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TROUBLESHOOTING, Kolmetz Handbook Of Process Equipment Design

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 Page : 1 of 69

KLM Technology
Group Rev: 01

Practical Engineering Engineering Solutions

Guidelines for Processing
Plant Solutions Rev 01 May 2013

www.klmtechgroup.com
Co Author
KLM Technology Group Kolmetz Handbook
Rev 01 Aprilia Jaya
P. O. Box 281 Of Process Equipment Design
Bandar Johor Bahru,
80000 Johor Bahru,
Johor, West Malaysia LIQUIFIED PETROLEUM GAS (LPG)
UNIT SELECTION, SIZING AND Author / Editor
TROUBLESHOOTING Karl Kolmetz

(ENGINEERING DESIGN GUIDELINES)

TABLE OF CONTENT

INTRODUCTION

Scope 3

General Design Consideration 4

DEFINITIONS 18

NOMENCLATURE 21

THEORY OF THE DESIGN 23

Physical Properties 23

Fractionator Column 26

Reboiler and Condenser 33

Pumps 35

Compressor 37
 Kolmetz Handbook Page 2 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

Petlyuk Column 39

APPLICATION

Example Case 1: LPG Unit with Conventional Column 47

Example Case 2: LPG Unit with Petlyuk Column 55

REFEREENCES 60

CALCULATION SPREADSHEET

LPG Unit with Conventional Column.xls 61

LPG Unit with Petlyuk Column.xls 62

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 3 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

LIST OF TABLE

Table 1 - Properties of LPG 5

Table 2: Typical Fractionator Parameters 27
Table 3: Heat transfer coefficient 34

LIST OF FIGURE

Figure 1: Process flow diagram of LPG unit 8

Figure 2: Petlyuk Configuration 13
Figure 3: Schematic of gas subcooled process 15
Figure 4: Schematic of residue split-vapor process 17
Figure 5: Relationship between Reflux Ratio and Number of Stages 31
Figure 6: Fractionation Schematic Diagram 32
Figure 7: Forced-Circulation Reboiler Arrangement 35
Figure 8: Internal Configuration of 4-Products Petlyuk Column 41

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 4 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

INTRODUCTION

Scope

This design guideline covers the basic elements in the field of LPG Units in sufficient
detail to allow an engineer to design a LPG unit with the suitable size of diameter,
velocity, reflux rate and actual stages. This design guideline includes design of
conventional LPG unit, Petlyuk column, condensers and reboilers.

LPG unit is utilized to separate the natural gas liquids into products which can be futher
processed. The sizing of the unit and the choice of column is important to give the
optimum efficiency and save the energy cost of LPG unit. There are several
technologies which have been developed in order to extract LPG from natural gas
vapors and liquids (NGL).

The design of LPG unit may be influenced by factors, including process requirements,
economics and safety. Include in this guideline is a calculation spreadsheet for the
engineering design. All the important parameters use in the guideline are explained in
the definition section which help the reader more understand the meaning of the
parameters or the term used.

In the application section of this guideline, three case studies are shown and discussed
in detail, highlighting the way to apply the theory for the calculation. The theory section
explained about conventional LPG sizing, Petlyuk column sizing and other equipment in
LPG unit.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 5 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

General Design Consideration

In natural gas processing plants, several stages of separation and fractionation are
used to purify the natural gas from the liquid heavier hydrocarbons. This separated
liquid is named as natural gas liquids (NGL). The source of Natural Gas Liquids is a
natural occurring mixture of gaseous hydrocarbons found in the ground or obtained from
specially wells. The composition of natural gas varies in different parts of the world. Its
chief component, methane, usually makes up from 80% to 95% of its composition. The
balance is composed of varying amounts of ethane, propane, butane, and other
hydrocarbon compounds approximately as follows:

1. Ethane (35-55%)
2. Propane (20-30%)
3. Normal Butane (10-15%)
4. Isobutane (4-8%)
5. Pentanes Plus (also called natural gasoline, debutanized natural gasoline) (10-15%)

The raw NGL is sent to LPG recovery plant to separate LPG (i-C3 and i-C4) from
stabilized NGL (C5+). Both products are very valuable and expensive in the market.
Liquefied Petroleum Gas (LPG) is a mixture of hydrocarbon gases, primary propane
and butane. The exact composition of LPG varies according to its source, processing
principles and depends on the season.

LPG is odorless, colorless and non-toxic. To reduce the danger of an explosion from
undetected leaks, commercial LPG usually contains an odorizing agent, such as
ethanethiol, which gives it a distinctive pungent odor. LPG has a higher calorific value
(94 MJ/m³ equivalents to 26.1 kWh) than natural gas (38 MJ/m³ equivalents to 10.6
kWh).

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 6 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

Table 1 - Properties of LPG

Name of the property Value for LPG

Freezing point -187oC

Specific gravity 0.588
Vapor pressure at 38oC 1212 kPa
Heat content 50221 kj/kg

There are several technologies which have been developed in order to extract LPG
from natural gas liquids (NGL). Some research and simulations have also been done to
find the most optimum and economic technology.

Conventional Technology

Natural gas processing begins at the wellhead. The composition of the raw natural gas
extracted from producing wells depends on the type, depth, and location of the
underground deposits and the geology of the area. The natural gas produced from oil
wells is generally classified as “associated-dissolved,” meaning that the natural gas is
associated with or dissolved in crude oil. Natural gas production without any association
with crude oil is classified as “non-associated.” About 60% of the world supply of LPG
comes from associated gas processing, and 40% of the LPG is produced in oil
refineries from crude distillation, fluid catalytic cracking units, hydrocrackers, etc.

There are 4 columns used in the conventional process. First stage of LPG extraction
from NGL is DeEthanizer. In the DeEthanizer column, methane and ethane are
expected to be separated and flow through the top of the column. Since there is no
requirement to liquefy methane and ethane, especially in small amounts, these
components will be kept in vapor phase and additional condenser is unnecessary.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 7 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

In this DeEthanizer, 100% methane and ethane in mixed feed can be separated and
leaves the top of the column. This product will be used internally as a fuel to generate
the steam which is used for reboiler of the column. Heat is supplied to the column by
forced circulation using reboiler pump to reboiler and into the column. The heavier
hydrocarbons other than ethane leave the column as bottom product in a liquid phase.
Next it is sent to DeButanizer column.

DeButanizer is used instead of DePropanizer because the bottom product of

DeEthanizer composed of small amount of propane (2 % of mass fraction) and butane
(5 % of mass fraction). So that smaller columns will be used for next extraction. This is
for economic reason and the efficiency of the separation as it is easier to extract the
product this way and less duty will be required for reboiler.

Before entering DeButanizer column, the DeEthanizer bottom product is expanded from
26 - 17 bar and fed into DeButanizer as mixed-phase feed. This feed is fractionated into
mixed propane and butane as overhead product and heavier hydrocarbons (C5+) as
bottom product. Then the overhead product is totally condensed in the condenser by
heat exchange with cooling water, and condensate is collected in reflux drum. The
reflux drum should be used in order to prevent cavitation on the pump due to vapor
phase. The DeButanizer reflux and product pump serve the dual purpose of supplying
reflux to the column and allowing withdrawal of column overhead product butane from
the reflux drum. The column heat is supplied by a reboiler and circulation is aided by
DeButanizer reboiler circulating pump.

About 100% propane and 99% butane can be recovered from the feed at the overhead
column product. This stream leaves the column and is sent to DePropanizer column to
separate propane and butane. Meanwhile, the bottom product composed of pentane
and heavier hydrocarbons will be stored as natural gasoline. Since the bottom product
has high temperature (> 200oC), it will be cooled by heat exchanger before being sent to
the storage.

Propane and butane stream is expanded from 16 - 10 bar and enters the DePropanizer
as mixed-phase feed. The DePropanizer separates propane as overhead product and
butane as bottom product. Condenser is used to totally condense the overhead vapor
from DePropanizer. Condensate is collected in DePropanizer column reflux drum. A

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 8 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

part of the condensed overhead product is sent back to the column as reflux via pump
while the remaining part is withdrawn as a liquid propane product. DePropanizer
reboiler heat is supplied by reboiler. Reboiler circulation is aided by reboiler circulation
pump.

It is about 99.9% of propane can be recovered as top product and 99.9% of butane is
recovered as bottom product. The butane product is field grade butane which is
composed of 30% i-butane and 65% n-butane. This is next being sent to butane splitter
to get i-butane and n-butane products separately, since it could be sold with higher price
than field grade butane.

The field grade butane is expanded from 10 - 5 bar before enter the butane splitter. I-
butane is recovered as overhead product and n-butane as bottom product. I-butane is
totally condensed by condenser. Condensate is collected in reflux drum. A part of the
condensed overhead product is sent back to the column as reflux via pump while the
remaining part is withdrawn as a liquid i-butane product. Butane splitter heat is supplied
by reboiler. Reboiler circulation is aided by reboiler circulation pump. Butane splitter
column separates 96% mole of i-butane in the overhead product and 96% mole of n-
butane in the bottom product. Both products have higher price than field grade butane.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 9 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

C1
C2

C3
Feed

DeEthanizer Depropanizer
i-C4

Debutanizer Butane
splitter

C5+ n-C4

Figure 1: Process flow diagram of LPG unit

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 10 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

There are several stages of gas processing in figure 1. Below is discussing their
purpose.

1. Gas-oil separators

A multi-stage gas-oil separation process is needed to separate the gas stream from the
crude oil. These gas-oil separators are commonly closed cylindrical shells, horizontally
mounted with inlets at one end, an outlet at the top for removal of gas, and an outlet at
the bottom for removal of oil.

2. Condensate separator

Condensates are most often removed from the gas stream at the wellhead through the
use of mechanical separators. In most instances, the gas flow into the separator comes
directly from the wellhead, since the gas-oil separation process is not needed.

3. Dehydration

Dehydration is the removal of this water from the produced natural gas and is
accomplished through several methods. Usually using ethylene glycol (glycol injection)
system as an absorption mechanism to remove water and other solids from the gas
stream. Alternatively, adsorption dehydration may be used, utilizing dry-bed dehydrators
towers, which contain desiccants such as silica gel and activated alumina, to perform
the extraction.

4. Contaminant removal

Removal of contaminants such as hydrogen sulphide, carbon dioxide, water vapor,

helium, and oxygen. The technique is to first direct the flow though a tower containing
an amine solution. Amines absorb sulphur compounds from natural gas and can be
reused repeatedly. After desulphurization, the gas flow is directed to the next section,
which contains a series of filter tubes. As the velocity of the stream reduces in the unit,
primary separation of remaining contaminants occurs due to gravity.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 11 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

5. Methane separation

Cryogenic processing and absorption methods are some of the ways to separate
methane from natural gas liquids (NGLs). The cryogenic method is better at extraction
of the lighter liquids, such as ethane. Cryogenic processing consists of lowering the
temperature of the gas stream to around -120 F. The turbo expander process is the
most effective to perform this function, using external refrigerants to chill the gas
stream. The quick drop in temperature that the expander is capable of producing,
condenses the hydrocarbons in the gas stream, but maintains methane in its gaseous
form.

The absorption method, on the other hand, uses a “lean” absorbing oil to separate the
methane from the NGLs. While the gas stream is passed through an absorption tower,
the absorption oil soaks up a large amount of the NGLs. The “enriched” absorption oil,
now containing NGLs, exits the tower at the bottom. The enriched oil is fed into distillers
where the blend is heated to above the boiling point of the NGLs, while the oil remains
fluid. The oil is recycled while the NGLs are cooled and directed to a fractionator tower.

Two Common Processes for Methane Separation - Gas Subcooled Process (GSP) and
Residue Split Vapor (RSV)

Gas subcooled process (GSP) and residue split-vapor (RSV) have been utilized for
efficient NGL/LPG recovery from natural gas, particularly for those gases containing
significant concentrations of carbon dioxide. To increase the ethane recovery beyond
the 80% achievable with the conventional design, a source of reflux must be developed
for the DeMethanizer. The GSP was developed to overcome this problem and others
encountered with the conventional expander scheme.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 12 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

A. Gas Subcooled process (GSP)

The GSP was developed to increase the ethane recovery beyond the 80% achievable
with the conventional design. a portion of the gas from the cold separator is sent to a
heat exchanger where it is totally condensed and subcooled with the overhead stream.
This stream is then flashed to the top of DeMethanizer, providing reflux to the
DeMethanizer. The expander feed is sent to the tower several stages below the top of
the column. Because of this modification, the cold separator operates at much warmer
conditions well away from the system critical. Additionally, the residue recompression is
less than with the conventional expander process.

The GSP design has several modifications. One is to take a portion of the liquid from
the cold separator along with the gas to the overhead exchanger. Generally, this can
help further reduce the horsepower required for recompression. Also, the process can
be designed to just use a portion of the cold separator liquid for reflux. This modification
is typically used for gases richer than 3 GPM (C+2 ).

When CO2 is present in the feed gas, the higher concentrations of C+2 components in
the cold liquids help reduce the amount of CO2 concentrating in the upper, colder
sections of the tower, allowing higher ethane recovery levels without CO2 freezing. This
same process can be operated to reject ethane, but propane recovery efficiency suffers
significantly when operated in this mode due mainly to the higher concentration of
propane present in the top feed

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 13 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

Subcooler

Residue gas to
compression

Expander

Inlet gas
De-methanizer

Bottom product

Figure 3: Schematic of GPC (gas subcooled process)

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 14 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

B. Residue split-vapor (RSV)

Another method of producing reflux is to recycle a portion of the residue gas, after
recompression, back to the top of the column, the RSV process. The process flow is
similar to the GSP design except that a portion of the residue gas is brought back
through the inlet heat exchanger. At this point, the stream is totally condensed and is at
the residue gas pipeline pressure. The stream is then flashed to the top of the
DeMethanizer to provide reflux.

The subcooled inlet gas split and the expander outlet stream are sent lower down in the
tower rather than to the top of the column. The reflux provides more refrigeration to the
system and allows very high ethane recovery to be realized. The recovery level is a
function of the quantity of recycle in the design.

It is CO2 tolerant and the recovery can be adjusted by the quantity of recycle used. The
RSV process can be used for very high ethane recoveries limited only by the quantity of
horsepower provided.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 15 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

Subcooler

Residue gas

Residue gas
compressor

Expander
Inlet gas
De-methanizer

Bottom product

Figure 4: Schematic of residue split-vapor process

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 16 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

6. DeEthanizer

The stripper bottoms from the extraction plant enter DeEthanizer column near the top.
The overhead vapor is partially condensed in DeEthanizer condenser by heat exchange
with medium-level propane. Condensed overhead product in overhead reflux drum is
pumped back to the DeEthanizer by reflux pump. The non-condensed vapor, mainly
ethane, leaves the plant to fuel the gas system. Heat is supplied to the column by forced
circulation reboiler. The DeEthanizer column operates at approximately 26.9 bar.
Approximately 98% of the propane in the DeEthanizer feed is recovered in the bottom
product. The residual ethane concentration is reduced to approximately 0.8 mole % in
the bottom product. The bottom product from DeEthanizer drains into DePropanizer
column.

7. DePropanizer

DeEthanizer bottoms are expanded from 26.9 - 20 bar and enter DePropanizer as
mixed-phase feed. The DePropanizer fractionates the feed into a propane-rich product
and a bottom product comprised of butane and natural gasoline. Tower overhead vapor
is totally condensed in the DePropanizer condenser by cooling water. Condensate is
collected in DePropanizer column reflux drum. A part of the condensed overhead
product is sent back to the column as reflux via pump while the remaining part is
withdrawn as a liquid propane product. Column reboiler heat is supplied by direct-fired
heater. Reboiler circulation is aided by reboiler circulation pump. The bottom product is
sent to DeButanizer.

8. DeButanizer

The DePropanizer bottoms are expanded from approximately 20 - 7.6 bar and then
enter the DeButanizer column as a mixed-phase feed. The column feed is fractionated
into a butane-rich overhead product and natural gasoline bottoms. The columns
overhead are totally condensed in the DeButanizer condenser by heat exchange with
cooling water, and condensate is collected in reflux drum. The DeButanizer reflux and
product pump serve the dual purpose of supplying reflux to the column and allowing
withdrawal of column overhead product butane from the reflux drum. The column reboil
heat is supplied by a direct-fired DeButanizer reboiler, and boiler circulation is aided by

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 17 of 69
KLM Technology Of Process Equipment Design
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LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

DeButanizer reboiler circulating pump. The bottom product leaving the column is cooled
in product cooler. A part of the gasoline product is recycled to the LPG extraction unit
and serves as lean oil for the absorber column

Petlyuk Column

In order to increase the process efficiency of such distillation processes, the following
two alternatives have been proposed both in the literature and by industrial
practitioners.

1. Integration of Conventional Distillation Arrangements - Includes sequential

arrangement of distillation columns with energy integration between the columns
or other parts of the plant.
2. Design of new configurations - Includes Dividing Wall Column; which consists of
an ordinary column shell with the feed and side stream product draw divided by a
vertical wall through a set of trays. The same configuration is usually denoted as
a Petlyuk column
A column arrangement separating three or more components using a single reboiler
and a single condenser, in which any degree of separation (purity) can be obtained by
increasing the number of stages (provided the reflux is above a certain minimum value).
The Petlyuk column consists of a pre-fractionator followed by a main column from which
three product streams are obtained and this arrangement has been shown to provide
higher energy savings than the systems with side columns, with savings of up to 30%
when compared to conventional schemes.

From figure 2, the Petlyuk design consists of a pre-fractionator with reflux and boilup
from the downstream column, whose product is fed to a 2-feed, 3-product column,
resulting in a setup with only one reboiler and one condenser. A pair of intermediate
liquid and vapor streams passes from the prefractionator to the secondary column. The
practical implementation of such a column can be accomplished in a single shell by
inserting a vertical wall through the middle section of the column, thus separating the
feed and the side product draw. Petlyuk’s main reason for this design was to avoid
thermodynamic losses from mixing different streams at the feed tray location.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 18 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

Typically, a light key and a heavy key are designated for the whole system. The light
key and lighter components will appear in stream Pv while the heavy key and heavier
components will appear in stream P3. The middle components will appear in stream P2.
To accomplish such a separation the prefractionator must split non-sharply with the
middle components distributing.

The Petlyuk configuration is quite complex. The first step in the analysis is to transform
the configuration into something that is easier to handle. To accomplish this goal the
secondary column is divided into two separate columns at the sidestream tray.

Petlyuk columns decrease energy expenditures for separation of threecomponent

mixtures, on the average, by 30% due to their thermodynamical advantages:

1. In the preliminary column, the composition of flows in feed crosssection is close to

feed composition (i.e., thermodynamic losses at mixing of flows are nearly absent);
2. These losses at the mixing of flows at the ends of the columns are nearly absent;
3. Absence of reboiler or condenser at output of component 2 decreases energy
expenditures due to the fact that liquid and vapor flows are used twice in the
sections located above and below output of component 2
4. Thermodynamic losses for the reason of repeated mixing of flows in the second
column at regular separation sequence are absent (the concentration of
component 2 at the end of the first column at direct split along distillation trajectory
decreases, which requires additional expenditures of energy in the second column
for obtaining pure component 2).

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 19 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

P1

V2 L2

V1 L1 V2 L2
Feed
P2

V3 L3
V1 L1

V3 L3

P3

Figure 2: Petlyuk Configuration

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 20 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

DEFINITIONS

Bottoms - The liquid or residual matter which is withdrawn from the bottom of a
fractionator or other vessel during processing or while in storage

Bubble point - The temperature at a specified pressure at which the first stable vapor
forms above a liquid.

Boiling point - the temperature corresponding to equilibrium between the liquid and
vapor phases at 101.325 kPa (or 14.696 psia).

Compressibility factor - A factor, usually expressed as "Z," which gives the ratio of the
actual volume of gas at a given temperature and pressure to the volume of gas when
calculated by the ideal gas law.

Condensate - The liquid formed by the condensation of a vapor or gas; specifically, the
hydrocarbon liquid separated from natural gas because of changes in temperature and
pressure when the gas from the reservoir was delivered to the surface separators. In a
steam system it may be water that is condensed and returned to the boilers.

DeButanizer - A fractionator designed to separate butane (and more volatile

components if present) from a hydrocarbon mixture.

Dehydration - The act or process of removing water from gases or liquids.

DeMethanizer - A fractionator designed to separate methane (and more volatile

components if present) from a hydrocarbon mixture.

DePropanizer - A fractionator designed to separate propane (and more volatile

components if present) from a hydrocarbon mixture.

Dew point - The temperature at any given pressure, or the pressure at any given
temperature, at which liquid initially condenses from a gas or vapor. It is specifically

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 21 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

applied to the temperature at which water vapor starts to condense from a gas mixture
(water dew point), or at which hydrocarbons start to condense (hydrocarbon dew point).

Distillation - The process of separating materials by successively heating to vaporize a

portion and then cooling to liquefy a part of the vapor. Materials to be separated must
differ in boiling point and/or relative volatility.

Extraction - The process of transferring one or more components from one liquid phase
to another by virtue of different solubility in the two liquids. It is also used to indicate
removal of one or more constituents from a stream.

Fractionation - Generally used to describe separation of a mixture of hydrocarbons into

individual products based on difference in boiling point and/or relative volatility.

Gas constant (R) - The constant multiplier in the Ideal Gas Law. Numerically, R=PV/T,
if V is the volume of one mole of an ideal gas at temperature T and pressure P.

Gas processing - The separation of constituents from natural gas for the purpose of
making salable products and also for treating the residue gas to meet required
specifications.

Heavy ends - The portion of a hydrocarbon mixture having the highest boiling point.
Usually hexanes or heptanes and all heavier hydrocarbons are the heavy ends in a
natural gas stream.

Light hydrocarbons - The low molecular weight hydrocarbons such as methane,

ethane, propane and butanes.

LP-gas (liquefied petroleum gas) - Predominately propane or butane, either

separately or in mixtures, which is maintained in a liquid state under pressure within the
confining vessel.

Natural gas - Gaseous form of petroleum. Consisting predominately of mixtures of

hydrocarbon gases. The most common component is methane.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 22 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

NGL (natural gas liquids) - Natural gas liquids are those hydrocarbons liquefied at the
surface in field facilities or in gas processing plants. Natural gas liquids include ethane,
propane, butanes, and natural gasoline.

Reflux - In fractionation, the portion of condensed overhead returned to the column to

enhance achievable purity of the overhead product.

Reflux ratio - A way of giving a relative measurement to the volume of reflux. Usually
referred either to the feed or overhead product.

Recovery - That percent or fraction of a given component in the plant feed which is
recovered as plant product.

Recycle - Return of part of a process stream to a point upstream from where it was
removed to enhance recovery or control.

Relative volatility – the ratio of the concentration of one component in the vapor over
the concentration of that component in the liquid divided by the ratio of the
concentration of a second component in the vapor over the concentration of that second
component in the liquid. For an ideal system, relative volatility is the ratio of vapor
pressures i.e. α = P2/P1

Specific gravity - The ratio of the mass of a given volume of a substance to that of
another equal volume of another substance used as standard. Unless otherwise stated,
air is used as the standard for gases and water for liquids, with the volumes measured
at 60°F and standard atmospheric pressure.

Splitter - A name applied to fractionators, particularly those separating isomers (e.g.,

butane splitter refers to a tower producing most of the isobutane in the feed as
overhead and most of the normal butane in the feed as bottoms).

Stripper - A column wherein absorbed constituents are stripped from the absorption oil.
The term is applicable to columns using a stripping medium, such as steam or gas.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 23 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

Traded - column A vessel wherein gas and liquid, or two essentially immiscible liquids,
are contacted, usually counter-currently on trays. Also refer to packed column.

NOMENCLATURE

B Bottom flow rate, lb/hr

BiA Flow rate of A in the bottoms of column i, lb mol/hr
BiB Flow rate of B in the bottoms of column i, lb mol/hr
BiC Flow rate of C in the bottoms of column i, lb mol/hr
D Distilate flow rate, lb/hr
D1C,underwood Flow rate of C in the distillate of 1 at min. reflux, lb mol/hr
DiA Flow rate of A in the distillate of column i, lb mol/hr
DiB Flow rate of B in the distillate of column i, lb mol/hr
DiC Flow rate of C in the distillate of column i, lb mol/hr
dT Tower diameter design, ft
DT2 The temperature difference between the hot outlet and the cold
inlet stream
EOC Overall efficiency
F Feed flow rate, lb/hr
FA Flow rate of A in the feed to the dividing wall column, lb/hr
FB Flow rate of B in the feed to the dividing wall column, lb/hr
FC Flow rate of C in the feed to the dividing wall column, lb/hr
H Tower height, ft
Li Rectifying section liquid flow rate in column i, lb mol/hr
Li’ Stripping section liquid flow rate in column i, lb mol/hr
Lw Weir length, in
N Number of theoretical stages
N1 Number of stages for column 1, Stages
N1min Minimum number of allowable stages for column 1, Stages
Nact Actual stages
Nm Minimum stages
Q Heat duty
qi Quality (saturated liquid fraction) of feed to the column I,
Ri Reflux Ratio in column i

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Kolmetz Handbook Page 24 of 69
KLM Technology Of Process Equipment Design
Group
LIQUIFIED PETROLEUM GAS (LPG) Rev: 01
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING AND
Solutions TROUBLESHOOTING
www.klmtechgroup.com May 2013
(ENGINEERING DESIGN GUIDELINES)

Rimin Minimum reflux ratio for column i

S Tray spacing, in
uV Max. allowable vapor velocity, ft/s
Vi Rectifying section vapor flow rate in column i, lb mol/hr
Vi’ Stripping section vapor flow rate in column i, lb mol/hr
Vm Maximum vapor rate, lb/s
XB Mole fraction bottom light key
XD Mole fraction overhead light key
XF Mole fraction feed light key

Greek letters

α Realtive volatility
αA Relative volatilities component A
αB Relative volatilities component B
αC Relative volatilities component C
Δt Log mean temperature difference
ΔT1 The temperature difference between the hot inlet and cold outlet
stream
μL Feed liquid viscocity, Cp
ρL Liquid density, lb/ft³
ρV Vapor density, lb/ft³
Φ1, Φ2, Θ, ψ Underwood roots. Use UWMulti to find the underwood roots

Superscript

B Bottom flow rate, lb/hr

D Distilate flow rate, lb/hr
F Feed flow rate, lb/hr
H Tower height, ft
N Number of theoretical stages
Q Heat duty

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

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