CFD study - LP Flash Column - Kranji Solutions

This movie shows a Computation Fluid Dynamics simulation of a LP Flash Column. For more CFD troubleshooting information see also http://kranjisolutions.com. LP FLASH COLUMN BUSINESS PROBLEM: Revamp internals will be installed by a vendor in a LP Flash Column on a downstream gas processing facility. The main interest is in the upper part of the LP Flash Column, where a new T-shaped inlet distributor and a collector tray with downcomers and risers is foreseen. 20 MMSCFD of gas and 140m3/hr of liquids will flow through the upper part of the column via the new distributor, located in the flash box. An additional 100MMSCFD of gas is flowing from the bottom part of the column upwards to the downstream random packing. Kranji Solutions was requested to conduct a Third-party Computational Fluid Dynamics (CFD) study of the unit with the internals recommended by the vendor for the revamp. ANALYSIS: CFD Simulations and associated analysis provided the following: • Visualisation of gas flow distribution throughout the upper part of the LP Flash Column • Liquid flow distribution through the downcomers • Gas (and liquid) flow through the risers • Droplet tracking of liquid (DPM), with liquid load evaluation towards the random packing Computational Fluid Dynamics indicated unexpected liquid flow distribution near the collection tray. CONCLUSION: The assessment determined that the gas flow within the column achieved an acceptable uniform flow distribution. Nevertheless, a less favorable liquid flow behavior is observed: • Unexpected liquid flow though the gas risers. • Uneven liquid flow distribution through the downcomers. Hence, further analysis and modifications to the revamp internals, such as adding perforated baffles, will be required, to improve the liquid distribution near the collector tray. SUMMARY: Expert application of CFD modelling revealed successful gas distribution but highlighted issues with liquid distribution. While the gas flow achieved uniformity across the vessel, the liquid phase exhibited maldistribution at the bottom risers and downcomers. CFD ANALYSIS BY KRANJI SOLUTIONS: In addition to many applications outside the process industry, for upstream, midstream and downstream Oil & Gas, CFD is an invaluable tool. It offers understanding of phase-interactions and quantifying velocities, forces and phase behaviour in complex flow systems.- Kranji Solutions has over 20 years’ experience assisting service companies and leading process operators to remedy process operation failures and constraints on production. Applying our industry knowledge and modelling skills we also develop unique equipment for our customers where they have challenging production and processing requirements involving 2-, 3- and 4-phase flows. TROUBLESHOOTING AND ANALYSIS Using CFD in combination with MySep separator modelling software (www.mysep.com), or heat exchanger and process modelling, Kranji provides insight into the root cause of malperformance. Our specialisation in the application of CFD to internal flows, where phase-interaction is key to equipment performance, has resulted in a unique skill profile which has brought us success in assisting Oil & Gas customers world-wide. Our main application areas include: • Phase-separation • Heat transfer • Multi-phase flow dynamics • Impact of motion on performance (FPSO’s) • Erosion • Flow induced vibrations VALIDATION OF REMEDIAL MEASURES Having identified the causes of sub-optimal performance or operational failure, Kranji has deep experience of defining practical industry remedies. This may involve developing modifications to a unique flow system or entail recommending a range of vendors supplying suitable equipment. CFD modelling provides the client with confidence that process requirements can be met with a retro-fit or new-build solution. DESIGN AND EQUIPMENT DEVELOPMENT We also undertake product development of proprietary equipment for customers. Sometimes this type of contract research involves CFD coupled with experimental test and validation using our in-house laboratory facilities and extensive research experience. BENEFITS OF CFD Whether the concern is mal-performance of existing operations or challenging new operational requirements, Kranji Solutions expert CFD modelling services allows our clients to: • Diagnose the root cause of mal performance or equipment failure • Verify the suitability of equipment designs before they are built • Optimise capital investment • Minimise risk of under-performance or down-time • Reducing project cycle time For more information please check http://kranjisolutions.com or email to [email protected]