2
Content
Natural Gas Processing.
NGL Recovery
o Introduction
o Reciprocating Compressors
o Centrifugal Compressors
o Comparison between Compressors
o Compressor Selection
o Multistage Compression
o Compressors Calculations
o Compressor Performance Maps
4
Definitions
2- Non associated gases: Gas produced from gas wells without liquids.
6
Definitions
15- Acid Gas : Feed stream to sulfur recovery plant consisting H2S, CO2,
H2O, and usually less than 2 mol % hydrocarbons.
16-Claus Process:
The process in which 13 of the H2S in the acid gas feed is burned to SO2
which is then reacted with the remaining H2S to produce sulfur. This is also
referred to as the modified Claus process. ( H2S + 12 O2 S + H2O )
18-Tail Gas Cleanup Unit: a process unit designed to take tail gas from a
Claus sulfur recovery plant and remove additional sulfur with the goal of
meeting environmental sulfur emission standards.
7
Introduction:
Natural Gas is a vital component of the world's supply of energy. It is
one of the cleanest, safest, and most useful of all energy sources.
8
The Formation of Natural Gas:
9
Natural Gas Under the Earth:
Methane
LNG
Ethane
NGLs Propane
Butane LPG
Pentane
Hexane C5 +
Heptane
Octane
11
Typical Composition of Natural Gas :
12
Oxygen: Max. ( 0.1% ) by mole.
* Carbon dioxide: Max. ( 3 % ) by mole.
* Hydrogen sulphide: Max. ( 4 ) PPM
* Sulphur: Max. (50 ) mgm / SCM
* Mercury: Max. (6 ) mgm / SCM
* H.C. dew point: ( +5 ) Deg.C
* Gross Heating Value : Min. 980
Max. 1180 BTU/SCF
* Water dew point : Max. ( 1 ) PPM or below
.( zero ) Deg. C at a pressure of ( 70 ) kg /cm2 gauge13
Natural Gas Properties
14
Ideal Gas Law
PV =
Where : nRT
P : Absolute pressure
V : Volume
T : Absolute temperature
R : Universal gas constant
n : Number of moles n = m / M
m : Mass of the gas
M: Molecular weight
The ideal gas law can be expressed as :
PV = (m/M) RT
m = MPV/RT
m/V = = MP/RT is density of gas 15
Behavior of Real Gases
PV = ZnRT
Where :
Z is deviation or compressibility factor and can be expressed as
Z = [ actual volume of n moles of gas / (ideal volume of n moles of gas
at certain P & T) at same P & T ]
where Z is dimensionless.
16
Properties of Gaseous
Mixtures
Composition of natural gas may be expressed as either mole fraction, volume
fraction or weight fraction.
Mole Fraction yi = ni/ni
where:
yi : Mole fraction of component i
ni : Number of moles of component i
ni : Total number of moles of all components in the mixtures
17
Determination of Z Factor
From the next chart after determination of Pr and Tr we can determine Z factor
Pr = P / P c Tr
Tr = T / T c
Z
Where :
Pc= Pci*Yi
Tc= Tci*Yi
Pr 18
Natural Gas Phase Behavior
The natural gas phase behavior is a plot of pressure vs temperature that
determines whether the natural gas stream at a given pressure and
temperature consists of a single gas phase or two phases: gas and liquid.
The phase behavior for natural gas with a given composition is typically
displayed on a phase diagram, an example of which is shown in Figure 1-1.
The left-hand side of the curve is the bubble point line and divides the
single phase liquid region from the two-phase gasliquid region.
The right-hand side of the curve is the dew point line and divides the two-
phase gasliquid region and the single-phase gas region.
19
20
:At point X
Xi=xy/zy Retrograde region
id
Yi=xz/zy liq u
z Gas
x y
21
Definitions
Phase Diagram-1
A record of the effects of temperature, pressure and composition on the kinds and
.numbers of phases that can exist in equilibrium with each other
Bubble Point-2
The point at which the first small vapour bubble appears in a liquid system. The
.bubble point curve on a phase diagram represents 0% vapour
Dew Point-3
The point at which the first infinitesimally small droplet of condensation forms in a
gaseous system. The dew point curve on a phase diagram represents 0%
.liquid
Phase Envelope-4
The area on a pressure-temperature phase diagram for a mixture enclosed by the
bubble and dew point curves. This area represents the set of conditions for the
. mixture were vapour and liquid phases co-exist in equilibrium
Cricondenbar (Pmax)-5
.The maximum pressure at which vapour and liquid can co-exist in equilibrium
22
Definitions
6-Cricondentherm (Tmax)
.The maximum temperature at which vapour and liquid can co-exist in equilibrium
Critical Pressure-7
.The vapour pressure at critical temp
8-Critical Temperature
The temp. above which all the mixture cannot be liquid
Quality Lines-9
Lines through the two-phase region showing a constant percentage of liquid and
.vapour
10-Retrograde
The name given to phase behaviour above the critical temperature and pressure
were vapour and liquid phases coexist and the amount of vaporisation or
condensation changes with pressure and temperature in the opposite
direction to normal behaviour. (e.g:condensation of liquids occur by lowering
pressure or increasing temperature)
23
Definitions
11-Equation of State (e.g : ideal gas law)
An equation which describes the relationship between pressure,
temperature and molar volume of any homogenous fluid at equilibrium
24
25
26
2500
( TSCF ) 36.2 %
2000
3.1 %
4.9 % 36.1 %
1500
7.2 %
1000
4.6 %
500 7.9 %
0
N-America S-America Europe Africa Mid-East Sov- Asia/Austr.
Countries
27
Fertilizer
Methane: /Methanol/Olefin / GTL
Feedstock
Ethane : Petrochemical Feedstock.
Petrochemical Feedstock
Propane: or Fuel.
NATURAL
Refinery Feedstock /
GAS I-Butane: Fuel.
Gasoline Blending / Fuel
N-Butane: / Petrochemical
Feedstock.
Natural Gasoline
(IC5+)
Refinery Feedstock or
Petrochemical Feedstock.
Condensate
28
Separation between the Oil &Gas
Sweetening remove the Acid Gases
Conditioning Dehydration remove the Water vapour
Main Target H.C Dew Point & Heating Value
30
31
Gas Conditioning
Field Separation.
Gas Sweetening.
Gas Dehydration.
33
Large Vessels are used to
separate the gas, oil, water and
sand using their different
densities.
Separator features :
Horizontal Separators Primary separation section to
Large liquid handling separate the bulk of the liquid from
the gas
capacity
Sufficient capacity to handle liquid
Sufficient time for settle out surges
of liquid droplets from the Sufficient liquid residence time to
allow small droplets to settle out
gas
Some inlet device to reduce
Vertical Separators turbulence and velocity in the main
separation section
(scrubbers)
A mist extractor to capture entrained
High gas volumes droplets
Small footprint area Back pressure and liquid level
controls 37
Relief and blowdown
Training Videos
30
38
39
Day#2
Sweetening process is to remove acid gases from natural gases.
The most famous adsorption process is solid desiccant beds which can
perform Sweetening and dehydration for natural gas at the same time with
higher efficiency.
40
AMINE PROCESS
41
CHEMICAL ABSORPTION
H H
-HO-C - C
H H
42
43
Ty
pi c
al
44
45
FIG. 21-5
Physical Properties of Gas Treating Chemicals
weak bases
46
A brief review of the more frequent problems and corrective
: procedures follow
1- Gas is Not Sweet /Dehydrated
48
3- Dirty, degraded amine
49
4- Excessive Corrosion
50
5- Foaming of amine solution
51
6- Hydrocarbon condensation
52
7- Wrong or off-spec
chemicals
53
9- Incoming gas is not adequately
scrubbed and contains salt water
54
10- Tray down comers are plugged,
causing amine to stack up in the trays
55
Training Videos
18
56
AMINE UNIT CASE STUDY
7
ge
Pa
57
Day#3
Water in NG :
Most free associated water removed by simple extraction method at
or near wellhead
Water vapor in NG solution need more complex treatment
Process of dehydration of NG absorption or adsorption
Pipeline specs: 7.0 lb H2O/MMSCF { max. =1 ppmv}
58
Water Removal
59
Solid-Desiccant Dehydration : Adsorption
60
61
HYDRATES IN NATURAL GAS SYSTEMS
62
HYDRATES IN NATURAL GAS SYSTEMS
63
64
Hydrocarbons )C1,C2,C3,iC4+nC4)
and / or H2S, N2, CO2
+
Metastable H20
@
)P, T)
------------------------------------------
=
HYDRATES
1- Primary Considerations
Gas or liquid must be at or below its water dew point or saturation condition.
To allow water droplet condensation
Temperature.
Pressure.
Composition.
2- Secondary Considerations
Mixing.
Kinetics
Physical site for crystal formation such as a pipe elbow, orifice, thermowell, or line
scale.
Salinity.
66
FIG. 20-4 Water Content of Hydrocarbon Gas
P
hydrate
formation line ,
function of
composition
Th 67
Hydrate Inhibition
70
71
72
73
74
75
76
77
78
Day #3
Glycol Dehydration Unit
79
80
GLYCOLS PHYSICAL PROPERTIES
81
Training Videos
15min
10 82
.min
83
GLYCOL DEHYDRATION UNIT
84
85
86
DEA : 2-6 M3/100 LIT
87
88
89
90
91
92
C99
C 195
93
94
95
96
Training Videos
97
Solid Adsorpant Dehydration Unit
98
99
100
Molecular Sieves Adsorber / Internal
Arrangement
101
GAS DEHYDRATION / Molecular sieves
102
GAS DEHYDRATION / Molecular sieves
103
GAS DEHYDRATION / Molecular sieves
104
GAS DEHYDRATION /
Molecular sieves
105
GAS DEHYDRATION / Molecular sieves
106
GAS DEHYDRATION / Molecular sieves
107
GAS DEHYDRATION / Molecular sieves
108
FV-4004
FV-4003
Dryers Scheme
4-D1C
4-D1A
4-D1B
2FV-4020
4-V43
4-C1A/B
PH-I
FV-4005
2FV-4011
Amine
Unit
RDV MDV RDV MDV RDV MDV
4008 4002 4010 4004 4012 4006
FV-4006
4-F17 4-C3A/B
Tie-in
4-V15
FV-4007 2FV-4013
2FV-4019
FV-4002
BDV-4001
4-C5A/B
FV-4001
2FV-4014
2FV-4012
2FV-4015
ESD-1908
2FV-4017
4-V143
4-D101C
4-D101A
4-D101B
4-C103A/B
4-C101A/B
PH-II
4-F217 ESD-1907
4-H1D
2FV-4018
2FV-4016
109
4-F117
Pg.9 Of 10 P. Eng. / A.Z
1 Ceramic Ball ( 52 CF )
Upper Screen
( 20 Piece )
6
3
3
Lower Screen
4-D1A/B/C Dimensions
110
Pg.10 Of 10 P. Eng. / A.Z
Table 1
Process Step 1 2 3 4 5 6
D1A-4 D D D H C D
D1B-4 D H C D D D
D1C-4 C D D D D H
D101A-4 D D D D H C
D101B-4 D D H C D D
D101C-4 H C D D D D
FV-4003, 2FV-4015, 2FV4018,
2FV-4020 Open Close Open Close Open Close
FV-4004, 2FV-4016, 2FV4017,
2FV-4019 Close Open Close Open Close Open
111
DAY# 4
113
1. By lean oil absorption
3. By Cryogenic Process
114
115
Compressor
Sales Flare
Sales .. Gas
Gas
Feed
Dry . Gas
LTS
Wet . Gas Exchanger
Inlet
Separator Dehydration
Stabilzer
Water
.Cond
F.G
Cooler
To. Stabilizer
116
Cryogenics : Is the study of the production of very low temperature materials
)below 43C) and the behavior of materials at those temperatures.
117
Process Units
Deethanizer separates ethane from NGL stream
Depropanizer separates propane
Debutanizer boils off butanes leaving pentanes and
heavier HC in NGL stream
Butane splitter (Desiobutanizer) separates iso and n
butanes
Component BP oF at 1 atm
Ethane -127 (-88 oC)
Propane -44 (-42) oC
Iso-butane 11 (-11 oC)
n-butane 31 (-0.5 oC)
Pentane 97 (36oC) 118
Turbo Expanders
The use of turbo expanders in gas processing plants began in the early sixties.
By 1970, most new gas processing plants for ethane or propane recovery were
being designed to incorporate the particular advantages characteristic of an
expander Producing usable work.
The trend in the gas processing industry continues toward increased use of the
turbo expander.
Selection of a turbo expander process cycle is indicated when one or more of the
following conditions exist:
Lean gas.
119
Flexibility of operation )i.e:easily adapted to wide variation in pressure and products).
Turbo expanders
120
This figure represents the pressure- Turbo expanders
temperature diagram for this expander
process.
The process operates Isentropically in the ideal case and produces something
less than the theoretical work in the real case.
In the process of producing work, the expander lowers the bulk stream
temperature which can result in partial liquefaction of the bulk stream.
122
To Sales Gas
Compressor
Re Expander
comp
3 4
Feed
Gas Lts
Jt
Valve
1
Dehydration
Pkg
Q-1
7
De-Methaniser To De-
De-Propaniser Ethaniser
De-Butans
123
"Mixed Refrigerant Processes
avail sub-cooling for natural gas where a single mixed refrigerant is used
)composed of nitrogen, methane,ethane, propane, butane and pentane).
The refrigerant is designed so that the refrigerant boiling curve nearly
matches the cooling curve of the gas being liquefied. The closeness of
the match of these two curves is a direct measure of the efficiency of the
process.
124
Cold box exchangers
The cold box is a series of aluminum plate fin exchangers which provide
very close temperature approaches between the respective process streams.
125
,see fig 16-31 GPSA sec.16 in which
Training Videos
15min
126
Examples for LPG,NGL and
LNG Gas Plants
127
Boosting & Sales Gas
Comp.
Send sales 4-W4A
gas to GASCO
net ) 64-100) kg/cm2
4-W1A
4-C3A 4-W4B
4-T1
Drying Area PH-I
4-T2
4-D1C
4-D1A
4-D1B
4-W4C
4-C3B
4-W1B 4-W105
COND.
Fractionation Area
- Produce LPG & Condensate
4-W101A
4-C103A Sales Gas
Drying Area PH-II
Utilities
4-D101B
4-D101A
4-D101C
4-T102
4-T101
- Inst. Air System
4-W104B - Heating Oil System
- Refrigeration
4-W101B Package
4-C103B - Cooling Water
Compression System
Area - Power House
-Compress gas COND. - Fuel Gas System
press from 6-47 - Multi-Nozzle Flare
kg/cm . Expansion & Chilling System
Area - Nitrogen Unit
- pre-separation - Loading Area
for heavy H.C Separate Heavy H.C by
cooling down to -60 c
-Storage 128
Area
-LPG Berth # 4
N.G ( 1043
Demethanizer MMSCFD )
26.3 Bar Depropanizer
Packed Tower Condenser
-76 C 25.6 Bar Condenser
Bubble cap
-43 C ( 30 Tray ) M
Packed Tower 18 Bar
26.6 Bar 27.3 Bar 50.7 C
-74.4 C -31.7 C
-74.5 C C3 Expert
27.3 Bar ( 925 T/D )
-74.4 C
Demethanizier
26.6 Bar
Depropanizer
Absorber
-68 C
-33 C
Debutanizer
Package
1100 66 Bar
MMSCFD Inlet Filter Mercury 40 C 64.7 Bar 64.7 Bar
70 Bar Separator Removal -24 C -35 C
Plat Fin
30 C 10.2 Bar
62 C
-58 C 1.85 Bar
120.8 C
-33 C M
10.2 Bar
129 50 C
DNG Rundoum Cools
Condensate ( Local Market )
( 348 T/D )
130
Regeneration Gas Compressors
C-111/112
Regeneration Gas Cooler
A-311
Feed U-104
PCV-410
Dehydration Dust Filter
F- 416/417
Regeneration Gas Scrubber
Dust Filter F-451 V-418
Depropanizer Reboiler
E-241
15min
132
NGL Extraction
Typical Product
Recoveries ( % ):
Plant Type Turbo- Joule Lean Oil Refrigera
-> Expander Thompson tion
Product
Ethane 60 96% 45 60% 25 45% 1 5%
C2
Propane 90 98% 85 95% 80 95% 20 40%
C3
Iso-Butane 96 100% 96 100% 93 99% 40 60%
IC4
N.Butane 97 100% 97 100% 94 99% 40 60%
NC4
134
Fractionation Towers
There are two main types of Fractionation Towers according to its
inside configuration :
1- Trays Towers .
2- Packed Towers.
135
Trays Towers
TRAY TYPS :Flow Regime
136
TRAY TYPS :Perforation Regime
137
TRAY TYPS :Perforation Regime
138
139
140
141
Tray Towers Problem
142
Tray Towers Problem
143
Tray Towers Problem
144
Tray Towers Problem
145
Tray Towers Problem
146
Packing Types
147
148
BOOSTER STATION UTILITIES
149
FT
FM-Ashrafi 20
20
FM-Hilal 20
PV-321
PI 4.7 Kg/cm2.g
TI 34 C To Flare
New
.GAS COMP Glycol d
C1C-2 Unit
m ove
d y re 16
a lrea
were
ls
.GAS COMP
te rna
C1D-2
ve s in 4
k val
c
che Fuel To Unit
8 8
Closed
-Gas compressor
-Heat Exchanger
- Inst. Air System
- Refrigeration Package
- Cooling Water System
- Power House
- Fuel Gas System
- Flare System
- Nitrogen Unit
- Storage Area
152
Natural Gas
Compression
Purposes of gas compression
Centrifugal Compressor
Reciprocating Compressor
Purposes of Gas
Compression
PV = ZnRT = Z (m/M)RT
P1V1/T1 = P2V2/T2
Main Types of Compressors
1- Dynamic type (Centrifugal) P1
T1
V1
Construction:
P2 T2 V2
1- Rotor
+ +
+ +
+
2- Stator
Anti-surge Control
2-Reciprocating Compressor:
Stroke
Compression chamber
Piston
Piston
Chemise
Inlet valve
Outlet valve
Comparison of reciprocating & centrifugal compressors
HEAT EXCHANGERS
15min
15min
vedio presentation
162
N2 UNIT
163
U-102
PIC -316B
V21-2
LV-716
V6-2
0
LV-710
Course Final quiz
1// What is Natural Gas , definition , composition ,formation and uses?
2// What the sections and devices of horizontal separators ?
3// What does this Appreciations' mean?
LNG - SRU
NGL - Acid Gas and tail gas
P&ID
PFD
LTS
Dew Point Depression .
4// What is the difference between the:
Absorption and Adsorption Process ? Give examples!
Hazard and Risk
5// what is the recommended temp. difference between Gas & Liquid desiccant
interring to a contactor tower ?
6// What are the Filter Types used at the TEG and DEA units ? (and purpose of every
type)
7// draw a schematic drawing for a TEG typical Dehydration Unit ?
8// What are the main four types of gas cryogenic process ?
9// what are the Towers performance constraints & main cause of every constraints ?
10// what are the rout parameters affect LPG Specifications at the Fractionation Area
?
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168
11// why the TEG is widely used at Glycol Dehydration?
15// what are the main types of heat exchangers ? Give exapmles of H.
Exchangers at your plant ?
169
11// what are the main reactions take place at SRU?
14// what are the precautions before the SRU start up?
15//what is the source of SRU acid gas ?
19//The 1/5 of h2s will be nurned out in the thermal claus reactor?
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170
THANKS ,,,
171