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TRAINING
SESSION
March 11, 2010
Course Outline
Overview
JV
Sweetening Methods
Process Flow Diagram / Specifications
General Operating and Design Considerations
Equipment
Metallurgy
Cost Considerations
Acid Gas Handling
Amine Workbook
Acid Gas Handling - Membranes
JM
OVERVIEW
Dry Lean
Gas
Sweet
Gas
Dehydration
(mol sieve,
glycol)
Dry Rich
Gas
Residue Gas
Compression
Spec
Gas
To Pipeline
HC Liquid
Recovery
(DPC, TE)
H2O
Sour, Wet
Gas
Recycle
Gas
LP Separation
HC Liquids
HC Liquid
Production
HC Liquid
Stabilization /
Fractionation
Compression
HP Separation
Sour H2O
To Disposal,
Reinjection, Treatment
NGL /
Stabilized
Condensate
To Pipeline or
Storage
Water
7 lb / MMSCF (US)
4 lb / MMSCF (Canada / Europe)
HC Dewpoint
15 32 F
H2S
CO2
< 2 mol%
CO2 / N2
< 2mol%
NGL
C3+
Stabilized Condensate
C5/C6+
SWEETENING
METHODS
Sweetening - Terminology
H2S
Hydrogen Sulfide
Gas Impurity
COS
Carbonyl Sulfide
Gas Impurity
CS2
Carbon Disulfide
Gas Impurity
CH3SH, C2H5SH
Mercaptans
Gas Impurity
EG
Ethylene Glycol
Dehydration
TEG
Triethylene Glycol
Dehydration
MEA
Monoethanolamine
Sweetening
DEA
Diethanolamine
Sweetening
MDEA
Monodiethanolamine
Sweetening
DGA
Diglycolamine
Sweetening
Sweetening - Methods
Chemical Absorption
Amines
Potassium Carbonate
Physical Absorption
Selexol, Methanol
Molecular Sieve
Non-Regenerative
Zinc Oxide
Expensive
SulfaTreat
(refined Iron Sponge)
NaOH
Product is NaSH
Direct Conversion
Membranes
Absorption Processes
Mixed or
Hybrid
Chemical
NaOH
DEA
Flexsorb
MEA
Physical
Water
Rectisol
(Methanol)
DGA
Sulfinol
Activated MDEA
(add DEA)
Selective MDEA
(proprietary additives)
Selexol
Amines
MEA
10 20 wt%
DEA
25 35 wt%
Similar to MEA
Reacts with COS and CS2
Removes H2S and CO2 (non-selective)
DGA
40 70 wt%
Proprietary designs
MDEA
30 50 wt%
Tertiary Amine
Proprietary designs
Reacts with H2S in presence of CO2 (selective)
Sulfinol D or M (Shell)
Proprietary Mixture of sulfolane, water and either DIPA (D) or MDEA (M)
MDEA Selectivity
Selectivity is improved by:
Colder Temperatures
Lower Pressures
Higher Ratios of CO2 to H2S
PFD
&
SPECIFICATIONS
Design Parameters
GAS FEED SPECIFICATIONS
PRODUCT SPECIFICATIONS
Estimation of MDEA
Circulation Rate
0.206 x MM x (H2S + CO2) x MWT
GPM =
ML x WT
GPM
MM
H2S
CO2
MWT
ML
WT
Estimation of MDEA
Circulation Rate
0.206 x MM x (H2S + CO2) x MWT
GPM =
ML x WT
=
0.30 x 50
218 GPM
GPM
MM
H2S
CO2
3.0%
MWT
119.9
ML
0.30
WT
50
44
120 ppm = 0.012%
GENERAL
OPERATING AND
DESIGN
CONSIDERATONS
Corrosion
Solution Degradation
Amine solutions will slowly oxidize when exposed to air. Products are
corrosive.
Minimized by gas blanketing amine storage
MEA / DGA react with COS to form insoluble salt (reclaiming to recover amine)
Some degradation products can not be regenerated
Foaming
Reclaiming
Batch operation
Distill the water and amine leaving behind entrained solids, dissolved salts and
degradation products that cause foaming and corrosion problems
Operates on 3% or less of the solution circulation rate
Sludge will accumulate below tubes
Not required on DEA and MDEA
Filtration
Extremely important
Removes iron sulfide
Filtration to 1 micron level
Full Stream filter used to remove particles to 10-25 micron
Sidestream (20% of circulation rate) activated charcoal filter to 1 micron
Activated carbon filter also removes hydrocarbons, some degradation
products, and reaction products
Full stream filter downstream of charcoal filter
Inhibitors
Foam Inhibitor
Corrosion Inhibitor
Extremely important
Minimizes foaming, corrosion, and reboiler tube burn-out issues
Removal of liquid hydrocarbons and entrained solids
Removal of upstream corrosion inhibitors and lube oil carryover
Amine Losses
Amine Regeneration
Piping Design
EQUIPMENT
Options
Separator with mesh pad
Porous Media coalescer
Peco filter separator
48 OD x 84 S/S
72 ID x 120 S/S
Contactor
48 ID x 660 S/S
72 ID x 768 S/S
Gas Cooler
48 OD
72 OD
200 GPM
72 ID x 192 S/S
650 GPM
Lean/Rich Exchanger
Typical Sizes:
50 GPM
2 MMBTU/HR
200 GPM
7.2 MMBTU/HR
650 GPM
15.5 MMBTU/HR
Amine Regenerator
Top Section
200 GPM
36 ID x 768 S/S
650 GPM
48 ID x 252 S/S
Bottom Section
84 ID x 612 S/S
50 GPM
1 MMBTU/HR
200 GPM
2.6 MMBTU/HR
650 GPM
17.6 MMBTU/HR
Reflux Accumulator
200 GPM
24 ID x 84 S/S
650 GPM
48 ID x 120 S/S
Reflux Pump
200 GPM
3 - 5 HP
650 GPM
5 HP
Regenerator Reboiler
50 GPM
3.6 MMBTU/HR
200 GPM
14.4 MMBTU/HR
650 GPM
46.8 MMBTU/HR
200 GPM
15 HP
650 GPM
50 HP
200 GPM
6.3 MMBTU/HR
650 GPM
28 MMBTU/HR
Particulate Filter
Charcoal Filter
200 GPM
18 OD x 56 OAH
42 OD x 49 S/S
650 GPM
36 OD x 60 S/S
84 OD x 264 S/S
50 GPM
50 HP
200 GPM
200 HP
650 GPM
500 HP
METALLURGY
METALLURGY
Reduce fluid velocity to < 6 ft/sec in rich amine carbon steel piping
Stainless steel in certain locations
Reboiler tubes
METALLURGY
For MDEA: PWHT for all carbon steel equipment, including piping, at operating
temperatures exceeding 180F
COST
CONSIDERATONS
%of
Total
$111,000
$271,000
$
$88,000
$52,000
$10,000
$171,000
$35,000
$18,500
$14,000
$65,000
$23,000
$62,000
$130,000
$20,000
$30,000
$335,000
7.7%
18.9%
0.0%
6.1%
3.6%
0.7%
11.9%
2.4%
1.3%
1.0%
4.5%
1.6%
4.3%
9.1%
1.4%
2.1%
23.3%
$1,435,500
100.0%
LOW SPEC
HIGH SPEC
Inlet Coalescer
Filters
Filters
Manual Valve
Reboiler
CS bundle
SS bundle
Reflux Condenser
CS tubes / header
SS tubes / header
Vessels / Shells
No corrosion allowance
1/8 CA
LOW SPEC
HIGH SPEC
SS Contactor LCV to Still Column
ACID GAS
HANDLING
Incineration
Flare
Incinerator / Thermal Oxidizer with Waste Heat Recovery Unit
Regenerative Thermal Oxidizer
Compression
Pumping
AMINE
WORKBOOK
ACID GAS
HANDLING
with MEMBRANES
Suppose Feed = 500 PSIA and 50% CO2. This = 250 PSIA Partial Pressure of
CO2
Suppose PERMEATE = 50 PSIA. Assuming high CO2%, CO2 partial pressure
on Permeate side may be about 45 PSIA
The difference between 250 PSIA and 45 PSIA of CO2 partial pressure drives
the CO2 across the membranes.
MEMBRANES
Typical CO2 membranes are applied with CO2 in Feed =15% and above
They work better at higher CO2% and higher Pressure in Feed Gas
Typically limited to about 400 PSIA CO2 Partial Pressure in feed
Typically limited to about 750 PSI differential pressure (Feed-Perm)
Typically limited to about 1200 PSI feed pressure. 700 PSI more common
Usually applied in moderate feed temperatures of +30 to +120 Deg F
Lower Feed Partial Pressures result in lower CO2% in Permeate Gas. This can
result in HC loss to permeate gas.
Membranes can be staged to reduce this HC loss, but needs more compression
MEMBRANES
Membranes applied in EOR projects usually have high CO2 Feed content. 35% to
>90% is typical. In this application, it is common to have about 10% CO2 in final
outlet HC gas.
Downstream DPC/NGL plants have Amine systems for the remaining10% CO2 in
their feed.
Common for EOR membrane plants to have permeate gas at 100 PSIA up to over
200 PSIA and to be 96%+ CO2 content. This usually needs compression to some
high reinjection pressure (1500# or more).
MEMBRANES
Membranes applied in pipeline sales gas applications are typically less than 10%
CO2 feed.
Outlet HC gas meet P/L Specs, usually CO2% = 2 to 3%
Note that 10% down to 2% is still a bulk removal.
Permeate Gas is lower CO2 content than EOR; typically 35 to 65% CO2.
Frequently this gas is compressed and permeated again to purify flared permeate
gas and recovers HCs (mostly methane) for lease fuel.
Usually NOT applied to meet an H2S spec.
Usually NOT applied to make a water content spec.
MEMBRANES
Membranes need significant pretreatment to protect membranes for long service life.
With proper pretreatment and operations, membranes can have up to a ten-year
service life but 3 to 6 years is more common service life.
Contaminants which may be harmful are:
MEMBRANES
MEMBRANES
Inlet Filter/Sep
Dehydrate to insure no liquid water and to allow carbon steel materials (dry
desiccant dehydration is common in large plants)
Dew Point to reduce C5+ to about 25-35 Deg F at feed pressure
Reheat to about 70 to 100 Deg F
MEMBRANES
BACKUP
SLIDES