Chapter 1: Mass and energy balances – hand calculations 1.1 Mass balance around the 3-phase separator 1.1.1 Feed calculations – state your assumptions: feed contents in mass rates (kg/s or kg/hr) for each of the total feed rate, rate of associated gas (kg/s) in the feed, same for oil in the feed and free and remnant water in the feed. A clear set of assumptions as needed should be made. 

 

1.1.2 Sketch of a three-phase separator, assumptions made, sample calculation and tabulated results should be presented. 

 

1.2  Mass Balance around 2-phase separator (one or more) until RVP of oil steam is assumed below 30 RVP. 1.2.1 A clear set of assumptions 1.2.2 Sketch, sample calculation and results 1.2.3 Tabulated results 

 

1.3  Desalter/de-emulsifier 

 

 

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1.3.1 A clear set of assumptions 1.3.2 Sketch, sample calculation and results until salt contents is between 29 and 30 PTB 

 

1.4  End usage of oil considered – shipping, sending by pipeline, unlikely possibility of short storage 

 

1.5  Treatment of water stream 1.5.1 Assumptions: Water-oil separator(s) until water is ready for re-injection 1.6  Gas gathering and processing 1.6.1 Collect all gas streams, decide on the best way to meet pressure requirements, do you need compression? 1.6.2 Remove all the water contents of the gas using an absorber and ethylene glycol as a solvent 1.6.3 Use a de-methaniser to produce C1 stream of 99.99 purity. 1.6.4 Use a de-ethaniser to produce C2 of 99.99 purity. 1.6.5 Use a de-propaniser to produce C2 of 99.99 purity. 1.6.6 Use a de-butaniser to produce C2 of 99.99 purity. 1.6.7 Assign the C5+ stream to gasoline blending – do not mix with crude oil. 

 

1.7  Energy integration: You should make every effort to reduce the direct heating (using steam) and cooling (using appropriate coolant depending on the desired temperature – Freon, liquid propane, etc.) 

 

1.8  Can you quantify your energy savings? This is mainly for later. At this stage a qualitative statement will do. 

 

1.9  Conclusions 

 

2 (Chapter 2) HYSYS Simulation 2.1  Present your full HYSYS simulation showing your feed properties (feederate, composition – from your chapter 1- and assumed T and P) 

 

2.2  Brief tabulation and description of main results and highlights of each unit operation: three-phase, two-phase, compression, mixing, pumping, absorption, distillation, etc. 

 

 

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2.3   Challenges and limitations 

 

2.3.1 Un-realistic level of water separation – need of addon license 2.3.2 Details of attempts to sweeten the gas stream – reason for not being able to: need for an add-on license. As a results gas composition was modified slightly: H2S and CO2 were deleted and the percentages allocated to them were added to C4. 2.3.3 Other challenges? 

 

2.3.4 Conclusions 

 

3 (Chapter 3) Sizing and Costing 3.1 Sizing of all separators (L and D of each): one sample calculation and table of the rest 3.2 Sizing of all columns: Diameter, height and number of trays – One sample calculation and  a table of all the rest 3.3 Sizing of all coolers, heaters, heat exchanges, condensers, reboilers – same as above: sample calculation and a table of rest – Areas only. 3.4 Sizing of any other equipment used, pumps, compressors, etc. 3.5 Capital cost (CAPEX): Costing of all the above equipment using empirical correlations given. Only cost of equipment. Not including land, licensing, buildings, infrastructure, insurance, abandonment, etc. 3.6 Operating Cost (CAPEX):  Including raw materials, solvents, cooling (do not use electricity), heating (steam – do not use electricity). 3.7 Do not provide economic analysis: no calculation of payback period, ROIC or NPW is needed. 

 

4 (Chapter 4) Conclusions/recommendations