ECUMED Sizing Report For The First Phase Rev - 0 MCH (Réparé)

Project: ECUMED-El Bibane
Feasibility Study for EBB Plant Upgrade For Gas

Commercialization
Project NO
AR11/12
WO3
Date
Contract NO
EPPM document NO
Client
document NO
Rev
XXXXX
XXXXX
XXXXX
XX/XX/XXXX
Page
of
53
REPORT
EQUIPMENTS SIZING REPORT FOR THE FIRST PART
ECUMED PETROLEUM
1
0
21/06/2013
Issued For
approval
18/06/2013 Issued For
Review
001/AR11/12
SANAMCH
MCH
MLI
SANA
MCH
MLI
04/10
NO.
R1112-RPT-PR00-001
REV.A
PAGE: 2 / 63
PROCESS REVIEW
REQUIRED MODIFICATION REPORT
REV
DATE
Designation
NAME
VISA
Prepared by
NAME
VISA
Verified by
NAME
VISA
Approved by
EQUIPMENTS SIZING REPORT FOR THE FIRST

PART
NO.
REV.
0
PAGE: 3 / 63
Revisions report:
Revision No
0
1
002/AR11/12
Revision Description
Issued For Review
Issued For Approval
NO.
REV.
0
PAGE: 4 / 63
TABLE OF CONTENTS
1.
INTRODUCTION........................................................................................6
1.1
GENERAL................................................................................................................. 6
1.2
PROJECT DETAILED SCOPE........................................................................................... 6
1.3
DOCUMENT SCOPE..................................................................................................... 7
1.4
DEFINITIONS & ABBREVIATIONS....................................................................................7
1.4
DEFTINO.S ............................................................................................................................ 7
21.4
ABREVOITNS............................................................................................................................. 8
1.5
UNITS OF MEASUREMENT............................................................................................ 8
2.
DESIGN DATA..........................................................................................10
2.1
ENVIRONMENTAL DATA.............................................................................................. 10
12.
MCLATINDMEORG ITNS........................................................................................................................... 10
2.1
GROUNDASILCT........................................................................................................................... 11
2.2
WELLS LOCATION................................................................................................... 11
2.3
PROCESS DESIGN DATA............................................................................................ 11
12.3
WELHADRMPT.S .......................................................................................................................... 11
2.3
COMPSITN........................................................................................................................... 12
2.4
CPFDESIGNAMRT........................................................................................................................... 12
2.5
GASREQUDISPCFOTNTE(IA.) .......................................................................................................................... 12
3.
4.
CALCULATION METHODS.........................................................................13
3.1
PROCESS DESIGN TOOLS.......................................................................................... 13
3.2
THERMODYNAMICS................................................................................................... 13
3.3
MODEL DESCRIPTION, BATTERY LIMITS
13.
DFLUIRESVO........................................................................................................................... 13
23.
WELHADS........................................................................................................................... 14
3.
PIENL........................................................................................................................... 14
43.
FIRSTSEPAO.N .......................................................................................................................... 14
53.
NAMEIT.U .......................................................................................................................... 14
63.
GLYCODEHRATNI.U .......................................................................................................................... 14
73.
CONDETSARMLV.UI .......................................................................................................................... 15
83.
INJECTOGASCMPR........................................................................................................................... 16
93.
CONDETSASLBIZ........................................................................................................................... 16
AND
ASSUMPTIONS...............................................13
DESIGN OF THE NEW AMINE UNIT............................................................20

4.1
SELECTION FACTORS FOR THE TYPE OF AMINE................................................................20
4.2
CO2 SELECTIVITY................................................................................................. 20
002/AR11/12

4.3
KINETICS
4.4
CORROSIVITY.......................................................................................................... 21
4.5
AMINE
4.6
THERMODYNAMICS
4.7
MAIN EQUIPMENTS SIZING......................................................................................... 21
14.7
DETRMINOAFWL........................................................................................................................... 21
24.7
NSIZGOFCO2ABRE........................................................................................................................... 22
34.7
NAMEIRGTO........................................................................................................................... 23
4.7
LEANMICRUTOPS........................................................................................................................... 23
4.8
NSIZGOFHEATXCR........................................................................................................................... 24
14.8
NSIZGOFLEAMRC........................................................................................................................... 24
24.8
NSIZGCOFRH/LEAMTXNG.R .......................................................................................................................... 24
34.8
NSIZGOFRETACD........................................................................................................................... 25
4.8
NSIZGOFRETALB........................................................................................................................... 25
54.8
NSIZGOFAMELHDRU........................................................................................................................... 26
5.
6.
NO.
REV.
0
PAGE: 5 / 63
OF REACTION WITH
CO2..............................................................................20
CONSUMPTION AND PRICE................................................................................21

OF REACTION WITH
CO2..................................................................21
REVISION OF TEG UNIT DESIGN...............................................................26

5.1
REVISION OF TEG
5.2
CURRENT TEG REGENERATION UNIT DESIGN......................................................28
15.2
GLYCOFASHTNKPERIDMOSN........................................................................................................................... 28
25.
THECAXNGRSIPUD........................................................................................................................... 29
25.1
AIR/GLYCOHETXN.E320 .......................................................................................................................... 29
25.
GLYCO/HEATXNR........................................................................................................................... 29
25.3
GLYCOREN/DASMIZ........................................................................................................................... 29
5.3
GLYCOPUMS........................................................................................................................... 30
5.4
CONDESRILXHAG........................................................................................................................... 30
5.
REGNATOILB........................................................................................................................... 30
5.6
LGPSTRNIUCOM........................................................................................................................... 30
5.7
LGSTICOUM.N: .......................................................................................................................... 31
5.8
REGENERATION PROCESS TROUBLE SHOUTING................................................................32
15.8
PSTRNIGAFLOWE........................................................................................................................... 32
25.8
PSTRNIGAUCOMLDE(TR.) .......................................................................................................................... 33
CONTACTOR
DESIGN..................................................................26
NEW CHILLING UNIT................................................................................34

6.1
REFRIGERANT
6.2
PROPANE RECEIVER................................................................................................. 34
6.3
PROPANE COMPRESSOR............................................................................................ 35
6.4
PROPANE CONDENSER.............................................................................................. 35
6.5
PROPANE ECONOMIZER VJ-4003:...............................................................................36
6.6
GAS/PROPANE HEAT EXCHANGER EJ-4003...................................................................36
002/AR11/12
FLUID SELECTION..................................................................................34
NO.
REV.
0
PAGE: 6 / 63
6.7
GAS/GAS OUTLET COLD SEPARATOR HEAT EXCHANGER EJ-4001A...................................37
6.8
GAS/LIQUID HEAT EXCHANGER EJ-4002......................................................................37
6.9
COLD SEPARATOR.................................................................................................... 37
7.
NITROGEN SKID......................................................................................38
8.
SIZING OF PIPELINE................................................................................39
9.
CONCLUSION..........................................................................................42
10. APPENDICES........................................................................................... 44
10.1
APPENDIX 1:
RECIRCULATION RATE OF
10.2
APPENDIX 2:
AMINE CONTACTOR DIAMETER CALCULATION..............................................44
10.3
APPENDIX 3:
AMINE REGENERATOR DIAMETER CALCULATION..........................................44
10.4
APPENDIX 4: GPSA
10.5
APPENDIX 5: NORSOK STANDARD FOR SIZING OF GAS LINE...............................46
10.6
APPENDIX 6: AMINE UNIT HEAT EXCHANGERS TEMA SHEETS..............................47
10.7
APPENDIX 7: GLYCOL UNIT HEAT EXCHANGERS TEMA SHEETS............................49
10.8
APPENDIX 8: CHILLING UNIT HEAT EXCHANGERS TEMA SHEETS.........................52
10.9
APPENDIX 9: STRIPPING GAS COLUMN DESIGN...................................................56
STANDARD FOR
DEA
TEG
SOLUTION..................................................44
CONTACTOR SIZING........................................45
10.10 TIE-IN PROCEDURE TO ADD AMINE FLASH VAPOR TO STRIPPING GAS PROCESS
58
002/AR11/12
NO.
REV.
0
PAGE: 7 / 63
1. INTRODUCTION
1.1GENERAL
El-Bibane offshore wells are located at about 18 km far from the CPF (the
onshore central processing facility) situated on the town of Zarzis.
Presently, El-Bibane field is operating as described below:
-
Producing from the offshore well EBB#5,

Gas injection in the offshore well EBB#4,
The well EBB#3 RE 2 is temporary closed.
The production is handled to the CPF through an 8 sea line and the treated gas
is rerouted from the CPF to be re-injected through 6 sea line.
Figure 1: The Onshore Wellheads Configuration

1.2PROJECT DETAILED SCOPE
The main engineering tasks for this project can be summarized into three (3)
parts as follows:
1/ Feasibility study for selling 1/3 of gas production and injection of the
remaining quantity:
-
Prepare the required simulations to sell 4-5 MMSCFD and inject 9-11
MMSCFD of gas in order to recover condensate.
Define the required process modifications for the first phase.
Perform needed calculations for modified or potential additional required

equipments.
002/AR11/12
NO.
REV.
0
PAGE: 8 / 63
Develop the cost estimation for the related modifications.
Based on the recovered condensate quantity and the gas sales, develop
the first phase economic analysis.
2/ Feasibility study for selling the total gas production:

-
Prepare the required simulations for treatment of 15 MMSCFD of gas to

the sales specification: the total gas production will be sold and no reinjection to be considered. Thus, no condensate recovery optimization to
be considered other than the gas treatment required to meet commercial
specifications. Condensate recovery will still be possible and it will be sold
separately.
Define the required process modifications for the second phase.
Perform needed calculations for modified or potential additional required

equipments.
Develop the cost estimation for the related modifications.
Based on the gas sales develop the second phase economic analysis.
As an alternative economic option, one analysis will be made for the

implementation of the required modifications on the facilities to treat the
complete 15 MMSCFD in one time and to start treatment of only 4-5
MMSCFD in the first phase and use the remaining quantity to recover
condensate.
3/ Feasibility study for sales gas transportation

-
Assessment of the different types of gas transportation methods, depend

on the tie-in point location and gas characteristics. The option of
transportation of non treated gas will be also assessed.
Prepare the required simulations/hydraulic calculations for transport of

15 MMSCFD of gas to a tie-in point to the STEG network.
Based on the gas sales develop an economic analysis.
The present report is devoted to the first phase; the feasibility study for
selling 1/3 of gas production and injection of the remaining quantity.
1.3DOCUMENT SCOPE
The objective of this document is to check the operability and the adequacy of
the existing facilities and to size required additional equipments on both CPF
002/AR11/12
NO.
REV.
0
PAGE: 9 / 63
and other units relevant to El Bibane Field Development Project. This study has
been carried out for a total gas production of 15MMSCFD, case of selling 1/3 of
gas production and injecting the remaining quantity in order to recover
condensate.
1.4DEFINITIONS & ABBREVIATIONS
1.4.1DEFTINOS
For the purpose of this document the following definitions shall apply:
Owner/Client
ECUMED Petroleum
Contractor
EPC contractor
Engineering company
Engineering
Procurement
and
Project
Management (EPPM)
Project
El Bibane-Detail Engineering for Gas Cycling

Production Pilot Project
Supplier/ Vendor
The
party
(s)
supplies
which
manufactures
equipment,
and/or
technical
Documents/drawings and services to perform the

duties specified
1.4.2 ABREOVITNS
The following abbreviations will be used:
BHP
CPF
EBB#
EOS
HP
HHV
JT
LP
PCV
PFD
SEEB
:
:
:
:
:
:
:
:
:
:
:
Bottom-Hole Pressure
Central Processing Facility
El Bibane Wellhead number
Equation of State
High Pressure
Higher Heating Value
Joule Thomson
Low Pressure
Pressure Control Valve
Process Flow Diagram
Electricity Company of El-Bibane ( Socit dElectricit El-
STEG
Bibane )
Tunisian Company of Electricity and Gas ( Socit Tunisienne
TEG
dElectricit et de Gaz)
Tri Ethylene Glycol
1.5UNITS OF MEASUREMENT
002/AR11/12
NO.
REV.
0
PAGE: 10 / 63
In general, SI units will be used. However, there are recognized exceptions and
preferred units that are used in the Oil & Gas industry.
Table 1: Units of Measurement
Measured Quantity
Corrosion Allowance
Preferred Unit
Millimeters
Designation
mm
Density
kilogram per cubic meter
kg/m3
Ampere
milli-ampere
mA
Volt
Watt
Kilowatt
kW
Megawatt
MW
Electric Resistance
Ohm
Ohm
Enthalpy
Kilo Joule per kilogram
kJ/kg
Force
Newton or kilo Newton
N or kN
Frequency
Hertz
Hz
Head
Meters
Heat Loading
Heat Transfer
Coefficient
Latent Heat
Kilowatts
watts per square meter per
degree Celsius
kilo Joules per kilogram
kW
Length
millimeters, meters, kilometers
mm, m, km
Luminance
Lux
Lx
Mass
Kilogram
kg
Mass Flow Rate
kilogram/hour
kg/h
Mechanical Power
kilowatts, megawatt
kW, MW
Diameter
In
Stress
Inches
bar gauge, bar absolute,
Kilopascal
revolutions per minute
kilocalories per Standard cubic
meter
kilojoules per kilogram degree
Celsius
Newton per square meter
Temperature
degree Celsius
Thermal Conductivity
watt per meter Celsius
W/m C
Time
y, d, hr, min, s
Vessel Dimensions
year / day/hour/minute /second

meters per second or meters
per hour
meters, millimeters
Volume (actual)
cubic meters
m3
Standard Gas Volume
Standard cubic meter
SCM (Note 1)
Electric Current
Electric Potential
Electric Power
Pressure
Rotational Speed
Lower Heating Value
(LHV)
Specific Heat
Velocity
002/AR11/12
W/m2 C
kJ/kg
barg, bara, kPa

RPM
kcal/SCM
kJ/kg C
N/m2
m/s, m/h
m, mm
Measured Quantity
Volume Gas Flow
Volume (liquid)
Volume Flow (liquid)
Pipe/Nozzle sizes
Dynamic Viscosity
Kinematic Viscosity
NO.
REV.
0
PAGE: 11 / 63
Preferred Unit
meter /day (per hour)
Million Standard cubic feet/day
Cubic meter
Cubic meter/ hour
Cubic meter/ day
Barrel/day, Barrel Oil/day, Barrel
Water/day, Barrel
Condensate/day
Inches
Designation
SCMD (SCMH)
MMSCFD
m3
Centipoises
cP
Centistokes
cSt
m3/h
m3/day
BPD, BOPD,
BWPD, BCPD
In
Standard conditions are 1.01325 bara at 15.56C.

Normal conditions are 1.01325 bara at 0C.
2. DESIGN DATA
2.1ENVIRONMENTAL DATA
2.1.1CTLIMCANDMEORGCTIS
El-Bibane weather is characterized by moderate winter and smoother summer;
meanwhile some occasional storms may occur.
Onshore Data:
Wind Direction and speed:

Dominant wind direction ENE.
Maximum wind speed:
One hour wind speed: 130 km/h.
One minute wind speed: 164 km/h.
Design Ambient Temperatures:
Mean minimum air temperature: 0 C;
Mean maximum air temperature: 32 C;
Maximum air temperature: 50 C.
Relative Humidity: 60-68%
Air pressure: 14.73 psia.
Rainfall:
Minimum monthly rainfall: 1 mm.
Maximum monthly rainfall: 41 mm.

Offshore Data:
Minimum seabed temperature: 13 C;

002/AR11/12
Still water level (average): 7.0 m;
Maximum centenary wave height: 5.5 m;
Swell height : 3.5 m
Period associated with maximum wave: 12.1 s;
Maximum tide elevation above still water: +1.1 m;
One hour wind speed: 130 km/h;
One minute wind gust: 164 km/h;
Surface current speed: 1.1 m/s;
50% depth current speed: 0.9 m/s;
Bottom current speed: 0.5 m/s;
Conductivity (20C): 50 mS/cm.
NO.
REV.
0
PAGE: 12 / 63
2.1.2GROUNDALSICT
The offshore soil properties are investigated by pressure-metric survey, the main
results could be summarized in the following table:
Table 2: El-Bibane Offshore Soil Profile
Depth
Soil Type
Effective
Limit
Pressure
Sub-Grade
Modulus
Friction
Angle
Sandstone +
35 bars
700-1000
30-35
Hard
Silt
40 bars
1000-1100
35-40
12m-20m
sandstone
The Seismic Zone: zone 0

2.2WELLS LOCATION
The table given below indicates wells location.
Table 3: Wells Location
Well
Statu
s
UTM x
(m)
UTM y
(m)
EBB#3RE2
(Horizontal)
None
713942
3702310
Same
as
unknown.
EBB#4
(Horizontal)
Inject
or
713570
3702746
Intersection of M82-1046 and M84-20.

Deviation unknown.
002/AR11/12
Remarks
EBB#3RE.
Deviation
EBB#5
Produ
cer
714321
3703214
NO.
REV.
0
PAGE: 13 / 63
Intersection of M82-1025 and M84-20

close to EBB#1. Subject to change.
Appendix 1 shows a schematic of the CPF and wellheads positions.

2.3PROCESS DESIGN DATA
2.3.1WELHADPRMTS
The table given below illustrates wellhead process parameters.
Table 4: Wellheads Process Conditions
Parameter
Pressure
(after
choke
valve) (barg)
Injection pressure(barg)
Temperature (C)
Design
Flow
rate
(MMSCFD)
EBB#5
EBB#4
wellhead
wellhead
36
64
158
-
10
10
2.3.2COMTPSIN
EBB#5 fluids compositions inlet and outlet HP separator are detailed in process
simulation reports
2.4CPFDESIGNARMT
The design parameters of the CPF are illustrated in the following table:
Table 5: CPF Design Parameters
Parameter
Equipment
HP
Separator(V1001)
V-100
V-101
Glycol Contactor (T710)
Gas/Gas Heat
Exchanger (EJ-4001)
Cold
4001)
002/AR11/12
Separator
(VJ-
Design
Pres. (barg)
Design
Temp. (C)
100
50
41.4
46
100
97.5
-29 to 65.5
Shell/Tube
Shell/Tube
Tubes: OD, 14
75.8/75.8
121.1/121.1
BWG, Length=40 ,
69.98
-45.5 to 51.6
Capacity/Dimensio
ns
60 OD 20
Length
36 OD 28
Length
22 Shell Diameter
No. 350
40 OD 120
Length
NO.
REV.
0
PAGE: 14 / 63
Equipment
Compress
or (K-400
A/B)
Parameter
First
Stage
Second
Stage
Design
Pres. (barg)
Suction/discha
rge
30/84.5
Suction/discha
rge
84.2/228
Heater (H-102)
Design
Temp. (C)
Capacity/Dimensio
ns
Outlet Temp. 55C
2.5GASREQUDISPFCTON(TEGIA)
The required sales gas specifications are summarized in the table below:
Table 6: Required Gas Specifications
Parameter
Unit
Value
Higher Heating
Value
kcal/Nm3
9300 10228
Wobbe Index
kcal/Nm3
11961 12640
Water content
(ppm)
<= 80
H2S content
Sulfur content
Gas temperature
CO2 content
H2
and
content
O2 content
N2
mg/Nm
<2
mg/Nm
< 50
10 50
% mol
< 0.5
% mol
<6
% mol
3. CALCULATION METHODS
3.1PROCESS DESIGN TOOLS
The software HYSYS (version 7.3) is used for the process simulation under
steady state conditions.
Schlumbergers PIPESIM modeling Software version 2009 is used for process
calculation and hydraulic simulation for the study at steady state for the pipeline
connecting the piping outlet the CPF with the tie-in point on the STEG gas
network.
3.2THERMODYNAMICS
The simulations have been performed based on Amine package in amine unit
simulation and Peng/Robinson EOS using the binary coefficient data provided
by HYSYS.
3.3MODEL DESCRIPTION, BATTERY LIMITS AND ASSUMPTIONS
002/AR11/12
NO.
REV.
0
PAGE: 15 / 63
3.3.1FUIDLRESVO
The gas and oil compositions (Appendix 2) respectively inlet and outlet the HP
separator are recombined and reintroduced as a feed stream. Hence the
separated gas composition is given in the table below:
Table 7: Estimated separated Gas composition
COMPONENTS
CO2
Nitrogen
Methane
Ethane
i-Butane
n-Butane
i-Pentane
n-Pentane
n-Hexane
Propane
Benzene
Cyclohexane
2-Mpentane
3-Mpentane
2-Mheptane
Toluene
n-Heptane
n-Octane
n-Nonane
2-Mhexane
MOLE FRACTION
0.0177
0.0172
0.8256
0.0783
0.0067
0.0098
0.0037
0.0031
0.0015
0.0336
0.0002
0.0002
0.0007
0.0003
0.0001
0.0001
0.0007
0.0001
0.0001
0.0002
3-Mhexane
0.0001
3.3.2WELHADS
The wellhead stream from EBB#5 conditions are as follows:
o
Maximum operating pressure: 148 barg.
Operating pressure: 35 barg.
Built up pressure: 160 barg.
Operating temperature: 64C.
An automatic/electric choke valve is used to adjust the well stream flow rate and
the pressure which will define the optimal CPF inlet pressure.
The injected gas in EBB#4 is at pressure 158 barg.
3.3.3PPELIN
A roughness of 45.7 m (Carbon steel) will be used for the pressure loss
002/AR11/12
NO.
REV.
0
PAGE: 16 / 63
calculations.
A thermal conductivity of the pipe material of 45 W/m.K will be assumed.
3.3.4FRSTISEPAON
The CPF inlet production is carried into the HP three phases separator (V-1001)
as a first removal of water and condensate. This separator has a design pressure
of 100 barg which can limit the CPF inlet pressure. The gas at the inlet of
separator is considered at 31 barg and 31C.
3.3.5AMINEUT
In order to remove carbon dioxide from inlet gas, an amine unit is foreseen
downstream HP three phase separator (V-1001).
The Amine unit will be designed to treat 16 MMSCFD of gas with 1.77 mol %
CO2, by circulating lean amine solution (30 wt% DEA) through the contactor to
remove carbon dioxide from inlet gas and satisfy the customers requirement of
0.5% CO2.
Rich amine from the bottom of the Contactor is flashed from
approximately 32 bara to 5 bara through a level control valve and sent to the
Amine Flash Drum to separate the hydrocarbon gas from DEA solution. The rich
DEA is heated to approximately 75C by the Rich/Lean Amine Exchanger and
then fed to the Amine Regenerator. The lean amine is cooled through the
Rich/Lean Amine Exchanger and pumped via the Amine Booster Pumps to the
Lean Amine Air Cooler and then through lean amine filters. The lean amine is
cooled to approximately 40C and routed back to the Amine Contactor after
adjustment of amine solution flow rate and composition by the water make-up.
3.3.6GLYCODEHTRINAU
In order to prevent hydrate formation, a TEG contactor unit is foreseen
upstream of the J-Thomson condensate removal unit.
In order to prevent hydrate formation, a TEG contactor unit is foreseen
upstream of the J-Thomson condensate removal unit.
The sweet gas from the Amine Contactor is routed to the Glycol contactor (T710) near its bottom and flows upward through the bottom tray to the top tray
and out at the top of the column. Lean glycol is fed at the top of the column and
its flows down from tray to tray, absorbing water vapor from gas. The Contactor
operates at @ 50 C and 30 bara with a lean TEG. Dehydrated gas from the
002/AR11/12
NO.
REV.
0
PAGE: 17 / 63
Contactor overhead is heated through the Gas/Glycol Heat Exchanger (E-310) to

55 C and routed to the J-Thomson unit to recover condensate.
Rich TEG from the contactor (T-710) will be preheated through the overhead
condenser on the glycol stripper still column and flashed to approximately 4.4
bara in the glycol flash tank (V-120). The flashed gas is sent to the flare network.
The rich TEG is next filtered before entering the Glycol reconcentrator (H-410)
to remove the absorbed water. The lean TEG separated from water is cooled in
the Air/Glycol heat exchanger (E-320) and pumped through two Glycol pumps
(P-510A/B) to the Gas/Glycol heat exchanger (E-310) for further cooling before
returning to Glycol contactor T-710.
3.3.7CONDESATRMVLUI
In order to remove any condensate, the gas should pass through a liquid
removal unit by reduction of temperature by using a Joule-Thomson expansion
unit. The condensate removal unit consists of the following items:
Heat Exchanger (EJ-4001): gas/gas heat exchanger
The heat exchanger design pressure is 75 barg for both shell and tubes side
which will limit the maximum operating pressure before the Joule-Thomson
expansion.
JT-Valve (PCV-4001)
The expansion pressure 30 barg is considered the lowest value reached by the
valve and which define the compressor first stage suction pressure. Actually the
JT valve is fully opened.
Separator (VJ-4001)
It is provided to separate gas from the formed condensate after pressure
expansion.
The figure given below shows a schematic of the condensate removal unit.
002/AR11/12
Wet Gas
Heat Exchanger
Gas/Gas
Dry Gas
002/AR11/12
NO.
REV.
0
PAGE: 18 / 63
NO.
REV.
0
PAGE: 19 / 63
Figure 2: Condensate removal unit (J-Thomson unit)

3.3.8IENCTJIOGASCMPR
A multistage injection gas compressor is simulated to increase the injection gas
pressure from 30 barg to approximately 158 barg via two stages compressor. At
the level of the compressors scrubbers, the possible formed condensate is
recycled to the MP separator (V-100).
3.3.9CONDESATSLBIZ
The removed condensate from different CPF units is sent to conventional two
phases separators (V-100 & V-101) requiring a long residence time for
condensate stabilization. Then the heated condensate flowing from the heater
(H-102) is sent to the storage tanks (T-101 A/B).
The recuperated quantity of condensate shall be stabilized at a suitable process
operating conditions.
002/AR11/12
NO.
REV.
0
PAGE: 20 / 63
The HYSYS flowsheet of the CPF considering the new configuration is shown in the following figure.
Figure 3: HYSYS PFD of the CPF
002/AR11/12
04/10
NO.
REV.
0
PAGE: 21 / 63

The sub-flowsheet of Amine Unit is modeled as shown in this figure:
Figure 4: The Amine Unit Modeled Flow sheet
002/AR11/12
04/10
NO.
REV.
0
PAGE: 22 / 63

The sub-flowsheet of Dehydration Unit is modeled as shown in this figure:
Figure 5: The TEG Unit Modeled Flow sheet
002/AR11/12
04/10
NO.
REV.
0
PAGE: 23 / 63
4. DESIGN OF THE NEW AMINE UNIT

4.1 SELECTION FACTORS FOR THE TYPE OF AMINE
The choice of the process solution is determined by the pressure and temperature
conditions at which the gas to be treated is available, its composition with respect to
major and minor constituents, and the purity requirements of the treated gas.
MEA: eliminates simultaneously and non-selective hydrogen sulfide and carbon
dioxide. It is inexpensive. However, it has several drawbacks. First, it reacts in an
irreversible manner with mercaptans. In addition, its vapor pressure is relatively
high, resulting in greater losses compared to other amines. For these reasons, it is
mainly used when the concentration of acid gases is relatively low, therefore we
cannot use it.
DGA: It is more expensive than the DEA and has also the disadvantage of
hydrocarbons absorption, therefore we cannot use it.
DIPA: applications mainly concern the treatment of gas containing COS, as well as
the recovery and recycling of H2S.
The two types of amines commonly used for removal of CO 2 from natural gas are
DEA and MDEA.
The main selection factors of types of amines for the purification of natural gas are
listed hereby:
-
CO2 Selectivity
Kinetics of reaction with CO2
Corrosivity
Amine consumption and price
Amine degradation
Thermodynamics of reaction with CO2
4.2CO2 SELECTIVITY
Selectivity is a balance between the mass transfer rates of the acid gases competing
for the amine in the solvent. The less reactive the amine, the better the selectivity
MDEA is fairly selective towards H2S removal gases containing both H 2S and CO2
because it does not react directly with CO2. In such case, DEA is the best solution.
002/AR11/12
04/10
NO.
REV.
0
PAGE: 24 / 63
4.3KINETICS OF REACTION WITH CO2

The reaction between CO2 and DEA amines is significantly faster than the reaction
between CO2 and MDEA, therefore the DEA is favored kinetically.
4.4CORROSIVITY
The DEA is more corrosive than MDEA but in this case the corrosion is not an
important factor for the selection of the amine type because the existing facility is
sized for the most corrosive amine type.
4.5AMINE CONSUMPTION AND PRICE
The boiling temperature of DEA is higher than that of MDEA therefore the losses of
amine are greater for the case of MDEA.
The DEA is less expensive than MDEA; therefore the DEA is favored according to
price factor.
4.6THERMODYNAMICS OF REACTION WITH CO2
Both
types
of
amine
solutions
are
almost
total;
therefore
they
are
thermodynamically favored. However, the MDEA does not react directly with CO 2;
therefore its conversion rate is lower compared to DEA conversion rate.
Hence in this case the DEA is thermodynamically favored.
To summarize, as per Selectivity for CO2, Price of amine, Kinetics of reaction with
CO2, Corrosivity, Amine degradation and Amine consumption, and thermodynamics
of reaction with CO2, the performed amine for the gas treatment is the DEA.
The criteria of choice of the type of amine are summarized in the following table:
Table 8: criteria of choice of the type of amine
Choice criteria
002/AR11/12
DEA (30)
MDEA (40%)
Selectivity for CO2
Thermodynamic
Price of amine
Kinetics of reaction with
CO2
Corrosivity
Amine degradation
04/10
Choice criteria
Amine consumption
NO.
REV.
0
PAGE: 25 / 63
DEA (30)
MDEA (40%)
Therefore we have chosen to use the DEA solution for natural gas treatment.
4.7MAIN EQUIPMENTS SIZING
4.7.1DETNRMOAIFLWE
The method to calculate the minimum amine flow rate in case of DEA solution is
shown in Appendix 1.
The main outcomes are summarized in the following table:
Table 9: amine flow rate calculation

Parameter
Actual Process
scheme
MM
15
Xa
(1.77 0.5)/1.77 =
0.717
8.59
ML
0.3
WT
30
DEA recirculation rate

(USGPM)
26.73
DEA recirculation rate

(m3/h)
6.07
For amine solutions with DEA, the minimum capacity of lean amine circulation
pumps for the actual process scheme shall be over than 6.07 m3/h.
Using the chemical reaction, to eliminate the acid gas the amine molar flow shall be
twice of the CO2 flow rate, in this case the DEA circulation rate is equal to 10.47
m3/h using a correction factor of 10%.
4.7.2SZINGOFCO2ABSRE
The method for calculating the diameter of the absorption column is shown in
Appendix 2.
002/AR11/12
04/10
NO.
REV.
0
PAGE: 26 / 63
The main design data are illustrated in the following table:

Table 10: CO2 Absorber Design Data
Parameters
Value
Gas processed flowrate (MMSCFD)

Gas
processed
flowrate
16
(MMSCMD)
Contactor pressure (kPaa)
Contactor diameter (m)
0.453
3200
0.962
The main HYSYS simulation results for the CO 2 absorber are illustrated in the
following table:
Table 11: CO2 Absorber Main Sizing Results
Parameters
Value
Gas processed flowrate (MMSCFD)
15.95
Contactor pressure (bara)
32
Number of stages
10
Absorber diameter (m)

Section height (m)
Tray spacing (m)
Amine solution liquid volume flow
(m3/h)
Mol % CO2 inlet contactor
Mol % CO2 outlet contactor
0.762
6.1
0.61
10.47
1.772
0.304
Considering the above calculation results, the sizing results of the worst case are
considered:
Table 12: Results of sizing of absorption column
Design Parameter
Diameter of column (m)
Value
0.962
Height of column (m)
6.1
Number of plates
10
4.7.3AMINERGATO
The method for calculating the diameter of the regeneration column is shown in
Appendix 3.
Tacking in consideration the design capacity of the recirculation pump of 10.47
m3/h; the minimum diameter of the amine regenerator column should be of 517.72
mm.
002/AR11/12
04/10
NO.
REV.
0
PAGE: 27 / 63
The main HYSYS simulation results for the Amine regenerator are illustrated in the
following table:
Table 13: Amine Regenerator Main Sizing Results
Parameters
Value
amine processed volume flow (m /h)

Fraction of CO2 in reach amine
10.47
outlet
1.62
absorber (mol %)
Regenerator pressure (bara)
1.5
Number of stages
10
Regenerator diameter (m)
0.609
Section height (m)
6.1
Reboiler duty (MMBTU/h)

Fraction of CO2
4.529
outlet regenerator (mol %)
0.2
Considering the above calculation results, the sizing results of the worst case are
considered:
Table 14: Results of sizing of regenerator column
Design Parameter
Value
Diameter of column (m)
0.61
Height of column (m)
6.1
Number of plates
10
4.7.4LEANMICRULOTPS
The data of lean amine circulation pumps are summarized in the following table:
Table 15: Data for lean amine circulation pumps calculation
Design Parameter
Unit
Value
Volume flow for the amine solutions
m /h
10.47
Suction pressure
bara
1.4
Discharge pressure
bara
32.2
Vapor pressure
bara
Mass density
Kg/m
0.43
3
1009
Sizing results are shown in the table given bellow:

Table 16: Lean amine circulation pumps main design parameters
Design Parameters
002/AR11/12
Unit
Value
Hydraulic power
kW
8.214
Electrical power
kW
14
04/10
NO.
REV.
0
PAGE: 28 / 63
Design Parameters
HMT
Unit
Value
mCE
302
4.8SNIZGOFTHEACXR
4.8.1SZINGOFLEAMRC
The sizing of the lean amine air cooler is performed using the software HTFS.
The data of lean amine air cooler are summarized in the following table:
Table 17: Calculation data of lean amine air cooler
Design Parameter
Unit
Temperature of amine solution inlet air
C
cooler
Temperature of amine solution outlet air
C
cooler
Amine solution flow rate
Kg/h
Air cooler inlet pressure
Value
80
40
9623.16
bar
32.2
Sizing results are mentioned in the table given bellow:

Table 18: Lean amine air cooler main design parameters
Design Parameter
Unit
Value
Tubes per bundle
45
Tube passes
4
2
Area required
Tube length
745
9.74
See TEMA sheet of amine air cooler in appendix 6.
4.8.2SZINGOFCRH/LEAMTXNGR
The sizing of the rich/lean amine heat exchanger is performed using the software
HTFS.
The data of rich/ lean amine heat exchanger are summarized in the following table:
Table 19: Calculation data of lean/rich amine heat exchanger
Design Parameter
Unit
Value
Temperature of rich amine inlet heat exchanger

Temperature of rich amine outlet heat
exchanger
Temperature of lean amine inlet heat exchanger
40.25
75
112
Kg/h
10055.72
Rich amine flow rate
002/AR11/12
04/10
NO.
REV.
0
PAGE: 29 / 63
Design Parameter
lean amine flow rate
Heat exchanger inlet pressure
Unit
Value
Kg/h
9623.16
bar
Sizing results are mentioned in the table given bellow:

Table 20: Calculation results of lean/rich amine heat exchanger
Design Parameter
Tube passes
Unit
Value
2
2
Area required
Tube length
7.1
3.048
See TEMA sheet of rich/ lean amine heat exchanger in appendix 6.

4.8.3SZINGOFREATCDS
The data of condenser are summarized in the following table:
Table 21: Design parameters of amine condenser
Design Parameters
Unit
Value
Temperature inlet condenser
99.5
Temperature outlet condenser
60
Condenser inlet pressure
bar
1.2
kg/h
MMbtu/
hr
1525.12
flow rate
Heat duty
2.26
4.8.4SZINGOFREATBL
The data of Regenerator Reboiler are summarized in the following table;
Table 22: Reboiler main design parameters
Design Parameters
Temperature inlet Reboiler
flow rate
Unit
Value
112.5
11598.5
2
1.6
kg/h
Reboiler inlet pressure

Heat duty
bar
MMbtu/
hr
4.472
4.8.5SZINGOFAMELSHDRU
The sizing of amine flash drum is determined by referring to standard DEP.
The data of amine flash drum are summarized in the following table.
Table 23: Amine flash drum input data
002/AR11/12
04/10
Design Parameters
Mass flow rate
Unit
Inlet vessel
kg/h
9717.08
Volumetric flow rate
m /h
Pressure
bara
11.23
3
Temperature
40
Mass density
kg/m3
NO.
REV.
0
PAGE: 30 / 63
Liquid outlet
9661.4
Gas outlet
55.68
1.87
9.36
40
40
1084
1.593
The results of sizing are summarized in the following table:

Table 24: Amine flash drum sizing results
Design Parameter
Unit
Value
Diameter
0.75
Length
3.37
5. REVISION OF TEG UNIT DESIGN

5.1REVISION OF TEG CONTACTOR DESIGN
Using GPSA standard
The review of the TEG contactor is performed using the GPSA standard, the
calculation procedures are attached in Appendix 4.
The integral scrubber is already modeled as per the actual process scheme.
The table below shows integral scrubber dimensions:
Table 25: integral scrubber dimensions
Parameter
Unit
Value
Diameter
0.9144
Height
2.286
The following data are considered for contactor sizing:
Table 26: Glycol contactor Input parameters
002/AR11/12
04/10
Parameter
NO.
REV.
0
PAGE: 31 / 63
Value
Contactor operating pressure

(bara)
Gas density (kg/m3)
23.65
Liquid density (kg/m3)
1106
Gas flow rate (Sm3/h)
18630
30
The main results are summarised in the following table:

Table 27: Glycol contactor Main Results
Parameter
Value
The water content inlet contractor

(mg/Sm3)
2835.19
The water content outlet

contractor (mg/Sm3)
Water removal (kg/h)
133.93
50.32
Glycol flowrate (m3/hr)
0.78
Diameter (m)
0.84
Number of trays
Tray spacing (m)
0.61
Absorber height (m)
4.88
Using HYSYS simulation
A HYSYS simulation performed to model the actual contactor T710 including its
diameter, internals (bubble cap trays) estimate the TEG contactor size considering
the following input data:
Table 28: Glycol contactor main simulation Input data
002/AR11/12
04/10
Parameter
NO.
REV.
0
PAGE: 32 / 63
Value
Contactor pressure (bara)
30
Gas Temperature inlet

contactor (C)
Maximum Glycol flowrate
(m3/hr)
Gas processed flowrate
(MMSCFD)
45
0.8
15.77
Absorber diameter (m)
0.914
Bubble Cap
Trays
Trays type
Number of trays
Section height (m)
4.877
Tray spacing (m)
0.61
The main Simulation results are shown in the following table:

Table 29: Glycol contactor Main sizing Results
Parameters
Water
(kg/h)
Water
(ppm)
Water
(kg/h)
Water
(ppm)
Value
content inlet contactor
50.17
content inlet contactor
3235.8
content outlet contactor
1.71
content outlet contactor
111.3
The water content downstream the Glycol contactor T-710 is 111.3 ppm, It doesnt
comply with STEG requirement (Wc <80 ppm), for this raison a design review of
regeneration unit with the expected gas flow rate is made available in next
paragraph.
5.2CURRENT TEG REGENERATION UNIT DESIGN
5.2.1GLYCOFASHTNKPERIGDMOSN
The data of Glycol flash drum are summarized in the following table.
Table 30: Glycol flash drum operating data
Design Parameters
Mass flow rate
Temperature
002/AR11/12
Unit
Inlet vessel
kg/h
873
3.93
80
m /h
C
Liquid outlet
870
Gas outlet
3
0.813
2.577
80
80
04/10
NO.
REV.
0
PAGE: 33 / 63
Design Parameters
Mass density
Unit
kg/m
Inlet vessel
Liquid outlet
1070
257.5
Gas outlet
1.168
The dimensions of Glycol flash drum are summarized in the following table:
Table 31: Glycol flash drum dimensions
Diameter
Existing
Value
0.406
Length
1.5
Design Parameter
Unit
5.2.2HEATXCHNGRSIPUD
5.2.2.1
AIR/GLYCOHETXNE320
The data of Glycol air cooler are summarized in the following table.
Table 32: Calculation data of Glycol air cooler
Design Parameter
Unit
Value
Temperature of glycol inlet air cooler
187.4
Temperature of glycol outlet air cooler
140
Glycol flow rate
Kg/h
897.9
Air cooler inlet pressure
bar
Btu/
hr
1.103
Duty
5.2.2.2
120000
GLYCO/HEATXNR
The data of rich glycol/lean glycol heat exchanger are summarized in the following
table.
Table 33: Calculation data of glycol/ glycol heat exchanger
Design Parameter
Temperature of lean glycol inlet heat
exchanger
Temperature of
lean glycol outlet heat
exchanger
Temperature of rich glycol inlet heat
exchanger
Temperature of
rich glycol outlet heat
exchanger
heat exchanger inlet pressure
5.2.2.3
Unit
Value
199.8
188
70
80
bar
5.5
GLYCOREN/DASMIZ
The data of glycol regen/dry gas economizer are summarized in the following table:
002/AR11/12
04/10
NO.
REV.
0
PAGE: 34 / 63
Table 34:Glycol regen/Dry gas economizer heat exchanger data

Design Parameter
Unit
Temperature of
glycol regen inlet heat
C
exchanger
Temperature of
glycol regen outlet heat
C
exchanger
Temperature of dry gas inlet heat exchanger
C
Value
139
54
48
Temperature of dry gas outlet heat exchanger
53.4
heat exchanger inlet pressure
bar
30.1
5.3GLYCOUMPS
The data of glycol pumps are summarized in the following table:
Table 35: Data for Glycol pumps sizing
Design Parameter
Unit
Value
Volume flow for the glycol
GPH
210
Suction pressure
bara
1.1
Discharge pressure
bara
30
138
Suction temperature
Vapor pressure
Mass density
bara
Kg/m
1.18
3
1087
5.4CONDESRCILXHAG
The data of condenser are summarized in the following table:
Table 36: Main Design parameters of Glycol unit condenser
Design Parameters
Type
Heat duty
Unit
Value
Coil exchanger
Btu/hr
47250
5.5REGNTROARBLI
The data of Regenerator Reboiler are summarized in the following table;
Table 37: Reboiler main design parameters
Design Parameters
Type
Heat duty
002/AR11/12
Unit
Btu/hr
Value
Fired heater
exchanger
480000
04/10
NO.
REV.
0
PAGE: 35 / 63

5.6LGSTRNIPUCOML
The lean glycol downstream the reboiler passes through the Lean Glycol
Stripping Gas Column that contacts the lean glycol with dry gas from flash drum,
further removing water from the glycol to the higher purities required by this
operation, the main design data for the LG stripping gas are summarized in the
following table:
Table 38: LG stripping gas data
Unit
Value
psia
20
Inlet temperature
80
Column outer diameter
0.273
Column height
1.4
Internals
packed
Packing Type
1 random packing
pall rings
Design Parameters
Inlet pressure
5.7LGLSTICOUMN:
The vapors leaving the glycol reboiler are contacted with cooler liquid on random
packing in the TEG still column and are further cooled by the still column condenser
to provide reflux to minimize glycol losses out of glycol reboiler.
Table 39:LG still column data
Design Parameters
Unit
Value
psia
16
Inlet temperature
80
Column outer diameter
0.355
Column height
3.81
Internals
packed
Packing Type
1 random packing
pall rings
Inlet pressure
The maximum allowable reboiler stage temperature in the distillation column is

204.4c in order to avoid glycol characteristics degradation. the purity of the
regenerated glycol downstream of regeneration column is 96.25% , this leads to a
002/AR11/12
04/10
NO.
REV.
0
PAGE: 36 / 63
higher water content in the dry gas stream leaving the contactor. The lower purity is
the higher dry gas water content is.
The next step is to perform the regeneration process trouble shouting as long as
the lean glycol purity is low.
the following regeneration parameters has to be reviewed to improve regenerated
glycol purity:
stripping gas flowrate

stripping gas column design
still column design
5.8 REGENERATION PROCESS TROUBLE SHOUTING
5.8.1 STPRINGAFLOWE
when increasing stripping gas flowrate
feeding LG stripping column , it will
condense the heavier component ( TEG ) in the stream leaving reboiler stage ,and
the water vapour goes back to the still column and will be rejected from the top, as
a result the regenerated glycol purity is improved.
The proposed solution is to add additional amounts of stripping gas coming from
amine flush drum to the existing one coming from glycol flash tank.
The following process scheme shows the glycol purity improvement , to bring it
from 96.2% to 98.65% when increasing stripping gas flowrate.
002/AR11/12
04/10
NO.
REV.
0
PAGE: 37 / 63
The new regenerated glycol purity 98.65% is sweet able decrease the dry gas water
content from 111.3 ppmH2o to 64.4 ppmH2o so that it meets closely the STEG
requirement ( < 80 ppmH2o ).
The following process flow scheme shows the main simulation results using the
improved regenerated TEG purity.
The stripping gas column diameter shall be reviewed since the feed gas flowrate
increased
5.8.2 STPRINGACOLUMDE(TR)
002/AR11/12
04/10
NO.
REV.
0
PAGE: 38 / 63
The stripping gas column diameter is being recalculated via HYSYS software ( tray
sizing utitlity ), the actual stripping gas diameter is 0.27 m , and as per the attached
sizing results the diameter should be 0.3 m.
The following table shows the required stripping gas column design:
stripping gas column

Section Start
1__TS-1
Section End
3__TS-1
Internals
Packed
Section Diameter
(m)
0.3048
Max Flooding
(%)
X-Sectional Area
(m2)
8.45
7.297e002
Section Height
(m)
1.354
Section DeltaP
(bar)
---
DP per Length
(kPa/m)
---
Flood Gas Velocity
(m3/h-m2)
3320
(m/s)
0.9223
(kg)
47.4
Flood Gas Velocity

Estimated Mass of
Packing
Estimated Packing Cost
(US$)
HETP
66.30
(m)
0.4514
HETP Correlation
Packing Correlation
Norton
SLEv73
6. NEW CHILLING UNIT

6.1REFRIGERANT FLUID SELECTION
Propane is a proven refrigerant used in operation worldwide; it does not have ozone
depletion potential and a negligible direct global warming.
As shown from its envelope phase, this refrigerant is suitable for decreasing the
temperature of the gas to -36C.
The main physical and chemical properties of Propane are summarized in the table
below:
Table 40 : Chemical and Physical Properties of Propane
Refrigerant
Chemical
Formula
Molecular
weight
Boiling point
@1bar (C)
Danger
002/AR11/12
Propane
C3H8
44.09
-42
Extremely
04/10
NO.
REV.
0
PAGE: 39 / 63
Refrigerant
Propane
flammable gas
Appearance
Skin
Corrosion/Irritati
on
/inhalation
Colorless
Not expected to
be irritating.
Not expected to
be irritating.
No classified
hazard
Protect from
sunlight. Store in
a well-ventilated
place
Eye Damage
Toxicity
Storage
6.2PROPANE RECEIVER
The sizing of Propane receiver drum is determined by referring to standard DEP.
The data of Propane receiver drum are summarized in the following table.
Table 41: Propane Receiver Input Data
Design Parameters
Unit
Inlet vessel
Liquid outlet
Gas outlet
Mass flow rate
kg/h
5741
0.58
5740
m /h
2514
0.0009
2514
Pressure
bara
1.06
1.06
1.06
Temperature
-39
-39
-39
2.3
585
2.3
Mass density
kg/m

Table 42: Propane Receiver Main sizing Data
Design Parameter
Unit
Value
Diameter
0.98
Height
2.25
6.3PROPANE COMPRESSOR
The main data required for compressor sizing are as follow:
Table 43 : Stage 1 Main Data
Property
002/AR11/12
Value
Gas Molecular Weight
44.1
Compressibility Factor
0.97
Gas Mass Flowrate (kg/hr)
5741
04/10
NO.
REV.
0
PAGE: 40 / 63
Property
Value
Suction Temperature (C)
-37
Suction Pressure (bara)
1.1
Discharge Pressure (bara)
4.5
Duty (kW)
143
Table 44 : Stage 2 Main Data
Property
Value
Gas Molecular Weight
44.1
Compressibility Factor
0.93
Gas Mass Flowrate (kg/hr)
5758
Suction Temperature (C)
24.2
Suction Pressure (bara)
4.5
Discharge Pressure (bara)
19
Duty (kW)
165
6.4PROPANE CONDENSER
The sizing of the condenser is performed using the software HTFS (see Appendix8).
The main data required for the simulation are as follow:
Table 45: Propane Condenser Input Data
Inlet
Outlet
19
18.8
Temperature (C)
104
54
Flowrate (kg/hr)
5758
5758
Parameters
Pressure (bara)

Table 46: Propane Condenser Main sizing Data
Design Parameter
Heat Exchanged
Unit
Value
kW
391
6.5PROPANE ECONOMIZER VJ-4003:

The sizing of Propane economizer drum is determined by referring to standard DEP.
The data of Propane economizer drum are summarized in the following table.
002/AR11/12
04/10
NO.
REV.
0
PAGE: 41 / 63
Table 47: Propane Economizer Input Data

Design Parameters
Unit
Inlet vessel
Liquid outlet
Gas outlet
Mass flow rate
kg/h
5758
3387
2371
m3/h
239.6
12.4
233.2
Pressure
bara
4.7
4.7
4.7
Temperature
-0.4
-0.4
-0.4
24.03
530.1
10.17
Mass density
kg/m

Table 48: Propane Economizer Main sizing Data
Design Parameter
Unit
Value
Diameter
0.45
Height
8.44
6.6GAS/PROPANE HEAT EXCHANGER EJ-4003

The sizing of the Gas/Propane is performed using the software HTFS (see
Appendix8).
The main sizing results of this heat exchanger are summarized in the table below:
Table 49: Gas/Propane Exchanger Main sizing Data
Design Parameter
Unit
Value
Exchange area
m2
19.5
Heat exchanged
kW
279.9
92
Shell ID
mm
336
Length
3.65
Tube Number
6.7GAS/GAS OUTLET COLD SEPARATOR HEAT EXCHANGER EJ-4001A

The sizing of the Gas/Gas Outlet cold separator is performed using the software
HTFS (see Appendix8).
Table 50: Gas/Gas Outlet Cold Separator heat Exchanger Main sizing Data
Design Parameter
002/AR11/12
Unit
Value
Exchange area
m2
8.5
Heat exchanged
Kw
211.4
04/10
Design Parameter
NO.
REV.
0
PAGE: 42 / 63
Unit
Value
Tube Number
34
Number of tube passes per shell
mm
193.68
Shell ID
6.8GAS/LIQUID HEAT EXCHANGER EJ-4002

The sizing of the Gas/Liquid is performed using the software HTFS (see Appendix
8).
Table 51: Gas/Propane Exchanger Main sizing Data
Design Parameter
Unit
Value
Exchange area
m2
2.4
Heat exchanged
Kw
40.8
Tube Number
36
Number of tube passes per shell
Shell ID
mm
193.68
Length
1.22
6.9COLD SEPARATOR
The sizing of cold separator drum is determined by referring to standard DEP.
The data of cold separator drum are summarized in the following table.
Table 52: Cold Separator Input Data
Design Parameters
Unit
Inlet vessel
Liquid outlet
Gas outlet
Mass flow rate
kg/h
5616
1105
4511
m /h
30.53
3.26
27.27
Pressure
bara
85.21
85.21
85.21
Temperature
-35
-35
-35
183.9
338.2
165.4
Mass density
kg/m
Table 53: Cold Separator Main sizing Data

Design Parameter
Diameter
002/AR11/12
Unit
Value
0.39
04/10
Design Parameter
Unit
NO.
REV.
0
PAGE: 43 / 63
Value
7. NITROGEN SKID
Option 1: Nitrogen injection only for the sales gas only
Table 54: Sales gas Nitrogen Skid main sizing Data
Design Parameter
Unit
Value
Nm3/h
181
Pressure
bar
85
Temperature
< 45
Purity
> 98
Nitrogen flowrate
Option 2: Nitrogen injection inlet the compressor for the total

gas flow rate
Table 55: Nitrogen Skid main sizing Data
Design Parameter
Unit
Value
Nm3/h
558
Pressure
bar
28.5
Temperature
< 45
Purity
> 98
Nitrogen flowrate
8. SIZING OF PIPELINE
002/AR11/12
04/10
NO.
REV.
0
PAGE: 44 / 63
A sensitive study is performed for different pipeline diameters (4 inch, 6 inch, 8

inch, 10 inch and 12 inch) to select the appropriate diameter for transferring the
treated gas from the EBB plant to the STEG network.
Simulation hypotheses are presented in following table:
Table 56: Simulation Hypotheses
Property
Value
Distance From the CPF to tie-in

point (km)
Elevation
Difference
(m)
[estimated]
Required Pressure in the tie-in
point with STEG Network (bara)
Pipeline Roughness (mm)
onshore
temperature (C)
Gas Flowrate (mmscfd)
5
76
0.045
Thermal Conductivity (W/m2.K)

Mean
25
ground
45
20
5.72
The results of this simulation are shown in the figures below:
002/AR11/12
04/10
NO.
REV.
0
PAGE: 45 / 63
Figure 6: Pressure Profile of gas export pipeline
002/AR11/12
04/10
NO.
REV.
0
PAGE: 46 / 63
Figure 7: Velocity Profile of gas export pipeline
002/AR11/12
04/10
NO.
REV.
0
PAGE: 47 / 63
The results of this simulation for different pipeline diameter are summarized below:
Table 57: Pipeline calculation Results
Diameter
(inch)
4
6
8
10
12
Gas flow
rate
(MMSCFD)
5
5
5
5
5
Pressure
downstre
Loading
Pressure
am PCV
(bara)
85.1
77.3
76.27
76.11
76
at tie-in
point
(bara)
76
76
76
76
76
Velocit
y (m/s)
2.36
1.163
0.664
0.426
0.296
Max
velocity
(m/s)
24
24
24
24
24
Pressure
Max
drop
pressure
(bar/100
drop
m)
(bar/100m)
0.0364
0.0052
0.001
0.0004
0
0.27
0.27
0.27
0.27
0.27
According to NORSOK standard for gas line sizing shown in appendix 5 the selected
pipeline diameter is 4.
9. CONCLUSION
The product streams of Ecumed gas treatment plant are in compliance with STEG
requirements due to the follwoings
Amine unit ( sweetning gas unit ) to remove carbon dioxide (CO2) present in
raw gas.
Increasing the stripping gas flowrate in the dehydration unit in order to
improve TEG purity , as a result the water content removal increases
significantly to reach 31.26 PPMH2O.
A chilling unit is installed to cool down the gas leaving dehydration unit . this
leads to the following :
-additional amount of condensate ( heavy components in the treated gas )
approximately 400 BBl/day.
-decreasing the higher heating value as well as the wobbe index to meet STEG
requirements.
Nitrogen injection into sales gas stream to comply with STEG wobbe index
specification.
The following table shows sales gas specifications versus STEG requirements:
Table 58: Sales gas specifications versus STEG requirements
002/AR11/12
04/10
NO.
REV.
0
PAGE: 48 / 63
Treated Gas
STEG
Specifications
Pressure (barg)
76
75 at tie in point
Temperature (C)
20
10 - 50
5.064
Parameter
Molar flow [MMSCFD]

Higher
heating
(kcal/Nm3)
Value
Wobbe Index (kcal/Nm3)

Mass Density (kg/m3) @ TP
9300 - 10228
10,056
11961 - 12640
12,397
81.9
28.01
Water content (ppm)
64.4
< 80
CO2 content (% mol)
0.3
< 0.5
H2S content (mg/Nm3)
<2
H2 and N2 content (% mol)
<6
O2 content (% mol)
Molecular Weight
The following table shows recovered condensate specification :

Table 59: Condensate specification
Actual
Property
volume flow (barrel/day)
50C/1Atm
808.5
True VP (bara) @ 37.8C
0.7269
Reid VP (bara) @ 37.8 C
0.6055
Mass Density (kg/m3)

Viscosity (cP)
002/AR11/12
Value
684.1
0.3981
04/10
NO.
REV.
0
PAGE: 49 / 63
10. APPENDICES
10.1
APPENDIX 1: RECIRCULATION RATE OF DEA SOLUTION
In case of using the DEA solution the recirculation rate is calculated by the following:
LDEA =
192 MM Xa
WT ML
Where:
LDEA: DEA solution minimum recirculation rate (USGPM)
MM : gas flow MMSCFD
WT : amine solution weight percent circulated
ML : mol loading, moles acid gas/mole
Xa : required reduction in total acid gas fraction.
: Solution density (lb/gal)
10.2
APPENDIX 2: AMINE CONTACTOR DIAMETER CALCULATION
The amine contactor column diameter is determined referring to the given correlation:
Dc=10750
Q
P
Where:
Dc = Contactor diameter in mm.
P = Contactor pressure
Q = gas processed flow rate
002/AR11/12
04/10

10.3
NO.
REV.
0
PAGE: 50 / 63
APPENDIX 3: AMINE REGENERATOR DIAMETER CALCULATION
The column diameter is determined using the given correlation
Dr=160 L
Where:
L =
Amine circulation rate (m3/h) = is the design capacity of the lean amine
circulation pump 330-PA-001A/B
Dr = Regenerator diameter in mm.
10.4
APPENDIX 4: GPSA STANDARD FOR TEG CONTACTOR SIZING
The quantity of water that shall be removed is:
W r =W iW o
(mg water/Sm3 wet gas)
The water content of sweet gas respectively inlet and outlet contractor can be
calculated using BUKACEK correlation:
W i=
A1
+ B1
P
W o=
A2
+ B2
P
With:
P:
The operating pressure at the TEG contactor (bara)
A1 ,
A 2 , B1 ,
B2
: constant at the operating temperature Using the KREMSER &
BROWN hart, we can define the absorption ratio (Ar=3.5)

Given this ratio the lean glycol flow rate can be determined using this correlation:
QTEG =
Wo
( E11 )
g (mg/h)
Arm
With:
E:
Efficiency of the absorber
WO : Water content outlet contractor (mg/Sm3)
m
g
: Gas flow rate (Sm3/h)
To calculate the contactor diameter, the following correlation can be used:
002/AR11/12
04/10
0.5
G=C( g( l g))
NO.
REV.
0
PAGE: 51 / 63
(kg/m.h)
g : Gas density (kg/m3)

l : Liquid density (kg/m3)
The contactor section can be calculated by the following equation:
S=
m g
G
With:
m
g
: Gas flow rate (kg/h)
The contactor diameter can be calculated by the following equation:
D=
10.5
4S
(m)
APPENDIX 5: NORSOK STANDARD FOR SIZING OF GAS LINE
In lines where pressure drop is not critical, gas velocity shall not exceed limits which may
create noise or vibrations problems. As a rule of thumb the velocity should be kept below:
0.43
()
V =175
Where:
V : The maximum velocity of gas to avoid noise in m/s

: The density of gas in kg/m3
or 60 m/s, whichever is ever the lowesr.
002/AR11/12
04/10
10.6
APPENDIX 6: AMINE UNIT HEAT EXCHANGERS TEMA SHEETS
002/AR11/12
NO.
REV.
0
PAGE: 52 / 63
Rich / Lean Amine heat exchanger
04/10
002/AR11/12
NO.
REV.
0
PAGE: 53 / 63
Amine Air cooler
04/10
10.7
002/AR11/12
NO.
REV.
0
PAGE: 54 / 63
APPENDIX 7: GLYCOL UNIT HEAT EXCHANGERS TEMA SHEETS
04/10
002/AR11/12
Gas/glycol heat exchanger
Gas/glycol heat exchanger
NO.
REV.
0
PAGE: 55 / 63
04/10
002/AR11/12
NO.
REV.
0
PAGE: 56 / 63
glycol/ glycol heat exchanger heat exchanger

04/10
002/AR11/12
NO.
REV.
0
PAGE: 57 / 63
04/10

10.8
APPENDIX 8: CHILLING UNIT HEAT EXCHANGERS TEMA SHEETS
002/AR11/12
NO.
REV.
0
PAGE: 58 / 63
Gas/Propane EJ-4003 TEMA Sheet
04/10
002/AR11/12
NO.
REV.
0
PAGE: 59 / 63
Gas/Gas Outlet cold separator EJ-4001A TEMA Sheet
04/10
002/AR11/12
NO.
REV.
0
PAGE: 60 / 63
Gas/liquid EJ-4002 TEMA Sheet
04/10
NO.
REV.
0
PAGE: 61 / 63
Air-Cooled Heat Exchanger Specification Sheet ( condenser -chilling unit )
10.9
002/AR11/12
APPENDIX 9: STRIPPING GAS COLUMN DESIGN

04/10
Tray Sizing: stripping gas column sizing ( diamater)

SETUP
NO.
REV.
0
PAGE: 62 / 63
Tray Section: TS-1 @COL5
Liquid Draw: 0.00 %
Section_1
Section Start
1__TS-1
Section End
3__TS-1
Internals
Packed
Mode
Design
Active
Off
Status
Complete
Design Limit
Chanelling
Limiting Stage
1__TS-1
Include Vapor Head
Off
SPECIFICATIONS
Section_1
Section Start
1__TS-1
Section End
3__TS-1
Internals
Mode
Packed
LIQUID PROFILE (FROM TRAY)
Design
Number of Flow Paths

1__TS-1
Section Diameter (m)

Mass Flow (kg/h)
Tray Spacing (m)
Liquid Flow (m3/s)
Tray Thickness (mm)
Molecular Weight
High Capacity Nye Tray
Temperature (C)
Foaming Factor
922.6
2.651e-004
----
-144.0
Off
200.9
1.000
Max Delta P (ht of liq)
SLEv73
HETP (m)
0.4514 *
PACKED RESULTS
Viscosity (cP)
Internals
912.1
2.634e-004
2.607e-004
145.8
147.2
199.4
197.0
Pall Rings (Metal, random) 1_inch
Density (kg/m3)
Section End
918.8
80.00
Packing Correlation
Surface Tension
(dyne/cm)
Section Start
VAPOUR PROFILE
3__TS-1
0.4086 kPa/m
Max Flooding (%)
Packing Type
2__TS-1
966.9
968.9
971.8
0.5994
0.6072
0.6246
29.49
29.70
29.37
Section_1
(TO TRAY)
1__TS-1
3__TS-1
Packed
1__TS-1
2__TS-1
3__TS-1
Section Diameter
(m)(kg/h)
Mass Flow
0.3048
17.79
13.96
7.215
Max Flooding
(%) (ACT_m3/h)
Gas Flow
20.47 8.45
15.78
8.460
X-Sectional
Area (m2)
Molecular
Weight
7.297e-002
32.14
31.27
21.18
Section Height
(m)
Temperature
(C)
199.41.354
197.0
57.25
Section DeltaP
Density(bar)
(kg/m3)
DP per Length
(kPa/m)
Viscosity
(cP)
Flood Gas
Velocity
(m3/h-m2)
Fluid
Pressure
(bar)
Flood Gas Velocity (m/s)
0.8691
--
0.8849
0.8528
--
1.695e-002
1.212e-002
1.0143320
1.058
1.103
1.615e-002
0.9223
Estimated # Pieces of Packing
4901
Estimated Mass of Packing (kg)
47.4
Estimated Packing Cost (US$)
66.30
HETP (m)
HETP Correlation
002/AR11/12
Packing Correlation
Packing Type
0.4514
Norton
SLEv73
Pall Rings (Metal, random) 1_inch
04/10
10.10
NO.
REV.
0
PAGE: 63 / 63
TIE-IN PROCEDURE TO ADD AMINE FLASH VAPOR TO STRIPPING GAS
PROCESS
Please refer to the piping and instrumentation diagram entitled PROCESS FLOW
GLYCOL DEHYDRATION
PACKAGE , document No R02-06-DWG-PR-00-004.
The Tie in point is located downstream of the ESDV-410 valave and the upstream of
the valve NE- 6008 ( the line in which mounted a restriction orifice RO-410).
The isolation work is guaranteed by closing , the ESDV-410 and valve NE- 6008.
002/AR11/12
04/10

ECUMED Sizing Report For The First Phase Rev - 0 MCH (Réparé)

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

ECUMED Sizing Report For The First Phase Rev - 0 MCH (Réparé)

Transféré par

Droits d'auteur :

Formats disponibles

Project: ECUMED-El Bibane

Feasibility Study for EBB Plant Upgrade For Gas

EQUIPMENTS SIZING REPORT FOR THE FIRST PART

EQUIPMENTS SIZING REPORT FOR THE FIRST

EQUIPMENTS SIZING REPORT FOR THE FIRST PART

PROJECT DETAILED SCOPE........................................................................................... 6

DEFINITIONS & ABBREVIATIONS....................................................................................7

PROCESS DESIGN DATA............................................................................................ 11

PROCESS DESIGN TOOLS.......................................................................................... 13

MODEL DESCRIPTION, BATTERY LIMITS

DESIGN OF THE NEW AMINE UNIT............................................................20

SELECTION FACTORS FOR THE TYPE OF AMINE................................................................20

EQUIPMENTS SIZING REPORT FOR THE FIRST PART

MAIN EQUIPMENTS SIZING......................................................................................... 21

CONSUMPTION AND PRICE................................................................................21

REVISION OF TEG UNIT DESIGN...............................................................26

CURRENT TEG REGENERATION UNIT DESIGN......................................................28

REGENERATION PROCESS TROUBLE SHOUTING................................................................32

NEW CHILLING UNIT................................................................................34

PROPANE ECONOMIZER VJ-4003:...............................................................................36

GAS/PROPANE HEAT EXCHANGER EJ-4003...................................................................36

EQUIPMENTS SIZING REPORT FOR THE FIRST PART

GAS/GAS OUTLET COLD SEPARATOR HEAT EXCHANGER EJ-4001A...................................37

GAS/LIQUID HEAT EXCHANGER EJ-4002......................................................................37

AMINE CONTACTOR DIAMETER CALCULATION..............................................44

AMINE REGENERATOR DIAMETER CALCULATION..........................................44

APPENDIX 5: NORSOK STANDARD FOR SIZING OF GAS LINE...............................46

APPENDIX 6: AMINE UNIT HEAT EXCHANGERS TEMA SHEETS..............................47

APPENDIX 7: GLYCOL UNIT HEAT EXCHANGERS TEMA SHEETS............................49

APPENDIX 8: CHILLING UNIT HEAT EXCHANGERS TEMA SHEETS.........................52

APPENDIX 9: STRIPPING GAS COLUMN DESIGN...................................................56

EQUIPMENTS SIZING REPORT FOR THE FIRST PART

Producing from the offshore well EBB#5,

Figure 1: The Onshore Wellheads Configuration

Define the required process modifications for the first phase.

Perform needed calculations for modified or potential additional required

EQUIPMENTS SIZING REPORT FOR THE FIRST PART

Develop the cost estimation for the related modifications.

2/ Feasibility study for selling the total gas production:

Prepare the required simulations for treatment of 15 MMSCFD of gas to

Define the required process modifications for the second phase.

Perform needed calculations for modified or potential additional required

Develop the cost estimation for the related modifications.

As an alternative economic option, one analysis will be made for the

3/ Feasibility study for sales gas transportation

Assessment of the different types of gas transportation methods, depend

Prepare the required simulations/hydraulic calculations for transport of

Based on the gas sales develop an economic analysis.

EQUIPMENTS SIZING REPORT FOR THE FIRST PART

El Bibane-Detail Engineering for Gas Cycling

Documents/drawings and services to perform the

EQUIPMENTS SIZING REPORT FOR THE FIRST PART

kilogram per cubic meter

Kilo Joule per kilogram

Newton or kilo Newton

millimeters, meters, kilometers

Mass Flow Rate

watt per meter Celsius

year / day/hour/minute /second

Standard Gas Volume

Standard cubic meter

barg, bara, kPa

EQUIPMENTS SIZING REPORT FOR THE FIRST PART