REVAMPING, RETROFITTING AND DEBOTTLENECKING

OF LPG PLANTS

Presson Descon Int. Pvt. Ltd.Ortloff Engineers, USA.

Enerflex

Descon

PDIL Profile

Oil & Gas Production and Processing Solutions

Scope

Basic Engineering

Training

Detailed Engineering

Procurement Fabrication

Construction Installation

Commissioning

Plant Operation & Maintenance

EPCC Solutions

PDIL Profile

Construction

Procurement

E P C C StrengthCommissioning

Engineering

PDIL Profile

ORTLOFF Profile

Ortloff Engineers, Ltd. was formed in 1986 to license Ortloff's proprietary know-how, to provide technical support for the licensing effort, and to perform engineering/consulting assignments for both process plant contractors and operators.ORTLOFF focuses efforts in the areas of cryogenic gas processing and sulfur recovery.  More recently, Ortloff has expanded its technology portfolio to include LNG production and processing as it relates to NGL/LPG recovery and extraction.

ORTLOFF Profile

Technologies Available•Ortloff’s patented & proprietary LPG recovery processes Licenses.•Ortloff’s patented & proprietary NGL recovery processes licenses.•Ortloff's patented & proprietary LNG liquefaction and LNG processing designs licenses.

•Ortloff's proprietary gas processing plant design know-how.•Licenses to use Amoco's sulfur recovery processes and know-how.•Ortloff's proprietary sulfur recovery processes and design know-how.•Ortloff's proprietary sulfur vapor valves and sulfur drain seals.•Geothermal Power Recovery.

ORTLOFF Profile

Split-vapor processes:•Ortloff Gas Sub cooled Process•Ortloff Overhead Recycle Process

Ethane Recovery Processes:•Cold Residue Reflux Process•Recycle Split-vapor Process• Recycle Split-vapor with Enrichment Process

Propane Recovery Processes:•Split-flow Reflux Process•Improved Overhead Recycle Process•Single Column Overhead Recycle Process

ORTLOFF Profile

Ortloff Experience:130+ plants retrofitted all over the world with Ortloff LPG/NGL recovery technology50+ LPG plant all over the world with Ortloff Proprietary technology65 LPG/NGL plants designed and installed by Ortloff Corporation

Cryogenic NGL Recovery Projects Detailed ListsExperience List (1980 - present)Plants Built by The Ortloff Corporation (1975-1986)

Recently PDIL has signed a MOU with Ortloff Engineers to work on LPG/NGL projects in the region.

This alliance will combine technical expertise of Ortloff with Project management and EPCC skills of PDIL to provide a single point solution to clients in LPG/NGL sector.

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With the letter of support from Ortloff and PDIL’s commitment to quality and customer satisfaction, clients in LPG/NGL sector have a unique opportunity of technical solutions at their door steps not available in the region before.

Introduction toLPG Revamp & Retrofit

At many locations, existing NGL and LPG recovery plants are generating less revenue than they might because of

limitation in capacityRecovery efficiencyOperating flexibility

In many cases, it is a better alternative to revamp, retrofit, debottleneck existing plant rather than building a new plant.

Return on investment required to revamp an existing plant is much greater than return from constructing a new facility, because existing plant already has significant infrastructure (utility system, buildings etc.) that can used as-is after revamp.

With careful process selection for retrofit, modifications to the existing processing plants can be minimized to:

Reduce capital costReduce construction periodMinimize the plant downtime required to

make final tie-insCapacity increase of 30% or more are

attainable with proper process selection

Retrofittingvs.

Debottlenecking

Understanding the difference between retrofitting and debottlenecking is crucial to seeing the possibilities for a given facility.

Most owners are familiar to debottlenecking approach to expansion and only think of current limitations of individual pieces of equipment rather than considering that the process conditions change significantly for retrofit process design to eliminate limitations and problem areas.

Advantagesof

Retrofitting

No constraint of existing equipment sizes

The retrofit design typically unloads the existing equipment by sharing the load with equipment added for process retrofit.

Supplemental new technology equipment is added to key areas to provide desired plant throughput by adding parallel capacity to existing equipment.

Existing equipment sizes no longer constrain the plant capacity.

Less plant downtime

A debottlenecking project typically requires much more plant downtime than a process retrofit

In debottlenecking project, equipment to be replaced must be removed before new equipment can be set it, requiring that plant must be down for entire time.

In retrofit projects, new equipment can be set, piped, tested, purged, and checked when existing equipment continues to operate.

When everything is ready, plant is shutdown, final tie-in are made and retrofitted plant is started back with new equipment in operation.

Faster pay-out period

In many retrofit projects, pay-out for process retrofit can be realized in due months due to improvements in plant capacity, recovery efficiency and ease of operation.

Process Retrofit Study Procedure

1. Simulation of original plant design using original feed stock composition.

This allows checking original basis and provides baseline information.

It may provide info missing for some items.

2. Simulation update based on any equipment changes in original design.

Both simulations should give good agreement with available equipment datasheets, otherwise discrepancies must be noted & explained.

3. Simulation and current operating conditions. Used to identify any equipment not performing as

expected.

4. Any significant deficiencies on equipment performance are analyzed and resolved.

Heat exchangers performance and pressure drop. Cold separator and tower capacity requirements. Performance of expander. Compression requirements.

5. Simulation with addition of new retrofit based on new technology.

6. Impact on other plant systems due to new conditions (gas treating, dehydration etc.).

7. Cost estimation for overall project economics.

Benefitsafter

Retrofit

After completion of retrofit/revamp project, the plant will be capable of:

Producing 30% more LPG product.10~20% increase ethane recovery (if

required).Ability to shift from full ethane reject to

enhanced ethane recovery mode without affecting high propane recovery (if required).

T h a n k Y o u