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The still column vent on glycol dehydrators can be a notable source of organic emissions
at some sites; however, overall, it is more significant as a potential source of odoriferous
emissions and toxic organic air pollutants.
The specific control technologies that may be used to reduce or eliminate emissions from
the still column vent include,
• Optimization of key process variables.
• Disposal of the vented vapours by thermal oxidation.
• Recovery of the vapours using a condenser unit.
• Specification of enhanced, lowemission glycol dehydration technology (i.e., the
DRIZO process).
• Specification of an alternate, more environmentally friendly dehydration
technology (i.e., membrane dehydration process).
Process optimization offers the most immediate and costeffective means of reducing the
amount of emissions. Disposal of the vapours by thermal oxidation is a simple, effective
means of controlling the emissions at a moderate cost. However, it has the disadvantage
of creating combustion emissions. Recovery of the vapours using a condenser is an
interesting solution that may actually have a positive economic benefit to it. Use of the
DRIZO process or possibly membrane dehydration technology may be worth
considering for use at new facilities.
An additional advantage of the vapour condenser and DRIZO processes is that they may
allow dehydration of some sour gas streams.
Source Characterization
Glycol dehydration is the most common process for removing water vapour from
natural gas. It is frequently used in the field to prevent hydrates in gas gathering
systems, and at gas processing plants to satisfy sales specifications.
Process Description
Glycol dehydration is a continuous liquid desiccant process in which water or water
vapour is removed from hydrocarbon streams by selective absorption and the glycol is
regenerated or reconcentrated by thermal desorption. The most common application of
this process is the dehydration of natural gas streams; however, variations of the process
are also used to dehydrate natural gas condensates at gas processing plants. The
discussions that follow are directed towards natural gas applications. Nonetheless, the
basic glycol regeneration process is the same regardless of the application so many of the
available emission reduction methods and technologies will apply to both types of
applications.
The use of triethylene glycol (TEG) is standard for dehydration of natural gas.
The absorption occurs in a trayed vessel called the contactor or absorber column. The
lean dry glycol liquor enters the top of the column and the wet gas enters the bottom of
the column. As the lean glycol flows down through the trays, it contacts the upflow of
the wet gas. The lean glycol absorbs the water from the wet gas and exits through the
bottom of the column as rich glycol. The gas exits the top of the column as a dry
product with an acceptable residual moisture content range of 0.03 to 0.06 g/m3 (2 to
4 lb/mmscf) of gas.
A low pressure flash separator is sometimes installed between the contactor and the
regenerator to release any solution gas that may be entrained in the rich (wet) glycol,
especially if a glycol energy exchange pump is used in the system. This type of pump
uses pressure energy in the rich glycol to pump dry glycol into the contactor. The gas
separated in the flash separator may be used to supplement the fuel and stripping gas
required for the reboiler. Any excess vent gas is discharged through a back pressure
valve to atmosphere.
From the flash separator, the rich glycol is passed through a heat exchange coil in the
surge tank to preheat the rich glycol. The rich glycol then flows to a packed stripping
still attached to the top of a reboiler. In the still column, the wet glycol flows down to
the reboiler while contacting hot gases (mostly water vapour and glycol) rising up from
the reboiler. The mixing of these two streams helps to further preheat the wet glycol
and to condense and recover any glycol vapours before the gases are vented from the
top of the still.
In the reboiler the glycol is heated to approximately 175o to 205oC to remove enough
water vapour to reconcentrate it to 99.5 percent or more. Sometimes a small amount of
natural gas is injected into the bottom of the reboiler to strip water vapour from the
glycol. The water vapour rises through the stripping still and the lean glycol flows to
the surge tank where it is cooled down by preheating the rich glycol from the flash
separator.
Finally, the glycol is pumped back to the top of the absorber column to repeat this
circuit. The required circulation rate is determined by the actual purity of the glycol at
the inlet to the contactor, the number of trays or packing height in the contactor, and the
desired dew point depression (API, 1990). Typical values for plant applications are 17 to
50 L TEG/kg H2O removed, and for field applications are 20 to 35 L TEG/kg H2O.
Atmospheric Emissions
The type and amount of emissions from the still column vent depends on the actual
process design, operating conditions, and the composition and flow rate of the raw
natural gas. For a typical unit equipped with a flash separator, the composition of the
vented vapours may be expected to vary (on a relative mass basis) as follows
(Schievelbein,1992): 50 to 90 percent water, 5 to 50 percent condensable hydrocarbons,
and small amounts of noncondensable hydrocarbons. The concentration of non
condensable gas increases dramatically if a flash separator is not used. Toluene is
usually the most concentrated condensable hydrocarbon component, but rarely does it
exceed 10 percent by weight. Dehydrators in field applications might be vaporizing 0.08
to 0.8 m3/d (0.5 to 5 bbls/d) of hydrocarbons.
The primary causes of hydrocarbon emissions are secondary absorption/desorption by
the TEG, entrainment of some gas from the contactor in the rich TEG, and use of
stripping gas in the reboiler. However, secondary absorption/desorption by the glycol
is perhaps the most important single cause.
The key secondary compounds that may be removed by the TEG are aromatic
hydrocarbons (e.g., benzene, toluene, ethylbenzene, and xylenes [BTEX]), which are
notable toxic substances. TEG also has a strong affinity for reduced sulphur species
(e.g., hydrogen sulphide, mercaptans and carbon disulphide), which are also toxic and
highly malodorous. However, for the purposes of this document, attention is focused
on the BTEX and other hydrocarbon emissions.
Through the concentrating effect of the absorption process, the presence of even small
amounts of BTEX in the natural gas can result in very high concentrations in the vented
effluent. The molar concentration of BTEX at the outlet of the vent can easily be several
hundred times higher than in the raw gas.
The amount of BTEX emitted depends largely on its concentration in the raw natural gas
and on the glycol circulation rate. BTEX does not occur in all raw natural gas streams,
but where it does occur, its concentration is usually less than one percent by volume
(Thompson et al., 1992). The glycol circulation rate is determined by the gas flow rate
and the amount of water to be removed. At 6900 kPa, glycol can absorb up to 7.5
standard litres of gas for every litre of glycol circulated (Sams, 1992). A gasdriven
glycol pump adds additional gas during its pumping operation. Approximately 0.5
actual litres of gas (i.e., at process conditions in the contactor) is required to pump one
litre of glycol. Stripping gas flows are normally 7.5 standard litres per litre of glycol.
Since the boiling points of BTEX range from 80oC to 140oC, very little of this material is
released in the flash tank (Thompson et al., 1992). Most of the BTEX is separated from
the glycol in the still. Although many of the lighter hydrocarbons (e.g., entrained gas
from the contactor) may be removed from the glycol in the flash tank, some remain in
the glycol and are separated in the still.
The amount of BTEX emitted by a glycol dehydrator in a given application may be
estimated using several different commercially available process simulation packages
which have been specifically tuned for this type of problem (e.g., HYSIMTM by
Hyprotech, PRO/IITM by Simulation Sciences, and PROSIMTM by Bryan Research &
Engineering, Inc.). However, a somewhat less accurate, although much less costly,
package named GRIDEHY has been developed for this same purpose and is available
from Gas Research Institute (Thompson et al., 1992). If the composition and flow rate of
the inlet gas and the design and operating conditions of the dehydrator are known, GRI
DEHI is reportedly able to calculate benzene emissions to within ±20 percent of actual
values, and toluene, ethylbenzene, and xylenes emissions to within ± 20 to 50 percent.
A variety of test methods are also available for establishing aromatic emissions from
glycol dehydrators (Schievelbein, 1992; Grizzle, 1992; Rueter and Evans, 1992). The
simplest and most cost effective approach of reasonable accuracy is perhaps the
rich/lean glycol mass balance method. This method consists of analyzing samples of the
rich and lean glycol and then performing a mass balance based on the glycol circulation
rate. The results are estimated to be low by as much as 20 percent for BTEX and as much
as 40 percent for VOC values (Schievelbein, 1992). The most accurate methods are total
capture condensation and partial stack condensation/flow measurement; however,
these methods are also much more costly to perform. The limited data available
(Grizzle, 1992) indicate that direct sampling and analysis of the vent stream may provide
good VOC values but poor BTEX results.
Emission Reduction Methods and Technologies
The amount of emissions and the concentration of toxic and odoriferous compounds in
the vapours are major factors in choosing the best option for reducing venting emissions
from the still column on glycol dehydrators. Maintenance needs in field applications
can also be important, particularly for remote locations.
Some simple process modifications and optimization work may be done to help
minimize the amount of emissions and lower the cost of any addon options. If resulting
total hydrocarbon emissions are low, then the simplest and most cost effective solution
may be to dispose of the emissions by thermal oxidation. This may be a minimum
requirement if malodour problems arise or if there is a risk to human health due to toxic
emissions. However, the use of condensers to recover the condensable hydrocarbons
may offer a very attractive payback in some cases. Moreover, the noncondensable
hydrocarbons can be used as fuel to improve the energy efficiency of the dehydration
process.
The DRIZO process may be considered for new applications or may possibly be retrofit
to existing units. It has the benefits of reduced emissions and increased water removal.
Process Optimization
There are several process options that may be implemented and process variables that
may be optimized to help minimize the amount of venting emissions from the still
column. These are itemized below and generally pertain to directly or indirectly
minimizing the glycol circulation rate and the heating load on the reboiler. For remote
field dehydrators, it may be worthwhile to install a SCADA system to allow central
monitoring of some of the key variables.
• Flash Tank: If appreciable quantities of natural gas are absorbed or entrained in
the glycol, a twophase flash separator should be installed downstream of the
glycolglycol heat exchanger and glycol pump (especially if a glycol energy
exchange pump is used). The separated gas can be used as fuel for the reboiler
or as stripping gas, or sent to flare for disposal.
If significant amounts of hydrocarbon liquids are encountered at this point, the
flash tank should be designed for threephase separation. Otherwise, the
hydrocarbon liquids could cause problems in the reboiler (i.e., gradual coke
accumulation on the fire tube [Pearce and Sivalls, 1984]) and lead to reduced
boiler efficiency and increased combustion emissions.
• Glycol Circulation Rate: The amount of moisture control provided by a glycol
dehydrator is, for the most part, determined by the glycol circulation rate.
However, since this rate also determines the amount of venting emissions, it is
important that the circulation rate not be set any higher than is needed.
Notwithstanding this, usual practice is to set the circulation rate for peak flows
plus a comfortable safety factor (e.g., 10 percent [Pearce, 1982]). Thereafter,
adjustments to the circulation rate with changes in throughput are made
infrequently, if at all. Consequently, there is considerable potential for
optimization of the glycol circulation rate. This will not only reduce venting
emissions, but will remove unnecessary load from the reboiler and thereby lower
combustion emissions and conserve fuel.
One option is to conduct periodic performance tests (e.g., sample the rich and
lean glycol) on each unit and manually adjust the glycol circulation rate.
Sometimes it may even be necessary to replace the existing pump with a smaller
pump (i.e., it is not uncommon for the glycol pump and other components of the
dehydrator to be oversized because of production declines or low gas demand).
According to Ballard (1986), the lean glycol weight percent should be about 98 to
99.5+. The rich glycol will vary from about 93 to 97 percent. If the spread
between the lean and the rich glycol content is too narrow (about 0.5 to 1.5
percent), it usually means the glycol circulation rate is too high and should be
decreased. If the spread is too wide (over 4 to 5 percent) it usually means the
glycol circulation rate is too low and should be increased.
• Inlet Gas Temperature and Pressure: The amount of emissions that may occur
for a well posed dehydration application involving properly trained operators is
ultimately determined by the amount of water in the inlet gas. This in turn is
determined by the inlet temperature and pressure of the gas. The water content
of the gas will decrease through condensation as temperature is lowered and
pressure is increased. So, also, will the concentration of higher boiling point
aromatics and their corresponding emissions. Accordingly, the operating
temperature should be minimized and the operating pressure maximized to the
fullest extent possible. However, in most cases temperature will be the easiest to
adjust and will likely offer the greatest gains.
Sometimes if the pressures are relatively low, it may be feasible to install an inlet
air cooler when the inlet gas temperature is too high.
It should be noted, however, that TEG becomes sufficiently viscous to impair
efficient contact at temperatures below about 15oC (API, 1990).
• Lean Glycol Temperature: It is important that the glycol entering the contactor
be cooled to 5o to 15o C above the temperature of the gas stream to prevent
hydrocarbon condensation in the absorber and subsequent foaming (Ballard,
1986; API, 1990). At higher temperatures, more water vapour will remain in the
gas stream resulting in the need for higher glycol circulation rates and increased
loading of the reboiler. Higher temperatures will also contribute to higher glycol
losses through vaporization into the sales gas stream.
• Stripping Gas: Stripping gas may be used to obtain higher glycol purities to
help lower glycol circulation rates. This will tend to lower BTEX emissions but
increase methane emissions. The benefits of using stripping gas diminish rapidly
beyond rates of about 15 to 20 L/L of TEG solution circulated (Hernandez
Valencia, 1992).
• Reboiler Temperature: The operating temperature of the reboiler should be as
high as possible without exceeding 205oC to ensure maximum reconcentration of
the TEG and thereby suppress the necessary glycol circulation rate. Higher
temperatures will lead to excessive glycol losses into the still column vent gas
and possibly thermal decomposition of the glycol.
On a standard unit (i.e. one with a gas fired reboiler) this temperature is
thermostatically controlled and fully automatic. Nonetheless, the reboiler
temperature should be occasionally verified with a test thermometer to make
sure true readings are being recorded (Ballard, 1986). The reboiler operates best
when it is able to achieve a uniform temperature. If the temperature fluctuates
excessively when operating below the design capacity, the fuel gas pressure
should be reduced. Conversely, if the reboiler temperature cannot be raised as
desired, it may be necessary to increase the fuel gas pressure up to about 200 kPa
and readjust the dampers on the air intake.
According to Ballard (1986), the temperature in the top of the still column should
be about 96oC. Below 93oC there is a possibility that the water will start
condensing and washing back into the still column. When this temperature
reaches 121oC and above, the glycol vaporization losses will sharply increase.
The limited data and experiences that have been presented in the literature (Ballard,
1986; Richardson and WhiteStevens, 1986) indicate that there is potential for substantial
reductions in BTEX emissions and fuel consumption by glycol dehydrators through
regular optimization of these units.
• Not all glycol dehydrators necessarily need to be optimized beyond what is
already being done.
• The potential for substantial improvements may be greatly limited by the
possible overcapacity of the unit for existing production rates. It may be more
sensible in some cases to simply replace the dehydrator with a more
appropriately sized unit or an alternate dehydration technology.
• A potential operating problem experienced by some moisture analyzers in
natural gas applications is interference due to coating of residual glycol on the
detector. This can apparently be overcome by installing and maintaining a good
filtering system on the sample line to the detector.
Oxidation Units
The vapours from the still column vent may be disposed of by routing them to a suitable
continuous oxidation unit. A low pressure flare system or thermal incinerator unit may
be considered. (A thermal incinerator may be distinguished from a flare by its use of a
refractory lined chamber to contain the flame heat and promote some post flame
combustion).
Both devices have been used successfully in this application and can be designed with
automatic ignition systems to ensure a continuous flame. If electric power is not
available on site, a solar panel and battery system may be used to operate the igniter or a
"piezometric" device may be employed.
However, the following factors generally make the incinerator the preferred choice for a
thermal oxidation unit:
• The low discharge pressure of the dehydrator still column provides little energy
to drive the vent gas to a flare. An eductor may be used to move the gas but this
may result in high operating costs (Rutberg et al., 1985). If an incinerator is used
there is generally enough natural draft for the vapours to flow to the unit
unassisted.
• The high water content of the gas may lead to freezeoff of the flare line during
winter operation unless the system is heat traced or designed for dedicated
dehydrator service (i.e., the flare line is sloped and insulated so any water that
condenses will drain back into the dehydrator). A dedicated incinerator can be
safely placed much closer to the dehydrator to help reduce the cost of doing this.
• Fuel gas must be added to the vent gas to increase its heating value to a point
where good combustion may be assured. The use of supplementary fuel is
usually not required with an incinerator due to its better retention of the flame
heat. Moreover, incinerators are able to provide better destruction efficiencies
than flare systems and are more aesthetically appealing since there is no visible
flame.
A properly designed and operated flare with a stable, smokeless flame may provide
destruction efficiencies above 98 percent (McCrills, 1988). An incinerator may provide
efficiencies above 99 percent.
A power source is needed for ignition of the waste gas and supplemental fuel may be
required to maintain a stable flame if the calorific value of the gases is low.
A number of different vapour recovery condenser (VRC) systems have recently been
developed in the United States to control BTEX emissions from the still column vent on
glycol dehydrators. Most of these systems have been inhouse developments by some of
the major operating companies. Patent application have been filed for at least four of the
VRC designs, namely the Texaco (Schievelbein, 1992), Conoco (Choi, 1992), RBTEX
(Lowell and Sivalls, 1992; Gamez et al. 1993) and Armellini Engineering (Armellini,
1992) processes. Field evaluations of the first two control systems have been conducted,
and demonstration of the RBTEX system is currently in progress.
The basic VRC process consists of cooling the vented gas from the still column to 50 oC or
less. A standard offtheshelf air cooler or other type of cooler is usually employed for
this purpose. The cooling causes the water vapour and most of the aromatics and other
heavy hydrocarbons to condense. The noncondensable vapour is essentially methane
and may be used for fuel, incinerated or compressed into the natural gas stream to be
dehydrated. The condensate is separated into water and hydrocarbon liquid and
transferred into appropriate storage tanks for subsequent disposition. The water must
be disposed of in an environmentally acceptable manner and the hydrocarbon liquid
may be used for fuel or sold.
The hydrocarbon liquid is mostly BTEX (about 60 percent [Choi, 1992]) and the
remaining constituents are nhexane and other paraffinic hydrocarbons.
There is some scatter in the measured efficiencies of VRCs with respect to BTEX
emissions (Schievelbein, 1992; Grizzle, 1992). However, the values are generally greater
than 90 percent if a flash tank is employed upstream of the reboiler. If a flash tank is not
used efficiencies generally drop to much less than 50 percent.