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14310 Mxico D.F. Mxico. Tel. 9999258163 Correo-e (e-mail): dpacho@idemexico.com Simulation and optimization of a gas separation and stabilization
plant Abstract The objective of a separation and stabilisation train is to receive
a multiphase hydrocarbon stream and separate it into three output streams: a
gas stream mainly composed by C1 to C3 plus other noncondensable gases, a
condensate stream normally composed by C3 to C6+ fractions, and an aqueous
stream. This processing train is also designed to prepare the gas and
condensate streams for its later transport through pipelines to other processing
plants. Even though the fundamentals of the process are well understood and
relatively simple, the design and operation of these plants present an
important challenge. To ensure the optimum performance of the process it is
required to determine the best relationship between the volume of condensate
and the volume of gas that is recovered. This optimum relationship is a
function of cost that it is subjected to several restrictions. For instance, the
condensate stream has the higher economic value and the recovered volume
increases with the pressure at which the separation takes place. However,
higher pressures involve operational risks and higher design costs. Additionally,
the gas volume to be recovered depends on the production targets that have to
be met in downstream plants where the gas can be used as fuel gas or as raw
material in petrochemical plants. Equally important is that the thermal
potential of the gas is influenced by the amount of C3 and C4 fractions on the
gas, so that a higher condensate recovery can also produce a gas stream of
lower quality. This paper presents the results of an optimization carried out in a
gas plant. The first step on the optimisation was the building up of a simulation
model of the whole separation and stabilisation process using chromatographic
data and historic data of an existing process. Based on these data, the normal
operating conditions were defined and used to calculate the actual efficiency of
the separation process. Additional simulation work was carried out to study the
effect of variations in pressure, temperature, and composition to determine the
key variables of the process. These sensitivity studies helped to define the
search region for the optimisation stage. The objective function was later
defined based on mass balances and trading prices, while the restrictions were
specified by maximum and minimum operating pressures production targets
and calorific value. The optimisation was carried out based on Successive
Quadratic Programming (SQP). Results suggest that it is possible to determine
new operating conditions and so to increase the process profitability by
maximising condensate recovery while still maintaining production targets.
Palabras clave: Procesamiento de gas, simulacin, optimizacin, programacin
cuadrtica sucesiva, PCS Keywords: Gas processing, simulation, optimisation,
successive quadratic programming, SQP