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Process Intensification and Integration for Sustainable Design. Группа авторовЧитать онлайн книгу.

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rate and composition pose major challenges when designing a gas processing plant of optimal size. In general, plants with larger process equipment are more flexible and are able to handle a wider range of inlet compositions. Nonetheless, these plants also have higher fixed and variable costs. A gas processing plant is needed to purify and separate natural gas and natural gas liquids (NGLs) and to isolate various possible containments including water, sulfur species, carbon dioxide, mercury, and oxygen [6]. Such separation operations may include acid gas removal, to remove sulfur species and carbon dioxide, dehydration, nitrogen rejection, mercury removal, NGL recovery, and NGL separation. One issue currently facing the gas production industry is a lack of capacity to handle greatly increased production [7]. Another issue is frequent unplanned shutdowns and a lack of efficiency in operations [8]. Regardless of the dynamic and spatial variability in shale gas flow rate and composition, gas processing facilities must have the ability to handle such variations and render a set of products with consistent qualities to satisfy pipeline constraints and downstream‐processing requirements [9-12]. In this chapter, the aim is to determine a method to find the optimal size of a plant and a strategy to process wellhead gas when feeds of various compositions are available to the facility. Process synthesis, simulation, and techno‐economic analysis were used to determine the optimal configuration and capacity of the gas treatment plant.

      The approach will also incorporate safety into the early stages of process design, before changes in design become more costly and difficult to make [13-15]. The concept of inherent safety is that, by eliminating or reducing the sources of hazards in a chemical plant, the severity and likelihood of process safety incidents will be reduced [8]. One challenge of implementing inherent safety is the lack of information in early design stages. Most existing safety assessment tools are used retroactively, after the process design is completed or near completion [16]. In order to quantify the inherent safety of alternative process designs during the early design stages, a number of safety indices have been developed [14,15,17]. In this work the safety of different process designs will be compared using a modified version of the process route index (PRI) [18]. This safety index was chosen because the chemicals involved in natural gas processing are highly flammable and explosive [18,19].

      Another important consideration is environmental impact. While natural gas is considered to be cleaner than coal and oil (from an emissions and energy consumption standpoint), there is potential for further reduction in environmental impact [20,21]. However to the author's knowledge fluctuating feedstock compositions have not been considered in literature for shale gas processing.

      The problem to be addressed in this work is stated as follows:

       A set of shale gas wells with anticipated profiles for variable flow rates and compositions and known, temperature, and pressure

       A known set of feedstock and product prices

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      To illustrate the applicability of the proposed approach, a case study is solved based on representative data for the Barnett Shale Play in Texas. The key objectives of the case study include:

       Design of a base case and several additional process designs for different feed compositions

       Economic evaluations of the proposed designs

       Process safety evaluation of the proposed designs

       Sensitivity analysis where product and feedstock prices are varied based on standard deviations from historical price data

      To streamline the study, the following assumptions are made:

       Average flow rate, temperature, and pressure: Although the flow rate, temperature, and pressure of shale gas coming out of the well can vary significantly, it was assumed that wellhead gas is sent to a centralized processing facility where these values on average would be relatively constant, and only composition would vary. Additionally it is common for gas to be saturated with water because water is sent down the well to maintain well pressure. It is not uncommon for there to also be free water in the incoming gas stream; however this is easily removed using a knockout drum on the front end of the process at minimal cost.

       Inlet feeds enter the processing plant at a standard vapor volumetric flow of 150 million standard cubic feet per day (MMSCFD), 100 °F, and 1000 psig. The Peng–Robinson equation of state was used in the process simulation model.

       The gas feedstock is saturated with water.

      2.4.1 Data

Feed type Methane composition (mol%) Probability of feed type (%)
1
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