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ABB Lummus Global, Inc.ABB Lummus Global, Inc.Lummus Process TechnologyLummus Process Technology
Randall Gas TechnologiesRandall Gas Technologies 8282stst AnnualAnnualGPA ConventionGPA Convention
San Antonio, TexasSan Antonio, Texas
1212--MarchMarch--20032003
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A Review of the Basics for Superior DesignA Review of the Basics for Superior DesignHazemHazem Haddad, Ph.D., PEHaddad, Ph.D., PE
Jorge Jorge FogliettaFoglietta, PE, PE
ABB ABB Lummus Lummus Global IncGlobal IncLummus Process Technology Lummus Process Technology -- Randall Gas TechnologiesRandall Gas Technologies
Houston, TexasHouston, Texas
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IntroductionIntroduction
Why Thermodynamic Analysis?
Minimum/Ideal WorkWith Actual Work known, it gives the process efficiency.Identifies areas in the process with large lost work or Operations that are “Highly Irreversible”
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What is a reversible process?
A reversible process is a process that undergoes a change in infinitesimally small steps such that, at all times, the system remains at equilibrium or infinitesimally away from equilibrium.
All heat transfer is to or from the environment via a Carnot engine.
A reversible process must produce useful work.
Introduction (…cont.)Introduction (…cont.)
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For a plant to be reversible
Every operation in the process has to be reversible
Introduction (…cont.)Introduction (…cont.)
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One Block Movie
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Two Block Movie
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Four Block Movie
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Types of Lost Work
Chemical Lost Work: Irreversible chemical reactions.
Heat Transfer Lost Work: Temperature gradient.
Mass Transfer Lost Work: Mixing of streams with different composition.
Momentum Lost Work: Pressure drop or irreversible change in pressure.
Introduction (…cont.)Introduction (…cont.)
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Ideal Work
For a work requiring process, this is the minimum work required to accomplish the process.
Shaft WorkThis is the work of rotating shafts like compressors, expanders and pumps etc.
Lost WorkThe difference between the Ideal and shaft work.
DefinitionsDefinitions
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Thermodynamic CalculationsThermodynamic Calculations
The Entire ProcessThe Entire Process
WWidealideal =T=Tee∆∆SS--∆∆HH
WWshaftshaft = = ΣΣ WWii
WWlostlost == WWidealideal -- WWshaftshaft
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Thermodynamic Calculations, Cont.Thermodynamic Calculations, Cont.
Heat ExchangersHeat Exchangers
WWidealideal=T=Tee∆∆SS--∆∆HH
∆∆H=0H=0
WWshaftshaft = 0= 0
WWlostlost == WWidealideal = T= Tee∆∆SS
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Thermodynamic Calculations, Cont.Thermodynamic Calculations, Cont.
Non Adiabatic Heat Exchangers and simplifying assumptionsNon Adiabatic Heat Exchangers and simplifying assumptions
Air CoolersAir Coolers
WWidealideal=T=Tee∆∆SS--∆∆HH
WWshaftshaft = 0= 0
WWlostlost = = WWidealideal
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ValvesValves
WWidealideal=T=Tee∆∆SS--∆∆HH
∆∆H=0H=0
WWshaftshaft = 0= 0
WWlostlost = = WWidealideal = T= Tee∆∆SS
Thermodynamic Calculations, Cont.Thermodynamic Calculations, Cont.
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Compressors, pumps, expandersCompressors, pumps, expanders
WWidealideal=T=Tee∆∆SS--∆∆HH
WWshaftshaft = = WWactualactual
WWlostlost = = WWidealideal -- WWshaftshaft
Thermodynamic Calculations, Cont.Thermodynamic Calculations, Cont.
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Distillation ColumnsDistillation Columns
Isolate the column from the heat exchangers!Isolate the column from the heat exchangers!
WWidealideal=T=Tee∆∆SS--∆∆HH
∆∆H=0, H=0, WWshaftshaft = 0= 0
WWidealideal = T= Tee∆∆S= S= WWlostlost
Thermodynamic Calculations, Cont.Thermodynamic Calculations, Cont.
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Conventional Propane RecoveryConventional Propane Recovery
T-100Deethanizer
X-101/C-101Expander/
Recompressor
PF1Condenser
Feed
NGL ProductFigure 1
Feed Chiller
Hot Oil
1290 psia68°F
1290 psia100°F
T-101Absorber
-9.5°F
Air Cooler
1
2120
2
16
51
5
18
3
OV2
OV1
15
9
11
8
10
17
7
19
13
Flow=0
Applications to Gas Plants Applications to Gas Plants –– CC33 RecoveryRecovery
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Conventional Propane RecoveryConventional Propane Recovery
Calculate the ideal and lost work for the entire process.
Disconnect the process into individual adiabatic processes.
Calculate the ideal and lost work for each individual operation.
Add up the total and lost work as a check.
Application to Gas Plants Application to Gas Plants –– CC33 RecoveryRecovery
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T-100Deethanizer
X-101/C-101Expander/
Recompressor
PF1Condenser
Feed
NGL ProductFigure 2
Feed Chiller
Hot Oil
1290 psia68°F
1290 psia100°F
T-101Absorber
-9.5°F
Air Cooler
Recommended ApproachRecommended Approach
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Simulation tools and SpreadsheetsSimulation tools and Spreadsheets
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Simulation tools and SpreadsheetsSimulation tools and Spreadsheets
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Thermodynamic Analysis of Conventional Propane RecoveryThermodynamic Analysis of Conventional Propane Recovery
11.85,01405,014Air Cooler
100.042,352-48,333-5,981Total
00-4,034-4,034Reboiler
44.018,647-42,299-25,652Rotating Equipment
16.26,84206,842Columns
0.143043Valves
27.911,805011,805Exchangers
% of lostWlostWshaftWidealEquipment
Application to Gas Plants Application to Gas Plants –– CC33 RecoveryRecovery
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Conventional Propane RecoveryConventional Propane Recovery
T-100Deethanizer
X-101/C-101Expander/
Recompressor
PF1Condenser
Feed
NGL ProductFigure 1
Feed Chiller
Hot Oil
1290 psia68°F
1290 psia100°F
T-101Absorber
-9.5°F
Air Cooler
1
2120
2
16
51
5
18
3
OV2
OV1
15
9
11
8
10
17
7
19
13
Flow=0
Applications to Gas Plants Applications to Gas Plants –– CC33 RecoveryRecovery
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New Concept DevelopmentNew Concept Development
The High Pressure Absorber The High Pressure Absorber -- HPAHPA
Operate the absorber at high pressure (500 to 700 psia). This pressure is limited by the approach to critical conditions and the amount of refrigeration needed from the expander to keep the process self refrigerated.
Install a compressor to compress the net deethanizer overhead.
Eliminate the pump at the bottom of the absorber.
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T-100Deethanizer
X-101/C-101Expander/
Recompressor
PF1Condenser
Feed
NGL Product
Figure 3
Feed Chiller
Hot Oil
1290 psia68°F
1290 psia100°F
T-101Absorber
-27.6°F
Air Cooler
HPA for Propane Recovery HPA for Propane Recovery
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Thermodynamic Analysis of the HPA Process for Propane RecoveryThermodynamic Analysis of the HPA Process for Propane Recovery
9.30-3,226-3,226Reboiler100.028,264-34,140-5,876Total
10.52,63602,636Air Cooler
38.410,843-30,914-20,071Rotating Equipment21.46,05106,051Columns
3.91,09701,097Valves
27.07,63407,634Exchangers
% of lostWlostWshaftWidealEquipment
Application to Gas Plants Application to Gas Plants –– CC33 RecoveryRecovery
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Comparison to Conventional TwoComparison to Conventional Two--Tower SchemeTower Scheme
HPA SchemeConventional Scheme
10.52,63611.85,014Air Cooler38.410,84344.018,647Rotating Equipment21.46,05116.26,842Columns3.91,0970.143Valves27.07,63427.911,805Exchangers
PercentLost WorkPercentLost Work
30,91444,299Total Actual Work
28,26442,352Total Lost Work
HPA HPA –– CC33 Recovery Recovery
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The High Pressure Absorber The High Pressure Absorber -- HPAHPA
With reasonable heat integration, if the temperature of the residue gas stream entering the recompressor is significantly colder than the temperature of the feed then the expander is generating excessive refrigeration and the absorber can be operated at higher pressure.
Factors favoring the HPA Process for CFactors favoring the HPA Process for C33 recoveryrecovery
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T-100Deethanizer
X-101/C-101Expander/
Recompressor
PF1Condenser
Feed
NGL Product
Figure 3
Feed Chiller
Hot Oil
1290 psia68°F
1290 psia100°F
T-101Absorber
-27.6°F
Air Cooler
HPA for Propane Recovery HPA for Propane Recovery
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0.00
10.00
20.00
30.00
40.00
50.00
60.00
-40.00 10.00 60.00 110.00 160.00 210.00
Stage Temperature (F)
Hea
t Flo
w (M
MB
tu/H
r)Deethanizer CGCC – Conventional C3 Recovery
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Column Grand Composite Curve
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
-70.00 -20.00 30.00 80.00 130.00 180.00
Stage Temperature (F)
Hea
t Flo
w (M
MB
tu/H
r)Deethanizer CGCC – HPA C3 Recovery
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T-101Demethanizer
X-101/C-101Expander/
Recompressor
PF1Gas Subcooler
Feed
NGL ProductFigure 4
Feed Chiller/Side reboiler
1290 psia68°F
1290 psia100°F
46°F
Air Cooler
Application to Ethane RecoveryApplication to Ethane RecoveryConventional Ethane RecoveryConventional Ethane Recovery
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Thermodynamic Analysis of a Conventional Ethane Recovery ProcessThermodynamic Analysis of a Conventional Ethane Recovery Process
100.038,035-47,348-9,313Total
12.04,57304,573Air Cooler
44.616,965-47,348-30,383Rotating Equipment
17.26,53906,539Columns
11.04,18404,184Valves
15.25,77305,773Exchangers
% of lostWlostWshaftWidealEquipment
Application to Gas Plants Application to Gas Plants –– CC22 RecoveryRecovery
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T-101Demethanizer
X-101/C-101Expander/
Recompressor
Gas Gas Exchanger Gas Subcooler
Feed
NGL ProductFigure 5
Feed Chiller & Reboilers
1290 psia68°F
1290 psia100°F
-22°F
Air Cooler
Application to Gas Plants Application to Gas Plants –– CC22 RecoveryRecoveryNew ConceptNew Concept
Patent Pending
ABB Lummus Global
All Rights Reserved
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Thermodynamic Analysis of HPA for Ethane RecoveryThermodynamic Analysis of HPA for Ethane Recovery
100.032,572-42,501-9,929Total
12.54,05804,058Air Cooler
42.313,792-42,501-28,709Rotating Equipment
21.46,97606,976Columns
10.73,49803,498Valves
13.04,24804,248Exchangers
% of lostWlostWshaftWidealEquipment
Application to Gas Plants Application to Gas Plants –– CC22 RecoveryRecovery
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Comparison to Conventional GSP SchemeComparison to Conventional GSP Scheme
HPA SchemeConventional Scheme
12.54,05812.04,573Air Cooler42.313,79244.616,965Rotating Equipment21.46,97617.26,539Columns10.73,49811.04,184Valves13.04,24815.25,773Exchangers
PercentLost WorkPercentLost Work
Comparison for the CComparison for the C22 Recovery ProcessRecovery Process
42,50147,348Total Actual Work
32,57238,035Total Lost Work
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0
10
20
30
40
50
60
70
80
-150 -125 -100 -75 -50 -25 0 25 50
Stage Temperature (°F)
Dut
y (M
MBt
u/H
r)Demethanizer CGCC – No Side Reboilers
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10
20
30
40
50
60
70
-150 -125 -100 -75 -50 -25 0 25 50
Stage Temperaure (°F)
Dut
y (M
MB
tu/h
r)Demethanizer CGCC – 1 Side Reboiler
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5
10
15
20
25
30
35
40
45
50
-150 -125 -100 -75 -50 -25 0 25 50
Stage Temperature (°F)
Dut
y (M
MB
tu/H
r)Demethanizer CGCC – 2 Side Reboilers
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T-101Demethanizer
X-101/C-101Expander/
Recompressor
PF1Gas Subcooler
Feed
NGL ProductFigure 4
Feed Chiller/Side reboiler
1290 psia68°F
1290 psia100°F
46°F
Air Cooler
Application to Ethane RecoveryApplication to Ethane RecoveryConventional Ethane RecoveryConventional Ethane Recovery
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More on Column TargetingMore on Column Targeting
0
20
40
60
80
100
120
140
160
180
30 50 70 90 110 130 150 170 190
Stage Temperature (F)
Hea
t Flo
w (M
MB
tu/H
r)
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More on Column TargetingMore on Column Targeting
Minimum Condenser/reboiler duties.
Percent above minimum reflux/stripping.
Maximum amount of heat that can be added/removed by a side exchanger.
A measure of reversibility.
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Column TargetingColumn Targeting
L, X*
V, Y*
LminX*
HL
VminY*
HV
D, XD
D, XDHD
F, XF HF
(a) (b)
Let’s consider a simple distillation column with a condenser and a reboiler.By definition, the streams exiting the ideal stage are at equilibrium.
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Column TargetingColumn Targeting
An overall material balance yields
A light key component material balance yields
LXDX=VY D**
minmin +
Solve for Lmin and Vmin
LD=V minmin +
DH-LH-VH=H DLVdeficit minmin
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Conclusions & RecommendationsConclusions & Recommendations
The statue was already in the rock…All I had to do was take it out… Michel Angelo
With current computer technology, thermodynamic analysis of a process is no longer a tedious process.
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Thank You!
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Comparison to Traditional Two-Tower Scheme
Absorber Pressure,psig 440 700Two-Tower Scheme High Pressure Absorber
Cooling/Heating, mmbtu/hr 177 126
Major Equipment Count 12 12
Residue Comp. HP 44,242 30,913
Overhead Compression --- 3,770
Plate-Fin UA / 106 5.1 19.3
High Pressure Absorber Process – C3 Recovery(Pat. Pending)
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Comparison to Traditional Two-Tower Scheme
Absorber Pressure,psig --- 580Two-Tower Scheme High Pressure Absorber
CO2 Freezing Margin,°F
Cooling/Heating, mmbtu/hr 108 100
Major Equipment Count 12 14
Residue Comp. HP 47,348 42,498
Overhead Compression --- 5,210
Plate-Fin UA / 106 20.6 47.7
High Pressure Absorber Process – C2 Recovery