The LPG Recovery Plant:

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2 The LPG Recovery Plant: Designed and commissioned by The Randall Corporation of USA, in 1982 Production capacity : MT of LPG MT of Condensate Gas throughput : 2.21 MMSCMD Feed Gas Pressure : 14 Kg/ Cm2 g Residue Gas Pressure : 11.2 Kg/ Cm2 g Water content : Saturated LPG Quality : To conform IS-4576:1999 specification

3 Feed gas composition (mole%) COMPONENT DESIGN PRESENT FLUCTUATION N CO C C C i- C n-c i- C n-c C

4 Production profile Fin. Year : * LPG (MT) : COND (MT) : LPG (TPD) : COND (TPD) : Low production was attributed mainly due to change in feed gas composition, more particularly decline in propane and butane content from the year * April May 2011

5 PRODUCTION PROFILE MT FINANCIAL YEAR LPG PRODUCTION CONDENSATE PRODUCTION

6 PRODUCTION PROFILE MT FINANCIAL YEAR LPG PRODUCTION CONDENSATE PRODUCTION

7 RATE OF PRODUCTION TONNES PER DAY FINANCIAL YEAR LPG PRODUCTION RATE TOTAL LIQUID PRODUCTION RATE CONDENSATE PRODUCTION RATE

8 RATE OF PRODUCTION TONNES PER DAY LPG PRODUCTION RATE TOTAL LIQUID PRODUCTION RATE FINANCIAL YEAR CONDENSATE PRODUCTION RATE

9 Need Of The Hour To find out ways and means to enhance the LPG production from the available feed gas or from the new gas finds which was under development, in order to sustain the market demand in the northeast.

10 Action initiated for enhancement of LPG Production Awarded a consultancy service to EIL on to prepare Techno Economic Feasibility Report (TEFR) with additional recovery of propane and/ or spiking of butane in OIL s LPG Recovery Plant at a cost of Rs Lakh. Report submitted by EIL on and a presentation was given to OIL Directors on Further study was carried out by EIL for recovery of propane without considering the limitations of existing plant and equipment and with no butane injection.

11 Action initiated for enhancement of LPG Production On EIL presented their findings to OIL Directors wherein the following case studies over base case towards maximizing propane recovery have emerged. Base case: Simulation was carried out on existing plant operating data of Throughput : 79 MMSCFD Butane content : 1.20 % Propane recovery :69.7% over the feed content. LPG production : 135 tones per day (45000 MT) Propane : Butane : 50.6:49.4 by weight.

12 Modified Case : Maximization of Propane recovery Recycling a part of product condensate (NGL) through deethanizer and debutanizer. Additional column height of deethanizer (about 1.5 meter) Small supplementary condenser and re-boiler A manhole has to be provided for inspection of the tower. Propane recovery : 87 % Additional LPG production : 6166 TPA Propane: Butane : 56:44 by weight. Expected plant downtime : 3-4 weeks Project cost: Rs 2-3 Crore Net Annual revenue : Rs.1520 Lakh based on LPG 27000/MT Investment will be returned in 100 days.

13 The road map towards implementation of the NGL Recycle Project Preparation of basic design engineering package (BDEP) Project management consultancy (PMC) Procurement and construction Installation and commissioning

14 ACTION PLAN Award of BDEP with extended deliverables to EIL on at a cost of Rs 75 lakh BDEP Report submitted on The total estimated cost works out to Rs lakh with following beak-up Equipment and Modification job : RS Lakh 2. Project Management Consultancy : Rs Lakh 3. Additional job : Rs Lakh TOTAL : Rs Lakh

15 ACTION PLAN LOA awarded to EIL for PMC on at a cost of Rs.135 lakhs. Procurement of equipment initiated. Tender document for LSTK job (NIT) prepared. The cost of LSTK has been increased from that was estimated in BDEP by EIL, R& D in Total cost of the project : Rs.1053 lakhs. (2010)

16 INNOVATIVE PROCESS Recycling one part of NGL (Condensate Product) as Deethanizer Feed Additional Propane can be retained at Deethanizer and subsequently Extra amount of LPG can be produced from Debutanizer top. Yield of the process : 15 Tones per day of additional LPG. (Expected) Specification of LPG : Composition C2 present Vapor pressure 56:44 of C3:C4 by Wt. 1% by Wt. 9.5 Kg/Cm 2 g at 40 o C

17 Modification Jobs : At a Glance PV to be cut at top dished end. Weld 1.5 M height of column section. Steel lining at dished end and the new section. New distributor plate at top section. New reflux nozzle at top section One manhole at new section. Three hand hole for removal of packing at bottoms of section. One new nozzle for NGL recycle at middle section. Contd

18 Modification Jobs : At a Glance Replacement of Deethanizer reflux line from pump to the tower. Topping of packing if necessary. Replacement of PV with new one. One NGL tank will be installed Two nos. of pumps for NGL recycle will be required. Three nos. of new heat exchangers will be installed. Deethanizer reflux condenser no2 Debutanizer reflux condenser no 2 Debutanizer feed pre heater HE will be replaced with a new one. HE will be replaced with a new one. Piping modification for new equipment and insulation

19 STATUS AS ON Pressure Vessels (3 Nos.) : Received. 2. Heat exchanger (6 Nos.) : Received. 3. NGL dosing pump (2 Nos.) : Received 4. Pressure Control Valves (8 Nos.) : Received. 5. Control Valves ( 4 Nos.) : Received. 6. Safety Relief Valves ( 2 Nos.) : Received 7. Column Internals : Delivery by LSTK job : NIT is ready 9. PMC Job : Extended up to Expenditure incurred : Rs 3.00 Crore

20 EC HE HE PV CM HE PV PV PV HE HE FC 2101 HE RESIDUE GAS FC 2102 FC 2103 REFLUX PV PV EXP SEP HE LPG INLET GAS HE COLD SEP PV PV HE HE LPG RECOVERY PLANT PROCESS FLOW DIAGRAM Drawn by: SANCHITA BANERJEE : HE PV PV HE CONDENSATE

21 FROM DEEHYDRATOR NGL RECYCLE AT LPG PLANT FROM COLD SEP BOTTOM FROM EXP SEP TOP HE 1504 HE1502 REFLUX PV1609 TO COLD SEP HE1510 PV1608 HE EXP SEP NGL COLD SEP MODIFIED PORTION HE1512 LPG PRODUCT PM HE1501 TO HE1511 FROM EXP SEP HE1503 HE HE1505 TO KOD He RESIDUE GAS RESIDUE GAS TO HE15102 INLET GAS FROM CM1101 PV1611 PV1610 NGL PV16101A/B HE1513 HOT OIL PM1703/04 PM17101A/B HE 1506 RESIDUE GAS CONDENSATE GASOLINE PRODUCT

22 Present consideration Plant can handle a total liquid (LPG + Condensate) of tones per day About 40 MT of NGL will be recycled through Deethanizer and Debutanizer to produce about 17 MT of additional LPG at base case (total liquid will be = 260 MT) Present production of liquid ( ) 240 MT. A margin of only MT left for NGL recycle and additional production of LPG. If LPG production goes to about 160 MT and above there will be hardly any margin left for NGL recycle. Further Deethanizer and Debutanizer are due for replacement in as per health survey report by EIL While simulating the base case for enhancement of LPG production the limitation of existing equipment was not considered particularly the case for Debutanizer Rebioler. Replacement of equipment to be planned phase wise

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