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Comprehensive Gas Treatment Plant Analysis: Process Flow, Equipment Costs, and Efficiency Estimate

This report outlines a detailed analysis of a gas treatment plant, focusing on process flow diagrams and equipment specifications involved in hydrocarbon recovery. Key areas of discussion include the block flow diagram, PFDs detailing stream compositions, pressure and temperature throughout the processes, energy sinks and loads, and equipment sizing. The Aspen estimator is utilized for cost analysis, highlighting the capital costs and operational expenditures of various equipment, such as demethanizers and molecular sieve adsorbers. Relevant previous questions illustrate optimization opportunities for feed gas processing.

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Comprehensive Gas Treatment Plant Analysis: Process Flow, Equipment Costs, and Efficiency Estimate

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  1. Gas Treatment Plant Chris, Stephanie, Mariam, Kyle Mentor: Jerry Palmer

  2. Report Outline • Previous Questions • Block Flow Diagram • Detailed PFD's (stream #, components, P&T) for each process • Energy sinks/loads, Equipment sizing, Cost in Aspen estimator for one process -- Hydrocarbon recovery

  3. Previous Questions 1. Sending 97% Nitrogen and 3% methane from Nitrogen rejection stream to NH3 plant. 2.Using thermal swing adsorber instead of a pressure swing adsorber. To prevent the loss of feed gas in the bed during depressurization and also,the short time cycle in PSA can cause rapid re-pressurization that will lead to transient variation in the feed and product flow which will affect the operation of the plant 3. Using only one turboexpander for Hydrocarbon recovery.

  4. Basis : 310 MMSCFD Revenues Midrex : 103 kmol/day (Transfer Cost) Syn Gas:111 kmol/day (Transfer Cost) Nh3 PLant : 50.4 kmol/day (Transfer Cost) CHP :195.4 kmol/day (Transfer Cost) Pipeline:4.8 kmol/day ($3.80/MSCFD) LNG: 5000 BBL/day ($10.40/BBL) NGL: 48990 BBL/day (~$22/BBL)

  5. Block Flow Diagram

  6. PFD-002

  7. PFD-003

  8. Aspen Estimate-Demethanizer in Hydrocarbon Recovery Size: Tower: • Vessel Diameter: 8.5 ft • Vessel Height 66 ft • Liquid volume: 11,249.5 gallons • 33 Trays • 24 inches between trays Condenser: • Area: 22,980.6 ft^2 Reboiler: • Area: 7,803.94 ft^2 • Tube length: 20 ft Reflux Pump: • Liquid flow rate: 1808.3 GPM • Efficiency: 70

  9. Aspen Estimate-Demethanizer in Hydrocarbon Recovery Equipment Cost: • Tower: $3,059,300 • Condenser: $419,000 • Reboiler: $268,000 • Reflux Pump: $17,200 Total equipment cost for one Demethanizer Column: $3,763,500

  10. Aspen Estimate-Demethanizer in Hydrocarbon Recovery Energy: • Tower: 28.03 MMBTU/hr • Condenser: 22.7 MMBTU/hr • Reboiler: 5.3 MMBTU/hr • Reflux ratio: .35

  11. Aspen Estimate-Demethanizer in Hydrocarbon Recovery Cost: • Total operation cost: 19,031,900 $/year • Total capital cost: $12,567,400

  12. Annotated Equipment List

  13. Energy Loads and Sinks • PFD-001: Compression = 6888 HP Heating = 1.7MMBTU/HR • PFD-002 and PFD-003: Estimated total of 139MMBTU/HR • PFD-004:Air Cooling =3.4MMBTU/HR Compression = 880HP Heating = 44.6MMBTU/HR • PFD-005: Refrigeration = 56.3 MMBTU/HR • PFD-006: Heating = 8 MMBTU/HR • PFD-007: Compression = 1260 HP Refrigeration = 58 MMBTU/HR • PFD-008: Compression = 920HP

  14. Major Equipment Costs • 6 molecular sieve Adsorbers installed $ 6,690,000 • 24 Tray Nitrogen Rejection Column Installed $2,300,000 • Absorbing and Stripping Columns for MDEA treatment, approximately 25 trays each intstalled $2,500,000

  15. Q & A

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