the lpg recovery plant - · pdf fileawarded a consultancy service to eil on 26.10.2006 to...
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Designed and commissioned by The Randall Corporation of USA, in 1982
Production capacity : 55000 MT of LPG 25000 MT of Condensate Gas throughput : 2.21 MMSCMD Feed Gas Pressure : 14 Kg/ Cm2 g Residue Gas Pressure : 11.2 Kg/ Cm2 g Water content : Saturated LPG Quality : To conform IS-4576:1999 specification
The LPG Recovery Plant:
Feed gas composition (mole%)
COMPONENT DESIGN PRESENT FLUCTUATION N2 0.26 0.93 0.44 CO2 1.10 0.64 1.15 C1 86.80 86.58 88.99 C2 6.50 3.75 4.31 C3 3.30 2.16 2.39 i- C4 0.72 0.48 0.56 n-C4 0.86 0.65 0.83 i- C5 0.18 0.23 0.31 n-C5 0.13 0.17 0.26 C6 + 0.15 0.39 0.77
Production profile
Fin. Year : 1992 – 2004 2006 - 2010 2011-2012 * LPG (MT) : 50417- 55780 43750- 48165 50500 COND (MT) : 23470 – 27905 23630 – 25615 29000 LPG (TPD) : 148.68 – 160.24 129.82 – 135.80 150.77 COND (TPD) : 69.45 – 78.61 70.12- 75.36 86.53 Low production was attributed mainly due to change in feed gas composition, more particularly decline in propane and butane content from the year 2006-07. * April – May ‘ 2011
PRODUCTION PROFILE 1992-200455780 54610 54320
24750 25350
0100002000030000400005000060000
1992-93
1993-94
1994-95
1995-96
1996-97
1997-98
1998-99
1999-00
2000-01
2001-02
2002-03
2003-04
FINANCIAL YEAR
MT
LPG PRODUCTION CONDENSATE PRODUCTION
PRODUCTION PROFILE 2006-2010
4375048165 47610 44950 45010
23630 25615 25295 24150 25170
0100002000030000400005000060000
2006-07 2007-08 2008-09 2009-10 2010--11
FINANCIAL YEAR
MT
LPG PRODUCTION CONDENSATE PRODUCTION
RATE OF PRODUCTION 1992-2004235.73235.16 231.58
0.0050.00
100.00150.00200.00250.00
1992-93
1993-94
1994-95
1995-96
1996-97
1997-98
1998-99
1999-00
2000-01
2001-02
2002-03
2003-04
FINANCIAL YEAR
TO
NN
ES
PE
R
DA
Y
LPG PRODUCTION RATE CONDENSATE PRODUCTION RATETOTAL LIQUID PRODUCTION RATE
RATE OF PRODUCTION 2006-2011
150.87
86.86
199.94 203.25 210.71 208.76 210.12237.73
0.00
50.00
100.00
150.00
200.00
250.00
2006-07 2007-08 2008-09 2009-10 2010--11 2011-12
FINANCIAL YEAR
TO
NN
ES
PE
R D
AY
LPG PRODUCTION RATE CONDENSATE PRODUCTION RATETOTAL LIQUID PRODUCTION RATE
Need Of The Hour To find out ways and means to enhance the LPG production from the available feed gas or from the new gas finds which was under development, in order to sustain the market demand in the northeast.
Action initiated for enhancement of LPG Production
Awarded a consultancy service to EIL on 26.10.2006 to prepare Techno Economic Feasibility Report (TEFR) with additional recovery of propane and/ or spiking of butane in OIL’s LPG Recovery Plant at a cost of Rs 36.00 Lakh. Report submitted by EIL on 12.03.2007 and a presentation was given to OIL Directors on 21.03.2007. Further study was carried out by EIL for recovery of propane without considering the limitations of existing plant and equipment and with no butane injection.
Action initiated for enhancement of LPG Production
On 25.04.2007 EIL presented their findings to OIL
Directors wherein the following case studies over base case towards maximizing propane recovery have emerged.
Base case:
• Simulation was carried out on existing plant operating data of 08.11.2006
• Throughput : 79 MMSCFD • Butane content : 1.20 % • Propane recovery :69.7% over the feed content. • LPG production : 135 tones per day (45000 MT) • Propane : Butane : 50.6:49.4 by weight.
Modified Case : Maximization of Propane recovery
Recycling a part of product condensate (NGL) through
deethanizer and debutanizer. • Additional column height of deethanizer (about 1.5 meter) • Small supplementary condenser and re-boiler • A manhole has to be provided for inspection of the tower. • Propane recovery : 87 % • Additional LPG production : 6166 TPA • Propane: Butane : 56:44 by weight. • Expected plant downtime : 3-4 weeks • Project cost: Rs 2-3 Crore • Net Annual revenue : Rs.1520 Lakh based on LPG price @ 27000/MT • Investment will be returned in 100 days.
The road map towards implementation of the NGL Recycle
Project • Preparation of basic design engineering package (BDEP) • Project management consultancy (PMC)
• Procurement and construction
• Installation and commissioning
ACTION PLAN
Award of BDEP with extended deliverables to EIL on
26.05.2007 at a cost of Rs 75 lakh BDEP Report submitted on 15.02.2008 The total estimated cost works out to Rs. 624.75 lakh with
following beak-up. --------------------------------------------------------------------------- 1. Equipment and Modification job : RS. 414.75 Lakh 2. Project Management Consultancy : Rs. 110.00 Lakh 3. Additional job : Rs. 100.00 Lakh --------------------------------------------------------------------------- TOTAL : Rs. 624.75 Lakh
ACTION PLAN
• LOA awarded to EIL for PMC on 10.05.2008 at a cost
of Rs.135 lakhs. • Procurement of equipment initiated. • Tender document for LSTK job (NIT) prepared. • The cost of LSTK has been increased from that was
estimated in BDEP by EIL, R& D in 2007.
• Total cost of the project : Rs.1053 lakhs. (2010)
INNOVATIVE PROCESS
Composition 56:44 of C3:C4 by Wt.
C2 present 1% by Wt.
Vapor pressure 9.5 Kg/Cm2g at 40o C
Yield of the process : 15 Tones per day of additional LPG. (Expected) Specification of LPG :
Recycling one part of NGL (Condensate Product) as Deethanizer Feed Additional Propane can be retained at Deethanizer and subsequently Extra amount of LPG can be produced from Debutanizer top.
Modification Jobs : At a Glance PV 16.09 to be cut at top dished end. Weld 1.5 M height of column section. Steel lining at dished end and the new section. New distributor plate at top section. New reflux nozzle at top section One manhole at new section. Three hand hole for removal of packing at bottoms of section. One new nozzle for NGL recycle at middle section. Contd
Modification Jobs : At a Glance
Replacement of Deethanizer reflux line from pump to the tower.
Topping of packing if necessary.
Replacement of PV 16-08 with new one.
One NGL tank will be installed
Two nos. of pumps for NGL recycle will be required.
Three nos. of new heat exchangers will be installed.
Deethanizer reflux condenser no2
Debutanizer reflux condenser no 2
Debutanizer feed pre heater
HE 15.04 will be replaced with a new one.
HE 15.05 will be replaced with a new one.
Piping modification for new equipment and insulation
STATUS AS ON 01.06.2011 1. Pressure Vessels (3 Nos.) : Received. 2. Heat exchanger (6 Nos.) : Received. 3. NGL dosing pump (2 Nos.) : Received 4. Pressure Control Valves (8 Nos.) : Received. 5. Control Valves ( 4 Nos.) : Received. 6. Safety Relief Valves ( 2 Nos.) : Received 7. Column Internals : Delivery by 30.09.11. 8. LSTK job : NIT is ready 9. PMC Job : Extended up to 31.03.10 10. Expenditure incurred : Rs 3.00 Crore
PV 16 03 PV 16 04
PV 16 01
PV-16 06
FC 2101
PV 16 02
PV 10 08
PV 16 10
PV 16 07
FC 2102FC 2103
HE 15 03
HE 15 08
HE 15 11
HE 15 10
HE 15 01
HE 15 02
CM 11-01
EC 12-01HE 15 09
HE 15 13
HE 15 12
HE 15 05
HE 15 06CONDENSATE
LPG
HE 15 07
RESIDUE GAS
INLET GAS
REFLUX
EXP SEP
COLD SEP
PV 16 09 PV 16 11LPG RECOVERY PLANT PROCESS FLOW DIAGRAMDrawn by: SANCHITA BANERJEE : 29.11.2006
GASOLINE PRODUCT
FROM DEEHYDRATOR
PV1609
PV1610
PV16101A/B
PM17101A/B
HE1512
HE 1504 HE1502
HE 15101
HE 15103
He151 02
HE1505
HE1503
REFLUX
EXP SEP
NGL
COLD SEP
HOT OIL
PV1611
HE1501
TO COLD SEP
FROM EXP SEP TOP
FROM COLD SEP BOTTOM
INLET GAS FROM CM1101
RESIDUE GAS TO HE15102
HE 1506 CONDENSATE
HE1513
PM1703/04
TO KOD
LPG PRODUCT
HE1510
PV1608
TO HE1511
FROM EXP SEP
NGL
RESIDUE GAS
RESIDUE GAS
MODIFIED PORTION
NGL RECYCLE AT LPG PLANT
PM170102
Present consideration Plant can handle a total liquid (LPG + Condensate) of 250-255 tones per day
About 40 MT of NGL will be recycled through Deethanizer and Debutanizer to produce about 17 MT of additional LPG at base case (total liquid will be 135+68+40+17 = 260 MT)
Present production of liquid (152+ 88) 240 MT.
A margin of only 15 – 20 MT left for NGL recycle and additional production of LPG . If LPG production goes to about 160 MT and above there will be hardly any margin left for NGL recycle.
Further Deethanizer and Debutanizer are due for replacement in 2015 – 2017 as per health survey report by EIL
While simulating the base case for enhancement of LPG production the limitation of existing equipment was not considered particularly the case for Debutanizer Rebioler.
Replacement of equipment to be planned phase wise