NGL RECOVERY TECHNOLOGIES

Irfan Hussain March 29 - 2011

AGENDA What is Gas Processing Introduction to NGL Recovery NGL Recovery Technologies
- Joule Thomson Process - Turbo Expansion Process - How Turbo Expander Works

Licensed Technologies for C2 & C3 Recovery Process Economics for C2 and C3 Recovery Shaybah NGL Recovery Unit Critical Equipment (BAHE)

Introduction to Gas Processing

Acid Gas Removal Sulphur Recovery

Sulphur Product

Feed from Wellhead

Inlet Separation Gas / LNG Product Dehydration Condensate Stabilisation

NGL Recovery

Condensate Product NGL Product

Introduction to NGL Recovery

What is NGL: C2 + C3 + C4 mixture (liquefied from gaseous phase) LPG = C3+C4; CNG = C1; LNG = C1 NGL Recovery Why? Meet Hydrocarbon Dew Point of sales gas Extract expansive product (C2/C3) from sales gas

NGL Use Petrochemical Plants Polypropylene & Ethylene Domestic (fuel)

NGL Recovery (basic schemes)

J-T Cooling System

Gas / Gas Exchanger

De-Methanizer Column

Treated Feed gas

J.T Valve

Low Temperature Separator

Sales Gas

Reboiler

NGL Product

NGL Recovery (basic schemes)

J-T Cooling System Advantages: - Low Capital Cost - Simplicity of design & operation (no rotating equipment) Broad range of flow (valves have high turndown capacity) - Can achieve gas dew point by condensate recovery (high revenue) J-T Cooling System Disadvantages: - NGL recovery may not be feasible if large P is not available - Effectiveness lost as field pressure declines (may require additional equipment) Mechanical Refrigeration can also be used with J-T valve

NGL Recovery (basic schemes) Turbo Expander Cooling System

Turbo Expander

Gas / Gas Exchanger

Brake Compressor De-Methanizer Column

Treated Feed gas

Low Temperature Separator

Sales Gas

Reboiler

NGL Product

NGL Recovery (basic schemes)

Turbo Expander Cooling System Advantages: - Can be used with medium to high feed gas pressure - Produces work useable as power for sales gas compression - Low gas dew point achievable when low P is available - High revenue with higher NGL recovery Turbo Expander Cooling System Disadvantages: - Higher capital cost - Extensive gas pre-treatment required to prevent water freezing and solid CO2 formation - Variation in feed gas pressure & composition can reduce efficiency - Special metal alloys in cryogenic area

How Turbo Expander Works

First Law of Thermodynamics Internal Energy can be converted into heat and mechanical work Basic Parts: - Outer housing to contain the gas - Expander wheel connected with a shaft to spin Function: - High pressure (high temp) gas exerts pressure on wheel causing it to turn - Gas exits through a hole in the housing - As gas energy is used to turn the shaft, gas leaves at low temperature & low pressure - NGL is recovered from cold gas - Lean gas is recompressed by the same work (brake compressor)
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How Turbo Expander Works

Isentropic Expansion through Turbo Expander

Point (1) is Inlet gas (after treating)

Point (2) is After cooling by gas/gas exchanger/De-Methanizer side draw coolers

Dotted Line is new 2 phase diagram after separation of heavier components in LTS

Point (2) (3) is Expansion via T.E (work is done by gas i.e. Isentropic Expansion)

Point (2) (4) is Expansion via J.T

Gas can be expanded to lower pressure by T.E than J.T (will recover via B.C)

At same DP, Lower Temp. is achieved via T.E

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Licensed Technologies
LICENSOR PROCESS NAME

Gas Subcooled Process (GSP) Single Column Overhead Recycle (SCORE) Overhead Recycle Process (OHR) Cold Residue reflux Process (CRR) Ortloff Engineering Ltd. Recycle Split-Vapour Process (RSV) Recycle Split-Vapour with Enrichment Process Split Flow reflux Process (SFR) Improved Overhead Recycle Process Enhanced NGL Recovery Process IPSI LLC Split Feed Gas Compression Process High Ethane Recovery Process ABB Lummus High Pressure Absorber (HPA) Shell Global Solutions Shell Deep LPG (SHDL)
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Licensed Technologies C2 & C3 Recovery

C3 Recovery Technologies: Single Column Overhead Recycle (SCORE) Shell Deep LPG Process (SHDL) Gas Subcooled Process (GSP) Cold Residue Reflux Process (CRR)

C2 Recovery Technologies:

C2 & C3 Recovery using Licensed Technologies

100 90 80 95 96 99 85 100 97

Recovery, %

70 60 50 40 30 20 10 0 BTC Shell SHDL

C2 Recovery

43 25 14

45

SCORE
C3 Recovery

GSP

CRR

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Licensed Technologies C3 Recovery

Shell Deep LPG
Turbo Expander Brake Compressor

Sales Gas

Gas / Gas Exchanger

Low Temp. Separator

Low Temp. Separator

De-Methanizer Column

Treated Feed gas

Gas / Gas Exchanger

Reboiler

NGL Product

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Licensed Technologies C3 Recovery

Single Column Overhead REcycle (SCORE)
Turbo Expander Brake Compressor

Sales Gas

Condenser

Low Temp. Separator

De-Methanizer Column Reflux Drum Gas / Gas Exchanger

Treated Feed gas

Reboiler

NGL Product

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Licensed Technologies C2 Recovery

Gas Subcooled Process (GSP)
Turbo Expander Brake Compressor

Sales Gas

Sub Cooler

De-Methanizer Column Flow Split

Side Draw Coolers

Treated Feed gas

Gas / Gas Exchanger

Low Temp. Separator

Reboiler

NGL Product

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Licensed Technologies C2 Recovery

Cold Residue Reflux Process (CRR)
Turbo Expander Brake Compressor

Sales Gas

O/H Compressor

Flow Split

Sub Coolers Flow Split Side Draw Cooler Low Temp. Separator

De-Methanizer Column

Treated Feed gas

Gas / Gas Exchanger

NGL Product

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Process Economics for C2 and C3 Recovery

Propane Recovery Processes: SHDL & SCORE
100

Propane Recovery, %

95 90 85 80 75 1000 SHDL SCORE

Propane Recovery Processes: SHDL & SCORE

1500 2000 2500 3000 3500 4000
100

Column Pressure, kPa

Propane Recovery, %

95 90 85 80 SHDL SCORE

75 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000

Booster Compressor Power, kW

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Process Economics for C2 and C3 Recovery

Ethane Recovery Processes: GSP and CRR 100
100 Ethane Re cov e ry Proce sse s: GSP and CRR

Ethane Recovery, %

Ethane Recovery, %

90 80
CRR GSP

90

80
CRR GSP

70 60 1500

70

2000

2500

3000

3500

4000

60 100,000

110,000

120,000

130,000

140,000

150,000

Column Pressure, kPa

Total Compression Power, kPa

Ethane Recovery Processes: GSP and CRR

100

Ethane Recovery, %

80 60 40 20 0 40,000
CRR GSP

50,000

60,000

70,000

80,000

90,000

Refrigeration Compression Power, kW

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Economics Higher NGL Recovery

IS HIGH NGL RECOVERY ALWAYS THE BEST SOLUTION? High NGL Recovery means: Lower sales gas flow Lower gas heating value Higher capital investment Higher operating cost (residue gas compression, refrigeration compressor ) Extra gas treatment required i.e. CO2, moisture removal, Hg removal etc. Recommendation: Detailed life cycle cost analysis to generate maximum revenue Sensitivity analysis for selected process: operating pressures, refrigeration requirement, flow split etc.

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NGL Fractionation

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Open Art NGL Recovery Unit (Pre-Treatment Section)

Regen Gas Compressor

Regeneration Gas Separator

Free Water to Drain

Gas Filter Separators Sweet Rich Gas Feed Gas Chiller Feed Gas Chiller Separators Condensate Filter Separator Liquid Molecular Water Degassing Drum Sieve Dehydrators Gas Molecular Sieve Dehydrators

Gas Mercury Removal Units Dehydrated Gas to NGL

Regen Gas Hot Oil Heater Condensate Mercury Removal Units

Dehydrated Condensate to Demethaniser

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Open Art NGL Recovery Unit (NGL Recovery Section)

FEED GAS

Feed/Residue BAHE Feed/Side draw BAHE 2

Demethanizer Overhead BAHE Feed/ Residue BAHE 3

To Residue Gas Compressor

Feed/Residu e BAHE 1 C3 out

Gas Chiller 1

JT Valve JT Valve

Demethanizer

C3 in From Condensate Mercury Removal Beds C3 out Condensate Chiller 1 C3 in C3 in Condensate Chiller 2 & Gas Chiller 2 Demethanizer Trim Reboiler Chiller Separator C3 out Expander Feed Separator

Turbo Expander /Brake Compressors A/B

To BAHE 3 To BAHE 2 To BAHE 1

heat out

To NGL Surge Spheres

heat in Demethanizer
Bottoms Pumps

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NGL Recovery Technologies

Shoaib is on Fire !

QUESTIONS?

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