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SPE 151894

Increasing Propane Productivity by Changing the Operating Conditions


without Adding any New Facilities
Tamer Hamdy Riad, The Egyptian Natural Gas Co. Gasco

Copyright 2012, Society of Petroleum Engineers


This paper was prepared for presentation at the North Africa Technical Conference and Exhibition held in Cairo, Egypt, 2022 February 2012.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
Gasco operates two NGL plants located in Alexandria; Amerya LPG plant and Western Desert Gas Complex (WDGC).
Recently, Gasco has started up a new project that integrates the two plants to maximize Ethane and Propane productivity.
The project design is based on adding new process facilities in Amerya plant to start producing C2+ that directed to WDGC,
while a new train is added in WDGC to increase the feed gas capacity and maximize C2+ recovery by applying the Gas
Subcooled Process (GSP) as Ethan mode of operation scheme.

This paper presents a study to increase the productivity of the two plants by using simulation software to help the decision
making for what the optimum conditions should be applied in different modes of operation to increase the production.

SPE 151894

1. Introduction
Gasco operates two NGL plants Amerya LPG and Western Desert Gas Complex WDGC

Amerya LPG plant is designed to treat 300 MMSCFD of feed gas to extract LPG and condensate. The feed gas sources of
this plant are Badr 2,3 (Bapetco), Abu-Sanan, south dabah, petro-alm, (neag & sheba), west setra and septco fields. The plant
produces the following :
250 MT/Y LPG for local market
25 MT/Y condensate for the refineries.

Fig. 1 shows block diagram for Amerya LPG plant and its products
WDGC plant receives & treats 600 MMSCFD of western desert gases from Al-Obayed (Bapetco), Salam, Tarek and ElQaser (Khalda) fields, to produce the following products:
465 MT/Y of Ethane/Propane mixture used as a feed stock for petrochemical industry
(SIDPEC Company) to produce Ethylene
280 MT/Y & 59 MT/Y of LPG and condensate for the local market consumption
adding value for national economy by reducing the imported quantities of the same
products
210 MT/Y of Commercial Propane for export to the international market increasing
income from the hard currency to support the national economy.

SPE 151894

Fig. 2 shows block diagram for WDGC and its products


Recently, Gasco has started up a new project that integrates the two plants to maximize Ethane and Propane productivity.
The project design is based on adding new process facilities in Amerya plant to start producing C2+ that directed to WDGC,
while a new train is added in WDGC to increase the feed gas capacity to 900 MMSCFD and maximize C2+ recovery by
applying the Gas Subcooled Process (GSP) as Ethan mode of operation scheme.

Fig. 3 shows block diagram for the integration between Ameryal LPG & WDGC

SPE 151894

The aim of study how to maximize the C3 productivity and switch the plant to propane mode of operation there are many
obstructs which constrain this change the study will take the new train in WDGC to change the mode of operation to
maximize the production of propane.

Fig. 4 shows process flow diagram (PFD) for a new train in WDGC

SPE 151894

2. Design basis of new train in WDGC


2.1 New feed characteristic
Table 1: Design capacity 300 MMSCFD
Min

Max

Pressure 70 kg/cm g

68

72

Temperature

14

30

Table 2: Feed gas composition


Components

Lean case mol %

H2O

N2

0.81

CO2

3.7

H2S

C1

79.22

C2

9.9

C3

4.45

IC4

0.71

NC4

0.91

IC5

0.1

NC5

0.1

NC6

0.04

NC7

0.03

NC8

0.03

2.2 Product specifications from new train in WDGC


Table 3: C2/C3 mixture specifications
Specifications mol%
C1 max

0.5

C2 without CO2

92

C3

8-15

C4+

0.1

CO2

Depends on CO2 in the feed

Table 4: LPG specifications


Specifications
Vapor pressure @ 50 0C

10 kg/cm2 g

C5+ LV%

SPE 151894

Table 5: Commercial propane specifications


Wt %
C1 max

0.1

C2 max

1.8

C3 min

95

C4

Table 6: Condensate specifications


Specifications
Red vapor pressure

12 psi

SPE 151894

3. Process description
The main areas of the new train are the following:
1- Gas dehydration through a molecular sieve dehydration package
2- Chilling trains
3- Turbo expander package
4- Demethanizer systems
5-

Fractionation, including deethanizer, depropanizer, debutanizer systems

6- Sales gas compression package


The new feed gas is directed to the WDGC firstly to dehydration molecular sieve package at 70 kg/cm2 and 27 0C (summer
case) in case of operating upsets leading to hydrate formation; provision has been made for methanol injection at a number of
positions within the cryogenic C2 recovery section of the plant which are most susceptible to hydrate formation.
The new feed gas from dehydration package entering to the cryogenic section is cooled by exchange heat with the
Demethanizer gas heat exchangers and propane package, further cooling to the dry gas happens by the expander for gases
and JT valves for liquids after that the cooled gas conditions becomes 22 kg/cm2 g and -93 0C.
The Demethanizer tower which separate methane from C2 and heavier C2+ it operated with a top pressure (21 - 21.5) kg/cm2
g and liquid bottoms are collected in a separate vessel which forms the liquid hold up capacity of the column

The Demethanizer bottom are pimped to the Deethanizer tower and


the overhead vapor from the Demethanizer first cools the feed gas and compress to the national grade by expander recompressor and residue gas compressor.

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the fractionation zone including Deethanizer, Depropanizer, Debutanizer towers which separate the fractionate the gas and
produce the products C2/C3 mixture, LPG, Propane and condensate with earlier specifications. This mode of operation called
Ethan recovery to produce C2/C3 mixture, in case of no C2/C3 and switch to Propane recovery mode of operation the
operating conditions will change to extract the amount of C3 in sales gas and C2/C3 which added to propane final product with
acceptable specifications for all products.
This paper take the deethanizer tower as a case of study, the main parameters will affect to increase the production of propane
are : 1- Reflux ratio of the deethanizer tower
2- Deethanizer bottom Temperature
The main constrains affect on these parameters are:

The design duty of the condenser and reboiler

The specifications of the products like the minimum weigh percent of C3 and maximum weight percent of C2 and
C5+ in the propane product, the vapor pressure of the LPG @ 50 0C and so on. all specifications are mentioned in
product specification part

SPE 151894

So, the study will introduce three cases by using HYSYS 7.1 and recommend the optimum condition to obtain maximum
production & profit these cases are: Case (1) Changing in Deethanizer bottom temperature and reflux flow
Case (2) Changing in Deethanizer bottom temperature, reflux flow and operating pressure
Case (3) Changing in Deethanizer reflux flow, bottom temperature, operating pressure and Demethanizer bottom temperature
3.1 Define constrains of the design
Table 7: The Related Design Parameters
Equipment availability
Demethanizer reboiler duty, MMcal/hr

11.2

Deethanizer condenser duty MW

4.33

Deethanizer reboiler duty, MMcal/hr

12.96

Deethanizer reflux pump flow rate, m3/hr

85

Table 8: Products specifications and limitations according to the contract obligations

C1 in propane production, mole %

Max. 0.1

C2 in propane production, wt %

Max. 1.8

C3 in propane production, wt %

Min. 95

LPG vapor pressure @ 50 C, kg/cm g

10

SPE 151894

3.2 Case I, Changing in Deethanizer bottom temperature and reflux flow

Fig. 5 shows Deethanizer tower


In this case the paper study takes the deethanizer tower and changes both bottom temperature and reflux flow (decrease
bottom temp. and increase the reflux flow) within the margin limites and constrains shown in above tables to reach for the
optimum conditions to maximize the propane produttion.
Firstly, study the effect of temp. only on the production rate

Fig. 6 The effect of decrease the de-ethnizer bottom temperature on C3 production


This figure shows that the relation is reverse proportional so, we decrease the temp. with in the main constrain limits

10

SPE 151894

Secondly, study the effect of reflux ration only on the production rate

Fig. 7 The effect of increase the de-ethnizer bottom temperature on C3 production


This figure shows that the relation is direct proportional so, we increase the reflux ration with in the main constrain limits
So that in this case the study makes a compination between the two parameters (decrase bottom temp. and increase reflux
ratio). The effect of this compination increases the C3 production, the results showns in a below table

Table 9: Case I, Changing in Deethanizer bottom temperature and reflux flow


Design operating C2

Proposed figure

recovery figure

Operating parameters
Deethanizer Reflux flow rate, m3/hr
Deethanizer bottom temperature,o C
Deethanizer operating pressure kg/cm2
Equipment availability
Condenser, Duty MW
Reboiler Duty, MMcal/hr
Measures
C2 in propane production, wt %
C3 in propane production, wt %
C3 in salse gase, mol %
Propane production, ton/d
C3 recovery, %

Added value ton/d


* In this case the production of propane increased by 60 ton /d

68.54
57.8
15

84.79
56.4
15

3.51
9.04

4.326
9.68

0.3
99.44
0.7
569.8

1.13
99.71
0.4
629.8

87.8

93.4

60

SPE 151894

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3.3 Case II, Changing in Deethanizer bottom temperature, reflux flow and operating pressure
In case II we add operating pressure factor by increasing the pressure plus the case I and its the effect of that about
increasing the production The effect of changing these parameters shown in a below table:

Table 10: Case II, Changing in Deethanizer bottom temperature, reflux flow and operating pressure
Design operating C2

Proposed figure

recovery figure

Deethanizer Reflux flow rate, m3/hr

68.54

84.97

Deethanizer bottom temperature, C

57.8

57

15

15.5

Condenser, Duty MW

3.51

4.21

Reboiler Duty, Mmcal/hr

9.04

9.425

C2 in propane production, wt %

0.3

1.79

C3 in propane production, wt %

99.44

98

0.7

0.4

569.8

633.8

87.8

93.6

Operating parameters

Deethanizer operating pressure kg/cm2


Equipment availability

Measures

C3 in salse gase, mol %


Propane production, ton/d
C3 recovery, %

Added value ton/d


* In this case the production of propane increased by 4 ton /d over the case I

64

12

SPE 151894

3.4 Case III, Changing in Deethanizer reflux flow, bottom temperature, operating pressure and Demethanizer
bottom temperature

Fig. 8 shows Deethanizer tower


In case III we Demethanizer bottom temperature add operating pressure factor by increasing the pressure plus the case I and
its the effect of that about increasing the production The effect of changing these parameters shown in a below
table:
Design operating C2
Proposed figure
recovery figure
Operating parameters
Deethanizer Reflux flow rate, m3/hr

68.54

84.9

Deethanizer bottom temperature, C

57.8

57.1

Deethanizer operating pressure kg/cm2

15

15.5

Demethanizer operating temperature

4.5

Condenser, Duty MW

3.51

4.21

Reboiler Duty, Mmcal/hr

9.04

9.404

Equipment availability

Measures
C2 in propane production, wt %

0.3

1.62

C3 in propane production, wt %

99.44

98.17

0.7

0.36

569.8

636.8

87.8

94

C3 in salse gase, mol %


Propane production, ton/d
C3 recovery, %

Added value ton/d


* In this case the production of propane increased by 3 ton /d over the case II

67

SPE 151894

13

4. Summary
Case III is the recommended case because we can recover about 24,000 Ton/Y from 38,000 which means profit
equal to 21 Million $/ Y

Fig. 9 the added values of C3 production in the three cases


So, to determine the optimum operating condition of swithching the plant from ethan to propane mode of operation you must
take care about the dynamics of the change inputs and plant response inbetween the design parameters and costrains of the
equipments so this study just a study of the effect of switching to propane mode of the respose of the plant between the
design conditions.

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SPE 151894

Referances
1- Enppi process design manual for WDGC and Amerya LPG plant
2- HYSYS 7.1 manual guide

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