Вы находитесь на странице: 1из 35

# Episode 7 : iCON

Basic Training

## Chemical Engineering , Al-Muthanna University, Iraq

Oil & Gas Safety and Health Professional
Trainer of Trainers (TOT) - Canadian Center of Huma
Development
1

## SKG 16 - iCON Basic Training Itinerary

Day

Training Modules

22 October 2013

Slides presentation
1. Compressor Train
2. Demethanizer Column
3. Fractionation Train
4. Propane Loop
5. Steam Reformer

23 October 2013

1. Oil Characterization
2. Refinery Separation
3. Amine System

24 October 2013

1.
2.
3.
4.

## Utility Optimizer Module 1

Utility Optimizer Module 2
Column Optimization
Property Regression

2013 PETROLIAM
2012 NASIONAL
(PETRONAS)

Outline

## Introduction to Process Simulation

iCON Software
Thermodynamic Property Package
Modeling Approach
Hands On Training

2013 PETROLIAM
2012 NASIONAL
(PETRONAS)

## Introduction to Process Simulation

Introduction
Process simulation is the representation/replication of the real world
process behavior through mathematical models.
Process Simulator is a software that predicts the condition, composition
and properties of a particular point (stream) from an initial condition through
mass and energy balances and thermodynamic principles.
iCON is based squarely on fundamental thermodynamic principles
(equation based).
These principles are used in two main features of the process simulator:
The thermodynamic calculation engine
The simulation solver for unit operation and flowsheet.

Introduction

## The thermodynamic engine provides:

Rigorous thermodynamic equilibrium and physical property estimation
for industrially important systems

## The simulation solver continually monitors:

The degrees of freedom of the flow sheet,
Immediately invokes the necessary calculations when the degrees of
freedom are complete,
Solved the system of equations describing the flow sheet.

Dynamic

Always balance

Time
dependence

No

Yes

Accumulation
i.e. level
simulation

No

Yes

Not required

Required

No impact

Impacts flow

## Mass & Energy

Balance

Equipment
dimension
Pressure profile
Typical
applications

Process Design
Equipment Rating &
Monitoring
Utility Balance

Process Control
Optimization
Plant Startup & Shutdown
Operator Training Simulator

## PETRONAS Official Process Simulation Software

What is iCON?
iCON is an innovative
simulation software
modeling tool for oil, gas,
petrochemical, utilities and
power generation
industries.
iCON is capable of solving a
wide range of engineering
problems and is industry
driven. It has been proven in
reliability in oil gas
production, oil refinery,
petrochemicals, utility &
power generation
10

## Thermodynamic Property Package

11

Property Package
A property package is a collections of equations that define (given set of
physical conditions) :
1. State of matter i.e vapor/mix/liquid phase
2. Physical properties.
Derived by fitting experimental data.

12

capacity etc.)

## To determine the in what proportion the component would exist in each

phase (equilibrium)

## The accuracy of the calculated/simulated results will greatly depend on the

accuracy of the thermodynamic package prediction.

13

2012 NASIONAL
2013 PETROLIAM

## Types of Property Package

Equation of State
Model
Good for non polar
liquid and gas
phase since can
calculate critical
point.
Covers a wide
temperature &
pressure range
Soave-RedlichKwong
Hydrocarbon
application

Activity Coefficient
Model

Special Packages

Good to represent
non-ideal liquid due
to presence of polar
components, but
cannot predict
critical point

Customized to
represent specific
process which may
include kinetics
equilibrium data

## Non Random Two

Liquids (NRTL),
UNIFAC, UNIQUAC,
Wilson

Urea, Amine,
Steam97

Chemicals with
high polarity i.e.
water, alcohol

14

## PETRONAS Technical Standards : Property Package Selection

(PTS 20.00.10.37 ) is available in AXIS

15

## 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Example
Objective:
To give an indication of NH3 purity, an online calculation can be implemented as part of
ELMS, to enable operators to take necessary action to drain any contaminants i.e.
compressor oil from NH3.
Actual saturation Pressure
& Temperature

& Temperature

16

## 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Example
Pure Ammonia Temp VS Pressure
1700

Lee
Kesler
Plocker
Thermo

1650

1600

NGL-PR

Pressure (kPaA)
Thermo
1550

1500

Actual
DCS
data

1450

1400
33

34

35

36

37

Temp (deg C)

38

39

40

APR
APR-NG
Refinery SRK
APR-LK
NGL-PR
API SOUR
GRAYSON
STREED
MAXWELL
BONELL
LKP
UNIQUAC
wilson
TK-WILSON
NRTL
VAN LAAR
MARGULES
MARGULES 4
UNIFAC
IDEALgas
PHYSICAL
SOLVENT
REFINERY APR
EXTRACTION
GASIFICATION

The figure above shows multiple plots of pure NH3 using 21 different
thermodynamic packages and a plot of actual DCS data.
Lee-Kesler-Plcker (LKP) is found to be the best suited thermo-package.

17

## 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Modeling Approach

18

Degree of
Freedom

## No. of specification required for the calculation to

complete
progress
Overspecified inconsistency error will created

Unit Operation in
iCON

19

2013 PETROLIAM
2012 NASIONAL
(PETRONAS)

## Modeling Approach Degree of Freedom

Unit
Operation

Typical Specification

Stream

Separator

## With feed stream, separator will converged

without having to specify anything

Cooler/Heater

## With feed stream, user needs to specify either:

1. Temperature outlet, Delta P
2. Temperature outlet, Pressure outlet

Heat
Exchanger

## User needs to have both fluids properties (2

streams; shell and tube)
Other specifications are similar to cooler/heater

Compressor/Pu
mp/Expander

## With feed stream, user needs to specify either:

1. Pressure outlet, Efficiency
2. Pressure outlet, Temperature outlet
If with compressor curve, speed is required as
specification

20

2013 PETROLIAM
2012 NASIONAL
(PETRONAS)

Hands-on
Training..

21

Desktop

22

New file..

23

## #1 Property package: Advance Peng Robinson

Water; Nitrogen; Carbon Dioxide; Methane; Ethane; Propane; isoButane; n-Butane; iso-Pentane; n-Pentane; n-Hexane;
h2o;n2;co2;c1;c2;c3;ic4;nc4;ic5;nc5;nc6;

Water

Nitrogen

Carbon
Dioxide;

Methane

Ethane

Propane

IsoButane

n-Butane

isoPentane

10

n-Pentane

24

## #1 Property package: Advance Peng Robinson

Water; Nitrogen; Carbon Dioxide; Methane; Ethane; Propane; isoButane; n-Butane; iso-Pentane; n-Pentane; n-Hexane;
h2o;n2;co2;c1;c2;c3;ic4;nc4;ic5;nc5;nc6;

Water

Nitrogen

Carbon
Dioxide;

Methane

Ethane

Propane

IsoButane

n-Butane

isoPentane

10

n-Pentane

25

## #3 Flash a material stream

Unit
Temperatu
re

Deg C

30

Pressure

Kpa

1000

Mass Flow

Kg/h

125

Water

Mol %
1

Nitrogen

Mol %
0.5

Carbon
Dioxide;

Mol %

Methane

Mol %

Ethane

Mol %

Propane

Mol %

Iso-Butane

Mol %

45

n-Butane

Mol %

40

isoPentane

Mol %

n-Pentane

Mol %

n-Hexane

Mol %

0.5

2
26

# 4 Flash options

P-T Flash

P-H Flash

Vapor Fraction
(VF) Flash
Calculation

,Composition

## Enthalpy, Pressure , Flow

,Composition
Vapor Fraction, Pressure , Flow
,Composition

27

## # 5 Pseudo component: Min data: Normal Boiling Point or Molecular Weight +

Liquid Density

28

Getting started
Starting iCON from
desktop.
Selecting thermo.
Selecting components.
Converging a stream.
Units.
Bubble / dew points.
Phase diagram.
Special properties.
Making a copy
Spec from
Clone
Copy stream
Show datasheet
Table
Writing

Controller
Temperature control
Process Calculator
Totalizer
Pseudo component
Ammonia ref choosing
thermo

29

## Modeling Approach Data Propagation

In port has a mass
flow of 200 kg/hr
(mole flow = 4.84
kg-mole/hr)
Since the cooler
has a single In and a
single Out material
port:
No accumulation
of matter
No chemical
reactions

Therefore, the:
Mole Flow
Mass Flow
of In and Out port must
be IDENTICAL

30

2013 PETROLIAM
2012 NASIONAL
(PETRONAS)

## Modeling Approach Data Propagation

Now click on the
(Mass Flow, In) cell
and press the
<Delete> key.
You will notice that
the since the mass
flow is not specified,
the mole flow is
automatically
forgotten.

## Note that even

though the mole and
mass flows are NOT
known, the
thermodynamic state
of the In port IS known.
Click on the
node and inspect the
physical properties of
the In port.

31

2013 PETROLIAM
2012 NASIONAL
(PETRONAS)

## Modeling Approach Data Propagation

Click on the
(MassFlow, Out) cell
and specify a mass
flow of 2000 kg/h as
shown below
Hit the <Enter>
key

32

2013 PETROLIAM
2012 NASIONAL
(PETRONAS)

## Modeling Approach Data Propagation

Note that the Out
port mass flow is now
specified (blue
background),
And the mole flow is
automatically
calculated at 4.84
kgmole/h.
Also, note that the
available information is
propagated backwards
to the In port.

33

2013 PETROLIAM
2012 NASIONAL
(PETRONAS)

Flash
Calculations

P-T Flash
P-H Flash
Vapor Fraction
(VF) Flash
Calculation

## Rigorous three-phase calculations except for Wilson

(only vapor liquid)
Type of flash calculation based on degree of freedom
concept depending on specifications imposed on the
system
Independent Variables: Temperature (T), Pressure
(P)
Dependent Variables: vapor fraction, enthalpy and
entropy
Independent Variables: Pressure (P), Enthalpy (H)
Dependent Variables: vapor fraction, Temperature
and entropy
Independent Variables: Vapor Fraction (VF) and
Temperature (T) or Vapor Fraction (VF) and Pressure
(P)
Dependent Variables: Pressure (P) or Temperature
(T) and enthalpy and entropy
Examples:
Dew Points: VF = 1.0, and either P or T
Bubble Points: VF = 0.0, and either P or T

34

2013 PETROLIAM
2012 NASIONAL