Gas Treatment Plant

Chris, Stephanie, Kyle, MariamMentor: Jerry Palmer

Outline1. Block Flow diagram2. Mass Balance2. Liquid Knockout3. Sour Gas Treatments4. Gas Dehydration5. NGL Recovery and CO2 Removal6. NGL Stabilization7. Inert Removal-N28. Equipment Cost9. Capital Cost10. Revenues11. Sample Calculations12. Question & Answer

Block Flow Diagram

Mass Balance

Liquid Knockout3- Horizontal Tanks and decreasing temperature and

pressure.In a dynamic refinery environment it is important to

have the capability to compensate for a surge of liquids and take out any non-volatile components which will cause issues in the future separation processes.

3 tanks are used because its the most efficient setup for large scale processes.

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Sour Gas Treatment

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Sour Gas TreatmentsLiquid Scavenger Solid Scavenger Liquid Redox Amine+Claus+Tail

gas

Gases treated

Acid Gas Yes Yes Yes Yes

Natural Gas Yes Yes Yes No

Turndown Sensitive Not Sensitive Not Sensitive Sensitive

Products Streams Biodegradable Liquid

Non-Hazardous Solid

Sulfur Cake for Fertilizer

Pure Sulfur

Operating Costs $10/lb. of S $3.50/lb. Sulfur $0.15/lb. of S Small

Equipment Costs Low Moderate Moderate High

General Application Guidlines

100 lb. of sulfur per day

300 lb. of sulfur per day

Less than 20 tons of sulfur per day

Greater than 15 tons of sulfur perday and greater than 15% H2S

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Why LO-CAT II?

-System Stability-Ease of operation and Catalyst consumption-Chemical Cost is roughly 1/2 to 1/3 of a Sulferox Unit-Uses a Patented chelate system that is more resistant to Oxidation

Gas Dehydration

Gas Dehydration & CO2 Rejection

The methods of dehydration looked into are lean gas absorption, adsorption and membrane separation.

Absorption Adsorption

TEG dehydration Mole sieve dehydration

Glycol is cost effective Adsorbent like silica gel is expensive

For removing large quantities of water Required for cryogenic systems which need low moisture content

Glycol can be replaced continuously Multiple adsorption beds are required for continuous use.

Does not remove CO2 Removes CO2

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PFD-003 Gas dehydration

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NGL Recovery + CO2 Removal

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NGL RecoveryMechanical Refrigeration Plant:- limited to -24 to -40 F- only 60% propaneLean oil absorption:- 40% ethane- 90% propane- 100% heavier hydrocarbons- Heating and cooling required- High operating costTurboexpander:- 60-90% ethane- 90-98% propane-100% of heavier hydrocarbons- Since high percent ethane recovery is needed, this is the most economical way

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NGL Stabilization

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NGL Stabilization

• NGL's need to be stabilized to a point that it can be stored and transported in non-pressurized vessels.

• Enhances the safety in handling, and improving the liquid's marketability.

• Stabilizing the liquid reduces the volatility.

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Inert Removal-N2

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Inert Removal-N2

Available options are cryogenic distillation, membrane separation and PSA.Cryogenic distillation has been selected on the

basis that is very efficient for large scale separation facilities.

Additionally because LNG is being produced in the following stage its worthwhile to expend the energy to process the methane.

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LNG Production

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LNG Production

• LNG is produced under very low temperatures.

• Effective for transportation of natural gas over long distances.

• Safer than transporting compressed natural gas in vehicles because LNG is comparably low in pressure.

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Equipment Cost Estimates

Equipment Costpump $20,000 to $85,000

distillation column $600,000

compressor $20,000 to $1,500,000

cryo distillation column $700,000

heat exchanger $50,000 to $100,000

primary LNG cryo heat exchanger $3,000,000

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Estimated Capital CostAmine Treating cost for 5% acid gas removal $10.0MM Dehydration cost $1.0MMCompression cost (7000hp x $1400/hp) $9.8MMCryogenic NGL recovery cost $23.0MMLiquid-Redox Sulfur Recovery at 5 T/d $4.0MMTotal cost of components $47.88MMOther costs and Contingency @ 30% $14.3MM

Total Estimate Plant Cost $62.1MM

-Based on a Natural Gas Treatment Facility that processes 100 MMscfd.-Prices based in 2008 and do not account for inflation.

Employee payroll with fringe benefits $3.5MM/year

Revenues

• Natural Gas: 300 Million $/year• NGL: 110 Million $/year • LNG: 50 Million $/year• Elemental Sulfur: 50,000 $/year

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Sample CalculationsSCFD to Lb/Hr conversion:X Lb/hr = ( Y SCFD) / [ ( 24 hr/1d)*(1 lbmol/ Z Lb)*(378.827 SCF /lbmol) ]V/n = RT/P = 378.827 @ 60FX : lb/hrY : SCFDZ: MW

X bbl = ( Y lbmol * MW lb/lbmol) / (5.615 ft^3/bbl*Z lb/ft^3)X= volumeY= n molesZ = density

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Q & A