Episode 7 : iCON Basic Training

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SAJJAD KHUDHUR ABBASChemical Engineering , Al-Muthanna University, IraqOil & Gas Safety and Health Professional – OSHACADEMYTrainer of Trainers (TOT) - Canadian Center of Human Development

Episode 7 : iCON

Basic Training

© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

SKG 16 - iCON Basic Training – Itinerary

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Day Training Modules

22 October 2013 Slides presentation1. Compressor Train2. Demethanizer Column3. Fractionation Train4. Propane Loop5. Steam Reformer

23 October 2013 1. Oil Characterization2. Refinery Separation3. Amine System

24 October 2013 1. Utility Optimizer Module 12. Utility Optimizer Module 23. Column Optimization4. Property Regression

2013 PETROLIAM NASIONAL BERHAD (PETRONAS)


Outline

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• Introduction to Process Simulation

• iCON Software

• Thermodynamic Property Package

• Modeling Approach

• Hands On Training


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Introduction to Process Simulation

Introduction

Process simulation is the representation/replication of the real world

process behavior through mathematical models.

Process Simulator is a software that predicts the condition, composition

and properties of a particular point (stream) from an initial condition through

mass and energy balances and thermodynamic principles.

iCON is based squarely on fundamental thermodynamic principles

(equation based).

These principles are used in two main features of the process simulator:

The thermodynamic calculation engine

The simulation solver for unit operation and flowsheet.

Introduction

The thermodynamic engine provides:

Rigorous thermodynamic equilibrium and physical property estimation

for industrially important systems

The simulation solver continually monitors:

The degrees of freedom of the flow sheet,

Immediately invokes the necessary calculations when the degrees of

freedom are complete,

Solved the system of equations describing the flow sheet.


Steady State Vs Dynamics

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Steady State Dynamic

Mass & Energy Balance

Always balance Not always balance

Time dependence No Yes

Accumulation i.e. level simulation

No Yes

Equipment dimension

Not required Required

Pressure profile No impact Impacts flow

Typical applications • Process Design•Equipment Rating & Monitoring• Utility Balance

• Process Control Optimization• Plant Startup & Shutdown•Operator Training Simulator

© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS) 8

Process Simulation & Optimization Cycle

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2

3

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PETRONAS Official Process Simulation Software


What is iCON?

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iCON is an innovative steady-state & dynamic simulation software modeling tool for oil, gas, petrochemical, utilities

and power generation industries.

iCON is capable of solving a wide range of engineering problems and is

industry driven. It has been proven in reliability in oil gas production, oil refinery, petrochemicals, utility &

power generation

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Thermodynamic Property Package


Property Package

A property package is a collections of equations that define (given set of

physical conditions) :

1. State of matter i.e vapor/mix/liquid phase

2. Physical properties.

Derived by fitting experimental data.


Why proper property selection is crucial?

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• To calculate the component properties at certain T&P (e.g. density, heat capacity etc.)

• To determine the phase of the component at certain T&P (e.g. V/L/V+L)

• To determine the in what proportion the component would exist in each phase (equilibrium)

• The accuracy of the calculated/simulated results will greatly depend on the accuracy of the thermodynamic package prediction.



Types of Property Package

Equation of State Model

• Good for non polar liquid and gas phase since can calculate critical point.

• Covers a wide temperature & pressure range

• Advance Peng-Robinson, Soave-Redlich-Kwong

• Hydrocarbon application

Activity Coefficient Model

• Good to represent non-ideal liquid due to presence of polar components, but cannot predict critical point

• Limited T & P range

• Non Random Two Liquids (NRTL), UNIFAC, UNIQUAC, Wilson

• Chemicals with high polarity i.e. water, alcohol

Special Packages

• Customized to represent specific process which may include kinetics data in addition to equilibrium data

• Limited T & P range

• Urea, Amine, Steam97


Property Package Selection Guideline

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PETRONAS Technical Standards : Property Package Selection

(PTS 20.00.10.37 ) is available in AXIS


Example

Objective:

To give an indication of NH3 purity, an online calculation can be implemented as part of

ELMS, to enable operators to take necessary action to drain any contaminants i.e.

compressor oil from NH3.

Actual saturation Pressure & Temperature

Actual saturation Pressure & Temperature


Example

• The figure above shows multiple plots of pure NH3 using 21 different thermodynamic packages and a plot of actual DCS data.

• Lee-Kesler-Plöcker (LKP) is found to be the best suited thermo-package.

1400

1450

1500

1550

1600

1650

1700

33 34 35 36 37 38 39 40

Pre

ss

ure

(k

Pa

A)

Temp (deg C)

Pure Ammonia Temp VS PressureAPR

APR-NG

Refinery SRK

APR-LK

NGL-PR

API SOUR

CHAO SEADER

GRAYSONSTREEDMAXWELLBONELLLKP

UNIQUAC

wilson

TK-WILSON

NRTL

VAN LAAR

Actual DCS data

NGL-PR Thermo

Lee KeslerPlockerThermo

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Modeling Approach


Modeling Approach – Degree of Freedom

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Unit Operation in iCON

Degree of Freedom • No. of specification required for the calculation to complete• Inadequate specification calculation will not progress• Overspecified inconsistency error will created



Modeling Approach – Degree of Freedom

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Unit Operation Typical Specification

Stream Pressure, Temperature, Flow, Composition

Separator With feed stream, separator will converged without having to specify anything

Cooler/Heater With feed stream, user needs to specify either:1. Temperature outlet, Delta P2. Temperature outlet, Pressure outlet

Heat Exchanger User needs to have both fluids properties (2 streams; shell and tube)Other specifications are similar to cooler/heater

Compressor/Pump/Expander

With feed stream, user needs to specify either:1. Pressure outlet, Efficiency2. Pressure outlet, Temperature outletIf with compressor curve, speed is required as specification


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Hands-on Training..

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Desktop

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New file..

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#1 Property package: Advance Peng Robinson

#2 Add components:Water; Nitrogen; Carbon Dioxide; Methane; Ethane; Propane; iso-Butane; n-Butane; iso-Pentane; n-Pentane; n-Hexane;

h2o;n2;co2;c1;c2;c3;ic4;nc4;ic5;nc5;nc6;

1 Water

2 Nitrogen

3 Carbon Dioxide;

4 Methane

5 Ethane

6 Propane

7 Iso-Butane

8 n-Butane

9 iso-Pentane

10 n-Pentane

11 n-Hexane

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#1 Property package: Advance Peng Robinson

#2 Add components:Water; Nitrogen; Carbon Dioxide; Methane; Ethane; Propane; iso-Butane; n-Butane; iso-Pentane; n-Pentane; n-Hexane;

h2o;n2;co2;c1;c2;c3;ic4;nc4;ic5;nc5;nc6;

1 Water

2 Nitrogen

3 Carbon Dioxide;

4 Methane

5 Ethane

6 Propane

7 Iso-Butane

8 n-Butane

9 iso-Pentane

10 n-Pentane

11 n-Hexane

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#3 Flash a material streamUnit

Temperature Deg C 30

Pressure Kpa 1000

Mass Flow Kg/h 125

Water Mol %

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Nitrogen Mol %

0.5

Carbon Dioxide;

Mol %

0.5

Methane Mol %1

Ethane Mol %1

Propane Mol %5

Iso-Butane Mol %45

n-Butane Mol %40

iso-Pentane Mol %2

n-Pentane Mol %2

n-Hexane Mol %2

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# 4 Flash options

P-T Flash

Vapor Fraction (VF) Flash Calculation

P-H Flash

Temperature , Pressure , Flow ,Composition

Enthalpy, Pressure , Flow ,Composition

Vapor Fraction, Pressure , Flow ,Composition

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# 5 Pseudo component: Min data: Normal Boiling Point or Molecular Weight + Liquid Density

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Getting startedStarting iCON from desktop.Selecting thermo.Selecting components.Converging a stream.Units.Bubble / dew points.Phase diagram.Special properties.

Making a copy• Spec from•Clone•Copy stream

•Show datasheet•Table•Writing

Controller• Temperature control

Process Calculator•Totalizer

Pseudo component

Ammonia ref – choosing thermo


Modeling Approach – Data Propagation

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• In port has a mass flow of 200 kg/hr (mole flow = 4.84 kg-mole/hr)• Since the cooler has a single In and a single Out material port:

No accumulation of matter No chemical reactions

•Therefore, the:

Mole Flow Mass Flow

of In and Out port must be IDENTICAL




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• Note that even though the mole and mass flows are NOT known, the thermodynamic state of the In port IS known.

• Click on thenode and inspect the physical properties of the In port.

• Now click on the (Mass Flow, In) cell and press the <Delete> key.

• You will notice that the since the mass flow is not specified, the mole flow is automatically forgotten.




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• Click on the (MassFlow, Out) cell and specify a mass flow of 2000 kg/h as shown below

• Hit the <Enter> key




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• Note that the Out port mass flow is now specified (blue background),

• And the mole flow is automatically calculated at 4.84 kgmole/h.

• Also, note that the available information is propagated backwards to the In port.



Flash Calculations • Rigorous three-phase calculations except for Wilson (only vapor liquid)

• Type of flash calculation based on degree of freedom concept depending on specifications imposed on the system

• Independent Variables: Pressure (P), Enthalpy (H)• Dependent Variables: vapor fraction, Temperature and entropy

P-T Flash

• Independent Variables: Vapor Fraction (VF) and Temperature (T) or Vapor Fraction (VF) and Pressure (P)

• Dependent Variables: Pressure (P) or Temperature (T) and enthalpy and entropy

• Examples: • Dew Points: VF = 1.0, and either P or T• Bubble Points: VF = 0.0, and either P or T

Vapor Fraction (VF) Flash Calculation

• Independent Variables: Temperature (T), Pressure (P)• Dependent Variables: vapor fraction, enthalpy and entropy

P-H Flash


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