UOP SeparexTM Membrane Technology

Mander Singh
UOP LLC

UOP Southeast Asia Gas Processing Tour October November 2009 Malaysia, Thailand, Indonesia & Vietnam
2009 UOP LLC. All rights reserved.
UOP 5241E-01

Agenda

y Membrane Technology Overview y Pretreatment Options y Flow Scheme Options y Commercial Experience

UOP 5241E-02

Regions of Use for Acid Gas Technologies

Partial pressure of acid gas in feed, psia

1000

SeparexTM Membrane
100

10

1.0

0.1 0.001

0.01

0.1

1.0

10

100

Partial pressure of acid gas in product, psia

UOP 5241E-03

What Is a Membrane?
A semi-permeable film of various: y Materials: Cellulose Acetate (CA), Polyimide (PI), Polyamide, Polysulfone, Silicone y Types: Asymmetric, Thin Film Composite y Construction: Spiral-Wound, Hollow Fiber

UOP 5241E-04

Asymmetric Membranes

Non -porous Layer Non-porous

y Single polymer y Thin selective layer y Porous support layer

Porous Layer

UOP 5241E-05

Composite Membrane Structure

Composite Membranes y Two or more polymers y Thin layer of highly optimized polymer y Mounted on an asymmetrical structure y Highly tailored properties at low cost

UOP 5241E-06

Membrane Elements - Spiral Wound

UOP 5241E-07

Spiral Wound Membrane Element and Tube

UOP 5241E-08

Hollow Fiber Membranes

UOP 5241E-09

Hollow Fiber Membranes

Feed Gas Inlet Permeate Outlet Permeate Outlet

Residue Gas Outlet

UOP 5241E-10

Separex Membranes
y Not A Filtration Process y Solution-Diffusion Based Separation Process
Components dissolve into membrane surface and diffuse through it More soluble components permeate quicker Smaller components permeate quicker
Hydrocarbons, N2 High Pressure Low Pressure
Fast Slow

CO2, H2S, H 2O

Membranes are characterized by permeability (flux) and selectivity

UOP 5241E-11

Driving Force A pressure differential across the membrane High Pressure M M (Feed) e e m m b b P CO CO2 2 PCO CO2 r 2 r a a Low Pressure n (Permeate) n e e

UOP 5241E-12

What Are Separex Membranes?

UOP 5241E-13

Separex Membranes Regions of Use

y Flow Rates: Economical only for > 5 MMSCFD y Feed Pressure: Up to ~ 2,000 psiA (138 barA) y Permeate Pressure: Typically below ~50 psiA (3.5 barA) y p (FeedPermeate): 1,500 psi max (100 barA) y Feed Temperature: 60 to 150F (16 to 65C)

UOP 5241E-14

Agenda

y Membrane Technology Overview y Pretreatment Options y Flow Scheme Options y Commercial Experience

UOP 5241E-15

Pretreatment Design Considerations

y Feed Composition
CO2 Content or Percentage of CO2 Removal Heavy Hydrocarbons

y Feed Contaminants
Compressor Oils Well Additives Pipeline Corrosion Inhibitors

All Membranes Require Some Form of Pretreatment

UOP 5241E-16

Standard Pretreatment

Feed

Filter Coalescer

NonRegenerative Adsorbent Bed

Particle Filter

Heater

Membrane

y Removes feed contaminants such as lube oil and corrosion inhibitor y Not meant for removal of heavy HC tail in very rich feed gas
UOP 5241E-17

Enhanced UOP MemGuard Pretreatment

Feed

Filter Coalescer

MemGuard Regenerable Adsorbent System

Particle Filter

Heater

Membrane

UOP 5241E-18

MemGuard Flow Scheme

Clean Gas
Regen Gas Blower Adsorbing Bed(s) Regen Heater Regen Gas Cooler Regen Gas Separator

Feed
Filter Coalescer Particle Filter Regenerating Bed

Liquids

UOP 5241E-19

MemGuard System Performance

700 600 500 400 300 200 100 0 Pretreatment Feed Gas Pretreatment Discharge Gas

Hydrocarbon Content, ppm

C6

C7

C8

C9+

UOP 5241E-20

Benefits of MemGuard System

y Selectively removes heavy HC tail and hence can provide efficient dew point suppression y MemGuard product gas is bone dry which allows use of carbon steel metallurgy y If permeate gas is to be sequestrated, additional dehydration is typically not required

UOP 5241E-21

Agenda

y Membrane Technology Overview y Pretreatment Options y Flow Scheme Options y Commercial Experience

UOP 5241E-22

Flow Scheme Options

1 Stage 2 Stage PreMembrane Hybrid

UOP 5241E-23

Processing Schemes
Residue Residue
(Low H2S/CO2)

Feed

Feed Permeate
(High H2S/CO2)

y No moving parts y Simple, reliable operation y Low hydrocarbon recovery

Permeate

y Allows greater CO2 removal y High hydrocarbon recover y Requires recycle compressor
Residue

Feed

y Feed with high CO2 y Intermediate hydrocarbon recovery y Reduced compression

Permeate
UOP 5241E-24

Hybrid
Single Stage Membrane
XXXX

Treated Gas

Amine System
XXXX

To Acid Gas Cooler

Reflux

Feed

Filtration System To Boiler

To/From Amine Reboiler

xxxx

y Debottleneck existing plants y Reduce size of Amine Unit y Allows high CO2 removal, low ppm of CO2 & H2S in sales gas y Minimizes capital and operating costs
UOP 5241E-25

Effect of CO2 Removal

Relative Area Requirement
4 100

3
Multistage System

90
One Stage System

80

70

0 0 20 40 60 80

60 100

% CO2 Removed
UOP 5241E-26

% Hydrocarbon Recovery (1 Stage)

Effect of Number of Stages

Hydrocarbon Retention 100% 95% 90%
One Stage Two Stage

85% 80% 75% 0% 20% 40% 60% 80% 100%

Percentage CO2 Removal

UOP 5241E-27

Effect of Feed Pressure on Performance

2.0 Relative Area or Losses 1.6 1.2 0.8
Membrane Area Hydrocarbon Losses

0.4 0.0 400

600

800

1000

1200

1400

1600

Feed Pressure, psia

UOP 5241E-28

Effect of Permeate Pressure on Performance

3.0 Relative Area or Losses 2.6 2.2 1.8 1.4 1.0 0.6 0 40 80 120 160 Permeate Pressure, psia
UOP 5241E-29

Membrane Area

Hydrocarbon Losses

Effect of Feed Temperature on Performance

1.6 Relative Area or Losses 1.3 1.1 0.9 0.7 0.5 70
Membrane Area Hydrocarbon Losses

90

110

130

150

170

Operating Pressure, F
UOP 5241E-30

Effect of CO2 Removal on Performance

2.0 18 16 14 12 10 8 6 4 2 0 0%

Relative Area or Losses

Membrane Area

Hydrocarbon Losses

20%

40%

60%

80%

100%

Percentage CO2 Removal

UOP 5241E-31

Agenda

y Membrane Technology Overview y Pretreatment Options y Flow Scheme Options y Commercial Experience

UOP 5241E-32

Small Large

Larger

Largest

Capacity Over Time

1000

Feed Flow (MMSCFD)

100

10

Avg Size

0.1 1980

1985

1990

1995

2000

2005

Year

UOP 5241E-33

Large Separex Membrane Projects

Location Nigeria Pakistan Pakistan Mexico Thailand * Egypt Egypt Egypt Indonesia Malaysia * Thailand *

MMSCFD 200 550+450 240 120 32 107 218 234 254 680 620

CO2 Inlet 7% 6.5% 12% 70% 50% 6.7% 6.8% 9% 40% 44% 40%

CO2 Outlet 2% 2% 3% 5% 20% 3% 3% 3% 20% 8% 21% Thailand * Egypt

In Construction

520 117 163 176

35% 9% 17% 25%

10% 3% 10% 5%
UOP 5241E-34

* Offshore

Thailand S.America *

Ease of Operation Remote Plants

Commercial Experience
Installation Type No. of Units y Natural Gas 52 y Enhanced Oil Recovery (EOR) 5 y Hybrids 5 y Offshore 3+2 y Landfill Gas 7 y Digester Gas 1 y H2 Purification 56

Total

130

UOP 5241E-35

Pakistan II Overall Layout

UOP 5241E-36

Pakistan II Expansion Skids

UOP 5241E-37

Pakistan II MemGuard System

UOP 5241E-38

Egypt I Plant Layout

UOP 5241E-39

Egypt I Plant Membrane Skid

UOP 5241E-40

Egypt I Plant 2nd-Stage Membrane Skid

Carbon Guard Bed

2nd Stage Membrane

UOP 5241E-41

Recent Project Offshore

Feed Flow, MMSCFD CO2, mol% Mercury, g/Sm3 Water, lb/MMSCFD 630 44.5 40 max Saturated

Product 350 <8.0 <5 <5

UOP 5241E-42

Hydrocarbon Recovery: 95%

Malaysia Platform

UOP 5241E-43

Optimized Layout & Packing Density

UOP 5241E-44

Installed Malaysian MemGuard System

UOP 5241E-45

Offshore Thailand Membrane Skids

UOP 5241E-46

Thailand Platform

UOP 5241E-47

Separex Technology Summary

y Modular supply advantages
High degree of shop fabrication Minimized installation time & cost

y Phased in expansion for future capacity or CO2 increase y Weight and space efficiency y Easy to start-up, operate, turndown and shutdown y High reliability and on-stream time
Low maintenance requirements

y Lowest processing cost as low as $ 0.09/MSCF y Advanced pretreatment and materials y Membranes operate in gas phase (no flammable liquids, refrigerants or chemicals) y Meets API-521 RP for system inventory blowdown during ESD
UOP 5241E-49

Separex Technology Summary

y Synergies with other UOP technologies with one system wide performance warranty y Unparallel capabilities
UOP manufactures its own membranes Membrane and Pretreatment development program

y Extensive commercial experience y Long-term proven commitment

Ongoing operational support Supply of continually improved membranes

UOP 5241E-50

UOPs Project Services Expertise

Project Schedule
Project Development Design & Construction Operations

UOP
Conceptual
y Project Definition & Optimization y Basic Design Studies

Engineering
y Hazop y Detailed Engineering y System Integration

Technical Support
y Commissioning and Startup Services y Ongoing Technical Services/ y Monitoring

UOP Ongoing R&D and Process Improvements

UOP 5241E-51