Oil Stab Op Tim Ization

Optimization
Oil
Stabilization
Optimization
By: Eng. Ahmed Deyab Fares http://www.adeyab.com

Mobile: 00201227549943 Email: eng.a.deab@gmail.com
Optimization
Workshop
A poor-boy stabilization scheme is used to separate an oil and gas mixture
into a stabilized oil and a saleable gas. A simple three-stage separation with
heating between each stage is used and the object of the exercise is to select
the let-down pressure and temperatures such that the products revenue less
the utilities cost is maximized. A special tool in HYSYS, the Optimizer, will
be
used
to
find
the
optimum
operating
conditions.
HYSYS includes additional modelling and decision support tools that can
be used to enhance the usability of your models. In this module, you will
use the HYSYS optimization tool available in HYSYS to investigate the
debottlenecking
and
optimization
of
crude
column.
Learning Objectives
Once you have completed this section, you will be able to:
Use the Optimizer tool in HYSYS to optimize flowsheets
Use the Spreadsheet to perform calculations

Optimization
OilStabilization
Afeedstream@10oC,4125kPawithaflowrateof1MMSCFDisfedtoa
heater (duty=4.25*105 kJ/hr) before entering the first separator where
the separated liquid is heated in a second heater (duty=3.15*105 kJ/hr).
The outlet from the heater is then sent to a letdown valve in order to
decreasethepressureto2050kPabeforeenteringthesecondseparator
wheretheseparatedliquidisheatedthroughathirdheater(duty=1.13*105
kJ/hr).Theoutletfromthethirdheateristhenthrottledthroughavalve
(outletpressure=350kPa)andthenfedtoathirdseparatortoobtainthe
finalliquidoilproduct.
Each gas stream from the 2nd & 3rd separators is fed to a separate
compressor to raise the pressure to 4125 kPa and then mixed (using a
mixer) with the gas stream from the 1st separator to get the final gas
productstream.
Notes:
Pressuredropacrossallheatersandseparatorsare0.0.
Calculate:
Thetotalliquidproduct=barrel/hr
Thetotalgasproduct=m3_gas/hr

Optimization
OilStabilizationOptimization
In this case, we want to maximize the total operating profit while
achievinganRVPofLiquidProductlessthan96.5kPa.Theincomesfrom
thePlantareboththeGasandLiquidProducts.Theoperatingcostsare
the Steam Costs for each Heater plus the Power Cost for each
Compressor.
Profit=IncomeCost
Profit=(GasProduct+LiquidProduct)(SteamCosts+CompressionCost)
Prices&costs:
OilPrice=15$/bbl
GasPrice=0.106$/m3_gas
SteamCost=0.682$/kWh
CompressionCost=0.1$/kWh
Thevariablestobeadjusted:
Heaterduties(forthe3heaters).Userangeof01e6kJ/hr
Valvesoutletpressures.
Userangeof6503500kPaforthefirstvalve
Userangeof701000kPaforthesecondvalve
Calculate:
Theoptimumvaluesfortheadjustedvariables
Themaximumprofit..$/hr

Optimization
Tostarttheprogram,FromStartMenu,SelectAllPrograms>>
AspenTech>>ProcessModelingV8>>>>AspenHYSYS>>Aspen
HYSYS

Optimization
1- First, Start a new case
2- Add the Components
3- Choose the system components from the databank:


Optimization
Now, select the suitable fluid package
In this case, select Peng-Robinson

Optimization
Now you can start drawing the flow sheet for the process by clicking the
Simulation button:
Now add a material stream to define the feed stream composition and
conditions

Optimization
From the palette:

Optimization
Addaheaterwithadutyof4.25*105kJ/hrandpressuredropof0.0

10
Optimization
Addthefirstseparator

11
Optimization
Theliquidstreamisthenheated,addasecondheaterwithapressure
dropof0.0&dutyof3.15*105
Addavalvewithoutletpressureof2050kPa

12
Optimization
Addthesecondseparator
Theliquidfromthesecondseparatorisnowfedtoathirdheaterwitha
pressuredropof0.0&dutyof1.13*105

13
Optimization
Addasecondvalvewithanoutletpressureof350kPa
Addthethirdseparator

14
Optimization
Thevaporfromthesecondseparatorisfedtoacompressortoraisethe
pressureto4125kPa
Addacompressorfromthepalette
Thevaporfromthethirdseparatorisfedtoasecondcompressortoraisethe
pressureto4125kPa
Addasecondcompressorwithanoutletpressureof4125kPa

15
Optimization
Thethreevaporstreamswillbemixedusingamixer
TheRVPoftheLiquidProductstreamshouldbeabout96.5kPatosatisfythe
pipelinecriterion.
UsecoldpropertiesanalysistoseethecurrentReidVaporPressureforthe
liquidproductfromthethirdseparator:
Fromtheattachmentstab,selectAnalysisandthenCreate:

16
Optimization

17
Optimization
ChangingtheUnits
Weneedtochangethedefaultunitsettofitthiscase
Changetheunitsasfollows:
Molarflow:m3_gas/hr
Liq.Vol.Flow:barrel/hr
Std.Vol.Flow:barrel/hr

18
Optimization
Optimization
HYSYS contains a multivariable Steady State Optimizer. Once your flowsheet has
been built and converged, you can use the Optimizer tool to find the operating
conditionswhichminimizeormaximizeanObjectiveFunction.TheOptimizerowns
its own Spreadsheet for definingthe Objective Functions as well as any constraint
expressions to be used. This allows you to construct Objective Functions which
maximizeprofit,minimizeutilitiesorminimizeexchangerUA.
Inthiscase,wewanttomaximizethetotaloperatingprofitwhileachievinganRVPof
LiquidProductlessthan96.5kPa.TheincomesfromthePlantareboththeGasand
LiquidProducts.TheoperatingcostsaretheSteamCostsforeachHeaterplusthe
PowerCostforeachCompressor.
Profit=IncomeCost
UsetheOptimizertool:

19
Optimization
Thevariablestobeoptimizedinordertomaximizetheprofitshouldbe
addednow,thesevariablesare:
The3HeatersdutiesandValvesoutletpressures

20
Optimization
Afteraddingallthe5variables,settheupperandlowerrangesforeach
variableasfollows:
TheOptimizerhasitsownSpreadsheetfordefiningtheObjectiveand
Constraintfunctions.
Nowwehavetostartbuildingtheprofitmoduleusingthespreadsheet
operation:

21
Optimization
Profit=IncomeCost
Prices&costs:
OilPrice=15$/bbl
GasPrice=0.106$/m3_gas
SteamCost=0.682$/kWh
CompressionCost=0.1$/kWh


22
Optimization
TheRVPspecfortheliquidshouldbeaddedinthespreadsheetinordertouseitas
aconstraint.
RVPspec=96.5kPa
Firstweneedtoincreasethenumberofrowsinthespreadsheettobe20fromthe
parameterstab:
Nowreturntothespreadsheettabagainandaddalltheprofitequation
parameters&variables.
Afteraddingthelabels,importthevariablesineachlabeledcell:

23
Optimization
Addalldutiesforheaters&compressorsthesamewayaswedidinthe
previousstep.


24
Optimization
DothesameforOil&gasproductionflowrates
TheRVPcurrentvalueshouldbeimportedfromtheAnalysis:

25
Optimization
ThePricesshouldnowaddedmanuallywithoutimportingit
CalculatetheIncome,Cost&Profitusingthecurrentformulas:
Income:=d7*b7+d8*b8
Cost:=(b1+b2+b3)*d1+(b4+b5)*d4
Profit:=d12d13


26
Optimization
Aftercalculatingtheoperatingprofit@currentconditions,usethe
optimizertomaximizetheprofitbychangingthe5variableswhichwe
addedbefore
OpentheoptimizerandgotoFunctionstab:

27
Optimization
YoumayneedtopresstheStartbutton2or3timestoensurereaching
theoptimumsolutionasfollows:
YoumayseethenewvaluesforthevariablesfromtheVariablestab:
Nowyoucanreturnbacktothespreadsheettoobservetheresults:

28
Optimization
SaveYourCase!

29
Optimization
Exercise:
OnethingyoumaynoticewiththeOptimizedsolutionisthatthePressure
of V3 has been decreased to 70 kPa (10 psia) which is less than
atmospheric.Thisisnotadesiredconditionfortheinletofacompressor.
Theinletofthesecondcompressor,cannotbelessthan125kPa(19psia).
Whatisthemaximumprofitifyouadheretothisguideline?

30

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Optimization

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

2- Add the Components

3- Choose the system components from the databank:

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

Now, select the suitable fluid package

In this case, select Peng-Robinson

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

By: Eng. Ahmed Deyab Fares http://www.adeyab.com

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