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Gas Plant Process Optimization Calculator

Economic Analysis ยท GPSA ยท Campbell

NGL Recovery Process Optimization
Optimizes NGL plant economics balancing product recovery against operating costs. Uses GPSA Section 16 correlations and GPM-based production calculations. Includes ethane rejection analysis for market-responsive operations.

Feed Gas Conditions

MMscfd
mol%
mol%
Typical Values:
Lean gas: C2 3-6%, C3+ 1-3%
Rich gas: C2 6-12%, C3+ 4-8%

Process Selection

%
Typical range: 85-98%
Process Types:
Turboexpander: 85-98% C2 recovery
JT Valve: 20-50% C2 (low CAPEX)
Refrigeration: 40-80% C2
Enhanced: 90-99% C2 (max recovery)

NGL Product Prices

$/gal
$/gal
$/gal
Mont Belvieu purity product prices. C2 typically $0.15-0.50/gal; C3 $0.70-1.20/gal.

Operating Costs

$/MMBtu
$/kWh
Optimization Goal:
Maximize: NGL Revenue - Operating Costs
Including ethane rejection economics

About This Calculator

Optimizes NGL recovery plant economics using GPSA Section 16 methodology and GPM-based production calculations.

Key Features:

  • GPM Analysis: Industry-standard gallons per Mscf metric
  • Process Types: Turboexpander, JT valve, refrigeration
  • Ethane Rejection: Breakeven analysis for low C2 prices
  • Shrinkage: Residue gas volume reduction

References:

  • GPSA, Section 16
  • GPA 2145 - Physical Constants
  • Campbell Gas Conditioning, Vol. 2

Frequently Asked Questions

What does the process optimization calculator do?

It optimizes gas processing facilities by providing economic analysis and debottlenecking recommendations to improve plant efficiency.

What type of analysis does it provide?

The calculator provides economic analysis and identifies debottlenecking opportunities for NGL recovery process optimization.

What facilities can be optimized?

It is designed for gas processing facilities including NGL recovery plants, evaluating overall plant efficiency and economics.

What NGL recovery process types can be compared?

The calculator compares turboexpander (85-98% C2 recovery), JT valve (20-50% C2, low CAPEX), refrigeration (40-80% C2), and enhanced processes (90-99% C2, maximum recovery). Each has different capital and operating cost profiles.

How does the calculator evaluate ethane rejection economics?

The calculator performs breakeven analysis comparing ethane recovery revenue against gas shrinkage cost. When ethane prices are low, rejecting ethane into the residue gas stream and recovering only propane and heavier components maximizes profitability.

What NGL product prices does the optimization use?

The calculator uses Mont Belvieu purity product prices as the reference. Typical ranges are ethane at $0.15-0.50/gal and propane at $0.70-1.20/gal. The frac spread between NGL value and gas shrinkage drives the optimal recovery level.