Project title

A DESIGN OF A 312 MT/DAY METHANOL PLANT FROM NATURAL GAS

Project definition:
A Methanol plant is to be set up at Birashar,Brahmanbaria in Bangladesh having a capacity
of 312 MT 99.49%(wt%) Methanol per day, corresponding to 112320 MT of 99.49% (wt%)
Methanol per year (360 stream day per year), and an important by product 46.872 MT/day of
96.88 % (wt%)

methanol per stream day corresponding to 16874 MT of 96.88% (wt%)

Methanol per year (360 stream day per year) including all offsites, auxiliaries, utilities and
supporting facilities using Natural gas (96.48% CH4) from near byTitas Gas Field as feed stock.

Specification of Raw material:

a.Natural gas from Titas gas field
Natural gas specification on the basis of methane composition
Constituents
Methane
Ethane
Propane
i-Butane
n-Butane
i-pentane
n-pentane
n-Hexen
n-Heptane
CO2
N2
Total

Composition(mol%)
96.48
1.60
0.35
0.10
0.08
0.05
0.04
0.05
0.19
0.72
0.35
100

b. Steam
Steam specification
100% pure superheated steam

Specification of product
conditions
Mass flow rate(ton/day)

312

Temperature(oC)
Pressure(kPa)
Aqueous fraction

118.3
607.9
1
Composition (Mass fraction)

CH3OH(Methanol)
H2O(Water)

0.995
.005
Properties

Mass density(Kg/m3)
Heat capacity(KJ/Kg-C)
Vapor phase fraction
Viscosity(cP)
Specific Heat(KJ/Kg-mole-C)
Surface tension(dyne/cm)

688.5
4.134
0
0.1853
126.7
19

By product
a.Specification of 96.88 % CH3OH
conditions
Mass flow rate(ton/day)
Aqueous fraction
Composition (Mass fraction)
CH3OH(Methanol)
CO2

46.87
1
0.968
0.031

b. Specification of fuel gas

conditions
Mass flow rate(ton/day)
Aqueous fraction
Composition (Mass fraction)
C-1
C-2
C-3
n C-4
i C-4
nC-5
iC-5
nC-6
nC-7

6.9
0
0.137
0.020
0.008
0.011
0.009
0.025
0.021
0.090
0.688

Utilities
Electric power requirement:3.27 10

13

kW electric power is required for pumping the process

fluid and to run the compressors,columns,heater etc.

Water requirement:19888.8 ton/day water.
Air requirement:15926.4 ton/day
Liquid propane requirement : 2116.6 ton/day

Plant location
Brahmanbaria/Birashar
Latitude =23.97o
Longitude =91.11o

Area
Total area required for the plant is

m2( acres) and required for processing unit is m2( acres)

Design Basis
Design basis includes site conditions,utilities, raw materials etc.which influence the process
design and the design of individual unit,equipment or facility of the overall project.Design basis
in the present context is different from that one defines in stoichiometry.Design basis here is to
be considered as conditions in existence with which to design the project.
Important design basis includes :

Geological Data
Climate Conditions
Utility Conditions
Structural Design
Raw Materials
Others

Geological Data

Geological data includes:

a.Site characteristics
Flood level: 5 m (max.)
Tidal level: 4.54 m(max.)
Ground water level: 3 m
Height from sea level:10 m
b. Soil type
Corrosion tendency : lightly corrosive
c.Seismic condition
Load bearing capacity: The seismic load coefficient for the plant area is 0.38.

Climate Condition
a.Design condition for equipment or facility
I. Process equipment: Summer day (dry bulb temperature =40 oC, Wet bulb
temperature =40oC, avg .relative humidity =90% ); winter day(dry bulb temperature
=12oC )
b.Design conditions for building
I. HVAC : summer day (maximum dry bulb =40oC, wet bulb =40oC)
Winter day (minimum dry bulb temperature =12oC)
II.Ventilation : summer day (maximum dry bulb =40oC)
Winter day (minimum dry bulb temperature =12oC)

c.Meteorological conditions :
I. Ambient temperature
Maximum = 40oC
Avg. daily maximum =38oC
Avg. monthly maximum =40oC
Average =28 oC
Avg. daily minimum =22 oC
Avg. monthly minimum =12 oC
Minimum =21 oC
II.Humidity
Relative humidity =80%

III.Rainfall
Avg. annual rainfall =3499.2 mm
Maximum monthly rainfall =1089.9 mm(July)
Maximum daily rainfall =405 mm
Maximum hourly rainfall =60 mm
Maximum intensity (in a 15 minute period)=108 mm/hr
Design intensity =100 mm/hr
IV. Barometric pressure (at sea level)
Minimum pressure =101253 pa

V. Wind velocity
Maximum recorded wind velocity = 199.8 km/hr
Design velocity =210 km/hr

Utility Condition
a.Raw water
I. Source:filtered water from titas river
II. Supply pressure : as per water treatment plant intake requirement
III. Supply temperature : 32oC
IV. TDS :149 ppm
V. Total hardness : 89 as gm (CaCO3)
VI. Total sulfate : 18 as gm (SO42-)
VII. PH : 7.0

VIII. Maximum alkalinity : 61 as gm (CaCO3)

IX. Total dissolved SiO2 :5.9 ppm
X. Total iron : 0.88 as gm (Fe2+)
b. air
I. Instrument air : as per instrument requirement condition

Raw materials
a.Natural gas from Titas gas field
Natural gas specification on the basis of methane composition
Constituents

Composition(mol%)

Methane

96.48

Ethane

1.60

Propane

0.35

i-Butane

0.10

n-Butane

0.08

i-pentane

0.05

n-pentane

0.04

n-Hexen

0.05

n-Heptane

0.19

CO2

0.72

N2

0.35

Total

100

b. Steam
Steam specification : 100% pure superheated steam

Other Information:
Natural catastrophe: A possibility of storm in the months of April-May.
Value of by-products: No economically feasible by-products are obtained.

Process Selection
1. Natural gas Sweetening:
Amine Process: Chemical absorption processes with aqueous alkanolamine solutions are used for
treating gas streams containing hydrogen sulfide and carbon dioxide. However, depending on the
composition and operating conditions of the feed gas, different amines can be selected to meet
the product gas specification. Amines are categorized as being primary, secondary, and tertiary
depending on the degree of substitution of the central nitrogen by organic groups. Primary
amines react directly with H2S, CO2, and carbonyl sulfide (COS). Examples of primary amines
include monoethanolamine (MEA) and the proprietary diglycolamine agent (DGA). Secondry
amines react directly with H2S and CO2 and react directly with some COS. The most common
secondary amine is diethanolamine (DEA), while diisopropanolamine (DIPA) is another example
of a secondary amine, which is not as common anymore in amine-treating systems. Tertiary
amines react directly with H2S, react indirectly with CO2, and react indirectly with little COS.
The most common examples of tertiary amines are methyldiethanolamine (MDEA) and activated
methyldiethanolamine. Processes using ethanolamine and potassium phosphate are now widely

used. The ethanolamine process, known as the Girbotol process, removes acid gases (hydrogen
sulfide and carbon dioxide) from liquid hydrocarbons as well as from natural and from refinery
gases. The Girbotol treatment solution is an aqueous solution of ethanolamine, which is an
organic alkali that has the reversible property of reacting with hydrogen sulfide under cool
conditions and releasing hydrogen sulfide at high temperatures. The ethanolamine solution fills a
tower called an absorber through which the sour gas is bubbled. Purified gas leaves the top of the
tower, and the ethanolamine solution leaves the bottom of the tower with the absorbed acid
gases. The ethanolamine solution enters a reactivator tower where heat drives the acid gases from
the solution. Ethanolamine solution, restored to its original condition, leaves the bottom of the
reactivator tower to go to the top of the absorber tower, and acid gases are released from the top
of the reactivator.
2. Natural Gas Liquid recovery: Choosing a cost-effective NGL recovery technology requires
consideration of a broad range of factors (Mehra and Gaskin, 1999). The main variables that
affect the choice of the most cost-effective process for a given application include inlet
conditions (gas pressure, richness, and contaminants), downstream conditions (residue gas
pressure, liquid products desired, and liquid fractionation infrastructure), and overall conditions
(utility costs and fuel value, plant location, existing location infrastructure, and market stability).
In addition to the feed gas composition and
operation mode, the most decisive technical characteristics of any process are the feed gas
pressure and permissible unit pressure drop. The following guidelines have been suggested for
the selection of a NGL recovery process (Brands and Rajani, 2001).
1. In case of sufficiently high pressure, the self-refrigeration process requires the lowest capital
investment. However, if the pressure differential between feed gas and treated gas is insufficient,
additional compression is required.
2. When the feed gas pressure is close to the treated gas pressure, over a large pressure drop
range, it may be more economical to employ a cryogenic refrigeration process.
3. When the feed gas pressure is clearly below the required pipeline pressure, it is usually most
economical to apply mechanical refrigeration with additional compression to remove heavy
hydrocarbons instead ofcompression followed by the self-refrigeration process. This is due to the
fact that compressors are capital intensive equipments.

4. When the feed gas pressure is equal to or lower than the required pipeline pressure, solid bed
adsorption seems a good option, as it is quick to start up and is robust against changes in the feed
gas composition and flow rate. Generally the solid bed process is only practical for gas that has
small amounts of heavy hydrocarbons. Richer gases require refrigeration. It is clear that the solid
bed adsorption process will usually be competing against the self-refrigeration process.
Specially, the solid bed adsorption unit is operated at lower differential pressure compared to
selfrefrigeration and thus no additional compression is required. In fact, at low feed gas pressure
and for strict dew point specifications, economical analysis favors the solid bed adsorption
process. With reference to the membrane application to control the hydrocarbon dew point, there
is no clear judgement. Current discussions look at this on a point-by-point base and compare the
economics with other processes.The window of opportunity is still to be seen, although its use in
lean fuel gas is more common.

3. Methane to Methanol conversion process

Catalytic Conversion
Features:

Conversion of methane to methanol with an economic yield of 10%

In most experiments with solid catalysts, selectivities to methanol fell rapidly as methane
conversions exceeded 59%
complete oxidation of methane to carbon dioxide (H = -877 kJ/mol) is highly favored
over partial oxidation of methane to methanol (H = -200 kJ/mol)
A noticeable progress, however, has been made in the field of molecular catalysis by
Periana et al., who demonstrated the selective conversion of methane to methanol at
temperatures around 473 K over platinum bipyrimidine complexes. According to their
experiment, 81% selectivity to methyl bisulfate, a methanol derivative, was reached at
methane conversion of 90% in concentrated sulfuric acid
Although these results are promising, commercial applications are hampered by difficult
separation and recycling of the molecular catalyst.

Thermal Cracking

Methane is converted to methanol by partial oxidation to hydrogen gas and carbon

monoxide (synthesis gas or syngas) at high temperatures normally several hundred
degrees celsius
Syngas is then catalytically converted to methanol over a copper or platinum surface, also
at a couple hundred degrees Celsius
It is only around five or ten percent efficient due to accidental total oxidation to carbon
dioxide and water.

Photo-Catalytic Conversion

Ultraviolet light breaks water into a hydrogen and hydroxyl free radical, which are highly
reactive. When a hydroxyl radical reacts with a methane molecule, a hydrogen is
displaced and methanol is produced.
With the use of tungsten oxide or a similar semiconductor, photons of lower energy than
ultraviolet (down to blue) can be used.
Using Of WO as photo-catalyst visible laser light can be used in room temperature
It is highly energy inefficient (only 2-3% efficiency)
The process is not out in commercial production yet

Biological conversion

Conversion combines both methane and ammonia streams using methane-oxidizing

bacteria and ammonia-oxidizing bacteria, in both wild type and genetically modified
forms

Can convert heterogeneous methane feedstocks, unlike existing commercial process

Does not require a pure source of methane

It does not require expensive chemical catalysts

Cleanup and dehumidification processes not required

Widely applicable to digester gas, landfill gas, peatbogs, marshes, and wastewater
treatment facilities

Conversion process is time consuming

ICI process

Catalyst: Copper-Zinc oxide catalyst

Temperature: 200-30000C
Pressure: 5-10 MPa
Activity of this catalyst is more sensitive to impurities (poisoning)
Reduced manufacturing costs.

Process description
1. Natural gas Sweetening:
The general process flow diagram for an amine-sweetening plant varieslittle, regardless of the
aqueous amine solution used as the sweetening agent (Figure 7-2). The sour gas containing H2S
and/or CO2 will nearly always enter the plant through an inlet separator (scrubber) to remove
any free liquids and/or entrained solids. The sour gas then enters the botto of the absorber

column and flows upward through the absorber in intimate countercurrent contact with the
aqueous amine solution, where the amine absorbs acid gas constituents from the gas stream.
Sweetened gas leaving the top of the absorber passes through an outlet separator and then flows
to a dehydration unit (and compression unit, if necessary) before being
considered ready for sale. In many units the rich amine solution is sent from the bottom of the
absorber to a flash tank to recover hydrocarbons that may have dissolved or condensed in the
amine solution in the absorber. The rich solvent is then preheated before entering the top of the
stripper column. The amineamine heat exchanger serves as a heat conservation device and
lowers total heat requirements for the process. A part of the absorbed acid gases will be flashed
from the heated rich solution on the top tray of the stripper. The remainder of the rich solution
flows downward through the stripper in countercurrent contact with vapor generated in the
reboiler. The reboiler vapor (primarily steam) strips the acid gases from the rich solution. The
acid gases and the steam leave the top of the stripper and pass overhead
through a condenser, where the major portion of the steam is condensed and cooled. The acid
gases are separated in the separator and sent to the flare or to processing. The condensed steam is
returned to the top of the stripper as reflux. The lean amine solution from the bottom of the
stripper column is pumped through an amineamine heat exchanger and then through a cooler
before being introduced to the top of the absorber column. The amine cooler serves to lower the
lean amine temperature to the 100F range. Higher temperatures of the lean amine solution will
result in excessive amine losses through vaporization and also lower acid gas-carrying capacity
in the solution because of temperature effects.

2. Natural gas liquid recovery:

When insufficient pressure is available to attain the required dew point with the self-refigeration
process, cryogenic refrigeration can be considered. Cryogenic refrigeration processes
traditionally have been used
for NGL recovery. These plants have a higher capital cost but a lower operational cost The inlet
gas is first cooled in the high-temperature, gas-to-gas heat exchanger and then in the propane

chiller. The partially condensed feed gas is sent to a separator. The liquid from the separator is
fed to the demethanizer, and the gas is cooled further in the low-temperature gasto- gas
exchanger and fed into a second cold separator. Gas from the cold separator expands through the
expansion turbine to the demethanizer pressure, which varies from 100 to 450 psia. The turbo
expander simultaneously produces cooling/condensing of the gas and useful work, which may be
used to recompress the sales gas. Typically 10 to 15% of the feed gas is condensed in the cold
separator, which is usually at 30 to 60F. The expander lowers the pressure from the inlet gas
value (600 to 900 psia) to the demethanizer pressure of 100 to 450 psia. Typical inlet gas
temperatures to the demethanizer are 130 to 150F, sufficiently
low that a great deal of the ethane is liquefied. The demethanizer is a low temperature distillation
column that makes a separation between methane and ethane. Methane and components lighter
than methane, such as nitrogen, are the principal products in the vapor near the top of the
column, whereas ethane and heavier components, such as propane, butanes, and heavier
hydrocarbons, comprise the principal components in the bottom product of the column. The
molar ratio of methane to ethane in the bottom product is typically 0.01 to 0.03. Because the
outlet of the expander is usually two-phase flow, the liquid produced in the expander serves as
reflux for the demethanizer (Elliot et al., 1996). The bottom product from the demethanizer can
be fractionated further to produce pure product streams of ethane, propane, butanes, and natural
gasolin. The bottom product temperature is often below ambient so that feed gas may be used as
the heat transfer medium for the reboiler. This provides additional refrigeration to the feed and
yields higher ethane recovery, typically 80% (Holm, 1986). The top product from the
demethanizer, after heat exchange with the inlet gas, is recompressed to pipeline pressure.

3. Methanol synthesis section

A mixture of CO, H2, and CO2 is produced by steam reforming , a process in which natural gas
and steam are mixed and reacted in a reformer operated at 1.6MPa .Natural gas consist of 99%
methane and rest inerts. In the present process , steam and natural gas are fed to the reformer in a
ratio of 3:1.The reformer consists of an arrangement of vertical tubes filled with nickel-

impregnated ceramic catalyst. Rows of these tubes are located inside an insulated firebox, where
they are heated by the combustion of natural gas. The natural gas and steam that are blended to
become the reformer feed enter the process at 300C and 210oC , respectively. The mixture is
preheated to 450 0C by exhaust gas from the firebox, and it is introduced to the reformer through
a header that distributes the mixture evenly among the parallel reformer tubes . Two key
reactions occur: the steam-reforming reaction itself,
CH4 + H2O

CO + 3H2

and the water gas shift reaction CO +H2O

CO2 + H2

The product gas leaves the reformer at 8550C and 1.6 MPa.
Energy efficiency in the steam reforming is improved by recovering heat from the burner exhaust
gas , which leaves the firebox at 960 0C. The exhaust gas is cooled in a series of heat-exchange
operations that preheat the reformer feed streams to 4500C , produce superheated steam at 4.8
MPa and 1000C superheat from the boiler feedwater at 300C, and preheat the combustion air to
3000C. The superheated steam is used to drive turbines elsewhere in the process or it can be
exported , for example to generate electricity. The burner exhaust gas leaves the heat-recovery
units and enters a stack at 1500C for release to the atmosphere.
The product gas leaving the reformer contains water that should be removed to reduce the
amount of gas that must be compressed and to minimize the impact on subsequent conversion of
CO to methanol. Heat is removed from the gas by generating superheated steam (at 4.8MPa ,
1000C superheat), cooling the gas to 15 0C above the temperature of the generated steam. Then ,
three steps occur in recovering heat , concomitantly, reducing the water content: first, heat
recovery for use elsewhere in the process control; second, cooling by ambient air in an air cooler;
and third, use of cooling water to reduce the temperature of the synthesis gas to 350C. Condensed
water is separated from the gas in each of these steps and collected in a condensate drum. With
much of the water now removed, the product can properly be referred to as synthesis gas. The
make-up gas (MUG) compressor increases the pressure of the synthesis gas from 1.6 MPa to 7.5
MPa in two stages , so that it can be injected into the converter loop. Between compressor stages,
cooling water is used to reduce the temperature of the gas to 1000C, and any condensate formed
is removed. The compressed synthesis gas is introduced into the converter loop, where it is
combined with recycle gas.
The converter loop consists of a recycle compressor , whose primary purpose is to provide the
pressure required for the gas to flow through the system, the methanol synthesis reactor (MSR) ,

heat exchangers , a methanol condenser , and a gas-liquid separator (flash drum). The mixture
that is to become the feed to the MSR consists of recycle gas and fresh synthesis gas. After the
recycle gas and fresh synthesis gas are blended, the mixture flows through the recycle
compressor and then is heated to 130C 0C by a partially cooled product stream leaving the MSR.
The recycle compressor is sized to circulate the recycle stream at a rate that is 7.8 times the rate
at which fresh synthesis gas is fed to the converter loop. The blended recycle-fresh feed mixture
leaving the heat exchanger following the compressor is split into two streams : one, containing
30% of the mixture , is sent to another heat exchanger where its temperature is raised to 220oC
by a fraction of the product stream from the MSR and injected into the first stage of the MSR :
the remaining 70% , which is still at 1300C , is injected at various location along the MSR.
The key reactions in the MSR are :
CO2 + 3H2

CH3OH + H2O

CO + 2H2

CH3OH

The product gas leaving the MSR is partially cooled by being split into two streams each of
which passes through a heat exchanger before being recombined ; one is used to heat the feed
stream to the first stage of the MSR to 2200C , and the other passes through a waste heat
recovery unit. The recombined product stream is cooled further in an air-cooled exchanger before
being brought to 350C by cooling water. At 350C ,a liquid consisting of the condensed methanol
and dissolved gases is separated from the gas stream in a flash drum and sent to a methanol
purification column. The uncondensed gases are split , with a portion being purged from the
system and the remainder forming the recycle gas that is blended with fresh synthesis gas to form
the feed to the recycle compressor. After the condensed crude methanol is recovered in the high
pressure separator, it is sent to a methanol purification column. Typically, methanol purification
requires two columns, one to remove the light ends ( mainly by-products generated in the
methanol synthesis reactor such as dimethyl ether and dissolved gases ) and another to separate
methanol and water and any other by-products with a lower volatility than methanol.
Specification- grade methanol (99% mole fraction) is recovered as the overhead product of the
heavy ends column and sent to storage.

Process block diagram for natural gas processing

(a) CO2 removal process
Acid

Reflux
Accumulato
r

Sweet
gas

Absorb
er

Regenerat
or
Lean
MEA

Recyc
le
pump

Lean-rich
Heat
Fuel Gas

MEA

Flash

Sour
gas

Separa
tor

Rich
MEA

pum

tank

Liquid
Make-up

(b) NGL recovery process

Expander

Cold
Separat
or

Gas to Gas
heat
exchanger

Separator

Propane
chiller

Gas to
Gas

Sweet

Demethani
zer

Heat
exchange

Compressor

Processed

Process Block diagram for methanol production

NGL
product

Secondar
y
Reformer
Primary
Reformer

Natural gas

Synthesis
gas

Preheater

WSG

Methanol
Stea
Converter
Combustion
air
m

Synthesis
Reactor

Produc
Recycle
t

Water
Gas
Shift
Convert
Condenser
Compres
DS
Gas
Distillation
sor
&
Separator
Column
Separator
PurgeMethano
Condensat
Waste

Process Flowsheet

91
89
99
88

E517
E514
86

84

VLV611

90
E515

97

64

67

98

101

D610

95

87

69
G440

76

81

82

73
E431

92

74
62

H421
59

E411

61

66

H430

78
H451

H420
71

70
58

107

H410
63

65

E516
83

G511
B11

H450

77

D620

96
93

80

79

68

100

R510

G512

E513

75
B84
72

56
60
57
E331

94
R330A
106
103

53

R330

E221
52

49

39

R320

51

G220

50

40
47

E321
G220A

VLV312

42
G216
38

45

41

32

48

46

54

E313
R310

33

E214
44

H215

55

E217

27

34
25

VLV114
D210
20

22

21
E211

24
E212

31
E218

H213

14

29

37

30
104

26

36
43
35

13

19

H122

E121
10

15
L123

4
D120

E1

E112

16

D110

E130
105

11

L124
3

7
8

Q314

18

H113
H111

17

12

Material and Energy balance

102

1.
MS2
1993 kmol/h

Methane 96.65%
Ethane 1.6%
Propane 0.35%
i-Butane 0.10%
n-Butane 0.08%
i-Pentane 0.04%
n-Pentane 0.03%
n-Hexane 0.03%
n-Heptane 0.06%
CO2 0.72%
Nitrogen 0.35%
@ 25 , 7000kPa

MS1

V-100

2000 kmol/h
Methane 96.48%
Ethane 1.6%
Propane 0.35%
i-Butane 0.10%

MS3
7 kmol/h

n-Butane 0.08%

Methane 46.72%

i-Pentane 0.05%

Ethane 3.71%

n-Pentane 0.04%

Propane 1.06%

n-Hexane 0.05%

i-Butane 0.86%

n-Heptane 0.19%

n-Butane 1.07%

CO2 0.72%

i-Pentane 1.6%

Nitrogen 0.35%

n-Pentane 1.91%

@ 25 , 7000kPa

n-Hexane 5.75%
n-Heptane 36%
CO2 0.83%
Nitrogen 0.04%
@ 25 , 7000kPa

2.
MS4 ( @ 25 , 7000kPa)

7450 kmol/h

E-100

MS5 ( @ 46.35 , 7000kPa)

1500 kmol/h

MEAmine 100%

Methane 97.35%

MS2

Ethane

0.18%

1993 kmol/h

MEAmine 0.0045

Methane 96.65%

CO2

Ethane 1.6%

Nitrogen 0.45%

0.40%

Propane 0.35%
i-Butane 0.10%

MS6

n-Butane 0.08%

7943 kmol/h

i-Pentane 0.04%

Methane 5.86%

n-Pentane 0.03%

Ethane 0.06%

n-Hexane 0.03%

Propane 0.08%

n-Heptane 0.06%

i-Butane 0.02%

CO2 0.72%

n-Butane 0.02%

Nitrogen 0.34%

i-Pentane 0.01%

@ 25 , 7000kPa

n-Pentane 0.008%
n-Hexane

0.0075%

n-Heptane 0.016%%
MEAmine 94%
CO2 0.11%%
Nitrogen 0.0007%
@ 45.5 , 7000kPa

3.

MS7
280.5 kmol/h

Methane 97.35%
Ethane 1.2%
Propane 0.25%
i-Butane 0.04%
n-Butane 0.03%
i-Pentane 0.009%
n-Pentane 0.005%
n-Hexane 0.002%
n-Heptane 0.002%
CO2 1.1%
Nitrogen 0.02%
MEAmine 0.009%
@ 44.73 , 3000kPa

MS6

7943 kmol/h
Methane 5.85%

V-101

Ethane 0.06%

MS8

Propane 0.08%

7662 kmol/h

i-Butane 0.02%

Methane 2.5%

n-Butane 0.02%

Ethane 0.02%

i-Pentane 0.01%

Propane 0.08%

n-Pentane 0.008%

i-Butane 0.02%

n-Hexane 0.0075%

n-Butane 0.02%

n-Heptane 0.015%

i-Pentane 0.01%

CO2 0.11%

n-Pentane 0.0085%

Nitrogen 0.0007%

n-Hexane 0.008%

MEAmine 94%

n-Heptane 1.6%

@ 45 , 7000kPa

CO2 0.07%
MEAmine 97.23%
@ 44.73 , 3000kPa

4.
MS 11

E-101

MS 4

7450 kmol/h

MEAmine 100%
@ 234.9 , 7000kPa

7450 kmol/h

MEAmine 100%
@ 45 , 7000kPa

5.
MS 10

MS 11

E 100

7450 kmol/h

MEAmine 100%

7450 kmol/h

MEAmine 100%

@ 263 , 7000kPa

MS 8

@ 235 , 7000kPa

MS 9

7662 kmol/h

7662 kmol/h

Methane 2.5%

Methane 2.5%

Ethane 0.02%

Ethane 0.02%

Propane 0.08%

Propane 0.08%

i-Butane 0.02%

i-Butane 0.02%

n-Butane 0.02%

n-Butane 0.02%

i-Pentane 0.01%

i-Pentane 0.01%

n-Pentane 0.0085%

n-Pentane 0.0085%

n-Hexane 0.008%

n-Hexane 0.008%

n-Heptane 1.6%

n-Heptane 1.6%

CO2 0.07%

CO2 0.07%

MEAmine 97.23%

MEAmine 97.23%

@ 44.73 , 3000kPa

@ 82.22 , 1000kPa

6.

MS 14

MIX-100

7450 kmol/h
MS 10

MEAmine 100%

7450 kmol/h

@ 263 , 7000kPa

MEAmine 100%
@ 263 , 7000kPa

MS 15

0.4275 kmol/h
MEAmine 100%
@ 25 , 7000kPa

7.
MS 9

MS 12

7662 kmol/h

420 kmol/h

Methane 2.5%

Methane 46%

Ethane 0.02%

Ethane 0.35%

Propane 0.08%

Propane 1.5%

i-Butane 0.02%

i-Butane 0.44%

n-Butane 0.02%

n-Butane 0.36%

i-Pentane 0.01%

i-Pentane 0.22%

n-Pentane 0.0085%

n-Pentane 0.17%

n-Hexane 0.008%

n-Hexane 0.17%

n-Heptane 1.6%
CO2 0.07%

T-101

n-Heptane 0.45%
CO2 1.26%

MEAmine 97.23%

MEAmine 49%

@82.22, 1000kPa

@228.3, 1000kPa

MS 20

MS 13

207 kmol/h

7450 kmol/h

Methane 0.07%

MEAmine 100%

Ethane 0.004%

@260.4, 1000kPa

Propane 0.048%
i-Butane 0.02%
n-Butane 0.03%
i-Pentane 0.03%
n-Pentane 0.03%
n-Hexane 0.065%
n-Heptane 0.32%
CO2 0.006%
MEAmine 99.37%
@ 25 .3 , 1000kPa

8.
MS 16

MS 12

420 kmol/h

212 kmol/h

Methane 46%
Ethane 0.35%

Methane 90.68%
V-102

Ethane 0.69%

Propane 1.5%

Propane 3%

i-Butane 0.44%

i-Butane 0.85%

n-Butane 0.36%

n-Butane 0.68%

i-Pentane 0.22%

i-Pentane 0.41%

n-Pentane 0.17%
n-Hexane 0.17%
n-Heptane 0.45%

n-Pentane 0.31%
n-Hexane 0.28%
n-Heptane 0.59%

CO2 1.26%

CO2 2.5%

MEAmine 49%

MEAmine 0.076%

@25, 100kPa

Nitrogen 0.0005%
@25, 90kPa
MS 18
207 kmol/h
Methane 0.07%
Ethane 0.0004%

Propane 0.05%
i-Butane 0.02%
n-Butane 0.03%
i-Pentane 0.03%
n-Pentane 0.03%
n-Hexane 0.06%
n-Heptane 0.31%
CO2 0.006%
MEAmine 99.4%
@ 25 , 90kPa

9.
MS 22

MS 23

1500 kmol/h

1499 kmol/h

Methane 97.35%
Ethane 1.8%
CO2 0.4%
MEAmine 0.0045%
Nitrogen 0.45%

Methane 97.39%
V-103

Ethane 1.8%
CO2 0.36%
Nitrogen 0.45%
@ -150, 1000kPa

@ -150, 1000kPa
MS 24
0.52 kmol/h
Methane 0.69%
Ethane 0.23%
Propane 0.007%

CO2 86%
MEAmine 13%
@ -150 , 1000kPa

10.
MS 25

MS 26

1499 kmol/h

1459 kmol/h

Methane 97.39%
Ethane 1.8%

Methane 99.5%
V-104

CO2 0.36%

Nitrogen 0.5%
@ -175, 1000kPa

Nitrogen 0.45%
@ -175, 1000kPa

MS 27
40.5 kmol/h
Methane 19.8%
Ethane 66.3%
CO2 13.65%
Nitrogen 0.11%
@ -175 , 1000kPa

11.

MS 29

MS 31

T-102

1459 kmol/h

1470 kmol/h

Methane 99.5%

Methane 99.34%

Nitrogen 0.5%

Ethane 0.20%

@ -140 , 800kPa

Nitrogen 0.46%
@ 175.5 , 689.5kPa

MS 37

MS 32

41 kmol/h

7662 kmol/h

Methane 19.65%
Ethane 65.5%

Ethane 79.8%

CO2 14.56%

CO2 19.9%

MEAmine 0.16%
Nitrogen

MEAmine 0.22%

0.11%

@ -150 , 1000kPa

@ -173.6 , 689.5kPa

12.
MS 41

MIX-102

4500 kmol/h
MS 43

H2O 100%
@ 210 , 1600kPa

5970 kmol/h
Methane 24.46%
Ethane 0.05%

H2O 75.37%
MS 94

1470 kmol/h

Nitrogen 0.11%

Methane 99.34%
Ethane 0.20%
Nitrogen 0.46%
@ 114.6 , 1600kPa

13.
MS 44

MS 45

5970 kmol/h

7408 kmol/h

Methane 24.46%
Ethane 0.05%

Methane 0.0075%
ERV-100

CO 13%

H2O 75.37%

H2O 47.69%

Nitrogen 0.11%

Hydrogen 39.15%

@ 450, 1600kPa

Nitrogen 0.09%
@ 690, 20kPa
MS 27

MS 46
496 kmol/h
Methane 99.4%
Ethane 0.6%
CO 0.007%
Hydreogen 0.0005
Nitrogen 0.0002%
@690 ,20kPa

14.
MS 45

MS 47

7408 kmol/h

25100 kmol/h

Methane 0.0075%
CO 13%
H2O 47.69%
Hydrogen 39.15% %

Ethane 0.011%
CRV-100

CO 3.85%
CO2 1.96%
H2O 18%

Nitrogen 0.09%

Nitrogen 54%

@ 690, 20kPa

Hydrogen 11.5%
Oxygen 10.5%
@ 700, 20kPa

MS 46
MS 48
496 kmol/h
Methane 99.4%
Ethane 0.6%
CO 0.007%

0 kmol/h

Hydreogen 0.0005
Nitrogen 0.0002%
@690 ,20kPa
MS 119
17200 kmol/h

Oxygen 21%
Nitrogen 79%

@ 544 , 101.3kPa

15.
MS 47

MS 51

25100 kmol/h

25110 kmol/h

Ethane 0.011%

CO 3.85%

CO 3.85%

CO2 1.96%

CO2 1.96%

CRV-102

H2O 18%

H2O 18%

Hydrogen 11.5%

Hydrogen 11.5%

Oxygen 10.5%

Oxygen 10.5%

Nitrogen 54%

Nitrogen 54%

@ 702, 20kPa

@ 700, 20kPa
MS 52
0 kmol/h

16.
MS 54
25110 kmol/h

MS 51
25110 kmol

CO 3.85%

CO 0.04%

CO 3.85%

CO2 5.8%

CO2 1.96%

ERV-101

H2O 14.22%

H2O 18%

Hydrogen 15.36%

Hydrogen 11.5%

Oxygen 10.4%

Oxygen 10.5%

Nitrogen 54%

Nitrogen 54%

@ 220, 20kPa

@ 700, 20kPa
17.
MS 54

MS 60

25110 kmol/h

25110 kmol
CO 0.0008%

CO 3.85%
CO2 1.96%

CO2 5.84%
ERV-101

H2O 14.2%

H2O 18%

Hydrogen 15.4%

Hydrogen 11.5%

Oxygen 10.4%

Oxygen 10.5%

Nitrogen 54%

Nitrogen 54%

@ 80, 20kPa

@ 200, 20kPa

18.
MS 62
25110 kmol/h
CO 0.0008%

MS 63
V-105

25110 kmol
CO 0.0008%

CO2 5.84%

CO2 5.84%

H2O 14.2%

H2O 14.2%

Hydrogen 15.4%

Hydrogen 15.4%

Oxygen 10.4%
Nitrogen 54%

Oxygen 10.4%

@ 40, 20kPa

Nitrogen 54%
@ 80, 20kPa

19.
MS 75

MS 78

32360 kmol/h

29020 kmol/h

CO 0.0008%
CO2 6%
H2O 18%

CO 0.0009%
V-108

CO2 6.73%
Hydrogen 17.8%

Hydrogen 16%

Oxygen 12%

Oxygen 11%

Nitrogen 62.5%

Nitrogen 56%

H2O 1%

@ 50, 1200kPa

@ 50, 1200kPa
MS 80
3320 kmol/h
CO2 0.03%
H2O 99.88%
Hydrogen 0.003%
Oxygen 0.02%
Nitrogen 0.06%

@ 50, 1200kPa

20.

MS 78

MS 79

29020 kmol/h

21760 kmol/h

CO 0.0009%
CO2 6.73%
H2O 1%
Hydrogen 17.8%
Oxygen 12%
Nitrogen 62.5%
@ 50, 1200kPa

CO 0.0009%
TEE-100

CO2 6.73%
Hydrogen 17.8%
Oxygen 12%
Nitrogen 62.5%
H2O 1%
@ 50, 1200kPa
MS 81
7254 kmol/h
CO 0.0009%
CO2 6.73%
H2O 1%
Hydrogen 17.8%

Oxygen 12%
Nitrogen 62.5%
@ 50, 1200kPa

21.
MS83

MS 84

MIX-104

21760 kmol/h

159900 kmol/h

CO 0.0009%

CO

CO2 6.73%

CO2 2.56%

H2O 1%

H2O 0.15%

Hydrogen 17.8%

Hydrogen 4%

Oxygen 12%

Oxygen 0.15

Nitrogen 62.5%

Methanol 0.06%

@85 ,1600 kPa

0.0003%

Nitrogen 78.5%
@20.5 ,1600 kPa a
MS 109

138100 kmol/h
CO 0.0002%
CO2 1.9%
H2O 0.008%

Hydrogen 1.8%
Oxygen 15%
Nitrogen 81%
Methanol 0.07%
@10 ,7500 kPa

22.
MS 86

MS 89

159900 kmol/h

63960 kmol/h

CO 0.0003%
CO2 2.56%

CO 0.0003%
TEE-101

CO2 2.56%

H2O 0.15%

H2O 0.15%

Hydrogen 4%

Hydrogen 4%

Oxygen 0.15%

Oxygen 0.15%

Methanol 0.06%
Nitrogen 78.5%
@ 220, 7500kPa

Methanol 0.06%
Nitrogen 78.5%
@ 220, 7500kPa
MS 90
95930 kmol/h
CO 0.0003%
CO2 2.56%
H2O 0.15%

Hydrogen 4%
Oxygen 0.15%
Methanol 0.06%
Nitrogen 78.5%
@ 220, 7500kPa

23.
MS 90

MS 95

95930 kmol/h

91170 kmol/h

CO 0.0003%
CO2 2.56%

CO 0.0003%
ERV-104

CO2 1.4%

H2O 0.15%

Hydrogen 0.34%

Hydrogen 4%

Oxygen 0.15%

Oxygen 0.15%

Nitrogen 82.5%

Methanol 0.06%

Methanol 0.15%

Nitrogen 56%
@ 50, 7500kPa

H2O 0.03%
@ 28, 7500kPa
MS 96
2398 kmol/h
CO2 0.07%
H2O 53.8%
Hydrogen 0.001%

Oxygen 0.035%
Methanol 45.96%
Nitrogen 0.06%
@ 28, 7500kPa

24.
MS 97
63850 kmol/h
CO2 2.56%

MIX-105

MS 85
155000 kmol/h
CO 0.0002

H2O 0.01%

CO2 1.88%

Hydrogen 4%

H2O 0.025%

Oxygen 0.14%

Hydrogen 1.85%

Methanol 0.03%

Oxygen 15.17%

Nitrogen 78.6%

Methanol 0.1%

@ 102.5, 7500kPa

Nitrogen 80.96%
@ 58.88, 7500kPa

MS 96
91170 kmol/h
CO 0.003%
CO2 1.4%

H2O 0.03%
Hydrogen 0.34%
Oxygen 15.48%
Methanol 0.15%
Nitrogen 82.6%
@ 28, 7500kPa

25.
MS 91

MS 92

63960 kmol/h
CO2 2.56%

63850 kmol/h
ERV-103

CO2 2.56%

H2O 0.15%

Hydrogen 4%

Hydrogen 4%

Oxygen 0.15%

Oxygen 0.15%

Nitrogen 78.6%

Methanol 0.06%

Methanol 0.03%

Nitrogen 78.5%

H2O 0.01%

@ 130, 7500kPa

@ 10, 7500kPa
MS 93
104.3 kmol/h
CO2 0.18%
H2O 81.82%
Hydrogen 0.008%
Oxygen 0.05%

Methanol 17.83%
Nitrogen 0.11%
@ 10, 7500kPa

26.
MS 104

MS 105

155000 kmol/h

155000 kmol/h

CO 0.0002%
CO2 1.88%
H2O 0.025%

CO 0.0002%
V-109

CO2 1.88%
Hydrogen 1.85%

Hydrogen 1.85%

Oxygen 15%

Oxygen 15%

Nitrogen 81%

Methanol 0.1%

Methanol 0.07%

Nitrogen 80.96%
@ 10, 7500kPa

H2O 0.008%
@ 10, 7500kPa
MS 106
74.46 kmol/h
CO 0.0002%
CO2 0.13%

H2O 35%
Hydrogen 0.01%
Oxygen 0.02%
Methanol 64.78%
Nitrogen 0.023%
@ 10, 7500kPa

27.
MS 104

MS 105

155000 kmol/h

15500 kmol/h

CO 0.0002%
CO2 1.88%

CO 0.0002%
TEE-102

CO2 1.88%

H2O 0.008%

Hydrogen 1.85%

Hydrogen 1.85%

Oxygen 15%

Oxygen 15%

Nitrogen 81%

Methanol 0.0%

Methanol 0.07%

Nitrogen 81%
@ 10, 7500kPa

H2O 0.008%
@ 10, 7500kPa
MS 108
139500 kmol/h
CO 0.0002%
CO2 1.88%
H2O 0.008%

Hydrogen 1.85%
Oxygen 0.15%
Methanol 0.07%
Nitrogen 81%
@ 10, 7500kPa

28.
MS 93
104.3 kmol/h

MIX-106

MS 110
2577 kmol/h

CO2 0.18%

CO2 0.07%

H2O 81.82%

H2O 54.46%

Hydrogen 0.008%

Hydrogen 0.002%

Oxygen 0.05%

Oxygen 0.035

Methanol 17.83%

Methanol 45.36%

Nitrogen 0.11%
@10 ,7500 kPa
,1600 kPa

MS 96
2398 kmol/h
CO2 0.07%
H2O 53.87%

Nitrogen 0.06%
@26.81

Hydrogen 0.001%
Oxygen 0.035%
Nitrogen 0.06%
Methanol 45.96%
@28 ,7500 kPa

MS 106
74.46 kmol/h
CO 0.0002%
CO2 0.13%
H2O 35%
Hydrogen 0.01%
Oxygen 0.02%
Methanol 64.78%
Nitrogen 0.023%
@ 10, 7500kPa

List of Major Equipments

Equipment Name

Absorber

Equipment
Designation
V100
V102
V103
V104
V105
V106
V107
V108
V109
T100

Distillation Colum

T101

Separator

No of equipment
8

T102
T103
T104

Reactor

Equilibri

ERV100

Capacity
1500 kmol/h
420 kmol/h
1124 kmol/h
1124 kmol/h
26700 kmol/h
26450 kmol/h
26330 kmol/h
33720 kmol/h
211400 kmol/h
1124 kmol/h gas
5970 kmol/h liquid
420 kmol/h gas &
5600 kmol/h liquid
1100 kmol/h gas &
24.24 kmol/h liquid
60.46 kmol/h gas &
1080 kmol/h liquid
407.3 kmol/h gas &
607.76 kmol/h
liquid

um
Reactor

Conversi
on
Reactor
Heat Exchanger

ERV101
ERV102
ERV103
ERV104
3

CRV100
CRV101
CRV102

18

E100
E101
E102
E103
E104
E105
E106
E107
E108
E109
E110
E111
E112
E113
E114
E115
E116
E117

4.207 10

kJ/h
6

-3.836 10

-3.754 10

-1.439 10

-6.844 10
5

4.349 10

1.185 10

5.276 10

4.457 10

kJ/h

1.664 10

kJ/h
kJ/h

kJ/h

8.770 10

kJ/h

4.086 10

kJ/h
8

-2.342 10

-2.804 10

-3.185 10

Compressor &

6000 kPa
910 kPa
-200 kPa

kJ/h

kJ/h

1.881 10

P100
P101
K100

kJ/h

kJ/h

kJ/h

kJ/h

4.876 10

Pump

kJ/h

kJ/h
kJ/h
kJ/h

Expander

K101
K102
K103
K104
K105

List of Vendors
For Heat Exchangers
-

Heat-Exchanger USA, McDonough, GA

30 kPa
1570 kPa
400 kPa
5900 kPa
880.8 kPa

Industrial Heat Transfer,Inc., Coon Valley, WI

PRE-HEAT,Inc.,Oostburg,WI
Ambassador Heat Transfer Company, Cincinatti, OH
JFD Tube & Coil Products,Inc.,Hamden
Yula Corporation,Bronx,NY

For Pumps
-

Afton Pumps
AKAY Industries B.V.
AlfaLaval
Ruhrpumpen
PumpEng
PACO Pumps
Magnatex
Layne / VertiLine

For Compressor/Expander
-

ATLAS COPCO, SWITZERLAND

BORSIG GMBH, GERMANY
DRESSER RAND, FRANCE
ELLIOTT TURBOMACHINERY LTD. UK,
INGERSOLL RAND CO. LTD., UK
KKK, GERMANY
LMF AG, AUSTRIA
MANNESMANN DEMAG DELAVAL,GERMANY

For Distillation and Absorption Column

-

Excel Plants & Equipment Pvt Ltd

Chem Dist Process Solutions
Rufouz Hitek Engineers Pvt. Ltd.
MaletaCD
Buflovak,LLC-Buffalo,NY
Fabco Products,Inc.-Hawkins,TX
Koch-Glitsch
Vessco

For Process Reactor

-

Zhengzhou Keda Machinery and Instrument Equipment Co., Ltd

Atlas
RamTech
Parr Instrument Company
Ace Apparatebau construction & Engineering GmbH
MAN DWE GmbH
Michael Glatt Maschinenbau Gmbh

Design of Gas (Vapor)-Liquid Separators" and should be amended with the

following selection and design criteria:

a) Selection criteria
a.1) Orientation

In general, a vertical vessel is preferred for gas/liquid separation for the following
reasons:
- when the gas/liquid ratio is high;
- a smaller plan area is required (critical on offshore platforms);
- easier solids removal;
- liquid removal efficiency does not vary with liquid level;
- vessel volume is generally smaller.
However, a horizontal vessel should be chosen if:
- large volume of total fluid is available;
- large amount of dissolved gas is available;
- large liquid slugs have to be accommodated;
- there is restricted head room;
- a low downward liquid velocity is required (for degassing purposes, foam
breakdown or
in case of a difficult liquid/liquid separation).
a.2) Components
Following the gas/liquid flow path through the separator, the following parameters
should be identified:

- Feed inlet

This comprises the upstream piping, inlet nozzle, and the inlet devices (if any).
The diameter of the inlet nozzle is a function of the feed flow rate and pressure.
The criterion for the nozzle sizing is that the momentum of the feed shall not
exceed prescribed levels. The maximum allowable inlet momentum can be
increased by applying inlet devices.
The function of the inlet device is to initiate the gas/liquid separation and to
distribute the gas flow evenly in the gas compartment of the vessel.
Commonly used inlet devices are the half-open pipe and their specific proprietory
inlet devices designed for introducing gas/liquid mixtures into a vessel or column.
- Separator internals
In knock-out vessels the diameter should be selected sufficiently large to keep the
gas velocity low at which the major portion ofthe droplets could be settled by
gravity.
In all other types of gas/liquid separators, internals should be considered, for
selection the required duty, wire mesh, vane-pack (either horizontal or vertical
flow), multicyclones axial or reversed flow, filter candles, etc. should be studied.
- Gas and liquid outlets
After completion of the gas/liquid separation process the two phases will leave the
vessel via the gas and liquid outlet respectively.
- Gas handling capacity

The separator shall be large enough to handle the gas flow rate under the most
severe process conditions. The highest envisaged gas flow rate should be
determined by including a margin for surging, uncertainties in basic data. This
margin is typically between 15 and 50%, depending on the application.
- Selection strategy
1) Gas handling capacity:
- max. capacity (gas load factor);
- turndown ratio.
2) Liquid removal efficiency:
- overall;
- with respect to fine mist;
- with respect to the possible flooding above the maximal load factor (which will
affect the sharpness of the efficiency decline above the maximum capacity).
3) Liquid handling capacity:
- slugs;
- droplets.
4) Fouling tolerance:
- sand;
- sticky material.
5) Pressure drop:

The following selection strategy is suggested:

First define the mandatory requirements which the separator shall satisfy. Check,
whether there are limitations which will rule out horizontal or vertical vessels.
b) Design criteria
b.1) General
Unless explicitly stated otherwise, both the maximum gas and liquid flow rates
should contain a design margin or surge factor
b.2) Vertical and horizontal separators
Specific indication to process application, characteristics, recommended and nonrecommended use of various vertical/horizontal separators used in OGP production
plants are given hereunder for design consideration:
- Vertical Knock-Out Drum
Application:
- Bulk separation of gas and liquid.
Characteristics:
- unlimited turndown;
- high slug handling capacity;
- liquid removal efficiency typically 80-90% (ranging from low to high liquid
load).
- Warning: Liquid removal efficiency for mist is very poor

- very low pressure drop;

- insensitive to fouling.
Recommended use:
- vessels where internals have to be kept to a minimum (e.g., flare knock-out
drums);
- fouling service e.g., wax, sand, asphaltenes;
- foaming service.
Non-recommended use:
where efficient demisting of gas is required.
Typical process applications:
vent and flare stack knock-out drums;
production separator;
bulk separator (e.g., upstream of gas coolers);
flash vessel.
- Horizontal Knock-Out Drum
Application:
Bulk separation of gas and liquid.
Characteristics:
can handle large liquid fractions;

 unlimited turndown;
very high slug handling capacity;
liquid removal efficiency typically 80-90% (ranging from low to high liquid
load).
- Warning: Liquid removal efficiency for mist is very poor
insensitive to fouling;
very low pressure drop.
Recommended use:
vessels where internals have to be kept to a minimum and where there are height
limitations;
slug catchers;
fouling service, e.g., wax, sand, asphaltenes;
for foaming or very viscous liquids.
Non-recommended use:
where efficient demisting of gas is required.
Typical process applications:
vent and flare stack knock-out drums;
production separator-low GOR;
bulk separator;

 slug catcher.
- Vertical Wire Mesh Demister
Application:
demisting of gas.
Characteristics:
high turndown ratio;
high slug handling capacity;
liquid removal efficiency > 98%;
sensitive to fouling;
low pressure drop.
Recommended use:
for demisting service with a moderate liquid load;
where slug handling capacity may be required.
Non-recommended use:
fouling service (wax, asphaltenes, sand, hydrates);
for viscous liquids where degassing requirement determines vessel diameter;
for compressor suction scrubbers unlessprecautions are taken to prevent the
possibility of loose wire cuttings entering the compressor or plugging of the
demister mat increasing suction pressure drop.

Typical process applications:

production/test separator:
- moderate GOR;
- non-fouling;
inlet/outlet scrubbers for glycol contactors;
inlet scrubbers for gas export pipelines;
for small diameter and/or low pressure vessels, where extra costs of vane of SMS
internals cannot be justified.
- Horizontal Wire Mesh Demister
Application:
demisting of gas where a high liquid handling capacity is required.
Characteristics:
high turndown ratio;
very high slug handling capacity;
liquid removal efficiency > 98%;
sensitive to fouling;
low pressure drop.
Recommended use:
typically for demisting service with a high liquid load and low GOR;

 applied where slug handling capacity may be required;

for viscous liquids where liquid degassing requirement determines vessel
diameter;
in situations where head room is restricted;
for foaming liquids.
- Vertical Vane-Type Demister
Application:
demisting of gas.
Characteristics:
liquid removal efficiency > 96%;
moderate turndown ratio;
suitable for slightly fouling service (if without double-pocket vanes);
robust design;
sensitive to liquid slugs (in-line separator cannot handle slugs).
Recommended use:
typically for demisting service;
in-line separator to be used only with relatively low flow parameter (feed
< 0.01);
two-stage separator to be used if feed 0.01;

 attractive for slightly fouling service (if without double-pocket vanes);

may be used where demister mats may become plugged, i.e., waxy crudes.
Non-recommended use:
heavy fouling service (heavy wax, asphaltenes, sand, hydrates);
for viscous liquids where degassing requirement determines vessel diameter;
the in-line vertical flow vane pack separator shall not be used where liquid
slugging may occur or where feed 0.01;
if pressure exceeds 100 bar (abs), due to the consequent sharp decline in liquid
removal efficiency.
Typical process applications:
compressor suction scrubbers-where vane packs are preferred to demister mats
since their construction is more robust;
demisting vessels with slightly fouling service.
- Horizontal Vane-Type Demister
Application:
demisting of gas where a high liquid handling capacity is required.
Characteristics:
liquid removal efficiency > 96%;
moderate turndown ratio;

 suitable for slightly fouling service (if without double-pocket vanes);

high slug handling capacity;
robust design.
Non-recommended use:
heavy fouling service (heavy wax, asphaltenes, sand, hydrates);
if pressure exceeds 100 bar (abs).
Typical process applications:
production separator where GOR is low and the service is slightly fouling.
- Cyclone
Application:
demisting of gas in fouling service.
Characteristics:
liquid removal efficiency > 96%;
insensitive to fouling;
limited turndown ratio;
high pressure drop.
Recommended use:
typically for use in a fouling (e.g., coke-formation) environment and where a high
demisting efficiency is still required.

Non-recommended use:
if high pressure drop can not be tolerated.
Typical process application:
in oil refineries: Thermal Gas-Oil Unit (TGU);
Visbreaker Unit (VBU);
in chemical plants: Thermoplastic Rubber Plants.
- Vertical Multicyclone Separator
Application:
demisting and dedusting of gas in slightly fouling service and high pressure.
Characteristics:
liquid removal efficiency > 93%;
suitable for slightly fouling service (e.g., low sand loading);
high pressure drop;
compact separator;
sensitive to high liquid loading or slugs.
Recommended use:
typically for use in a slightly fouling environment where the gas pressure is
higher
than 100 bar (abs) and a compact separator is required.

Non-recommended use:
low gas pressure;
heavy fouling service (high sand loading will cause erosion);
high liquid loading;
slug;
when high liquid removal efficiency is required.
Typical process application:
wellhead separators;
primary scrubbers under slightly fouling service and when the liquid loading is
low;
compressor suction scrubbers if sand is present in the feed.
- Filter Separator
Application:
after-cleaning (liquid and solids) of already demisted gas when a very high liquid
removal efficiency is required.
Characteristics:
liquid removal efficiency > 99%;
very high pressure drop;
sensitive to high liquid loading or slugs;

 sensitive to fouling by sticky material.

Recommended use:
typically as a second-line gas/liquid separator to after-clean the gas stream exiting
from the first-line gas/liquid separator.
use filter candles with the flow from OUT to IN where solids are present.
use filter candles with the flow from IN to OUT where ultimate efficiency is
required and NO solids are present.
Non-recommended use:
heavy fouling (sticky material) service;
high liquid loading;
slugs.
Typical process application:
last demisting stage of natural gas prior to despatch for sale.

1.
2.
3.
4.
5.
6.
7.

UDHE METHANOL TECHNOLOGY

JACOBS METHANOL TECHNOLOGY
LURGI METHANOL TECHNOLOGY
MITSUBISHI GAS CHEMICAL METHANOL TECHNOLOGY
HALDOR TOPSOE METHANOL TECHNOLOGY
TOYO PROCESS
LINDE PROCESS

 Water treatment plant

Cooling tower
Steam generator/boiler
Electric power generator
Compressed air unit
Instrument air unit
Inert gas generation plant
Refrigeration plant
Flares and stack
Effluent treatment plant
Uninterrupted power supply
Facilities for support services
Laboratories
Maintenance shops
Garage and vehicular parking
Warehousing
Communication

 Utilities for housing colony

Area of application

No
.
1

Materials

2
3
4

Pressure Vessels
Fired Boiler
Process Furnace

Organization Issuing Codes and Standard

American Society for Testing and

Materials(ASTM),American Society of
Mechanical Engineers(ASME)
ASME
ASME
API

5
6

Welding Material
Shell and Tube Heat Exchanger

7
8
9
10

Surface Condensers
Cooling Tower
Storage Tank
Rotating Equipment(Centrifugal
Compressor,Reciprocating
Compressor,Blower,Turbine)
Refrigeration and Air Conditioning
Equipment

11

12
13
14
15
16
17
18
19

Pressure piping
Pressure Relieving System
Steel Structure
Building and Concrete Structure
Material Handling Facility
Electrical
Fire Protection and Safety
Safety

20

Corrosion Protection

ASME,American Welding Society(AWS)

Tubuler Exchanger Manufacturers
Association(TEMA),American Petroleum
Institute(API)
Heat Exchanger Institute(HEI)
Cooling Tower Institute(CTI)
API, ANSI
API

American Society of Heating Refrigeration

and Air Conditioning Engineering
(ASHRAE)
ANSI, National Plumbing Code (NPC)
API
ANSI
American Concrete Institute
CEMA,ANSI
National Electric Code,API,ANSI
National Fire Protection Association
Occupational Safety and Health
Administration
National Association of Corrosion Engineers

TECHNICAL INFORMATION
Gas/Liquid Separators
Application Data Sheet
Name: ________________________________________________ Date:
________________________________________________________
Title:
______________________________________________________________________________
___________________________________

Company:
______________________________________________________________________________
______________________________
Address:
______________________________________________________________________________
_______________________________
City: __________________________________________ State: _______ Zip:
__________________________________________________
Phone: _________________________________ Fax:
_______________________________________________________________________
E-Mail:
______________________________________________________________________________
_______
Equipment ID: H111
Product(s) of Interest
Cast ST and T Type Separators Fabricated L and T Type Separators Exhaust Heads
Cast LST Type Separators Receiver & Coalesce Type Separators Accessories
Air & Gas Drain Traps Air Vents
Application Parameters
Pipe Size: ___________ in ___________ mm
Flow Medium: Air Steam Natural Gas Other
___________________________________________________
Volumetric Flow: ___________ SCFM _______0.07____ MMSCFD ___________ NM3/hr
Weight Flow: _____________ lb/hr _____25390________ kg/hr
Average Molecular Weight:
_____________________________________19.5_____________________________________
_______
Minimum Operating Pressure: _______________ psig ___________ kg/cm2 ____70_____bar
Maximum Operating Temperature: ______________ F _____25__________ C

Flow Configuration Preference:

__Vertical Flow____

Design Pressure of Vessel: _________________ psig ___________ kg/cm2 _____70____bar

Design Temperature of Vessel: _________________ F ________25_______ C
Maximum Entrained Liquid: ______________ lb/hr ____________ gpm _______88.865_____
kg/hr
End Connections Required:

Threaded

Flanged

Socket Weld

125 lb 150 lb 300 lb Other

____________________________________________________________________
Materials of Construction:

Cast Iron

Carbon Steel

304L SS

316L SS

Other
______________________________________________________________________________
______________________