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Flow Sheet Development and Simulation with Optimization of Industrial Scale

Natural Gas Processing Plant by Using Aspen-Hysys

Conference Paper · December 2015

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 International Conference on Mechanical, Industrial and Materials Engineering 2015 (ICMIME2015)
11-13 December, 2015, RUET, Rajshahi, Bangladesh.

Paper ID: IE-29

Flow Sheet Development and Simulation with Optimization of Industrial

Scale Natural Gas Processing Plant by Using Aspen-Hysys
Md.Nurus Sakib[1], Noor Mohammad[2], Niloy Barua[3], Dr. Md Ruhul Amin [4],
[1], [2], [3]
Department of Chemical Engineering, Bangladesh University of Engineering University,
BUET
[4]
Associate Professor, Department of Chemical Engineering, Bangladesh University of Engineering
University, BUET
Email addresses: [email protected], [email protected], [email protected],
[email protected]

Abstract

Bangladesh has a gas field discovery success ratio 3.1:1 of which two of the gas fields are located in offshore
area. Bibiyana gas field has been selected for the study of flow sheet development and simulation with
optimization of industrial scale natural gas processing plant by using Aspen-Hysys as it is a world class gas
reservoir. Flow sheet development and simulation of 150 MMSCFD natural gas producing Bibiyana gas plant
was done by means of Aspen-Hysys. The steady state simulation was performed based on both the design and
physical property data of the plant. The main purpose of optimization was cost minimization by regulating the
process stream flows and heat duty and hence profit maximization. The objective function, Profit, was
calculated from the difference of sales gas, LPG and condensate selling revenue and condenser or reboiler duty
costs. Hysys Optimizer has been used to optimize the present process which resulted in more than 8.5% increase
in profit with negligible change in optimized methane composition (around 99.46 %). In addition, LPG was also
recovered with a production rate of around 1746 barrel/day.

Keywords: Natural Gas; Aspen-Hysys; Gas Processing; Separation; Simulation; Optimization.

1. Introduction
Natural Gas is among the top most used energy sources in the world. Since natural gas can be processed and
distributed easily, the demand is growing rapidly [Rahman and Tamim, 2012]. Hence, fast and efficient gas
processing and optimization are needed. Natural gas processing plants are used to purify the raw natural gas
extracted from underground gas fields and brought up to the surface by gas wells.
Natural gas processing consists of separating all of the various hydrocarbons and fluids from the pure natural
gas, to produce what is known as ‘pipeline quality’ dry natural gas. Many removal processes can be adopted, for
example, amine base process for the removal of carbon di oxide [Kinigoma and Osharode, 2013] or by Benfield
process [Chowdhury and Chowdhury, 2013]. Furthermore, Dehydration of Natural Gas which is another
important step in gas processing. Deethanization and also depropanization can be enhanced by using dividing
wall column [Long and Lee, 2012]. Nitrogen-removal processes using liquid solvents, adsorption, and cryogenic
processing are currently available, but all of these methods require recompression of the methane product, which
penalizes their economics. However, the Use of three column system requires less compression and higher
methane recovery (around 98%) than other methods available [MacKenzie et al. 2012].
Analysis of industrial scale Natural Gas plant includes many complicated aspects which are mainly assessed by
simulation programs. Aspen HYSYS is an easy-to-use process modeling environment that enables optimization
of conceptual design and operations and removes process bottlenecks. Simulation of plant model and
optimization of natural gas processing plant that reduces process loss and maximizes profit can be developed
though Aspen-Hysys [Roy and Amin, 2011]. The role of Hysys is to provide a capable and accurate design.
Aspen Hysys introduced the novel approach of steady state and dynamic simulations in the same platform. It has
become the defacto standard in industry, and today enjoys universal acceptance [Amber et al. 2012]. Simulator
response modeling relates key process variables to plant performance satisfying the remaining unknown
information from the material balance equations [Bullin and Hall, 2000]. In a gas simulation process, the inlet
conditions (Composition, pressure and temperature) affect the throughput and quality of products. However, to
counter such problems, about 80 % of the bumps can be reduced by using Hysys [ Ramzan et al. ]. Owing to
such performance, Hysys simulation has been used to optimize process condition for maximum profit.
2. Simulation of gas process unit
For the Bibiyana plant simulation, there are five major units which processes the raw natural gas. These are:
separation unit, dehydration unit, heat exchanger, de-ethanizer and final purification & CO2 removal
units. The simulation process is based on Bibiyana gas production process and following are the description of
units of the process:

2.1 Separation unit: Gas is drawn from three wells: Well-1, Well-2, Well-3 respectively in simulation of the
processing plant. The feed Composition can be found in datasheet. Then the feed gas is passed through the
pressure control valve to relief some pressure & then fed into 3 ‘three phase separators’ (H-110A, H-110B, H-
110C) to separate each valve out stream in heavy liquid, light liquid & vapor streams. Most of the liquids are
separated at this separation unit. The 3 heavy liquid streams(mostly H2O) is removed & the 3 light liquid
streams are mixed together in a mixer & then entered into a distillation column(D-320) through an expansion
valve, the bottom liquid product is liquefied petroleum gas(LPG) & is stored in a tank(F-210). The overhead
product of D-320 is mixed with refined gas stream to prepare the very final product.

2.2 De-hydration unit & heat-exchanger unit: There are three vapor streams of the separators(H-110A,
H-110B, H-110C) which are mixed in a mixer and passed through the dehydration unit for water removal. The
dehydration unit consists of an absorption tower (D-310) where Tri Ethylene Glycol is used to absorb water.
The overhead vapor product of (D-310) contains dehydrated hydrocarbons which is passed through two heat
exchangers (E-230) & (E-250) so that temperature is decreased. The tube out of E-250 heat exchanger is then
entered into a separator (H-140). Then expander (G-152) lowers streams temperature using Joule-Thomson
principle of pressure relief & then three phase separator separates the remaining water in the mixed inlet more
precisely. Heavy liquid is removed & light liquid (H-150 liq out) and vapor(H-150 vap out) is used for further
processing.

On the other hand, bottom product of the absorption tower(D-310) is passed through an expansion valve (K-
131) & a two phase separator(H-130) ,bottom product of which is used as a tube side inlet of heat exchanger (E-
240). The tube side outlet is then entered into a column(D-330) whose bottom product is make-up Glycol
solution & is entered into the shell side of the heat-exchanger(E-240) & heat-exchanger(E-230). Between the
heat-exchangers a pump is used to increase the pressure. The shell outlet of E-230 is mixed with TEGlycol feed
to use in the absorption tower (D-310)

2.3 De-ethanizer unit: The liquid stream of the three phase separator(H-150) is then used in the de-ethanizer
which is a distillation column (D-340). Bottom product of the column(D-340) is LPG which is passed through
the heat-exchanger(E-101) to prepare ‘Final LPG’ at low temperature. Stream(H-150 vap out) is mixed with the
over-head vapor product of (D-340). Mixed stream out (M-231) is entered into the shell side of the heat
exchanger (E-250) to increase the temperature.

2.4 Purification & CO2 removal unit: Stream (M-251 shell out) is then undergone through CO2 removal
process. In this stage, we used principles of liquefaction to separate CO 2. Using cooler (E-100) we cooled shell
out stream and this cool gas stream is passed to a separator (V-100) preceded by a valve (VLV-100). Then the
final product stream enters compressor & then again thorough consecutive separations and thus CO 2 from
natural gas has been decreased significantly (less than 0.03%). CO2 can also be removed using absorption
process where MEAmine solution is used to absorb CO2.

3. Optimization of gas processing plant simulation

After performing the whole simulation process, profit optimization was done. Optimization was done by
controlling two main prospect. One is the flow of the revenue earning stream and the other is the duty
corresponding to cost of the process. The main purpose of optimization was cost minimization. The objective
function, Profit, was calculated from the difference of sales gas, LPG and crude gasoline (a stream having many
of the properties of gasoline) selling revenue and condenser or reboiler duty costs. . Some energy was also
extracted from an expander (G152) that was included with the revenue too. In the process, the profit is a
function of both cost of heat duty and the revenue of flow rates of products i.e. sales gas, LPG and crude
gasoline. The objective function is given as :
Profit=Total revenue –Total cost

Several user defined variables were considered as primary variables; i.e.: outlet stream pressures of absorption,
de-methanization and de –ethanizaion units, compressors and valves to name a few.
3.1 Optimization effect: This part illustrates on the optimization function and optimized condition of the
final simulation. Here, the optimizer spread sheet (Fig 3.1) lists all the variables relating with price. This spread
sheet was formed by opening the spreadsheet of Hysys Optimizer® tool. Then functions were listed in the
functions tab of the tool. By means of Hysys Optimizer® which uses both static and dynamic simulation
modeling tool, optimization is achieved. Hysys uses the dynamic analysis of a process system that provides
understanding of process system which is not possible with steady state modeling. Following is the
mathematical formulation:

Table3.1: Market Value of Products and utilities: (Prices estimated from the year book of Petrobangla and
Bangladesh Energy Regulatory Commission)
Natural Gas 9.580 taka/m3
LPG 56 taka/kg
Crude Gasoline 42470taka /m3
Heating or Cooling Duty 0.737 taka/KWh

Revenue Calculation:
Sales gas volume = B1 Sales gas price per unit volume, B2=9.580 tk/m3
LPG sales volume= B3 Sales LPG price per unit volume, B4 = 56 taka/kg
Crude Gasoline sales volume= B5 Crude Gasoline sales price per unit volume, B6= 42470 taka/m3
Revenue, B7 = B1×B2+B3×B4+B5×B6
Cost Calculation:
Expander Duty = D1 , D320 Re-boiler Duty= D2 ,D330 Re-boiler Duty= D3, D330 Condenser Duty = D4
D340 Re-boiler Duty = D5 , D340 Condenser Duty = D6, L231 Pump Duty = D7, Cooling Duty = D8
Heating Duty = D9, E100 Heat Duty = D10, Compressor Duty = D11, E104 Duty = D12, Price per KWh, D13 =
0.737 $, Total Cost,
D14 = (D1+D2+D3+D4+D5+D6+D7+D8+D9+D10+D11+D12) × D13, Profit = B7-D13

Before Optimization After Optimization

Figure 3.1: Spread Sheet Values of the simulation after optimization

4. Results and discussions

After the optimization, both flow rates of LPG and Sales Gas were increased. Consequently, theoretical increase
in revenue and total profit was about 8 percent as shown in the spread sheet of Figure 3.1. Following tables
shows the before and after condition of the process which shows the variability in composition due to
optimization. Comparing these tables shows the efficacy of optimization since the desired components
compositions varies in a positive way. Even though the methane fraction lowered but the sales flow increased
hence the revenue.
 Table 4.1: Composition of significant components of sales gas before optimization*
Name of Components Composition Name of Components Composition
Water(H2O) 5.95E-06 Methane(CH4) 0.995707
N2 2.11E-03 Ethane 9.29E-04
CO2 2.70E-04

Table 4.2: Composition of significant components of LPG(Liquified Petroleum Gas)*

Name of Components Composition in LPG Name of Composition in
Components LPG
Propane 0.236602 n-Heptane 0.144678
i-Butane 0.154207
n-Butane 0.15947

Table 4.3: Optimized composition of significant components of sales gas

Name of Composition Name of Composition
Components Components
N2 2.11E-03 Propane 2.61E-04
CO2 5.41E-04 i-Butane 1.21E-04
Methane(CH4) 0.994594 n-Butane 1.61E-04
Ethane 1.78E-03 i-Pentane 1.71E-04

Table 4.4: Optimized composition of significant components LPG(Liquified Petroleum Gas)

Name of Components Composition in LPG Name of Composition in
Components LPG
Propane 0.241527 n-Hexane 9.74E-02
i-Butane 0.153288 n-Heptane 0.143707
n-Butane 0.158469 n-Pentane 5.73E-02
i-Pentane 9.15E-02

0.25
Composition

0.2
0.15
0.1
0.05
0

Components

Figure 4.1: Graphical representation of LNG components

* Tablular Data were taken from Bibiyana Gas Fields of Bangladesh

5. Process flow diagram
Following is a depiction of part of the simulated process on Hysys.
.

Figure 5.1: PFD of a part of the simulation process

6. Conclusion
At present time natural gas is a major source of energy. Most of the industries are run by energy using natural
gas as their main source. Near about 95% of the natural gas is used as fuel gas. So, it is a major prospect to focus
on and develop for the betterment of energy utilization. The model for natural gas processing plant is developed
in this paper. Different process can be used to meet the specification required for processing of natural gas.
Environmental constraints and the need to reduce cost require innovative processes. The process used here
derived from earlier processes, but tend to offer significant reductions in investment and operating costs. In the
longer term, new concepts such as gas permeation can be expected to play a growing role and the natural gas
processing will keep changing. In this plan, the composition of sales gas is satisfactory. The percentage
removals of unwanted elements are good enough to run the process. Furthermore, profit was maximized by
means of optimization. Optimization provides a better process with higher benefits.

7. Acknowledgment
We are very thankful to BUET Chemical Engineering Forum (BCEF) for their support. The technical and
administrative backup given by the Department of Chemical Engineering, BUET is highly appreciated.

Nomenclature
Symbol Meaning

HC Hydrocarbon
H Two and three phase separator
E Heat Exchanger
M Mixer
LPG Liquefied petroleum gas
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