Oil Gas Technologies 1

Oil & Gas Technologies
Feker Engineering Training Center 25 June 2015
Presentation content
Introduction to oil and gas processing
Oil & Gas separatoin plant typical block scheme
Central processing facilities (CPF) / Inlet Facilities overview
Oil treatment train ( Oil stabilization / Dehydration / Storge ang
export )
Gas treatment train (Gas Dehydration /Sweetening /compression)
NGL Recovery & Fractionation
Sulphur Recovery
export )
Gas treatment train (Gas Dehydration /Sweetening /compression)
Sulphur Recovery

Introduction
It was not until 1859 that "Colonel" Edwin Drake drilled the first successful
oil well, with the sole purpose of finding oil.
The Drake Well was located in the middle of quiet farm country in
northwestern Pennsylvania, and sparked the international search for an
industrial use for petroleum
These wells were shallow by modern
standards, often less than 50 meters
deep, but they produced large quantities
of oil. In this picture of the Tarr Farm,
Oil Creek Valley, the Phillips well on the
right initially produced 4,000 barrels per day
in October, 1861, and the Woodford well on
the left came in at 1,500 barrels per day in
July, 1862.
Crude Oil Products
Usage of oil internationally
World wide Oil production Crude Oil Locations
World wide Oil Production

Where is Natural Gas?
World wide Oil Production

Natural Gas world demand
Reservoir and wellheads

Reservoir:
There are three main types of conventional wells. The most common is an oil well
with associated gas. Natural gas wells are drilled specifically for natural gas, and
contain little or no oil. Condensate wells contain natural gas, as well as a liquid
condensate.

Oil & Gas formation & composition
Crude Oil: Crude Oil is a complex mixture consisting of up to 200 or more different organic
compounds, (hydrocarbons & Non hydrocarbons)
The hydrocarbons in crude oil are mostly (alkanes, cycloalkanes, aromatic- hydrocarbons)
The other organic compounds contain nitrogen, oxygen and sulfur, and trace amounts of metals (Fe,
Ni, Cu, etc.)
Meanwhile Non Hydrocarbons are ( Carbon Dioxide, Hydrogen Sulfide, Nitrogen, Mercury, Hydrogen,
Argon, Helium, etc.)
Crude Oil is always associated with water and gaseous hydrocarbons.
The API (American petroleum institute) gravity of a
particular crude is merely a measure of its specific gravity, or density
Crude oil API gravities typically range from 7 to 52 corresponding to
about 970 kg/m3 to 750 kg/m3, but most fall in the 20 to 45 API
gravity
range
API < 35 (Heavy Oil)
API > 35 (Light Oil)

Oil & Gas formation & composition
The reservoirs fluids stratify to Natural Gas, Oil, Water
Natural gas found at the wellhead, although still composed primary methane, is by no means as pure.
Raw natural gas comes from three types of wells: oil wells, gas wells, and condensate wells.
Natural Gases are classified as follows:
Natural gas that comes from oil wells is typically termed associated gas (free gas / dissolved gas).
Natural gas from gas and condensate wells is termed non associated gas
Wellheads
The wellhead sits on top of the actual oil or gas

well leading down to the reservoir.
A wellhead may also be an injection well, used to
inject water or gas back into the reservoir to
maintain pressure and levels to maximize
production.
Manifolds/gathering
Gas gathering systems collect wet natural gas or
crude oil from the wellheads located at well pads where
they are diverted to manifolds and transport it to (CPF )
Central Process Facilities .
Gathering systems can be very simple, short-distance flow control piping systems
for the output of just a few wells, or complex systems requiring thousands of
miles of piping and valves to control the pressure and flow of more than 100 gas
wells.
GOSP definition
GOSP means Gas-Oil Separation Plant.

GOSP is the first facility downstream wellheads/flowlines. Scope of this plant is to
provide first separation of Crude Oil in Oil, associated Gas and associated Water
and delivers those products, at defined conditions, to downstream facilities
(refinery) for further
treatments.
Typical Block Flow Diagram

Gas
Compression
Unit
M
A
N
I
F
O
L
D
Gas to other Plants

or to re-injection
Inlet
Separation
De-hydration
and
Desalting Unit
WOSEP
STABILIZATION
Unit
Stabilized Oil
to storage & delivery
Water
to re-injection
Oil treatment train ( Oil stabilization / Dehydration / Storge
ang export )
Gas treatment train (Gas Dehydration/Sweetening
/compression)
Sulphur Recovery

Oil and gas processing
Oil and gas wells produce a mixture of hydrocarbon gas, condensate or oil water
with dissolved minerals, usually including a large amount of salt other gases,
including nitrogen, carbon dioxide (CO2), and possibly hydrogen sulfide (H2S)
and solids, including sand from the reservoir, dirt, scale, and corrosion products from
the tubing.
The purpose of oil and gas processing is to separate, remove, or transform these
various components to make the hydrocarbons ready for sale.
For the hydrocarbons(gas or liquid) to be sold, they must be:
separated from the water and solids
measured
sold
transported by pipeline, truck, rail, or ocean tanker to the user
ACID GAS
REMOVAL
Feed from
manifold
DEHYDRATION
DEW POINT
CONTROL
STABILIZATION
Stabilized Oil
Gas & Oil

Separation
De-hydration /
Desalting
GAS
COMPRESSION
GAS TO
MARMARKT
SULPHUR
RECOVERY
ACID GAS
REMOVAL
Feed from
manifold
SULPHUR
DEHYDRATION
DEW POINT
CONTROL
STABILIZATION
Stabilized Oil
Gas & Oil

Separation
De-hydration /
Desalting
GAS
COMPRESSION
GAS TO
MARMARKE
T

SULPHUR
RECOVERY
ACID GAS
REMOVAL
Feed from
manifold
DEHYDRATION
Gas & Oil

Separation
De-hydration /
Desalting
SULPHUR
DEW POINT
CONTROL
NGL RECOVERY
&
FRACTIONATION
STABILIZATION
Stabilized Oil
GAS
COMPRESSION
C2
C3
C4
GAS TO
MARMARKE
T
SULPHUR
RECOVERY
ACID GAS
REMOVAL
Feed from
manifold
DEHYDRATION
Gas & Oil

Separation
SULPHUR
DEW POINT
CONTROL
NGL RECOVERY
&
FRACTIONATION
C5+
De-hydration /
Desalting
STABILIZATION
Stabilized Oil
GAS
COMPRESSION
C2
C3
C4
GAS TO
MARMARKT
Oil treatment train ( Oil stabilization / Dehydration / Storge
ang export )
/compression)
Sulphur Recovery

Hydrocarbon preparation
The goal is to produce oil that meets the purchasers specifications that define the
maximum allowable amounts of the following:
water
salt
other impurities
Similarly, the gas must be processed to meet purchasers water vapor and
hydrocarbon dew point specifications to limit condensation during transportation.
The produced water must meet the following requirements:
1. regulatory requirements for disposal in the ocean if the wells are offshore
2. reservoir requirements for injection into an underground reservoir to avoid
plugging the reservoir

3.
technical requirements for other uses, such as feed to steam boilers in thermalflood operations, or in special cases, for irrigation
Field facilities :
The equipment between the wells and the pipeline, or other transportation system, is
called an oilfield facility. An oilfield facility is different from a refinery or chemical
plant in a number of ways.
The process is simpler in a facility, consisting not of chemical reactions to make new
molecules, but of:
phase separation
temperature changes
pressure changes

Oil facility
An oil facility encompasses the equipment between the oil wells and the pipeline or
other transportation system.
The purpose of an oil facility is to make the oil ready for sale to
the purchaser's standards (maximum allowable water, salt, and other impurities).
We will describes the key equipment and functions found in an oil facility.

Typical oil facility

Function of a facility
The main function of an oil facility is to :
1.
2.
3.
4.
separate the oil, gas, water, and solids

treat the oil to meet sales specifications (e.g., BS&W*, salt content, vapor pressure
measure and sample the oil to determine its value
Deliver it to the transportation system (i.e., the pipeline, truck, ship, or railroad car)
*Basic sediment and water (BS&W)

Oil Separation Process Flow Diagram
Requirements of separators
Separators are required to provide oil/gas streams that meet saleable pipeline
specifioation as well as disposal.
Oil must have less than 1% (by volume) water and sales Gas
less than 7bbm water/MMscf .
Water stream must have less than 20 ppm oil
Gas facility
A gas facility includes all the equipment necessary for Gas treatment & conditioning
between the gas wells and the transportation
pipeline or other transportation method.
The purpose of the gas facility is to remove impurities and

contaminants from the gas, remove liquids and solids, and prepare the gas to meet
the sales requirements of the purchaser.

CPF Scope :
Gas Plant Feedstock normally includes heavier hydrocarbons that shall be separated
from the main gas flow (lighter ends). Heavier ends shall be conditioned in order to
make them suitable for storage or transportation.
CPF Design :
Heavier ends separation is typically performed by a Slug Catcher that collects the
liquid phase. These liquids are routed to the stabilization unit
Slug Catcher
Slug catcher is a static equipment used in the upstream oil production facilities to
minimize the slug from oil and gas pipeline

Typical gas facility

Function of a facility
The main function of a facility is to :
1.
2.
separate the oil, gas, water, and solids

deliver it to the transportation system (i.e., the pipeline, truck,
ship, or railroad car)
The gas must be treated for sales or disposal. In the past, disposal sometimes meant
flaring or venting, but now gas that cant be transported is usually compressed for
reinjection into the reservoir
Gas treating may involve only separation from the liquids, or it may include
additional processes such as:
Gas treating may involve only separation from the liquids, or it may include
additional processes such as:
compression
dehydration
removing H2S and CO2
gas processing to condense heavier components that can be transported as a liquid

Condensate Stabilization Process Flow Daigram

Central processing facilities (CPF) / Inlet Facilities
overview
Oil treatment train ( Oil stabilization / Dehydration /
Storage and export )
/compression)
Sulphur Recovery
Oil Treatment Train

( Oil stabilization / Dehydration / Storge ang export )
Oil treating
No separation is perfect, there is always some water left in the oil. Water content can
range from less than 1% water to more than 20% water in the oil by volume.
The lower the American Petroleum Institute (API) gravity
(i.e., the higher the molecular weight and the oil viscosity), the less efficient the
separation.
Dehydration and Desalting Unit :

Crude oil often contains water, inorganic salts, suspended solids, and water-soluble
trace metals. As a first step in the refining process, to reduce corrosion, plugging, and
fouling of equipment and to prevent poisoning the catalysts in processing units, these
contaminants must be removed by desalting (dehydration).
Oil Treatment Train

The two most typical methods of crude-oil desalting chemical and electrostatic
separation, use hot water as the extraction agent.
In chemical desalting, water and chemical
surfactant (demulsifiers) are added to the
crude, heated so that salts and other
impurities dissolve into the water or attach
to the water, and then held in a tank where
they settle out.
Electrical desalting is the application of high-voltage electrostatic charges to
concentrate suspended water globules in the bottom of the settling tank.
Oil Treatment Train

Surfactants are added only when the crude has a large amount of suspended solids.
Oil Treatment Train

SULPHUR
RECOVERY
ACID GAS
REMOVAL
Feed from
manifold
DEHYDRATION
Gas & Oil

Separation
SULPHUR
DEW POINT
CONTROL
NGL RECOVERY
&
FRACTIONATION
C5+
De-hydration /
Desalting
STABILIZATION
Stabilized Oil
GAS
COMPRESSION
C2
C3
C4
Oil Treatment Train

Oil stabilization
Stabilization removes light gases, along with hydrogen sulfide, befor the oil is stored.
Hydrogen sulfide is commonly found in crude oil, and when exposed to water also
commom in crude , it forms H2SO4 sulfuric acid.
This acid can eat its way through a steel pipline or storage tank.
If released into the air, it is poisonous to all who inhale it
The Stabilization process dose two jobs: it sweetens the sure crude (remove the
hydrogen sulfide) and it reduces vapor pressure, making the crude safe for shipment
in tankers.
The vapor pressure is caused by light hydrocarbons such as Methane, Ethane,
Propane, and Butane changing from liquid to gas as the crudes pressure is lowered.
Oil Treatment Train

SULPHUR
RECOVERY
ACID GAS
REMOVAL
Feed from
manifold
DEHYDRATION
Gas & Oil

Separation
SULPHUR
DEW POINT
CONTROL
NGL RECOVERY
&
FRACTIONATION
C5+
De-hydration /
Desalting
STABILIZATION
Stabilized Oil
GAS
COMPRESSION
C2
C3
C4
Oil Treatment Train

FEED
SP
Static head for
natural convention
circulation (BY
APRES)
STABILIZER
COLUMN
FC
Steam
Balance line
PC
TC
Condensate
Mixed Phase
As per pump
NPSH
requirements
(BY PROTEC)
Static head for

condensate return
(by PROTEC)
LC
Oil Treatment Train

Typical Control Parameters

Section
Inlet separator
Dehydrator / Desalter
Stabilizer
Compression
Controlled Parameters
Oil/water levels
Vessel pressure
Levels
Differential pressure across mixing
valve
Level
Pressure
Bottom temperature
Suction Pressure
Aircooler outlet temperature
Oil Treatment Train

Typical Design Parameters/Guarantees
Item
Design Parameters
Water content in oil
0.1 0.3 % volume
Salt content in oil
10 20 ptb (pounds per thousand

barrel)
Oil RVP
13 psia
Oil content in water
50 100 ppm weight

Central processing facilities (CPF) / Inlet Facilities
overview
Storge ang export )
Gas treatment train (Gas Sweetening /Gas
Dehydration/compression)
Sulphur Recovery
Gas treatment train (Gas Sweetening /Gas Dehydration/compression)
Gas Sweetening
Acid/sour gas removal (CO2 and H2S)
Most natural gas contains acid gas
CO2 (acid)
H2S and other sulfur compounds (sour)
Why remove acid gas:
Corrosion induced by acid gas (+ free water)
Freezing of acid gas in process equipment
Sales specifications
Toxicity and reactivity (H2S)
Typical specification for sweetened gas:
CO2 in pipeline gas: <2 - 2.5 mol%
CO2 in LNG: <50 ppmv CO2 (very low because of very low process temperatures)
H2S: a few ppmv
Sour gas sweetening

Sour natural gas compositions can vary over a wide concentration of H2S and
CO2 and a wide concentration of hydrocarbon components.
If the H2S content exceeds the sales gas specification limit, the excess H2S must
be separated from the sour gas.
The removal of H2S from sour gas is called sweetening.
Overview of sweetening process

The process selected for sweetening a sour gas depends on the general conditions:
H2S and mercaptan concentration in the sour gas, and sales gas H2S and total
sulfur limits
maximum design flow rate
raw gas inlet pressure
requirement for sulfur
acceptable method of waste products disposal

SULPHUR
RECOVERY
ACID GAS
REMOVAL
Feed from
manifold
DEHYDRATION
Gas & Oil

Separation
SULPHUR
DEW POINT
CONTROL
NGL RECOVERY
&
FRACTIONATION
C5+
De-hydration /
Desalting
STABILIZATION
Stabilized Oil
GAS
COMPRESSION
C2
C3
C4
Process summary:
Unit Scope
Gases coming from Inlet Facilities contain acid gases (H2S e CO2) have to be
removed in order to assure the product spec and to avoid corrosion phenomena in
downstream units
Unit design
Feed is contacted by a solvent where, at high pressure and low temperature, acids
components are chemically absorbed.
Solvents are fully regenerable at higher temperature and lower pressure in order to
assure a continuous process.
Unit Spec
Sweetened gas specification depends by market or by the downstream units.
NGL/LPG
CO2 < 1-2% vol
H2S < 2 ppm
LNG
CO2 < 50 ppm vol
H2S < Traces
Amine Selection
In Gas plants taken in account here, the CO2 and H2S removal take place with
chemical absorption processes employing as absorbent a ETHANOLAMINE aqueous
solution
Complete Removal
Primary and Secondary Amines
Selective H2S Removal
Tertiary Amines
MEA
MDEA
DEA
TEA
Activated Solvents
Activated Solvents
The amine commonly used is the MDEA (Methil-Diethanol-Amine)
(OH CH 2 CH 2 ) 2 N CH
Chemical Absorption with MDEA
Slow Step
Fast Step
CO2 Adsorption step is slow;

If amine flow is underdesigned, CO2
replaces H2S in the upper part of the
absorption colum.
H2S Absorption step is istantaneous;

Few trays are enough to assure a
complete absorption.
MDEA
CO2
H2S
Amine Reactions
Acid gases (H2S e CO2) reactions with Amine are reversible:
Acid gases Absorption reactions are promoted by high pressure and low
temperature
Amine Regeneration reactions are promoted by low pressure and high temperature
H2S Reactions
CO2 Reactions
RRNH+2
H+ + RRNH
RRNH+2
H+ + RRNH
H2 S
H+ + HS -
RRNH+2+H2O
RRNH+ + HCO3-
HS-
H+ + S - -
H2O+CO2
H+ + HCO3=
H2 O
H+ + OH -
HCO3-
H+ + CO3=
H2 O
H+ + OH -
Typical Process Scheme
SWEET GAS
ACID GAS
Absorber
OFF GAS
Regenerator
Flash Drum
FEED
Rich Amine
Lean Amine
Main Paramenters
Sweet Gas Specification

Amine Circulating Capacity
Amine Concentration
Absorption Column Pressure
Regenerator Bottom Temperature
Regeneration Quality
Acid Gas Loading
Gas Dehydration
All raw natural gas is fully saturated with water vapor when produced from an
underground reservoir, Because most of the water vapor has to be removed from
natural gas before it can be commercially marketed, all natural gas is subjected to
a dehydration process.
One of the most common methods for
removing the water from produced gas
are Glycol and Molecular sieve .
Water dew point
Water occurs naturally in the reservoir

Free water phase is removed in 3-phase separators
Water (vapour) is naturally dissolved in the natural gas
Water must be removed from the gas to avoid:

Free water in gas pipelines (corrosion)
Ice/hydrate formation (plugging of equipment and pipes)
Water removal processes:

Condensation (cooling and separation)
Absorption by glycol processes (moderate dew-pointing)
Adsorption on solids (severe dew-pointing)
Water dew point

Offshore processes
Transport specification:
-18C at 69 barg
(20-30 ppm)
Process needed:
Glycol absorption process
Onshore processes
Process specification:
0.1 to 1 ppmv
Process needed:
Adsorption on solids
Water removal onshore - Adsorption on solids

Adsorption in to a solid material
Used in deep gas processing at low temperatures
Removal of smaller amounts of water
Extreme dryness, down to 0.1 ppm water
Porous structures with high internal
surface area (200 800 m2/g)
Strong affinity for water, 5 25 % by weight
Solids like
Molecular sieve (3A or 4A type) (Zeolite)
Activated alumina (Al2O3)
Silica gel (SiO2)
Activated carbon
Dehydration process summuary

Unit Scope
The sweetened gas coming from the Acid Gas Removal Unit is water saturated.
Sweet Gas water content shall be reduced to prevent ice and hydrate formation in the
downstream units, which would cause blockage of lines and equipment.
Unit design
In gas plants, water removal is based on adsorption on Alumina/Silica Gel Beds,
called Molecular Sieve working in swing operation.
Molecular Sieves can adsorb selectively polar substances like water within their
pores.
Water molecules leave the pores if the bed is crossed by a current dry and hot gas
(regeneration).
Unit Spec
Residual water content shall be less than 0.5 ppm (mol) in the dryer effluent.
Typical Process Scheme dehydration System Molecular sieve

Regeneration gas
(63.0)<230>
Dry gas
(64.0)
< 27.6>
(pressure, bara)
<Temp, Celsius>
Hot Oil
Regeneration
gas
(63.7)
<27.5 >
(64.9) <26.6 >

Wet gas
(63.2) <233.0 >
molecular sieve
Regeneration gas
<230>(63.0)
Dry gas
(64.0)
<27.6 >
(pressure, bara)
<Temp, Celsius>
Hot Oil
Regeneration
gas
(63.7)
<27.5 >
(64.9) <26.6 >

Wet gas
(63.2) <233.0 >
The dehydration plants consist of N towers, fixed bed of molecular sieves:

N-M are in Adsorption:
wet gas crosses
theabed
from
bottom
of thecrosses
vessel; the
Regeneration
occurs at highthe
temperatures
using
warm
drythe
gas.
This flow
bed,
the absorbed
water,isand
is condensed
angas.
Air Cooler before being
M isremoves
in Regeneration:
the vessel
flowed
by a dry andinhot
separated. In terms of Dew Point it can be achieved a requirement of -100C @
atmospheric pressure.
Glycol dehydration
Natural gas is dried by absorption,
often in a countercurrent scrubbing
unit
A liquid having a strong affinity for
water is used as an absorbent
Increasing values
Molecular
weight
MEG
DEG
TEG
T4EG
62 194
Viscosity (25 C)
MEG
DEG
TEG
T4EG
17- 49
Freezing point
C
MEG
T4EG
DEG
TEG
-13 - -7
Vapor pressure
25 C
MEG
DEG
TEG
T4EG
A good absorbent should have:

.1 Strong affinity for water
.2 Low cost
.3 Non corrosive
.4 Low affinity for hydrocarbons and
5.
6.
7.
8.
9.
acid gases
Thermal stability
Easy
regeneration
Low viscosity
Low vapor pressure at the contact
temperature
Low tendency to foam
Basic glycol properties
Simplified flow diagram for a glycol dehydration unit. from the GPSA Engineering Data
Book, 11thed.

Wet gas (no liquid water) enter bottom
of absorber and flows
countercurrent to the glycol. Lean
glycol enters at the top
Absorber internal
Tray
Bubble cap
Reactor
Valve
One, two pass trays
Sieve
Maximize
Contact area
and time
Gas/glycol
Packing
Berl Saddle, Raschig Ring
Bearl Saddle
Sieve tray
Bubble Cap tray
Typical profiles of the mol fraction of

water in glycol as a function of tower
height. For tray and structural
packing
Typical profiles of the mol fraction of

water in gas as a function of tower
height. For tray and structural
packing
Minimum tray spacing 610 mm
Discrete and continues concentration profile
Flooding, foaming
Equilibrium assumption
Glycol regeneration
Increased
temperature
A; Wet stripping
gas
B; stripping
gas
still
column
Water
Re boiler
Rich TEG
Heat
Exchanger
TEG unit
Heat
A; Stripping gas
A) Open stripping loop

B) Closed stripping loop
A) Any inert gas is suitable. Theoretically best to insert
stripping gas between re boiler and surge tank
B) A closed stripping loop, isooctane can be used.
Vaporizes at re-boiler temperature and condenses and
can be separated from water in a three phase separator.
High stripping gas rates with little venting of
hydrocarbons. Glycol cons> 99.99% (w/w) has been
C) Cold finger
C) A cold finger is inserted into a bucket in the

surge drum vapor space. A TEG mixture rich in
water condenses out. This mixture is taped off.
H2O partial pressure is lowered and lean glycol
concentration is increased. 99.5-99.9 % (w/w)
glycol has been achieved.
Glycol regeneration Component

Reboiler:
Temperature should not exceed 204 C (TEG) due to
degradation.
Some degradation of glycol in contact with heat
transfer surface maximum heat flux rates.
Heat provided with direct fired fire tubes immersed in
the bath, hot oil, steam or electric resistance heating.
Stripping Colum:
Flash tank:
Used to remove light hydrocarbons,
CO2, H2S. Operation pressure 15% of
the contactor operating pressure.
Filters:
Captures chemical impurities and solid
particles. Pressure drop is measured
and used as a replacing criteria.
Can be trayed or structural packed. Stripping gas

lowers the partial pressure of H2O in the gas phase,
and more water can be absorbed by the gas (Raoults
law).
Surge drum:
Retention time >20 min
Be able to hold all the re-boiler glycol, to allow repair
or inspection of the re-boiler heating coil.
Main Paramenters of Dehydration
Inlet water content

Hydrates temperature formation
Outlet water specification
Number of beds
Max allowable pressure drop
Regeneration available time
Regeneration available flowrate
Regeneration temperature

Storge ang export )
Sulphur Recovery
Natural gas liquid NGL

NGLs are hydrocarbon liquids that can be separated from a natural gas stream after the
heavier hydrocarbon components have already been removed by separation at ambient
Temperatures NGLs include:
ethane
propane
Butane
natural gasoline.
Main reasons:
HC dew point control (Sales Gas spec)

Economics: high value HC recovery

Refrigeration cycle
Principal thermodynamic path
Liquid recovery by refrigeration

Thermodynamic path
A-B,E cooled by heat exchange with the process gas.
B-C Natural gas is cooled by heat exchange with the refrigeration cycle. The gas temperature is lowered at
constant pressure.
E-F Natural gas is cooled by isentropic (constant entropy S) expansion through a turbine (turbo expander), EF
actual path.
B-D Natural gas is cooled by isenthalpic (constant enthalpy) expansion through a valve (Joule Thompson).

SULPHUR
RECOVERY
ACID GAS
REMOVAL
Feed from
manifold
DEHYDRATION
Gas & Oil

Separation
SULPHUR
DEW POINT
CONTROL
NGL RECOVERY
&
FRACTIONATION
C5+
De-hydration /
Desalting
STABILIZATION
Stabilized Oil
GAS
COMPRESSION
C2
C3
C4
GAS TO
MARMARKE
T

Refrigeration cycle by Hysys

Unit Scope
Avoid liquid HC condensation in the downstream unit/pipeline.
Recover and separate heavier components mixed in the dry gas.
Unit design
Design is different case by case.
A lot of licensed unit are available depending by the scope of the unit.
As a general rule, gas is cooled by an external cooling medium; liquid are separated
and sent to the separation columns to obtain C2, C3 and C4.
A Propane cycle could be foreseen in order to increase the heavier recovery (Deep
Cut).
Unit Spec
Depending by the process and by the downstream unit/market requests.
Ethane and propane recovery could vary from 70% to 98%.

SULPHUR
RECOVERY
ACID GAS
REMOVAL
Feed from
manifold
DEHYDRATION
Gas & Oil

Separation
SULPHUR
DEW POINT
CONTROL
NGL RECOVERY
&
FRACTIONATION
C5+
De-hydration /
Desalting
STABILIZATION
Stabilized Oil
GAS
COMPRESSION
C2
C3
C4
GAS TO
MARMARKE
T

NGL Fractionation

Main Paramenters
Critical conditions
Products requested recovery
Products requested purity
Demethanizer upper temperature
Expander efficiency
Available cooling medium
Available heating medium
export )
Sulphur Recovery
Sulphur Recovery
Sulphur Recovery
SULPHUR
RECOVERY
ACID GAS
REMOVAL
Feed from
manifold
DEHYDRATION
Gas & Oil

Separation
SULPHUR
DEW POINT
CONTROL
NGL RECOVERY
&
FRACTIONATION
C5+
De-hydration /
Desalting
STABILIZATION
Stabilized Oil
GAS
COMPRESSION
C2
C3
C4
GAS TO
MARMARKE
T
Sulphur Recovery
Unit Scope
Convert H2S into liquid sulphur (S2, S4, S6, S8) in order to contain the plant toxic
emission,
Unit design
Design depends by the requested conversion and by Licensors.
Normally design are improvement of the original Claus process.
As a general rule, acid gas preheated and burned in the Thermal Reactor where a part of
the H2S conversion is performed. Subsequent catalitic stages complete the sulphur
conversion. Generally the requested conversion is higher than the maximum
achievable by this process. It is then requested an additional unit (e.g. Tail Gas Clean
Up) capable to achieve the target.
Unit Spec
Max H2S emissions are regulated by each Country laws.

Claus process can achieve about the 95-96% of the sulphur conversion.
Modified Claus processes can improve the conversion up to 99.8%.
Sulphur Recovery
Main Reactions
Catalytic Stage
Thermal Stage
H2S + 3/2 O2
SO2 + H2O
SO2 + 2 H2S
Overall : Claus Reaction

H2S + O2
S + H2O
3S + 2H2O
Sulphur Recovery
Claus typical scheme
Sulphur Recovery
Sulphur Recovery Plant
Sulphur Recovery
Main Paramenters
H2S concentration in Acid Gas

Requested sulphur conversion
H2S/SO2 ratio @ last condenser outlet
Content of contaminants
Thermal reactor temperature
Catalytic converters temperature

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Oil & Gas Technologies

Feker Engineering Training Center 25 June 2015

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