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Optimization of a saturated gas plant: Meticulous simulation-based optimization - A case study.

ABSTRACT: An optimization-simulation strategy has been applied by coupling a commercial process simulator (Aspen HYSYS®) with a programming tool (MATLAB®) to produce a precise steady state simulation-based optimization of a whole green-field saturated gas plant as a real case study. The plant has more than 100-components and comprises interacting three-phase fractionation towers, pumps, compressors and exchangers. The literature predominantly uses this coupling to optimize individual units at small scales, while paying more attention to optimizing discrete design decisions. However, bridging the gap to scalable continuous design variables is indispensable for industry. The strategy adopted is a merge between sensitivity analysis and constrained bounding of the variables along with stochastic optimization algorithms from MATLAB® such as genetic algorithm (GA) and particle swarm optimization (PSO) techniques. The benefits and shortcomings of each optimization technique have been investigated in terms of defined inputs, performance, and finally the elapsed time for such highly complex case study. Although, both GA and PSO were satisfactory for the optimization, the GA provided greater confidence in optimization with wider ranges of constrained bounds. The implemented strategy precisely reached the best operating conditions, within the range covered, by minimizing the total annual cost while maintaining at least 92% butane recovery as a process guarantee for the whole plant. The optimization-simulation strategy applied in the current work is recommended to be used in brownfields to optimize the operating conditions since they are susceptible to continuous changes in feedstock conditions.

SUBMITTER: Bayoumy SH

PROVIDER: S-EPMC6961219 | biostudies-literature | 2020 Mar

REPOSITORIES: biostudies-literature

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Optimization of a saturated gas plant: Meticulous simulation-based optimization - A case study.

Bayoumy Salah H SH El-Marsafy Sahar M SM Ahmed Tamer S TS

Journal of advanced research 20191130

An optimization-simulation strategy has been applied by coupling a commercial process simulator (Aspen HYSYS®) with a programming tool (MATLAB®) to produce a precise steady state simulation-based optimization of a whole green-field saturated gas plant as a real case study. The plant has more than 100-components and comprises interacting three-phase fractionation towers, pumps, compressors and exchangers. The literature predominantly uses this coupling to optimize individual units at small scales ...[more]

PMID: 31956439

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Project description:The development of water drive gas reservoirs (WDGRs) with fractures or strong heterogeneity is severely influenced by water invasion. Accurately simulating the rules of water invasion and drainage gas recovery countermeasures in fractured WDGRs, thereby revealing the mechanism of water invasion and an appropriate development strategy, is important for formulating water management measures and enhancing the recovery of gas reservoirs. In this work, physical simulation methods were proposed to gain a better understanding of water invasion and to optimize the water control of fractured WDGRs. Five groups of experiments were designed and conducted to probe the impacts of the distance between the fractures and the gas well, the drainage position, the drainage timing and the aquifer size on the water invasion and production performance of a gas reservoir. The gas and water production and the internal pressure drop were monitored in real time during the experiments. Based on the above experimental works, a theoretical analysis was conducted to quantitatively evaluate the performance of the gas reservoir recovery via the gas well production performance, water invasion, dynamic pressure drop and residual gas and water distribution analysis. The results show that when the fracture scale was appropriate, a gas well drilled close to a fracture (Experiment 1-3) or a high-permeability formation could also produce gas and achieve drainage efficiently. The recovery factor of Experiment 1-3 reached 62.5%, which was 24.6% and 21.1% higher than those of Experiments 1-1 and 1-2, respectively, which had wells drilled in low-permeability areas. Draining water near an aquifer can effectively inhibit water invasion during the early stage of gas recovery. The setup in Experiment 2-1 effectively inhibited water invasion and avoided the formation of water-sealed volumes of gas to recover 30% more gas than recovered with that of Experiment 1-1 without drainage wells. A shorter distance between the drainage well and the aquifer increased the drainage capacity and decreased the gas production capacity, respectively (Well 2 at Point A vs Point B). A larger aquifer had a lower gas recovery, which reduced the economic benefit. For example, due to an infinitely large aquifer, the reserves in Experiment 4-1 were developed by a single well, the gas recovery was only 33.4%. These research results are expected to be beneficial for the preparation of development plans and the optimization of water control measures for WDGRs.

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Optimization of a saturated gas plant: Meticulous simulation-based optimization - A case study.

Publications

Optimization of a saturated gas plant: Meticulous simulation-based optimization - A case study.

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