Optimal Retrofit of Natural Gas Liquids Separation Direct Sequence and Feed Condition Sensitivity Analysis

Abstract

The objective of this paper is to present the retrofitting analysis for the direct sequence natural gas liquids (NGLs) separation process and to analyse the process sensitivity with respect to feed conditions. To perform the study and analysis, the energy efficient NGLs separation process methodology is developed. Hence, the methodology consists of four hierarchical steps. In Step 1, a simple and reliable short-cut method for distillation column design of process simulator (Aspen HYSYS) is used to simulate a base (direct) NGLs sequence. The energy used to perform the separation is obtained that will be used for comparison purpose. In the Step 2, an optimal NGLs sequence is determined using driving force method. All individual driving force curves for all adjacent components are plotted and the optimal sequence is determined based on the plotted driving force curves. The optimal sequence is then simulated in Step 3 using a simple and reliable short-cut method (using Aspen HYSYS), where the energy used in the optimal NGLs sequence is analysed. Finally, the energy and sensitivity used in the optimal NGLs sequence is compared with the base sequence in Step 4. Several case studies involving several sequences have been used to test the performance of the developed methodology. A maximum energy saving of 11.7 MW was achieved when compared with the optimal (driving force) sequence with the direct sequence. For sensitivity analysis, the results show that the driving force sequence has the best sensitivity compared to other sequences. These findings show that the developed methodology is not only able to design energy efficient distillation columns sequence but also better process sensitivity with respect to the feed conditions for NGLs separation process in an easy, practical and systematic manner.