LPG Gas Farm Process Simulation
Defining phase conditions and energy duties across multiple seasonal scenarios for the Qiddiya development.
Engineering Requirement
As part of Saudi Arabia’s Vision 2030, the Qiddiya destination is being developed as a major entertainment hub. The EPC contractor engaged ChemKlub India to conduct a rigorous simulation modeling project focused on the process design of the bulk utility LPG Gas Farm.
The core objective was to define flows, pressures, temperatures, phase conditions, and energy duties across LPG storage bullets, transfer pumps, electrically heated vaporizers, and PRMS units.
This data was critical to ensure safe system operation and precise equipment sizing across three distinct development stages and multiple seasonal LPG compositions.
Our Engineering Approach
A structured multi-scenario simulation methodology to ensure reliable operation under every possible peak and minimum demand limit.
Scenario Mapping
Defining 20 specific operating cases considering 100% Propane, 100% Butane, and 50/50 mix compositions across Summer, Winter, and Off-Season.
Steady-State Simulation
Building the complete plant topography in Aspen HYSYS V14 utilizing the Peng-Robinson Equation of State for precise phase behavior.
Extremes Testing
Testing the model under minimum turn-down demand (30%) up to extreme peak conditions (consuming 3x daily demand within 8 hours).
HMB & Data Extraction
Generating the Heat & Mass Balance alongside critical fluid properties (density, viscosity, Cp/Cv) for final equipment sizing.
Project Deliverables
The critical data outputs provided to the EPC contractor for facility construction.
Complete Heat and Mass Balance (HMB) tables covering all 20 simulated operational cases.
Vaporizer heating duty requirements to guarantee stable vaporization across winter extremes.
Pump flow rates, suction conditions, and discharge pressures for accurate hydraulic line sizing.
Pressure Reducing & Metering Station (PRMS) inlet and outlet specifications.
Phase conditions verification at key process nodes to prevent unintended condensation.
Extraction of critical fluid properties including density, viscosity, molecular weight, and Cp/Cv values.
Challenges & Engineering Solutions
Key technical challenges encountered during the project and how our team resolved them.
The facility required the flexibility to handle multiple LPG compositions (Summer, Winter, Off-season) alongside extreme seasonal temperature fluctuations in the region.
We developed 20 distinct steady-state simulation scenarios, mapping varying physical properties against ambient conditions to ensure electrically heated vaporizers and PRMS possessed adequate turndown and peak capacities.
Accurately predicting phase transitions to prevent liquid dropout in the vapor distribution network under rapid demand spikes (consuming 3x daily demand in 8 hours).
Utilized the Peng-Robinson Equation of State (EOS) within Aspen HYSYS to accurately model the thermodynamic behavior, validating that phase conditions remained securely in the vapor region post-PRMS across all nodes.
Related Projects
Other process equipment design and simulation projects by ChemKlub India.
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Our team specialises in thermal-mechanical design, simulation, and code compliance for process equipment.