Hydrogen Recovery form Refinery Off-gases

Background 

Hydrogen is one of the main intermediate products largely utilized in 

 

oil and petrochemical industries.

 

• It is used as a raw material and obtained in some processes as a by-product.

 

• The off-gas streams contain considerable amount of hydrogen, which are

 

mostly incinerated in refinery flares as a waste gas.

 

>Hydrocarbons are converted into hydrogen reformers in order to produce

 

the hydrogen needed for hydrogen consuming processes.

 

>Separation of hydrogen from an existing refinery off-gas stream

 

represents an opportunity to achieve significant cost reductions in refineries

>Cryogenic Technology (CT)

 

Separation principle:

 

Cryogenic technology is based on the difference in the relative

 

component volatility at low temperatures.

 

Disadvantages:

 

Extra compressors to increase the pressure at least 20 bar. CO2 separation

 

is necessary to avoid freezing the CO2 in line at low temperatures.

see simulation 

 

Flash Calculations

Learning Objectives

How to make flash calculation in Hysys.

Flash evaporation is one of the simplest unit operation that

 

separates components into liquid and

 

vapor phased on relative volatility.

see simulation 

 

Saturated Steam Table

Learning Objective 

How to obtain saturated steam properties in HYSYS

Background

 

The temperature window for saturated steam is up

 

to critical point of water that is 373.94 °C. So the

 

saturated steam table will be between 100 °C to 373 °C.

 

HYSYS property packages:

 

ASME Steam (1967)- Outdated NBS Steam (1984)-

 

higher pressure range up to 10000 bar and 2000 K.

Problem statement Calculate

 

the saturated steam properties from 100°C to 373°C. Create a table that shows pressure, molar enthalpy and molar entropy.

see simulation

 

Bubble Point and Dew Point Calculation

  Learning Objective 

Bubble point and dew point of pure components. 

 Bubble point and dew point of mixtures

Definitions 

Bubble Point: The bubble point is the point at which the first

 

drop of a liquid mixture begins to vaporize.

 

Dew Point: The dew point is the point at which the first vapor

 

of a gaseous mixture begins to condense.

see simulation 

 

OIL AND GAS SEPARATION

Learning objective 

How to conceptual design builder  to process the gas oil separation from an oil field 

l

 

Reactive Distillation in DWSIM

Learning Objective 

• How to setup chemical reaction kinetics in distillation column. 

• How to specify reaction chamber inside distillation column. 

• How to recover unreacted reactant and recycle it. 

• How to use pump and valve unit operations

Basic Information 

It integrates chemical reaction and distillation in a single apparatus. (reversible,

 

liquid phase reactions)

 Removing one or more of the products is one of the principles behind

 

reactive distillation

>reduced capital investment 

>significant energy savings 

>surpass equilibrium limitations 

>simplify complex processes

 >Increase product selectivity

>improve separation efficiency 

SEE SIMUALTION

 

Relief Valve Sizing

Learning Objectives 

How to set up a pressure safety valve in HYSYS 

SEE SIMULATION

 

Distillation Column Internals

 

Learning objectives 

• How to Design the distillation column internal

. Flooding and weeping concepts 

Flooding 

• Excessive liquid build-up in column leads to flooding condition.

 • Liquid cant get down the column due to high vapor velocity. 

• It sets the upper limit of vapor velocity for steady State column operation

Weeping 

• At low vapor flow rates, liquid starts to leak from the plate holes.

 • When none of the liquid reaches to downcomers at extreme weeping 

condition at very low vapor flow, is called dumping

see simulation 

HYSYS,VACUUM DISTILLATION/ PART4

Learning objectives

 How to simulate vacuum distillation column to treat atmospheric

unit residue

Problem Statement

 

Additional steam is injected into the Vacuum Feed Heater to increase

 

velocity & minimize coke formation within the heater

 

HYSYS, Debutanizer Simulation part3

 learning Objective Part 3  

 How to simulation debutanizer column to stabilize the Naphtha and to recover LPG 

 

ALL DATA IN YOU ARE NDD IN SIMULATION  

PART3 SIMULATION 

 

HYSYS. Atmospheric Crude Distillation Part2

‏Learning objectives

 Simulation of atmospheric distillation column

How to setup crude distillation unit with three side strippers

 and three pump arounds in HYSYS

part2

 

Petroleum Assay Crude Oil Distillation

 

Learning objectives

• How to generate petroleum assay from Light crude, Medium crude and Heavy

 crude to have mix crude for atmospheric distillation.

 

• Preheat train for atmospheric distillation.

 

Problem Statement Crude Oil Feed:

 

100°F, 300 Psig, 101,000 bpd ,Preheater-1 outlet: 260°F, 294 Psig ,Desalter outlet: 260°F, 294

    

.psig, 500 bpd water , Preheat-2 outlet: 450°F, 260 psig 

 

Table 1 

 

Table2

 

See Simulation                                    

 

Hysys Dynamic Modelling _ Filing of Water Tank

 

learning objective

How to build dynamic simulation. 

Interaction between set points and process variables


It is an extension of steady-state whereby time-dependence

 

is built into the models i.e. accumulation of mass and energy.

 

Control of real processes are possible.

 

The calculations are more complex and time consuming.

 

Interaction between set points and process variables

Crude Oil Simulation 2

>called Water, at 15°C and a mass flow rate of 21600 kg/h cooler 

>Delta P of 50 kPa. temperature of 65°C Temperature 180 C,

 >Pressure 200 kPa and Std Ideal Liq Vol Flow of 175 m3/h

Min Approach = 30°C heater 

 >Delta P 375 kPa To Preflash Temperature 175°C %3D heater 2 

>Delta P 250 kPa Feed Temperature 400°C

PART3

PART4

PART5

 

Crude Oil Simulation

 

>called Water, at 15°C and a mass flow rate of 21600 kg/h cooler 

>Delta P of 50 kPa. temperature of 65°C Temperature 180 C,

 >Pressure 200 kPa and Std Ideal Liq Vol Flow of 175 m3/h

Min Approach = 30°C heater 

 >Delta P 375 kPa To Preflash Temperature 175°C %3D heater 2 

>Delta P 250 kPa Feed Temperature 400°C

very important sumilation 

Aspen Hysys Simple Distillation Column Walkthrough

Simple Distillation Column 

 simple simulatio Distillation Column 1,2- Dichloroethane and  1,1,2-Trichloroethan  

SEE SIMULATION 

 

Heat Exchanger

 

Heat Exchanger Hot water at 500°C and 2000psig is

 

used to heat cold stream of water in a shell and 

 

tube heat exchanger. The inlet temperature and

 

pressure of the cold stream is 50°C and 260psig, 

 

respectively. The outlet temperature of the cold and hot

 

streams are 300°c and 360°C, if the flow rate of the

 

 hot stream is 100kg/h,determine the flow rate of the

 

 cold stream passing throughout the exchanger.

 

see simulation

 

Design of Heat Exchanger ASPEN Shell & Tube Exchange

 

 Design of Heat Exchanger V10 An example: 

 

Design an exchanger to sub-cool condensate from a methanol

 

condenser from 95°C to 40°C. Flow-rate of methanol 100,000 kg/h.

 

Cooling water will be used as the coolant, with a temperature rise

 

from 25°C 40°C.

 

HYSYS SIMULATION/CSTR

 

INTRODUCTIC 
 

In this lecture, a flowsheet for the production of propylene glycol is presented. Propylene

 oxide is combined with water to produce glycol in a CSTR • The propylene oxide and

 

water feed streams are combined in a mixer. The combined stream is fed to a reactor,

 

operating at atmospheric pressure, in which propylene glycol is produced.

PROBLEM STATEMENT

 Simulate the production of Propylene Glycol from Propylene oxide and excess water

 

using a CSTR. 

                         H2O+ C3H6O -----------------> C3H8O2 

 

>Fluid package: UNIQUAC 

• Base Component: PropyleneOxide. 

• Reaction Phase: Combined Liquid.

 • Forward Reaction Arrhenius Parameters:

 -Frequency Factor: 1.7 x 10^13

- Activation Energy: 3.24 x 10^4. btu/Ibmole

 

see the simulation 

 

Simulate Equilibrium Reactor

PROBLEM STATEMENT

 The new application of hydrogen as a raw  for fuel cells for mobile power source

 (PEM fuel cells) requires that the inlet gas have a concentration lower than 10-20 ppm.

 Otherwise, the anode is poisoned and the cell efficiency abruptly drops. Hence, if the

hydrogen is produced from hydrocarbon or alcohol reforming, purification is required in 

 

order to reduce the CO levels to cell requirements. The most technologically feasible

 

purification train consist of a water gas shift reaction (WGS). The reaction 

CO + H20 <----------------->CO2 + H2 

has been employed for 40 years in the industrial process for H2 production from liquid

 

and gaseous hydrocarbon. The role of the WGS reaction is to increase the H2 ryield and

 

decrease the CO concentration, which is a poison for some catalyst used.

LEARNING OUTCOMES

>Simulate equilibrium reactor and reactions in HYSYS. 

>Re-Add the reactions and reaction 

>Attach reaction sets to the fluid package. 

SEE VIDIO PART1 AND 2

PART 1 SIMULATION

                  PART 2 SIMULATION 

 

Conversion of HYSYS Simulation

 

PROBLEM STATEMENT . 

Develop a model that represents partial oxidation of methane to produce hydrogen. 

• Given the following

 conditions; Fluid package: Peng- Robinson Temperature: 25°C. Molar flow for CH4 : 100 kgmole/hr

 Pressure: 2 bar. Molar flow for Air(79% N2 & 21% O2): 260 kgmole/hr %Conversion: 40% and 60% for

 Rxn 1 and 2 resp

BUILDING THE SIMULATION

 • Access Hysys. 

Define Simulation Basis. 

• Add reactions. Add reaction sets. Make sequential reactions. 

• Attach reaction to fluid package. Add feed streams 

• Add the conversion reactor 

Flash Separator

INTRODUCTION • 

A flash separator is a device or an equipment used in several industrial applications to separate a vapour- liquid mixture. It is performed to determine the product condition and phases. It is referred also to as flash drum or knock- out drums.

PROBLEM STATEMENT 

We have a stream containing 15% ethane, 20% propane, 60% i- butane, and 5% n- butane at 50°F and atmospheric pressure and a flowrate of 100lbmoles/hr. Th compressed to 50 psia, and then cooled to 32°F. The resulting vapour and liquid are to be separated as the two product streams. What the flowrates and compositions of these two streams?

 

Pipe Sizing- Hysys- pressure drop

 

 Pressure drop calculation and how use of adjust function  

Q= A . V  

P= 2 bar 

T=25c 

flow rate =?

 

 

Hysys Simulation of Pump

 

Estimate the outlet temperature of n-hexane and note down the duty of the pump 

Use hysys to find solution

ex: estimate  n-hexane pressure in  3 atm to 10 atm 

 

 

Adding Material Streams

 Hysys simulation -

>Starting HYSYS 

>Simulation Basis Manager

>Creating A New Simulation

>Adding Components to the Simulation

>Selecting A Fluids Package 

>Selecting Thermodynamics Model 

>Enter Simulation Environment

>Adding Material Streams

>Review and Summary Problems