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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.
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Fig. 3 shows block diagram for the integration between Ameryal LPG & WDGC
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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
Max
Pressure 70 kg/cm g
68
72
Temperature
14
30
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
0.5
C2 without CO2
92
C3
8-15
C4+
0.1
CO2
10 kg/cm2 g
C5+ LV%
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0.1
C2 max
1.8
C3 min
95
C4
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-
5
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 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
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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
4.33
12.96
85
Max. 0.1
C2 in propane production, wt %
Max. 1.8
C3 in propane production, wt %
Min. 95
10
SPE 151894
10
SPE 151894
Secondly, study the effect of reflux ration only on the production rate
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, %
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
11
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
68.54
84.97
57.8
57
15
15.5
Condenser, Duty MW
3.51
4.21
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
Measures
64
12
SPE 151894
3.4 Case III, Changing in Deethanizer reflux flow, bottom temperature, operating pressure and Demethanizer
bottom temperature
68.54
84.9
57.8
57.1
15
15.5
4.5
Condenser, Duty MW
3.51
4.21
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
67
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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
14
SPE 151894
Referances
1- Enppi process design manual for WDGC and Amerya LPG plant
2- HYSYS 7.1 manual guide