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June 2012
Introducing Petrofac
Petrofac is the largest UK-listed service provider to the international oil & gas
industry (FTSE #60), with more than 15,000 employees across the world
We have 30 years experience and a track record of several hundred projects
across our key markets of the Middle East, Africa, CIS, Asia Pacific and UK
Continental Shelf
Our capabilities span the oil & gas value chain; subsurface, asset management,
field development, engineering, construction, operations, maintenance and training
We provide these services as standalone offerings but increasingly we offer our
capabilities as integrated services to resource holders to enable them to develop
their assets we call this business Integrated Energy Services (IES)
Whilst IES may deploy capital, we are fundamentally a service company, not an oil
company we dont do exploration and we dont seek to book reserves
We have been ranked number one EPC contractor in 2010 and 2011 in Oil & Gas
Middle East and annually train more than 50,000 delegates
June 2012
Global footprint,
local capability
Moscow
Atyrau
Baku
Milan
Abu Dhabi
Aberdeen
Sharjah
Ashgabat
Sakhalin
Houston
Woking
Bishkek
London
Beijing
Algiers
Mumbai
Delhi
Tunis
Villahermosa
Chennai
Muscat
Doha
Lagos
Bangkok
Basra
Ahmadi
Khobar
Kuala Lumpur
Singapore
Jakarta
Brisbane
Main operational centres
Other operating locations
Corporate services
Exchanger Selection & Design in an LPG
Recovery Unit
June 2012
Outline
Background
o Where does LPG recovery fit into the overall oil & gas process
o Introduce typical turbo-expander based recovery processes
Case Study
o Impact of approach temperatures on recovery and exchanger design
o Advantages of plate fin exchangers
o Design in Aspen HYSYS using HTFS modules (Aspen Shell& Tube and
Aspen Plate Fin Exchanger program)
o Design considerations for plate fin exchangers
June 2012
INJECTION GAS
COMPRESSOR
GAS
DEHYDRATION
LPG RECOVERY
NATURAL
GAS LIQUIDS
(NGL)
GAS
SWEETENING
INLET
FACILITIES /
SLUG
CATCHER
FRESH
TO GAS
INJECTION
SALES GAS
COMPRESSOR
TO GAS EXPORT
LPG
SEPARATION
TO LPG EXPORT
PIPELINE
PIPELINE
OIL
PROCESSING
WATER
C5 +
TO OIL EXPORT
PRODUCED
WATER
TREATMENT
Exchanger Selection & Design in an LPG
Recovery Unit
June 2012
PIPELINE
Processes
Lean Oil Absorption
External Refrigeration
Expansion Refrigeration Joule Thompson Cooling
J-T Valve
Turbo Expander
June 2012
Recompressor
RESIDUE GAS
Heat Exchangers
INLET GAS
Turbo Expander
Low
Temperature
Separator
Deethaniser
C3+ PRODUCT
June 2012
Recompressor
Condenser
RESIDUE GAS
Turbo Expander
Reflux Drum
Heat Exchangers
INLET GAS
Low
Temperature
Separator
Deethaniser
C3+ PRODUCT
June 2012
Recompressor
Condenser
RESIDUE GAS
Turbo
Expander
Absorber
Heat Exchangers
INLET GAS
Low
Temperature
Separator
Deethaniser
C3+ PRODUCT
June 2012
Feed gas
Inlet Pressure 74 barg
Design Case
Flow rate,
MMSCFD
Normal
500
C2 and lighter
Iso & N Pentane
% mol
Composition
Nitrogen
CO2
Methane
Ethane
Propane
i-Butane
n-Butane
i-Pentane
n-Pentane
1
1.5
75
16
4
0.5
1.5
0.5
0
<2.6% mol
<0.4% mol
June 2012
June 2012
OHR process
June 2012
51 oC
55 oC
E-1
-4 oC
40.7 oC
INLET GAS
21.7 bar
E-2
-48oC
41 oC
Turbo
Expander
Low
Temperature
Separator
-24 oC
45 oC
65 bar
June 2012
Absorber
-36.5 oC
49.5oC
E-3
-33.5 oC
21.7 bar
-55oC
E-2
49.5 oC
65.7 bar
Low
Temperature
Separator
55oC
INLET GAS
-11.5oC
June 2012
Turbo
Expander
Absorber
-36.6oC
LNG-1
51.84oC
-15.7oC 66.2bar
55oC
INLET GAS
Low
Temperature
Separator
45.8oC
-38.8oC
21.7 bar
-59.5oC
June 2012
Turbo
Expander
Absorber
96
9.6
94
9.4
92
9.2
90
88
8.8
86
8.6
84
8.4
82
8.2
80
78
7.8
0
June 2012
10
12
T-E
E Power MW
LPG Recovery %
LPG recovery %
Turbo Exp
power MW
Case
Exchanger
Heat exchanged, kW
Configuration
Surface area, m2
Geometry
Total cost, $ (HTFS)
10 deg C app
aE1
1418
1P, 1S
238
BEM
E2
2157
1P, 2S
223
BEU
2.8 million
June 2012
5 deg C app
E3
21278
2P, 2S
4586
NFU
E2
E3
7865
23756
1P, 2S
2P, 2S
5734
9756
NFU
NFU
6.4 million
June 2012
June 2012
Plate-fin Summary
June 2012
June 2012
June 2012
Comparison of configurations
6 Shell & Tube Exchangers
Single Plate-fin
Replaced by
June 2012
June 2012
Comparison
5 deg C approach 3 deg C approach
Exchanger type
LPG recovered
Additional revenue @ $400 /
ton LPG
TPH
S&T exchanger
68.12
69.85
Million $
/annum
5.5
Exchanger volume
m3
284
70
MT
564
100
MT
812
130
Million $
6.4
Expected to be less
(1/2 to 1/3)
Exchanger cost
June 2012
June 2012
June 2012
Conclusion
LPG recovery operations require efficient heat (cold) recovery to maximize
product recovery
Conventional S&T exchangers difficult to design due to problems of
o Temperature cross due to close approach temperatures
o Possible vibration in gas-gas exchangers
Plate fin exchangers fill this need
o Simulations help in initial design of plate fin exchanger configurations
which will be further refined with vendor input
o Process with plate-fin exchangers could bring a about $5.5M/year
additional revenue in addition to capital cost savings due to smaller
exchanger footprint
o Proper installation and care need to be taken realise potential of plate
fin exchangers
Exchanger Selection & Design in an LPG
Recovery Unit
June 2012