CME 8022 Assignment - Ethane-Propane Separation

Introduction
A pr oc ess t o s epar at e et hane and pr opane us ing distillat ion is shown in Figur e 1. In this pr oc ess a f eed c ont aining et hane and pr opane is c ompr ess ed fr om 101. 3 kPa t o 850 kPa (compr ess or is entr opic eff ic ienc y = 85%). The c ompr ess ed f eed is then c ooled in th r ee st ages, firstly us ing the et hane and pr opane pr oduct streams, sec ondly us ing a r efr iger at ed pr e-c ooler and f inally by pass ing it thr ough the r eboiler of the dist illat ion c olumn. The c ompr ess ed c ooled f eed is then let down t hr ough a valv e t o a pr ess ur e of 101. 3 kPa. Aft er the valv e t he vapour and liquid phas es ar e in equilibr ium. They ar e s epar at ed and t he liquid is f ed t o the t op plat e of the dist illat ion c olum n. The vapour fr om the s epar at or and t he vapour fr om the t op of the c olumn ar e c ombined t o form the et hane pr oduct stream. The pr opane pr oduct stream is t ak en fr om the r eboiler. The two pr oduct streams ar e heat ed us ing ener gy fr om pr e-c ooler 1. Eac h pr oduct str eam r ec eives half of the heat load of Pr e-c ooler 1. The Aim of this course work is to 1. Using the data provided and assuming that the liquid phase is incompressible and that the gas/vapour phase is an ideal gas: (a) Find the mass flow rates, compositions, pressures and temperatures of all the process streams in Figure 1. (b) Calculate the work required to compress the feed. (c) Calculate the number of stages required in the column. This is accomplished in the Numerical approach section below. 2. Model the process using HYSYS process simulation software and compare the simulation results with those from part 1. 1. Numerical Approach

Dat a av ailable t o us ar e as f ollows: Ethane:

       



 

Propane:
       



 

Submitted By :Jinny Varkey (B0916817)

C GEPBDP

WV Q U ` b S T S CGEPBDP B C ED RB QQEA WV Q U ` b S T S CGEH C B C ED RB QQEA X QQEY a` IGE CGEH C QQEY a` S GB QBPYB F ICC WV Q U T S ICC B C ED RB QQEA ICC CH G CGEPBDP IGE CGEH C B GB FED C BA
l f ti f t fl t ff iti fl fl t t f f t K  * % t * i t . K . K  ti l i f :

2 7) 501 ' )( ) 27) 501 220( '& @7 1'97)5 84 '7)6 2 2 &% " $ 6' 0 35 0 5 '4 ) 2 '13 ( '& ) 220( 10 )( '&%
l ft ixt i t l t i i ti t f t . l f ti

" !  
s

 

   
: fl i

Fi s s g

 

 

 

,C m

ss

Fig

C m

ss

 



2
 " #    

No: of moles of ethane = No: of moles of propane = Mole fraction of ethane, = =

 

 

= =


= 48.86 mol s-1 = = 34.01 mol s 0.59 0.41

and   respectively.
-1

Mole fraction of propane,

=

Therefore, molar fraction of propane and ethane will be We can then calculate the molar mass of the mi ture


The compression is assumed to be isentropic, which applies there is no change in entropy,

       


, therefore:





= =

[Si, t R ln i] [Si, t R ln {

(for liquid mi ture) ] (for gas/vapor mi ture)

1.1

ompre

or I entropic work

 

 

ee



To estimate the isentropic work done by the compressor, the isentropic enthalpy change across the compressor is required.

   

Enthalpy at the inlet of the compressor,

Enthalpy at the inlet of the compressor,

  

  

   

      

   

I entropic Work done by the compre

  

or i

 

=


= 593604.16 J s


-1

 





We can now calculate the real enthalpy chan e

hh

hh

Real Work done by the compre e iciency.

or i

g
calculated dividin the i entropic work by the compre or

gg

pp





i :

 

  

 

 

 




 

 

 

 

 

 


+  

 

xy yx

u w v

2.

Pre-cooler

Es im ion

t s

 x x }  } } ~~}
X X V V+L f L l f t Y + XL L Y + XL V t 7. K, t  x   i t  V

x  u x x  } x } } ~~} ~
Vapour composition at 268K from Txy diagram at 850 Pa: Ethane = 0.57, Propane = 0.43 Liquid composition at 268K from Txy diagram at 850 Pa: Ethane = 0.21, Propane = 0.79

{ zy } }
i t

y  }  ~  | }  }  ~}|
f it ti T4 [K] t i t l 267.4 f

} ~ ~ } }  }} u  wv { zy x u
t

p dhdde t
Q@ Q@ Q@ Q@

o r o rof rs oqf q f dhdde

7. . . .7

s f o f rs rq f q po f k
[K ] . . 7 . 7 .

qo oo o po ed deie
t [K] [K] [K] [K]

e g g je m de jd el hije ddhg el jed deie ejj el jkhlj kh en e n el h i jj j l e m h e m em el h edihg e g g j h hh g el e delk e jj edek jed deie e h ede de hh gfed
:P l

The method of calculating Tout:

t tl t t t Diff l t li t t i f l l l t : t

Si

1.2

Pre-cooler 2

7 K

l + Li

: i

IN E POLA ION

ti

 

KP

li

7. K

i t



l t t

KW

t t

6
t

V=

 

Assuming vapour fraction (266 K)

    

Therefore

Datum point chosen = VHv H

2 1, therefore HF = 0

Ener y Balance: FHF = VHv H

Therefore

=3V = 0.56 Kg/s

Feed = Vapour F=V =3

iquid ,


Vapour Enthalpy

Hethane(vap) = Hpropane(vap) =

e(vap)

dT = dT =

= 1 41 (-3.6) = - 626 .6 J/Kg = 1 15 (-3.6) = - 61 4 J/Kg

p(vap)

1. .1 i uid Enthalpy i uid Ethane

Li uid Propane

    

Usin Ener y balance



 

Hmi = 2.5 [ 0.5 (-626 .6)

0.43 (-61 4) ] = - 1

.3

J/

Hmi = Ye(v) [He(vap) ]

Yp(v) [Hp(vap) ]


1.3

Re-boiler

Fig 5: Re-boiler Flow composition, from T y diagram at 850 KPa and 254. K Vapour mass fraction of ethane = 0. 9 Vapour mass fraction of propane = 0.21 iquid mass fraction of ethane = 0.39 iquid mass fraction of propane = 0.61 V= Vapour fraction of mass flow , V= = 2.1 = 0.

1.4

Valve

Flow composition at 203 K and 101.2 kPa : Vapour mass fraction of ethane = 0. 9 Vapour mass fraction of propane = 0.21 iquid mass fraction of ethane = 0.2 iquid mass fraction of propane = 0. 3

iquid fraction of mass flow,

= 1.

/s

Vapour fraction of mass flow, V =

= 1.32

iquid fraction of mass flow ,

/s

/s,

/s

Fig 6: Valve

1.

Mi ture entering the separator: Vapour fraction of mass flow, V = 1.32 Kg/s

Ethane mass fraction in vapour = 1.043 Kg/s Propane mass fraction in vapour = 0.2 Kg/s

Fig : Separator

iquid fraction of mass flow, = 1.6 Kg/s Ethane mass fraction in liquid = 0.45 Kg/s Propane mass fraction in liquid = 1.22 Kg/s Separator outlet: Top vapour line /s Mass flow rate = 1.32 /s Ethane = 1.043 Propane = 0.277 /s Bottom liquid line iquid flow rate = 1. 7 /s Ethane = 0.4 /s Propane = 1.22

/s

Mass balance of whole system: F = 3Kg/s D = ethane product line B = propane product line F=D B Mass balance of ethane: F =D B 3 0.5 = 0. 5D 0.005B 1.5 = 0. 5D 0.005B

Substituting the equation of whole system into mass balance Equation of ethane B and D are found to be, B = 1.01 Kg/s (propane product line mass flow) D = 1.99 Kg/s (ethane product line mass flow) Vapour leaving the reboiler from T y diagram at 0.5% ethane is 231 K Temperature of ethane product line from T y diagram at 5% ethane is 205 K Following McCabe Thiele principles which states that liquid and vapour flow rate through the column are constant, therefore iquid into reboiler = liquid into column = 1.6 kg/s

1.

Distillation olumn

Fig 8: Multistage Separator

Separator

10

The vapour stream out of top of column can therefore be calculated as the Mass flow rate of ethane product vapour mass flow rate from separator, 1.99 1.32 = 0.6 Kg/s This applies that the vapour out of reboiler into separator is 0.6 Kg/s Ethane product line contains 5% ethane, 1.99 0. 5 = 1.49 kg/s ethane

Therefore ethane vapour coming from column = De(product line) De(first separator) = 1.49 1.043 = 0.449 Kg/s Propane vapour coming from column = 0.6 0.449 = 0.221 Kg/s The temperature of the vapour coming out of the column can be read from the T y diagram using the mass fraction of ethane, which is calculated as follows, 0.6 mass fraction = 0.449, mass fraction = 0.6 Therefore temperature of ethane is 209 Number o sta es re uired: To plot the operation line on the y diagram the following calculations are required, iquid feed in moles, n =
   

Ethane: n = Propane: n

= 14.69 moles = 2 .64 moles = = 0.343, the -a is coordinate of the operating line on

Mole fraction of ethane =

the y diagram for ethane propane system at 101.3 kPa Vapour, ethane product line in moles: Ethane: n = Propane: n = 14.625 moles = 5.01 moles = 0. 45, the y-a is coordinate of the operating

Therefore mole fraction of ethane in ethane product line = line on the y diagram for ethane propane system at 101.3 kPa Vapour, propane product line in moles: Ethane: n = Propane: n


= 0.164 moles

= 22.69 moles = 0.00 1, the second coordinate of the y-a is of

Therefore mole fraction of ethane in propane product line =

the operating line on the y diagram for ethane propane system at 101.3 kPa. This low value effectively means that the operating line is going through the origin of the graph. Figure 9 below shows the operating line plotted using the data calculated above:

11

Fig 9: y Diagram for Ethane- Propane system at 101.3kPa

From the above diagram it can be derived at that a separator with 6 stages is required with 100% efficiency.

To calculate the output temperature of both product lines an energy balance is carried out;

Therefore,

EP = Ethane product line PP = Propane product line



1.7

Pre-cooler 1 (Heatin )

12

And,
   

33260 = 511 .0 Tout 110 161.46 Therefore, Tout = 3 9.6

Tout is equal for both product lines.

The process was modelled in HYSYS and simulated. The results obtained showed slight variations from the numerical solutions but there was some degree of adherence too. The process flow diagram and the report including the various parameters of the streams are included.

Fig 10: HYSYS PFD Screen Shot

2. HYSYS Modellin

1 41 (Tout 205) 1 = 1.99 [0. 5 oooo0.995 1 15 (Tout -231) ]

0.25

1 15 (Tout 205)]

1.006 [0.005 1 41 (Tout -231)

13

Conclusion

Some deviations were observed in the results obtained from the HYSYS simulation and the numerical method. This can be accounted to two main reasons. They are as follows: Specific heat capacity (Cp) was assumed to be constant value in the numerical method , which inn reality is a function of temperature .This assumption is overridden by the temperature calculation in HYSYS calculation. The gas was assumed it to be an ideal gas in the numerical method, which is not the case in HYSYS. Peng Robinson Equation was used in HYSYS modelling.

14

15