ChE Tulsa University

 
           

ChE 6423 Gas-Processing Plant Design
Required course for ChE program

Catalog Description:   The application of chemical engineering and economic principles to the design of natural gas plant equipment; includes use of state-of-the-art simulation packages. Prerequisite: Permission of instructor.

Recent Textbook:   F.S. Manning and R.E. Thompson, “Oilfield Processing of Petroleum: Volume 1, Natural Gas”, PennWell Publishing Co., 1991; R.E. Thompson, “Natural Gas Processing”, O&GCI, 1995

Recent References:   Gas Processors Suppliers Association, “Engineering Data Book”, 11th ed., GPSA, 1998; HYSYS manual

Set of Course Goals/Objectives:   (1) To take incomplete design assignments and translate them into more complete assignments; (2) To propose alternative solutions to design problems and make choices between alternatives; (3) To make preliminary cost estimates for alternative processes; (4) To learn basic gas-processing schemes; (5) To learn basic calculation and optimization techniques used in gas-processing plant design.

Prerequisites by Topic:   (1) Stoichiometry; (2) Basic and advanced thermodynamics; (3) Fluid mechanics; (4) Heat transfer; (5) Mass transfer

Major Topics Covered in the Course:   (1) Natural gas sources, composition, properties; specifications, nomenclature, special definitions; (2) Phase behavior and phase equilibrium calculations; (3) Gas processing schemes; (4) Gas liquids recovery using mechanical refrigeration and a cryogenic expander cycle; (5) Gathering and transportation, water content and hydrate formation and prevention; (6) Methods of gas dehydration; (7) Expansion turbines and compressors; (8) Flow line, separator, and exchanger sizing; (9) Demethanizer simulation; (10) Cost estimation: equipment costs, installed costs, operating costs, revenue, income tax, cash flow analysis, rate of return; (11) Gas treating: acid-gas removal; sulfur recovery; (12) Treating and handling of liquid products; (13) Extended processing: Ryan-Holmes, N2 rejection, ethane rejection; (14) Guest lectures.

Class/Laboratory Schedule:  Three (3) 50-minute lectures per week for 14 weeks

Professional Component Contribution:  Three (3) hours of Engineering Science and Design

Relationship to Program Outcomes: 

  • Outcome a:  Students learn the theory and basic equations behind designing a NGL plant.  Multi-component vapor-liquid equilibrium, multi-component distillation, hydrate formation are involved extensively.  When necessary, the theoretical basis for sizing equipment is reviewed.
  • Outcome b:  Students are required to analyze and interpret natural gas compositions and select the most promising process flow diagram.  Checking the reliability and/or uncertainty of data is emphasized.
  • Outcome c:  Students spend approximately over 75 percent the course on semester-long design project.  The complete flowsheet is developed and then all major equipment is sized and costed.  Finally, a cash flow analysis is developed.
  • Outcome d:  Undergraduates work in teams of two on the design project. While nearly all students are ChEs, frequently international and US students are paired.
  • Outcome e:  Class discussions and the design project focused on finding the necessary information to design the NGL recovery plant.
  • Outcome f:  Ethical behavior is required in the course. Safety has to be emphasized throughout the course, because, as produced natural gas is highly flammable and if sour (contains hydrogen sulfide) extremely toxic.  All designs include estimating emissions and safety considerations such as flaring.
  • Outcome g:  Students are required to write a major design report modeled after the requirements specified in recent AIChE Student Design Competitions.  Students are required to revise their reports until they are acceptable.
  • Outcome h:  Lectures and the design project included issues relating to environmental and societal needs.  OSHA safety and EPA environmental issues are addressed whenever pertinent.
  • Outcome i:  The design project required students to find the appropriate design information (e.g., heat transfer coefficients) well as to find kinetic data.
  • Outcome k:  Students are required to use computers throughout the course.  HYSYS and Excel are required. 

Prepared by: Francis S. Manning, PE and Keith D. Wisecarver, Ph.D.

Modified by:    Laura Ford