44,000 Bbl/day NGL Fractionation System

System Stock #222331 - Immediately Available

This Natural Gas Liquids (NGL) Fractionation System takes 44,000 barrels per day (Bbl/day) of Y-Grade NGLs and fractionates them into ethane, propane, and a stream of heavier compounds (butane, isobutane, pentane, etc.) which we will refer to as C4+. The NGL composition used in the past ranged from equal parts of each component to 40/40/20 parts of C2/C3/C4+.

44,000 Bbl/day NGL Fractionation System - System Stock #222331

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Process Description:

The incoming Y-Grade NGLs traveling through 6” diameter piping are first directed through two filters; one horizontal and one vertical. Then the NGLs enter the fractionator feed heater which uses 75 psig steam for heating. The heated NGLs then enter the horizontal feed tank which is 12’ diameter by 26’ long operating at 480 psig. This tank has a 24” diameter bottom nipple section for water separation and removal.

NGL Fractionation System Process Flow Diagram

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The heated NGLs are then pressured over to the Ethane Fractionator Column (C2 Fractionator Column) at tray #17 (alternate feed points are available). This column is seven feet diameter in the top section and 11’ diameter in the bottom section and operates at about 450 psig. It is 105.5’ tall with 44 trays and is rated for 550 psig at 600oF. The column system includes two bottom reboilers, one side reboiler, and a refrigerated overhead condenser with accumulator.

C2 Fractionator Column

The two bottom reboilers are “kettle-style” which allows for some vaporization of the NGLs. These reboilers use 75 psig steam for heating on the tube side and the process flows through the shell side of the horizontal exchangers.

The side-reboiler takes feed from tray #29 and is also a “kettle-style” using 75 psig steam for heating which provides partial vaporization on the shell or process side. The vapor returns at tray #28. There are a pair of process return pumps on the side-reboiler with are rated for 620 gpm each. The liquid returns to tray #30.

C2 Fractionator Column Side-Reboiler

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The ethane going overhead in the fractionation column is condensed in a liquid propylene refrigerated kettle-style condenser. The liquid ethane flows into the horizontal accumulator which is 11.5’ diameter by 26’ long and operating at 435 psig and 46oF. Liquid ethane is pumped from the accumulator back to the fractionator column for reflux injection through a 6” nozzle at tray #1 using two horizontal, centrifugal pumps rated for 1,082 gpm each. The reflux pumps also feed the ethane injection pumps which are high-pressure pumps used to store ethane in the underground salt caverns. These injection pumps can move 160 gpm at 1,250 psig. Ethane gas can also be taken from the accumulator overheads for direct feed to the ethane cracker system. This line has a skid-mounted CO2 removal system using diethanolamine (DEA) at 40 gpm recirculation flow rate. The skid includes the main contactor column, regeneration still, and all associated pumps, exchangers, and other miscellaneous equipment. The ethane is metered with a 4” Micromotion flow meter. The two propylene mechanical refrigeration units (MRU) are 24 MM BTU/hr skid-mounted systems from York. One unit uses a 1,250 hp Westinghouse electric motor to drive a York compressor through a Philadelphia gearbox. The other unit has a 1,730 hp Elliott steam turbine drive with a Lufkin gearbox.

Propylene MRUs

The bottoms stream from the C2 Fractionator flows through 8” diameter piping to the C3 Fractionator feed cross-exchanger. This exchanger uses heat from the bottoms stream leaving the C3 Fractionator to heat the bottoms stream leaving the C2 Fractionator and entering the C3 Fractionator.

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The hot feed to the C3 Fractionator enters through an 8” nozzle at tray #28 (alternate feed points available). This column is 8.5’ diameter and 91.5’ tall with 51 trays. It is rated for 250 psig at 300oF. The column system includes one bottom reboiler and one overhead condenser with accumulator.

C3 Fractionator Column

The vertical reboiler for the C3 Fractionator Column uses 75 psig steam for heating. The reboiler has a 24” inlet and 30” outlet on the process (tube) side. The overheads from the C3 Fractionator leave through 14” pipe to the four overhead condensers. These condensers are paired and the two pairs are piped in parallel. The exchangers use cooling tower water for condensing the column overheads.

C3 Fractionator Column Condensers

The condensed liquid propane flows into the horizontal accumulator which is eight feet diameter by 30’ long. Liquid propane is pumped from the accumulator back to the fractionator column for reflux injection through a 6” nozzle at tray #1 using two horizontal, centrifugal pumps rated for 1,500 gpm each. The reflux pumps also feed the propane product cooler, which cools the product before moving to the high-pressure injection pumps.

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The propane injection pumps are high-pressure pumps used to store propane in the underground salt caverns. These injection pumps can move 220 gpm at 1,250 psig. Propane gas can also be taken from the accumulator overheads for direct feed to the propane cracker system. Propane gas can also be taken from the top of the accumulator for feeding directly to a propane cracker or propane dehydrogenation (PDH) facility. The propylene flows through a 4” Micromotion flow meter.

The bottoms stream from the C3 Fractionator Column flows through 4” diameter piping to the C3 Fractionator Feed cross-exchanger mentioned earlier. This cross-exchanger uses the heat from the C2 Fractionator bottoms to heat the C3 column feed. The C4+ product from the bottoms of the C3 Fractionator Column then flows to the two C4+ product coolers. Cooling tower water is used to cool the C4+ product prior to the charcoal filter. After filtering, the product moves to the storage spheres.

The C4+ storage system consists of four Hortonsphere® spherical storage vessels from Chicago Bridge and Iron (CBI). They are 44.5’ diameter with 8” diameter inlet and outlet nozzles and a 20” manway. They are rated for 60 psig at 650oF with an 8,000 gallon capacity.

C4+ Storage Spheres

There are five pumps associated with this storage sphere system. They are vertical, centrifugal pumps rated for 510 gpm. Four of the pumps have 50 hp electric motors and one has a 75 hp steam turbine drive.

There are three horizontal, centrifugal Pacific high-pressure pumps from Dresser with 400 hp, 4160 volt Siemens electric motors which are used for pumping the C4+ product into the salt caverns or into a pipeline. These pumps are rated for 220 gpm at 1,250 psig.

C4+ Hi-Pressure Cavern Pump

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Equipment Details: All equipment is constructed of carbon steel and is vintage 1987 unless mentioned otherwise:

• C2 Fractionator Feed Filters (2): One is vertical; 34” diameter by 7.3’ tall and the other is horizontal; 20” diameter by 6’ long; both with 6” inlet and outlet nozzles. Both are rated for 550 psig at 150oF.

• C2 Fractionator Feed Heater: Horizontal shell and tube exchanger with 6” inlet and outlet nozzles. Steam (75 psig) inlet is 6” and condensate outlet is 2”. Shell is rated for 150 psig at 355oF and tubes are rated for 550 psig at 200oF. Heat duty is 6.6 MM BTU/hr with 1,345 sq ft of surface area.

• C2 Fractionator Feed Tank: Horizontal tank 12’ diameter by 26’ long with 6” diameter inlet and outlet nozzles. Bottom drain nipple is 24” diameter for water separation and removal. Rated for 550 psig at 200oF and weighing 129,854 lbs.

• C2 Fractionator Column: 7’ diameter in the top section and 11’ diameter in the bottom section. 105.5’ tall with 44 trays. Rated for 550 psig at 600oF. Two bottom reboilers, one side reboiler, and a refrigerated overhead condenser with accumulator.

• C2 Fractionator Reboilers (2): Horizontal, kettle-type shell and tube exchangers with 16” inlet and 20” outlet nozzles. Steam (75 psig) inlet is 8” and condensate outlet is 3”. Shell (process side) is rated for 550 psig at 300oF and tubes (steam side) are rated for 100 psig at 355oF. Heat duty is 23 MM BTU/hr each.

• C2 Fractionator Side-Reboiler: 1998 horizontal, kettle-type shell and tube exchanger with 8” inlet and two - 10” outlet nozzles. Steam (75 psig) inlet is 8” and condensate outlet is 3”. Shell (process side) is rated for 561 psig at 325oF and tubes (steam side) are rated for 561 psig at 325oF. Heat duty is 17 MM BTU/hr.

• C2 Fractionator Side-Reboiler Return Pumps (2): Horizontal, 6” x 3” centrifugal pumps rates for 620 gpm each with 30 hp electric motors.

• C2 Fractionator Overhead Condenser: Horizontal, four-pass kettle-type shell and tube exchanger with 10” inlet and outlet nozzles on the tube side. Liquid propylene refrigerant (shell side) inlet is 8” and two propylene vapor outlets are 10” each. Shell is rated for 250 psig at 150oF and tubes are rated for 550 psig at 150oF. Heat duty is 21 MM BTU/hr. The exchanger weighs 77,800 lbs.

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• C2 Fractionator Propylene Refrigeration Units (2): The two model 326B7 propylene mechanical refrigeration units (MRU) are 24 MM BTU/hr skid-mounted systems from York. One unit uses a 1,250 hp Westinghouse electric motor to drive a York compressor through a Philadelphia gearbox. The other unit has a 1,730 hp Elliott steam turbine drive with a Lufkin gearbox.

• C2 Fractionator Accumulator: Horizontal tank 11.5’ diameter by 26’ long with 6” diameter inlet and outlet nozzles. Bottom drain nipple is 18” diameter for water separation and removal. Rated for 550 psig at 150oF. Capacity is 26,353 gallons.

• C2 Fractionator Reflux Pumps (2): Two horizontal, 8” x 6” centrifugal pumps rates for 1,082 gpm each with 60 hp electric motors.

• C2 Injection Pumps (2): Two horizontal, centrifugal high-pressure 6” x 4” high-pressure pumps rated for 160 gpm each at 1,250 psig with 70 hp electric motors.

• C3 Feed Cross-Exchanger: Horizontal shell and tube exchanger with 6” inlet and outlet nozzles on the tube side and 4” inlet and outlet nozzles on the shell side. Shell (C3 Fractionator bottoms) is rated for 250 psig at 300oF and tubes (C2 Fractionator bottoms which is C3 Fractionator feed) are rated for 550 psig at 200oF. Heat duty is 5.6 MM BTU/hr with 1,184 sq ft of surface area.

• C3 Fractionator Column: 8.5’ diameter and 91.5’ tall with 51 trays. Rated for 250 psig at 300oF. Shell thickness is 1.0” and head thickness is 1.125”. Column weighs 150,000 lbs. One bottom reboiler and one overhead condenser with accumulator.

• C3 Fractionator Reboiler: Vertical shell and tube exchanger with 24” inlet and 30” outlet nozzles. Steam (75 psig) inlet is 16” (only 8” steam supply piping is used) and condensate outlet is 6”. Shell (steam) is rated for 75 psig at 337oF and tubes (process) are rated for 505 psig at 204oF. Heat duty is 17 MM BTU/hr.

• C3 Fractionator Overhead Condensers (4): Four 1998 horizontal shell and tube exchangers with 10” inlet and outlet nozzles on the shell (process) side and 16” inlet and 10” outlet nozzles on the tube (cooling tower water) side. These exchangers are in “piggy-backed” pairs, with the two pairs piped in parallel. Shell is rated for 250 psig at 450oF and tubes are rated for 175 psig at 200oF. Heat duty is 38 MM BTU/hr.

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• C3 Fractionator Accumulator: Horizontal tank 8’ diameter by 30’ long with two 8” diameter inlet nozzles and a 10” outlet nozzle. Rated for 240 psig at 650oF.

• C3 Fractionator Reflux Pumps (2): Horizontal, 8” x 6” centrifugal pumps rates for 1,500 gpm each with 100 hp electric motors.

• C3 Product Cooler: 1998 horizontal shell and tube exchanger with 6” inlet and outlet nozzles on the shell or process side. Cooling tower water is used on the tube side with 8” inlet and outlet nozzles. Shell (process) is rated for 350 psig at 300oF and tubes (cooling tower water) are rated for 240 psig at 200oF. Heat duty is 1.1 MM BTU/hr.

• C3 Injection Pumps (3): Horizontal, centrifugal high-pressure 6” x 4” high-pressure pumps rated for 220 gpm each at 1,250 psig with 150 hp electric motors.

• C4+ Product Coolers (2): Horizontal shell and tube exchangers with 4” inlet and outlet nozzles on the shell or process side. Cooling tower water is used on the tube side with 6” inlet and outlet nozzles. Shell (process) is rated for 260 psig at 300oF and tubes (cooling tower water) are rated for 260 psig at 200oF. Heat duty is 4.8 MM BTU/hr each.

• C4+ Charcoal Filter: Vertical packed vessel 5’ diameter by 24’ tall with 4” diameter inlet and outlet nozzles. Rated for 250 psig at 300oF.

• C4+ Storage Spheres (4): Four Hortonsphere® spherical storage vessels from Chicago Bridge and Iron (CBI). 44.5’ diameter with 8” diameter inlet and outlet nozzles and a 20” manway. Rated for 60 psig at 650oF with shell thickness ranging from 0.787” to 0.950”. Capacity is 8,000 gallons.

• C4+ Storage Sphere Pumps (5): Five vertical, centrifugal pumps rated for 510 gpm. Four pumps have 50 hp electric motors and one has a 75 hp steam turbine drive.

• C4+ Hi-Pressure Cavern Pumps (3): Three horizontal, centrifugal Pacific pumps from Dresser with 400 hp, 4160 volt Siemens electric motors. Rated for 220 gpm at 1,250 psig.

• All instrumentation, control valves, and process control databases are provided with this system.