Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production

Mohamed Magdy El-Eishy; Galal Mohamed Abdelalim; Tarek Mohamed Aboul-Fotouh

doi:doi:10.11648/j.ogce.20180601.12

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Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production

Mohamed Magdy El-Eishy, Galal Mohamed Abdelalim, Tarek Mohamed Aboul-Fotouh

Published in International Journal of Oil, Gas and Coal Engineering (Volume 6, Issue 1)

Received: 3 October 2017 Accepted: 23 October 2017 Published: 15 January 2018

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Abstract

Nowadays, gas processing for NGLs (Natural Gas Liquids) and LPG (Liquefied Petroleum Gas) recovery has gained a great interest due to the increase of the market demand as well as the higher prices of these products. Based on sales gas calorific value from ABU-SANNAN Condensate Recovery Plant (General Petroleum Company-Egypt) and by close monitoring of NGLs content in feed and sales gas, it is clear that there is a valuable amount of NGLs leave with sales gas without recovery. NGLs have significantly greater value as separated products than as part of the gas stream, so General Petroleum Company could seek ways and means to maximize NGLs recovery. The current research work proposes a possible modification of ABU-SANNAN Condensate Recovery Plant to produce liquefied petroleum gas (LPG) from natural gas liquids (NGLs), instead of producing lighter hydrocarbon gases during the stabilization process, in addition to the current condensate and sales gas products. The new LPG recovery unit will comprises of: Molecular Sieve based-dehydration unit, Turbo-Expander unit, Cold Box heat exchanger, DE-ETHANIZER system, DE-ETHANIZER Overhead compressor, DE-BUTANIZER system, and two LPG storage bullets. New process equipment selection, sizing and rating will be performed by using Aspen HYSYS simulation program V8.8. The results show that the retrofitted plant can produce 87 Tons/Day of LPG. The produced LPG can participate to solve the LPG shortage problem in Egypt. The economic evaluation for the Retrofitted Plant is conducted by using Aspen Capital Cost Estimator V8.8, to ensure rapid return of investment and good profitability over the expected lifetime. It is remarkable that the Retrofitted plant has a great value from the economic point of view as the total capital investment will be paid back within two years, so the Retrofitted plant will achieve a high and rapid return on investment (ROI). The efforts done in this work are helpful and can be applied for plants in operation as well as the plants under design for increasing their profits.

Published in	International Journal of Oil, Gas and Coal Engineering (Volume 6, Issue 1)
DOI	10.11648/j.ogce.20180601.12
Page(s)	8-17
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2018. Published by Science Publishing Group

Keywords

Retrofitting, Condensate Stabilization, Simulation, LPG

References

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[2]	Speight, James G. "Natural gas: a basic handbook." Elsevier, 2007.
[3]	Richards, G. A., et al. "Issues for low-emission, fuel-flexible power systems." Progress in Energy and Combustion Science 27.2 (2001): 141-169.‏
[4]	Gary, James H., Glenn E. Handwerk, and Mark J. Kaiser. "Petroleum refining: technology and economics." CRC press, 2007.‏
[5]	Kidnay, Arthur J., William R. Parrish, and Daniel G. McCartney. "Fundamentals of natural gas processing. Vol. 218." CRC Press, 2011.‏
[6]	Turton, Richard, et al. "Analysis, synthesis and design of chemical processes." Pearson Education, 2008.
[7]	Ahmed, Musab Mukhtar. "Recovery Of Natural Gas Liquids And Produce Liquified Petroleum Gas From Assosiated Natral Gas. Diss." Sudan University of Science & Technology, 2016.‏
[8]	Ikoku, Chi U. "Natural Gas Production Engineering", Krieger publishing company, Malabar, Florida, 1992.
[9]	Mondal, Sukanta Kumar, M. Rakib Uddin, and A. K. Azad. "Simulation and optimization of natural gas processing plant." International conference on mechanical, industrial and materials engineering, Bangladesh. 2013.‏
[10]	Chowdhury, Niaz Bahar, Zahid Hasan, and A. H. M. Biplob. "HYSYS Simulation of a Sulfuric Acid Plant and Optimization Approach of Annual Profit." Journal of Science (JOS) 2.4 (2012).‏
[11]	Lynch, J. T., J. P. McCann, and P. Carmody. "Retrofit of the Amerada Hess sea Robin plant for very high ethane recovery." 84th Annual Convention of Gas Processors Association, San Antonio, TX. 2005.‏
[12]	Lynch, J. T., et al. "Process retrofits maximize the value of existing NGL and LPG recovery plants." 82nd Annual Convention of the Gas Processors Association, San Antonio, TX. 2003.‏
[13]	Mehrpooya, Mehdi, Farhad Gharagheizi, and Ali Vatani. "An optimization of capital and operating alternatives in a NGL recovery unit." Chemical engineering & technology 29.12 (2006): 1469-1480.‏
[14]	Mohamed, Mohamed Shaaban Khater. "An optimization of gas condensate extraction from Abu Sannan fields using optimal process operating conditions." CU Theses (2012).‏
[15]	Peters, Max Stone, et al. "Plant design and economics for chemical engineers. Vol. 4." New York: McGraw-Hill, 1968.‏
[16]	ENPPI. "Abu Sannan Condensate Recovery Plant Operation and Maintenance commissioning protocol." Egypt (1990).
[17]	Bhran, Ahmed Abd El-Kader, Mohamed Hassan Hassanean, and Mohamed Galal Helal. "Maximization of natural gas liquids production from an existing gas plant." Egyptian Journal of Petroleum 25.3 (2016): 333-341.‏

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Mohamed Magdy El-Eishy, Galal Mohamed Abdelalim, Tarek Mohamed Aboul-Fotouh. (2018). Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production. International Journal of Oil, Gas and Coal Engineering, 6(1), 8-17. https://doi.org/10.11648/j.ogce.20180601.12

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ACS Style

Mohamed Magdy El-Eishy; Galal Mohamed Abdelalim; Tarek Mohamed Aboul-Fotouh. Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production. Int. J. Oil Gas Coal Eng. 2018, 6(1), 8-17. doi: 10.11648/j.ogce.20180601.12

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AMA Style

Mohamed Magdy El-Eishy, Galal Mohamed Abdelalim, Tarek Mohamed Aboul-Fotouh. Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production. Int J Oil Gas Coal Eng. 2018;6(1):8-17. doi: 10.11648/j.ogce.20180601.12

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@article{10.11648/j.ogce.20180601.12,
  author = {Mohamed Magdy El-Eishy and Galal Mohamed Abdelalim and Tarek Mohamed Aboul-Fotouh},
  title = {Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production},
  journal = {International Journal of Oil, Gas and Coal Engineering},
  volume = {6},
  number = {1},
  pages = {8-17},
  doi = {10.11648/j.ogce.20180601.12},
  url = {https://doi.org/10.11648/j.ogce.20180601.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ogce.20180601.12},
  abstract = {Nowadays, gas processing for NGLs (Natural Gas Liquids) and LPG (Liquefied Petroleum Gas) recovery has gained a great interest due to the increase of the market demand as well as the higher prices of these products. Based on sales gas calorific value from ABU-SANNAN Condensate Recovery Plant (General Petroleum Company-Egypt) and by close monitoring of NGLs content in feed and sales gas, it is clear that there is a valuable amount of NGLs leave with sales gas without recovery. NGLs have significantly greater value as separated products than as part of the gas stream, so General Petroleum Company could seek ways and means to maximize NGLs recovery. The current research work proposes a possible modification of ABU-SANNAN Condensate Recovery Plant to produce liquefied petroleum gas (LPG) from natural gas liquids (NGLs), instead of producing lighter hydrocarbon gases during the stabilization process, in addition to the current condensate and sales gas products. The new LPG recovery unit will comprises of: Molecular Sieve based-dehydration unit, Turbo-Expander unit, Cold Box heat exchanger, DE-ETHANIZER system, DE-ETHANIZER Overhead compressor, DE-BUTANIZER system, and two LPG storage bullets. New process equipment selection, sizing and rating will be performed by using Aspen HYSYS simulation program V8.8. The results show that the retrofitted plant can produce 87 Tons/Day of LPG. The produced LPG can participate to solve the LPG shortage problem in Egypt. The economic evaluation for the Retrofitted Plant is conducted by using Aspen Capital Cost Estimator V8.8, to ensure rapid return of investment and good profitability over the expected lifetime. It is remarkable that the Retrofitted plant has a great value from the economic point of view as the total capital investment will be paid back within two years, so the Retrofitted plant will achieve a high and rapid return on investment (ROI). The efforts done in this work are helpful and can be applied for plants in operation as well as the plants under design for increasing their profits.},
 year = {2018}
}

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TY  - JOUR
T1  - Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production
AU  - Mohamed Magdy El-Eishy
AU  - Galal Mohamed Abdelalim
AU  - Tarek Mohamed Aboul-Fotouh
Y1  - 2018/01/15
PY  - 2018
N1  - https://doi.org/10.11648/j.ogce.20180601.12
DO  - 10.11648/j.ogce.20180601.12
T2  - International Journal of Oil, Gas and Coal Engineering
JF  - International Journal of Oil, Gas and Coal Engineering
JO  - International Journal of Oil, Gas and Coal Engineering
SP  - 8
EP  - 17
PB  - Science Publishing Group
SN  - 2376-7677
UR  - https://doi.org/10.11648/j.ogce.20180601.12
AB  - Nowadays, gas processing for NGLs (Natural Gas Liquids) and LPG (Liquefied Petroleum Gas) recovery has gained a great interest due to the increase of the market demand as well as the higher prices of these products. Based on sales gas calorific value from ABU-SANNAN Condensate Recovery Plant (General Petroleum Company-Egypt) and by close monitoring of NGLs content in feed and sales gas, it is clear that there is a valuable amount of NGLs leave with sales gas without recovery. NGLs have significantly greater value as separated products than as part of the gas stream, so General Petroleum Company could seek ways and means to maximize NGLs recovery. The current research work proposes a possible modification of ABU-SANNAN Condensate Recovery Plant to produce liquefied petroleum gas (LPG) from natural gas liquids (NGLs), instead of producing lighter hydrocarbon gases during the stabilization process, in addition to the current condensate and sales gas products. The new LPG recovery unit will comprises of: Molecular Sieve based-dehydration unit, Turbo-Expander unit, Cold Box heat exchanger, DE-ETHANIZER system, DE-ETHANIZER Overhead compressor, DE-BUTANIZER system, and two LPG storage bullets. New process equipment selection, sizing and rating will be performed by using Aspen HYSYS simulation program V8.8. The results show that the retrofitted plant can produce 87 Tons/Day of LPG. The produced LPG can participate to solve the LPG shortage problem in Egypt. The economic evaluation for the Retrofitted Plant is conducted by using Aspen Capital Cost Estimator V8.8, to ensure rapid return of investment and good profitability over the expected lifetime. It is remarkable that the Retrofitted plant has a great value from the economic point of view as the total capital investment will be paid back within two years, so the Retrofitted plant will achieve a high and rapid return on investment (ROI). The efforts done in this work are helpful and can be applied for plants in operation as well as the plants under design for increasing their profits.
VL  - 6
IS  - 1
ER  -

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Author Information

Mohamed Magdy El-Eishy

Chemical Engineering and Petroleum Refining Department, Suez University, Suez, Egypt
Galal Mohamed Abdelalim

Chemical Engineering and Petroleum Refining Department, Suez University, Suez, Egypt
Tarek Mohamed Aboul-Fotouh

Mining and Petroleum Engineering Department, Al-Azhar University, Cairo, Egypt

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Plain Text BibTeX RIS

APA Style

Mohamed Magdy El-Eishy, Galal Mohamed Abdelalim, Tarek Mohamed Aboul-Fotouh. (2018). Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production. International Journal of Oil, Gas and Coal Engineering, 6(1), 8-17. https://doi.org/10.11648/j.ogce.20180601.12

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ACS Style

Mohamed Magdy El-Eishy; Galal Mohamed Abdelalim; Tarek Mohamed Aboul-Fotouh. Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production. Int. J. Oil Gas Coal Eng. 2018, 6(1), 8-17. doi: 10.11648/j.ogce.20180601.12

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AMA Style

Mohamed Magdy El-Eishy, Galal Mohamed Abdelalim, Tarek Mohamed Aboul-Fotouh. Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production. Int J Oil Gas Coal Eng. 2018;6(1):8-17. doi: 10.11648/j.ogce.20180601.12

Copy | Download

@article{10.11648/j.ogce.20180601.12,
  author = {Mohamed Magdy El-Eishy and Galal Mohamed Abdelalim and Tarek Mohamed Aboul-Fotouh},
  title = {Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production},
  journal = {International Journal of Oil, Gas and Coal Engineering},
  volume = {6},
  number = {1},
  pages = {8-17},
  doi = {10.11648/j.ogce.20180601.12},
  url = {https://doi.org/10.11648/j.ogce.20180601.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ogce.20180601.12},
  abstract = {Nowadays, gas processing for NGLs (Natural Gas Liquids) and LPG (Liquefied Petroleum Gas) recovery has gained a great interest due to the increase of the market demand as well as the higher prices of these products. Based on sales gas calorific value from ABU-SANNAN Condensate Recovery Plant (General Petroleum Company-Egypt) and by close monitoring of NGLs content in feed and sales gas, it is clear that there is a valuable amount of NGLs leave with sales gas without recovery. NGLs have significantly greater value as separated products than as part of the gas stream, so General Petroleum Company could seek ways and means to maximize NGLs recovery. The current research work proposes a possible modification of ABU-SANNAN Condensate Recovery Plant to produce liquefied petroleum gas (LPG) from natural gas liquids (NGLs), instead of producing lighter hydrocarbon gases during the stabilization process, in addition to the current condensate and sales gas products. The new LPG recovery unit will comprises of: Molecular Sieve based-dehydration unit, Turbo-Expander unit, Cold Box heat exchanger, DE-ETHANIZER system, DE-ETHANIZER Overhead compressor, DE-BUTANIZER system, and two LPG storage bullets. New process equipment selection, sizing and rating will be performed by using Aspen HYSYS simulation program V8.8. The results show that the retrofitted plant can produce 87 Tons/Day of LPG. The produced LPG can participate to solve the LPG shortage problem in Egypt. The economic evaluation for the Retrofitted Plant is conducted by using Aspen Capital Cost Estimator V8.8, to ensure rapid return of investment and good profitability over the expected lifetime. It is remarkable that the Retrofitted plant has a great value from the economic point of view as the total capital investment will be paid back within two years, so the Retrofitted plant will achieve a high and rapid return on investment (ROI). The efforts done in this work are helpful and can be applied for plants in operation as well as the plants under design for increasing their profits.},
 year = {2018}
}

Copy | Download

TY  - JOUR
T1  - Retrofitting of an Existing Condensate Recovery Plant to Maximize Natural Gas Liquids Production
AU  - Mohamed Magdy El-Eishy
AU  - Galal Mohamed Abdelalim
AU  - Tarek Mohamed Aboul-Fotouh
Y1  - 2018/01/15
PY  - 2018
N1  - https://doi.org/10.11648/j.ogce.20180601.12
DO  - 10.11648/j.ogce.20180601.12
T2  - International Journal of Oil, Gas and Coal Engineering
JF  - International Journal of Oil, Gas and Coal Engineering
JO  - International Journal of Oil, Gas and Coal Engineering
SP  - 8
EP  - 17
PB  - Science Publishing Group
SN  - 2376-7677
UR  - https://doi.org/10.11648/j.ogce.20180601.12
AB  - Nowadays, gas processing for NGLs (Natural Gas Liquids) and LPG (Liquefied Petroleum Gas) recovery has gained a great interest due to the increase of the market demand as well as the higher prices of these products. Based on sales gas calorific value from ABU-SANNAN Condensate Recovery Plant (General Petroleum Company-Egypt) and by close monitoring of NGLs content in feed and sales gas, it is clear that there is a valuable amount of NGLs leave with sales gas without recovery. NGLs have significantly greater value as separated products than as part of the gas stream, so General Petroleum Company could seek ways and means to maximize NGLs recovery. The current research work proposes a possible modification of ABU-SANNAN Condensate Recovery Plant to produce liquefied petroleum gas (LPG) from natural gas liquids (NGLs), instead of producing lighter hydrocarbon gases during the stabilization process, in addition to the current condensate and sales gas products. The new LPG recovery unit will comprises of: Molecular Sieve based-dehydration unit, Turbo-Expander unit, Cold Box heat exchanger, DE-ETHANIZER system, DE-ETHANIZER Overhead compressor, DE-BUTANIZER system, and two LPG storage bullets. New process equipment selection, sizing and rating will be performed by using Aspen HYSYS simulation program V8.8. The results show that the retrofitted plant can produce 87 Tons/Day of LPG. The produced LPG can participate to solve the LPG shortage problem in Egypt. The economic evaluation for the Retrofitted Plant is conducted by using Aspen Capital Cost Estimator V8.8, to ensure rapid return of investment and good profitability over the expected lifetime. It is remarkable that the Retrofitted plant has a great value from the economic point of view as the total capital investment will be paid back within two years, so the Retrofitted plant will achieve a high and rapid return on investment (ROI). The efforts done in this work are helpful and can be applied for plants in operation as well as the plants under design for increasing their profits.
VL  - 6
IS  - 1
ER  -

Copy | Download