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7/28/2019 Day2 01 Nicola Mondelli
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Gas Flaring Recovery:
Our recent experience
in
Gas Fieldsand
Petroleum Refineries
February 20, 2013 Rev.0
Gas Flare Reduction Conference
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Confidential Information
1. Introduction
2. Case Study 1 – Gas Field in North Africa
3. Our experiences in fast track projects and plant operation
4. Case Study 2 – Petroleum Refinery in North Africa
5. Our experiences in revamping and fast track projects
6. Questions & Answers
7. Conclusions
Agenda
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Approximately 150 bcm (3,5 bcf) of gas are flared to the atmosphere in
the world. This huge quantity is equivalent to 5% of the world gas
production
Tecnimont KT S.p.A. (TKT) and GEA signed a Cooperation Agreement
to collaborate together in the field of Gas Flaring Recovery
The mission of the Cooperation Agreement is to manage the complexity
of our customer’s needs by providing innovative products andcustomized solutions.
TKT and GEA can work for you to solve this issue with the purpose to
recover valuable products in Gas Fields, Petroleum Refinery and
Chemical & Petrochemical complex
Introduction
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Our Range of Services
R&D/IPL
Full Plant Life CycleSupport
EPCTrainingServices
After SalesServices
Op. & Maint.Services
FEEDBasic
DesignConceptual
DesignFeasibility
Study
Decom.
PMCServices
CMSServices
PlantOptimization
RevampingStudies
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Our Value
TECHNOLOGY & KNOW-HOW
KNOWLEDGE
EXPERTISE
REFERENCES
“We know how to define, design, built and operate Industrial Plants”
Full Plant Life CycleSupport
44
AMINEREGENERATION AMINEREGENERATIONSECTIONSECTION
33
22
CLAUS TAILGAS
H2RICH GAS
SOURWATERSOUR WATER
SWEET TAIL GASSWEETTAIL GAS
ACID GAS TOCLAUS ACID GASTOCLAUSLEANAMINELEAN AMINE
RICHAMINE
RReductioneduction
Typical 10Typical 10--250 ppm Vol. H250ppm Vol. H22SS
COOL PROCESSGAS
A Absorptionbsorption RRecycleecycle
11
HEATING / COOLINGHEATING /COOLING
SECTIONSECTION
“From White Paper ” … through Process Scheme … up to Plant in operation
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In a North Africa Country, the wells overhead associated gas were flared
to the atmosphere with a significant pollution to the atmosphere due to
the presence of heavy hydrocarbons and important economic loss
The basic idea of Client was to identify the best and fast technological
solution to be implemented within 24 months from the contract award,
including also the time for a conceptual study
Introduction to Case Study 1
Fast Track Project
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Fast track project to be implemented within 24 months from contractaward (from white paper up to the plant in operation)
Plant design parameters:
Raw Gas flow rate…………………………………51,000 Nm3/h
Raw Hydrocarbon liquid flow rate……………..25 m3/h
Min Butane production (97% purity)…………...5,9 t/h
Min Gasoline production (99,5% purity)……....4,2 t/h
ROI max 2 years (preferred 1 year!)
Utilise an existing pipeline from wells to site
Minimise emissions
3 years of continuous operation executed by EPC Contractor after 1st
plant start-up
Case Study 1 – Main Constrains
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Assignment of a dedicated project task force lead by a project manager ful l empowered to execute the project
Combined team work between technology provider (EPC Contractor) andClient (Owner)
Selection of the best scheme selected during the proposal phase
Execution of basic design overlapped with engineering activit ies
Identification and selection of LLI within 2 weeks from the contractaward (CA). Management of the procurement with a fast track approach
First si te activi ties after 3 months from CA
Completion of detailed engineering within 14 months from CA
Optimisation of construction and precomissioning through a detailedstudy of systems and sub-systems
Start of commissioning activities at month 22, plant full in operation atmonth 24
3 years of continuous operation and Training on e Job of Client'soperators
Case Study 1 – Project Execution Strategy
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Dehydration at wells and preliminary gas-liquid separation
Gas phase: from C1 to C3
Liquid phase: gasol ine with a portion of C3 and C4
The gas separation is achieved by a simple refrigeration system, propylene fluid
based, utilising an Oil Flooded Screw Compressor. The aim of the separation was
to set a volumetric flow rate capable to uti lise the exist ing pipeline connecting the
wells with the plant site, no hydrocarbon fractionation at wells
The liquid stream and the gas stream are processed at plant site to obtain:
Gasol ine stream
Butane stream
Propane stream
Propane, Ethane Rich Stream
Main goal was to minimise gas flaring of incondensable gas
Case Study 1 – Process Description
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The selected scheme is quite simple: dehydration of the gas followed byrefrigeration. The subcooled liquid is fed to rectifying section of the De-Ethanizer, while the liquid stream, after dehydration is fed to thestr ipping section of the De-Ethanizer
Dehydration is achieved with molecular sieves, treated gas is utilized for the regeneration
The fractionating section consists of:
De-Ethanizer
De-Propanizer
De-Butanizer
Hot oil is used as heating medium
The plant is also equipped with ut ili ties and off-sites section
Case Study 1 – Selection of the Process Scheme
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Case Study 1 – Process Flow Scheme
EXP. GAS
Condensate
RICH GAS
Hot Oil
Dehyd.
Dehyd.
Refrig.
Sections
DEETHANIZER
DEPROPANIZER
DEBUTANIZER
FLARE SYSTEM
BUTANE
PROPANE
BUTANE
GASOLINE
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Case Study 1 – “ The Plant”
GAS
IN
TreatedGAS
Condesate
IN
Hot
Oil
System
Fractionating
System
Refrigeration
System
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Fast Track Project
Plant in operation within 24 months from the contract award
Plant in operation with full satisfaction of the Client since 2010???
ROI less then 1,5 years
Deep reduction of CO2
emissions
Case Study 1 – Conclusions
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In north Africa, a Refinery experienced pressure instability and oscillation
problems in the fuel gas network.
The pressure in the Fuel Gas Drum was subject to large fluctuations causing
disturbances to the fuel gas users, reducing the steady performance of heaters,increasing the risk of process shut down, causing instability in burner’s pilots
operation and large quantity of fuel gas flaring was experienced.
As consequence of this instability, all the refinery boilers were operated with fuel
oil only and continuous fuel gas flaring leads to a Refinery emission issue in
addition to a valuable fuel gas loss.
Fuel Gas pressure stabilization and recovery of flared Fuel Gas became a vital
requirements for the Refinery
the main goal was to minimize OPEX, to increase reliability and safety and mostimportant to be in compliance with new stringent environmental regulations
reducing as much as possible the use of fuel oil
Introduction to Case Study 2
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The following graph represents fuel gas flow rate, fuel gas pressure and gas flaring flow rateduring one month of operation
Refinery is subject to a fluctuation of fuel gas request that produces fuel gas pressureinstability, frequent and prolonged fuel gas flaring.
Case Study 2 – operating data from Refinery
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
6/30 7/1 7/2 7/3 7/4 7/5 7/6 7/7 7/8 7/9 7/10 7/11 7/12 7/13 7/14 7/15 7/16 7/17 7/18 7/19 7/20 7/21 7/22 7/23 7/24 7/25 7/26 7/27 7/28 7/29 7/30
One month trend
FG flow rate [T/h] P FG-drum [kg/cm2] gas to flare [T/h]
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Phase (1) assessment of the original design (Design Basis, ProcessFlow Scheme, Util ities Consumption Summary, flare loadsummary, P&ID’s, plot plan, burner and furnaces design,etc.);
Phase (2) analysis of the current operation (DCS data, trends, logbook, lab analysis, etc.;
Phase (3) identification of the causes of fluctuations
Phase (4) definitions of several corrective actions
Phase (5) selection of the best solution capable to minimize OPEXand CAPEX in full compliance with the environmentalregulation in force in that Country
Phase (6) Value Engineering and Constructability Analysis
performed with a joint team of Refinery and Contractors toidentify further possibility of optimization as well asconstrains during construction and operation
Case Study 2 – Process Study
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The source of instability has been identified in the dimensions of the fuel gas KO drum thatwas not properly designed to cover the possible operating scenarios of the Refinery
The following figure shows the effect of fuel gas pressure and fuel gas demand duringtransient conditions
The analysis of the design of the KO drum has demonstrated that the current gas drumvolume is not suffic ient to cover such quick gas flow rate variations. In addition the location of such drum is not symmetrical in respect of the major users.
Case Study 2 – Results of the assessment
5
3
bar
hour1 2
2
4
1
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Necessity to install an additional Collection Balance Drum to better
compensate for the fluctuations of the Fuel Gas network
Identify a stable source of fuel gas make-up (vaporization of LPG), to
cover unexpected and rapid shortage of fuel gas
New fuel gas pressure control philosophy integrated with a Flare Gas
Recovery System (FGRS)
Identification of “ driven users” which can handle some fuel gas
fluctuations without affecting the process units
Constrain the fuel gas network within operating limits (min and max
pressure) through adjustment of FG fired in dedicated special users
Split-range control for fuel gas minimization to flare
Minimization of fuel oil consumption through proper design of the burner
system
Case Study 2 – Corrective actions
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Case Study 2 – Pressure ControlConceptual Scheme
Flare Gas
Compressor
Capacity
FGRS
LPG
make-up
to FG
network
FG to
“driven”
users
LPG make-up
to “driven”
users
Max FG Pressure………. 4 barg
Normal FG Pressure……3 barg
Min FG Pressure………...2 barg
FG KO
Drum
FG pressure
“driven”
users
Flow rate
LPG
vaporized
Split Range
PTPT
PV PV PV PV
FT
PYP=maxopen
PY PYP=minopen
PYP=normopen
PY PY
TI
PI
FV
PIC FIC
Compensation.
Overpressure Contro l
PIC
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Fluctuations of fuel gas network can be controlled with the proper
design of the Fuel Gas network system (hardware and software)
Flare Gas Recovery Systems is a key factor to minimize emissions and
fuel gas consumptions
It was possible to recover up to 2,5 t/h of Fuel Gas from the flare
All the corrective actions have been implemented through a fast track
project
ROI was less than 1,5 years.
Case Study 2 – Conclusions
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Questions & Answers
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CONCLUSION
WE HAVE KNOW-HOW, KNOWLEDGE, EXPERTISE AND
REFERENCES
WE ARE ABLE TO DELIVER A CORRECT AND TROUBLE FREE
SUPPLY
WE CAN ASSURE AND GUARANTEE THE SUCCESS OF THE
PROJECT WITH FULL SATISFACTION OF THE CLIENT
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Stop to Gas Flaring!
Thank you!
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Contacts
Tecnimont KT S.p.A.
Mr. Michele Colozzi
[email protected].: +39 348 2250034
KT ARABIA
Mr. Nicola Mondell i
Mob.: 0500654266
GEA
Mr. Giuseppe Falsiroli
[email protected].: +39 347 4559294