World Scale LNG Feed Pretreatment Technology The Advantages of an Integrated Approach

ABSTRACT Natural gas streams are typically treated for control and removal of multiple acid gas contaminants and in most cases these compounds can not be removed cost effectively by a single technology. The geographic origin of the gas will define the quantity and type of acid gases that must be dealt with. A complex project for treating Middle East source natural gas will be required to deal with mercaptan sulfurs as well as the traditional H2S. The addition of mercaptan sulfur as a contaminant makes the acid gas control a little more technically challenging. The type and quantity of acid gas components that need to be controlled will dictate the number of technologies and units required to meet required product specifications. The number of technology units and how they are integrated will significantly impact overall project economics and success. UOP has designed and implemented a unique flow-scheme which is being utilized to effectively remove and control all acid gas components prior to liquids recovery. The flow-scheme takes advantage of each technologys strength while maximizing integration to minimize capital and operating costs. The flow-scheme minimizes the number of required units and optimized integration results in a very cost effective and technically comprehensive complex. This presentation will provide information on the technical approach to treat complex feed streams along with the technical advantages to the integrated design. INTRODUCTION Gas processing can range from simple treating and conditioning for pipeline delivery to complex operations needed to meet specifications to produce liquefied natural gas (LNG). Natural gas requires a removal of acid gas compounds such as CO2, H2S, COS, organic sulfur compounds, water and mercury to meet end product specifications and to avoid product blockages in the downstream process equipment. The level of treating requirements varies according to the treated gas product specifications and local environmental regulations. World-Scale LNG & NGL Plants face ever increasing challenges and complexities. Some of the key issues are: Larger Single Train Size More Difficult Feedstocks More Stringent Product Specifications More Stringent Environmental Regulations More Remote Locations

To maximize performance and production, while addressing these challenges, some of the key considerations for gas processing selection for facilities are: Mitigation of Risk Control on Project Schedule
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Replication of the Same Process Design for Subsequent Trains Plant Availability/Reliability Longer Run Times between Turnaround Maximize Hydrocarbon Yield Maximize Sulfur Recovery Maximize Efficiency Elimination of Waste and By-Product Streams

Historically, front-end gas processing purification and separation with Conventional Process Flow Schemes has been used. In such flow schemes, the natural gas feedstock is first treated by removing H2S, CO2, H2O, and Mercury (Hg) to extremely low levels in various gas purification steps. The feedstock is then separated into individual hydrocarbon C1 through C5+ fractions. The gas-phase C2 fraction undergoes further CO2, H2S, & H2O removal, while the liquid-phase C3 through C5+ fractions are treated Traditionally the for Mercaptan (RSH), Carbonyl Sulfide (COS), & H2O removal. Engineering Contractor (EPC) is responsible for pulling together the individual unit operations, with the assistance of product vendors for each of the unit technologies. An alternate method is to use an Integrated Systems approach, whereby a single gas processing technology supplier works directly with the client/operator to determine the optimal design for the facility on an integrated basis. The EPC still plays an important but supporting role in this approach. The result is that the challenges and complexities cited above are more effectively addressed. The Integrated Systems approach was used in a number of Middle East projects with UOP as technology supplier. Three trains have been successfully commissioned since early 2004, with two more under construction. Additionally a project for the production of Sales Gas has been commissioned, and second train is currently under construction.

CONVENTIONAL FLOWSCHEME WITH INDIVIDUAL PROCESSES (Liquid-Phase Desulfurization) The Conventional Flow scheme is composed of gas-phase and liquid-phase processes, as illustrated in the block flow diagrams of Figures 1 Gas-phase treating compromises H2S and CO2 removal via an Amine Acid Gas Removal Unit, water removal via a Molecular Sieve Dehydration Unit, separation of C1 through C5+ hydrocarbon fractions utilizing a Turbo Expander and NGL Fractionation. The CO2 or CO2 and H2S removal from the C2 fraction is done using Amine processing followed by water removal using Glycol or a Molecular Sieve Dehydration Unit.

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. Figure 1. LNG & NGL Processing Block Flow Diagram Liquid Phase RSH Removal -- Conventional Flow Scheme Liquid-phase treating of the NGL streams is accomplished in either of two routes, but we will focus on the scheme requiring mercaptan sulfur removal as well as COS. The C3 Fraction is first treated specifically for COS removal, typically using either Diglycolamine (DGA) or Diisopropylamine (DIPA). The Propane is then Merox treated using the regenerable caustic process to remove the mercaptan sulfur and convert it to Di-Sulfide Oils. The Propane is then dehydrated and the remaining sulfur is removed using a Molecular Sieve Unit. The C4 Fraction is Merox treated for mercaptan sulfur removal and conversion to disulfide, and is then dehydrated and the remaining sulfur removed using a Molecular Sieve Unit. The Conventional flow-Scheme can be used but without very careful project management can easily result in a non optimized complex with reduced overall facility efficiency and lower overall hydrocarbon yields. As can be seen above this approach requires multiple processing steps are required to assure complete removal of mercaptan sulfur and COS. INTEGRATED FLOWSCHEME (Gas-Phase Desulfurization) The Integrated Flow Scheme is also composed of gas-phase and liquid-phase processes, as illustrated in the block flow diagram in Figure 2. The dominant difference between it and the Conventional Flow Scheme is that the mercaptan sulfur and COS is captured in the gas-phase. This is accomplished by complete H2S & CO2 removal, and bulk COS removal, are done via an Amine Acid Gas Removal Unit. Water, mercaptan sulfur & mercury removal are accomplished via a multi-adsorbent Molecular Sieve Desulfurization Unit. The spent regeneration gas from the Molecular Sieve

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Desulfurization Unit is treated in a Selexol Unit with the acid gas stream sent to a Claus SRU for conversion into elemental Sulfur and the desulfurized regeneration gas is either compressed and recycled back to the entry of the Amine Unit, and/or used as fuel for a gas turbine for facility power generation. In this flow-scheme the C1 through C5+ hydrocarbon fractions are also separated via a Turbo Expander and subsequent NGL Fractionation but the C3 and C4 Fractions are treated in liquid-phase Molecular Sieve Units for sulfur polishing to insure all product specifications are met.

Figure 2. UOPs Integrated Flow Scheme (Gas-Phase RSH Removal) The potential advantages of the Integrated Flow Scheme are clearly higher overall efficiency, higher overall hydrocarbon yields and higher overall sulfur recovery. The combination of the Molecular Sieve Unit and the Selexol system removes mercaptan sulfur from the regeneration gas and delivers it to the Claus SRU. Additionally, in situations where NGL recovery is not planned, the Integrated Flow Scheme achieves the final purified gas product specifications, particularly total sulfur content. The installation of a Turbo Expander to condense the Sulfur species into the liquid NGL is not required. The Integrated Flow scheme results in lower overall operating costs, in terms of lower utilities, lower waste disposal costs, higher hydrocarbon recovery, and higher sulfur recovery. COMMERCIAL EXPERIANCE For several large processing trains in the Middle East the clients were looking to change the approach for the front end gas processing. The critical project objectives included a technology approach with a flexible design but one that would be easily applied and copied for all trains. This would achieve project cost savings, schedule improvements and execution benefits.

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The client elected to utilize UOPs Integrated Front-end Gas Processing technology as the project basis. Figure 7 presents the Block Flow Diagram for the UOP Integrated Flow Scheme, which is comprised of an Amine Guard FS unit for complete H2S & CO2 removal and bulk COS removal, a Molecular Sieve system for H2O, RSH, & Hg removal, a Selexol unit to treat the spent regeneration gas from the Molecular Sieve Unit. When NGL recovery is part of the complex flow-scheme it has been accomplished using Ortloff Engineers LTD Turbo Expander and Fractionation technology. UOP and Ortloff have an alliance that incorporates Ortloffs NGL Recovery technology in UOPs Integrated Flow scheme. There are four trains now in successful operation using the UOPs Integrated Flow scheme approach and three additional trains are expected to be operation in 2008 and 2009 with a total capacity of ~14 Bcfd. All these trains reflect the largest single-train capacity natural gas processing plants in the world. UOP PROCESS TECHNOLOGIES & KEY DESIGN ISSUES Amine Guard FS(1) The Amine Guard FS Unit incorporates the use of UCARSOL(2) AP-814, a proprietary, promoted Methyldiethanolamine (MDEA) Amine solvent. The amine absorber utilizes UOPs Multiple Downcomer (MD) Trays. These permit high vapor/liquid load handling of large feed gas flows, leading to smaller tower diameter and reduced tower wall thickness, especially for the high-pressure Absorber Tower. Additionally, UOPs direct design control of the mass transfer internals insures the critical product gas specifications will be met. Molecular Sieve Unit The Molecular Sieve Unit design and performance is critical to assure all product specifications are met. The removal of H2O, RSH, and Hg is accomplished by using three distinct adsorbents. Tailoring the adsorbent to the intended species for removal maximizes performance while minimizing bed size. Selexol Unit2 The Selexol Unit is accountable for capturing the mercaptan sulfur in the Molecular Sieve Unit regeneration gas. UOP has designed the Selexol Unit with peak-dampening operation of the sulfur concentration in the acid gas. A constant flow of 1 rich solvent, with a constant sulfur composition from the surge drum to the Regenerator, permits minimal fluctuation in the sulfur composition in the acid gas.
1 2

. Amine Guard FS is a registered trademark of UOP LLC1. .SELEXOL and UCARSOL are registered trademarks of DOW Corporation.

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Ortloff NGL Recovery The Ortloff Engineering Ltd. Turbo Expander technology is used for efficient recovery of the individual C2 C5 hydrocarbon fractions. Ortloff is a recognized leader in patented NGL Recovery technology that maximizes NGL recovery while minimizing product gas compression requirements. UOP and Ortloff have an alliance that allows UOP to incorporate their technology into the Integrated Flow scheme. This permits UOP and Ortloff to eliminate interfaces between different technology suppliers, and allows them to work closely to insure the NGL Recovery technology is well optimized in the Flow Scheme. CONCLUSIONS & FUTURE DIRECTION There are four trains now in successful operation using the Integrated Flow Scheme approach. Three larger trains are expected to be commissioned in 2008 and 2009. These seven trains all reflect the largest single-train capacity natural gas processing plants in the world. Reflecting back to when the initial design approach for these trains was being formulated, and also looking forward after the experiences of the past 9 years, we offer our vision as to the path forward for future world-scale natural gas plants: Large LNG and NGL Plants will continue to face even greater challenges A market transition to effectively deal with these challenges is occurring. It focuses on a fundamental shift from generic Conventional Flow Schemes to tailored Integrated Flow Schemes for front-end natural gas processing in worldscale LNG and NGL Plants. The benefits of an Integrated Flow Scheme approach are: o Integration and optimization of individual unit technologies into a systems package o Single-source systems engineering integration with elimination of interfaces o Full wrap commercial guarantees for the systems package o Greater facility efficiency and better environmental performance o Significantly shorter project schedule and lower costs by replicating a flexible systems package design for all trains. o Establishing a partner-like relationship between client and technology provider that covers all needs from initial facility design through continuing technical support after years of operation. 2

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