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Feasibility of converting gas condensate into consumable fuels (gasoline)

Number of pages: 86 File Format: word File Code: 31829
Year: 2012 University Degree: Master's degree Category: Chemical - Petrochemical Engineering
Tags/Keywords: Catalytic reforming - Consumable fuels - crude oil - Gas condensate - Gas condensate conversion - gasoline - kerosene - Natural gas extraction - Simulation
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  • Summary of Feasibility of converting gas condensate into consumable fuels (gasoline)

    Dissertation for M.Sc master's degree

    Treatment: Process Engineering

    Abstract

    The upcoming project is the feasibility of converting gas condensate into products with higher added value and consumable fuels such as gasoline. Considering the huge gas and oil reserves in Iran, this country is one of the major importers of gasoline. Therefore, it is very necessary to implement gasoline production plans to cut off foreign dependence on gasoline. In the meantime, the gas condensates that are extracted from gas reservoirs along with the extraction of natural gas, in terms of carbon structure, are mainly in the range of gasoline hydrocarbons and therefore have a high ability to be converted into gasoline. In this project, a sample of South Pars gas condensate was sent to the laboratory to analyze its composition by chromatography. Then, in the simulation environment, gas condensate was converted into gasoline and kerosene. The percentage of conversion to gasoline is more than 70%. The results of economic calculations show that the cost of producing gasoline from gas condensate is less than a third of the cost of producing gasoline from crude oil.

    Key words: gas condensate, gasoline, kerosene, simulation, catalytic reforming.

    Chapter One

    Introduction

    Oil, gas and their derivatives not only play a fundamental role in meeting human needs in the field of fuel, energy and fibers, but also have caused the emergence and development of various important industries, some of which are mentioned. At the same time as the refining of crude oil, the use of internal combustion engines became general and millions of gasoline-burning cars were released to the market.

    Carbon and hydrogen atoms surprisingly can combine with each other to create an extremely large number of aromatic chain and ring hydrocarbon compounds, so far a hydrocarbon that has 60 carbon atoms in its molecular structure has been traced. On the other hand, increasing the number of carbon atoms increases the number of hydrocarbon isomers. For example, a hydrocarbon that has 30 carbon atoms can form more than four billion isomeric hydrocarbon compounds. In addition, due to the fact that saturated hydrocarbon compounds are also abundant in crude oil, the number of compounds in it is extremely large and diverse. This diversity is further increased with the participation of other atoms such as sulfur, nitrogen and oxygen in the hydrocarbon chain.

    Gas fields can be compared to oil fields where the oil layers, which are mainly composed of C5 and later hydrocarbons, are very small compared to the amount of recoverable gas. However, during the exploitation of gas fields, a considerable amount of petroleum liquids is obtained from each of the production units, which will be different in different fields. Therefore, gas condensate[1] is one of the side products of gas extraction from gas wells. Gas condensates are hydrocarbon liquids separated from natural gas, which are obtained as a result of pressure and temperature changes in gas produced from gas fields, after being transferred to surface separators. [25]

    These condensates are of high value and are often used as feed for refineries to produce the main product of gasoline and by-products such as kerosene and diesel, etc.

    Gas condensates, unlike butane and propane, do not require special conditions to remain liquid and can be converted into light oil, gasoline, jet fuel, etc. in different ways. Compared to the crude oil refinery, in the gas condensate refinery, the conversion and refining processes are less, so its investment cost is lower than the investment cost of the crude oil refinery.

    This product is of significant importance for export due to its high calorific value.In such a way that its export can return the initial investment cost of a gas refinery within a short period of time, provided that it has the desired technical characteristics.[26]

    The country of Iran, with vast gas fields and recoverable reserves of 1.33 trillion cubic meters of gas, has 18% of the world's gas and is the second country in gas reserves until 2012. Due to the high volume of gas quantities, there will be an expectation of harvesting a large amount of gas condensate. This gas field is the largest gas source located on the common border line between Iran and Qatar in the Persian Gulf and 105 km from the southern coast of Iran. Studies show that it contains more than 14 trillion cubic meters of natural gas and more than 18 billion barrels of gas condensate. According to the estimate of the Energy Facts Research Institute, based in Honolulu, America, Iran's gas condensate production capacity will reach from 95 thousand barrels per day in 2001 to nearly one million barrels per day in 2013. Currently, 400,000 barrels per day (47,700 cubic meters) of gas condensate are extracted from South Pars, which is expected to increase to 1,200,000 barrels per day by the end of 2013. Meanwhile, due to the lack of refinery capacities, about 31,000 barrels per day of gas condensate are currently being used as feed for the country's refineries. Considering the huge amount of gas condensate produced in the country, a practical investigation is very necessary to reach a desirable technical characteristic for this product for optimal use. According to Iran's oil and gas reserves, but this country is the largest importer of gasoline. So, executing gasoline production projects is necessary to cut foreign oil dependency. In the meantime, gas condensates that come with natural gas extraction from gas reservoirs, in terms of carbon structure, are predominantly in the range of gasoline hydrocarbons and they have high potential for conversion into gasoline. In this plan, an example of the south pars gas condensate was sent to the lab to analyze its compounds with chromatography method. Then at simulation environment condensate was converted into gasoline and kerosene. The percentage of over 70% is converted into gasoline. Economic results do show, the cost of producing gasoline from condensate is less than a third of the cost of producing gasoline from crude oil.

    Keywords: gas condensate, gasoline, kerosene, simulation, catalytic reforming.

  • Contents & References of Feasibility of converting gas condensate into consumable fuels (gasoline)

    List:

    The first chapter: Introduction

    1-1- Introduction ..1

    1-2- South Pars ..7

    1-3- Gas condensate compounds ..10

    1-4- Gasoline ..11

    1-5- Reid vapor pressure ..11

    1-6- Octane number ..12

    1-7- Generalities ..17

    The second chapter: Gasoline production methods 2-1- Gasoline production refinery units 20. Desalination unit 24. Atmospheric and vacuum separation unit 24. Naphtha hydrotriter improvement unit 24. Catalyst modification unit 24.

    Catalytic fission unit. 25. Hydrocracker fission unit. 26

    Merax reforming unit 26

    Alkylation unit 27

    Isomerization unit 27

    2-2 types of gasoline production methods 28

    Natural gasoline or direct distillation 28

    Gasoline from reforming 29

    Gasoline from cracking Catalytic. 30

    Gasoline obtained from alkylation. 30

    Gasoline obtained from isomerization. 31

    2-3- Gasoline additives. 34

    2-4- Chromatography..35

    Chapter three: Simulation

    3-1- DMD/DMC technology.38

    Extraction of CS2, D2S, COS and light mercaptans.38

    Oxidation of light mercaptans.

    3-3- DMC process ..39

    Introduction of DMC process .39

    3-4- Analysis of gas condensate compositions .40

    3-5- Obtainable products ..42

    3-6- Tower simulation ..44

    Thermodynamic calculations .44

    Tower simulation Distillation .46

    Choosing the type of optimization process .48

    Catalytic reforming .50

    Simulation of reforming unit .52

    Simulation of gasoline stabilization unit .53

    Chapter four: Results and discussion 4-1- Production products 56 White oil 57 Gasoline 58 4-2 Economic calculations Estimate total investment 61 Working capital 63 Total refinery income 63

    Production costs .64

    Results of economic calculations .65

    Chapter five: Conclusions and suggestions

    5-1- Conclusion ..67

    5-2- Suggestions ..68

    References ..70

    English abstract ..73

    Source:

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