REPORT

DESIGN AND COMPARISON STUDY OF
NITROGEN REJECTION UNIT FOR 100

MMSCFD NATURAL GAS PLANT
HAFIZ MUHAMMAD NOORUL HUDA B1233007
HAMZA SHEIKH B1233009
MUHAMMAD UZAIR B1233022
MUJEEB ALAM FARHAN B1233024
SYED SHAHEER KAMAL B1233044
DEPARTMENT OF CHEMICAL ENGINEERING
UNIVERSITY OF KARACHI
KARACHI, PAKISTAN
2016
i
Design and Comparison Study of Nitrogen
Rejection Unit for 100 MMSCFD Natural Gas
Plant
NAME SEAT NO
1. HAFIZ MUHAMMAD NOORUL HUDA B1233007

2. HAMZA SHEIKH B1233009
3. MUHAMMAD UZAIR B1233022
4. MUJEEB ALAM FARHAN B1233024
5. SYED SHAHEER KAMAL B1233044
DEPARTMENT OF CHEMICAL ENGINEERING
UNIVERSITY OF KARACHI
KARACHI, PAKISTAN
ii
CERTIFICATE
This is to certify that the following students of Chemical Engineering Department

have successfully completed the final year project in partial fulfillment of
requirements for a Bachelor’s Degree in Chemical Engineering from University of
Karachi, Karachi, Pakistan.
HAFIZ MUHAMMAD NOORUL HUDA B1233007
HAMZA SHEIKH B1233009
MUHAMMAD UZAIR B1233022
MUJEEB ALAM FARHAN B1233024
SYED SHAHEER KAMAL B1233044
_____________________ ____________________
Project Supervisor Project Supervisor
(Internal) (External)
____________________
Incharge
iii
TABLE OF CONTENT
CERTIFICATE ..................................................................................................................... iii

TABLE OF CONTENT........................................................................................................ iv
LIST OF TABLES ................................................................................................................. x
NOTATIONS......................................................................................................................... xi
ACKNOWLEDGMENT ..................................................................................................... xii
ABSTRACT ......................................................................................................................... xiii
DEDICATION..................................................................................................................... xiv
INTRODUCTION.................................................................................................................. 2
1.1 Natural Gas Processing .............................................................................................. 2
1.2 Natural Gas History .................................................................................................... 2
1.3 Natural Gas Origin and Sources: ................................................................................ 3
1.4 Natural Gas Properties ............................................................................................... 4
1.4.1 Considerable Impurities in Natural Gas ..................................................................... 5
1.5 Objective and Scope of Project .................................................................................. 7
NITROGEN REJECTION TECHNOLOGIES .................................................................. 9
2.1 Introduction ............................................................................................................... 9
2.1.1 The Need of Removing Nitrogen ............................................................................... 9
2.2 Nitrogen Rejection Technologies for Gas Upgrading ............................................... 10
2.2.1 Cryogenic Distillation ............................................................................................... 11
2.2.2 Pressure Swing Adsorption ...................................................................................... 12
2.2.3 Temperature Swing Adsorption .............................................................................. 18
2.2.4 Membrane Separation............................................................................................. 19
MATERIAL AND ENERGY BALANCE ......................................................................... 22
3.1 Introduction ............................................................................................................. 22
3.1.1 Mass Balance ........................................................................................................... 22
3.1.2 Energy Balance ........................................................................................................ 22
3.2 Mass And Energy Balance For Cryogenic NRU ......................................................... 23
3.2.1 Material Balance ...................................................................................................... 23
3.2.2 Energy Balance ......................................................................................................... 30
3.3 Separator ................................................................................................................. 31
3.4 Absorption Column .................................................................................................. 33
iv
3.5 Dea Regeneration Column ....................................................................................... 36
3.5.2 Energy Balance ........................................................................................................ 39
3.6 Pressure Swing Adsorber ......................................................................................... 39
EQUIPMENT DESIGNING AND SIZING ...................................................................... 44
4.1 Separators ................................................................................................................ 44
4.1.1 Separator Designing Calculation.............................................................................. 45
4.1.2 Summary .................................................................................................................. 47
4.2 Pump ........................................................................................................................ 47
4.2.1 Pumps Designing Calculation................................................................................... 47
4.3 Control Valve............................................................................................................ 48
4.3.1 Valve Designing Calculation..................................................................................... 49
4.4 Heat Exchanger ........................................................................................................ 50
4.4.1 Heat Exchanger Designing Calculation .................................................................... 51
4.4.2 Pressure Drop .......................................................................................................... 53
4.5 Summary .................................................................................................................. 54
4.6 Absorber................................................................................................................... 54
4.6.1 Absorber Designing Calculation............................................................................... 55
4.7 Pressure Swing Adsorption Designing: .................................................................... 56
4.7.1 Bed Designing For Nitrogen (N2) Removal............................................................... 58
4.7.2 Bed Designing For Carbon Dioxide (Co2) Removal .................................................. 61
4.8 Cryogenic Distillation Column Designing ................................................................. 63
4.9 Gas Receiver (Storage Tank) Designing.................................................................... 64
SIMULATION ..................................................................................................................... 66
5.1 Introduction ............................................................................................................. 66
5.2 Hysys ........................................................................................................................ 66
5.3 Acid Gas Removal Unit ............................................................................................. 66
5.3.1 Equipments .............................................................................................................. 66
5.3.2 Simulation Environment .......................................................................................... 67
5.3.3 Feed And Solvent Parameters ................................................................................. 68
5.3.4 Absorption ............................................................................................................... 69
5.3.5 Regenerator ............................................................................................................. 70
5.4 Cryogenic Distillation Unit ....................................................................................... 71
5.4.1 Equipments .............................................................................................................. 71
5.4.2 Simulation Environment .......................................................................................... 72
v
5.4.3 Feed Parameters...................................................................................................... 72
5.4.4 Nitrogen Rejection Unit ........................................................................................... 72
5.4.5 Ngl Column .............................................................................................................. 74
5.4.6 Product Gas ............................................................................................................. 75
5.5 Introduction To Aspen Adsorption .......................................................................... 76
HYDRAULICS ..................................................................................................................... 81
6.1 Introduction ............................................................................................................. 81
6.2 Liquid Flow ............................................................................................................... 82
6.3 Gas Line Flow ........................................................................................................... 82
6.4 Two Phase Flow ....................................................................................................... 83
6.5 Line Sizing Of Pressure Swing Adsorption Unit ........................................................ 84
6.6 Line Sizing For Cryogenic Distillation Unit................................................................ 89
HAZOP AND ENVIRONMENTAL ASSESSMENT ....................................................... 95
7.1 Environmental Aspect Of The Projects ................................................................... 95
7.1.1 Safety And Environmental Considerations Of Nitrogen ......................................... 95
7.1.2 Safety Measures Regarding The Hydrocarbons In The Process.............................. 95
7.1.3 Safety Measures Regarding Nitrogen In The Process ............................................. 96
7.2 HAZOP Study ............................................................................................................ 96
INSTRUMENTATION AND PROCESS CONTROL ................................................... 106
8.1 Instrumentation ..................................................................................................... 106
8.2 What Is Process Control? ....................................................................................... 106
8.3 Why Do We Need Process Control ........................................................................ 107
8.4 Benefits Of Process Control ................................................................................... 107
8.5 Process Control Terms ........................................................................................... 108
8.5.1 Process Variable .................................................................................................... 108
8.5.2 Set Point................................................................................................................. 108
8.5.3 Measured Variables, Process Variables, And Manipulated Variables ................... 108
8.5.4 Error ....................................................................................................................... 109
8.5.5 Offset ..................................................................................................................... 109
8.5.6 Closed And Open Control Loops ............................................................................ 109
8.6 Control Loop Equipment ........................................................................................ 109
8.6.1 Primary Elements/Sensors .................................................................................... 109
8.6.2 Transmitters .......................................................................................................... 110
8.7 Types Of Control System ........................................................................................ 110
8.7.1 Feed Backward Control.......................................................................................... 110
8.7.2 Feed Forward Control ............................................................................................ 111
vi
8.7.3 Ratio Controller ..................................................................................................... 111
8.7.4 Cascade Control ..................................................................................................... 111
8.8 Types Of Controller ................................................................................................ 112
8.8.1 Proportional Control (P) ........................................................................................ 112
8.8.2 Proportional-Integral Control (Pi) .......................................................................... 112
8.8.3 Proportional Plus Integral Plus Derivative Control (Pid) ....................................... 112
ECONOMICS ANALYSIS ............................................................................................... 114
9.1 Introduction ........................................................................................................... 114
9.2 Costing Implementation ........................................................................................ 114
9.2.1 Costing Of Amine Unit ........................................................................................... 115
9.2.2 Cryogenic Distillation Unit ..................................................................................... 116
9.2.3 Pressure Swing Adsorption (Psa) Unit ................................................................... 119
9.3 Summary ................................................................................................................ 122
REFERENCES ................................................................................................................... 125
APPENDIX ......................................................................................................................... 127
Appendix 1A: Equipment Designing................................................................................ 128
Appendix 1B: Costing Analysis ........................................................................................ 136
vii
LIST OF FIGURES
PAGES
Figure 2.1 NRU-by use of two-columns cryogenic distillation 11
Figure 2.2 Process Flow diagram of Pressure swing adsorption 12
Figure 2.3 PSA processing steps transition for the first bed 16
shown.
Figure 2.4 The framework structure of zeolite 18
Figure 2.5 Comparison of pressure swing and temperature swing 19

adsorption for adsorbent generation.
Figure 2.6 Flow diagram for membrane separation technique. 20
Figure 4.1 Vertical Separator 42
Figure 4.2 Pump 44
Figure 4.3 Control Valve 46
Figure 4.4 Heat Exchanger 49
Figure 4.5 Absorber 53
Figure 5.1 Amine Unit Simulation 63
Figure 5.2.1 Feed and solvent Parameter 64
Figure 5.2.2 Feed and Solvent parameter 64
Figure 5.3 Flow rate of sweet gas and rich DEA 65
Figure 5.5 Regenerator re boiler duty 66
Figure 5.6 Temperature and pressure profile of Regenerator 67
Figure 5.7 Cryogenic distillation simulation 68
Figure 5.8 Cryogenic Feed conditions 68
Figure 5.9 Nitrogen rejection unit Product composition 69
viii
Figure 5.10 Nitrogen rejection unit Product Parameter 69
Figure 5.11 Re boiler duty of Nitrogen rejection unit 70
Figure 5.12 Pure methane products from NGL columns 70
Figure 5.13 NGL product 71
Figure 5.14 Reboiler duty of NGL columns 71
Figure 5.15 Product Gas Parameters 72
Figure 5.16 PSA process simulation 73
Figure 5.17 Bed simulation specification 73
Figure 7.1 Feedback Controller 91
Figure 7.2 Feed forward Controller 92
ix
LIST OF TABLES
PAGES
Table 1.1 Physical Properties of Natural gas 5
Table 2.1 Typical pipeline specifications of Natural gas 10
Table 2.2 Some major commercial adsorption separations 17
Table 3.1 Component Flows of stream B and D 25
Table 3.2 Sensible and latent heat of Stream entering NRU 26
Table 3.2 Component Flows of stream V and D 27
Table 3.3 Mol% of stream F2 28
Table 3.4 Component flows of stream P1 and P2 31
Table 3.5 Component flows of stream B and D 32
Table 3.6 Component flows of stream N and D1 33
Table 3.7 Component flows of N and D 34
Table 6.1 HAZOP chart for adsorption column 77
Table 6.2 HAZOP chart for glycol-glycol HeatExchanger 78
Table 6.3 HAZOP chart for pump 79
Table 6.4 HAZOP chart for separator 80
Table 8.1 Typical factors for project fixed cost 98
Table 8.2 Typical factors for project fixed cost 98
x
NOTATIONS
Qg = Gas flow rate

Ql = Liquid flow rate
Dp = Droplet Diameter
ρg = Density of gas
ρL = Density of liquid
t = Retention time
u = Viscosity
Cd = Drag coefficient
Re = Reynolds number
A = Area
V = Volume
VT = Terminal velocity
D = Diameter
L = Length
C = Concentration
Cv = Discharge coefficient
Ud = Overall heat transfer coefficient
B = Baffle spacing
ID = Inner diameter
P = Pitch
BWG = Birmingham wire gauge
Z = Compressibility Factor
UM = Superficial Velocity
Cs= concentration in adsorbent
Vm = vapour rate
ρv = density of vapour
Uc = vapour velocity
Dc = column diameter
l = plate spacing
PPC = Total Physical Plant Cost
Io = Cost Index
xi
ACKNOWLEDGMENT
We are extremely thankful to Almighty Allah. The most Beneficent, The most
Merciful, Who gave us the courage and energy to complete this project.
We wish to express our sincere gratitude to our external Sir Zubair (ZEL Pvt.
Limited), for giving us their precious time along with cooperation and guidance
during our project. Their sincere efforts and support for us to prepare this project.
We would like to express our gratitude to our project supervisor Engr. Obaid ur
Rehman for his advice, guidance and his enormous patient throughout the
development of the work. We also like to thank our project co-ordinator Engr. Ahsan
Abdul Ghani, for being very helpful especially when we experienced problems with
the simulation
We would like to thank all the teachers of Chemical Engineering Department of

University of Karachi for giving us instructions and guidance.
xii
ABSTRACT
Natural gas is a good choice for its lower emissions compared with other fossil fuels.
Once a gas field has been discovered, the 100 MMSCFD gas accumulations must be
developed, produced, gathered, processed and transported to the customer. Transport
of gas by pipelines to distant delivery points present unique challenges of flow
through long conduits. Processing of the gas to meet delivery specifications is
required and this requires process systems design for each production facility.
The major objective of the project is to design and comparison study of different
technologies for nitrogen removal. Basically nitrogen is consider as the contaminant
in the natural gas due to this reason nitrogen lowers the BTU value of the gas and
makes it un-saleable to most pipelines.
In this report different processes are discuss for nitrogen removal and make natural
gas to meet pipe line specifications. Further, it involves brief overview of each
process has been described, prevalent process schemes, material energy balance,
HAZOP study on different equipments, environment constraints, instrumentation and
control strategies and simulations have been performed on the selected processes
(cryogenic distillation and pressure swing adsorption). And also draw the comparison
between different nitrogen rejection technologies on the basis of economics analysis
and their performance ability means which gives greater purity or to remove
undesired material.
xiii
DEDICATION
This project is especially dedicated to our parents, our supervisor and co supervisor
for helping us out during the completion of the entire project.
xiv
CHAPTER NO 01
INTRODUCTION OF
NATURAL GAS
PROCESSING
1
CHAPTER NO 01
INTRODUCTION
1.1 Natural Gas Processing
Natural gas is a fossil fuel primarily made up of methane along with traces of heavier
hydrocarbons such as ethane, methane, propane and butane. The gas is colorless and
odorless, but generates a great deal of energy when combusted. Natural gas is favored
as a fuel source because unlike other energy sources, the combustion of natural gas is
clean and does not harmful substances into the atmosphere. Natural gas is an
important fuel sources as well as a major feedstock for fertilizers and petrochemicals.
Raw material gas after transmission through the field gathering network must be
processed before it can be moved into long distance pipeline systems for use by
consumers. The objective of gas processing is to separate natural gas, condensate,
non-condensate, acid gases and water from a gas producing well and condition these
fluids for sale or disposal. In some cases, little processing is needed ,however, most
natural gas requires processing equipment at the gas processing plant to remove
impurities, water and excess hydrocarbon liquid and to control delivery pressure.[1]
1.2 Natural Gas History:
The discovery of natural gas dates from ancient times in the Middle East. It was
considered by ancients to be a supernatural manifestation. Noticed only when ignited,
it appeared as a mysterious fire bursting from fissures in the ground. Natural gas seeps
were discovered in Iran between 6000 and 2000 BC. The practical use of natural gas
dates back to the Chinese of 2500 years ago, who used bamboo pipes to collect it
from natural seeps and convey it to gas-fired evaporators, where it was used to boil
ocean water for the salt. Apparently, natural gas was unknown in Europe until its
discovery in England in 1659. However, since manufactured gas (coal gas) was
already commercially available, natural gas remained unpopular. In 1815, natural gas
was discovered in the United States during the digging of a salt-brine well in
Charleston, West Virginia. In 1821, an American gunsmith named William Aaron
Hart drilled the first natural gas well in the United States. It was covered with a large
barrel, and the gas was directed through wooden pipes that were replaced a few years
2
later with lead pipe. One of the earliest attempts of monetization occurred in 1824 in
Fredonia, New York, which led to the formation of the first natural gas company in
the United States, the Fredonia Gas Light Company, in 1858. The nineteenth century
is considered as the starting point of the gas industry. In the early 1900s, huge
amounts of natural gas were found in Texas and Oklahoma, and in the 1920s modern
seamless steel pipe was introduced. The strength of this new pipe, which could be
welded into long sections, allowed gas to be carried under higher pressures and, thus,
in greater quantities. As the technology to create seamless steel pipe and related
equipment advanced, the size and length of pipelines increased, as did the volumes of
gas that could be transported easily and safely over many miles. The first natural gas
pipeline longer than 200 miles was built in 1925, from Louisiana to Texas. Steady
growth in the use of gas marked the early and mid-twentieth century. However, it was
the shortages of crude oil in the late 1960s and early 1970s that forced major
industrial nations to seek energy alternatives. Since those events, gas has become a
central fossil fuel energy source. Today, natural gas has become extremely important
as a concentrated, clean fuel for home heating and cooking and electrical power
generation, and is sought after almost as much as oil. [2]
1.3 Natural Gas Origin and Sources:
There are different theories as to the origins of fossil fuels. The most widely accepted
theory of the origin of natural gas assumes that natural gas hydrocarbons come from
organic matter (the remains of land and aquatic plants, animals and microorganisms)
that was trapped within sediments as they were deposited and transformed over long
periods of time into their present form. Two main mechanisms, namely, biogenic and
thermogenic are responsible for the degradation of fossil organic material in
sediments. Biogenic gas is formed at shallow depths and low temperatures due to the
action of bacteria on the organic debris accumulating in the sediments. In contrast,
thermogenic gas is formed at deeper depths by degradation of organic matter, called
kerogen, accumulated in fine-grained sediments, especially clays and shales. This
degradation occurs through the combined effects of temperature and pressure.
Thermogenic gas is believed to be produced by two mechanisms, namely, direct
thermal cracking of sedimentary organic matter and secondary thermal cracking of oil
that is formed in the first stage. The former is called the primary thermogenic gas that
3
coexists with oil, while the latter is called secondary thermogenic gas that coexists
with insoluble solid matter, called pyrobitumen. Both mechanisms involve thermal
cracking with some degree of sustained pressure, mainly through the weight of the
sedimentary formation. Little information is available on the time required to generate
thermogenic gas other than the general assumption that it is a long time. Natural gas
comes from both “conventional” (easier to produce) and “unconventional” (more
difficult to produce) geological formations. Conventional gas is typically “free gas”
trapped in multiple, relatively small, porous zones in various naturally occurring rock
formations such as carbonates, sandstones, and siltstones. Conventional natural gas
generally occurs in deep reservoirs, either associated with crude oil (associated gas) or
in reservoirs that contain little or no crude oil (no associate gas). Natural gas from
coal (also known as coal-bed methane), tight gas sands, gas shales, geopressurized
aquifers, and gas hydrates3 are often referred to as unconventional gas resources. The
common characteristic of the different types of unconventional gas resources is that
they contain large quantities of natural gas, but it is usually more difficult to produce
this gas as compared to conventional reservoir rocks. New technologies are
continually being developed to allow more accurate estimations of the amount of gas
in these unconventional reservoirs and to stimulate these rocks to produce the gas. [3]
1.4 Natural Gas Properties:
Natural gas is colorless, odorless, tasteless, shapeless, and lighter than air (see Table
1-1). The natural gas after appropriate treatment for acid gas reduction, and moisture
and hydrocarbon dew point adjustment, would then be sold within prescribed limits of
pressure, heating value and possibly Wobbe Index (often referred to as the Wobbe
Number). One of the principal uses of natural gas is as a fuel, and consequently,
pipeline gas is normally bought and sold on the basis of its heating value that can be
produced by burning the gas. The heating value of natural gas is variable and depends
on its accumulations which are influenced by the amount and types of gases they
contain. The gas industry always uses the gross heating value (frequently called
higher heating value) in custody transfer. Obviously, the numerical difference
between the two net and gross heating values is the heat of condensation of water at
the specified conditions. Heating values for custody transfer are determined either by
direct measurement, in which calorimetry is used, or by computation of the value on
4
the basis of gas analysis. Since meters measure volume and not energy content, a
conversion factor of 1000 Btu/ft3 is commonly used by gas companies to convert the
volume of gas used to its heat equivalent, and thus calculate the actual energy use.
The Wobbe Index (defined as the gross heating value of the gas divided by the square
root of the specific gravity) gives a measure of the heat input to an appliance through
a given aperture at a given gas pressure. [4]
Table 1.1: physical properties of natural gas [5]
1.4.1 Considerable Impurities in Natural Gas:
Natural gas consists of impurities which are necessary to be removed. These

impurities, generally, include:
a) Water: Natural gas stream from production wells is saturated with water
vapor, which will condense and form gas hydrates if the gas is cooled below
its hydrate formation temperature. Gas hydrates are solids that can
agglomerate and plug pipelines and equipment, interrupting operations and
stopping gas production. This may create an unsafe condition, especially if
5
significant pressure differential occurs across the hydrate plug. Also, water
vapor may condense in pipelines, resulting in erosion and corrosion. When
accumulated in the pipelines, it might form liquid plug, reducing the pipeline
flow capacity. To avoid these potential problems, the gas stream needs to be
dried to lower its water dew point.[6]
b) CO2 and Sulfur Species: Natural gas, which consists of mainly methane and
light hydrocarbons, also contains acid gases such as hydrogen sulfide (H2S)
and carbon dioxide (CO2). In addition to acid gases, natural gas may contain
other sulfur contaminants such as mercaptans (R–SH), carbonyl sulfide
(COS), and carbon disulfide (CS2). Natural gas with H2S or other sulfur
compounds is called sour gas, whereas gas with only CO2 is called sweet gas.
Sour gas can cause corrosion to natural gas processing equipment and
pipelines. Combustion of sulfur compounds produces sulfur oxide air
pollutants that must be limited to protect the environment and to prevent
health-related problems. Carbon dioxide is an inert gas that does not have any
heating value, but it is the main source of greenhouse gas responsible for
climate changes.[7]
c) Nitrogen gas N2: Nitrogen can be naturally occurring in high concentration in
production fields, such as in the U.S. Midwest, North Sea, Eastern Europe, and
South East Asia. Approximately 15% of the nonassociated gas reserves in the
world are high in nitrogen content and would not meet the specification for
normal pipeline quality gas (typically 3–4 mol %). Nitrogen, being an inert,
will not support combustion, and the gas when burned will lead to unstable
combustion. In addition, nitrogen will strip off the NGL components in the
NGL recovery plants, and would increase the size of the compression
equipment and transmission pipeline. In LNG plant, high nitrogen is not
desirable as it will create liquefaction problem and Increase boil-off gas from
the storage tanks.[8]
6
1.5 Objective and Scope of Project:
a) To carry out literature survey on different technologies of nitrogen rejection

unit.
b) To design and comparison study of pressure swing adsorption PSA &
Cryogenic distillation unit.
c) Environmental and economic study of the designed plants.
d) Provides a basis and detailed designing for nitrogen rejection unit. (PSA &
cryogenic system)
e) It also provides a substantial comparison between the two technologies.
7
CHAPTER NO 2
NITROGEN
REJECTION
TECHNOLOGIES
8
CHAPTER NO 2
NITROGEN REJECTION TECHNOLOGIES
2.1 Introduction
Nitrogen rejection is a difficult technical separation because of similar molecular size

of nitrogen (N2) and methane (CH4) and the lack of a selective reactivity such as there
is with carbon dioxide or hydrogen sulfide in an amine plant. Nitrogen can be
naturally occurring in high concentration in production fields, such as in the U.S.
Midwest, North Sea, Eastern Europe, and South East Asia. Approximately 15% of the
non-associated gas reserves in the world are high in nitrogen content and would not
meet the specification for normal pipeline quality gas (typically 3–4 mol %).
Nitrogen, being an inert, will not support combustion, and the gas when burned will
lead to unstable combustion. In addition, nitrogen will strip off the NGL components
in the NGL recovery plants, and would increase the size of the compression
equipment and transmission pipeline. In LNG plant, high nitrogen is not desirable as
it will create liquefaction problem and Increase boil-off gas from the storage tanks
Pressure swing adsorption, cryogenic separation, and lean oil absorption have been
employed to remove nitrogen from natural gas. [12]
2.1.1 The Need of Removing Nitrogen
Nitrogen gas is a common contaminant in natural gas and is quite difficult to remove.
Causes behind its reduction include:
a) Natural gas will be accepted for transport by pipeline only if it contains less than a
special amount of nitrogen, typically somewhere between 4% and 6%.
b) Excess nitrogen present in a pipeline might be danger of vapor lock or
combustion.
c) Nitrogen also dilutes the heating value of the gas, resulting in a lower BTU and
decreased value. High nitrogen natural gas is essentially stranded, as it cannot
feasibly be transported through pipeline to market.
d) Also to avoid NOx formation, and to ignore bottle-necking and equipment
[12]
corrosion, nitrogen needs to be removed up to acceptable level.
9
Table 2.1: Typical Pipeline Specifications of Natural Gas. [9]
2.2 Nitrogen Rejection Technologies for Gas Upgrading:
Out of above mentioned methods, core methods are described below:
a) Cryogenic distillation
b) Pressure swing Adsorption
c) Membrane separation
d) Temperature Swing Adsorption
At low gas volumes, membranes and pressure swing adsorption (PSA) by use of
molecular sieves are economically feasible.
In regard to hydrocarbon recovery, only PSA has heavier hydrocarbons (all C4+ and
part of propane) going with the nitrogen stream. This situation is caused by adsorption
in the sieve binder, as the components are too large to enter the Sieve pores. The
binder also adsorbs water and CO2. The loss of hydrocarbons may or may not be
beneficial.
10
2.2.1 Cryogenic Distillation
The most common method of removing nitrogen from natural gas is cryogenic
Distillation. The Engineering Data Book (2004b) notes that for feed concentrations
below 20% N2, a single-column design can be used. For higher concentrations, a dual-
column is better. With the addition of a recycle compressor, it can be used at lower N2
contents. Figure shows a flow diagram for a two-column NRU receiving feed that
contains 15% N2 from a demethanizer in conventional turboexpander plant.
Figure 2.1: NRU by Use of Two-Column Cryogenic Distillation [10]
Gas from the demethanizer overhead is cooled by heat exchange and pressure
reduction and fed to a distillation column operating at 200 psig (14 barg). The
bottoms product from this high-pressure column is reduced in pressure to cool the
stream to −240F (−151C). This stream, combined with the bottoms product from the
second low-pressure column, is fed to a heat exchanger in the top of the high-pressure
column to provide the necessary reflux.
The overhead from the high-pressure column flows through three heat exchangers, is
reduced in pressure to approximately 15 psig (1 bar g), and enters the low-pressure
column at −300F (−184C). The overhead from this column is 98% N2, and the
11
bottoms product is approximately 98% CH4. The Hannibal Gas Plant of British Gas
Tunisia (Jones et al., 1999) uses cryogenic distillation to reduce the N2 content of the
feed gas from 16.9% N2 to the sales-gas specification of 6.5%. Operations are given
by Jones et al. (1999) and Howard (1998). [10]
2.2.2 Pressure Swing Adsorption:
After cryogenic distillation, pressure swing adsorption (PSA) is probably the most
widely used process. The amount of gas adsorbed during adsorption depends on four
factors:
a) The adsorbent itself

b) The species being adsorbed (adsorbate)
c) The temperature
d) The partial pressure of the adsorbate
Once the adsorbent and adsorbate are selected, the temperature and partial pressure
become the governing variables. All industrial regenerative adsorption separations
involve two steps:
a) Adsorption to separate the species, followed by desorption.

b) Removal of the adsorbate (regeneration) to prepare the adsorbent for further use.
Figure 2.2 process flow diagram of pressure swing adsorption.
12
Dynamic nature of PSA is attributed to its periodic operation, where each bed in the
PSA assembly undergoes a fixed simultaneous steps of processing, repeated in a
cyclic fashion for achieving desired product purity (high pressure)as well as adsorbent
regeneration (low pressure), simultaneously. The dynamic swing or shift from one
processing step to another for a given bed is achieved by a network of bed
interconnecting switch valves, whose active status keeps changing over the period of
time. Consequently, the timing of these valves in turn controls the duration of process
steps that each PSA bed undergoes in one cycle.
The dynamic operation also affects the gas-solid hydrodynamics inside the packed
bed. The strong interplay between the equilibrium and kinetic mechanisms is
significantly affected by the changing bed pressure levels and transient boundary
conditions. The fact that off-gas stream leaving the PSA system, In addition to
containing impurity components, also has significant amount Of product component,
points towards the possibility of PSA integration with Other separation devices such
as membranes to improve the overall product recovery but at the stake of cost. [11] [12]
[13]
2.2.2.1 Separation Principle of PSA
The key separation principle used in a PSA operation is based on adsorption

phenomena.
Adsorption, in general can be defined as ‘’a process where the molecules or atoms of
a single or multi-component fluid system in liquid, gas or even a super-critical phase
tends to concentrate at the surface of a solid surface, under the effect of
intermolecular interactions among the fluid (adsorbate) and solid phase (adsorbent)’’.
If the strength of interactive forces between the adsorbent and the fluid system is very
strong, resulting in an electron transfer driven bonding, the phenomena is called
chemisorption. On the other hand physiosorption, or physical Adsorption results when
the surface forces between the adsorbent and the fluid system are rather weak and
involve only weak natured electrostatic interactions. PSA processes are usually
employed for ‘gas-solid system’ exhibiting physiosorption, where both fast adsorption
and desorption at the adsorbent surface is realized by changing the pressure levels
inside the bed.
In general, PSA separation processes are broadly classified in two categories:
13
a) Equilibrium based separation.
b) Mass transfer kinetics driven separation.
Depending upon which of this mechanism is playing the limiting role.
equilibrium based PSA separations exploits the equilibrium adsorbed phase

concentration relationship of the impurity with its bulk phase partial pressure. The
adsorbent material is designed to have the least affinity for the product component.
The pressure during the adsorption step is kept at the highest level in order to increase
the adsorbed amount of impurities, leading to enrichment of product component in the
gas phase, while regeneration is performed at significantly lower pressure allowing
the impurities to desorb back to the gas phase and be taken out of the bed. It is
important to note that the mass transfer rate of all the species can be quite similar in
pure equilibrium driven separation.
On the other hand, in kinetic driven separation, the mass transfer rates of the
components from the bulk phase to the adsorption site are exploited through the
suitable selection and design of adsorbent pore characteristics for the given gaseous
[12] [13]
species, in order to achieve an effective separation.
2.2.2.2 Detailed Description of PSA Cyclic Operation
In order to gain further understanding of the PSA periodic operation, each processing
Step of the PSA cycle shown in Figure 2.3 is explained here in detail.
a) Adsorption with feed:

Feed gas mixture enters the feed of the column. The product gas containing the
desired pure component leaves the other end of column at product pressure, which is
only slightly less than the inlet pressure. During this stage the impurities get adsorbed
on the solid adsorbent, and the weakly adsorbed component comes out as a product.
The time length of this step is very important as the impurity front keeps moving
ahead from the feed end during this process step. If it advances too much towards the
product
End, then later on during the co-current depressurization steps, where the system
pressure is decreasing and desorption happens as well, the impurities can break
through the column with the leaving product, bringing down its performance.
14
b) Adsorption with feed and product pressurization:
At the start of this stage a side stream from the main product is taken out and is used
to pressurize another bed undergoing re-pressurization with product step (step 10).
c) First co-current depressurization:
During this stage the inlet flow to the bed is stopped and the outlet valve is opened to
another bed undergoing second counter-current pressure equalization (step 9). As the
pressure in the column reduces, the outlet stream containing pure product leaves the
column and pressurizes other column. This efficient usage of the pure product gas left
in the bed void space to pressurize other columns greatly improves the overall product
recovery, as this not only minimizes the product losses during the counter-current
depressurization stage but also reduces the system dependency on external Sources
for bed pressurization.
d) Second co-current depressurization:
In this stage the inlet to bed remain closed and outlet is now connected to another bed
which has just finished counter current depressurization. The Pure product coming out
of the bed acts as an excellent source of purge Stream for the other bed (step 7).
Consequently, the system dependence on the external supply of product stream is
further reduced.
e) Third co-current depressurization:
The column continues to depressurize itself and is now connected to another column
at lower pressure which has just finished purge step (step 8), in order to fully utilize
the pure product gas at the product end to pressurize other columns.
f) Counter current depressurization:
This is the blowdown stage, where the feed end is now opened to a lower pressure
sink and the product is closed. During this stage the impurities, which are most
concentrated near the feed end gets desorbed and leaves the column as an off gas, thus
bringing adsorbent bed regeneration.
g) Counter current purge:
The feed end still remains open to a low pressure sink, while the product end is now
connected to a bed which has just finished first co-current depressurization (step 4).
The pure product stream entering the bed at low pressure sweeps away the remaining
impurities.
15
h) First counter-current pressure equalization:
The column feed end is now closed and the product end is connected to another
column undergoing step 5. Consequently, the pressure inside the bed starts rising.
i) Second counter-current pressure equalization:
The pressure inside the column continues to rise as the product end is connected to
another column undergoing step 3.
j) Counter-current re-pressurization with product:
This is the final stage in the cycle where the column is pressurized with the product
coming out of another bed in step2. By the end of this step, the pressure inside the
column is at the same level as the feed pressure. [13]
[13]
Figure 2.3: PSA processing steps transition for the first bed shown.
2.2.2.3 PSA performance indicators
A challenging task in comparing various process alternatives and design options for
PSA systems is the quantification of their performance. In this regard, the knowledge
of capital and operating costs provides an accurate account of the monetary value
associated with the plant installation and operational features. An alternative
approach, which does not require detailed information of the pricing and
manufacturing data involves measuring other important performance indicators such
as recovery, purity and productivity.
In past PSA studies, the combination of product recovery and purity, defined in
equations 2.1 and 2.2 has been extensively used to benchmark different processes.
Product purity is usually set by the customer requirements while recovery is to be

maximized at the specified purity levels. In most of the PSA systems, this leads
16
towards a trade-off situation as design changes to improve product recovery adversely
affects the system purity. [12] [13]
Product recovery = (Amount of component in the product stream
Amount of component in the feed stream) (2.1)
Product purity = (Amount of component in the product stream
Total amount of product stream) (2.2)
2.2.2.4 Selection of Adsorbent
There are various commercially adsorbents are available for separation of Nitrogen
either from air or from natural gas. The common adsorbents used for separation of
nitrogen are:
a) Activated carbon
b) Silica gel
c) Zeolite or molecular sieves
d) Activated alumina
The choice of adsorbents is summarized in the table for different separation and
purification adsorption process.
Table 2.2 some major commercial adsorption separations. [11]
For separation of nitrogen from natural gas, Zeolite 13x and Carbon molecular sieve
3k is recommended. [11] [13] Molecular sieves are generally of types A or X. there are
three categories under type A namely (3A, 4A and 5A). 3A means a variety having a
nominal pore diameter of 3 Ao (angstrom). The type X molecular sieve may be 10X or
17
13X (13X means nominal pore diameter= 10 Angstrom) and its general formula is
Na12 (Al2O2)86 (SiO2)106.nH2O.
Figure 2.4 the framework structure of zeolite
The carbon molecular sieves (CMS) are largely used for N2 production by employing
the pressure swing adsorption. It is powdered, mixed with a polymeric binder and
pelletized. The pellets are carbonized and further processed. A CMS adsorbs O 2 much
faster than it can adsorb nitrogen.
2.2.3 Temperature Swing Adsorption:
In the case of PSA, the adsorbent regeneration operation is performed by lowering the
bed pressure, as the impurities at lower pressure have less affinity for the adsorbent.
An alternative way to perform desorption is to raise the bed temperature levels, as
employed in the temperature swing adsorption (TSA) cycle.
A TSA operation usually employs the following three basic steps.
a) Adsorption or production step at low temperature

b) Heating the bed for desorption of impurities
c) Cooling the bed back to the adsorption conditions
d) For heating and cooling operation both, direct means such as using purge/inert
e) Gas or indirect means involving heating jackets, coils or microwave can be
employed.
The key advantage of TSA over PSA is its ability to separate impurities having a
tendency to form strong bonding with the adsorbent (chemisorption), as a change of
only few degrees in temperature can cause considerable change in the loading
18
amount, leading to an effective separation. Consequently, TSA is usually preferred for
purification purposes instead of bulk separation. On the other hand, a major challenge
related to the use of TSA is the relative long duration of the processing steps
necessary to change the bed temperature, as compared to a PSA system. It should be
noted that bed pressure transients can be quickly realized in a packed bed by changing
the valve settings, while temperature changes requires heating the whole mass of
adsorbent and metallic wall requiring hours or even days to complete one cycle,
adversely affecting the cycle productivity. [11]
Figure depicts the comparison between the PSA and TSA cycles for a given
adsorption isotherm.
Figure 2.5: comparison of pressure swing and temperature swing adsorption for adsorbent generation. [11]
In natural gas systems, if adsorption is used to remove a relatively small amount of

material to a very low level, or if the heat of adsorption is very high, TSA is generally
used. An example is natural gas dehydration, which meets both criteria. For bulk
removal of one component from another (e.g., upgrading natural gas to pipeline
specifications by removal of CO2 or N2), PSA may be the choice because
concentrations of the adsorbate are high and the heat of adsorption is low.
2.2.4 Membrane Separation:
Gas separation employing membrane technology is also very widely used in the
process industry. Here, the separation principle is based on the difference in the rate
of permeation across the membrane material for different components in the feed
mixture. In terms of ease of operability, membrane offers significant advantage over
19
PSA, as its module is much simpler to operate as compared to the periodic operation
requirement of PSA separation systems. Furthermore, for the bulk separation
applications, which are characterized by low to moderate selectivity requirements,
membrane is an attractive operation.
For gas purification purposes, the requirement of high membrane selectivity translates
into low permeation rate across the membrane material, making them suitable only for
small scale applications. In order to perform gas purification at large scales, re-
compression equipment and extra membrane modules are necessary to obtain the
desired purity in several stages, making it a highly energy intensive operation. In
contrast, the selectivity in PSA is typically much higher than the membranes, and
furthermore, since the product leaves the system as retentive, high production levels
can be achieved.
Enrichment
separation
consists of
increasing the
concentration of
one or
Figure 2.6: flow diagram for membrane separation technique.
Enrichment separation consists of increasing the concentration of one or several

species in a desired stream. This operation does not mean high recovery or purity.
Sharp separation consists of obtaining two high-purity, high-recovery product streams
from one input stream. The concentration of components in input is not restrictive.
Purification separation is meant here as the removal of one or more impurities from a
stream to achieve very high concentration (purity) of the dominant component. The
initial concentration of impurity in mixture should be lower than 2% or 2000 ppm.
20
CHAPTER NO 3
MATERIAL AND
ENERGY BALANCE
21
CHAPTER NO 3
MATERIAL AND ENERGY BALANCE
3.1 INTRODUCTION:
3.1.1 Mass Balance:
A mass balance, also called a material balance, is an application of conservation of

mass to the analysis of physical systems. By accounting for material entering and
leaving a system, mass flows can be identified which might have been unknown, or
difficult to measure without this technique. Mathematically the mass balance for a
system without a chemical reaction is as follows:
Input= Output + Accumulation (3.1)
The Eq for mass balance of a system involving chemical reaction is as follow:
Input + Generation = Output + Accumulation + Consumption (3.2)
3.1.2 Energy Balance:
Energy balance is the relationship between “energy in” and “energy out”. The energy
balance eq. derived from law of conservation of energy is as follow:
Ein - Eout = EAccumulation (3.3)
The total amount of energy entering the system is the sum of all of the different types
of energy entering the system. Here are the expressions for the different types of
energy entering or leaving the system:
Kinetic Energy: K.E= mv2/2 (3.4)
Potential Energy: P.E= mgh (3.5)
Enthalpy: H= U+PV (3.6)
22
3.2 MASS AND ENERGY BALANCE FOR CRYOGENIC NRU:
3.2.1 MATERIAL BALANCE:
Nitrogen rejection unit is used to separate the nitrogen content from the natural gas.
Suppose feed F is entering the column and two products bottom (W) and distillate (D)
are drawn from the column. Stream W is free from nitrogen and contains 95.9%
methane and stream D is nitrogen drawn from the top of the column. Mass balance eq
for the column can be given as follow:
F= W+D (3.7)
Taking Basis: 3424 kgmol/hr of Feed
Figure 3.1 Nitrogen Rejection Unit
Now making the methane balance eq:
2615 = (0.959) (W) + (3424-W) (Xd) (3.8)
The Composition of methane in top product is 0.000079 so we take Xd = 0 and solve

for stream W and D
W= 2728 kgmol/hr
23
D= 698 kgmol/hr
Reflux Ratio= 0.4 kgmol/hr
In Distillation column the section above the feed point is called the rectification
section and the section below the feed point is called stripping section. Rectification
section is denoted by ‘n’ and stripping section is denoted by ‘m’. The liquid and vapor
flow above and below the feed plate are calculated by the eq given below the table:
Table 3.1 Component flow of stream D and W
FEED(F) DISTILLATE(D) BOTTOM(W)
Component kmol Mol Fraction kmol Mol Fraction Kmol Mol Fraction
Methane 2615 0.763726636 0.055079 0.000079 2615 0.959
Ethane 106 0.030957944 0 0 106.3452 0.039
Nitrogen 703 0.205315421 697.1462 0.999921 1.5 0.002
ABOVE FEED PLATE
Ln= RD
Ln=278 kgmol/hr
and
Vn = Ln + D
Vn = 215992.9 kgmol/hr
24
BELOW FEED PLATE
Lm = Ln + F
Lm= 3702 kgmol/hr
and
Vm = Lm - W
Vm= 976 kgmol/hr
The operating Eq for the Stripping section is shown below:
Methane: Ymm= 3.79Xm+1-2.68 (3.9)
Ethane: Yme= 3.79Xm+1-0.11 (3.10)
Nitrogen: Ymn=3.79Xm+1-0.06 (3.11)
Similarly, the operating equation of the rectification section for each of the three
species is represented below:
Methane: Ynm= 0.286Xn+1+2.55E-07 (3.12)
Ethane: Yne= 0. 286Xn+1 (3.13)
Nitrogen: Ynn= 0.286Xn+1+0.0032 (3.14)
The relative volatility of nitrogen with respect to ethane is found to be 2.3. By using
the relative volatility and the above equations we can find out the number of plates
required to achieve the desired composition, the plate at which the feed should be fed
and composition of vapor and liquid of all three specie at each tray. The vapor liquid
equilibrium of methane at each tray is shown below:
25
Table 3.2 Vapor Liquid Equillibrium of Methane
PLATE NO: VAPOR LIQUID
STRIPPING SECTION
1 0.951 0.956
2 0.938 0.951
3 0.911 0.939
4 0.855 0.912
5 0.75 0.856
FEED PLATE
6 0.588 0.753
RECTIFICATION SECTION
7 0.392 0.589
8 0.223 0.394
9 0.112 0.223
10 0.052 0.112
11 0.024 0.052
12 0.01 0.023
26
13 0.005 0.01
14 0.002 0.004
15 0.001 0.002
16 0.0003 0.001
Similarly, for Ethane and nitrogen the vapor liquid equilibrium at each plate of the distillation
column is shown in fig 3.4 and 3.5.
Table 3.3 Vapor Liquid Equilibrium of Nitrogen
STRIPPING SECTION
1 0.01 0.004
2 0.023 0.01
3 0.052 0.023
4 0.11 0.051
5 0.219 0.109
6 0.388 0.216
7 0.592 0.386
27
8 0.768 0.59
9 0.883 0.767
10 0.945 0.883
11 0.975 0.945
12 0.985 0.975
13 0.995 0.989
14 0.998 0.995
15 0.999 0.998
16 0.999 0.999
Table 3.4 Vapor Liquid Equillibrium of Ethane
STRIPPING SECTION
1 0.038 0.039
2 0.038 0.038
3 0.037 0.038
4 0.035 0.037
28
5 0.031 0.034
6 0.388 0.031
7 0.024 0.024
8 0.016 0.016
9 0.01 0.009
10 0.005 0.005
11 0.001 0.002
12 0.0004 0.001
13 0.0001 0.0004
14 0 0.0002
15 0 0
16 0 0
The above result shows that the 16 plates are required to achieve the desired
separation because the desired composition of nitrogen in the distillate is nearly
achieve on the plate 16. As shown by the above result at plate 6 the vapor
composition of methane, ethane and nitrogen is nearly the same as the feed
composition, therefore the feed mixture of methane, ethane and nitrogen should be fed
at feed plate 6.
29
3.2.2 ENERGY BALANCE:
The nitrogen rejection unit contains both the condenser and the reboiler therefore,
energy balance equation for nitrogen rejection distillation unit will include both the
reboiler and the condensor. Six different stream from the separator are mixing and
entering into the nitrogen rejection distillation unit and energy releasing from the
expander is utilized in the nitrogen rejection unit which reduces the reboiler duty. The
boiling Point of the components at the given condition is:
Methane = -156.50C
Ethane = -850C
Nitrogen = -1910C
The boiling point of feed mixture can be found by multiplying the mole fraction of
each component with its boiling point.
Feed = (0.763) (-156.5) + (0.031) (-85) + (0.205) (-191.5)
Feed= -161.110C
Specific Heat of Feed= 49.98 kJ/kgmol 0C
First, we will have to find the sensible heat.
Sensible heat= m*C*ΔT
Sensible Heat= 3429*49.98*(-181+161)
Sensible Heat= -3.17 MMBtu/hr
Now, we will find the latent heat.
Heat of vaporization= 9734 Btu/hr
Latent Heat= m *ΔH
Latent Heat= 702*9734
Latent Heat= 6.83 MMBtu/hr
30
Therefore, total heat required can be found by summation of the latent heat and the
sensible heat.
Total Heat= 6.83-3.17
Total Heat= 3.66 MMbtu/hr
The heat release from the expander i.e. 1.332 MMbtu/hr is utilized in the nitrogen
rejection unit. As a result the energy required by the reboiler is reduced. The reboiler
duty is coming as;
Reboiler Duty= 3.66-1.332
Reboiler Duty= 2.32 MMbtu/hr
Condenser Duty can be found by the use of reflux ratio.
Reflux Rate= 278 kgmol/hr
Distillate Rate= 702 kgmol/hr
Total moles to condenser= 981 kgmol/hr
Latent Heat removed by the condenser= 278.9*9734
Latent Heat removed by the condenser= 2.71 MMbtu/hr
3.3 SEPARATOR:
Separator used in the scheme is two phase separator. It is used to separate the heavier
hydrocarbon from the feed of nitrogen rejection distillation unit. The mass balance
equation eq for two phase separator is as follow:
F= V+L (3.15)
31
V
Fig 3.2 Two Phase Separator
Balance eq for methane may be given as:
(2.41E+03) = (0.734)(V) + (0.5)(L) (3.16)
Solving Eq 3.15 and 3.16 simultaneously will give molar flow of stream V and L:
V= 3218.1kgmol/hr
L= 86.25kgmol/h
Component flow in stream V and L is given as:
Table 3.5 Component flows of stream V and L
Components Stream V(kgmol/hr) Stream L(kgmol/hr)
Methane 2360.07328 47.68343053
Ethane 160.7481195 20.13304532
Propane 20.34268263 9.599882086
i-butane 1.316721621 1.551734755
32
n-butane 1.159452145 1.999776471
i-pentane 0.102860835 0.43188637
n-pentane 0.048935942 0.290838785
n-hexane 0.002186414 0.042548404
Water 0.003994491 0.000165383
CO2 1.63708529 0.09087511
N2 673.3146813 4.425816787
3.4 ABSORPTION COLUMN:
Absorption column is used to remove CO2 content from natural gas. For that an
aqueos solution of DEA is introduced from the top (F1) and natural gas is fed from the
bottom (F2) and sweet gas is drawn from the top (P1) and rich DEA is drawn from the
bottom (P2).Material balance on the absorber is given by:
F1+F2= P1+P2 (3.17)
F1 P1
F2 P2
Fig 3.3 Absorption column
33
DEA in the aqueos solution is 10% and natural gas has the following composition:
Table 3.6 mol% of stream F2
Component mol%
Methane 0.557411
Ethane 5.69E-02
Propane 1.62E-02
i-butane 2.69E-03
n-butane 3.89E-03
i-pentane 1.30E-03
n-pentane 1.10E-03
n-hexane 3.99E-04
Water 3.67E-03
CO2 0.20914
N2 0.147277
CO2 content remaining in the sweet gas is reduced to 0.002%.The mol fraction of
DEA in rich DEA is reduced to 9.7%.Therfore; making mass balance on DEA will
yield Following Equation:
(0.1)(F1) = (0.097) (P2) (3.18)
34
DEA is not present in stream F2 and stream P1 therefore F1 and P1 stream are
omitted from Equation 3.17. Solving Equation 3.17 and 3.16 simultaneously will
yield the flow rate of all streams:
P1= 3780 kgmol/hr
P2= 21030 kgmol/hr
Molar Flow of all the components present in stream P1 and P2 are as follow:
Table 3.7 Component flows of stream P1 and P2
P1 (kgmol/hr) P2 (kgmol/hr)
Methane 2664.9 10.0944
Ethane 272.16 0
Propane 77.49 0
i-butane 12.852 0
n-butane 18.522 0
i-pentane 6.048 0
n-pentane 5.292 0
n-hexane 1.89 0
Water 14.742 17959.62
CO2 0.0756 1009.44
N2 703.08 0
35
Amine 0 20399.1
Heat of absorption of CO2 can be calculated by first finding the moles of CO2
absorbed than from that finding the DEA required to achieve that absorption.
Moles of CO2 absorbed= (100) (0.204) / (379.5)
Moles of CO2 absorbed= 53755 mol/day
Now we find the moles of DEA required to achieve absorption:
Moles of DEA required= (2799) (8.71) (0.35) (1440) / (105.14)
Moles of DEA required= 116864.8 DEA/day
Now, we find the ratio of CO2 absorbed and the moles of DEA charged.
Loading moles CO2/ moles DEA= 0.46
Using above fraction and find heat of absorption from (table 1.5), Gas sweetening and
processing Field manual.
Heat of absorption of CO2= 610Btu/lb CO2
Heat of absorption of CO2= 32.8MMBtu/day
3.5 DEA REGENERATION COLUMN
Regeneration column is used to regenerate the aq. DEA solution by heating the
solution so that CO2 along with some water vaporizes and draw out from the top of
the column and lean DEA is collected from the bottom.26930 kgmol/hr of rich DEA
is fed to the regeneration column. Material balance equation for regenerator may be
represented as:
36
F= D+B (3.19)
Fig 3.4 Regenerator
Amine Balance gives the following eq.
2243.2 = (0.087) (B) (3.20)
D= 1146 kg mol/hr
B= 25784 kg mol/hr
Molar flow of component in stream D and B are given in table 3.8 given on the next
page:
37
Table 3.8 Component flows of stream B and D
COMPONENT D(kgmol/hr) B(kgmol/hr)
Methane 8.98E-02 0.00E+00
Ethane 6.84E-03 0.00E+00
Propane 1.11E-03 0.00E+00
i-butane 1.72E-06 0.00E+00
n-butane 2.43E-06 0.00E+00
i-pentane 1.48E-06 0.00E+00
n-pentane 1.22E-06 0.00E+00
n-hexane 2.85E-05 0.00E+00
Water 6.32E+02 2.35E+04
CO2 5.13E+02 2.73E+01
N2 7.06E-03 0.00E+00
Amine 4.21E-02 2.26E+03
38
Provides the heat input to an amine stripper, which reverses the chemical reactions
and drives off the acid gases. Heat duty of amine Reboiler varies with the system
design. Typically for a stripper with twenty trays the Reboiler duties will be 900-1000
btu/lb lean solution for DEA system. Thus, the Reboiler duty can be estimated by:
qreb= 77421LDEA (3.21)
qreb= Reboiler Duty, Btu/hr
LDEA= DEA circulation rate, gpm
Using eq 3.16 we find the Reboiler duty
qreb= 77421*2799
qreb = 216.7 MMBtu/hr.
3.6 PRESSURE SWING ADSORBER:
In pressure swing adsorber we are first removing CO2 than the gas passes though the
second pressure swing adsorber where N2 content is removed. Material Balance eq for
pressure swing adsorber can be written as:
F= D+N (3.22)
D D1
F F
N
N C
Fig 3.5 CO2 removal PSA Fig 3.6 N2 removal PSA
39
And balance on nitrogen and CO2 gives the following eq.
53231= 0.0006D+0.99C (3.23)
37221.25= 0.03D1+0.99N (3.24)
C= CO2containing stream.
D= product gas from both absorbers.
N=Nitrogen containing stream.
By solving Equations 3.22 and 3.24 simultaneously we get the following molar flow
rates of stream D1 and stream N
D1= 166628.1 lb mol/day
N= 32547 lb mol/day
Molar flow of each component in stream D and N are given below:
Table 3.9 Component flow of Nitrogen removal PSA
COMPONENTS lbmol/day(D1) lbmol/day(N)
Methane 139867.79 325.5
Ethane 1.43E+04 0
Propane 4.11E+04 0
i-Butane 6.84E+02 0
n-Butane 9.88E+02 0
i-pentane 3.29E+02 0
40
n-pentane 2.79E+02 0
Hexane 1.01E+02 0
H2O 8.37E+02 0
Carbon dioxide 9.14E+01 0
Nitrogen 4998.8 32222.4
Table 3.10 Component flow of CO2 removal PSA
COMPONENTS lbmol/day(D) lbmol/day(C)
Methane 140193.2 536.4149
Ethane 1.43E+04 0
Propane 4.11E+03 0
i-Butane 6.84E+02 0
n-Butane 9.88E+02 0
i-pentane 3.29E+02 0
n-pentane 2.79E+02 0
Hexane 1.01E+02 0
H2O 8.37E+02 0
Carbon dioxide 1.26E+02 5.31E+04
Nitrogen 3.72E+04 0
41
Similarly solving equations 3.22 and 3.23 will give:
D=209878.5 lb mol/day
C=53641 lb mol/day
42
CHAPTER NO 4
EQUIPMENT
DESIGNING AND
SIZING
43
CHAPTER NO 4
EQUIPMENT DESIGNING AND SIZING
4.1 SEPARATORS
Two and three phase separators remove and collect liquids from natural gas, available
in horizontal and vertical applications. Three phase separators increase the efficiency
of well effluents. Vertical Separators are ideal when there are space constraints at the
well side or gathering station. Horizontal separator should be utilized when large
amount of fluid are expected and generally at initial stage horizontal three phase
separators is use for preliminary separation.
In horizontal three phase gas/liquid separators, the incoming multiphase mixture
flows into vessel through an inlet device which ensures preliminary gas/liquid
separation. The production stream first encounters the inlet deflectors, which causes
initial separation of gases from liquids. The heavier liquids descend while the gas
flows. In second stage the streams slows even further and the larger liquid particles
entrained in to the gas. Liquid exits the bottom of the vessel and natural gas exits the
top. Downstream of the inlet device the gas section ensures pre-separation of
entrained liquids. After the gas has travelled through the gravity separation section, it
will only contain fine mist droplets. The third section is mist eliminating section
which ensures the separation of these mist particles. Next step is liquid/liquid
separation that is separation between oil and water. The liquid introduced into the
vessel maximizing the liquid/liquid separation efficiency, the flow needs to be evenly
distributed over the entire cross sectional area of the vessel’s liquid section. For this
reason, perforated baffles need to be installed in three phase separators. [16]
44
Figure 4.1 Vertical Separator. [16]
4.1.1 Separator Designing Calculation:

DATA:
PARAMETER SYMBOL VALUE UNIT
Gas Flow rate Qg 10.67 ft3/sec
Liquid Flowrate Ql 1.85 ft3/min
Droplet Dia Dp 0.000498 ft
Gas Density ρg 4.85 lb/ft3
Liquid Density ρl 62.4 lb/ft3
Viscosity U 0.1 cP
Retention Time T 5 min
The design equation used for this equipment is as follow [16]
9.51∗107 𝜌𝑔(𝜌𝑙−𝜌𝑔)∗𝑑𝑝^3
CdRe2 = (4.1)
𝑢^2
45
CdRe2 =25493.89
From appendix 1A-3, we get
Cd= 0.8
Formula used to evaluate VT (terminal velocity)
𝑔𝐷𝑝 ( 𝑃𝑙−𝑃𝑔)
VT = 1.15 √ (4.2)
𝑃𝑔 𝐶𝑑
VT=0.49999 ft/sec
a) For gas section:
Q = AV
A=Qg / V => 10.67 / 0.499999 => 22 ft3
4𝐴
D= √3.14 => 5.5 ft
b) For liquid section:
V = Ql * Retention time
V= 1.85 * 5
V = 9.5 ft3
c) Height of liquid section:
V = 𝜋D2L / 4
L = 4V / 𝜋D2
L = 4*9.5 / 3.14*(5.5)2
L = 0.5 ft
L = 1 ft
d) Height of whole separator:-
H/D=3
H = 3 * 5.5
46
H= 16.5 ft
4.1.2 Summary:
The results of separator sizing are comes as height is 16.5 ft and diameter of it come
as 5.5ft.
4.2 PUMP:
A pump is a device that moves fluids (liquids or gases) or sometimes slurries, by
mechanical action. Pump can be classified into three major groups according to the
method they use to move the fluid: direct lift, displacement, and gravity pumps.
Pumps operate by some mechanism and consume energy to perform mechanical work
by moving the fluids. Pumps operate via many energy sources, including manual
operation, electricity, engines or wind power, come in many sizes, from microscopic
for use in medical applications to large industrial pumps.
Figure 4.2 Pump
4.2.1 Pumps Designing Calculation:

a) Calculate DEA Circulation Rate:
DEA Circulation Rate (LDEA) = 192 Qg XA / C ρ AL [17] (4.3)
Qg= 100 gas flowrate, MMSCFD
XA= 0.2020 concentration of CO2 in feed to be removed
C= 0.35 amine weight fraction
ρ= 8.71 amine density, lb/gal

47
AL= 0.50 acid gas load
DEA Circulation Rate (LDEA) = 192 * 100 * 0.2020 / 0.35 * 8.71 * 0.50
DEA Circulation Rate (LDEA) = 2544.46 gpm
Add 10 % Safety [17]
DEA Circulation Rate (LDEA) = 2800 gpm
b) Break horse power:
Break horse power (BHP) = PLDEA / 1714 e (4.4)
e = 0.65
Pressure drop due to
 Exchangers = 10 psi
 Piping = 20 psi
 Cooler = 10 psi
 ∆P= 40psi
I) Boost Pump:
Break horse power (BHP) = 40 * 2800 / 1714 * 0.65
Break horse power (BHP) = 100 hp
II) Circulating Pump:
Break horse power (BHP) = 900 * 2800 / 1714 * 0.65
Break horse power (BHP) = 2265 hp
c) Total Power Required:
Break horse power (BHP) = (2265 + 100) hp
BHP = 2365 hp pump is required
4.3 CONTROL VALVE:

Control valves are also called as final control elements are the most important element
in the control system of a process plant. It is the last device in the control loop. A
control valve is a variable orifice used to regulate the flow of a process fluid in
48
accordance with the requirement of processes. It absorbs the proper amount of
pressure drop to maintain system balance under all operating conditions. [18]
Figure 4.3 Control Valve
4.3.1 Valve Designing Calculation:

Pressure drop achieved between absorber and separator by using valve would be 700
psi
Max Open = 5046 gpm
a) Valve opening, H = 0.5*(50%)
X = ln 𝜏 * H (4.5)
X= ln50 * 0.5
X= 1.956
𝑒 𝑥 ∗ Vmax
V= (4.6)
𝜏
𝑒 1.956 ∗5046
V= 50
V= 713 gpm
b) Valve opening, H=0.1(10)
49
X = ln 𝜏 * H
X = ln50 * 0.1
X= 0.39
𝑒 𝑥 ∗ Vmax
V=
𝜏
𝑒 0.39∗5046
V=
50
V= 149.20gpm
Maximum Q = 5046 gpm
Medium Q = 713 gpm
Minimum Q = 149.5 gpm
 10 % of total pressure drop would be 70 psi.

 Equal characteristics valve is used for these purpose.
C) CALCULATE Cv:-
𝐶
Cv= Q√∆𝑃 (4.7)
1
Cv= 5046√10
Cv= 603
From Appendix 1A-4:
Valve Size= 8 Inch
4.4 HEAT EXCHANGER:

A shell and tube exchanger is a class of heat exchanger design. It is most common
type of heat exchanger in oil refineries and other large chemical processes, and is
suited for high pressure applications. As it name implies, this type of heat exchanger
consist of shell (a large pressure vessel) with a bundle of tube inside it. One fluid runs
through the tube and another fluid flow over the tube (through the shell) to transfer
50
heat between two fluids. The set of tube is called a tube bundle, and may be composed
of several types of tubes, Plain or longitudinally finned etc.
There can be many variations on the shell and tube designs. Typically, end of each
tube are connected to plenums through the hole in tube sheets. The tube may be
straight or bent in shape of U called U Tubes. [19] [20]
Figure 4.4 Heat Exchanger
4.4.1 Heat Exchanger Designing Calculation:

Hot Fluid Cold Fluid
T2 = 243.3 F High Temp t2 = 167 F
T1 = 217.2 F Low Temp t1 = 161.3 F
∆T= 26.1 F Difference ∆t = 5.7 F
a) Flow rate:
Cold Fluid = 2.637*106 lb/hr.
Hot Fluid = 2.024*106 lb/hr.
51
b) Energy balance:
Q = m*Cp*T (4.8)
Q =2.637*106 * 0.9740 * 5.7
Q = 14.64 MMBtu/hr
c) LMTD temp:
(𝑇2−𝑡2)−(𝑇1−𝑡1)
LMTD = ∆𝑡2 (4.9)
2.3log( )
∆𝑡1
76.3−55.9
LMTD = 76.3
2.3log( )
55.9
LMTD = 65.64 F
d) Correction correlation:
𝑇2−𝑇1
R= (4.10)
𝑡2−𝑡1
R=26.1 / 5.7
R= 4.57
𝑡2−𝑡1
S= 𝑇2−𝑇1 (4.11)
S= 5.7
Ft = 0.99 from figure 1A-5
1-2 exchanger will be satisfactory
t = 65.64 * 0.99
∆t = 65 F
Ud should be between 250-500 so, we assume 370
𝑄
A = Ud∗∆t (4.12)
A = 14.64*10e6 / 370 * 65
A = 608 ft2
𝑎,, = 0.2618 (from APPENDIX 1A-6)
52
ID = 0.670 (from APPENDIX 1A-6)
608
No of tube = 0.2618 ∗ 20
No of tube= 120
From APPENDIX 1A-7, we get
Shell ID = 19.25 in
No of tube = 132
e) Corrected Ud would become:
A = 690 ft2
Ud = 326
4.4.2 Pressure Drop:

Shell side Tube side
𝑓𝐺 2 𝐷(𝑁+1) 𝑓𝐺 2 𝐷𝐿𝑛
∆P=5.22∗1010 𝐷∅𝑆 (4.13) ∆P=5.22∗1010 𝐷∅𝑆 (4.14)
B=1D (baffle spacing) =19.25 inch 𝑁𝑎

at=144𝑛=0.162
𝐼𝐷∗𝐶𝐵 𝑤 2.687∗106
as=144𝑃𝑇=0.1336 G= 𝑎 = =16.2*106
0.162
12𝐿 L=20,n=2,f=0.00005
N+1= =12.46
𝐵
Putting values in (equation 4.13) Putting values in (equation 4.14)
∆P= 5.10 psi ∆P= 10.055 psi
53
4.5 Summary
Shell side Tube side
ID = 19.25 in No of tube = 132
Passes = 1 Length = 20 ft
Baffle spaces = none Passes = 2
P = 5.10 psi OD = 1 Inch
Pitch = 1 inch (square shape)
BWG = 16
4.6 ABSORBER:
An absorption tower is an industrial tower used to separate out components of a rising

gas with the use of a falling liquid to trap the gas. This equipment is used in a variety
of settings for purification, processing of materials, and other activities. The
absorption tower usually needs to be custom designed for a specific application to
ensure efficient and smooth operation. Like other components of a factory, it needs
regular cleaning and maintenance to function properly and can be subject to
inspection by regulatory officials.
In an absorption tower, the gas is pumped in at the bottom of the tower. It, along with
any impurities it contains, begins to float to the top. As it moves toward the top,
aerosolized liquid is sprayed into the tower. The droplets catch impurities in the gas
and carry them to the bottom of the tower for collection. Some towers can have
multiple points where liquid is sprayed out to capture different impurities or maximize
the amount of material trapped. [21]
54
Figure 4.5 Absorber
4.6.1 Absorber Designing Calculation:

𝑇𝑍𝑄𝑔 𝑃𝑔 𝐶𝐷 0.5 [21]
d2 = 5040 * * ⌈{𝑃𝑔−𝑃𝑙 ∗ ⌉ (4.15)
𝑃 𝑑𝑚
a) Data Given
Cd = 0.7 Qg = 100 MMSCFD
dm = 150 microns Z = 0.85
T = 591 R ρg = 4.85 lb/ft3
P = 910 psia ρl = 65.1 lb/ft3
By putting the values in equation 4.15 we get,
d2 = 5392
d = 74 inch
As standard design [21] we used
d = 84 in or 7ft
55
4.7 PRESSURE SWING ADSORPTION DESIGNING:
The key separation principle used in a PSA operation is based on adsorption
phenomena.
Adsorption, in general can be defined as ‘’a process where the molecules or atoms of
a single or multi-component fluid system in liquid, gas or even a super-critical phase
tends to concentrate at the surface of a solid surface, under the effect of
intermolecular interactions among the fluid (adsorbate) and solid phase (adsorbent)’’.
The feed gas entering the bed from the top and the upper zone becomes saturated first,
where equilibrium between the impurity partial pressure in the gas and the substance
adsorbed on the desiccant is established and no additional adsorption occurs. This
zone is called the equilibrium zone (EZ).
Figure 4.6 Zones in Pressure Swing Adsorption
With the adsorption going on, the EZ will grow and more and more component will
be adsorbed. The length of the absorber bed across which the concentration of the
56
adsorbate is reduced from inlet to outlet conditions is known as the mass transfer zone
(MTZ). This is simply a zone or section of the bed where a component is transferring
its mass from the gas stream to the surface of the solid bed.
a) At the inlet of the bed and for a certain distance into it, the adsorbent is saturated
to essentially equilibrium value with the adsorbable component in the fluid, such
as nitrogen in natural gas. (Equilibrium Zone)
b) At the outlet of the bed, the adsorbent is unsaturated and the nitrogen content of
the gas is in equilibrium with the unsaturated activated adsorbent.
c) The MTZ is defined as the zone between these two zones, where the concentration
of the impurity in the natural gas is falling.
d) MTZ lengths can be obtained experimentally for various materials and systems
and used in graphical correlations for design purposes.
Figure 4.7 schematic of mass transfer zone
As the flow of gas continues, the MTZ moves downward through the bed and
displaces the previously adsorbed gases until finally the entire bed is saturated with
component which is adsorb. When the leading edge of the MTZ reaches the end of the
bed, breakthrough occurs (see Figure 4.7). At this time, the adsorber vessel should be
switched to the regeneration mode.
57
Fig 4.8 Breakthrough Curve
The above graph shows the relationship between time and the ratio between the
concentrations of adsorbate in the bed to the concentration of the adsorbate in the
feed. C represents the concentration of the adsorbate in the bed and Co represents the
concentration of the adsorbate in the feed. At time to mass transfer of the adsorbate
from the feed to the bed start taking place as a result the value of C/Co is increase
from 0 value to Cb due to the change of concentration of adsorbate in the bed from 0
value. As the time goes on the value of C is increased due to which C/Co starts
approaching towards unity. When this ratio reaches unity than equilibrium is
achieved. Time tb at this ratio is called breakthrough time and the following curve
achieved is called break through curve. The significant use of this curve in adsorption
bed designing that gives the knowledge of adsorption behavior between adsorbate and
adsorbent and also provides the saturation time of adsorption bed by which we adjust
the bed height, diameter and it also helps for adsorbent selection.
4.7.1 Bed Designing For Nitrogen (N2) Removal:

PARAMETERS SYMBOLS VALUE UNIT
Pressure P 910 psia
Temperature T 140.1 F
Flow rate Qg 75.6 MMSCFD
58
Compressibility factor Z 0.85 -
Superficial velocity UM 40 Ft/min
Formula: (bed diameter)
d2 = 3600 *Q *T *Z / Um * P [22] (4.16)
By putting the values in above formula, we get
d= 92 in
Maximum pressure drop ∆p should not be greater than 8psi. [22] so in this case
diameter would be
d = 120 in or 10ft (recommended)
Recalculated superficial velocity
Um = 12.45 ft / min or 0.0633 m/s
Formula: (bed height)
𝑈𝑚∗𝑡
Z= 1 𝑐𝑠 (4.17)
( 1+ ∗ )
𝑚 CN2
Where
z= bed height (m)
Um=superficial velocity (m/s)
T= time (sec)
e= 0.4 (voidage)
m=e/ (1-e) =0.667
CN2=initial concentration of adsorbate
Initial concentration of adsorbate (nitrogen) in feed:
CN2 = ¥N2 P / R * T (4.18)
59
¥N2=0.19 (specific gravity)
P=6274.22 kpa
R=8.314 j/mol.k
T=319 K
CN2= (0.19 * 6274.22) / (8.314 * 319)
CN2 = 0.449 mol / dm3
Cs = 0.0076 CN2 + 0.1745 (equation from isotherm graph APPENDIX 1A-1)
Putting the values in equation 4.17, we get
@ t = 5 min => 300 sec
Bed height to diameter ratio (z/d) should be 2.5 or higher than 2.5 recommended. [22]
0.0633∗300
z= 1 0.0076∗0.449+0.174
1+( )∗( )
0.667 0.449
z = 11.925m
Evaluate pressure drop:
1.75∗𝜌𝑓𝑈 2 (1−𝑒)
∆p=𝑧 ∗ ( ) (4.19)
𝑥𝑒 3
e =0.4
ρ =77kg/m3
x =1.6*10-3 m
U =0.0633 m/s
z = 11.925m
Putting value in equation 4.19, we get
∆P=1.709 psi
Therefore, column designing would be satisfactory because pressure drop is less than
8psi. [22]
60
4.7.2 Bed Designing For Carbon Dioxide (CO2) Removal:
PARAMETERS SYMBOLS VALUE UNIT
Pressure P 1000 psia
Temperature T 140.1 F
Flow rate Qg 100 MMSCFD
Compressibility factor Z 0.85 -
Superficial velocity UM 40 Ft/min
Formula: (bed diameter)
d2 = 3600 *Q *T *Z / Um * P (4.16)
By putting the values in above formula, we get
d= 92 in
Maximum pressure drop ∆p would not be greater than 8psi. [22] So in this case
diameter would be
d = 120 in or 10ft or 3.04m (recommended)
Recalculated superficial velocity
Um = 12.45 ft / min or 0.0633 m/s
Formula :( bed height)
𝑈𝑚∗𝑡
z= 1 𝑐𝑠 (4.17)
( 1+ ∗ )
𝑚 Cco2
Where
z= bed height (m)
Um=superficial velocity (m/s)
T= time (sec)
e= 0.4 (voidage)
61
m=e/ (1-e) =0.667
CCO2=initial concentration of adsorbate
Initial concentration of adsorbate (nitrogen) in feed:
CCO2 = ¥CO2 P / R * T (4.18)
¥CO2=0.2020 (specific gravity)
P=6874.22 kpa
R=8.314 j/mol.k
T=319 K
CCO2= (0.19 * 6874.22) / (8.314 * 319)
CCO2 = 0.520 mol / dm3
Cs = 0.0062CCO2 (equation from isotherm graph APPENDIX 1A-2)
Putting the values in equation 4.17, we get
@ t = 3 min => 180 sec
Bed height to diameter ratio (z/d) should be 2.5 or higher than 2.5. [22]
0.152∗120
z= 1 0.0062∗0.520
1+( )∗( )
0.667 0.520
z = 11.3 m.
Evaluate pressure drop:
1.75∗𝜌𝑓𝑈 2 (1−𝑒)
∆p=𝑧 ∗ ( ) (4.19)
𝑥𝑒 3
e =0.4
ρ =77kg/m3
x =1.6*10-3 m
U =0.0633 m/s
z = 11.3m
62
Putting value in equation 4.19, we get
∆P=1.68 psi
Therefore, column designing would be satisfactory because pressure drop is less than
8psi.
4.8 CRYOGENIC DISTILLATION COLUMN DESIGNING:
Formula used [24]
4𝑉𝑚
Dc = √𝜋𝜌𝑣𝑈𝑐 (4.20)
Vm = vapour rate, kg / s
ρv = density of vapour, kg/m3
Uc = vapour velocity, m/sec
Dc = column diameter, m
𝑃𝑙−𝑃𝑣 0.5
Uc = = ( −0.171𝑙 2 + 0.27l – 0.047 ) ∗ ( ) (4.21)
𝑃𝑣
l = plate spacing, m
l =0.5, m (range 0.3m to 1m) [24]
ρl = 440.4, kg/m3
ρv = 2.901, kg/m3
Uc becomes after putting above values in (equation 4.21) we get,
Uc = 0.055, m/sec
Vm = 1.94*104 Kg/hr OR 5.39 kg / sec
Now, putting the values in (equation 4.20) we get
4 ∗ 5.39
Dc = √3.14∗2.901∗0.055
Dc = 2.07m
Downcomer should be 12 % so diameter of column will become
63
Dc = 2.07 * 1.12
Dc = 2.32 m
4.9 GAS RECEIVER (STORAGE TANK) DESIGNING:
Gas Flow qs = 2708333 scf/h = 45138.88 scf/m

Atmospheric Pressure Po = 14.7 Psia
Max. Reciever Pressure P1 = 850 Psia
Min. Reciever Pressure P2 = 840 Psia
Time* t = 0.083 Min = 5 S
𝑡 𝑞𝑠 𝑃𝑎
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐺𝑎𝑠 𝑅𝑒𝑐𝑒𝑖𝑣𝑒𝑟 = 𝑉 = (𝑃1 −𝑃2 )
(4.22)
Volume of Air receiver V = 5529.51 ft3
Diameter of receiver D = 12 Ft
Height of Receiver H = 48.892 Ft ~ 49 ft
64
Chapter NO 5
SIMULATION
(ASPEN HYSYS AND ASPEN ADSORPTION)
65
CHAPTER NO 5
SIMULATION
5.1 INTRODUCTION:
Simulation is the imitation of the operation of a real-world process or system over

time. The act of simulating something first requires that a model be developed; this
model represents the key characteristics or behaviors/functions of the selected
physical or abstract system or process. Here we have used HYSYS software to
perform simulation.
5.2 HYSYS:
Aspen HYSYS is the energy industry’s leading process simulation software that is
used by the top oil and gas producers, refineries and engineering companies for
process optimization in design and operations. We have simulated the following cases
on Aspen HYSYS.
a) Acid Gas Removal Unit.

b) Cryogenic Distillation for Nitrogen Rejection.
5.3 ACID GAS REMOVAL UNIT:
5.3.1 EQUIPMENTS
Following equipments are used in this process:
a) Separator.
b) Absorption Column.
c) Regeneration Column.
d) Valve.
e) Pump.
f) Heat exchanger.
g) Cooler.
66
5.3.2 Simulation Environment:
Figure 5.1 Amine Unit Simulation
67
5.3.3 Feed and Solvent Parameters
Figure 5.2.1 Feed and Solvent Parameter
Figure 5.2.2 Feed and Solvent Parameter
68
5.3.4 ABSORPTION
Absorption is carried out to remove CO2 from natural gas by using Di ethyl amine as
a solvent. Absorption of CO2 from natural gas depends on the following parameter:
5.3.4.1 Pressure
The Operating pressure of Absorption column is about 6274 KPa which gives the
following top (sweet gas) and bottom (Rich DEA) streams:
Figure 5.3 Flowrate of Sweet Gas and Rich DEA
If the operating pressure of the absorption is increase than we observed that some
moles of methane is lost in Bottom and if the operating pressure of the absorption
column is below the above pressure than CO2 content in the sweet gas is increased.
5.3.4.2- Rate of Solvent
Molar Flowrate of Di-ethyl amine is 25780 kg mol/hr and it is an aqueous solution

having 8.42% molar concentration. If the flowrate of aqueous DEA is decrease than
CO2 in the sweet gas is increase. 25780 kg mol/hr reduces CO2 concentration to 0.02
mol%.
5.3.4.3- Composition and Temperature of DEA
In the following simulation the fluid package used is the amine package. For amine
package, the concentration (wt %) of DEA should be0-50% and temperature should
be between (77-260) 0F . Concentrations and temperature of DEA above the following
limitation will not be acceptable in amine package. Here temperature and composition
of DEA used is 1100F and 35(wt %). If we reduce the concentration of DEA than
higher flowrate of solvent is required and if the conc of DEA is increased than the
69
heat of absorption increases as a result the temperature of the bottom stream increases
and may exceed the temperature limitation.
5.3.5 REGENERATOR:
Rich DEA from the absorber goes to the separator to remove some acid gas and
hydrocarbon than it is preheated with lean amine and goes to the regeneration column.
Regeneration of DEA is dependent on the temperature and pressure of the
regenerator. The regenerator is operated at a temperature and pressure about (200-
210) KPa and (104-124)0C. If the operating pressure of regenerator is increase than
high temperature is required to achieve separation, hence high Reboiler duty is
required. Temperature above 125oC is not suitable for amine package therefore the
Regenerator is operated at such pressure which gives the following Reboiler duty.
Figure 5.5 Regenerator Reboiler Duty
The temperature and pressure profile of the regenerator is shown in figure 5.6:
70
Figure 5.6 Temperature and Pressure profile of Regenerator
Lean DEA from the Regenerator is cooled from Rich DEA in the Heat exchanger to
about 90oC from 124oC and further cooled in the cooler to about 43oC and pumped
back to the absorption column.
5.4 CRYOGENIC DISTILLATION UNIT:
5.4.1 Equipments:
Following equipments are used in this process:
a) Separator.
b) Valve.
c) Heat exchanger.
d) Cooler.
e) Compressors.
f) Expanders.
g) Distillation Column.
71
5.4.2 Simulation Environment:
Figure 5.7 Cryogenic Distillation Simulations
5.4.3 Feed Parameters:
Figure 5.8 Cryogenic Feed Conditions
5.4.4 Nitrogen Rejection Unit:

Nitrogen rejection unit is used to separate nitrogen content from the natural gas. Natural gas
is expanded in series of expanders to reduce the pressure to about (300-400) KPa, passing
72
through separator in order to remove water and heavier hydrocarbons from natural gas.
Nitrogen rejection unit is operated at about (-195 to -165)oC and (60-100)KPa.
Figure 5.9 Nitrogen rejection unitProduct Composition
Figure 5.10 Nitrogen rejection unit Product Parameter
Distillation column consists of 18 trays. Heat Duty requires to achieve the separation is 1402
hp. Nitrogen rejection unit utilizes the heat released by the expanders i.e 523.4 hp which
reduces Reboiler duty from 1926 hp to 1402 hp.
73
Figure 5.11 Reboiler Duty of Nitrogen rejection unit
5.4.5 NGL Column:

NGL distillation column uses the heat release by the expanders to separate methane
from the gas and produces pure methane and NGL.
Figure 5.12 Pure Methane products from NGL Column
74
Figure 5.13 NGL Product
NGL column Reboiler uses the heat released from the expanders i.e 269 hp which
reduces the Reboiler duty from 1125 hp to 556 hp.
Figure 5.14 Reboiler Duty of NGL Column
5.4.6 Product Gas:

Product gas produces from cryogenic distillation is free from nitrogen and it contain
96% methane and 4% ethane.
75
Figure 5.15 Product Gas Parameters
Product gas is cooled in a heat exchanger than is compressed. The compressor also
uses the duty from the expander. As a result the gas is compresses from 70 KPa to 945
KPa.
5.5 INTRODUCTION TO ASPEN ADSORPTION:
Aspen Adsorption simulates gas processes with adsorption only, or adsorptive

reaction gas processes where both reaction and adsorption occur simultaneously.
Aspen Adsorption is a comprehensive flow sheet simulator for the optimal design,
simulation, optimization and analysis of industrial gas and liquid adsorption
processes. It enables to,
a) Identify optimal designs and improve profitability.

b) Improve process understanding with rigorous rate-based adsorbent bed models.
c) Manage cycles and increase capacity
76
d) Utilize the world’s largest database for physical properties.
Figure 5.16 PSA process simulation
Figure 5.17 Bed simulation specification
Simulation of PSA involves thorough knowledge of adsorption kinetics and it has

been the hardest thing to accomplish so far since this software demands some extra
77
expertise to successfully simulate it. Despite the hurdles, we have been successful to
complete the 80% of the simulation but to complete it; we do need some more
information regarding its technical handling to fix rest of the parameters out of
numerous variable and models.
Figure 5.18 operating condition specifications
78
Figure 5.19 Adsorption Bed Specification
The above figure shows the simulation environment with all variables specified and the data
about the adsorption bed is also specified as shown in figure. The error is occurring due to
some unknown reasons which are also depicted here. Efforts are required to get expertise in
this software the learning material of which is not available. This software can be helpful in
generating models and research papers can also be written using the results of simulation.
79
CHAPTER NO 6
HYDRAULICS
(Line sizing)
80
CHAPTER NO 6
HYDRAULICS:
6.1 INTRODUCTION:
Piping design in production facilities involve the selection of a pipe diameter and a
wall thickness that is capable of transporting fluid from one piece of equipment to
other, within allowable pressure drop and pressure rating imposed by the process.
According to Darcy-weisbach equation, the friction head loss between two points in a
completely filled, circular cross section pipe is proportional to velocity head and loss
of pipe and inversely proportional to length of pipe. [28]
So,
𝑓 𝑙 𝑉2
H= (6.1)
𝐷 2𝑔
Where,
L = length of pipe, ft
D = Diameter of pipe, ft
f = factor of proportionality
The factor of proportionality in an equation is called the moody friction factor. The
friction factor is sometimes expressed in terms of fanning friction factor, which is one
fourth of moody friction factor.
The friction factor is a function of Reynolds number, Re and the relative roughness of
the pipe, E/D. For laminar flow, f is the only function of Re.
64
f = 𝑅𝑒 (6.2)
For turbulent flow, f is the function of both pipe roughness and the Re.
1/√𝑓 = 2log (E/D/3.7 + 1.256 / Re√𝑓 ) (6.3)
At high values of Re, f is the function of only E/D.

81
6.2 LIQUID FLOW:
We determine pressure drop in liquid flow lines by using following equation:
0.00115 𝑓 𝑄 2 𝑆.𝐺.
∆𝑃 = (6.4)
𝑑2
Where,
P = pressure drop, psi
f = moody friction factor
S.G = specific gravity of liquid relative to water
D = diameter of pipe
Hazen-Williams equation is used to calculate Hl, head loss due to friction. This can be
expressed as follows:
0.015 𝑄 1.85𝐿
Hl = (6.5)
𝑑4.87 𝐶 1.85
Where,
L = Length, ft
C = Friction factor constant, dimensionless (140 for new steel pipe, 130 for new cast
iron pipe, 100 for riveted pipe)
D = diameter of pipe, ft
Ql = liquid flow rate, bbl
6.3 GAS LINE FLOW:
To calculate pressure drop in gas flow lines we are used following general gas flow
lines:
25.2 𝑍 𝑇1 𝑓𝑙 𝑆 𝑄𝑔2
P12 – P22 = (9.6)
𝑑5
82
It is recommended that a minimum velocity between 10-15 ft/sec be maintained as to
minimize liquid settling out in low spots. Typically, gas velocities are normally kept
below 60-80 ft/sec so as to minimize the effect of noise and allow for corrosion
inhibition.
6.4 TWO PHASE FLOW:-
Two phase flow of liquid and gas are complex physical processes. Even when the best
existing best correlations for pressure drop and liquid holdup are used, prediction may
be in error as much as 20%. In two phase flow line equation for pressure drop we
calculate equation:
3.4𝑒10−6 𝐹 𝑙 𝑊 2
∆𝑃 = (6.7)
𝑃𝑚 𝑑5
Where,
D = pipe id, inch
W = rate of flow of liquid and vapor, lb/hr
𝑙𝑏
Pm = density of mixture, 𝑓𝑡 3
The density of mixture is given by:
Pm = 12409 S.G. + 2.7 RSP/198.7 P + RTZ (6.8)
Where,
P = Operating pressure, psia
R = Gas/liquid ratio, ft3/lb
T = Temperature, R
Z = Compressibility factor
The rate of flow of mixture to use in this equation can be calculated as follows:
83
W = 3180 SQg + 14.6Ql S.G (6.9)
6.5 LINE SIZING OF PRESSURE SWING ADSORPTION UNIT:
Line 03
Dia (inch) ∆P/100ft V (ft/s) L (ft)
10 0.741325 27.08737 32800
Line 04
10 0.835541 33.97103 5
Line 05
10 0.835578 33.97253 5
Line 06
10 0.835615 33.97402 5
Line 07
10 0.835651 33.97551 5
84
Line 08
10 0.835688 33.97699 5
Line 09
10 0.835725 33.97849 5
Line 10
10 0.835794 33.98087 8
Line 10A-1
10 0.666233 27.08737 8
Line 11
10 0.666227 27.08737 5
85
Line 11A
10 0.666227 27.08737 5
Line 11B
10 0.666227 27.08737 5
Line 11C
10 0.666781 27.10996 4
Line 11D
10 0.666781 27.10996 4
Line 11E
8 1.201635 31.76949 7
86
Line 11F
8 1.201635 31.76949 7
Line 12
10 0.666779 27.10996 3
Line 13
10 0.375806 20.33247 10
Line 14A
8 0.903299 27.53356 13
Line 14B
8 1.201623 31.76949 5
87
Line 14C
10 0.375804 20.33247 6
Line 14D
10 0.375804 20.33247 6
Line 14E
8 0.903275 27.53356 6
Line 14F
8 0.903275 27.53356 6
Line 15
8 0.903271 27.53356 5
88
Line 16
8 0.903295 27.53356 12
Line 17
8 0.903316 27.53356 18
Line 19
8 0.770042 25.41559 10
6.6 LINE SIZING FOR CRYOGENIC DISTILLATION UNIT:
Line 03:
Dia (inch) ∆P/100ft (psi/ft) V (ft/s) L (ft)
10 0.502023909 27.197672 5
Line 04:
8 1.051878128 27.618737 8
89
Line 05:
8 1.051890396 27.618737 10
Line 05A:
8 0.818313504 24.463917 5
Line 05B:
D (inch) V (ft/s) ∆P/100 ft L (ft)
2 3 0.3353899 6
Line 05C:
4 3.37974 0.19361675 10
Line 06:
8 0.818313504 24.463917 5
90
Line 07:
8 0.925736648 27.675021 6
Line 07A:
8 0.883567622 27.02136 12
Line 07B:
2.25 1.759845 0.99972209 12
Line 08:
8 0.967483445 29.588465 6
Line 08A:
8 0.936815533 29.113955 12
91
Line 08B:
Dia (inch) V (ft/s) ∆P/100 ft L (ft)
1.5 2.73241 0.42627865 12
Line 09:
8 1.46270402 45.455992 6
Line 09A:
8 1.294638159 42.75613 12
Line 09B:
Dia (inch) V (ft/s) ∆P/100 ft L (ft)
2.5 3.591958 0.40535041 12
Line 10:
10 0.624348163 69.584279 6
92
Line 10A:
10 0.544038413 60.52182 12
Line 10B:
2 6.025731 0.01410956 12
Line 11:
10 0.882774294 63.862254 12
93
CHAPTER NO 7
ENVIRONMENTAL
CONSIDERATIONS OF
PROJECT AND HAZOP
STUDY
94
CHAPTER NO 07
HAZOP AND ENVIRONMENTAL ASSESSMENT
7.1 ENVIRONMENTAL ASPECT OF THE PROJECTS:
The project has been chiefly concerned with the up gradation of natural gas especially
for being reducing nitrogen up to pipeline specification. The separation processes
have given the separated components that are nitrogen and natural gas. The
processing of natural gas poses low environmental risk, primarily because natural gas
has a simple and pure composition and contains fewer impurities other than fossil
fuels.
Although the primary use of natural gas is as a fuel, it is also a source of hydrocarbons
for petrochemical feed stocks and a major source of elemental sulfur, an important
industrial chemical. Its popularity as an energy source is expected to grow
substantially in the future because natural gas presents many environmental
greenhouse gas linked to global warming.
7.1.1 Safety and environmental considerations of nitrogen:
Both atmospheric nitrogen and nitrogen in fuel are sources of nitrogen oxides (NOX),
which are greenhouse gases and a source of acid rain. Venting nitrogen gas needs to
be controlled since it might pollute the surrounding atmosphere. [14]
7.1.2 Safety measures regarding the hydrocarbons in the process:
Safety systems are critical to all gas plants. These systems include;
a) The emergency shutdown of inlet gas.

b) Relief valves and vent systems leading to the flare.
c) Proper sizing of relief valves, rupture disks, and piping.
Installation of the stated above components in a plant are important to ensure that
operating systems can be vented quickly. If the plant is venting mostly methane, the
flare flame is bright but smokeless. If methane plus heavier hydrocarbons are flared,
the flame will smoke. To make the flare smokeless, steam or high-flow-rate air or fuel
95
gas is added. If the fuel has a low Btu content (e.g., tail gas from a sulfur recovery
unit), fuel gas is added to ensure complete combustion.
7.1.3 Safety measures regarding nitrogen in the process:
Release of Low -temperature nitrogen encountered in NRUs either intentionally

through vent or unintentionally through pipe leakage might accumulate in a confined
space and it would probably cause an accidental asphyxiation. [15] To get rid of such
release of nitrogen, it should be vented at higher pressure than atmosphere so that its
accumulation possibility would be minimized.
7.2 HAZOP STUDY:
The hazard and operability study, commonly referred to as, the HAZOP study, is a
systematic technique for identifying all plant or equipment hazards and operability
problems. In this technique, each segment (pipeline, piece of equipment, instrument,
etc.) is carefully examined and all possible deviations from normal operating
conditions are identified. This is accomplished by fully defining the intent of each
segment and then applying guide words to each segment as follows:
No or not-no part of the intent is achieved and nothing else occurs (e.g., no flow)
More-quantitative increase (e.g., higher temperature)
Less-quantitative decrease (e.g., lower pressure)
As well as-qualitative increase (e.g., an impurity)
Part of-qualitative decrease (e.g., only one of two components in mixture)
Reverse-opposite (e.g., backflow)
Other than-no part of the intent is achieved and something completely different
occurs (e.g., flow of wrong material)
These guide words are applied to flow, temperature, pressure, liquid level,
composition, and any other variable affecting the process. The consequences of these
deviations on the process are then assessed, and the measures needed to detect and
correct the deviations are established
96
Hazard assessment is a vital tool in loss prevention throughout the life of the facility.
Ideally, the assessment should be conducted during the conceptual design phase, final
design stage, and pre startup period as well as when the plant is in full operation. In
the conceptual-design phase many potential hazards can be identified and significant
changes or corrections made at minimal cost .Results of these assessments is key
inputs to both site-selection and plant layout decisions. The major hazards usually
include toxicity, fire, and explosions; however, thermal radiation, noise, asphyxiation,
and various environmental concerns also need to be considered. A thorough hazard
and risk assessment of a new facility is essential during the final design stage. At this
stage, the piping and instrument diagrams, equipment details, and maintenance
procedures are finalized. However, since equipment often has not been ordered, it is
still possible to make changes without incurring major penalties or delays.
97
CHAPTER NO 8
INSTRUMENTATION AND
PROCESS CONTROL
105
CHAPTER NO 8
INSTRUMENTATION AND PROCESS CONTROL
8.1 INSTRUMENTATION
Instrumentation is provided to monitor the key process variables during plant

operation. They may be incorporated in automatic control loops, or used for the
manual monitoring of the process operation. In most modern plant, the
instrumentation will be connected to a computer control and data logging system.
Instruments monitoring critical process variable will be fitted with automatic alarms
to alert the operators to critical and hazardous situation.
It is desirable that the process variable that is to be monitored should be measured

directly; however this is often impractical and some dependent variable that is easier
to measure is monitored in its place. For example, in the control of distillation
columns the continuous, on-line, analysis of overhead product is desirable but
difficult and expensive to achieve reliably, so monitored as an indication of
composition. The temperature instrument may be a part of control loop controlling,
say, reflux flow; with the composition of the overheads checked frequently by
sampling and laboratory analysis.
8.2 WHAT IS PROCESS CONTROL?
Process control is the act of controlling a final control element to change the
manipulated variable to maintain the process variable at a desired set point.
Following are the definitions of some terms we will be using in out discussion of
process control:
a) The Manipulated Variable (MV) is the measure of resource being fed into the
process.
b) A Final Control Element (FCE) is a device that changes the value of manipulated
variable.
c) The controller output (CO) is the signal from the controller to the final control
element.
106
d) The process variable is a measure of the process output that changes in response
to changes in the manipulated variable.
e) The set point is the value at which we wish to maintain process variable
8.3 WHY DO WE NEED PROCESS CONTROL
Effective process control is required to maintain safe operation, quality product and
business viability
a) Safety
The primary purpose of process control system is Safety: personnel safety,
environmental safety & equipment safety .the safety of plant personnel and the
community is the highest priority in any operation
b) Quality
In addition to safety, process control systems are central to maintaining product
quality.
c) Profit
When safety and quality are met .Process control objectives can be focused on
profit.
8.4 BENEFITS OF PROCESS CONTROL
a) Following benefits can be achieved by implementing good process control system;
b) Increased productivity
c) Reduced raw material
d) Increased efficiency
e) Improved profitability
f) Comfort and convenience of operation
g) Increased safety of operation environmental condition
107
8.5 PROCESS CONTROL TERMS
8.5.1 Process Variable
A process variable is a condition of the process fluid (a liquid or gas) that can change
the manufacturing process in some way. Common process variables include:
a) Pressure
b) Flow
c) Level
d) Temperature
e) Density
f) PH (acidity or alkalinity)
g) Liquid interface (the relative amounts of different liquids that are Combined in a
vessel)
h) Mass
i) Conductivity
8.5.2 Set Point
The set point is a value for a process variable that is desired to be maintained. For
example, if a process temperature needs to keep within 5 °C of 100 °C, then the set
point is 100 °C. A temperature sensor can be used to help maintain the temperature at
set point.
8.5.3 Measured Variables, Process Variables, and Manipulated Variables
The measured variable is the condition of the process fluid that must be kept at the
designated set point. Sometimes the measured variable is not the same as the process
variable. For example, a manufacturer may measure flow into and out of a storage
tank to determine tank level. In this scenario, flow is the measured variable, and the
process fluid level is the process variable.
108
8.5.4 Error
Error is the difference between the measured variable and the set point and can be
either positive or negative. For Example, in a temperature control loop, if the
measured variable is 110 °C and the set point is 100 °C, error is the difference
between both—that is, and the error is +10 °C.
8.5.5 Offset
Offset is a sustained deviation of the process variable from the set point. In the
temperature control loop example, if the control system held the process fluid at 100.5
°C consistently, even though the set point is 100 °C, then an offset of 0.5 °C exists.
8.5.6 Closed and Open Control Loops
A closed control loop exists where a process variable is measured, compared to a set
point, and action is taken to correct any deviation from set point. An open control
loop exists where the process variable is not compared, and action is taken not in
response to feedback on the condition of the process variable, but is instead taken
without regard to process variable conditions.
8.6 CONTROL LOOP EQUIPMENT

8.6.1 Primary Elements/Sensors
In all cases, some kind of instrument is measuring changes in the process and
reporting a process variable measurement. Because sensing devices are the first
element in the control loop to measure the process variable, they are also called
primary elements.
Examples of primary elements include:
a) Pressure sensing diaphragms, strain gauges
b) Resistance temperature detectors (RTDs)
c) Thermocouples
d) Orifice plates
e) Venturi tubes
109
f) Magnetic flow tubes
g) Radar emitters and receivers
h) Ultrasonic emitters and receivers
8.6.2 Transmitters
A transmitter is a device that converts a reading from a sensor or transducer into a

standard signal and transmits that signal to a monitor or controller. Transmitter types
include:
a) Pressure transmitters
b) Flow transmitters
c) Temperature transmitters
d) Level transmitters
e) Analytic (O2 [oxygen], CO [carbon monoxide], and pH) transmitters
8.7 TYPES OF CONTROL SYSTEM
We have used four types of controls:
a) Feed forward control

b) Feed backward control
c) Ratio controller
d) Cascade control
8.7.1 Feed backward control
A Feedback control system is one in which the output signal is sampled and then fed
back to the input to form an error signals that drives the signals. Feedback control is a
mechanism in a system that monitors performance of outputs and then work to
maintain it as specified. The controller receives a feedback signals representing the
condition of the controlled process variable, compares it to the set point, and adjusts
the controller output accordingly. We used feedback control loop in level control
system, used at separator.
110
8.7.2 Feed forward control
A feed forward control is a type of control which takes corrective action based on
disturbances before the process variable is upset .feed forward control is a mechanism
in a system that monitor performance of input rather than output and reacts so as to
maintain specified state. Thus, preventing and minimizing problem before they
occurs. We used feed forward control in regeneration.
8.7.3 Ratio controller:
Ratio control architecture is used to maintain the relationship between two variables
to control a third variable. Ratio control architecture is used to maintain the flow rate
of one (dependent controlled feed) stream in a process at a defined or specified
proportion relative to that of another (independent wild feed stream) (3) in order to
control the composition of a resultant mixture.
Ratio Control is the most elementary form of feed forward control. These control
systems are almost exclusively applied to flow rate controls. There are many common
usages of ratio controls in the context of chemical engineering. They are frequently
used to control the flows on chemical reactors.
8.7.4 Cascade control
The simplest cascade control scheme involve two control loops that use two
measurement signals to control one primary variable .in such a control system ,the
output of the primary controller determine the set point for secondary controller. The
output of the secondary controller is used to adjust the control variable. Generally, the
secondary controller changes quickly while the primary controller changes slowly.
Once the cascade control is implemented, disturbances of the rapid changes in the
secondary controller will not affect the primary controller.
To illustrate how cascade control works and why it is used ,a typical control system
will be analyzed .This control system is one that is used to adjust the amount of steam
used to heat up the fluid stream in a heat exchanger . We used cascade control in
condensate stabilization heat exchanger.
Cascade control is generally useful when:
111
a) A system error affects the primary control variable only after a long period of
time as it propagates through dead time and lag time.
b) A system has long dead times and long lag times.
c) Multiple measurements with only one control variable are required for better
response to a disturbance of a system.
d) Variance occurs in multiple streams Ratio Control system
8.8 TYPES OF CONTROLLER:

8.8.1 Proportional Control (P):
With proportional control, the controller output varies in Proportion to the error.
8.8.2 Proportional-Integral Control (PI):
With proportional plus integral control, an integral term is added to the output
equation. The integral term causes its output to continue changing as long as there is
non-zero error.
8.8.3 Proportional plus Integral plus Derivative Control (PID)
With the presence of the derivative term, the PID controller anticipates what the error
will be in the immediate future and applies a control action which is proportional to
the current rate of change in the error. Due to this property, the derivative control
action is sometimes referred to as anticipatory control.
112
CHAPTER NO 09
ECONOMICS
ANALYSIS
113
CHAPTER NO 09
ECONOMICS ANALYSIS
9.1 INTRODUCTION:
An acceptable pant design must present a process that is capable of operating under
conditions which will yield a profit. Since net profit equals total income minus all
expenses, it is essential that chemical engineer must aware of the many different types
of cost involved in manufacturing processes. Capital must be allocated for direct plant
expenses, such as those for raw materials, labour, and equipment. A capital
investment is required for any industrial processes, and determination of the necessary
investment in an important part of a plant design project.
The total investment for any process consist of fixed capital investment for the
physical equipment and facilities in the plant thus working capital which must be
available to pay salaries, keep raw materials and products on hand, and handle other
special items requiring a direct cash outlay. Thus, in an analysis of cost in industrial
processes capital investment cost and manufacturing cost must be taken into
considerations. This potential for saving was a fine opportunity for increasing profit,
as well as decreasing loss of valuable BTUs and substantially decreasing pollution.
All these units operation consist of equipment, whose complete list can found in
previous chapter. The purpose after of this chapter is economically justify this project
i.e.to prove that it is economically feasible.
9.2 COSTING IMPLEMENTATION:
Cost index 2002 = 390.4 (Io) at 2002 ……….. [25]
Cost index 2016 = 659.5 (Io) at 2016
Io at 2016
Purchased cost in 2016 = Purchase cost in 2002 *( Io at 2002)
114
9.2.1 COSTING OF AMINE UNIT:
9.2.1.1- Separator:
Length( Ft ) Diameter( Ft ) Bare Cost($) Material Factor Pressure Factor
16.5 5.5 2*10e4(fig 1B-4) 1 3.8
Purchase Cost in 2002 = Bare Cost * Material Factor * Pressure factor
Purchase Cost in 2002 = 92000 $
There are two separators in Amine unit, so
Cost of two separators = 2 * 155350
Cost of two separators = 310700 $
9.2.1.2- Absorber:
Bare Cost ($) Material Factor Pressure Factor
3*10e4(fig 1B-2) 1 2.30
Absorber Diameter = 2.13 m
Cost per Tray = 850 $ (fig 1B-3)
No of Trays = 20
Total Cost of Tray = Cost per tray * No of tray
Total Cost of Tray = 850 (fig 1B-3) * 20
Total Cost of Tray = 17000 $
115
Cost in 2012 =17000 $
Cost in 2016 =28560 $
Cost of One Absorber =145090 $
Cost of Two Absorber =290180 $
9.2.1.3- Heat Exchanger:-
Surface area = 690 ft2
From appendix fig 1B-1
Purchased 2002 = 1.8*104 $
Purchased 2016 = 1.8*104 * 1.68
Purchased 2016 = 30393.44 $
9.2.1.4- Total Cost of Amine Unit:
Total Capital Cost Of Amine Unit = 290180 + 30393 + 310700
Total Capital Cost Of Amine Unit = 631273 $
9.2.2 CRYOGENIC DISTILLATION UNIT:
9.2.2.1- Sum of All Purchase Equipment Cost (PEC):
Separator Cost = 1398150 $
Heat Exchanger Cost = 30400 $
Reboiler Absorber = 290220
Compressor (12200 KW) in 2012 = 5*10e6
Compressor (12200 KW) in 2016 = 8400000 $
Total Capital =Amine unit + Cryogenic unit
116
Total Capital Cost or PEC= 13362003 $
9.2.2.2- Total Physical Plant Cost (PPC):
Total Physical Plant Cost (PPC) = PEC (1 + F1 + F2 +……...+ F9)
Table 9.1 typical factors for project fixed cost [26]
Equipment Reaction , F1 0.4
Piping , F2 0.7
Instrumentation , F3 0.2
Electrical , F4 0.1
Building , F5 0.15
Utilities , F6 0.5
Storage , F7 0.15
Site Development,F8 0.05
Auxiliary Building,F9 0.15
Total Physical Plant Cost (PPC) = 45430810 $
9.2.2.3- Fixed Capital Investment (FCI):
Fixed Capital Investment (FCI) = PPC (1 + F10 + F11 + F12)
117
Table 9.2 typical factors for project fixed cost [26]
Design & Engineering , F10 0.30
Controller , F11 0.05
Contingency , F12 0.1
Fixed Capital Investment (FCI) = 65874670 $
9.2.2.4- Operating Cost of Cryogenic Distillation:
Energy required = 69 MMBTU / hr
Energy required = 1656 MMBTU / day
Operating Cost required = 1656 MMBTU / day * 21 $ / MMBTU (K-electric rate)
Operating Cost required = 34776 $ / day
Operating Cost required = 12693240 $ / year
9.2.2.5- Revenue Generate Per Year:
A) Natural gas flowrate = 10550 m3 /hr
Natural gas flowrate = 92418000 m3 / day
Cost per year = 92418000 ×0.227 (OGRA prices)
Cost per year = 20978886 $ / year
B) NGL flowrate = 3014 bbl / day
NGL flowrate = 1100110 bbl/year
NGL prices per barrel = 21.77$/bbl (www.midstreambusiness.com/prices-natural-gas-

liquids)
Revenue generate per year = 1100110 × 21.77
118
Revenue generate per year = 23949394 $/year
Total revenue generate per year = 44928880 $/year
Total net profit per year = 32235640 $/year
9.2.2.6- Payback Period:
fixed capital cost(FCI)

Payback Period =
net profit
Payback Period = 2years 15days.
9.2.3 PRESSURE SWING ADSORPTION (PSA) UNIT:
Vessel Diameter, Bare Cost($) Material Factor Pressure Factor

Height(m)
3.05m , 7.8 m 4*10e4(fig 1B-2) 1 3.8
Cost in 2002 = 152000 $
Cost in 2016 = 255360 $
9.2.3.1- Sum of Purchase cost of Equipment (PEC):
Sum of Purchase cost of Equipment (PEC) = 1021440 $
9.2.3.2- Total Physical Plant Cost (PPC):
Total Physical Plant Cost (PPC) = PEC (1+F1+F2+………..F9)
Equipment Reaction , F1 0.4
Piping , F2 0.7
Instrumentation , F3 0.2
Electrical , F4 0.1
119
Building , F5 0.15
Utilities , F6 0.5
Storage , F7 0.15
Site Development,F8 0.05
Auxiliary Building,F9 0.15
Total Physical Plant Cost (PPC) = 3472896 $
9.2.3.3- Fixed Capital Investment (FCI):
Fixed capital investment (FCI) = PPC (1 + F10 + F11 + F12)
Design & Engineering , F10 0.30
Controller , F11 0.05
Contingency , F12 0.1
Fixed capital investment (FCI) = 5036000 $
9.2.3.4- Operating Cost of PSA:
a) Volume of Bed:
𝜋𝐷2 𝐿
Volume of bed =
4
3.14∗3.06∗3.06∗7.8
Volume of bed =
4
Volume of bed = 57 𝑚3
b) Bulk Density of Zeolite = 730 kg m-3
120
Mass of Zeolite = 730 * 57
Mass of Zeolite = 41610 Kg (life of zeolite 1 year)
Cost per Kg of zeolite = 1.6 $ (https://www.alibaba.com › Chemicals › zeolite)
Cost of 41610 Kg zeolite = 41610 * 1.6
Cost of 41610 Kg zeolite = 66576 $
Cost of four PSA bed = 66576$*4
Cost of four PSA bed = 266304 $/year
9.2.3.5- Revenue Generate Per Year:
Gas production rate per day = 1187307 ft3/day
Gas production rate per day = 33620 m3/day
Gas production rate per year = 12271692 m3/year
Cost per m3of gas=0.227$/m3 (Oil and Gas Regulatory Authority OGRA)
Revenue generate per year = 0.227×12271592
Revenue generate per year = 2785651 $/year
Total net profit = 2519347$/year
9.2.3.6- Payback Period:
fixed capital cost(FCI)

Payback Period =
net profit
Payback Period = 2 years or 24 months
121
9.3 SUMMARY:
PSA CRYOGENIC DISTILLATION
Fixed Capital Cost
3780964 $ 65874670 $
Operating Cost
266304 $/year 12693240 $/year
Annual Revenue
2785651 $/year 44928880 $/year
Total Net Profit
2519347 $/year 32235640 $/year
Payback Period
2 years 2years 15days
122
SUGGESTIONS AND RECOMMENDATIONS:
Nitrogen rejection unit is setup to reduce nitrogen content in the natural gas. For this
purpose, different technologies can be utilized which are discussed in the above
chapters .Following are the some recommendations and suggestions:
a) If high purity of the product is required up to 99%, cryogenic distillation is

the best option.
b) Cryogenic distillation process can generate more revenue (44.9 million $ per
year) than PSA which will generate only 2.7 million $ per year for the given
specifications.
c) Net profit generated by Cryogenic distillation process will be more (32.2
million $ per annum) as compared to PSA which is estimated to be only 2.5
million $ per annum.
d) PSA is relatively cheaper to setup requiring the capital cost of only 3.8
million $ as compared to cryogenic technology which requires a huge amount
of 65 million $ approx.
e) Also PSA is feasible to operate economically with the operating cost being
only 0.27 million $ yearly while for meeting same specifications, cryogenic
will require operating cost around 12.7 million $ yearly.
f) Cryogenic technology requires Acid gas removal unit to be setup to remove
sour gases, while for PSA, there is no need to setup Acid gas removal unit
since it will remove the sour gases in the adsorber, reducing the plant area.
g) Payback period for both the technologies is approximately same which 2 to
2.05 years.
CONCLUSION:
Our objective was to study and carry out detailed designing of Nitrogen Rejection unit
for the natural gas feed (whose composition is described in above chapters). For this
purpose, literature survey was done and on the basis of which the two technologies
(PSA and Cryogenic technology) out of other technologies were found to be more
feasible and hence selected to carry out comparative analysis. Material and energy
balance for both the technologies was done followed by the sizing of the equipments
used in the processes. Afterwards line sizing was performed and then instrumentation
123
as well as computer simulation was carried out to reach the thorough outcome of the
project. To figure out hazardous conditions, HAZOP studies and environmental
assessment was carried out. Finally economic analysis was executed to evaluate the
net cost involved in setting up the plants. The economic analysis suggests that the
PSA requires lesser capital cost and running costs than the Cryogenic technology.
Although cryogenic technology appeared to be relatively expensive but it will
generate more profit than PSA .Payback period for both the technologies are appeared
to be approximately same.
124
REFERENCES
1. S.Mokhatab, William A. Poe, Schneider Electric, John Y. Mak. “Natural gas
fundamentals” in Natural Gas Transmission and Processing, Third Edition, pp 1-1
6. S.Mokhatab, William A. Poe, Schneider Electric, John Y. Mak. “Natural Gas
Dehydration” in Natural Gas Transmission and Processing, Third Edition, pp 223-
223
7. S.Mokhatab, William A. Poe, Schneider Electric, John Y. Mak. “Natural Gas
Treating” in Natural Gas Transmission and Processing, Third Edition, pp 181-181
8. S.Mokhatab, William A. Poe, Schneider Electric, John Y. Mak. “Nitrogen Rejection”
in Natural Gas Transmission and Processing, Third Edition, pp 335-335
9. S.Mokhatab, William A. Poe, Schneider Electric, John Y. Mak. “Basic Concept Of
Natural Gas Processing” in Natural Gas Transmission and Processing, Third Edition,
pp 124-124
10. S.Mokhatab, William A. Poe, Schneider Electric, John Y. Mak. “Nitrogen Rejection”
in Natural Gas Transmission and Processing, Third Edition, pp 338-343
11. Binay.k.dutta. “Adsorption” in Principles Of Mass Transfer And Separation
Processes, PHI learning private limited 2012, pp 629-640
12. JF Richardson & JH harker, “Adsorption” in Particle Technology And Separation
Processes, Vol 2, fifth edition, pp 970-1022
13. Douglas M Ruthven, Shamsuzzam Farooq, Kent S Knaebel.” PSA cycle, basic
principle” in Pressure swing adsorption, VCH publisher inc. 1994, pp 67-94
14. Arthur J. Kidney, William R. Parrish. Overview of the Natural Gas Industry in
Fundamentals of Natural Gas Processing. L. L. Faulkner, Columbus Division,
Battelle Memorial Institute and Department of Mechanical Engineering The Ohio
State University Columbus, Ohio Taylor and Francis Group, LLC, 2006, pp 1-2.
15. Arthur J. Kidney, William R. Parrish. Nitrogen rejection in Fundamentals of Natural
Gas Processing. L. L. Faulkner, Columbus Division, Battelle Memorial Institute and
125
Department of Mechanical Engineering The Ohio State University Columbus, Ohio
Taylor and Francis Group, LLC, 2006, pp 206.
16. Arnold Ken, Stewart. ”Two Phase Oil And Gas Separation” In Surface Production
Operation, Vol 1,Second Edition,pp 101-134
17. Arnold Ken, Stewart. ”Acid Gas Treating” In Surface Production Operation, Vol
2,Second Edition,pp 186-187
18. A.bhatia. Control Valve Basic, continuing education and development, inc, pp 1-64
19. Robert W Serth, Thomas G Lestina, “Heat Exchangers” In Process Heat Transfer,
Second Edition, pp 86-92
20. DQ.Kern, ”Shell And Tube Heat Exchangers” In Process Heat Transfer, pp 127-174
21. Arnold Ken, Stewart. ”Acid Gas Treating” In Surface Production Operation, Vol
2,Second Edition, pp 193-194
22. Arnold Ken, Stewart. ”Gas Dehydration” In Surface Production Operation, Vol
2,Second Edition, pp 233-234
23. JF Richardson & JH harker, “Adsorption” in Particle Technology And Separation
Processes, Vol 2, fifth edition, pp 1008-1011
24. R.K. Sinnott & JH harker, “Separation Column” in chemical engineering design, Vol
6, fourth edition, pp 557-557
25. Max S.Peter, “analysis of cost estimation” in plant design and economics for
chemical engineers, fifth edition, pp 238-238
26. R.K. Sinnott & JH harker, “Cost And Project Evaluation” in chemical engineering
design, Vol 6, fourth edition, pp 252-253
27. Arnold Ken, Stewart. ” choosing a line sizing and wall thickness” In Surface
Production Operation, Vol 1,Second Edition, pp 285-332
28. Ken Arnold, Maurice Stewart. “Pressure drop in piping” in Surface production
operation, 2nd edition, volume 1. United States of America: Gulf Publishing
Company, 1989-1999, pp 252-258.
126
APPENDIX
Appendix 1A: Equipment Designing
Appendix 1B: Costing Analysis
127
Appendix 1A: Equipment Designing
Cs/q
Cs
Figure 1A-1 Experimental Data of Nitrogen Adsorption Equilibrium On Zeolite 13X
(Journal Chemical Engineering Data Vol 49)
128
Cs/q
Cs
Figure 1A-2 Figure 1A-1 Experimental Data Of carbon dioxide Adsorption Equilibrium on Zeolite 13X
(Journal Chemical Engineering Data Vol 49)
129
Figure 1A-3 relation between drag coefficient (C) and Reynolds number (Re) (from GPSA)
130
Figure 1A-4 valve sizing sheet
Figure 1A-5 LMTD correction factor for 1-2 exchanger (PROCESS HEAT TRANSFER BY DQ-KERN)
131
Figure 1A-6 Heat Exchanger And Condenser Tube Data (PROCESS HEAT TRANSFER BY DQ-KERN)
132
Figure 1A-7 Tune Sheet Layout (Tube Count) Square Pitch (PROCESS HEAT TRANSFER BY DQ-KERN)
133
Figure 1A-8 Maximum Velocity For Bed Absorber (Surface Production And Operation Volume
2)
134
Figure 1A-9 Standing and Katz Compressibility Factor Chart (Natural Gas Engineering
Handbook)
135
Appendix 1B: Costing Analysis
Figure 1B-1 Purchase Cost of U-Tube Heat Exchanger in US dollars (Plant Design and Economics for
Chemical Engineer by Max Peter Fifth Edition)
136
Figure 1B-2 Purchase Cost of Column without Trays in US dollars (Plant Design and Economics
for Chemical Engineer by Max Peter Fifth Edition)
Figure 1B-3 Purchase Cost of Trays in US dollars (Plant Design and Economics for Chemical
Engineer by Max Peter Fifth Edition)
137
Vessel height
Figure 1B-4 Purchase Cost of Vertical Separator in US dollar (Plant Design and Economics for
Chemical Engineer by Max Peter Fifth Edition)
138

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DESIGN AND COMPARISON STUDY OF

NITROGEN REJECTION UNIT FOR 100

HAFIZ MUHAMMAD NOORUL HUDA B1233007

HAMZA SHEIKH B1233009

MUHAMMAD UZAIR B1233022

MUJEEB ALAM FARHAN B1233024

SYED SHAHEER KAMAL B1233044

DEPARTMENT OF CHEMICAL ENGINEERING

1. HAFIZ MUHAMMAD NOORUL HUDA B1233007

DEPARTMENT OF CHEMICAL ENGINEERING

This is to certify that the following students of Chemical Engineering Department

HAFIZ MUHAMMAD NOORUL HUDA B1233007

HAMZA SHEIKH B1233009

MUHAMMAD UZAIR B1233022

MUJEEB ALAM FARHAN B1233024

SYED SHAHEER KAMAL B1233044

CERTIFICATE ..................................................................................................................... iii

Figure 2.1 NRU-by use of two-columns cryogenic distillation 11

Figure 2.2 Process Flow diagram of Pressure swing adsorption 12

Figure 2.4 The framework structure of zeolite 18

Figure 2.5 Comparison of pressure swing and temperature swing 19

Figure 2.6 Flow diagram for membrane separation technique. 20

Figure 4.1 Vertical Separator 42

Figure 4.2 Pump 44

Figure 4.3 Control Valve 46

Figure 4.4 Heat Exchanger 49

Figure 4.5 Absorber 53

Figure 5.1 Amine Unit Simulation 63

Figure 5.2.1 Feed and solvent Parameter 64

Figure 5.2.2 Feed and Solvent parameter 64

Figure 5.3 Flow rate of sweet gas and rich DEA 65

Figure 5.5 Regenerator re boiler duty 66

Figure 5.6 Temperature and pressure profile of Regenerator 67

Figure 5.7 Cryogenic distillation simulation 68

Figure 5.8 Cryogenic Feed conditions 68

Figure 5.9 Nitrogen rejection unit Product composition 69

Figure 5.11 Re boiler duty of Nitrogen rejection unit 70

Figure 5.12 Pure methane products from NGL columns 70

Figure 5.13 NGL product 71

Figure 5.14 Reboiler duty of NGL columns 71

Figure 5.15 Product Gas Parameters 72

Figure 5.16 PSA process simulation 73

Figure 5.17 Bed simulation specification 73

Figure 7.1 Feedback Controller 91

Figure 7.2 Feed forward Controller 92

Table 1.1 Physical Properties of Natural gas 5

Table 2.1 Typical pipeline specifications of Natural gas 10

Table 2.2 Some major commercial adsorption separations 17

Table 3.1 Component Flows of stream B and D 25

Table 3.2 Sensible and latent heat of Stream entering NRU 26

Table 3.2 Component Flows of stream V and D 27

Table 3.3 Mol% of stream F2 28

Table 3.4 Component flows of stream P1 and P2 31

Table 3.5 Component flows of stream B and D 32

Table 3.6 Component flows of stream N and D1 33

Table 3.7 Component flows of N and D 34

Table 6.1 HAZOP chart for adsorption column 77

Table 6.2 HAZOP chart for glycol-glycol HeatExchanger 78

Table 6.3 HAZOP chart for pump 79

Table 6.4 HAZOP chart for separator 80

Table 8.1 Typical factors for project fixed cost 98

Table 8.2 Typical factors for project fixed cost 98

Qg = Gas flow rate