SIMULATION MODEL OF LPG RECOVERY PLANT TO

OPTIMIZE THE PROCESS PARAMETERS

Naeem Akbar*, Mudassar Habib**
*
Department of Chemical Engineering, University of Engineering and Technology, Peshawar, Pakistan
**
Department of Chemical Engineering, University of Engineering and Technology, Peshawar, Pakistan
Abstract
Controlling the hydrocarbon dew point by extracting natural gas liquids (NGL) from wet gas is an important step
that prevents condensation of hydrocarbon in pipeline for transporting natural gas. Recovering Liquefied Petroleum
Gas (LPG) using Turbo Expander is an important effort to reduce the HCDP. This is a process where internal energy
of system is incorporated. Parameters like flow, temperature and pressure play vital role in determining the extant of
LPG recovery from wet gas. In this study, LPG Recovery plant in Pakistan is simulated on AspenTech® HYSYS 10
at steady state mode and the process parameters were optimized. The simulated parameters (Pressure, Temperature,
Flow rate) are validated with actual running parameters of plant. Also this simulation study ran case studies for
determining the most optimum flow rate of 25.09 bpd of NGL stream which is recycled back to deethanizer. This
recycle stream has increased the LPG production by 2.88 Metric ton per annum. With improving the production of
LPG, NGL condensation in Residual gas is minimized (HCDP dropped from -81.0 to -81.1 °F) which is going into
customer pipeline network (M/s SNGPL) who is further distributing this gas at domestic level.
Keywords: Hydrocarbon dew point, HCDP, LPG, NGL, Turbo expander

1. Introduction
1.1 Background
Natural gas is mostly not usable at well head. In order to make it marketable as fuel, it must be processed to remove
by-products, impure state and impurities like moisture, free water and acid gases (CO 2, CO, NOx, SOx) to meet the
specifications of marketable natural gas. Typically, the side-products of treating natural gas are heavier like C2
(ethane), C3 (propane), C4 (butanes), C5 (pentanes) and similarly higher chain hydrocarbons with more atomic
weights, H2S (hydrogen sulfide) which is usually converted in elemental sulphur, CO2 (carbon-di-oxide), free water,
sometimes He (helium) and N2.
Oil and gas companies especially involved in transportation or movement of natural gas realized that controlling and
minimizing Hydrocarbon dew point (HCDP) generates operating revenue, reduces system liabilities and opens up
new gas markets like selling LPG [19]. By optimizing HCDP, heavier components condensation can be minimized
especially in cold portion of pipeline under water like lakes or rivers where the liquids gather in the low areas and
then frequently create a slug in pipeline, loading the system, building back pressure and overpowering liquid
handling arrangements, flowing into compressors resulting in damaging the machines and end user custody transfer
points resulting in domestic hazard. Most prominently, liquids in household stoves, flare-pilots at site and at end user
locations can cause accidents involving explosion or fire. Also, removing pipeline liquids assist to avoid pipeline
corrosion in the low portions where water is trapped under the condensed hydrocarbon (HC) liquids’ layer and
slowly, destroys the pipe integrity.
LPG recovery from wet gas is major effort in reducing HCDP for pipeline transportation. Various methods can be
used to condense the heavier components from a natural gas stream; listed as follows [24]
1.2 Lean Oil Absorption
NGL Recovery from Natural gas with this method is similar to TEG (Triethylene Glycol) Gas dehydration plant. In
this case Lean Oil is used instead of TEG which has affinity for NGL. It is most earlier method of recovering NGLs.
In this method [25], Lean Oil is showered from top of tray or packed column while gas enters from bottom at
ambient temperature and higher pressure close to sale gas network. Rich oil is then regenerated with temperature.
This method is inefficient and modified by adding Propane refrigeration arrangements for added recovery of NGLs.
1.3 Solid-Bed Adsorption
Adsorbents are used in such methods, which have ability to absorb heavier components of Natural gas like Propane,
Butane, Pentane, Hexane or heavier Components which usually exist in traces. Silica gel or activated charcoal is
mostly used absorbent. Due to fouling the absorbent, activated-alumina cannot be utilized for the gas with heavy
hydrocarbons [26]. We should also note the design for any adsorbent based system involving heavier hydro-carbon
removal is relatively more complicated in comparison to plants for removing only water/moisture.
1.4 Membrane Separation Process:
Membrane-separation process offers simple and cost wise inexpensive solution for elimination of heavy
hydrocarbons from gas [27]. Available in market are gas permeable membranes with variety of polymers which
posses’ good diffusion selectivity. A high-flux membrane is used. In this membrane Heavier HC are selectively
permitted while methane is stopped. The permeate of these membranes which are heavy Hydrocarbons and is
obtained in form of liquid which normally requires compression or re-condensation. Residual stream which is
gaseous state coming out of membrane is then depleted of heavy hydrocarbons to partial extent and requires to be
compressed in customer pipeline as sales gas or residual gas.
1.5 Refrigeration Process:
In this method for NGL recovery, some refrigeration processes are presented for discussion in the following section
which is widely used in LPG recovery field:
1.5.1 Mechanical Refrigeration Process:
This is the simple method as the name suggests. External Mechanical refrigeration is employed by a vapor
compression refrigeration-cycle which employs refrigerant gas like C3(Propane) and gas compressors to raise
pressure of the refrigerant from low pressure to high pressure. Converting the cold separator countercurrent to the
warm inlet gas, the gas-gas heat exchanger is used to recover additional refrigeration by passing the gas through it.
Temperature approach (delta T, temperature gap between exiting fluid and inlet fluid) is as near to 5 F. For the
chiller duty, mostly shell and tube or kettle-type heat exchanger is used.
A mechanical refrigeration process is used when substantial amounts of NGL are expected. LPG recovery up to 90%
can be achieved with such refrigeration system (involving Propane as refrigerant) at temperatures of −40 F [28].
Russell has given a detailed discussion for designing of Straight refrigeration method which differs in terms of
variables, like Temperature required Gas composition, pressure and extent or required LPG recovery [29].
1.5.2 Self Refrigeration Process:
Natural gas deviates from ideal gas theory. This deviation of Feed Natural gas is foundation of the fact that gas
temperature to drop with the rapid pressure decreasing. The temperature drop in such cases depends on the pressure
drop, the more the Pressure drop, more is temperature drop [27]. In this method, heavy hydrocarbons and water are
condensed when pre-cooled feed gas is entered adjacent to the treated gas (by means of the heat exchanger, mostly
gas-gas BAHX, Plate type exchangers or Shell and tube Heat exchanger) and then cooled further by iso-enthalpic
expansion (Joule–Thomson expansion) with a valve (JT-Valve).
1.5.3 Cryogenic Refrigeration Process:
With high capital costs, Cryogenic Refrigeration plants offers lower OPEX (operational expenditure) as well as
increased efficiency. This method is widely used for LPG recovery in Natural gas treating industry. They contain
many high speed moving parts and are complex to operate [30]. The Joule–Thomson JT valve and heat exchangers
used in previous methods are substituted by an Expander usually turbo expander for energy economy.

1.6 Literature Survey:

LPG recovery plant offers a lot of operational and controlling difficulties. Technological advances and studies have
been made to improve the controlling of parameters at plant and achieving the Process safety management to avoid
human as well as product losses with focusing on environmental aspects. Hydrocarbon emissions are major source
of pollution like smog formation. For example, detailed study about range of controlling systems was done by
Ansari et al. in 1998 [1]. Another study by J. Fernandez et al have taken both nonlinear and PID control systems for
the job of controlling i-C5 in top product stream of the plant and concluded that nonlinear controlling systems are
more efficient as compared to PID controlling strategies [2]. In Gas Processing Plants, environment pollution is
always a concern especially release of Carbon dioxide concentration in the flared gases. Davoudi et al have taken
this task in 2014 to study the amount of CO2 in flaring system at South Pars (Iran) Gas Processing plants. They have
modeled the collected information and calculated the amount of gas flared in five refineries. They concluded that
flare size is important factor in release of CO2 in environment which can further be allocated to different fire zones
[3]
. Another simulation and sensitivity analysis of Gas treating plant was done by Nemati Roozbahani et al. in 2014
with more focus on Dehydration unit of plant. Resulting best range of parameters were chalked out from this study
[4]
. Similar study was performed by Amid pour et al. in 2015 for mixed refrigerant cycles by NLP technologies.
Objection of study was economic feasibility and sensitivity analysis along with design sequence study. They
concluded that 1-stage mixed refrigerant refrigeration cycle (MRRC) with cascade arrangement as most efficient
way to replace Ethene cycle at Tabriz Petrochemical Complex(TPC) which was an Olefin plant [5]. Furthermore
material and energy balance, operating parameters and equipment specification was done with a simulation study
which was executed by Al Sobhi and Elkamel for LNG Plant along with GTL unit. Also they included attached
upstream units of these processes. As result, they presented a simulation model with best optimization [6]. To our best
knowledge regarding research using simulators, author believe using simulation for production loss, pollution,
greenhouse gas emissions, optimization and economic analysis of industries like Oil and gas, Waste management
[7–10]. In 2015, Raheem et al. conducted detailed study of comparative methods of recovering LPG and NGL and
their economic impact [33]. Another technology of recovering LPG using Lean oil absorption method was studied
by Saeid Mokhatab et al in 2015 covering the production of NGL from wet gas [35]. Membrane Process for
recovering LPG was studied by Bhupender S. Minhas et al 2007 using multiple membrane stream with good yield
[36]
.
In this study, simulation study is conducted at LPG recovery plant located in Attock, Pakistan with 75 MMSCFD
design capacity and operating at 13 MMSCFD feed gas. Objection was to optimize the running parameters and
reduction of Hydrocarbon dew point (HCDP) in residual gas.
1.7 Process Description: Temperature = 95 °F

This study is performed for LPG Recovery Pressure = 600 psig

plant located at Attock, Pakistan which use Volumetric Flow (molar) = 13 MMSCFD
turbo expander technology to recovery
Natural gas liquids (NGL) namely Liquefied Table 2: Composition of Feed Gas
Petroleum Gas (LPG) consisting mainly of
Propane and Butane, Gasoline consisting MOLE
mainly of Pentane, Solvent Oil consisting S# COMPONENTS
FRACTION
mainly of Hexane and heavier hydrocarbon.
13 MMSCFD Sweet gas is fed to LPG plant. Methane (C1)
i 0.858
Plant design is 75 MMSCFD and hence a
ii Ethane (C 2 ) 0.077
certain stream is recycled. To avoid free water
or hydrocarbons condensed to reach iii Propane (C 3 ) 0.031
compressor driven expander, whose iso-Butane (i-C )
iv 4 0.0068
performance would be severely impaired by
such slugs, a Knock Out drum (V106) is v n-Butane (N-C 4 ) 0.0086
installed at the inlet. In order to remove vi iso- Pentane (i-C 5 ) 0.0028
moisture (Dehydrate) up to 0.5 ppm or even
vii n-Pentane (N-C 5 ) 0.0022
less, three molecular sieve dehydrators
(D101) are utilized, operating on a viii Hexanes plus (C 6 +) 0.0042
conventional 12 hours cycle and regenerated Carbondioxide (CO )
ix 2 0.0049
at 600 F maximum. To minimize regeneration
x Nitorgen (N 2 ) 0.0033
heat the water content of the inlet gas has
been reduced cooling the gas at 80 F and xi 0.0000
Hydrogensulfide (H2S
discharging the condensed water from
separator (V101) at upstream of the
Table 1: Gas specifications for feed
dehydrator. Moreover the dehydrator
regeneration gas heater is charged with hot residue gas from gas turbine driven residual gas compressors (K103).
Natural gas from the dehydrator is further cooled. Gas-gas exchangers (E104), a cold liquid to gas exchanger
(E102), a high pressure separator (V103) constitute the cold train. Gas is cooled to approximately -23 F through
heat exchange with cold residue gas from the low pressure separator and with the cold liquid from the high pressure
separator (V103). This cold gas stream at 798 psig is expanded in turbo-expander (GE101) to 225 psig, the
expansion lowers the process temperature to -110 F. Expander outlet stream consisting of vapor liquid mixture is
then separated in the low pressure separator (V104).

Figure 1: PFD for LPG recovery plant located in District Attock of Pakistan considered in this study

Cold gas from V104 is joined with the Deethanizer (C102) overhead vapor stream which further flows to heat
exchangers (E104 and E102) to cool the inlet gas. After heat exchange the residue gas is compressed from about 218
psig to approximately 700 psig for further injection into customer gas distribution network. Deethanizer tower
(C102) operates at 220 psig with a top temperature of -57 F and a bottom temperature of 150 F. Hydrocarbon
Liquid-phase from the V104 is passed to the C102 for feed and reflux. Cold gas from the low pressure separation
(V104) is used to make additional reflux for the separation of Ethane and retention of propane. Liquids condensed in
the high pressure separator (V103) enters the tower after heat exchange in E102 at about 60 F. Reboiler heat is
supplied by hot gas from the compressor (K103).
Deethanizer product is heated in the feed / residual gas (E109) and then flows to the Debutanizer Column (C104)
where reboiler heat is also provided by hot gas from compressor K103. Reflux and LPG is furnished by air cooler.
LPG mixture is pumped to the battery limits at 200 psig. The gasoline from the LPG column bottom is sent to E105
after cooling to the battery limits at 150 psig. Compression required to deliver residual gas at 670 psig is supplied by
the two final compressors driven by gas turbine GT103 A/B.
2- Problem Statement:
2.1 Valid Simulation of plant is required in order to evaluate the running parameters of plant. It is not possible in
running plant to change the parameters (temperature, pressure, flow rate or liquid levels in vessels etc) to study the
impact on rest of the process.
2.2 Optimum flow rate of recycle stream of NGLs is required. Efficiency of LPG recovery is measured in terms of
propane slipped in residual gas. Propane slippage of running plant is 0.38 mol % [32]. Certain flow rate of NGL
collected from bottom of debutanizer (C104) can be recycled back to gas expander (GE101) inlet vessel. Liquids
drain of this vessel is going in deethanizer (C102). This recycle stream can enhance recovery of LPG by showering
in Deethanizer to absorb LPG from the over head going vapors in tower.
3- Simulation of Plant using Aspen HYSYS® 10:
Conditions and composition for feed gas which is shown in Table 1. The fluid package of simulation selected for this
work was Ping Robinson (PR). PR fluid package was developed by Ding-Yu Peng and Donald Robinson with goal
of satisfying all calculations of fluid properties in Natural gas processes [33]
The Simulation environment was created, in the tab (flow sheet modify) the feed stream is provided by selecting the
streams and other models. New interface will open with numerous streams such as energy streams, material
streams. Also one can find various units and vessels such as pumps, absorber, separators (2 or 3 phase separators),
different kind of valves, variety of heat exchangers like Chillers, heaters, coolers, Shell and tube heat exchangers,
makeup and recycle functions icons, liquid-liquid hydro-cyclone, solid-liquid hydro-cyclone, expander, various
Compressors, precipitator, neutralizers, mixer, filter and other operation equipments.

Name Feed To To To To OVHD To To To VAP1

K101 E107 E104 V101 V103 Expan V104 04
der

Pressure [psia] 610 610 784.8 774.8 769.8 764.1 757.1 757.1 234.7 234.7

Temperature [F] 95 95 134.2 125 89.1 80 -40 -36.6 -114 -114

Molar Flow [MMSCFD] 13 13 13 13 13 13 13 11.11 11.11 10.54

Std Ideal Liq Vol Flow [BPD] 5743 5743 5743 5743 5743 5743 5743 4693 4693 4368

Molecular Weight 19.81 19.81 19.81 19.81 19.81 19.81 19.81 17.76 17.76 17.03

Mass Enthalpy [Btu/lb] -1759 -1759 -1742 -1747 -1769 .1773 -1874 -2010 -2010 -2055

Mol Density [lbmol/ft3] 0.1163 0.1163 0.1394 0.1406 0.1543 0.1573 0.275 0.2412 0.078 0.078
6 6 5
Table 2: The different material-streams with respective operation parameters using HYSYS

Name To E102 To To Residual To C102 Feed Feed LPG

V109 E105 Gas C104 C105

Pressure [psia] 228.7 226.7 683 680 234.7 232.7 24 230

Temperature [F] -103.7 124 228 110 -114 88 140 61.5

Molar Flow [MMSCFD] 11.96 11.96 11.96 11.96 0.57 1.133 0.243 0.889

Std Ideal Liq Vol Flow [BPD] 5018 5018 5018 5018 325.2 813.1 215 598.1

Molecular Weight 17.35 17.35 17.35 17.35 31.19 50.67 75.63 43.84

Mass Enthalpy [Btu/lb] -2025 -1903 -1855 -1925 -1552 -1134 -855 -1212

Mol Density [lbmol/ft3] 0.0698 0.0372 0.0967 0.122 1.07 0.6497 0.0047 0.715
Table 3: The different material-streams with respective operation parameters using HYSYS

Deethanizer (C102) is first column when we are talking flow wise. Expanded gas streams coming from gas expander
GE101 are separated in natural gas (residual gas) and mixture of NGLs in this distillation column. Objective of
Deethanizer is to separate methane and ethane rich components of stream to make residual gas stream while propane
and heavier components are taken out from bottom for further fractionation in next column called as Debutanizer
(C104 in this case)
Table 4 shows the condition of deethanizer (C102) calculated through HYSYS. Key Performance indicator for
deethanizer is propane slippage in residual gas stream. At these conditions C3 -slippage is 0.35 mol%. Figure 3
shows the temperature profile tray wise for C102 (left side). Tray wise monitoring of temperature is important in
deethanizer as minute adjustment in temperature may lead in propane to vaporize or vice versa. Liquids coming
from V103 are showered at tray 25 which also play important role in keeping the tower temperature low. This stream
also includes the recycled NGL coming from downstream of debutanizer (C104).
Liquefied hydrocarbon from bottom of C102 enters the tower Debutanizer (C104) after passing through a pre heater
(E108) to raise the temperature up to 330 F) at tray # 14. Debutanizer is a 50 tray column with Re-boiler (shell and
tube exchanger) arrangement at bottom and reflux at top. Overhead Vapor are fed to fin fan cooler (E113) and totally
condensed as LPG at 130 F and collected at Reflux vessel (V107) Vapor from V107 are fed to vessel (V109) at
upstream of Residual gas compressors (K103 AB). Bottom product of tower is raw gasoline and pumped to storage
tanks. Table 4 show the condition of tower predicted by HYSYS. Key performance indicator for Debutanizer tower
(C104) is amount of residue in LPG. This residue consists of mainly Pentane and traces of heavier [21].

Figure 2: A screenshot of the simulation of subject plant using HYSYS 10 Simulation

Figure 3 shows the temperature profile tray-wise for C104 at right side. It shows that dropping the temperature of
tower bottom may lead to condensation of more butane while increase in tower re-boiler temperature may lead to
increase in Pentane (residue in LPG).
Propane and Butane comprise the LPG and are Name C102 C104
extracted from Debutanizer top while Pentane and
heavier are taken from Tower bottom. Tray wise Number of Trays 50 50
profile of this composition is simulated in Figure 4. Distillation Tower Distillation Tower
Type of Tower
E102 and E104 are also major units in this process with Reboiler with Reboiler
and are analyzed in detail using HYSYS. Both
Internal Type Valve Type Trays Valve Type Trays
exchangers are brazed aluminum heat exchanger
type. Brazed-aluminum-heat-exchangers (BAHX), Diameter [ft] 3.937 4.921
are widely utilized in cryogenic treatment methods Tray Spacing [ft] 1.804 1.804
like fractionation and gas-processing as compared Tray Volume [ft3] 21.97 34.32
to other heat exchanger types. This is because of
their higher thermal efficiency and reliability and Weeping Factor 1.0 1.0
totally customized design for specific utility. They Tray Hold up [ft ] 3
3.12 3.12
are commonly applied in Nitrogen Rejecting Units, Feed from Expander Tray # 10 Tray # 14
Air-separation, natural-gas-liquefaction (LNG),
Pressure (psig) 229.7 230
natural gas liquid extraction (like LPG), ethane
recovery, hydrogen extraction and propane (C3) de- Reboiler Pressure (psig) 232.7 235
hydrogenation[21]. HYSYS has predicted the Stage Efficiency 0.7 (Overall) 1.0 (Overall)
performance of both the BAHX in table 5. Modified HYSIM Modified HYSIM
When with internal energy of expanding gas, work Solving Method
Inside-Out Inside-Out
is done too with the help of specific arrangements
to run a load like turbine or compressor with a Damping Fixed Fixed
common shaft in between, such expander is called Reboiler Duty
0.279300 0.4956
as turbo expander [22]. Partial liquefaction of the [MMbtu/hr]
expanded gas is common. Reflux Ratio 0.072 1.214
Due to the reason that work is being obtained with
Boil up Ratio 0.1504
the expanding high pressure gas, the expansion is
almost an isentropic process (that is, at constant
Table 4 Simulation parameters of Deethanizer (C102) & Debutanizer (C104)
entropy) and also the outlet expanded low pressure
exhaust gas from the Turbo-expander is fallen to
very decreased temperature of upto −150 °F or even more, depending upon the pressure drop and natural gas
composition [23]. In our case -113 F is temperature at outlet of Expander (GE101).

Figure 3: HYSYS prediction of tray wise temperature profile of C102 (left side) and C104 (right side). In C102, note that recycled NGL
stream is entered at Tray 25 of Deethanizer tower impacting the temperature profile of Tower C102.
At industrial level, Turbo-expander is widely used
Figure 4: Tray-wise composition of Debutanizer C104
as source of refrigeration/chilling in different
processes like extraction of ethane(C2) and
natural gas liquid (NGL) from natural gas, the
liquefaction of various gases such-as Helium,
Oxygen, Argon, Nitrogen, helium) and in any
many low temperature processes.
Table 6 shows the simulated condition for turbo
expander GE101 which are validated with
running machine parameters.
NGL mostly comprising of Raw Gasoline
(Pentane and traces of heavier hydrocarbon) are
extracted from bottom of Debutanizer (C104). A
material stream in HYSYS was made to recycle
back to Deethanizer (C102) through Expander to
avoid slipping of Propane with overhead gas stream of Methane and Ethane. Flow rate and conditions of this stream
are simulated in this study.
Name E104 E102
Duty [MMBtu/hr] 2.867 0.607

UA [Btu/F-hr] 123200 121500

Hot Pinch Temp [F] 80 125

Cold Pinch Temp [F] 75 123.97

LMTD [F] 23.26 5.0

Cold inlet Equilibrium Temp [F] -103.741 75

Hot inlet Equilibrium Temp [F] 80 125

Simple Simple Weighted

Rating Method
Weighted

Table 5: Design Specifications of Heat Exchangers E102 & E102

Table 6: Showing simulated conditions of Turbo Expander (GE101)

Name Description
Speed [rpm] 29000

Power [hp] 187.8

Delta P [psi] 522.4

Adiabatic Efficiency [%] 61.87

Duty [hp] 187.8

Polytrophic Head [ft] 28900

Adiabatic Fluid Head [lb-ft/lbm] 27750

Total Head [ft] 28900

Polytrophic Efficiency 59.412

Polytrophic Head Factor 0.9938

Delta T [F] 78

Friction Loss Power [hp] 0

 Table 7: Design Conditions of NGL Recycle stream by HYSYS
Parameters Value
Liquid Phase 1.0
Temperature [F] 100.3
Pressure [psig] 757.1
Molar Flow [MMSCFD] 0.1007
Mass Flow [Tonne/D] 9.056
Standard Ideal Liquid Vol Flow [bpd] 88.76
Heat Flow [btu/hr] -7.5E4
Composition of NGL stream (mol %) by HYSYS
Methane 0.0
Ethane 0.0
Propane 0.0
i- Butane 0.0001
n- Butane 0.0253
i- Pentane 0.3755
n- Pentane 0.2654
Hexane and higher 0.3336
CO2 0.0
N2 0.0
H2O 0.0
The purpose of NGL recycle stream is enhancing Propane recovery in deethanizer tower by creating absorption
effect. It increase the flow rate of down comers and captures increased amount of Propane slipping with vapors in
overhead stream of deethanizer consisting mainly of Residual gas (Methane and Ethane). Table 7 shows the
conditions of this stream predicted by HYSYS.
3- Results and discussions:
3.1 Simulation Validation:
Simulation model was developed with Aspen HYSYS 10 simulation software and compared with real time plant
parameters of running plant in Pindigheb distt, Pakistan. Conditions and composition of the feed are given in Table 1
and 2. The model was simulated for LPG Recovery plant using turbo expander technology. The LPG plant is feed
with temperature around 110°F while pressure of 600 psig. M/s Aspentech HYSYS 10 was used then to simulate
plant which removed the Propane and heavier hydrocarbon from Natural gas, minimizing the HCDP and making it
saleable in clients pipeline net work (M/s SNGPL, Pakistan in this case). The composition of sale gas is shown in
Table below (Table-8). On the other hand, this table also compares the composition data of Sales gas of real plant.
Table 8: Comparison between HYSYS and real plant parameters at Residual / Sale Gas stream

S.NO Component Feed Composition Residual gas Composition Residual Gas Composition (Plant-
(HYSYS) mol% data) mol%
Mol%
1 Methane 85.8 91.64 90.847
2 Ethane 7.7 6.96 7.804
3 Propane 3.1 0.35 0.438
4 i-Butane 0.68 0.01 0.022
5 n-Butane 0.86 0.01 0.018
6 i-Pentane 0.28 0.0 0.002
7 n-Pentane 0.22 0.0 0.0
8 H2O 0.0 0.0 0.0
9 CO2 0.49 0.66 0.52
10 H2S 0.0 0.0 0.0
11 Nitrogen 0.33 0.37 0.38
12 C6+* 0.42 0.0 0.005
Total 100 100 100
D
3.2 Optimization of NGL recycle Table 9: HYSYS Case Study: Optimizing the Flow rate of NGL Recycle stream
stream: Hydrocarbon Dew
Expander
Flow rate of Recycle stream (in section Flow Rate LPG Power
Point of Residual
3.4) of NGL recovered in Debutanizer to (bpd) (Mton/Day) (GE101)
gas (F)
(hp)
inlet of De-ethanizer was studied in a Case 1
case study. Important results of this study 0.0 -81.08 45.78 167
are: Case 2
11.44 -81.10 45.89 168
3.2.1 Recovering maximum LPG from
Case 3
gas 25.09 -81.16 46.02 168
3.2.2 Minimizing Propane slippage in Case 4
41.94 -81.22 46.16 178
residual gas
3.2.3 Reducing Hydrocarbon Dew point Case 5
62.89 -81.30 46.38 182
(HCDP) of sale gas.
Case 6
3.2.4 To attain above benefits with 89.71 -81.36 46.60 188
minimum of no sacrifice of power
consumed on turbo expander (GE101). Table 9 shows that at the flow rate of 25.09 Barrel/Day (Case 3) power
consumed (HP) by turbo expander (GE101) remained almost unaffected hence, this is out optimum flow rate of
recycling of NGL stream back to Expander Inlet. Increase in LPG is 0.25 MTon / Day (2.88 Mton / Year).
3.3 Feed Gas Increase (addition of new gas well to the plant)
Model is well validated for existing plant at feed gas flow rate of 13 MMSCFD. A case study was developed from
this model in which a new well can be added in future. Different Flow rates of up to 3 MMSCFD are studied in
comparison with impacts on following:

3.3.1 Duties of Heat Exchangers

3.3.2 Power consumed by rotary machines
3.3.3 NGL flow rate from V-103 to Deethanizer
3.3.4 LPG Production

3.3.1 Duties of Heat Exchangers

With increase of feed stream upto 3 MMSCFD,
duties of Exchanger is increasing but design duty of
both exchanger is shown in dotted line and well
above the running duties of exchangers. That means
design of exchanger is well above the running
conditions of exchangers.
Figure 5 shows the case of one of the exchangers
E104 at plant although same scenario was seen for Figure 5: Duty of Heat Exchangers E104 is increasing
case studies of rest of the heat exchangers also. with increasing the feed gas flow rate

3.3.2 Power consumed by rotary machines

With increase in feed flow rate, Power of Gas expander and Residual gas compressors increases. This also pictures
the profile of energy consumed when a certain volume of gas is depressurized (expanded) in Gas Expander (power
generated) needs to be pressurized back to sale gas pressure (Power consumed). Figure 6 shows the HYSYS
prediction of power consumed in turbo expander (GE101) and residual gas compressor (K103).
3.3.3 NGL flow rate from V-103 to Deethanizer
When the flowrate of feed gas increased, the amount of NGL condensing after cooling in E102 also increases.
HYSYS predicted this change in flow rate of NGL condensation and subsequently flowing in to Deethanizer tower
in figure 7. This NGL stream is showered in Deethanizer tower to replicate the”Lean Oil Absorption” method of
HCDP control.
Figure 6: Power consumed by turbo expander (GE101) and Residual gas compressor increased with increase in feed gas flow rate

Figure 7: NGL flow rate from V-103 to Deethanizer (C102)

oopo
3.3.4 LPG Production
With the increase in feed gas, there is expected increase in LPG production. HYSYS quantifies this change.
Following figure shows the increment of LPG production with increase in feed flow.

Figure 8: LPG Production with increasing feed flow rate

4- Conclusions
In this study a simulation model of LPG recovery plant is developed. Simulation result is compared further with
running plant recovering LPG from natural gas at Attock, Pakistan. Process conditions are optimized to maximize
the production of LPG as well as reduce the HCDP of residue gas.
Aspen HYSYS V10 is useful simulation tool in predicting the complex interaction of Hydrocarbon at gas treating
facility and works close to accuracy for the Process people to perform the project activities. It is accommodating in:
1. When trouble-shooting the actual plant operating condition in comparison with the optimized-with-
simulation plant results.
2. Decrease in Propane slippage in Residual gas (Sale gas) with the help of recycling NGL back to Expander
inlet for showering from top of Deethanizer. HCDP of sale gas also decreased which was aim of this
simulation model.

Objective of this study was to perform a proven and validated simulation of a LPG Recovery plant to perform a
‘sensitivity-analysis’ on critical stream-conditions of the unit like LPG flow-rate at C104 De-butaniser tower (DBT)
top side and temperature across heat exchangers (E102, E104). According to the simulation results, the unit can
safely take this injection of NGL but also increase its efficiency in terms of LPG production rate and improved
efficiency of Heat exchangers which in broader picture may result in less downtimes due to back flushing to those
exchangers as this exercise required shut down of LPG plant with a downtime of about 3.5 hours. Additionally, after
some adjustment, an increase of 3 Mton in LPG production rate was obtained per year by recycling the NGL stream
at the flow rate of 25.09 Barrel/Day. Hence the company was successful in making 2017.6 USD extra annual income
as well as obtained reliable simulation for monitoring the plant performance.

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