Optimization of Propane

Refrigeration System for

Hydrocarbon Dew Pointing and NGL
Extraction
Mahmood Moshfeghian
mahmoodm@jmcampbell.com
TGTC
Lowlands, Tobago
October 7-10, 2008

Outline

Objectives
Dew Pointing & NGL Extraction
Refrigeration System
Simple
Two stage with Flash Economizer
Two Stage with HEX Economizer

Simulation & Optimization Results

Conclusions & Recommendations

Objectives

To pump low temperature heat from the

process fluid to high temperature
To optimize the performance of a propane
refrigeration system
To compare the performance of simple to
economizer systems
To study the effect of impurities

Dew Pointing & NGL Extraction

Technologies

Pressure and or Temperature Change

Mechanical Refrigeration
Turboexpansion
Valve Expansion
Twister

Absorption
Adsorption

Dew Pointing & NGL Extraction

Mechanical Refrigeration

Pros
Simple, proven
Best choice for gas conditioning when inlet & outlet pressure are
the same
Propane most popular refrigerant
Can provide reasonable NGL recoveries (C4+) when feed gas is rich

Cons
Not suitable in gas conditioning applications when feed gas
pressure exceeds about 80 bara (1160 psia)
Not the optimum gas conditioning process when free
pressure drop is available
Limited to about -40C [-40F] for C3

P, kPa

T, C

3000

-3.0

5000

-7.2

7000

-19.4

7500

-25.1

7900

-34.0

Two-Stage Compression with Flash

Economizer

Two-Stage Compression with HEX

Economizer

Case Study-Design Parameters

Chiller Duty = 1.0x107 kJ/h (2778 kW)

Chiller Exit T = -35 C
Ambient T = 35 C
Chiller P = 5 kPa
Compressor Suction Line P
= 30 kPa
Discharge Line & Condenser P = 50 kPa
Compressor Discharge P = 1270 kPa

Impact of interstage pressure on

power

Impact of interstage pressure on

stage compression ratio

Impact of suction-line pressure drop on power

saving (Interstage pressure drop=0 kPa)

Impact of compressor interstage pressure drop on

power saving (Suction-line pressure drop=30 kPa)

Composition of the working fluids

Composition, Mol Fraction
Case
No

Ethane

Propane

i-Butane

Molecular
Weight

Molecular
Weight
Ratio

n-Butane

44.10

1.000

0.01

0.99

43.96

0.997

0.02

0.98

43.82

0.994

0.03

0.97

43.68

0.990

0.04

0.96

43.54

0.987

0.05

0.95

43.40

0.984

0.99

0.005

0.005

44.24

1.003

0.98

0.010

0.010

44.38

1.006

0.97

0.015

0.015

44.52

1.010

10

0.96

0.020

0.020

44.66

1.013

11

0.95

0.025

0.025

44.80

1.016

Effect of ethane and butane

impurities on circulation rate

Effect of ethane and butane

impurities on condenser duty

Effect of ethane and butane

impurities on compressor power

Summary of Simulation results

(Simple vs. HEX Economizer)
HEX Outlet (Stream R14-2-2) Temp
Parameter

Simple

30 C

20 C

10 C

0 C

-5 C

Compressor Inlet T, C

-35.3

-25.7

-7.3

9.4

24.8

32.0

Compressor Outlet T, C

67.5

84.6

104.2

121.9

138.1

145.8

Total Single Stage Power, kW

1691

1821

1769

1721

1677

1657

Circulation Rate, kg/h

41985

39526

35544

32443

29947

28870

Compressor Outlet P, kPa

1270

1270

1270

1270

1270

1270

Compressor Inlet P, kPa

127.4

107.4

107.4

107.4

107.4

107.4

Compressor Comp Ratio

10.0

11.8

11.8

11.8

11.8

11.8

Condenser Duty, kW

4469

4598

4546

4499

4455

44350

Summary of simulation results (Simple vs.

Two Stage Flash Tank and HEX Economizer)
HEX Cold Side Approach Temperature
Parameter

Flash Tank

2 C

3 C

4 C

5 C

1st Stage Power, kW

874.0

858.2

865.0

872.1

879.2

2nd Stage Power, kW

714.2

746.4

747.7

749.0

750.4

Total Two Stage Power, kW

1588.3

1604.6

1612.8

1621.1

1629.6

Total Single Stage Power, kW

1848.1

1848.1

1848.1

1848.1

1848.1

Inter Stage Pressure, kPa

530.0

510.0

510.0

510.0

510.0

% Compressor Power Savings*

14.1

13.2

12.7

12.3

11.8

Circulation Rate, kg/h

40127.0

40206.5

40246.8

40287.9

40329.8

1st Stage outlet P, kPa

550.0

530.0

530.0

530.0

530.0

1st Stage inlet P, kPa

107.4

107.4

107.4

107.4

107.4

1st Stage Comp Ratio

5.1

4.9

4.9

4.9

4.9

2nd Stage outlet P, kPa

1270.0

1270.0

1270.0

1270.0

1270.0

2nd Stage inlet P, kPa

510.0

490.0

490.0

490.0

490.0

2nd Stage Comp Ratio

2.5

2.6

2.6

2.6

2.6

Single Stage Condenser Duty, kW

4625.9

4625.9

4625.9

4625.9

4625.9

Economizer Condenser Duty, kW

4366.0

4382.4

4390.5

4398.9

4407.4

% Decrease in Circulation Rate*

5.6

5.3

5.1

4.9

4.7

Conclusions & Recommendations

Impurities increases the power consumptions

The desired ranking
1.
2.
3.

Two-Stage compression with flash tank economizer

Two-Stage compression with HEX economizer
Simple

The minimum power is not at equal

compression ratio
Line pressure drop increases power
consumption