.
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Modeling Approach – Data Propagation
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• Click on the (MassFlow, Out) cell and specify a mass flow of 2000 kg/h as shown below
• Hit the <Enter> key
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Modeling Approach – Data Propagation
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• Note that the Out port mass flow is now specified (blue background),
• And the mole flow is automatically calculated at 4.84 kgmole/h.
• Also, note that the available information is propagated backwards to the In port.
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS) 34
Flash Calculations • Rigorous three-phase calculations except for Wilson (only vapor liquid)
• Type of flash calculation based on degree of freedom concept depending on specifications imposed on the system
• Independent Variables: Pressure (P), Enthalpy (H)• Dependent Variables: vapor fraction, Temperature and entropy
P-T Flash
• Independent Variables: Vapor Fraction (VF) and Temperature (T) or Vapor Fraction (VF) and Pressure (P)
• Dependent Variables: Pressure (P) or Temperature (T) and enthalpy and entropy
• Examples: • Dew Points: VF = 1.0, and either P or T• Bubble Points: VF = 0.0, and either P or T
Vapor Fraction (VF) Flash Calculation
• Independent Variables: Temperature (T), Pressure (P)• Dependent Variables: vapor fraction, enthalpy and entropy
P-H Flash
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)
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