OlefinandAlcoholProductionfromWetNaturalGasHoldings

Background
Recently, a wet natural gas supply was acquired near a small pilot scale
productionandresearchfacility.Thisexistingfacilitybecameveryprofitablethroughthe
productionofsmallquantitiesofspecialtychemicals.Thisnewrawmaterialsupplyis
veryintriguingbecauseitcanbeusedasafeedstocktotheexistingplantitselforas
salableproductsviathedesignofnewunits.
ThemaingoalistodesignaplantfortheproductionofC4andC5olefinsand
alcoholsfromthefeedstockofwetnaturalgas.Thecompositionofthenaturalgasisas
follows:
Component
Methane
Ethane
Propane
Isobutane
nButane
Isopentane
CO2,N2,He

Volume%
78.00
4.75
6.50
1.60
3.45
4.75
0.95

Theyearlyfeedofthissupplyisapproximately5000metrictonsperyear.Thedesigned
processconsistsoffoursteps:
1. SeparationofC4andC5alkanesfromthewetnaturalgas.Also,includedisacolumn
designforthecryogenicseparationofpropanefromthemethaneandethane.This
propanemayeitherbesoldifthemarketisfavorable,orreturnedtothewellwiththe
methaneandethane.
2. DehydrogenationoftheC4andC5alkanestomonoolefins.
3. HydrationoftheC4andC5monoolefinstoalcohols.

Theblockflowdiagram(Figure1)showshowthenaturalgasplantwillbebuilt
aroundthealreadyexisting,SemiWorks,plant.Theoverallplantdesignconsistsofthree
sections:cryogenicseparationoftheC4andC5hydrocarbonsfromthelighter
hydrocarbons in the wet natural gas, production of monoolefins from these
hydrocarbons,andhydrationoftheseolefinstoalcohols.Thisplantisnotonlytobe
designedtoproducemarketableproducts,butalsotosupplytheSemiWorksplantwitha
small supply of heavy hydrocarbons, olefins, and alcohols. These processes are very
distinct and are more easily handled separately. The titles of the three processes are
CryogenicsSeparation,Olefins,andAlcohols.Theuniquenessofthisdesignisthetime
elementused.IntheOlefinandAlcoholunits,thesameequipmentisusedtoproduce
threedifferentproducts.Theplantissetuptomakeoneproductforacertainperiodof
timeandthennewrawmaterialsareaddedtomakedifferentproductsoverthecourseof
ayear.

Unit100CryogenicSeparation
Background
Thepurposeofthissectionistoseparatehigherhydrocarbonsfromthenatural
gasstream.ApreliminaryPFDfortheunitisshowninFigure2alongwiththePFDfor
therefrigerationsysteminFigure3.TheflowsummaryisgiveninTable1.Aflashis
usedtoseparatemostofthemethaneandethanefromthepropane,nbutane,ibutane,
andipentane.Thenextstepinvolvesthefurtherseparationofthepropaneandremaining
methaneandethanefromthehigherhydrocarbons.Anotherseparationtowerisusedto
separatethemethaneandethanefromthepropane.Themethaneandethanearereturned
to the well while the propane is sold for profit if desired. Most of the heavier
hydrocarbonsaresentontothenextunitforfurtherprocessing.Butsomearesuppliedto
theSemiWorksplantwhenneeded.
ProcessDescription
Thenaturalgas,whichisamixtureofC1C5hydrocarbons,isfedtothisprocess
at10Cand8bar(Figure2).Thegasispipedthroughtwoheatexchangers,E101&E
102,whichlowersStream6toatemperatureof23Cusingtheoutletsfromtheflash,V
101.Itisthensentthroughanotherheatexchanger,E103,coolingStream7to63C.
The natural gas is then flashed at 63C and 7.4 bar in V101. The top product,
predominatelymethaneandethane,issentbacktothewell.Thebottomproduct,mainly
C3andhigherhydrocarbons,issenttodistillationcolumn,T101,whereC1C3
hydrocarbonsareseparatedfromtheC4C5hydrocarbonswhichwillbefurtherprocessed
intheolefinsplant.Thetopproductissentbacktothewell.ThebottomsoutofT101,

Stream14consistsmostlyofnbutane,ibutane,andipentane.Itissenttoadistillation

tower,T102,wheretheC5isseparatedfromtheC4s.Thedistillate,Stream17,from
thistowerissenttoathirdcolumn,T104.HeretheiC4isseparatedfromthenC4.The
C5,iC4,andnC4streams(Stream18,Stream19,andStream20)arethensenttoholding
tanks.Fromhere,theseshigherhydrocarbonsaresenttotheSemiWorksplantortothe
olefinunitforfurtherprocessing.
Therefrigerationloopforthesystem(Figure3)compressesandexpandsethylene
forcryogeniccooling.Theethyleneiscompressedto100barinC102.Heatexchanger,
E104,coolsthestreamfrom167Cto45C.E105coolsStream28furtherto10Cwith
refrigeratedwater.Thepressureisthenreleasedto4bar.Byreleasingthepressure,the
ethylenecoolsto76.2C.Theflashvessel,V102,separatestheliquidandvaporof
Stream21.TheliquidisusedinthecondenserofT101.Stream23isvaporizedata
temperatureof75C.Stream24ismixedwiththevaporstreamfromflashvessel,V
102.Stream25,thecombinedstreamat75.7Cand4bar,isusedasthecoolantinheat
exchanger,E103.Stream26,49.6and3.7bar,issentbacktocompressor,C102.
[ThereareafewextrapiecesofequipmentonthePFD(Figure2).Compressor,
C101,anddistillationtower,T103,areonlytobeusedwhenthesaleofpropaneis
desirable.Propaneistypicallysoldatapressureof20bar.Thereforethesystemneedsto
berunatahigherpressure.Therefore,theprocessneedstobeadjustedfortheincreaseof
pressurethroughoutthesystem.Whensellingpropane,T103isneededtoseparatethe
lowercarbons,methane,ethane,andpropane.WiththeadditionofT103,thecryogenic
loopneedstobeadjustedforthelowtemperatureoftheheatexchanger,E110.]

NecessaryInformationandSimulationHints
When optimizing the separation towers, the number of stages, sequencing of
columns,andoperatingpressureneedtobevariedinordertominimizetheEAOC.The
majorcostofthecryogenicplantistherefrigerationloop(Figure3).Theelectricitycost
ofthecompressorishighduetothelargeamountofrefrigerantneededtocoolthefeed
from10Cto63C.Usingtwoheatexchangers,onewithcoolingwaterandonewith
refrigeratedwater,reducedtheutilitycosts.Thesignificantsavingscanalsobeobtained
byoptimizingtherefrigerationloop.Theuseofdifferentrefrigerantsinatemperature
cascadeshouldbeconsidered.
EquipmentDescription
E101

Cooler

E102

Cooler

E103

Cooler(Cryogenicloop)

E104

Cryogenicloopcooler(CW)

E105

Cryogenicloopcooler(RW)

E106

C1,C2,C3condenser(Cryogenicloop)

E107

C4,C5reboiler

E108

C4scondenser

E109

C5reboiler

E110

C1,C2condenser

E111

C3reboiler

E112

iC4condenser

E113

nC4reboiler

P101

Pump

P102

C1,C2,C3refluxpump

P103

C4srefluxpump

P104

C1,C2refluxpump

P105

iC4refluxpump

C101

Optionalcompressorifpropaneisdesiredforsale

C102

Cryogenicloopcompressor

V101

Flashvessel

V102

Cryogenicloopflashvessel

T101

C1C5distillationtower

T102

C4,C5distillationtower

T103

C1,C2,C3distillationtower

T104

C4sdistillationtower

Table1:StreamTableforUnit100
Stream
Temp.(C)
Press.(bar)
VaporFraction
TotalFlow(kg/h)
TotalFlow(kmol/h)
ComponentFlows(kmol/h)
Methane
Ethane
Propane
IButane
IPentane
NButane

2
10.0
8.0

1.0
593.75
25.41

10.0
8.0
1.0
359.70
15.39

19.76
1.20
1.64
0.41
1.20
0.88

11.97
0.73
1.00
0.25
0.73
0.53

4
10.0
8.0

1.0
234.05
10.02

21.0
7.7
0.9
359.70
15.39

25.0
7.7
0.9
234.05
10.02

22.6
7.7
0.9
593.75
25.41

7.79
0.47
0.65
0.16
0.47
0.35

11.97
0.73
1.00
0.25
0.73
0.53

7.79
0.47
0.65
0.16
0.47
0.35

19.76
1.20
1.64
0.41
1.20
0.88

Nitrogen
CarbonDioxide
Helium
Ethylene
Stream
Temp.(C)
Press.(bar)
VaporFraction
TotalFlow(kg/h)
TotalFlow(kmol/h)
ComponentFlows(kmol/h)
Methane
Ethane
Propane
IButane
IPentane
NButane
Nitrogen
CarbonDioxide
Helium
Ethylene

0.08
0.08
0.15

0.05
0.05
0.09

0.03
0.32
0.06

0.05
0.05
0.09

0.03
0.03
0.06

0.08
0.08
0.15

10

11
62.9
12.3
0.0
233.80
4.56

12

63.0
7.4
0.8
593.75
25.41

8
63.0
7.4
1.0
359.95
20.85

0.1
233.80
4.56

19.76
1.20
1.64
0.41
1.20
0.88
0.08
0.08
0.15

19.30
0.83
0.35
0.02
0.01
0.03
0.08
0.07
0.15

0.47
0.37
1.29
0.38
1.19
0.85

0.47
0.37
1.29
0.38
1.19
0.85

63.0
7.4
0.0
233.80
4.56
0.47
0.37
1.29
0.38
1.19
0.85
**
0.01
**

4.4
7.1
1.0
359.95
20.85
19.30
0.83
0.35
0.02
0.01
0.03
0.08
0.07
0.15

**

4.0
12.0

**
0.01

**

0.01
**

Stream
Temp.(C)
Press.(bar)
VaporFraction
TotalFlow(kg/h)
TotalFlow(kmol/h)
ComponentFlows(kmol/h)
Methane
Ethane
Propane
IButane
IPentane
NButane
Nitrogen
CarbonDioxide

13
74.7
12.0
0.0
76.01
0.17
0.47
0.37
1.29
**

**

14
100.5
12.0
1.0
157.80
2.43

**

0.47
0.35
0.02
0.38
1.19
0.85

0.01

15
106.3
12.0
0.0
19.24
0.84

**
0.01

16

17
32.3
12.0

82.7
12.0

0.0
56.77
1.29

0.0
71.41
1.23

**

0.02
1.27
**

0.38
**
0.84

18
124.1
12.0
0.0
86.39
1.20

**
1.19
0.01

Helium
Ethylene

**

**

Stream
Temp.(C)
Press.(bar)
VaporFraction
TotalFlow(kg/h)
TotalFlow(kmol/h)
ComponentFlows(kmol/h)
Methane
Ethane
Propane
IButane
IPentane
NButane
Nitrogen
CarbonDioxide
Helium
Ethylene

19

20

21
76.2
4.0
0.6
2358.40
84.01

22
76.2
4.0
1.0
1350.40
48.14

23
76.2
4.0
0.0
1008.00
35.93

24
75.0
4.0
1.0
1008.00
35.93

84.01

48.14

35.93

35.93

73.6
12.0
0.0
22.17
0.38

**
0.38

**

87.3
12.0
0.0
49.24
0.85

**
**
0.84

10

Stream
Temp.(C)
Press.(bar)
VaporFraction
TotalFlow(kg/h)
TotalFlow(kmol/h)
ComponentFlows(kmol/h)
Methane
Ethane
Propane
IButane
IPentane
NButane
Nitrogen
CarbonDioxide
Helium
Ethylene

**Verysmalltraces

25
75.7
4.0
1.0
2358.40
84.01

26
49.6
3.7
1.0
2358.40
84.01

27
166.9
100.0
1.0
2358.40
84.01

28

29

45.0
100.0
1.0
2358.40
84.01

10.0
100.0
1.0
2358.40
84.01

84.01

84.01

84.01

84.01

84.01

E201

Reactorinletheater

R201A/C

Reactor

E202

Reactoreffluentcooler

C201

Compressor

E203

Preflashcooler

E204

Preflashcooler

V201

Flash

E205

Heater(onlyusedintheproductionof1Butene)

T201

Hydrogendistillationtower

E206

Condenser

E207

Reboiler

V202

Refluxdrum

16

P201

Refluxpump

T202

Distillationtower

E208

Condenser

E209

Reboiler

P202

Refluxpump

T203

Distillationtower

E210

Condenser

E211

Reboiler

P203

Refluxpump

TK301

Mixingtank

P301

Pump

TK302

MixingTank

E301

Cooler

R301

PackedBedReactor

A301

AnionExchangeBed

E302

Heater

V301

FlashVessel

E303

Cooler

E304

Heater

V302

FlashVessel

V303

FlashVessel

T301

AlcoholPurificationTower

P302

RefluxPump

E305

Condenser

E306

Reboiler