Executive Summary

How it works Separating fluids is based on the principal of density differences The immiscibility of two liquid phases allows them to be separated in a separator Sufficient space within the separator must be given in order to allow the droplets

of a specific size (diameter) to reach terminal velocity and settle before the gas is extracted.

Advantages (vertical) Advantages (horizontal) Does not need significant liquid retention volume

They are less expensive than vertical separators, though they are used for liquids with less sludge and sediments.

Vertical separators are capable of handling large slugs of liquid and are therefore most often used on low to intermediate gas-oil ratio well streams

Horizontal separators are ideally suited for streams having high gas-oil ratios, constant flow, and small liquid surge characteristics

They are well suited for handling liquids that contain sands and other sediments

Better at handling larger feed flow rate

The separator occupies a small amount of plot space

Due to its large interfacial areas, it has better phase separation capability

Sizing Cost Estimation – Capital cost)

Cost (2011) Lower Bound ($) Upper Bound($)

$ 41374.74 $24824.84 $57924.63

Abdel-Aal, H. A. (2003). Petroleum and Gas Field Processing. Marcel Dekker Inc. James H. Taylor, A. F. (n.d.). Modeling and Control of Three-Phase Gravity Separators in Oil Production Facilities. Retrieved November 10, 2012, from http://www.ece.unb.ca/jtaylor/Publications/acc07_pilot.pdf

References

Carbon Capture Sequestration

Ultrafiltration for CCS

Hollow Fibers

Overview of annual operating

cost Membrane Replacement

Membrane lifetime

Rate of replacement

Energy

Power and efficiency of pumps

Total flow rate

Reference

◦ Wilcox.Jennifer “Carbon Capture”, New York: Springer, 2012

◦ Sandeep. S, “Transient permeate flux analysis, cost estimation, and design optimization in cross-flow membrane filtration” Department of Environmental Science and Engineering, Rice University,1997Danny Luu

Jessica Tang

GLYCOL DEHYDRATIONby Dan Gariepy and Kristen Kolynchuk

Triethylene Glycol (TEG) Molecular Structure:

Purpose:● removes water vapour from wet natural gas● water content decreases process efficiency

and can damage process equipment● companies have specifications on the water

content of gas they will purchase○ (approx. 0.000112 kgH2O/m3gas)

Separation Mechanism:● an absorption column can remove water

vapour from natural gas, using TEG as the absorbent

● TEG has high affinity for water, facilitated by it's hydroxyl & ether groups

● water vapour in the gas will be absorbed by TEG as the streams are contacted

● bubble-cap trays contact the wet natural gas with TEG

Absorption Column:

Bubble-Cap Tray:

COST ESTIMATION

References:1. Manning. Francis. S, Thompson, Richard. E. “Oilfield Processing: Natural Gas” PennWell Publishing Company, South Sheridan, Tulsa, Oklahoma. 1991. 2. Guo. Boyun, Lyons. William. C, Ghalambo. Ali, “Petroleum Production Engineering: A Computer Assisted Approach” Linacre House, Jordan Hill, Oxford. 2007.

Column Properties# of Trays 8

Spacing 3.625 ft

Diameter 5.0 ft

Height 29.0 ft

Volume 569.4 ft3

Temperature 100oF

Pressure 1200 psig

Capacity 169.93 m3/h

Circulation 25 LTEG/kgH2O

TEG Price $0.09/kgTEG

Duration 3840 h/year

Mass Balance:● amount of H2O in inlet gas was

determined using Raoult's law:

(Vapour pressures from Antoine's Equation)

● mass of H2O removed determined using the company specifications

● circulation determined amount of TEG required to remove H2O

First Year Costs[2012 dollars]

Unit Cost $136,436

Installation $272,872

Maintenance $10,593/year

Labour $200,000/year

TEG Flow $53,896/year

Total Cost: $673,797

Biodiesel  Produc-on  from  Vegetable  Oil  

Triglyceride   Methanol   Glycerol   Methyl  Esters  (Biodiesel)  

Tubular  Centrifuge  

Light  Liquid=  Glycerol-­‐  Methanol  mixture  Heavy  Liquid=  Biodiesel  

Cos-ng    

BIODIESEL  PRODUCTION     70,000,000  L/year  

PRODUCTION  PERIOD   52  weeks  a  year,  24/7    

ANTICIPATED  SALES   $49,421,000/year  

CAPITAL  COST  (MOTOR+CENTRIFUGE)   $2,455,000  

UTILITY  COSTS  (ONLY  ASSOCIATED  WITH  MOTOR)  

$2,428/year  

INLET  FEED  COMPOSITION   60.2%  Biodiesel,  39.1%  Methanol,  0.7%  Glycerol  

EXTRA  READING  OPPORTUNITIES:  • Oh,  P.,  Lik,  H.,  Lau,  J.C.,  Junghui,  C.,  Chong,  M.F.,  Choo,  Y.M.  A  review  on  convenSonal  technologies  and  emerging  process  intensificaSon  (PI)  methods  for  biodiesel  producSon.  Renewable  and  Sustainable  Energy  Reviews  16(2012)  5131-­‐5145  • Coulson,  J.M.,  Harker,  J.H.,  Backhurst,  J.R.,  Richardson.  (2002).  Coulson’s  and  Richardson’s  Chemical  Engineering:  Par6cle  technology  and  separa6on  processes.  Buberworth-­‐Heinemann  

HF Alkylation – Process Overview

HF Alkylation – Costs

Inlet

Column

Condenser

Kettle Reboiler

Alkylate

Side draw

Separator

HF

Light Oil

Steam

Condensate

Item Cost (C$)

Total CapEx 5,381,000

Operators 44,000

Steam 645,000

Maintenance 161,000

Electricity 93,000

Total OpEx 943,000

[1] G. Towler & R. Sinnot (2009), Chemical Engineering Design, 5th Ed., Elsevier [2] R. Meyers (2004), Handbook of Petroleum Refining Processes, 3rd Ed., McGraw-Hill

Production of Benzene from Hydrodealkylation of Toluene (Alaa Salam and Saeed Mobayed)

Process Flow Diagram

Reaction: Toluene + H2 → Benzene + CH4 (Irreversible reaction)

2 Benzene ⇌ Diphenyl + H2 (By-product of the reaction)

Separation Units: Flash drum, Three Distillation Columns ( Stabilizer, Benzene, Toluene)

Physical Principle: Exploiting the boiling point of component

Estimated Costs of the Separation Process in HDA

Production Rate of benzene : 265 mol/hr Value of benzene is : $ 9.04/mol Value of the produced Benzene in one year: $ 17,410,500

Benzene column

(product) Cost

Toluene Column

(recycling) Cost

The Grand Total of the Separation Process is: $ 672,800 / year References: [1]Richard Turton: Analysis, Synthesis and Design of Chemical Processes, Third Edition, (2008), Chapters 1-4. [2]Robert Perry; Don Green: Perry’s Chemical Engineers’ Handbook, Eighth Edition, McGraw-Hill, (2008), Chapter 13 Distillation

Cost

Benzene Distillation Column 120,000 $

Installation 20,000 $

Separation of (benzene) & (Toluene and diphenyl)

81,000 $/year

Cooling Water 12,900 $/year

Condenser 26,700 $/year

Heat 20,800 $/ year

Steam 102,600 $/year

Total 384,000 $ /year

Cost

Toluene Distillation Column 85,000 $

Installation 15,000 $

Separation of Toluene & Diphenyl 26,300 $/year

Cooling Water 2,600 $/year

Condenser 6,500 $/year

Heat 8,600 $/ year

Steam 49,600 $/year

Total 193,600 $/year

Disk Stack Centrifuge for Insulin Production

Manufacturing Process of insulin

Inside of a Disk Stack Centrifuge

By: Ushna Ikram Allen Winata

Design and Cost Analysis

N 120

r1 (m) 0.13

r2 (m) 0.08

(rpm) 6000

Angle 35

Sigma 35944.94

Design parameters

Equipment Cost - $155,000+/- 40%Operational Cost - $14,256/yr

Design Equation

References: Leung, Wallace Woon-Fong. (2007). Centrifugal Separations in Biotechnology. Elsevier Science & Technology. Retrieved 14 November 2012 (Disk Stack Centrifuge)Petrides D. Bioprocess Design. 2000 (Insulin Process)

Uranium Recovery using Counter Current Solvent Exchange

Stokes Law:

𝑣𝑠 =2 𝜌𝑝−𝜌𝑓

9𝜇𝑔𝑅2

Operating Costs and Installation

Element Cost

Bare Module $543,000-$1,627,000

Agitator Costs $1247/yr

Solvent Costs ($4.5/gal) $121,000/yr

Total Operating Costs $122,000/yr

Useful References: IAEA (1980). Technical Report Series No. 196. Significance of Mineralogy in the Development

of Flowsheets for Processing Uranium Ore [Online].

Available: http://www-pub.iaea.org/MTCD/publications/PDF/trs196_web.pdf

D. C. Seidel (1981). Vol . 32 No. 2. Extracting Uranium From its Ores [Online].

Available: http://www.iaea.org/Publications/Magazines/Bulletin/Bull232/23204882428.pdf

Decanter Centrifuge Unit Overview Capable of handling feed with significant solids concentration

Ideal for solid-liquid separation processes

Capable of three phase separation

Solid cylindrical bowl, conical shaped

Screw Conveyer, operated at differential speed

Thomas Oszustowicz Jordon Perry

Mass Balance on Solids:

F – Feed S – Solids stream C – Clarified liquids stream

Annual Operating Costs

References: 1. Perry’s Chemical Engineering Handbook (Don Green and Robert Perry) 2. Decanter Centrifuge Handbook (Alan Records and Ken Sutherland)

Perry’s Chemical Engineering Handbook was used to obtain the purchase cost and energy usage for a typical decanter centrifuge, which are $160,000 and 30 hp respectively. The following table summarizes annual operating costs:

*Using salvage value = $10,000 and an average life of 20 years **Assuming it runs 24 hours/day every day of the year with an energy cost of 8 cents.

Froth Flotation

• Separation based on gravity, densities and hydrophobic properties of bitumen

• Separation unit sized as a typical clarifier

• Feed : 8 wt% bitumen, 50 wt% water, 42 wt% sand

• Froth: 66 wt% bitumen, 25 wt% water, 9 wt% sand

• Calculated dimensions: Diameter = 37 m , Height = 14.5 m

• Total Capital Cost: $1,401,150 to $3,269,350

Operating Costs

•12 kW electricity requirement for skimmer/rake

•Slow rotative speed of skimmer results in low operating costs

•Annual Operating Cost = approx. $12,500

References:

1. Perry, R.H., and D.W. Green, Eds. Perry’s Chemical Engineering Handbook 6 th Edition., McGraw-Hill New York (1984).

2. Heinemann, H., Speight, J. (2006). The Chemistry and Technology of Petroleum 4 th Edition, Recovery of Heavy Oil and Tar Sand Bitumen (pp. 117- 208). New York: CRC Press.

CAPITAL AND OPERATING COSTS

Ethanol production from sugarcane – Absorption Column James Scott & Sahil Azeez

The absorption column exploits the relatively high miscibility

of ethanol (EtOH) in water to separate it from carbon dioxide

(CO2)

Mass Balance/operating line:

Equilibrium line:

Installation and Operating Costs

Item Material

Cost (USD $)

Labour Cost (USD $)

Equipment and

setting

152,400 7,491

Piping 17,676 16,792

Civil 1,845 2,745

Structural steel 14,952 5,005

Instrumentation 24,907 9,107

Electrical 3,311 1,358

Insulation 13,041 11,523

Paint 780 1,586

Subtotal 228,912 55,607

Total Installation

Costs

284,519

Provided by Aspen Icarus in 2006 US dollars

Table 2: Absorbent costs Table 1: Material and Labour costs

Parameter Value

Flow rate (m3/hr)

6.26

Cost ($/m3) 0.20

Cost

($/year)

$14,000

References: 1. Sieder, Henly and Roper, Separation Process Principles, 3rd Edition, Wiley,

Chapter 6 2. B.Jaime, Priniples and Modern Applications of Mass Transfer Operations¸

Wiley & Sons, New Jersey, 1948 pg 252-270

Condensers in the Production of Sulfur in the Claus Process

The Claus Process:

• Makes sulfur from sour gas

(H2S)

• Direct contact condensers separate sulfur

Direct Contact Condenser:

• Mixes vapour and coolant

streams

• Results in liquid sulfur product

1 Jonathan Howell & Heera Marway Chem Eng 4M04 ~ 2012 ~ Course Project

Condensers in the Production of Sulfur in the Claus Process

Condenser cost: For one direct contact condenser = $17177-40053* *Calculated using Table 5-9 Woods, D. R. Cost Estimation for the Process Industries (Fall 1993.).

Annual Operating cost: Main cost is cooling water = $ 2958000/year ** ** based on industrial water cost in Toronto (Nov. 2012)

Considering an operation of 340 days a year and not considering recycle

Suggested references: Geankoplis, C. J. (2009). 8.6 Condensers for Evaporators. Transport Processes

and Separation Process Principles (Third ed.). Upper Saddle River, New Jersey: Prentice Hall.

El-Bashtawi, R., & Haimour, N. Claus Recycle with Double Combustion Process. Elsvier Fuel Processing Technology, 86(2004), 245–260.

2 Chem Eng 4M04 ~ 2012 ~ Course Project Jonathan Howell & Heera Marway

FLOTATION SEPARATION IN POTASH PRODUCTION By: Viktoriya Todorova and Hisham Al Dosouky

Capital Cost

F.O.B. Cost: $27,121±11000 PER BANK (x5 CELLS)

Operation:

24h/day/365 days/yr/

8 h/shift

3 operators/day

Salary: $35/hr

Operating Cost

ENERGY COST $ 24,470

LABOR COST $ 306,600

MATERIALS COST (COST+20%LOSSES)

$ 52,700 (ONCE)

REFERENCES

[1]Wills, B. (1992). Mineral Processing Technology. Cornwall: Wheatons Ltd [2]Tech:, M. (2012). Flotation Fundamentals. Retrieved 2012, from Department of Chemical Engineering: http://www.chem.mtu.edu/chem_eng/faculty/kawatra/Flotation_Fundamentals.pdf [3] Ives, K. (1984). The Scientific Basis of Flotation. London: NATO Scientific Affairs

 Purpose: Removal of hydrogen sul5ide from natural gas Solvent: Methyl diethanolamine (MDEA)  Gas Absorption unit acting in countercurrent 5low between the incoming sour gas 5low and MDEA solvent.  Tower Choice: Trays were selected due to incredibly high 5low rate of natural gas Flow rate: 2000 cubic kilometers / day 

Andrew Bovell, Jamie Chung 

Cost Es8ma8on Sizing 

Tower Height 45.72 m Tower Diameter 1.67 m Trays 21

Tray Spacing 2.1 m

Material 316 S.S.

Feed Rate 2000 km3/Day

Cos)ng 

Unit Sizing (Height)*(Diameter)1.5

Using Don Woods Table 6-6

1970 Base $192,632

1970 Bare Module $801,353

2010 Bare Module $3,891,904 Actual Cost (1968 Cost Inflated) $4,787,042

References [1] Kohl, A. L. and F. C. Riesenfeld, Gas Purifica8on, 3rd Ed., Gulf Publishing Co., Houston [2] The Dow Chemical Company, "Gas Sweetening," October 1998. [Online].  Available:  hSp://msdssearch.dow.com/PublishedLiteratureDOWCOM/dh_0039/0901b803800391f8.pdf?filepath=gastrea8ng/pdfs/noreg/170‐01395.pdf&fromPage=GetDoc

Andrew Bovell, Jamie Chung