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United Arab Emirates University College of Engineering Training and Graduation Project Unit Graduation Project II

United Arab Emirates University College of Engineering Training and Graduation Project Unit Graduation Project II . Gas –To– Liquid (GTL) Plant Design. Faculty Advisor: Dr. Mohamed A. Nakoua Chemical & Petroleum Engineering Department. Rasha Ahmed Ali 200440204

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United Arab Emirates University College of Engineering Training and Graduation Project Unit Graduation Project II

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  1. United Arab Emirates UniversityCollege of Engineering Training and Graduation Project UnitGraduation Project II Gas –To– Liquid (GTL) Plant Design Faculty Advisor: Dr. Mohamed A. Nakoua Chemical & Petroleum Engineering Department Rasha Ahmed Ali 200440204 Latefa Salem Ahmed 200323476 Fatima Sulaiman200401351 AminaAbdulrahman 200440256

  2. Outline

  3. GTL technology converts simple carbon-, hydrogen-, and oxygen containing molecules to hydrocarbons (fuels) through a three step process. IntroductionGas-to-liquid(GTL) Products Feed stocks Process Steps Natural gas (CH4 ) Power Fischer-Tropsch H2 +CO LPG Simple Molecules Syngas Production Syngas Conversion Product Upgrading Naphtha Kerosene Oxidant Diesel Wax O2 Lubes Chemicals The Fischer-Tropsch synthesis has been used for >80 years (mainly coal!) as feedstock

  4. Introduction Gas-to-liquid (GTL)

  5. PFD

  6. Heat Exchangers • A device built for efficient heat transfer from one medium to another & the media may be separated by a solid wall, so that they never mix or they may be in direct contact. • Classification : according to their flow arrangement: • Parallel-flow heat exchangers • Counter-flow heat exchangers • Cross-flow heat exchanger Parallel-flow heat exchangers • Counter-flow heat • exchangers • Cross -flow heat • exchangers

  7. Heat Exchanger • Types of Heat Exchanger: • Double- pipe exchanger • Shell & tube exchanger • Plate & frame exchanger • Plate –Fin exchanger • Spiral heat exchanger • Air cooled . • Direct contact • Fired heaters .

  8. Heat Exchanger • Shell & Tube Exchanger: • It is consisted of a series of tubes; • one set of these tubes contains the fluid that must be either heated or cooled. The second fluid runs over the tubes . • It is the most common type of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-pressure applications.

  9. Design Methodology • Define the duty: heat transfer rate, fluid flow and temperature. • Collecting the fluid physical properties required. • Decide on the type of exchanger to be used. • Select the trial value for the overall coefficient, U. • U = 20-300 W/m2.°C • Calculate the mean temperature difference (∆Tm).

  10. Cont. Design Methodology = = m m 0 . 33 0 . 14 Nu h * d / k j * Re* Pr * ( / ) o i n w • Calculate the area required. • Calculate the individual coefficients. • Calculate the overall coefficient and compared with the trial value. • Calculate the exchanger pressure drop.

  11. Heat Exchanger Specifications

  12. Gas compressor Mechanical device increases pressure of a gas by reducing its volume C-107A/B Stream 7 P in= 0.1 atm Tin= 473K Stream 8 Po = 1.5 atm

  13. Compressor Design Type of compressor Positive displacement Dynamic Reciprocating Rotary Centrifugal Axial

  14. What type to use for C-107A/B? High volumetric flow rate ( 5.87 m3/s)

  15. Compressor Design Main objective is to find the discharge temperature and the work that’s applied The outlet temperature of the compressor was calculated by the following equation: The work which is applied on the system is calculated based on the inlet and outlet conditions:

  16. Results

  17. Reactors • Heart of a chemical process • Characteristics to classify reactor design: • Mode of operation: batch or continuous. • Phase present: homogeneous or heterogeneous. • Reactor geometry: flow pattern and manner of contacting the phase • Stirred tank reactor • Tubular reactor • Packed bed, fixed and moving • Fluidized bed

  18. Examples of reactors • There are a wide variety of reactors in use in the chemical processing industry. Packed Bed British Petroleum (BP) Batch CSTR

  19. Reactor Design • Main objective is to find the volume of the • reactor and the weight of the catalyst . • Various catalyst particle shapes are sold • commercially for a wide variety of process • technologies • Our Catalyst was (Ni supported on Al2O3) • cylindrical shape for R-103

  20. Reactor Design • The effectiveness of the catalyst is a ratio where • ractual = rate of diffusion at the mouth of the pore • rideal = rate on the assumption that all of the pore surface • is exposed to the concentration at the external surface • Effectiveness factor for cylindrical pellets is given by: 1 4 5 2 6 3

  21. Cont .Reactor Design • The volume of the reactor was found assuming no pressure • drop and no temperature change in the reactor. • Volume of the reactor was found to be 25 m3 • When dividing the volume of the reactor by porosity(0.4) • to find cat Vol. and using density we found W= 38840 Kg

  22. Cont .Reactor Design results

  23. Separator • Remove impurities and separate the different fluids from each other • GTL (gasoline, a mixture of gases (CH4, H2, CO) and water) • Separators are usually characterized as • Vertical • Horizontal • Spherical

  24. Characteristics of separator Vertical Horizontal • When sand , paraffin or wax • are produced • Plot space is limited • Ease of level control is desired • Small flow rate • Very low or very high gas oil ratio (GOR) • streams • Large volumes of gas and/or liquid • High to medium GOR streams • Foaming Crudes • Three phase separation

  25. AdvantagesvsDisadvantages

  26. Vertical Separator V-101 Design P = 1 bar, S = 944.83 bar E = 0.9 CA = 0 t= 0.000337m (less than min) →t= 0.005 m

  27. Bare module estimation

  28. Bare module estimation *CAPCOST

  29. Manufacturing cost estimation

  30. Cash Flow Analysis

  31. Pilot Plant Cost

  32. Hazardand Operability study (HAZOP) • Brainstorming, Multidisciplinary Team Approach • Structured Using Guide Words (like no, less, more) Problem Identifying • Cost Effective • When to use it ??? • when applied to new plants at the point where the design is nearly firm and documented or • to existing plants where a major redesign is planned. • It can also be used for existing facilities.

  33. HAZOP HAZOP STUDY

  34. PRINCIPLES OF HAZOPS CAUSE DEVIATION CONSEQUENCES (from standard (trivial, important, condition catastrophic) or intention) -hazard -operating difficulties *COVERING EVERY PARAMETER RELEVANT TO THE SYSTEM UNDER REVIEW: i.e. Flow Rate. Flow Quantity, Pressure, Temperature, Viscosity, Components

  35. HAZOP Example Node = Deviation PARAMETER + GUIDE WORD (Temperature) (High) (High Temperature) Causes:1. Less utility Flow rate with high processing fluid Flow 2.Heat Exchanger failure Consequences: 1.Less conversion (less production) in reactor due to working outside the reaction favored temperature range. 2.Deactivation of the catalyst. Actions: 1.High Temperature Alarm (HTA) 2.Increase utility flow rate and decrease processing flow rate . 3.Use cascade control cw cw

  36. ProjectManagement GP1 Planning, organization, directing and controlling of assigned resources in order to accomplish a given objective within the constraints of time, cost and performance

  37. ProjectManagement GP2

  38. Conclusion

  39. Conclusion • GTL is an exciting new way to bring natural gas energy to the market. • The total cost for starting this project was calculated to be $2.65*106US$ with net profit of 6.42*106 US$/yr which will have a breakeven after the 4th year on a 10 year plant life time. • HAZOP study was established. • Plant was specified on Um Al Naar due to the availability of the petroleum refining for the fuel blending.

  40. Recommendations • Cost for equipment should be compared with the industry • Project management Issues is IMP to achieve the objectives • Environmental consideration should be studied in details.

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