Post on 12-Apr-2020
Executive Summary
How it works Separating fluids is based on the principal of density differences The immiscibility of two liquid phases allows them to be separated in a separator Sufficient space within the separator must be given in order to allow the droplets
of a specific size (diameter) to reach terminal velocity and settle before the gas is extracted.
Advantages (vertical) Advantages (horizontal) Does not need significant liquid retention volume
They are less expensive than vertical separators, though they are used for liquids with less sludge and sediments.
Vertical separators are capable of handling large slugs of liquid and are therefore most often used on low to intermediate gas-oil ratio well streams
Horizontal separators are ideally suited for streams having high gas-oil ratios, constant flow, and small liquid surge characteristics
They are well suited for handling liquids that contain sands and other sediments
Better at handling larger feed flow rate
The separator occupies a small amount of plot space
Due to its large interfacial areas, it has better phase separation capability
Sizing Cost Estimation – Capital cost)
Cost (2011) Lower Bound ($) Upper Bound($)
$ 41374.74 $24824.84 $57924.63
Abdel-Aal, H. A. (2003). Petroleum and Gas Field Processing. Marcel Dekker Inc. James H. Taylor, A. F. (n.d.). Modeling and Control of Three-Phase Gravity Separators in Oil Production Facilities. Retrieved November 10, 2012, from http://www.ece.unb.ca/jtaylor/Publications/acc07_pilot.pdf
References
Carbon Capture Sequestration
Ultrafiltration for CCS
Hollow Fibers
Overview of annual operating
cost Membrane Replacement
Membrane lifetime
Rate of replacement
Energy
Power and efficiency of pumps
Total flow rate
Reference
◦ Wilcox.Jennifer “Carbon Capture”, New York: Springer, 2012
◦ Sandeep. S, “Transient permeate flux analysis, cost estimation, and design optimization in cross-flow membrane filtration” Department of Environmental Science and Engineering, Rice University,1997Danny Luu
Jessica Tang
GLYCOL DEHYDRATIONby Dan Gariepy and Kristen Kolynchuk
Triethylene Glycol (TEG) Molecular Structure:
Purpose:● removes water vapour from wet natural gas● water content decreases process efficiency
and can damage process equipment● companies have specifications on the water
content of gas they will purchase○ (approx. 0.000112 kgH2O/m3gas)
Separation Mechanism:● an absorption column can remove water
vapour from natural gas, using TEG as the absorbent
● TEG has high affinity for water, facilitated by it's hydroxyl & ether groups
● water vapour in the gas will be absorbed by TEG as the streams are contacted
● bubble-cap trays contact the wet natural gas with TEG
Absorption Column:
Bubble-Cap Tray:
COST ESTIMATION
References:1. Manning. Francis. S, Thompson, Richard. E. “Oilfield Processing: Natural Gas” PennWell Publishing Company, South Sheridan, Tulsa, Oklahoma. 1991. 2. Guo. Boyun, Lyons. William. C, Ghalambo. Ali, “Petroleum Production Engineering: A Computer Assisted Approach” Linacre House, Jordan Hill, Oxford. 2007.
Column Properties# of Trays 8
Spacing 3.625 ft
Diameter 5.0 ft
Height 29.0 ft
Volume 569.4 ft3
Temperature 100oF
Pressure 1200 psig
Capacity 169.93 m3/h
Circulation 25 LTEG/kgH2O
TEG Price $0.09/kgTEG
Duration 3840 h/year
Mass Balance:● amount of H2O in inlet gas was
determined using Raoult's law:
(Vapour pressures from Antoine's Equation)
● mass of H2O removed determined using the company specifications
● circulation determined amount of TEG required to remove H2O
First Year Costs[2012 dollars]
Unit Cost $136,436
Installation $272,872
Maintenance $10,593/year
Labour $200,000/year
TEG Flow $53,896/year
Total Cost: $673,797
Biodiesel Produc-on from Vegetable Oil
Triglyceride Methanol Glycerol Methyl Esters (Biodiesel)
Tubular Centrifuge
Light Liquid= Glycerol-‐ Methanol mixture Heavy Liquid= Biodiesel
Cos-ng
BIODIESEL PRODUCTION 70,000,000 L/year
PRODUCTION PERIOD 52 weeks a year, 24/7
ANTICIPATED SALES $49,421,000/year
CAPITAL COST (MOTOR+CENTRIFUGE) $2,455,000
UTILITY COSTS (ONLY ASSOCIATED WITH MOTOR)
$2,428/year
INLET FEED COMPOSITION 60.2% Biodiesel, 39.1% Methanol, 0.7% Glycerol
EXTRA READING OPPORTUNITIES: • Oh, P., Lik, H., Lau, J.C., Junghui, C., Chong, M.F., Choo, Y.M. A review on convenSonal technologies and emerging process intensificaSon (PI) methods for biodiesel producSon. Renewable and Sustainable Energy Reviews 16(2012) 5131-‐5145 • Coulson, J.M., Harker, J.H., Backhurst, J.R., Richardson. (2002). Coulson’s and Richardson’s Chemical Engineering: Par6cle technology and separa6on processes. Buberworth-‐Heinemann
HF Alkylation – Process Overview
HF Alkylation – Costs
Inlet
Column
Condenser
Kettle Reboiler
Alkylate
Side draw
Separator
HF
Light Oil
Steam
Condensate
Item Cost (C$)
Total CapEx 5,381,000
Operators 44,000
Steam 645,000
Maintenance 161,000
Electricity 93,000
Total OpEx 943,000
[1] G. Towler & R. Sinnot (2009), Chemical Engineering Design, 5th Ed., Elsevier [2] R. Meyers (2004), Handbook of Petroleum Refining Processes, 3rd Ed., McGraw-Hill
Production of Benzene from Hydrodealkylation of Toluene (Alaa Salam and Saeed Mobayed)
Process Flow Diagram
Reaction: Toluene + H2 → Benzene + CH4 (Irreversible reaction)
2 Benzene ⇌ Diphenyl + H2 (By-product of the reaction)
Separation Units: Flash drum, Three Distillation Columns ( Stabilizer, Benzene, Toluene)
Physical Principle: Exploiting the boiling point of component
Estimated Costs of the Separation Process in HDA
Production Rate of benzene : 265 mol/hr Value of benzene is : $ 9.04/mol Value of the produced Benzene in one year: $ 17,410,500
Benzene column
(product) Cost
Toluene Column
(recycling) Cost
The Grand Total of the Separation Process is: $ 672,800 / year References: [1]Richard Turton: Analysis, Synthesis and Design of Chemical Processes, Third Edition, (2008), Chapters 1-4. [2]Robert Perry; Don Green: Perry’s Chemical Engineers’ Handbook, Eighth Edition, McGraw-Hill, (2008), Chapter 13 Distillation
Cost
Benzene Distillation Column 120,000 $
Installation 20,000 $
Separation of (benzene) & (Toluene and diphenyl)
81,000 $/year
Cooling Water 12,900 $/year
Condenser 26,700 $/year
Heat 20,800 $/ year
Steam 102,600 $/year
Total 384,000 $ /year
Cost
Toluene Distillation Column 85,000 $
Installation 15,000 $
Separation of Toluene & Diphenyl 26,300 $/year
Cooling Water 2,600 $/year
Condenser 6,500 $/year
Heat 8,600 $/ year
Steam 49,600 $/year
Total 193,600 $/year
Disk Stack Centrifuge for Insulin Production
Manufacturing Process of insulin
Inside of a Disk Stack Centrifuge
By: Ushna Ikram Allen Winata
Design and Cost Analysis
N 120
r1 (m) 0.13
r2 (m) 0.08
(rpm) 6000
Angle 35
Sigma 35944.94
Design parameters
Equipment Cost - $155,000+/- 40%Operational Cost - $14,256/yr
Design Equation
References: Leung, Wallace Woon-Fong. (2007). Centrifugal Separations in Biotechnology. Elsevier Science & Technology. Retrieved 14 November 2012 (Disk Stack Centrifuge)Petrides D. Bioprocess Design. 2000 (Insulin Process)
Uranium Recovery using Counter Current Solvent Exchange
Stokes Law:
𝑣𝑠 =2 𝜌𝑝−𝜌𝑓
9𝜇𝑔𝑅2
Operating Costs and Installation
Element Cost
Bare Module $543,000-$1,627,000
Agitator Costs $1247/yr
Solvent Costs ($4.5/gal) $121,000/yr
Total Operating Costs $122,000/yr
Useful References: IAEA (1980). Technical Report Series No. 196. Significance of Mineralogy in the Development
of Flowsheets for Processing Uranium Ore [Online].
Available: http://www-pub.iaea.org/MTCD/publications/PDF/trs196_web.pdf
D. C. Seidel (1981). Vol . 32 No. 2. Extracting Uranium From its Ores [Online].
Available: http://www.iaea.org/Publications/Magazines/Bulletin/Bull232/23204882428.pdf
Decanter Centrifuge Unit Overview Capable of handling feed with significant solids concentration
Ideal for solid-liquid separation processes
Capable of three phase separation
Solid cylindrical bowl, conical shaped
Screw Conveyer, operated at differential speed
Thomas Oszustowicz Jordon Perry
Mass Balance on Solids:
F – Feed S – Solids stream C – Clarified liquids stream
Annual Operating Costs
References: 1. Perry’s Chemical Engineering Handbook (Don Green and Robert Perry) 2. Decanter Centrifuge Handbook (Alan Records and Ken Sutherland)
Perry’s Chemical Engineering Handbook was used to obtain the purchase cost and energy usage for a typical decanter centrifuge, which are $160,000 and 30 hp respectively. The following table summarizes annual operating costs:
*Using salvage value = $10,000 and an average life of 20 years **Assuming it runs 24 hours/day every day of the year with an energy cost of 8 cents.
Froth Flotation
• Separation based on gravity, densities and hydrophobic properties of bitumen
• Separation unit sized as a typical clarifier
• Feed : 8 wt% bitumen, 50 wt% water, 42 wt% sand
• Froth: 66 wt% bitumen, 25 wt% water, 9 wt% sand
• Calculated dimensions: Diameter = 37 m , Height = 14.5 m
• Total Capital Cost: $1,401,150 to $3,269,350
Operating Costs
•12 kW electricity requirement for skimmer/rake
•Slow rotative speed of skimmer results in low operating costs
•Annual Operating Cost = approx. $12,500
References:
1. Perry, R.H., and D.W. Green, Eds. Perry’s Chemical Engineering Handbook 6 th Edition., McGraw-Hill New York (1984).
2. Heinemann, H., Speight, J. (2006). The Chemistry and Technology of Petroleum 4 th Edition, Recovery of Heavy Oil and Tar Sand Bitumen (pp. 117- 208). New York: CRC Press.
CAPITAL AND OPERATING COSTS
Ethanol production from sugarcane – Absorption Column James Scott & Sahil Azeez
The absorption column exploits the relatively high miscibility
of ethanol (EtOH) in water to separate it from carbon dioxide
(CO2)
Mass Balance/operating line:
Equilibrium line:
Installation and Operating Costs
Item Material
Cost (USD $)
Labour Cost (USD $)
Equipment and
setting
152,400 7,491
Piping 17,676 16,792
Civil 1,845 2,745
Structural steel 14,952 5,005
Instrumentation 24,907 9,107
Electrical 3,311 1,358
Insulation 13,041 11,523
Paint 780 1,586
Subtotal 228,912 55,607
Total Installation
Costs
284,519
Provided by Aspen Icarus in 2006 US dollars
Table 2: Absorbent costs Table 1: Material and Labour costs
Parameter Value
Flow rate (m3/hr)
6.26
Cost ($/m3) 0.20
Cost
($/year)
$14,000
References: 1. Sieder, Henly and Roper, Separation Process Principles, 3rd Edition, Wiley,
Chapter 6 2. B.Jaime, Priniples and Modern Applications of Mass Transfer Operations¸
Wiley & Sons, New Jersey, 1948 pg 252-270
Condensers in the Production of Sulfur in the Claus Process
The Claus Process:
• Makes sulfur from sour gas
(H2S)
• Direct contact condensers separate sulfur
Direct Contact Condenser:
• Mixes vapour and coolant
streams
• Results in liquid sulfur product
1 Jonathan Howell & Heera Marway Chem Eng 4M04 ~ 2012 ~ Course Project
Condensers in the Production of Sulfur in the Claus Process
Condenser cost: For one direct contact condenser = $17177-40053* *Calculated using Table 5-9 Woods, D. R. Cost Estimation for the Process Industries (Fall 1993.).
Annual Operating cost: Main cost is cooling water = $ 2958000/year ** ** based on industrial water cost in Toronto (Nov. 2012)
Considering an operation of 340 days a year and not considering recycle
Suggested references: Geankoplis, C. J. (2009). 8.6 Condensers for Evaporators. Transport Processes
and Separation Process Principles (Third ed.). Upper Saddle River, New Jersey: Prentice Hall.
El-Bashtawi, R., & Haimour, N. Claus Recycle with Double Combustion Process. Elsvier Fuel Processing Technology, 86(2004), 245–260.
2 Chem Eng 4M04 ~ 2012 ~ Course Project Jonathan Howell & Heera Marway
FLOTATION SEPARATION IN POTASH PRODUCTION By: Viktoriya Todorova and Hisham Al Dosouky
Capital Cost
F.O.B. Cost: $27,121±11000 PER BANK (x5 CELLS)
Operation:
24h/day/365 days/yr/
8 h/shift
3 operators/day
Salary: $35/hr
Operating Cost
ENERGY COST $ 24,470
LABOR COST $ 306,600
MATERIALS COST (COST+20%LOSSES)
$ 52,700 (ONCE)
REFERENCES
[1]Wills, B. (1992). Mineral Processing Technology. Cornwall: Wheatons Ltd [2]Tech:, M. (2012). Flotation Fundamentals. Retrieved 2012, from Department of Chemical Engineering: http://www.chem.mtu.edu/chem_eng/faculty/kawatra/Flotation_Fundamentals.pdf [3] Ives, K. (1984). The Scientific Basis of Flotation. London: NATO Scientific Affairs
Purpose: Removal of hydrogen sul5ide from natural gas Solvent: Methyl diethanolamine (MDEA) Gas Absorption unit acting in countercurrent 5low between the incoming sour gas 5low and MDEA solvent. Tower Choice: Trays were selected due to incredibly high 5low rate of natural gas Flow rate: 2000 cubic kilometers / day
Andrew Bovell, Jamie Chung
Cost Es8ma8on Sizing
Tower Height 45.72 m Tower Diameter 1.67 m Trays 21
Tray Spacing 2.1 m
Material 316 S.S.
Feed Rate 2000 km3/Day
Cos)ng
Unit Sizing (Height)*(Diameter)1.5
Using Don Woods Table 6-6
1970 Base $192,632
1970 Bare Module $801,353
2010 Bare Module $3,891,904 Actual Cost (1968 Cost Inflated) $4,787,042
References [1] Kohl, A. L. and F. C. Riesenfeld, Gas Purifica8on, 3rd Ed., Gulf Publishing Co., Houston [2] The Dow Chemical Company, "Gas Sweetening," October 1998. [Online]. Available: hSp://msdssearch.dow.com/PublishedLiteratureDOWCOM/dh_0039/0901b803800391f8.pdf?filepath=gastrea8ng/pdfs/noreg/170‐01395.pdf&fromPage=GetDoc
Andrew Bovell, Jamie Chung