United Arab Emirates University College of Engineering Chemical Engineering Department Graduation Project II

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United Arab Emirates UniversityCollege of
EngineeringChemical Engineering Department
Graduation Project II
Purity Improvement of De-propanizer Products in
Umm Al Nar Refinery
Alia Salem 200002345 Maryam Aziz
200104921 Najat Abdullah
200002416 Rabaa Al Awar 200105282
Dr. Mamdouh Ghannam Academic year - 2006/2007
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Outline

• Problem statement.
• HYSYS.
• Case studies.
• Column specifications.
• Material Balance.
• Energy Balance.
• Costing and project Evaluation.
• Environmental Impact and Safety.

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Problem statement

• One of the main problems relating to the
  industrial refineries is how to improve the
  purity percentage in order to produce more pure
  products so, the main objective of our project is
  to enhance the purity percentage of the
  de-propanizer column unit in Umm Al Nar Refinery
  in order to obtain pure products of propane and
  butane.

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HYSYS
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HYSYS

• Definition
• Powerful software for simulation of chemical
  plants and oil refineries.
• Includes
• Tools for estimation of physical properties and
  liquid-vapor phase equilibrium.
• Heat and material balances.
• Simulation of many types of chemical engineering
  equipment.

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Goal of HYSYS

• To provide the user with the capability to design
  an entire process as completely and accurately as
  possible.
• To catch the errors among the simulation.

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HYSYS Features

• Easy-to-Use Windows Environment.
• Comprehensive Thermodynamics Foundation.
• Comprehensive Unit Operations.
• Detailed Heat Exchanger Design and Rating.
• Economic evaluation of process designs

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HYSYS benefits

• Helps process industries
• Improved Process Designs
• Equipment Performance Monitoring
• Reduced Engineering Costs

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Case studies
Pressure
Temperature
Flash
Reflux ratio
Feed plate location
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Case studies
C4 C3 Optimum Range of study Case study
-- 7.070 85 70 - 88 Temperature (oC)
2.289 -- 15 15.4 - 20 Pressure (atm)
-- 71.327 4 0.6 - 4.5 Reflux
-- -- -- 14 - 21 Feed plate location
16.247 -- 13.65 16.7 - 14 Flash pressure (atm)
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Column specifications
Values Parameters
17 Operating pressure (atm)
70 Temp. feed (oC)
41.40 Temp. top (oC)
85.64 Temp. bottom (oC)
Stage Contact type
4 Reflux ratio
30 Actual number of tray
18 Feed plate location
0.6 Plate spacing (m)
0.08 Column diameter (m)
 18.8 Column height (m)
Valve Tray type
0.05 Weir height (m)
1.2 Weir length (m)
0.51 Valve hole diameter (m)
8 of valve hole per plate
Carbon steel Material of construction
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Final Diagram
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Material Balance

• Chemical engineers do a material balance to
  account for what happens to each of the chemicals
  that is used in a chemical process.
• A material balance was cared out over complete
  process to determine the quantities of row
  materials required.

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Material Balance

• The general conservation equation for any process
  system

Accumulation Material in - Material out
generation - consumption
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Sample of Calculation

• Overall material balance

Component Balance
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Result

• Table (1) flow rate calculated in tower
•   

Flow rate (Kmol/hr) Pressure (atm) Temperature( C)  
188.4 17 70 Feed
7.53 15.9 41.4 Top
180.8 16.6 85.6 Bottom
Table (2) composition of feed, top and bottom in
tower
Composition Xw Composition XD Composition Xf Component
0.001 0.053 0.003 C2
0.261 0.947 0.288 C3
0.724 0.000 0.695 C4
0.014 0.000 0.013 C5
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Result

• For the Flash

Table (3) flow rate calculated in flash
Flow rate (Kmol/hr) Pressure (atm) Temperature( C)  
180.8 13.65 85.6 Feed
170.2 13.65 85.6 Top
8.6 13.65 85.6 Bottom
Table (4) composition of feed, top and bottom in
flash
Composition Xl Composition Xv Composition XT Component
0.0034 0.0014 0.0013 C2
0.1312 0.2496 0.244 C3
0.8335 0.734 0.738 C4
0.034 0.014 0.015 C5
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Energy Balance

• Energy balances are established to determine the
  energy requirements of processes (heating or
  cooling).
• The energy conservation equation
• Energy out Energy in generation -
  consumption -accumulation

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Energy Balance
Overall energy balance

• Condenser duty

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Result
Table (5) condenser and reboiler duty calculated
Energy duty (Kj/hr) Pressure (atm) Temperature( C)  
  17 70 Feed
496692.7486 15.9 41.4 Top
946797.9842 16.6 85.6 Bottom
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• Costing and project Evaluation

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Costing and project Evaluation

• Objective
• To estimate the investment required for the
  project and the cost of production.

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• Parameters needed to estimate the cost

Column Height )m) Column diameter (m) Plate spacing (m) Parameter
18.8 0.51 0.6 Measurement
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Cost Calculation

• Trays Cost
• D 0.5 m
• Type of Tray (valve)
• Number of Trays 29 trays.
• Cost of the 29 trays (29280 )
• 8,120

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Cont. Calculation

• Column Cost
• H 18.8 m
• Equipment Cost 20,000 (from figure)
• Purchased cost (equipment cost (figure)
  material factor Pressure factor)
• (20,000 21.2)
  
• 48,000
• De-propanizer column cost Trays cost
  purchased Cost
• 8,120
  48,000
• 56,120
  (year1998)

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Cost Correction
From Figure
Cost index in year (1998) 390 Cost index in
year (2003) 395
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Total Physical Plant Cost
process type (Fluids) Item
0.4 Equipment erection
0.7 Piping
0.2 Instrumentation
PPC (1 Equipment erection Piping
Instrumentation)cost in year (2006)
PPC (10.40.70.2)(60,548 ) PPC139,260
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Environmental Impact and Safety
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Study Environmental Impact and Safety
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Study environmental impact and safety for each
compounds
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Methane

• Application
• Its used as a fuel in a gas turbine to ignite
  the electrical generator by burning it
• it is the feedstock of choice for the production
  of hydrogen, methanol
• acetic acid.

• Methane is a stable compound which has different
  health hazard
• effects on the vapor and liquid phases.
• Characteristics
• it is cleaned burning fuel , non-corrosive, and
  may be used with structural material.
• It is difficult to transport from the areas that
  produce it to the areas that use .
• it was converted from gas phase to liquid phase
  that are more easily transported
• It is inactive biologically and nontoxic.
• it is commonly found near swamps and wetland
  areas.
• Health effect
• high concentrations of methane causes dizziness
  and deeper breathing .

Table1 Fire and explosion hazards data for
methane
Structure
Flash point -188 oC
Lower explosion limit 5 (vol ) gas in air
Higher explosion limit 15 (vol) gas in air
extinguishing media CO2, Dry chemical, water
Boiling point -161.6 oC
Freezing point -182.5 oC
Auto ignition Temperature 537oC
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Ethane

• Ethane
• It consists of two carbons and six hydrogen's
  which is connected each other by covalent single
  bonds
• Characteristics
• it is a stability and resistance to reactivity.
• It is nonpolar component and insoluble in polar
  solvent .
• It is a liquid under pressure.
• Health effect
• It cause headache,vomiting, and dizziness .

• Application
• It is used in many applications such as a fuel,
  in making chemicals, or as a freezing agent.

Table 2 Fire and explosion hazards data for
ethane.
Structure
Flash point -135 oC
Lower explosion limit 5 (vol ) gas in air
Higher explosion limit 12.5 (vol) gas in air
extinguishing media CO2, Dry chemical, water
Boiling point -88.6 oC
Auto ignition Temperature 472 oC
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Propane

• Application
• it is used to make petrochemicals which are the
  building blocks for
• plastics, alcohols, fibers, and
  cosmetics.
• It is a feedstock for propyl alcohol and a
  common solvent.
• It is used as fuel in hot air balloons and as a
  fuel for lubrication in guns.

• Propane it's hydrocarbon component and occurs as
  a gas at atmospheric pressure.
• Characteristics
• it is liquefied under high pressure.
• It is stored and transported in its compressed
  liquid form.
• Propane is non-toxic and odorless.
• Health effect
• It cause irritate the eyes and dizziness at high
  concentrations.

Table3 Fire and explosion hazards data for
propane.
Structure
Flash point -104 oC
Lower explosion limit 2.37(vol ) gas in air
Higher explosion limit 9.5 (vol) gas in air
extinguishing media CO2, Dry chemical, water
Boiling point -42.09 oC
Auto ignition Temperature 432 oC
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Butane

• Application
• It is used as a fuel for cooking and camping .
• It is used as a refrigerant in automobiles
• It is consider a petrol component .

• Butane It's hydrocarbon component and is
  consider unbranched alkane with four carbon atoms
  
• Characteristics
• It's highly flammability gas, colorless, odorless
  and acute toxicity.
• easily liquefied gases
• Health effect
• It causes sleepiness, irritation, and frostbite,

Table 4 Fire and explosion hazards data for
butane
Structure
Flash point -60 oC
Lower explosion limit 1.8(vol ) gas in air
Higher explosion limit 8.4 (vol) gas in air
extinguishing media CO2, Dry chemical, water
Boiling point -0.5 oC
Auto ignition Temperature 487 oC
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Pentane

• Application
• It could be used as a source of H2 through steam
  reforming..

• Pentane It is a longer hydrocarbon than butane
  and is generally obtained from the processing of
  crude oil or natural gas.
• Characteristics
• It is a product chemical and it is mainly a fuel
  and a solvent.
• It is often used in the laboratory as a solvent
• its nonpolarity
• Health effect
• It has a negative effect on our eyes, bodies and
  the environment in general

Table 5 Fire and explosion hazards data for
pentane
Structure
Flash point -49 oC
extinguishing media CO2, Dry chemical, water
Boiling point 36.1 oC
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