Design of Flare Gas Recovery Plant - Case Study - Science Assignment Help

Assignment Task:

Task:

The present practice in an Oil Refining Company is flaring the residue gases produced from different process units. Currently 16.5 MMSCFD of flared gases are continuously burnt through the flare stack. The plan is to install a proper plant that can recover and reduce the flared gases to as minimum as possible. The recovered gas will be used as a fuel gas instead of losing it through burning in a flare stack.

Therefore, you are requested to design a Flare Gas Recovery Plant to recover 15 MMSCFD of the flare gas. The remaining unrecovered gas will be routed to the flare stack. The flare gas contains 0 - 40 % Hydrogen, 1 - 2 % H2S and remaining components are hydrocarbons from C1 to C5.

The Plant should consist of the following main equipment, but not limited to :
1- Compressor(s): These compressors should be designed under special control scheme to ensure that at no stage the flare header is under negative pressure. Also, you should decide whether the compressors should be driven by steam turbine or speed electric motor or combination of both if you have more than one compressor.

2- Knock out drum(s): Make sure to have them in all stages where there is a chance for liquid accumulation. i.e. Feed, intermediate, final stages...etc
3- Water Seal drum(s): This is for the uncovered gas before routing it to the flare stack.
Hint : Refer to the “Oil Refinery Unit” taken in Diploma or Search for the scheme and description from the internet.
4- Cooler(s): As required.
5- Gas Treatment facilities : The recovered gas should be sent for further treatment before using it as fuel gas.
6- Flare Stack: the system should be designed to ensure not to have vacuum formation, burn back situation or air ingress through the flare tip.

Assessment Tool

1. Process Flow Diagram (PFD) of the process covering all main equipment, as reflected above. (6 marks, 1 mark for each above section)
Hint:
1) You need to use a proper software for developing your PFD but simple one and not complicated one such as a simulation software program due to non- availability of the detailed data for your project.

You may refer to the following link to explore different software that can be used for free. https://thegeekpage.com/best-free-tools-for-creating-flowcharts/

2) Refer to the “Oil Refinery Unit” taken in Diploma or Search in the internet to find the common symbol for each equipment needed under your project.

2. Process Description of the plant. (6 marks, 1mark for each above section)
3. Economics of the process. i.e. cost vs. profits. (3 marks)

Please note that, discussion and Q&A sessions will be conducted for all the groups to evaluate the understanding and contribution of each student within the group.

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