Chapter 1

Introduction

A typical Gas Processing & Conditioning Plant

Chapter - 1 INTRODUCTION
is well recognized that nineteenth century was a century of coal that supported the initiation of industrial revolution in Europe. Twentieth century was the century of oil that was the prime energy source to support the growth of global economy but the demand of oil is ever increasing and energy disruptions should be a genuine concern. It may be possible that the world will face chronic energy shortage as early as 2010. The way to avoid such energy shortage is to expand energy supply and move from oil to natural gas, LPG as well as gas to liquid conversion (GTL). It is a historical imperative that the transition from oil to natural gas and LPG must be made in the early twenty-first century. This is not only motivated by environmental considerations but also technological innovations and sophistications.

It

Natural gas is a subcategory of petroleum that is a naturally occurring, complex mixture of hydrocarbons, with minor amount of inorganic compounds. Natural gas was once a by-product of crude oil production. Since its discovery in the United States in Fredonia, New York, in 1821, natural gas has been used as one of the major fossil energy sources. Because natural gas is petroleum in a gaseous state, it is always accompanied by oil that is liquid petroleum. There are three types of natural gases: non-associated gases, associated gases and gas condensate. Non-associated gas is from reservoirs with minimal oil. Associated gas is the gas dissolved in oil under natural conditions in the 1

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Introduction

oil reservoir. Gas-condensate refers to gas with high content of liquid hydrocarbon at reduced pressures and temperatures. Hydrocarbon reservoirs can be classified as gas well, condensate wells and oil wells. Gas wells are wells with producing gas-oil ratio (GOR) greater than 100,000 scf/stb; condensate wells are those with producing GOR less than 100,000 scf/stb but greater than 5,000 scf/stb; and well with producing GOR less than 5,000 scf/stb are classified as oil wells. This project is associated with handling of rich gas produced from gas-condensate reservoir, particularly dealing with recovery of LPG from natural gas liquids recovered from rich gas.

GAS PROCESSING
Natural gas to be transported by pipeline must meet certain specifications. In addition to specification regarding delivery pressure, rate and temperature, other specifications include maximum water contents (water dew point), maximum condensable hydrocarbon content (hydrocarbon dew point), and allowable concentration of contaminants such as H2S, CO2, Mercaptans, minimum heating value and cleanliness (allowable solid contents). Natural Gas from the well must be processed as soon as possible after bringing it to the surface. Field processing consists of following four basic processes: 1. Separation of gas from free liquids such as crude oil, hydrocarbon condensate, water and entrained solids 2. Natural Gas Dehydration (removal of condensable water vapors) 3. Natural Gas Purification (removal of acid gases; CO2, H2S) 4. Hydrocarbon Dew Point Control (removal condensable and recoverable hydrocarbon vapors) Separation of Gas and Liquids Separation of well stream gas from free liquids is the first and most critical stage of field processing operation. Composition of the fluid mixture determines the type of separator required. However, pressure is another key factor affecting selection of separators. Three types of separators are generally available from manufacturers: vertical, horizontal and spherical separators. Selection of separator type is based on several factors including characteristics of the production stream to be treated, floor space availability at the facility site, transportation and cost. Most separators work based on gravity segregation and/ or centrifugal segregation. Natural Gas Dehydration Water vapor is probably the most common undesirable impurity in the gas stream. Usually, it is not the water vapor itself that is objectionable, but rather the liquid or solid phase that may precipitate from the gas when it is compressed or cooled. Liquid 2

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Introduction

water always accelerates corrosion, and ice (or solid hydrates) can plug valves, fittings and even gas transmission lines. The quantity of water in saturated natural gas at various pressures can be estimated from the correlation chart developed by McKetta and Wehe in 1958. The water vapor contents in saturated natural gas are also affected by gas composition. The presence of substantial concentration of CO2 and H2S increases the equilibrium water concentration, particularly at pressures above 1000 psia. Commercial processes for removing water vapors from gas streams can be classified as follow: 1. Absorption by Hygroscopic Liquids (Tri-ethylene Glycol is the most common hygroscopic liquid used for this application) 2. Adsorption by Activated Solid Desiccants (Mostly Silica bases desiccants are used) 3. Condensation by Cooling and/ or Compression The first two are the most commonly used methods for gas dehydration. Third method is primarily mechanical and is normally economical only under special circumstances. At most of the places the maximum allowable water contents in sales gas are less than 7 lbs/ MMscf of natural gas. Natural Gas Purification In addition to heavy hydrocarbon and water vapor, natural gas often contains other contaminants that should be removed before any domestic or commercial use. CO2, H2S, and other sulfur compounds such as Mercaptans require complete or partial removal. These compounds are known as Acid Gases. H2S combined with water forms weak form of Sulfuric Acid, while CO2 and water forms Carbonic Acid. Natural gas with H2S and other Sulfur compounds is called Sour Gas, while gas with only CO2 is called Sweet Gas. Both CO2 and H2S are undesirable as they cause corrosion and reduce heating value of the natural gas. In general, sales gas contracts limit the concentration of these acid gases as CO 2 up to 3 mole% and 0.25 grains per 100 standard cubic feet (scf) of H2S. Numerous processes have been developed for gas sweetening based on a variety of chemical and physical principles. These processes can be categorized by the principles used in the process of separating acid gases from natural gas. The processes are as follow: 1. Solid Bed Absorption a. Iron sponge b. Molecular Sieve c. Zinc Oxide 2. Chemical Solvents a. MEA Mono-Ethanol Amine b. DEA Di-Ethanol Amine c. DGA Di-Glycol Amine

Chapter 1 d. DIPA - Di-Isopropanol Amine e. MDEA - Methyl Di-Ethanol Amine f. Hot Potassium Carbonate g. Proprietary Carbonate Systems Physical Solvents a. Fluor Solvent b. Shell Sulfinol c. Selexol d. Rectisol Direct Conversion of H2S to Sulfur a. Clause b. LOCAT c. Stretford d. Sulfa-Check Distillation Gas Permeation

Introduction

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Natural Gas Purification through chemical solvents using MEA and MDEA is the most common and extensively used technology in recent times Hydrocarbon Dew Point Control The term Gas Processing is used to refer to removing of ethane, propane, butane and heavier components from the gas stream. They may be fractionated and sold as a pure component or they may be combined and sold as a natural gas liquids mix or NGL. The extraction of natural gas liquids from rich gas is more economical even though it reduces the heating value of the gas. The value of the increased volume of liquids sales may be significantly higher than the loss in gas sales revenue due to decrease in heating value of the gas. Another objective of the gas processing is to reduce the hydrocarbon dew point. In general, hydrocarbon dew point less than 32 F is preferred for gas transmission lines. Condensable hydrocarbon content must be reduced to a level that will prevent condensation anywhere in the downstream pipeline system. Removal of water and heavy hydrocarbons is particularly important as an excess of these components leading to condensation in adverse conditions, can cause hydrate formation within the pipeline leading to excessive pressure drop and potential blocking of the pipe. Following processes are used to recover natural gas liquids from rich gas: 1. Lean Oil Absorption 2. Refrigeration 3. Cryogenic Plants Lean-oil absorption plants are the oldest kinds of gas plants where kerosene type oil is circulated through the plant. The lean oil is used to absorb light hydrocarbon components from the gas. The light components are separated from the rich oil and the lean oil is recycled.

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Introduction

In a refrigeration plant the inlet gas is cooled to a low enough temperature to condense the desired fractions. Freon or Propane is used as refrigerant. Because of greater liquid recoveries, cryogenic plants are the most common design currently being installed. In a typical cryogenic plant gas is cooled to -100 to -150 F through a turbine or Joule-Thompson (J.T) valve. In terms of value, the equation is simple: the gas is processed to give it the best balance of value (measured by its calorific value) against processing cost. Removal of acid gases, water and heavy hydrocarbons costs money, but these processes improve the value of the gas at fiscal transfer. So control on acid gases contents, water dew point and hydrocarbon dew point will produce an optimal gas composition that meets the fiscal requirements of seller and buyer and minimizes the safety risks involved in transporting the gas at high pressure.