In September 2016, Enterprise Products inaugurated its ethane export terminal at Barbours Cut in La Porte, Texas,
with an export capacity of 240 MBD, making it the largest ethane export terminal in the world. Ethane, a component
of natural gas that is a key feedstock for chemical manufacturing, is already responsible for a revival of the
chemicals industry on the Gulf Coast. With ethane export capacity online, manufacturers overseas will be able to
take advantage of Texas’ low-cost ethane.
Background on Natural Gas Processing
Ethane is a component of the raw natural gas production stream and, at atmospheric pressure and temperature, it is a
gas that is colorless, odorless, and quite flammable. The production stream of raw natural gas is primarily composed
of methane with small amounts of ethane, propane, and butane, as well as other gases and impurities.
Once the flow of natural gas from the producing well reaches the surface, it passes through a multi-phase gas
processing activity designed to separate each of the components contained within the production stream. These
phases include oil and gas separation, if the natural gas is produced in association with oil; dehydration, which
removes water; and various additional phases that remove other gases, such as carbon dioxide, hydrogen sulfide, and
nitrogen.
At this juncture, the production stream now contains only the hydrocarbon gases. The next phase is to separate the
methane from the other gases, which is most efficiently accomplished by cryogenic separation. This process cools
the hydrocarbon gases to -120°C at which point the methane remains as a gas while all other components are
condensed to liquids. With the methane now separated from the remaining hydrocarbon gases, it is injected into the
national natural gas pipeline grid for distribution throughout the country.
The remaining hydrocarbon gases then pass through a fractionator, which is either co-located with the processing
plant or transported to a centrally located fractionation operation, where this additional processing occurs. The
fractionation process separates the remaining hydrocarbons, ethane, propane, butane, pentane, and natural gasoline
based on the individual and sequentially higher boiling points of each component. See Figure 1.
Ethane Demand
The primary use of ethane is as a feedstock for the production of ethylene. Specifically, the ethane is the chargestock
to a thermal cracking process that re-arranges the carbon atoms in the ethane molecule from a single bond to a
double bond. This process creates ethylene (formally named ethene), a product used in the manufacture of plastics,
anti-freeze, and various detergents. Figure 3 displays the wide array of petrochemical products sourced to ethane.
Thermal cracking facilities are generally clustered near fractionation plants to minimize transport of the raw
material. A 2015 survey published in the Oil and Gas Journal noted that there are 34 thermal cracking units located
in the U.S., 21 of which are in Texas, representing all types of feedstock with a nameplate capacity of just over 28
million metric tons a year. The greater Houston area boasts 9 of the 21 Texas facilities with capacity of about 12
million metric tons a year, or 41% of the national total.
Ethane Exports
Large scale international trade in ethane was de minimis until recently. That changed, however, as suppliers from
the U.S. proactively and successfully sought foreign markets for the increased ethane being produced from shale
gas. Pipeline exports to Canada began in December 2013 and saw a boost in May 2014, reaching a level of 70 MBD
by the end of that year. Export volumes remained relatively constant until the spring of 2016 when waterborne
exports of ethane began. The first waterborne cargo embarked from Philadelphia during March 2016, and exports
increased again in September with the initial cargo sailing from Houston. Both initial cargos were destined for
Europe. Through November 2016, U.S. exports of ethane averaged about 90 MBD with about 20 MBD being
waterborne exports. See Figure 4.