United Arab Emirates University

1
United Arab Emirates University College of
Engineering Training Graduation Projects
unit Graduation project II
Design of Natural Gas Processing Plant
Students Names
ID Osama Husain Al-Bloushi 200101379
Emad Ali Mubarak
200101527Abdullah Saeed shamsi
200337479
Advisor Dr. Nayef Ghasem
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Presentation Out-line

• GP I and GPII.
• Process Description.
• Mechanical Design
• Heat Exchanger design.
• Distillation column design.
• Separator design.
• HAZOP Study.
• Cost estimation.

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First semester
Activity 1
Literature search
Processes
4
First semester
Process selection
Activity 2
Activity 3
Material Energy Balances
5
Layout
First semester
Second semester
1- Design Sizing of Equipment
2- Hazard Operability Study
3- Cost and Economical Evaluation
4- Conclusion
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Sweetening Unit (Process Flow Diagram)
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Heat Exchanger

• The Transfer of heat is an essential part of most
  chemical process.
• Heat exchangers are devices built for efficient
  heat transfer.
• widely used in engineering processes.

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Basic design procedure and theory

• Define the duty heat-transfer rate, fluid
  flow-rate and temperatures.
• Find the fluid physical properties required.
• Decide the type of heat exchanger.

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Physical Properties
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Basic design procedure and theory

• Calculate the heat load (Q)
• From the temperatures calculate log mean
  temperature difference (L.M.T.D)

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Basic design procedure and theory

• Select a trial value for the overall heat
  transfer coefficient (U).
• Calculate the area required.
• Find the number of tubes.

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Basic design procedure and theory

• Calculate the hi.
• Calculate the ho.

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Basic design procedure and theory

• Calculate the overall heat transfer coefficient.

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Basic design procedure and theory

• Calculate the pressure drop in tube side.
• Calculate the pressure drop in the shill side.

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Results
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Distillation Unit
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Distillation Design
Main design parameters
1- Diameter 2- Height 3- Weeping 4- Entrainment
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Distillation Design
dome
0.6 m
Column Diameter
Column Height
Hvessel Plate spacing NA Hdomes 3m (Bot.)
2m (Top)
Htotal Hvessel Hdomes
HTotal 16 m
D 3 m
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Description
Gas out
Liquid in
Feed
Liquid out
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Section in distillation column
Liquid flow
Gas flow
Perforated tray
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Weeping
The lower limit of the operating range occurs
when liquid leakage through the plate holes
become excessive.
Gas velocity lt liquid velocity
Min. actual gas velocity 15.1 m/s
Min. design gas velocity 11 m/s
15.1 m/s gt 11 m/s
Hole Diameter
Vapor density
Plate spacing
No weeping
Max. Volumetric Flow rate
Hole area
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Entrainment
Caused by an excessive liquid flow rate generated
by droplets carried out of the gas-liquid
dispersion on the tray and up to the next tray by
the gas stream.
Fractional entrainment should be less than 1
Percentage flooding 77
Plate spacing 0.6 m
0.0045 lt 0.1
No entrainment
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Total plate pressure Drop
ht hd hw how hr
1- Dry plate drop
3- Maximum Weir crest
2- Residual head
4- Minimum Weir crest
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No. of holes 27475 holes
No. of trays 16 trays
Total pressure drop 1400 Pa
Height 10.60 m
Diameter 3 m
Plate spacing 0.6 m
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Gas-Oil Separators

• Select of Gas-Liquid Separator
• Vertical Separator
• Horizontal Separator
• Limitation of sizing
• No foaming take place.
• Cloud and hydrate point below operation T.
• Smallest droplet of liq. have 100 µm diameter.
• ? gt 99.
• Retention time from 30s to 3 min

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Gas-Oil Separators

• The basis of sizing are flow rate (?l - ?g).
• Terminal velocity is the critical to calculate D
• Vertical Separator ? high Gas-Liq. ratio
• Horizontal Separator ? low Gas-Liq. ratio

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Determine of Terminal velocity
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Selection of Separator todesign
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Vertical Separator
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Vertical Separator
For one Separator
For Two Separator
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Selection of Separator to design
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Horizontal Separators
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HAZOP Studies

• Its include a systematic study of the design
• There are seven guide words with a meaning and
  comments
• No or not ? None of the design intent is
  achieved.
• More (more of, higher) ? Quantitative increase in
  a parameter.
• Less ? Quantitative decrease in a parameter.
• As well as (more than) ? An additional activity
  occurs.
• Part of ? Only some of the design intention is
  achieved.
• Reverse ? Logical opposite of the design
  intention occurs.
• Other than (other) ? Complete substitution.
  Another activity takes place.

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HAZOP Studies on REGENARATOR
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HAZOP Studies on REGENARATOR
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Cost of the Plant
Working capital cost
Fixed capital cost

• Variable operating cost
• Raw materials
• Utilities
• Shipping and packing.
• 2. Fixed operating cost
• Maintenance
• Operating labor
• Laboratory, supervision
• Plant overheads
• Capital charge
• Insurance
• Local taxes

• The design cost
• Equipment and installation
• All piping
• Instrumentation and control systems
• Building and structures auxiliary facilities such
  as utilities
• Land and civil engineering work

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Equipment Cost
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Cont..
CTM 1.18 ?CBMo,i
CGR CTM 0.35 ?CBM,i
Total purchase cost (FCI) 18,421,879
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Cost of Manufacturing (COM)
Operating Labor Cost
Total salary (COL) 234,000 /yr
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Cont..
Utility Cost

• Heat Exchanger
• Pump

Yearly Cost , Q (GJ/h)(Csteam)(t)(SF)
Yearly Cost Electric Power Utility Cost (t)
(SF)
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Cont..

• The total yearly utility costs are
• Steam mps 3,510,466 / yr
• Cooling Water 4986 144,476 149,462/ yr
• Electricity 688,565 /yr

Utility Cost 4348493 /yr
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Cont
Raw Material Waste Treatment Unit Cost

• Raw Material (Di-Ethanol Amine)
• C(RM) 148.74 m3/h 0.15 h 6574 /m3
  146,655 /yr
• Waste Treatment Unit Cost
• C(WT) 0.0 /yr

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Cont
COM 0.304 FCI 2.73 Col 1.23 (CUT CWT
CRM)
11,768,104 /yr
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Conclusion

• How to work as group.
• Make the dream true.
• Classified the work.

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