United Arab Emirates University College of Engineering Chemical Engineering Department Graduation Project II

1. ENGINEERING UAEU United Arab Emirates UniversityCollege of EngineeringChemical Engineering Department Graduation Project II Purity Improvement of De-propanizer Products in Umm Al Nar Refinery Alia Salem 200002345 Maryam Aziz 200104921 Najat Abdullah 200002416 Rabaa Al Awar 200105282 Dr. Mamdouh Ghannam Academic year - 2006/2007

2. Outline • Problem statement. • HYSYS. • Case studies. • Column specifications. • Material Balance. • Energy Balance. • Costing and project Evaluation. • Environmental Impact and Safety.

3. Problem statement One of the main problems relating to the industrial refineries is how to improve the purity percentage in order to produce more pure products so, the main objective of our project is to enhance the purity percentage of the de-propanizer column unit in Umm Al Nar Refinery in order to obtain pure products of propane and butane.

4. HYSYS

5. HYSYS • Definition: Powerful software for simulation of chemical plants and oil refineries. • Includes: • Tools for estimation of physical properties and liquid-vapor phase equilibrium. • Heat and material balances. • Simulation of many types of chemical engineering equipment.

6. Goal of HYSYS • To provide the user with the capability to design an entire process as completely and accurately as possible. • To catch the errors among the simulation.

7. HYSYS Features • Easy-to-Use Windows Environment. • Comprehensive Thermodynamics Foundation. • Comprehensive Unit Operations. • Detailed Heat Exchanger Design and Rating. • Economic evaluation of process designs

8. HYSYS benefits • Helps process industries • Improved Process Designs • Equipment Performance Monitoring • Reduced Engineering Costs

9. Case studies Pressure Temperature Flash Reflux ratio Feed plate location

10. Case studies

11. Column specifications

12. Final Diagram

13. Material Balance • Chemical engineers do a material balance to account for what happens to each of the chemicals that is used in a chemical process. • A material balance was cared out over complete process to determine the quantities of row materials required.

14. Material Balance • The general conservation equation for any process system Accumulation =Material in - Material out + generation - consumption

16. Sample of Calculation • Overall material balance: Component Balance:

17. Result • Table (1) flow rate calculated in tower Table (2) composition of feed, top and bottom in tower

18. For the Flash: Result Table (3) flow rate calculated in flash Table (4) composition of feed, top and bottom in flash

19. Energy Balance • Energybalances are established to determine the energy requirements of processes (heating or cooling). • The energy conservation equation : Energy out = Energy in + generation - consumption -accumulation

20. Energy Balance Overall energy balance • Condenser duty

21. Result Table (5) condenser and reboiler duty calculated

22. Costing and project Evaluation

23. Costing and project Evaluation • Objective: • To estimate the investment required for the project and the cost of production.

24. Parameters needed to estimate the cost :

25. Cost Calculation • Trays Cost: D =0.5 m Type of Tray (valve) Number of Trays =29 trays. Cost of the 29 trays = (29*280 $) = 8,120 $

27. Cont. Calculation • Column Cost: • H = 18.8 m • Equipment Cost = 20,000 $ (from figure) • Purchased cost = (equipment cost (figure)* material factor* Pressure factor) = (20,000* 2*1.2) = 48,000 $ • De-propanizer column cost = Trays cost + purchased Cost = 8,120 $ + 48,000 $ =56,120 $ (year1998)

29. Cost Correction From Figure Cost index in year (1998) = 390 Cost index in year (2003) = 395

31. Total Physical Plant Cost PPC = (1+ Equipment erection+ Piping+ Instrumentation)*cost in year (2006) PPC =(1+0.4+0.7+0.2)*(60,548 $) PPC=139,260 $

32. Environmental Impact and Safety

33. Study Environmental Impact and Safety

34. Study environmental impact and safety for each compounds

35. Methane • Application : • Its used as a fuel in a gas turbine to ignite the electrical generator by burning it • it is the feedstock of choice for the production of hydrogen, methanol & acetic acid. • Methaneis a stable compound which has different health hazard • effects on the vapor and liquid phases. • Characteristics : • it is cleaned burning fuel , non-corrosive, and may be used with structural material. • It is difficult to transport from the areas that produce it to the areas that use . • it was converted from gas phase to liquid phase that are more easily transported • It is inactive biologically and nontoxic. • it is commonly found near swamps and wetland areas. • Health effect : high concentrations of methane causesdizziness and deeper breathing . Table1 : Fire and explosion hazards data for methane

36. Ethane • Ethane: : It consists of two carbons and six hydrogen's which is connected each other by covalent single bonds • Characteristics : • it is a stability and resistance to reactivity. • It is nonpolar component and insoluble in polar solvent . • It is a liquid under pressure. • Health effect : • It cause headache,vomiting, and dizziness . • Application : It is used in many applications such as a fuel, in making chemicals, or as a freezing agent. Table 2:Fire and explosion hazards data for ethane.

37. Propane • Application : • it is used to make petrochemicals which are the building blocks for plastics, alcohols, fibers, and cosmetics. • It is a feedstock for propyl alcohol and a common solvent. • It is used as fuel in hot air balloons and as a fuel for lubrication in guns. • Propane:it's hydrocarbon component and occurs as a gas at atmospheric pressure. • Characteristics : • it is liquefied under high pressure. • It is stored and transported in its compressed liquid form. • Propane is non-toxic and odorless. • Health effect : It cause irritate the eyes and dizziness at high concentrations. Table3 : Fire and explosion hazards data for propane.

38. Butane • Application : • It is used as a fuel for cooking and camping . • It is used as a refrigerant in automobiles • It is consider a petrol component . • Butane:It's hydrocarbon component and is consider unbranched alkane with four carbon atoms • Characteristics : • It's highly flammability gas, colorless, odorless and acute toxicity. • easily liquefied gases • Health effect : It causes sleepiness, irritation, and frostbite, Table 4:Fire and explosion hazards data for butane

39. Pentane • Application : • It could be used as a source of H2 through steam reforming.. • Pentane:It is a longer hydrocarbon than butane and is generally obtained from the processing of crude oil or natural gas. • Characteristics : • It is a product chemical and it is mainly a fuel and a solvent. • It is often used in the laboratory as a solvent • its nonpolarity • Health effect : It has a negative effect on our eyes, bodies and the environment in general Table 5:Fire and explosion hazards data for pentane

40. Thank you for listening