Advanced Gas Processing
A. Shahsavand
Chemical Engineering Department Faculty of Engineering Ferdowsi University of Mashad 2010
Feedstock & Product
Receives
crude oil associated gases from production units or
wellhead separators.
Produces
sale gas, Ethane (as
petrochemical feed stock), LPG (C3 C4) and light naphtha (C5+)
Onshore and Offshore NGL plant facilities
Onshore Associated Gases
Gas Compression Acid Gas Removal NGL Recovery Unit
Offshore Associated Gases Acid Gas incineration or
SRU
Sale Gas
C2
C3
C4
C5+
Condensate
NGL Recovery Unit
A
conventional natural gas liquid plant includes a separator that receives a cooled low pressure feed gas (heavy HC separation). The separator is coupled to an absorber (or distillation column) and a demethanizer. Refrigeration duty of the absorber and demethanizer are provided at least in part by expansion of a liquid portion of the cooled low pressure feed gas and an expansion of a liquid absorber bottom product. Propane recovery is at least 99 mol %.
Ethane Recovery
As
ethane recovery becomes increasingly economically attractive, various configurations have been developed to improve the recovery of ethane from natural gas liquids (NGL). Most commonly, numerous processes employ either cooling of feed gases via turbo expansion or a sub-cooled absorption process to enhance ethane recovery.
Typical NGL unit
Feed gas Slug Catcher Condensate Separator C2 Recovery Refrigeration & Compression C3 & C4 C5+ Refrigeration C5+ Recovery Dehumidification
Water
Sale Gas C2
LPG Absorber
Conventional NGL unit
NGL Recovery Unit Features
Low
Operating Costs: Less compression to operate and maintain. Feed Pretreatment: CO2 removal is not necessary, glycol injection for dehydration is adequate. Wide Pressure Range: 250 to 1,200 psig feeds without inlet gas compression. High Ethane Recovery: One pass ethane recovery can exceed to 96%. NGL Flexibility: One-line switching from high C2-plus to high C3-plus with simple controls. Inexpensive Metallurgy: Lowest temperature, limited by C3 refrigeration, permits the use of carbon steel metallurgy predominantly. Upgrading Refrigeration Plants : Add-on unit enhances propane recoveries from typical 30-55% to 96+% by processing cold separator gases.
Ideas
Can
we use new separation processes such as PSA or membrane instead of conventional Refrigeration process. These new processes are more energy efficient and may be attractive from economical point of view.
60 MMSCFD NGL Plant, Alberta, Canada (Start up: January 1998 )
Hawiyah NGL Recovery Project, Saudi Arabia
The
Hawiyah NGL Recovery Program produces 310,000 bbl/d of ethane and NGL products from around four billion SCFD of associated gas. This project is completed in early 2008. The contract valued at $1.2 billion This plant also produces 170,000 bbl/d of condensate, and 1,000 t/d of sulphur. Facilities at the plant, in addition to the four gasprocessing trains that perform gas dehydration, dewpoint control and sales-gas compression, include two gas sweetening and sulphur recovery trains, two condensate stabilizers and two sour-water strippers.
Supply and Demand
NIOC associated gas gathering systems
AMAK Project
Environmental Issues
AMAK Products
Economic Aspects
Annual Product Value: 210 MMUSD Total Cost : Payback period: 530 MMUSD 2 years
AMAK Gas Treating Unit
AMAK Compressor Station
Kharg NGL recovery unit
Kharg NGL recovery unit
Approximate Location
Approximate Location
Kharg NGL unit Project
Kharg Associated Gas Gathering Project
Onshore Acid Gas
303 MMSCFD
Containing Following Impurities:
H2S : 12.7 mole %
(38.5 MMSCFD) (16.7 MMSCFD)
CO2 : 5.5 mole % COS : 222 ppm RSH : 217 ppm RSR : 34 ppm
Offshore Acid Gas
297 MMSCFD
Containing Following Impurities:
H2S : 3.8
mole % ppm ppm ppm
(11.3 MMSCFD) (13.7 MMSCFD)
CO2 : 4.6 mole % COS : 88 RSH : 46 RSR : 4
Problems & Solution
80 MMSCFD Acid Gas Removed
H2S : 50 MMSCFD (2034 tone sulfur)
Problems: Warehousing Sales and Marketing,
CO2 : 30 MMSCFD (Emission To Atm.)
Problems: Greenhouse Gas, Environmental Concerns
Acid Gas Injection
Sweet Gas Sour Gas
AGR
Acid Gas
C&C
Disposal Well Pipeline Disposal Layer
T=40 C P=180 Bar
Acid Gas Injection
Injection Depth: 4500m under seabed Injection Time: 25 years Total Injection volume : 128 MMbbl THE BIGGEST ACID GAS INJECTION PLANT IN THE WORLD!
Economical aspect
Price Correlation Price Per Unit (2004)
Sales Gas Ethane Propane Butane Pentane Condensate 25 $/MSCM 65 $/Tone 405 $/Tone 406 $/Tone 30 $/Barrel 35 $/Barrel
Economical aspect
Annual product value: 720 MMUSD Onshore NGL facilities cost: 1200 MMUSD Onshore GC facilities cost: 67 MMUSD Offshore pipeline: 90 MMUSD Total Cost : Payback period: 1357 MMUSD 2 years
Sox Emission by Flares
Nox Emission by Flares
NOx and Sox emission Comparison
Siri NGL recovery unit
Siri NGL unit Project
Economical aspect
Siri Island Associated Gas Gathering Project
Economical Aspect
Annual product value: 180 MMUSD Onshore NGL facilities cost: 216 MMUSD Onshore GC facilities cost: 12 MMUSD Offshore pipeline: 72 MMUSD Total Cost : Payback period: 300 MMUSD 2 years
Environmental Aspect
Project Schedules (Jan 2005)
Siri Onshore NGL plant: 40 months (ongoing) Offshore pipeline project: Executed Offshore Gas compression platform: 12 months (ongoing)
Sirri NGL plant to be completed in two years (Jan 2007)
Sirri NGL Plant will collect 140 MMSCFD of associated gases, of which 40 mcf will be used to produce condensates. This is equal to the production of 12,000 barrels per day of condensates, project manager Mohammad-Reza Abrishami said: Operations to construct the plant have so far progressed by 20 percent and expected to come on stream over the next two years. Gases from the fields are to be sent to power plants at Qeshm and Kish, while the extracted gas condensates are to be exported. The gas transfer pipelines from Sirri to Qeshm and Kish have been completed in offshore part.
Canadian NGL Prices
Date
02/07 01/07 12/06 08/06 05/06 12/05
C3 ($/m3)
282.36 250.61 269.74 307.23 279.10 332.77
C3 (US/US gal.)
90.75 ( 40 US$/bbl) 80.65 88.95 103.44 93.63 107.60
C4 ($/m3)
245.00 247.90 255.00 380.48 345.16 334.03
Iranian NGL units
NGL 100, 200, 300 (Aghajari) NGL 400, 500, 600 (Ahwaz) NGL 700, 800, 900 (Ahwaz) NGL 1000, 1100, 1200 (Ahwaz) NGL 1300, 1400 (Ahwaz) NGL 1500 (Karanj)
