United Arab Emirates University College of Engineering Training and Graduation Project Unit Graduation Project II

1. United Arab Emirates UniversityCollege of Engineering Training and Graduation Project UnitGraduation Project II Gas –To– Liquid (GTL) Plant Design Faculty Advisor: Dr. Mohamed A. Nakoua Chemical & Petroleum Engineering Department Rasha Ahmed Ali 200440204 Latefa Salem Ahmed 200323476 Fatima Sulaiman200401351 AminaAbdulrahman 200440256

2. Outline

3. GTL technology converts simple carbon-, hydrogen-, and oxygen containing molecules to hydrocarbons (fuels) through a three step process. IntroductionGas-to-liquid(GTL) Products Feed stocks Process Steps Natural gas (CH4 ) Power Fischer-Tropsch H2 +CO LPG Simple Molecules Syngas Production Syngas Conversion Product Upgrading Naphtha Kerosene Oxidant Diesel Wax O2 Lubes Chemicals The Fischer-Tropsch synthesis has been used for >80 years (mainly coal!) as feedstock

4. Introduction Gas-to-liquid (GTL)

5. PFD

6. Heat Exchangers • A device built for efficient heat transfer from one medium to another & the media may be separated by a solid wall, so that they never mix or they may be in direct contact. • Classification : according to their flow arrangement: • Parallel-flow heat exchangers • Counter-flow heat exchangers • Cross-flow heat exchanger Parallel-flow heat exchangers • Counter-flow heat • exchangers • Cross -flow heat • exchangers

7. Heat Exchanger • Types of Heat Exchanger: • Double- pipe exchanger • Shell & tube exchanger • Plate & frame exchanger • Plate –Fin exchanger • Spiral heat exchanger • Air cooled . • Direct contact • Fired heaters .

8. Heat Exchanger • Shell & Tube Exchanger: • It is consisted of a series of tubes; • one set of these tubes contains the fluid that must be either heated or cooled. The second fluid runs over the tubes . • It is the most common type of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-pressure applications.

9. Design Methodology • Define the duty: heat transfer rate, fluid flow and temperature. • Collecting the fluid physical properties required. • Decide on the type of exchanger to be used. • Select the trial value for the overall coefficient, U. • U = 20-300 W/m2.°C • Calculate the mean temperature difference (∆Tm).

10. Cont. Design Methodology = = m m 0 . 33 0 . 14 Nu h * d / k j * Re* Pr * ( / ) o i n w • Calculate the area required. • Calculate the individual coefficients. • Calculate the overall coefficient and compared with the trial value. • Calculate the exchanger pressure drop.

11. Heat Exchanger Specifications

12. Gas compressor Mechanical device increases pressure of a gas by reducing its volume C-107A/B Stream 7 P in= 0.1 atm Tin= 473K Stream 8 Po = 1.5 atm

13. Compressor Design Type of compressor Positive displacement Dynamic Reciprocating Rotary Centrifugal Axial

14. What type to use for C-107A/B? High volumetric flow rate ( 5.87 m3/s)

16. Compressor Design Main objective is to find the discharge temperature and the work that’s applied The outlet temperature of the compressor was calculated by the following equation: The work which is applied on the system is calculated based on the inlet and outlet conditions:

17. Results

18. Reactors • Heart of a chemical process • Characteristics to classify reactor design: • Mode of operation: batch or continuous. • Phase present: homogeneous or heterogeneous. • Reactor geometry: flow pattern and manner of contacting the phase • Stirred tank reactor • Tubular reactor • Packed bed, fixed and moving • Fluidized bed

19. Examples of reactors • There are a wide variety of reactors in use in the chemical processing industry. Packed Bed British Petroleum (BP) Batch CSTR

20. Reactor Design • Main objective is to find the volume of the • reactor and the weight of the catalyst . • Various catalyst particle shapes are sold • commercially for a wide variety of process • technologies • Our Catalyst was (Ni supported on Al2O3) • cylindrical shape for R-103

21. Reactor Design • The effectiveness of the catalyst is a ratio where • ractual = rate of diffusion at the mouth of the pore • rideal = rate on the assumption that all of the pore surface • is exposed to the concentration at the external surface • Effectiveness factor for cylindrical pellets is given by: 1 4 5 2 6 3

22. Cont .Reactor Design • The volume of the reactor was found assuming no pressure • drop and no temperature change in the reactor. • Volume of the reactor was found to be 25 m3 • When dividing the volume of the reactor by porosity(0.4) • to find cat Vol. and using density we found W= 38840 Kg

23. Cont .Reactor Design results

24. Separator • Remove impurities and separate the different fluids from each other • GTL (gasoline, a mixture of gases (CH4, H2, CO) and water) • Separators are usually characterized as • Vertical • Horizontal • Spherical

25. Characteristics of separator Vertical Horizontal • When sand , paraffin or wax • are produced • Plot space is limited • Ease of level control is desired • Small flow rate • Very low or very high gas oil ratio (GOR) • streams • Large volumes of gas and/or liquid • High to medium GOR streams • Foaming Crudes • Three phase separation

26. AdvantagesvsDisadvantages

27. Vertical Separator V-101 Design P = 1 bar, S = 944.83 bar E = 0.9 CA = 0 t= 0.000337m (less than min) →t= 0.005 m

28. Bare module estimation

29. Bare module estimation *CAPCOST

30. Manufacturing cost estimation

31. Cash Flow Analysis

32. Pilot Plant Cost

33. Hazardand Operability study (HAZOP) • Brainstorming, Multidisciplinary Team Approach • Structured Using Guide Words (like no, less, more) Problem Identifying • Cost Effective • When to use it ??? • when applied to new plants at the point where the design is nearly firm and documented or • to existing plants where a major redesign is planned. • It can also be used for existing facilities.

34. HAZOP HAZOP STUDY

35. PRINCIPLES OF HAZOPS CAUSE DEVIATION CONSEQUENCES (from standard (trivial, important, condition catastrophic) or intention) -hazard -operating difficulties *COVERING EVERY PARAMETER RELEVANT TO THE SYSTEM UNDER REVIEW: i.e. Flow Rate. Flow Quantity, Pressure, Temperature, Viscosity, Components

36. HAZOP Example Node = Deviation PARAMETER + GUIDE WORD (Temperature) (High) (High Temperature) Causes:1. Less utility Flow rate with high processing fluid Flow 2.Heat Exchanger failure Consequences: 1.Less conversion (less production) in reactor due to working outside the reaction favored temperature range. 2.Deactivation of the catalyst. Actions: 1.High Temperature Alarm (HTA) 2.Increase utility flow rate and decrease processing flow rate . 3.Use cascade control cw cw

37. ProjectManagement GP1 Planning, organization, directing and controlling of assigned resources in order to accomplish a given objective within the constraints of time, cost and performance

38. ProjectManagement GP2

39. Conclusion

40. Conclusion • GTL is an exciting new way to bring natural gas energy to the market. • The total cost for starting this project was calculated to be $2.65*106US$ with net profit of 6.42*106 US$/yr which will have a breakeven after the 4th year on a 10 year plant life time. • HAZOP study was established. • Plant was specified on Um Al Naar due to the availability of the petroleum refining for the fuel blending.

41. Recommendations • Cost for equipment should be compared with the industry • Project management Issues is IMP to achieve the objectives • Environmental consideration should be studied in details.