All Natural Gas Slides

4/16/2013
1
NNPC FSTP Engineers
Natural Gas Processing and
Transmission
Course Code:
Lesson 4
NGPT Assessment Plan
4/16/2013
2
Lesson 4
Introduction to
Natural Gas Processing
Lesson 4 Contents
Introduction to Natural Gas Processing
Heat Transfer Process
Refrigeration Processes and Plants
LNG and GTL Processes
Natural Gas Water Content and Hydrate Formation
Dehydration
Sweetening
Gas-to-Liquid Process (GTL)
Natural Gas
C
o
u
r
s
e

W
o
r
k
3
0
%
P
r
o
j
e
c
t

2
0
%
F
o
r
m
a
l
E
x
a
m

4
5
%
A
T
C

5
%
T
o
t
a
l

1
0
0
%
5
-
A
p
r
1
2
-
A
p
r
1
9
-
A
p
r
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Natural Gas Processing
4 Processing of reservoir natural gas involving its separation into its component phases and
the subsequent treatment of the phases into either merchantable or disposable qualities.
Processes include:
4 Separation
4 Heat Transfer
4 Refrigeration
4 Dehydration
4 Sweetening
4 Factional Distillation
4 LPG and, NGL recovery
4 LNG production
4 GTL production
4 Compression and Transmission
Basic Components of Natural Gas
Name Chemical Formula Boiling point(
o
C) State at atm. Pressure
Methane CH4 -165.5 Gaseous at normal
Ethane C2H6 -88.6 atmospheric temp.
Propane C3H8 -42.1 and pressure
Is Butane C4H10 -11.7
Normal Butane C4H10 -0.5 Extremely Volatile
Is Pentane C5H12 27.9 Liquid at normal
Normal Pentane C5H12 36.1 atmospheric
Normal Hexane C6H14 68.7 temperature and
Normal Heptane C7H16 98.4 Pressure
Normal Octane C8H18 125.7
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Version
Why do we process gas ?
4To add value
4To make it dry
4To meet customers specifications
4To manage toxicity and corrosion concerns
4To allow for delivery conditions
4To account for availability requirements
Version
Undesirables in Natural Gas
4 Water (Corrosion / Hydrates)
4 H
2
S (Corrosion / Toxic)
4 CO
2
(Corrosion)
4 Mercury (Aluminum Corrosion)
4 Heavy Hydrocarbons (2 Phase Flow)
Natural Gas Standard Conditions
Standard Cubic Metre
15
o
C (288.15 K) @ 101.325 Pa (1.01325 bar)
Normal Cubic Metre
0
o
C (273.15 K) @ 101.325 Pa (1.01325 bar)
Standard Cubic Foot
60
o
F @ 14.696 psi
(1 scf = 0.0283 scm)
4/16/2013
5
Version
HC States Phase Diagrams
Temperature
Pressure
Dry Gas
Gas Condensate
Light Oil
Heavy Oil
Version
Temperature
Pressure Gas Out
Feed Liquid
Liquid Out
Separator Conditions
(P,T)
Bubble Point (Liquid Out)
Dew Point (Gas Out)
Changing Phase Diagram with Separation
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SLIDE 11
SWEETENING
Specifications
P
T
Water Dew Point
HC Liquid Dew Point
HC LIQUID
REMOVAL
DEHYRATION
Basic Natural Gas Processing Train
Dehydration
Sweetening
LNG
Regasification
GTL
Fractionation
Expansion
Separation
Cooling
NGL Sales
Compression
NG Sales
Gas Well
Oil Well
Crude Oil
Condensate
Gas
Propane
Butane
Pentane+
Separation
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SLIDE 13
NG Ex-Well Mol.% Field Treated mol.% LNG Mol. %
Methane CH
4
70-90%
89.26 88-96
Ethane C
2
H
6
0-20%
4.63 5.0
Propane C
3
H
8
2.65 1.63 - 4
Butane C
4
H
10
- IC
4
0.495 0.2 -1
C
4
H
10
- nC
4
0.785 0.3 -1.5
Pentane+ C
5
H
12
+ 0.681 0.12
Carbon Dioxide CO
2
0-8%
1.5 0.1
Avg Mol.Wt = 18.77 g/mol Gross heating value =
42.7 Mj/std m3
Oxygen O
2
0-0.2%
Water Content 150 ppm Gross heating value =
42.7 Mj/std m3
Nitrogen N
2
0-5%
- -
Hydrogen
sulphide
H
2
S 0-5%
- 5 mg
/m
3
Rare gases A, He, Ne, Xe trace
0.2%
SLIDE 14
Escravos-Lagos Pipeline System (ELPS)
Nominal capacity of 270 MMscf
HC dew point spec of 15 C at 76 barg
Water dew point spec of 7 C at 76 barg
West African Gas Pipeline (WAGP)
620 km pipiline from Nigeria to Ghana
Nominal capacity of 360 MMscfd
HC dew point spec of 10
0
C at 26 barg
Water dew point spec of 7 lb/MMSCF
4/16/2013
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Lesson 4-1
Heat Transfer Processes
Treatment Processes
Processes involving the Transfer of Heat From a Hotter (Higher Temperature)
Medium to a Cooler or Less Hot(Low Temperature) Medium
Treatment Operations Requiring Heat Transfer
Fluids Out of Process Equipment Requiring Specific Temperature Status
Fluids Going into Process Equipment Requiring Specific Temperature Status
Use of Waste Energy for Efficient Processing and Economic Purposes
Fluids Out of Well Requiring different Temperature Processing Conditions
Storage Conditions Requiring Different Temperature From Processing Conditions.
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Treatment Processes
Heat Transfer Benefits
Process Efficiency
Energy Conservation
Reduces Maintenance
Types of Heat Transfer Processes
Refrigeration
Liquefaction
Factors Affecting Heat Transfer
Type of Material.
4Only Materials That Conduct Heat
Thickness of Material.
4The Thicker the Material the Less Its Ability to Conduct.
Conductivity.
4The More Conductive the Material The More Efficient.
Surface Area.
4The Larger the Exposed Area the More Efficient.
Rate of Transfer
4The Higher the Rate the More Efficient.
Flow Rate
4The Higher, the More Heat Transferred.
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Factors Affecting Heat Transfer
Turbulence
4The Greater the Heat Transfer.
The Two Exchanging Media Temperature Difference AT
4the Greater, the Better.
Corrosion and Contaminants
4Reduces the Rate of Heat Transfer.
Fluid API Gravity.
4Generally the Lesser the Better.
The Flow Path
4Counter and Cross Flow Patterns Provide More Heat Transfer
Tube Arrangement
4Triangular Arrangement Provides More Heat Transfer.
Types of Heat Exchangers
Shell and Tube Heat Exchanger
4Major Components
Shell
Tubes and Tube Sheet
Head
Baffles
4Tubes Content
Corrosive and Fouling Fluids
High Pressure Fluid
High Viscosity Fluid
Low Flow Rate Fluid
Dirty Fluid
Internal of Heat Exchanger
Tubes
Baffle
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SLIDE 21
Double Tube Heat Exchanger
4Shell and Tube Sections are Both Tubes
4One Fluid Passes Through Outer Tube While the Other
Passes through the Inside Tube(s)
4Tubes and Shell Configuration
U-Tubed
Manifolded in Parallel and Series
Finned
Manifolded in Parallel
Cut-out Tube area
SLIDE 22
Tubes and Shell Configuration
Fins Configuration
Single Finned Tube
Multiple Finned Tube
Fins Types
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SLIDE 23
4Tubes and Shell Configuration
Types of Shell
4One or Several Pass Shell
4Cross Flow Shell
4Kettle Type Shell
1-Pass Shell, 2-Pass Tube Exchanger
Kettle Reboiler
Floating Tube Sheet
Fixed Tube Sheet
Flow Passes and Pattern
Heat Exchanger Flow Passes.
4This is the number of times the fluid upon entering the heat exchanger passes the
length of the heat exchanger before it exits
4One-Pass Flow
4Two-Passes Flow
4Multi-passes Flow
1-1 pass flow
2-2 pass flow
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Flow Passes and Pattern
Heat Exchanger Flow Patterns
4This is the direction with which the fluids flowing and exchanging heat inside the
heat exchanger cross one another.
4Parallel Flow Pattern
4Cross Flow Pattern
4Counter Flow Pattern
SLIDE 26
Plate-Type Heat Exchanger
4Major Components
Carrying Bars
Fixed Frame/Plate
Pressure Plate
End Plate with Open Ports
End Plate with Blind Ports
Channel Plates with Open Ports
4Plates are Corrugated or Embossed
4Ports Serving One Side of a Plate are Connected to the Side
Carrying Same Fluid on the Alternative Plate
4They are:
Less Expensive
Lighter
More Compact
High in Performance
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SLIDE 27
Plate and Frame Heat Exchanger
SLIDE 28
Plate and Frame Heat Exchanger
Corrugated Plates with Ports
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SLIDE 29
Plate-Fin Heat Exchanger
Basic Construction
4Alternating Aluminium Layers of Corrugated Fins
4Brazed Together and Separated with Flat Aluminium Plates (Parting Sheets)
4Stack of Parting Sheets and Core is Called the CORE
4Can Handle Many Fluids at Once
4Fluid Flow Configuration can be:
Counter Flow
Cross Flow
Cross-Counter Flow
4Can Operate in Very Low Temperature (-269
0
C or -452
0
F)
SLIDE 30
Plate-Fin Heat Exchanger
Basic Construction
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SLIDE 31
Brazed Aluminium Plate-Fin and Tube
Combination Heat Exchanger
Tube Fin-Plate Tube Combination Heat Exchanger
SLIDE 32
Combination Heat Exchanger
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SLIDE 33
Cryogenic Heat Exchangers
Mostly Consists of
4Plate Fins
4Aluminum Core Tubes
Mostly Applicable in
4Very Cold Operations
4High Heat Transfer Operation
They Have:
4Less Weight.
4Maximum Surface Area per Unit
Volume and weight
4Minimum Resistance to Flow
4Low Heat Capacity
Examples of Cryogenic Exchanger
Joy-Collins
Trane
Hampson Ramens Lamella
SLIDE 34
Aerial Coolers
4Forced Draft Aerial Coolers
4 Induced Draft Aerial Coolers
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SLIDE 35
Fired Heaters
Direct Fired Heaters
4Applications
Direct Heating of Process Fluid
Direct Boiling of Process Fluid
Direct Heating of Circulating Fluid(Oil) Which Then Heats or Boils Process Fluid
Direct Heating of Regeneration Gas in Solid Desiccant Dehydration Plants
4Major Components
Burners
Radiant Tubes
Convection Coils
SLIDE 36
Fired Heaters
Direct Fired Heaters
4Types of Direct Fired Heaters
Vertical-Tube Cylindrical Heaters
Horizontal-Tube box-Type Heater
Radiant Tubes
Convection Tubes
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Ono
SLIDE 37
Fired Heaters
Indirect Fired tube Heater
4 Heating Process
Flame and Combustion Gas Heat a Pool of Intermediate Fluid
Intermediate Fluid Transfers Heat to Process Fluid in Coils or Series of Tubes
Transfer of Heat is by Both Radiation and Convection
SLIDE 38
Fired Heaters
Indirect Fired tube Heater
4Heating Process
Flame and Combustion Gas Heat a Pool of Intermediate Fluid
Intermediate Fluid Transfers Heat to Process Fluid in Coils or Series of Tubes
Transfer of Heat is by Both Radiation and Convection
4/16/2013
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Ono
SLIDE 39
Flow Diagram Symbols
SLIDE 40
Heat Exchangers Classification
by Service Types
Coolers.
4Cools /Reduces Temperature by the use of Water/Air.
Air Cool
Water Cool
Heater
4Raises Temperature by Direct Heat Addition (Application).
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SLIDE 41
Heat Exchangers Classification
by Service Types
Phase-change heat exchangers
Condenser .
4Removes Heat while Changing gas to Liquid.
Vaporizer.
4Adds Heat while Changing Liquid to Gas.
Reboiler.
4Adds Heat.
Chiller or Evaporator.
4Process fluid in tubes is Cooled through heat
removal by a Flowing Pool Refrigerant.
Water Condenser
Evaporator
NNPC FSTP Engineers
Transmission
Course Code:
Lesson 4
4/16/2013
22
Lesson 4-2
Refrigeration
Processes & Plants
Lesson 4-2 Contents
Refrigeration
Compression Refrigeration
Expansion Refrigeration
Cascade Refrigeration
Cryogenic Refrigeration
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SLIDE 45
REFRIGERATION
Refrigeration is the cooling of air or liquids to lower(chilled) temperature Level
The lower temperature is used to preserve food, cool beverages, make ice, etc, at out
homes, the medical and food/beverage industry.
In Natural Gas processing, the lower temperature provided by refrigeration is
employed to condense liquid hydrocarbon and water from the gaseous well stream and
also liquefy the natural gas for storage and transportation
Methods of Refrigeration.
4Cooling by Evaporation of a Refrigerant in an Evaporator(Chiller).
4Cooling by Expansion of Process Fluid.
4Combination of the Above Processes.
Refrigeration Systems.
4 Compression Refrigeration.
4 Expansion Refrigeration.
4 Absorption Refrigeration
SLIDE 46
NGL Liquefaction
NGL
4Natural Gas Liquid
4Liquefied Portion (Fraction ) of Gaseous Reservoir Fluid
4Includes Ethane, Propane, Butane, Pentane, Natural Gasoline, and Condensate.
LiquefactionProcesses
4Compression.
4Cooling by Expander.
4Absorption.
4Combination of Any Two or Three of Above.
4CascadeRefrigeration
4Cryogenic Refrigeration
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SLIDE 47
NGL Liquefaction
NGL ExtractionSchematic
SLIDE 48
Mechanical Refrigeration (Vapour Compression Refrigeration).
4Cooling by Evaporation of Compressed Liquid Refrigerant in a
Chiller or Evaporator.
4Principle of Operation:
Liquid Refrigerant Takes Latent Heat of Evaporation to Vaporize.
Heat is Exchanged With the Process Fluid in the Tubes.
Process Fluid Supplies the Needed Heat and Gets Cooled in
the Process.
REFRIGERATION
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SLIDE 49
Mechanical Compression Refrigeration System
Basic Components
4Refrigerant
4Evaporator/Chiller
4Compressor
4Condenser
4Receiver
4Thermostatic
Expansion Valve (TXV)
SLIDE 50
Vapour Compression Refrigeration Process Cycle
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SLIDE 51
Vapour Compression Refrigeration
Process Description
1. Evaporator - point 4 to point 1
Cold liquid from the expansion valve boils
inside evaporator, absorbing latent heat
Reversible heat addition at P
e
= const.
Isobaric boiling (horizontal line on
PV diagram)
Results in evaporation to saturated vapor
Latent heat of vaporization Q (cold)
used
2. Compressor - point 1 to point 2
Cold saturated vapor from the
evaporator is compressed to the
condensing pressure Pc ,
Temperature is raised
SLIDE 52
Vapour Compression Refrigeration
Process Description
3. Condenser - point 2 to point 3
Hot vapor from the compressor condenses
releasing latent heat.
Isobaric condensation (horizontal line on PV diagram)
High Temperature
Latent heat of vaporization Q (hot) released
Reversible heat rejection at P
c
= const.
Results in condensation to saturated liquid.
4. Expansion Valve - point 3 to point 4
Liquid from the condenser is depressurized, lowering its pressure and
boiling point temperature.
Process is adiabatic expansion (vertical line on PV diagram)
No work done W= 0
Throttling (irreversible process) from high pressure Pc to lower
pressure P
e
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SLIDE 53
Refrigeration Load
Refrigeration Load Depends on:
Process Fluid Composition.
Pressure.
Temperature.
Heat Required for Process Fluid Reduction to Chiller Temperature.
Latent Heat Required to Condense Liquefiable Hydrocarbons.
Richer Fluids Require More Refrigeration Load.
SLIDE 54
Refrigerant
Refrigerants.
4Properties of Refrigerants:
Non-toxic.
Non-corrosive.
High Latent Heat of Vaporization.
Compatible With System Needs.
Types of Refrigerants.
4At Chiller Temperature > -25
0
C
Propane.
Ammonia.
4At Chiller Temperature < -25
0
C (Cryogenic)
Methane.
Ethane.
Ethylene
4/16/2013
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SLIDE 55
.
Table 4-1
Properties of Common Refrigerants
No. Refrigerant Boiling Point Chiller
Temp.
Remark
1
Propane
- 44
0
F (- 42
0
C) > -25
0
C Good for 13
0
F (-25
0
C)
Poor Quality Impairs Compressor
Performance
2
Ammonia
- 28
0
F > - 25
0
C Problem of Odor.
Odor Helps to Prevent Large
Accumulation or Spillage without
Notice.
Requires Lower Refrigeration
Circulation than C
3
Requires Higher
hp.
Easier to Handle with Ordinary Steel.
3
Freon 12
-21.6
0
F(-29.8
0
C) > - 25
0
C Safe to Use.
Requires More Hp per Ton of
Refrigeration than C3 and NH4
Requires Low Vapor Pressure and
Low Compression Ratio.
It is Difficult to Store.
Must Avoid the Use of Water with
Freon 12.
Cryogenic Refrigerants
1
Methane
-259
0
F( -161
0
C) < - 25
0
C
2
Ethane
-128
0
F( -89
0
C) < - 25
0
C Quantity above 22% will increase
Compressor Discharge Pressure.
3
Ethylene
- 154
0
F < - 25
0
C
Table 4-1
Properties of Common Refrigerants
No. Refrigerant Boiling Point Chiller
Temp.
Remark
1
Propane
- 44
0
F (- 42
0
C) > -25
0
C Good for 13
0
F (-25
0
C)
Poor Quality Impairs Compressor
Performance
2
Ammonia
- 28
0
F > - 25
0
C Problem of Odor.
Odor Helps to Prevent Large
Accumulation or Spillage without
Notice.
Requires Lower Refrigeration
Circulation than C
3
Requires Higher
hp.
Easier to Handle with Ordinary Steel.
3
Freon 12
-21.6
0
F(-29.8
0
C) > - 25
0
C Safe to Use.
Requires More Hp per Ton of
Refrigeration than C3 and NH4
Requires Low Vapor Pressure and
Low Compression Ratio.
It is Difficult to Store.
Must Avoid the Use of Water with
Freon 12.
Cryogenic Refrigerants
1
Methane
-259
0
F( -161
0
C) < - 25
0
C
2
Ethane
-128
0
F( -89
0
C) < - 25
0
C Quantity above 22% will increase
Compressor Discharge Pressure.
3
Ethylene
- 154
0
F < - 25
0
C
Refrigerant
SLIDE 56
Refrigerant
Sales Gas
Liquid to
Stabilization
Chiller
Separator
Gas-Gas
Heat Exchanger
Inlet Gas
Applications.
4NGL extraction
4Natural Gas Pre-cooling in LNG Processes
Basic Compression Refrigeration NG Processing Schematic
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SLIDE 57
Pressure Expansion
Refrigeration Systems
Refrigeration or Temperature Reduction Due to Expansion of the Process Fluid
on Passing Through Valve/Choke or Turbine
Two Possible Causes
4Joule-Thompson Effect
Without Work Done or Heat Transfer
4Turbine Expansion
With Removal of Work from the Gas Stream
Types of Expansion Refrigeration Systems.
4Valve or Choke Expander Cooling System
4Turbine Expander Cooling System
4Pressure Expander(Reducing) Cooling System
SLIDE 58
4Joule-Thompson Valve/choke
Major Features
Expansion (Joule-Thompson) Valve. Choke Valve.
Self-refrigeration Process
Process Flow and Principle of Operation.
Process Fluid Gets Expanded Going Through Pressure
Reducing Valve/Choke.
Temperature Reduction is Achieved by Joule-Thompson
Effect of Stream Expansion
Constant Enthalpy.
No Heat Transfer
No Work Done
Pressure Drops.
Temperature Drops Due to Non-ideal Behaviour of Fluid.
Pressure Expansion
Refrigeration Systems
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SLIDE 59
Joule-Thompson Valve or
Choke Refrigeration System
Temperature Change is Proportional to Pressure Drop.
Process Fluid Vapour Condenses.
Condensed Fluid May Be Fractionated to Meet Vapour Pressure and
Composition Specification.
J-T Valve
or Choke
Sales Gas
Liquid to
Stabilization
Separator
Gas-Gas
Heat Exchanger
Inlet Gas
Basic J-T Expansion Refrigeration NG Processing Schematic
SLIDE 60
Joule-Thompson Valve or
Choke Refrigeration System
Cooling Associated with Constant Enthalpy is Estimated from Correlation Chart
Temp Drop Vs Press Drop @ Given Press
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SLIDE 61
Low Temperature Separation (LTS) Refrigeration
Plants
Factors Affecting Constant Expansion Systems
4Choke Up-Stream Temperature
Should be as Low as Possible
Determines Amount of Liquid Formed
4Pressure Differential Across Choke
Constant and Property of Choke Design
Determines and Proportional to Temperature Drop
4Amount of Liquid Formed
Determined by the Choke Up-stream Temperature and Pressure
Drop Across Choke
Types of Low Temperature Separation Plants
4LTS Plant Without Hydrate Formation
4LTX Plant With Hydrate Formation
SLIDE 62
LTS Expansion Refrigeration Plant
Without Hydrate Formation
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Typical LTS Schematic
SLIDE 64
Typical LTX Expansion Refrigeration
With Hydrate Formation
4/16/2013
33
SLIDE 65
Typical LTX Expansion Refrigeration
With Hydrate Formation
SLIDE 66
4Any refrigeration system that reduces temperature Extremely Low level -
150
0
F
4Cryogenics
Study that Deals with Effects and Production of Extremely Low Temperature -
150
0
F.
Used in Liquefaction of Natural Gas.
Methane (and Ethane Sometimes) is Removed in the Process.
The Rest Ethane Propane, Butane and Natural Gasoline is Liquefied.
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SLIDE 67
Turbine Expansion Refrigeration System
Expansion Turbine
Sales Gas
Liquid to
Stabilization
Separator
Gas-Gas
Heat Exchanger
Inlet Gas
SLIDE 68
Demethanizer
Separator
Separator
Exchangers
Compressor
Expander
4/16/2013
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SLIDE 69
Major Features.
4ExpansionTurbine Replaces the Joule-Thompsonor Choke Valve.
4Direct-Connected Compressor Makes Use of Work Made Available from
Gas Expansion at Turbine.
4Cooling associated with Turbine Expansion is Modelled Along Lines of
CompressionCalculation
SLIDE 70
Process Flowand Principle of Operation.
4Process Fluid Gets Treatedfor Water and Contaminants.
4Process Fluid is Split into Two Parts;
One Goes Through 1
st
Gas/Gas Heat Exchanger.
The Other Goes Through Demethanizer Side Heat Exchanger.
Two Flows Meet to Enter 2
nd
Gas/Gas Heat Exchanger.
4Cold Residue Gas is Used in Both 1
st
and 2
nd
Heat Exchangers.
4Liquid Condensed at the Heat Exchangers is Separated at the Cold Separator and
Enters the Demathanizer at an Intermediate Point.
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SLIDE 71
4Process Vapour Gets Expanded on Going Through the Turbine.
4Work is Removed from the Process Fluid and It gets Cooled.
4Turbine is Designed to Handle Condensate Formed During this Expansion.
4Process Fluid Expansion Supplies Work to Turbine Shaft.
4Direct-Connected Compressor Extract Work from Turbine Shaft to
Compress Out-Let Sales Gas.
SLIDE 72
4Expansion and Work Supply Reduces Process Fluid Enthalpy.
4Decrease in Enthalpy Causes Larger Temperature Drop and Process Fluid
Condensation.
4Mixture of Gas and Liquid from the Expander Enters Demathanizer through a Top
Separator where Residue Gas is Separated Out.
4Inlet-Gas Temperature to Demethanizer Should be Low (-130 to 150
0
F) to Liquefy
a Lot of Ethane.
4Demethanizer Stabilizes Liquid by Reducing Methane Content to the
Lowest.
4/16/2013
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SLIDE 73
4Bottom Product Temperature is Below Ambient so it is Used to Cool Feed
Gas for Better Refrigeration.
4Bottom Product Methane/Ethane Molar Ratio 0.02 to 0.03.
4Residue Gas
Used for Cooling Inlet Gas in the Gas/Gas Exchangers.
Gets Compressed to Sale Gas Pressure at the Expander Compressor and
Another Regular Compressor.
Gets Heated up at the Reboiler and Leaves for Sales Line.
4Condensed Liquid Gets Stabilized by Demathanizer or De-ethanizer
SLIDE 74
Major Considerations For Turbo-Expander.
4 Materials.
4Carbon Steel > -20
0
F
4Charpy-Impact-Tested Carbon Steel > -50
0
F
43.5% Nichel Steel- 50
0
F to 150
0
F
4Stainless Steel < -150
0
F
4 Water Content of Process Fluid.
Very Low To Prevent Hydrate Formation.
Dehydrator Unit Should be Installed Upstream.
4 CO
2
Content of Process Fluid.
Should be Below 0.5 % Mole.
Higher than 0.5% Mole.
Solid CO
2
Forms on Expander Out-let Gas.
Must Be Removed.
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SLIDE 75
Major Considerations For Turbo-Expander.
4Operating Conditions.
Must Not be severe and Liquid Should not Formed inside Turbine
Will Impair Performance and Result in Plant Shut down.
Operated at Lowest Possible Temperature.
4Gas Final Temp. Depends on:
Amount of Liquid Recovered
Pressure Expansion Ratio
Amount of Work Removed
CO
2
Content
SLIDE 76
4Cryogenic Refrigeration.
4Mostly on Methane and Ethane Recovery from Natural Gas.
4Used in Recovery of Power From Expanding Streams.
4Used in Helium, CO
2
and Hydrogen Recovery Processing.
4Very Low Temperature Separators.
4Refrigeration or Cooling Up To 150
0
F.
4Processes Requiring Pressure Drop Up to or Greater than 500 psia
Turbo-Expander Applications
4/16/2013
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SLIDE 77
4NGL, Helium and Hydrogen Liquefaction.
4Easy and Simple to Operate.
4Require Relatively Low Investment Cost.
4Range of Horse-Power Available 250 10,000 hp.
4Efficiency is Higher (85%) than Mechanical Refrigeration (65 %) For
Processes below 75
0
F.
4Turbo-Expander Must be located at the Lowest Possible Temperature
Point in view of Above.
4Typical Recovery is Between 8 to 12 % of Feed Gas.
Turbo-Expander Applications
SLIDE 78
Special Considerations
in Cryogenic Process.
Contaminants
4Gases
CO
2
H
2
S.
Nitrogen.
4Liquids
Water.
Liquid Hydrocarbons(C
5
+)
4Solids
Dirt
Wax
Iron Sulfide
4/16/2013
40
SLIDE 79
Effects of Contaminants
4Reduce Quality.
4Plug Fine Passages
4Foul Cryogenic Heat Exchangers.
Contaminants Removal by:
4Dehydration ( Molecular Sieve).
4Separation (Separators, Filters, etc.)
4Sweetening.
4Filtration.
4Condensation
SLIDE 80
Cryogenic Heat Exchangers.
4As Treated Earlier.
Cryogenic Pumps
4ShouldHave Extended Shaft Between the Motor and the Pump Body.
4Pump is Inside InsulationBox and Motor Outside.
Cold Box
4Cryogenic Devices are Always Locatedin a Cold Box to Provide Insulation.
Instrument and Control Valves
4Require Extended Shaft.
4/16/2013
41
SLIDE 81
Cryogenic Refrigeration Methods
Basic Cryogenic RefrigerationMethods
4Expander-Compression. Combination Method(As TreatedEarlier)
4Cascade Refrigeration Method.
4Mixed Refrigerant Method
4Multi-Component
4Propane-MRCMethod
SLIDE 82
Cryogenic Refrigeration Methods
Cascade Refrigeration Method.
4Consists of Two or More Separate but Interlocked Refrigeration Systems.
4Cascade Component Systems Mostly Differ in Refrigerants Only.
4System Provides Low Power Consumption.
4Has High Cost of Installation.
4Has Large Number of Equipment.
4Requires Controlling and Monitoring of Many Streams.
4Grades of Refrigerants Used are Normally Expensive.
4/16/2013
42
Ono
SLIDE 83
Propane- Ethane
Cascade Refrigeration System
Propane Refrigeration System Carries out
the First Refrigeration of the Process Fluid
to 40
0
F.
4Ethane refrigeration System then
Chills the Propane Vapor to Liquid
and Process Fluid to 120*
0
F
.
Residue Gas For Sale
Treated Inlet Gas
C
3
C
o
m
p
C
2
Surge Tank
C
3
Surge Tank
C
2
Chiller -120
0
F
C
3
Chiller -40
0
F
De-methanizer
C
2
C
o
m
p
Liquid Gas
Ono
SLIDE 84
Propane-Ethylene- Methane
Cascade Refrigeration System
-250
0
F
Chiller Chiller Chiller
Ethylene
Evaporator
Water
Condenser
Propane
Evaporator
-30
0
F -150
0
F
Second Refrigeration is Done by Ethylene
to 150
0
F.
Third refrigeration is Done by Methane
to 250*
0
F
.
First Refrigeration is Done by Propane to
30
0
F.
.
4/16/2013
43
SITP / O & G
Ono
SLIDE 85
Liquid Stabilization
SLIDE 86
Liquid Stabilization
Stabilization.
4Removal of Liquefiable Gaseous Components of Liquefied Process
Fluid.
4Done by Stripping or Heating.
4Produces Stable Liquid
To Satisfy Gas Line Transport Specification
To Meet Storage TemperatureRequirement
To Obtain Additional Revenue.
4Its Vapour Pressure Must NOT be Greater than the Storage Pressureat
the MaximumStorage Temperature
Liquid TVP = C +RVP
TVD is a Function of Composition so Below is Approximation
4/16/2013
44
SLIDE 87
Fractionation
Recovery of Max. HC Liquid Stable Under Storage Condition with Minimum
Vol. of Soln Vapour Removed
This is Achieved by Fractionation
Separation of Raw HC Liquid into its Components in Series of Columns or
Towers.
Bottom Component is C5+ (Natural Gasoline)
SLIDE 88
Fractionation
Stabilizer
4/16/2013
45
SLIDE 89
Liquid Stabilization Unit with LTS
SLIDE 90
Refrigeration Applications
RefrigerationApplications.
4Propane Liquefaction.
4NGL.
4LNG.
4Recovery of Liquid fromOil Treaters.
4Recovery of Liquid from Stock Tank Vapour.
4Low-Temperature Separation.
4Well Stream Must be Rich of Hydrocarbons.
4Note that a Btu of Heat Subtracted From a System by Refrigeration
4Requires More Work to Achieve than a Btu Supplied To System by Heating.
4Refrigeration Systems Must be Totally and Carefully Insulated.
4/16/2013
46
SLIDE 91
Basic Features
4Gas Expansion By Gas Flow Velocity Increase To Supersonic Level
4Supersonic gas Velocity Results In Astronomical Pressure Drop
4Pressure Drop Attended With Subsequent Temperature Drop
4Liquid Hydrocarbon and Water Condenses out of Gas Stream
Twister Supersonic Separator
SLIDE 92
Basic Components
4Multiple Inlet Guide Vanes Generate A High Vorticity, Concentric Swirl of gas
4Laval Nozzle Expands Saturated Feed Gas Thereby Transforming Pressure Drop To Kinetic Energy
(i.e Supersonic Velocity).
4Pressure Drop Results In A Low Temperature.
4Mist of Water and Hydrocarbon Condensation Droplets Form.
4Cyclic Separator High Vorticity Swirl Centrifuges Droplets to Equipment Wall While Gas Travels
in Middle
4Diffuser Slows Down gas Stream Velocity Gaining Back About 70 - 75% Of The Initial Pressure.
4The Liquid Stream Typically Contains Slip-gas, Which Is Degassed at Compact Liquid De-gassing
Vessel and Then Recombined With The Dry Gas Stream.
4Separated Liquids Get Discharged at About 7 0C. At
4/16/2013
47
SLIDE 93
SLIDE 94
Applications:
4Condense and separate water and heavy hydrocarbons from natural gas
4Water Dewpointing (Dehydration)
4Hydrocarbon Dewpointing
4Natural Gas Liquids extraction (NGL/LPG)
4Heating Value Reduction
4Fuel gas treatment
4Other New Applications such as;
Offshore fuel gas treatment for large aero-derivative gas turbines,
Pre-treatment upstream CO2 membranes and
Bulk H2S removal upstream sweetening plants .
4/16/2013
48
NNPC FSTP Engineers
Transmission
Course Code:
Lesson 4
Lesson 4-3
Natural Gas Water Content
and Hydrate Formation
4/16/2013
49
Lesson 4-3 Contents
Natural gas Water content
Hydrates and Hydrates Formation
SLIDE 98
NG Contains Some Degree of Water at ALL Conditions
Water Content of Natural Gas is expressed in
4lb(water)/MM SCF(NG) for Gas
4Obtained from McKetta and Wehe Correlation Chart
Solubility of Water in Gas
4Increases with Increasing Temperature
4Decreases with Increasing Pressure
4Dissolved Salt in Water Reduces Solubility of Water in Gas
4/16/2013
50
SLIDE 99
Water Dew Point
4Temperature and pressure at which natural gas is saturated with water.
4Temperature at Which Natural Gas is Saturated with Water Vapour at a
Given Pressure
4Water Vapour is in Equilibrium at Dew Point.
4Reduction of Temperature OR Increase of Pressure Will Result Water
Condensation
Water Dew Point Depression
4Difference in Dew Point Temperature of Water Saturated Natural Gas
Before Dehydration and After Dehydration
WDPD = DP(Before) - DP(After)
SLIDE 100
McKetta and Wehe Correlation Chart
.
0
F
5
10
30
60
40
85
4/16/2013
51
SLIDE 101
The Use of McKetta and Wehe Correlation Chart
4The chart is good for 0.7 SG natural gas at 60
0
F with zero Salt content.
4Corrections are obtained from chart
4Water is in lb.water per mm/scf of NG
Example;
What is the water content of 0.9 SG natural gas operating at 85
0
F
and 1000 psia with 2% salt content.
1. Correction for salt content = 0.954
2. S.G correction = 0.98
3. Water content 85
0
F and1000 psia from chart = 40 lb.water/mmscf NG
1. Corrected water content = 40 x 0.954 x 0.98 = 37.4 lb.water/mmscf NG
McKetta and Wehe Correlation Chart
SLIDE 102
Exercise
Exercise
A 0.85 SG Natural gas flowing at 67 mm scf/day contains 55 lb.water/mm
scf with 2% salt content . How many pounds of water will be required
removed by a dehydration plant per day if the pipeline water dew point
require is 20
0
F ? The natural gas feed line operates at 87
0
F and 75 bar.
Does this stream contain any free water?
Solution
Qsc = 67 mm.scf/day, salt = 2%, SG = 0.85, P = 75 x 14.7 = 1100psi,
T = 87
0
F., Water Content = 55 lb.h2o/mm.scf. Required Dew point 20
0
F
From Chart:
At , P = 1100psi, & T = 87
0
F
Salt correction = 0.95, SG corr = 0.98, Water content = 45 lb.H2O/mm.scf
Corr. WC = 0.95x098x45 = 41.9 lb.H20/mm.scf.
Free Water = 55 41.9 = 13.1 lb.H2O/mm.scf.
At T = 20
0
F , P = 1100psi, - from chart
Water content at required Dew Point = 4 lb.H2O/mm.scf
Corrected WC = 0.95x0.98x4 = 3.724
Water removed per day (41.9 3.724)x67 = 2557.79 lb.H20/day
4/16/2013
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SLIDE 103
Hydrates
HYDRATES
4Definition.
Hydrates Are Crystalline(ice-like) Compounds Formed by Combination of
Water and Hydrocarbons Under Pressure at Considerable Higher
Temperature Than Water Freezing Point.
4Hydrates Occurrence
In Pipeline.
In Equipment
Valves.
Regulators.
Chokes
In Formations As Hydrate Rock.
Burning Snow
140
120
100
80
60
40
20
0
0 5 10 15 20 25
TEMPERATURE
P
R
E
S
S
U
R
E
CONDITIONS IN WHICH
HYDRATES ARE LIKELY
TO BE FORMED
HYDRATE CURVE
4/16/2013
53
SLIDE 105
Hydrates Crystal
Hydrocarbons in Hydrates.
4Methane CH
4
. 7H
2
O
4Ethane C
2
H
6
. 8H
2
O
4Propane C
3
H
8
. 18H
2
O
4Butane C
4
H
10
. 24H
2
O
4CO
2
CO
2
. 7H
2
O
4H
2
S H
2
S .6H
2
O
SLIDE 106
Hydrates Crystal
The Hydrate Crystal
4The Water or Host Molecules Are Linked Together by
Hydrogen Bonds Into Cage-like Structures Called Clathrates.
4The Water Framework Though is Ice-like, but
it Has Void Space and It is Weak.
4The Hydrocarbon or Guest Molecules are held together
by Weak Bonds within the Void of the Crystalline Network
or Structure of the Water to Stabilize Water Structure.
4The Water Framework Holds the Hydrocarbon Molecules in
a Void Space or Network.
Hydrate Clathrate
Hydrate Clathrate
4/16/2013
54
SLIDE 107
Hydrate Crystalline Structure
Two Basic Structures:
4Structure II Diamond
4Structure I Cubic or Body-Centered
4Smaller Hydrocarbon Molecules (C
1
,C
2
,CO
2
, & H
2
S) Form More Stable
and Cubic Structures.
4Larger Hydrocarbon Molecules (C
3
& iC
4
) Form Less-stable and
Diamond Structures.
4Molecules Larger Than C
4
Cannot Form Hydrates Because They Cannot
Fit Into the Cavity in the Water Molecule Structure.
Ono
SLIDE 108
Hydrate Crystalline Structures.
.
4/16/2013
55
Ono
SLIDE 109
Hydrate Crystalline Structures.
.
SLIDE 110
Properties of Hydrates
STRUCTURE I STRUCTURE II
Lattice Shape Body- Cubic Centered Diamond
Stability More Stable Less Stable
Water Molecules
per Unit Cell 46 136
Cavities per Unit Cell
Small 2 16
Large 6 8
Typical Gases That Methane* Propane**
Form in Each Cavity Ethane* I-Butane**
of this Structure H
2
S n-Butane**
CO
2
neo-Pentane**
* Small
**Large
4/16/2013
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SLIDE 111
Properties of Hydrates
They Have Fixed Chemical Composition BUT No Chemical Bond
They Behave Like Chemical Compounds.
They are Physically Like Ice or Wet Snow Crystals but Do Not Have Solid
Structure of Ice.
They Have Less Density Than Ice.(SG 0.96 0.98)
They Sink in Liquid Hydrocarbons and Float in Water.
They Contain 90% Water by Weight
SLIDE 112
Conditions for Hydrates Formation
4 Presence of High Concentration of Hydrate forming Gases
4 Presence of Free Water.
4 Natural Gas at or Below its Water Dew Point.
4 Operating Temperature BelowHydrate Formation Temperature for That Pressure and
Fluid Composition.
Hydrate Formation Temperature
Temperature Below Which Hydrates Will Form at a Particular Pressure.
They Form at Hydrate Temperature of the Gas and NOT That of the Component
Gases.
4 The Hydrates Formed are Mixtures of the Hydrates of the Component Gases Rather
than Hydrate of the Natural Gas.
4/16/2013
57
SLIDE 113
4 Presence of Small Hydrate Crystal.
4 Operating at High Velocity or Agitation Through Equipment and Pipe Network.
4 Turbulence Encourages Hydrate Formation; Hence Their Presence Mostly Downstream of
Valves, Regulators, Orifice Plates, Chokes, Sharp Bends, Pipe Elbows, etc. and Upstream
of these Devices if Flow is Turbulent and Temperature is Low.
4 Hydrates Form at Gas-water Boundary With the Forming Molecules Coming From the
Solution.
4 Parameters Such as High Temperature That Encourages High Solubility Enhances
Hydrate Formation.
4 Contaminants Such as H
2
S and CO
2
are More Soluble in Water Than Hydrocarbon and as
Such, More Conducive for Hydrate Formation.
4 Very High Solution GOR Encourages Hydrates Formation Due to High Gas
Molecules Presence
Conditions for Hydrates Formation
SLIDE 114
Hydrates Formation
4/16/2013
58
SLIDE 115
Effect of GOR on Hydrates Formation
SLIDE 116
Hydrates Formation Prediction
Parameters Predicted
4Temperature
OR
4Pressure
at Which Hydrates Will Form.
Katz Gas Gravity Method.
4Uses Gas Gravity, Pressure and Temperature.
4It is Simple but Only an Approximation.
4Values Excellent for Methane and 0.7 or Less SG Natural Gas.
4Not Good for Pipeline Gases.
4Less Accurate for Natural Gas With SG Between 0.9&1.0
4Useless for Streams With Sulfur Compounds and/or Larger Molecules.
4/16/2013
59
SLIDE 117
4 Katz Hydrate Formation Temperature Determination Procedure
Given Gas Gravity and Temperature or Pressure
Hydrate Formation Pressure or Temperature is Got From Katz Graph
If Gas Composition Fractions are Given, Gas SG is then Calculated B4 Going
to Graph
SLIDE 118
Katz Pressure-Temperature Curves for
4/16/2013
60
SLIDE 119
Katz Hydrate Formation Condition
Estimation Method
Example 4-3
Estimate Hydrate Formation
Temperature of Natural Gas With the
Composition Shown Below at 1000
Psia.
Component Mole %
N 10.1
C
1
77.7
C
2
6.1
C
3
3.5
i-C
4
0.7
n-C
4
1.1
C
5
+ 0.8 (Assume C6)
Step 1
Compute the Specific Gravity
Component Mole % MW Z.MW
N 10.1 28 2.83
C
1
77.716 12.43
C
2
6.1 30 1.83
C
3
3.5 44 1.54
i-C
4
0.7 58 0.41
n-C
4
1.1 58 0.64
C
5
+ 0.8 86 0.69
100.0 20.38
SG = 20.38/28.9625 = 0.7 .
Step 2
Read Hydrate Formation
Temperature From Katz Curve
Hydrate Formation Temperature = 65
0
F
SLIDE 120
Baillie and Wichert Method.
Method Used Mostly to Predict Hydrate Formation Temperature of Acid
Gases
Range of Application
4Total Acid Gas Content: 170%
4H
2
S Content 1 50%
4H
2
S/CO
2
Ratio 1:3 10:1
4Correction Has to Be Made for C
3
Content.
4Chart Good for C
3
Content Up to 10%
4/16/2013
61
SLIDE 121
Estimation Procedure
For the Above Gas at 1000 psia
4Compute SG As in Example 4-3 Above.(SG = 0.7)
4Enter Fig. 4-35 at 1000 psia
4Move Horizontally to 0% H
2
S
4Descend Vertically to the Horizontal (SG = 0.7)
4Follow Sloping Lines to the Horizontal Bottom Temperature Scale.
4Read off the Hydrate Temperature = 62
0
F
Ono
SLIDE 122
.
62
3
Correlation Lines
4/16/2013
62
SLIDE 123
Determine Correction for C
3
.
4Interpolate For C
3
= 3.5 Position on C
3
Adjustment Chart.
4Enter Chart at H
2
S = 0%
4Descend Vertically to 1 X 10
3
psia Line
4Move Horizontally to Read the Correction. = +3
0
F
Add Correction.
Hydrate Temperature = 62 + 3
= 65
0
F
SLIDE 124
Other Methods of Hydrates Formation Temperature Estimation
4 Pressure -Temperature Curves
by Gas Processors Suppliers Ass.
4 Hydrates Formation Curves for Gases Undergoing Expansion
by Gas Processors Suppliers Ass.
4/16/2013
63
SLIDE 125
Hydrates Control and Prevention
High Stream Flow Rate (Helps to destroyed week formed hydrates).
Reduction of H
2
S and CO
2
Content.
Keep Lines and Equipment Dry of Liquid Water.
If Water Must Be Present, Stream Must Flow at Above Hydrate Formation
Temperature.
Application of Heat.
Dehydration
If Stream Must Have Water and Must Flow at Low Temperatures, Then
Inhibitors Must Be Injected.
SLIDE 126
Inhibitors .
4Materials Added to Water to Depress its Freezing and Hydrate
Forming Temperature.
Inhibitor Temperature Range
Methanol Any
Di-Ethylene Glycol (DEG). > -10
0
F
Ethylene Glycol (EG) < -10
0
F
Tri-ethylene Glycol (TEG) >> -10
0
F
4/16/2013
64
SLIDE 127
.
Inhibitor Concentration in Water Phase
W = D. M 100
K
i
+ D . M
W = Weight % Inhibitor in the Water Base
M = Mol. Weight of Inhibitor
D =
0
C (
0
F) Depression of Hydrate Point.
K
i
= Constant
Inhibitor K
i
Methanol, 1297 (
0
C) or 2335 (
0
F)
Glycols 2220 (
0
C) or 4000(
0
F)
SLIDE 128
Effect of DEG on Hydrate Formation
Freezing Point of DEG Glycol
4/16/2013
65
SLIDE 129
.
Problems Caused by Hydrates
4Hydrates in Flow Line Reduces Well Head Pressure.
4Hydrates Can Block Flow Line and Equipment.
4Hydrates Can Constrict Equipment Surface Lines and Flow Strings.
4Fouling of Heat Exchangers.
Problems Caused by Hydrates
SLIDE 130
In-Class Exercise
A natural gas is to be compressed to flow 150 mm scf/day at 95.24 barg from
Lagos to Syracuse in Italy in the new Nigeria-European transcontinental
line. Yearly average temperature of Lagos is 30
0
C while Syracuse lowest
temperature in Winter is 5
0
C. Frictional losses on this journey have been
estimated at about 7.14% by the Crypto Inc. the pipeline designers. In
Lagos, Tolu Laboratories Ltd using equilibrium calculation method
estimated this gas hydrate formation temperature to be 46.4
0
F at 1283 psi.
MW = (150 gm/mol), density = 9.35 ppg
Questions:
1. Does this gas journey require any hydrate formation prevention
intervention?
1. If so, how many gallons of glycol would you recommend to prevent hydrate
formation?
4/16/2013
66
NNPC FSTP Engineers
Transmission
Course Code:
Lesson 4
Lesson 4-4
Dehydration
4/16/2013
67
Lesson 4-4 Contents
Dehydration
Batch Dehydration Process
Continuous Dehydration process
SLIDE 134
Dehydration
Dehydration
4Removal of water and/or water vapour
Reasons for Water Removal
4Water reduces natural gas heating value
4Water and Natural gas form solid, ice-like hydrate that plugs equipment.
4Natural gas with water and CO
2
/ H
2
S is corrosive.
4Condensed water from natural gas causes slugging flow condition.
4Water increases natural gas volume and the natural gas line capacity.
4/16/2013
68
SLIDE 135
Dehydration Equipment
Equipment
4Free Water Knock-out.
43 Phase Separators.
4Emulsion Treaters.
4Heater Treaters.
4Chemical Treatment.
SLIDE 136
Dehydration Processes
Processes
4Director Cooling.
Cooling Gas Stream for Dehydration Purpose
Mechanical Refrigeration
Expansion Through Choke
LTS
4Compression followed by Cooling.
4These Two Methods Do not Reduces Gas Dew Point.
4 Absorption.
4 Adsorption.
4/16/2013
69
SLIDE 137
Adsorption Dehydration
Removal of Water by Solid Materials Called Desiccants
Desiccants.
Solids That Have Affinity For Or Ability To Hold Water To Their Surfaces.
Adsorption.
4The Process Whereby Solids Take In And Hold Water or Gas Molecules
To Themselves.
4Process Whereby Solids Are Used To Remove Water.
SLIDE 138
Characteristics of Solid Desiccants
4They Have Large Surface Area Per Unit Weight. - 500 to 800 m
2
/gm
4The Surface Area Consists of Small Pores With Capillary Openings.
4Liquid Vapor is Held and Concentrated at the Surface by Forces
Presumably Caused by Residual Valency, Capillary, Chemical Reaction or
Intermolecular Forces.
4They Have Capability to Remove Almost All Water Content of Gas to the
Tune of 1.0 lb/MM SCF;
4Has Higher Efficiency than Other Dehydration Agents.
4/16/2013
70
SLIDE 139
Characteristics of Desiccants
4They are Applicable to High Temperature Operation to the Tune of 125
0
F.
4Lower Dew Points can be Achieved Over a Wide Range Conditions of
Operation with Solid Desiccants.
4Their Efficiency Reduces with Each Regeneration and Material Deteriorate
due to Surface Attrition or Abrasion.
4They Produce Dry Gas.
4Cheap and Easily/Economically Regenerated.
4Non-Corrosive, Non-Toxic and Chemically Inert.
SLIDE 140
Types of Desiccants .
4Silica Gel.
4Silica-Based Beads
4Activated Alumina
4Activated Bauxite
4Membranes
4Carbon(Charcoal) -Not for Water
4Molecules Sieves.
Crystalline or Metal Alumino-Silicates Zeolite) Which Have Great
Affinity for Water.
They are Synthetic Crystals Manufactured to Contain Uniform
Cavities
They are also used for CO
2
and H
2
S Sweetening
4/16/2013
71
SLIDE 141
Molecular Sieves Characteristics
4 Cavities Have Electric Charges that Attract Polar Molecules
4 Polar Molecules are Adsorbed in Preference to Non-Polar Molecules
4 Unsaturated Hydrocarbons are Also Adsorbed in Preference to Saturated Hydrocarbons.
4 Cavities are interconnected by pores
4 Adsorption Takes Place in the Crystalline Cavities
4 Diameter of Cavity Determines Size of Molecules that can be Adsorbed.
SLIDE 142
Molecular Sieve Structure Diameter
.
4/16/2013
72
SLIDE 143
.
.
SLIDE 144
Solid Desiccant Dehydration Plant
Components
4Contractor (Absorber or Sorber)
Has beds of Granular Desiccants Where Adsorption Occurs.
Fluid Inlet and Outlet Connections.
Flow is Down the Column; Reduces Disturbances.
4Filter Separator
Removes all Solids and Contaminants.
4Regeneration Gas Heater.
Produces Hot Regeneration Gas
4Regeneration Gas Cooler
Cools the Rich Regeneration Gas.
4Regeneration Gas Scrubber.
Removes the Water from the Regeneration Gas.
Produces the Cool Gas for Contractor Beds Cooling.
4/16/2013
73
SLIDE 145
Process Plant Lay-Out
Ono
SLIDE 146
Inlet Gas Dehydration Cycle
.
4Rich Inlet Gas Stream Goes Through Filter
For Contaminant Removal.
Inlet gas Flows Contactor From
Top, Goes Through Desiccant Beds
and Got its Water Removed.
4/16/2013
74
SLIDE 147
Desiccant Beds Regeneration Cycle
4 Desiccant Beds Regeneration
4 Hot Regeneration Gas From Heater is
Released at the End of Dehydration Cycle
to Remove All Water From Beds Flowing
from Bottom to Top.
.
4 Boiling and Evaporation Starts at 240
0
F
and Continues Till 350-375
0
F for 4 Hours.
4 While One Adsorber is Dehydrating, The
Other is Being Regenerated.
.
SLIDE 148
Desiccant Beds Cooling Cycle
4 Hot Regenerated Desiccant Beds are
Cooled by Shutting off or Bypassing the
Heater.
4 Cool Regeneration Gas from Scrubber then
Flows From Top Downwards to Cool Beds.
Cooling Terminate at 125
0
F.
.
4 The Cool and Hot Regeneration Gas
Finally Goes Through the Regeneration
Cooler and Scrubber for All Adsorbed
Water to Condense Out.
4 Power Operated Valves, Activated by a
Timing Device, Switch the Adsorber
Between Dehydration, Regeneration and
Cooling Steps
.
4/16/2013
75
SLIDE 149
Major Points of Consideration.
4Efficiency Decreases With Each Regeneration.
4Plant is Always Put in Operation More Quickly after Shut Down.
4Plant can be Adopted For Hydrocarbon Liquid Recovery.
4Removal of all Contaminants Must be Ensured.
4Operating Life of Desiccants is Between 1- 4 Years.
4Sudden Pressure Surges Should be Avoided.
SLIDE 150
Absorption Dehydration Process.
Definition
Absorption is a Process Whereby Water or Water Vapor is Attracted or
Removed by a Liquid Agent.
Liquid Desiccant
4Liquid that absorbs water.
Types of Liquid Desiccants.
4Ethylene Glycol - EG
4Di-ethylene Glycol DEG
4Tri-ethylene Glycol TEG
4Tetra-ethylene Glycol T
4
EG
4/16/2013
76
NATURAL GAS
WATER
GLYCOL
Absorption
Process
GLYCOL
NATURAL GAS
Rich Glycol
NG
Water
Molecules
SLIDE 152
Advantages of Tri-ethylene Glycol (TEG)
4Lower Capital and Operating Cost.
4Decomposition Temperature is Very High (404
0
F)
DEG is 328
0
F
4Low Viscosity (Above 70
0
F)
4Lower Vaporization Loss than EG or DEG
4More Easily Regenerated to Concentration of 98- 99.95% due to its High
Boiling and Decomposition Temperature.
4/16/2013
77
SLIDE 153
Tri-Ethylene Glycol(TEG) Dehydration
Requirements for TEG Dehydration
4Inlet Gas Stream Must Be Free of:
Free Liquid Water
Liquid Hydrocarbon
Wax
Sand
Mud
Other Solid Contaminants
4Dew Point Depression Achieved Depends on:
The Contact Temperature With TEG
Dew Point /Temperature of TEG.
SLIDE 154
TEG Dehydration Plant
4 Components
Inlet Scrubber
Removes Entrained or Free Water Which:
Increases Fuel Cost
Increases Reboiler Heat Load.
Increases Glycol Re-circulation Rate.
Causes System Over Load Resulting in Glycol Carry-over From
Contactor or Still.
4/16/2013
78
SLIDE 155
Removes Oils or Dissolved Hydrocarbons Which:
Reduces Drying Capacity of Glycol
Combined With Water to Cause Foaming.
Undissolved Oils Can Plug Absorber Trays.
Undissolved Oil Also Increases Glycol Viscosity and Cokes on Heat
Transfer Surfaces of the Reboiler
4 Removes Entrained Brine Which
Dissolves on Glycol and Becomes Corrosive.
Deposit on Boiler Fire Tubes
Cause Hot Spots
SLIDE 156
Removes Down-Hole Additives Such as:
Corrosion Inhibition Materials
Acidizing Materials
Fracturing Materials
4These Can Cause
OFoaming
OCorrosion
OHot Spots
Removes Solids(Sand, Rust, Fe, etc)
Promote Foaming
Erode Valves
Erode Pumps
Plug Trays and Packing
4/16/2013
79
SLIDE 157
TEG Dehydration Plant
.
Aerial
Cooler
SLIDE 158
Contactor Absorber
.
4/16/2013
80
SLIDE 159
4Contactor (Absorber).
Scrubber Section.
4Centrifugal Separator
4Mist Extractor
4Removes Remaining Entrained Liquid Droplets.
4Minimize Contamination of Glycol.
4Prevent Presence of Free Water
Absorber Section
4Cooling Coils
4Drying Section
OBubble Cap
ODowncomers
4Mist Extractor
TRAY COLUMNS:
Bubble cap tray, Sieve tray, Valve tray and
Baffle tray.
Internals and Operations of Contactor,
Distillation and Stabilization Columns.
Advantages of Tray Columns.
SLIDE 160
Typical Commercial Trays
.
.
Bubble-Cap Tray
Sieve Tray
Standard Flexitray Valve
Flexitray Valve Tray
4/16/2013
81
SLIDE 161
4 Drying Section
4 Mechanism of Operation
Bubble Cap Trays
Divides Gas into Small Bubbles in Continuous Liquid Phase
Spray Chambers (Sieve or Valve Trays):
Forming the Liquid into Small Droplets in a Continuous Gas Phase
Packed Columns
Spreading the Liquid into Thin Films that Flow through a Continuous Gas Phase
SLIDE 162
4 Drying Section
4 Gas Gets in Contact on Moving Up
With Glycol in Bubble Cap or Valve
Trays.
4 Trays Spacing Should 18 to 24-30 to
Prevent Foaming.
4 Circulation Rate of TEG Per lb. of Water
Removed is Inversely Proportional to
the No. of Trays.
3-6 Trays 3 gal TEG/lb. Water
> 8 Trays s 2 gal TEG/lb. H
2
O
.
Operation of the Bubble Cap
4/16/2013
82
Gas
flow
Liquid
flow
Holes drilled
1/8to 1/2 in.dia
Sieve plate
Sieve Tray Column
Liquid inlet
Liquid outlet
Gas inlet
Gas outlet
Gas bubble
Gas
flow
Liquid
flow
VALVE PLATE
Valve open
(Gas flows)
Valve close
(No Gas flow)
Liquid inlet
Liquid outlet
Gas inlet
Gas outlet
4/16/2013
83
SLIDE 165
Packed Columns
.
.
Packed Elements
Intalox Packing
SLIDE 166
Glycol Cooler.
4Inlet Lean Glycol Got Cooled by
Exchanging Heat with the Out Going
Dehydrated Gas.
4Shell & plate type
Shell : rich glycol
Plate : lean glycol
Mist Extractor
4 Extracts all Entrained Glycol Droplets
From Out Going Dehydrated Gas.
Glycol Pump
4/16/2013
84
Mist Extractor GAS OUTLET
MIST
EXTRACTOR
TOP TRAY
LIQUID
STREAM
ENTRAINED
LIQUIDS
SLIDE 168
Glycol Strainer
Removes Solid Content From Lean Glycol.
Solid Should be Kept to 0.0I Weight % to Prevent
4Heat Exchanger Plugging
4Fouling of Contactor Trays.
4Foaming.
4Pump Wear, etc
4/16/2013
85
SLIDE 169
Heat Exchangers Surge Tank.
4Cold Wet Glycol from the Flash Separator Gets Heated Up by the Hot Lean Glycol
From Reboiler
4It Also Serves as Surge Tank for the Lean Glycol
Reboiler with Stripping Still.
4Regeneration of glycol by heating/boiling: rich lean
4Heat source: natural draught burner
4Operating @ 118 C and 100 mbarg
To achieve required purity of glycol
To minimize glycol decomposition
4Normally Boils Glycol to Re-concentrate it to 98.7 %
4Gets to 99.6% with Stripping Gas.
4Mostly Heated by Direct Fire Tube(Box) Using NG as Fuel or
Hot Heated Coil Fire Box or
SLIDE 170
Re-Boiler and Stripping Still
Typical Direct Fired Reboiler Temp. Profile
4Operating @ 118 C and 100 mbarg
To achieve required purity of glycol
To minimize glycol decomposition
4/16/2013
86
SLIDE 171
Re-Boiler and Stripping Still
Stripping Still
4Distillation of glycol and water
4To minimize glycol losses via overhead vapour
4Stripping Still Strips water from Glycol
4Internals:
Random packing: Pall rings
Inlet device: half open pipe
Reflux condenser
4To minimize glycol losses via overhead vapour
4Rich glycol is cooling medium
4Shell (overhead vapour) and Coil (glycol) design
4Globe valve to set reflux ratio; normally closed
Rich Glycol
IN
Rich Glycol
OUT
Reflux
Condenser
SLIDE 172
4 Stripping Gas
Any Gas that is Insoluble in Water and Can Withstand 400
0
F
Natural Gas is Commonly Used.
Sometimes Taken From the Fuel Gas Line by a Valve and Injected Into the Reboiler.
It Rolls the Glycol to Release Any Pockets of Water Vapor.
It Also Sweeps All the Water Vapor From the Reboiler and the Still Column.
Raising TEG Concentration Beyond (to 99.96%)
4 Vacuum Pump
Installed in the Reboiler or the Still Column Can Also Achieve the Same Feat
4/16/2013
87
SLIDE 173
Factors for Consideration in TEG Plant Operations.
4Water, Hydrocarbon Liquids and Lubricating Oils in Gas Require That an
Efficient Separator Be Installed Upstream of Absorption Tower.
4Water With High Concentration of Minerals in Gas May Crystallize Over a
Long Period and Fill the Reboiler With Solid Salts.
4Highly Concentrated Glycol May Be Difficult to Pump at Low
Temperature Because of Their High Viscosity.
SLIDE 174
Factors for Consideration in TEG Plant Operations.
4In Cold Weather Regions, Glycol Lines Have Tendency to Solidify If Not
in Use, Therefore Continuous Circulation is Required.
4Sudden Surges Should Be Avoided in Starting and Shutting Down the
Plant to Avoid Occurrence of Large Carry-over Losses of Glycol.
4Foreign Matter Such As Dirt, Iron Oxide, etc. Can Contaminate Glycol.
4Decomposition of Glycol May Occur If Overheated.
4The Presence of Oxygen and Hydrogen Sulphide May Cause
Corrosion.
4/16/2013
88
Typical TEG Dehydration Plant
Process Flow Diagram
SLIDE 176
AGG Plant
Major Processes.
4Compression
4Cooling
4Condensate Extraction
4Dehydration
Compression
(12.3 bar)
Condensate
Extraction
Dehydration
Cooling
Cooling
Cooling
Condensate
Extraction
Condensate
Extraction
Compression
(70 bar)
Compression
(30 bar)
Sales Gas
Inlet
Gas
4/16/2013
89
Typical Compression Station
NNPC FSTP Engineers
Transmission
Course Code:
Lesson 4
4/16/2013
90
Lesson 4-4
Dehydration
SLIDE 180
Disadvantages Of TEG Plants.
4Water, Hydrocarbon Liquids and Lubricating Oils in Gas Require That an
Efficient Separator Be Installed Upstream of Absorption Tower.
4Water With High Concentration of Minerals in Gas May Crystallize Over a
long Period and Fill the Reboiler With Solid Salts.
4Highly Concentrated Glycol May Be Difficult to Pump at Low Temperature
Because of Their High Viscosity.
4In Cold Weather Regions, Glycol Lines Have Tendency to Solidify If Not in
Use, Therefore Continuous Circulation Is Required.
4/16/2013
91
SLIDE 181
Disadvantages Of TEG Plants.
4Sudden Surges Should Be Avoided in Starting and Shutting Down the
Plant to Avoid Occurrence of Large Carry-over Losses of Glycol.
4Foreign Matter Such As Dirt, Iron Oxide, etc. Can Contaminate Glycol.
4Decomposition of Glycol May Occur If Overheated.
4The Presence of Oxygen and Hydrogen Sulphide May Cause Corrosion.
SLIDE 182
Comparison of Solid Desiccant
and Glycol Dehydration Systems
4/16/2013
92
SLIDE 183
TEG Dehydration Design
Basic Information
4Inlet Gas Water Content (lb/mm Scf)
4Dehydrated(outlet) Gas Water Content. (lb/mm Scf)
4Inlet Gas Flow Rate. (mm Scf/day)
4Inlet Gas Temperature(
0
F)
4Inlet Gas Pressure.(psig.)
4 Inlet Gas Specific Gravity.
4Contactor Working Pressure. (psig)
SLIDE 184
Major Factors For Consideration
4TEG Circulation Rate(L
W
).
Gal/lb. H
2
O Removed
2-6 Gal/lb.H
2
O(Normal Ops.)
2.5 4 Gal/lb.H
2
O(Field Ops)
4TEG Concentration
99.9% Possible
99.5% Adequate
Sivalls Charts and Tables
Scrubber Design
4Determine Type of Scrubber
Guided by Gas Stream Composition
Either 2-phase or 3-phase
4/16/2013
93
SLIDE 185
4 Calculate Gas Flow Rate
Operating Pressure.
Operating Temperature.
Gas Compressibility.
4 Determine Scrubber Diameter.
Gas Capacity
Operating Pressure.
Scrubber Capacity(mm scf/day)
4 Note that Fig. is 0.7 SG and 100
0
F. Gas
Charts for Other Conditions are Available.
4 Determine Other Scrubber Specs. From Tables 4-
6 and 4-7.
Gas Capacity of Vertical Gas Scrubber.
SLIDE 186
Vertical Scrubbers Specifications
Gas Capacity of Vertical Gas Scrubber.
4/16/2013
94
SLIDE 187
Glycol Contactor (Asorber)
4Select a Contactor Diameter.
Fig. For Trayed Column
Fig. For Packed Column
Using;
Operating Pressure
Concentrator Inlet Gas Flow Rate.
Approx. Contactor Required Gas
Capacity
+ Obtained Gas Capacity has to be Corrected
for Gas Gravity(0.7) and Operating(100
0
F)
Temp.
Gas Capacity for Tray Glycol Contactors
SLIDE 188
Gas Capacity for Packed Column Contactors
4/16/2013
95
Ono
SLIDE 189
TEG Contactors Specifications
SLIDE 190
TEG Contactors Specifications
4/16/2013
96
SLIDE 191
4 Correct Approx. Capacity to Actual Contactor Gas Capacity q
op
q
op
= q
s
. C
t
. C
g
q
op
= Contactor Gas Capacity at Operating Condition(mmscf/day)
q
s
= Contactor Gas Capacity at Standard Conditions of 100
0
F with 0.7 SG and
From Fig 4-50.
= Contator Inlet Gas Flow Rate(mm Scf/day)
C
t
= Operating Temperature Correction Factor
0
F(Table 4-6A)
C
g
= SG Correction Factor(Table 4-6C)
SLIDE 192
Correction Factors for Temperature and Specific Gra vity

Operating
Temperature,
O
F
40
50
60
70
80
90
100
110
120
Source: After Sivalls.

Correction
Factor
Ct
1.07
1.06
1.05
1.04
1.02
1.01
1.00
099
098

50
50
70
80
90
100
110
120

0.93
0.94
0.96
0.97
0.99
1.00
1.01
1.02
C
Gas Capacity Correction F actors for
Trayed Glycol -Gas Contactors
Specific Gravity Correction Fac tors, Cg
Gas Specific Correction Factor,
Gravity C g

D
Gas Capacity Correction Factors for
Packed Glycol -Gas Contactors
Specific Gravity Correction Factors, C g
Gas Specific Correction Factors
Gravity Cg

0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90

1.14
1.08
1.04
1.00
0.97
0.93
0.90
0.88

0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90

1.13
1.08
1.04
1.00
0.97
0.94
0.91
0.88
A
Gas Capacity Correction Factors for
Trayed Glycol -Gas Contactors
Temperature Correction Factors, C t
B
Gas Capacity Correction Factors
for Packed Glycol -Gas Contactors
Temperature Correction Factors, Ct.
Operating Correction
Temperature, Factor,
OF Ct
Operating
Temperature
0
F
Correction
Factor
Ct
Table 4-6
Gas Capacity Correction Factors
4/16/2013
97
SLIDE 193
Determine Required Dew Point
Depression.
4Determine Outlet Gas Dew Point From
Fig. 4-53 Using
Operating Pressure.
Required Outlet Gas Water Content.
4Inlet Gas Assumed Saturated With Vapor
and is at Its Dew Point Temp. and
Pressure.
Dew Point Depression =
Inlet Gas Temp.- Outlet Gas Dew
Point Temp.
0
F
5
10
30
60
SLIDE 194
Rate of Water Removal (W
r
).
= lb.(H
2
O) Removed
hr
= (Inlet Gas - Outlet Gas) Water Content x (Gas Flow)
24
W
r
= (W
i
- W
o
) q
o
24
W
r
= Rate of Water Removed(lb/hr)
W
i
= Inlet Gas Water Content (lb.H
2
O/mm cf Gas)
Wo = Outlet Gas Water Content (lb.H
2
O/mm cf Gas)
q
o
= Gas Flow Rate (mm scf/day)
4/16/2013
98
SLIDE 195
Correct Water Content for H
2
S and CO
2
if Present
Tray Contactor Special Consideration
4Number of Trays Selection.
Sivalls Tray Chart
Determines Trays Number Using
Dew Point Depression From Above.
Selected Glycol(gal) to Water(lb) Circulation Rate(L
w
).
4Gives Approx. No. Required for Field Dehydrators
SLIDE 196
Sivalls Number of Trays/Packing Chart
4/16/2013
99
SLIDE 197
Modified McCabe-Thiele Diagram.
4Gives More Detailed Consideration For Required number for Economic Sizing.
4Gives Theoretical Number of Trays.
4Above Converted to Actual Tray Number by Tray Efficiency Factor
TN
actual
= TN
theor
X E
ct
E
ct
= Tray Efficiency Factor
SLIDE 198
Construction of Modified McCabe-Thiele Diagram
4Determine Rich TEG Conc. Leaving Contactor.
Rich TEG Conc. =
= Density of Lean TEG - lb/gal
= 8.33 x SG
SG = Specific Gravity of Lean Glycol at Contactor Operating Temperature.
= TEG to Water Circ. Rate Gal.Teg/lb.H
2
O
Rich TEG Conc. Conc. of TEG From Contactor(%)
Lean TEG Conc. Conc. of TEG Entering Contactor(%)
w
i
i
L
Conc TEG Lean
1
.) (
+

i
w
L
4/16/2013
100
SLIDE 199
The Diagram Construction
4McCabe-Thiele Diagram Operating Line.
Determine Gas Water Content and TEG Conc. at Column Top.
Point of Gas Outlet With Given H
2
O Content and Lean TEG Entry With Given
Conc.
lb(H
2
O)/mm scf(gas) and % Conc. Lean TEG
Determine Gas Water Content and TEG Conc. at Column Bottom
Point of Gas Inlet With H
2
O Content As Determined by Operating Press. and
Temp. and Rich TEG Outlet With Conc. as Calculated.
lb(H
2
O)/mm scf (Gas) and % Conc. Rich TEG.
Plot These Points and Draw the Operating Line as Shown Between the Two Points.
SLIDE 200
McCabe-Thiele Diagram
4 McCabe-Thiele Diagram Equilibrium Line.
Represents Water Content of Gas That
Will Be in Equilibrium With Various TEG
Conc.
With the Operating Temp, Choose Various
Conc. Fig 4-56
Determine Equilibrium Dew Points at
Contactor Operating Temp.
Determine Gas Water Content for Each
Conc. From Fig. 4-53
Construct the Equilibrium Line With the
Above Points
4/16/2013
101
SLIDE 201
Dew Point of Aqueous TEG Vs Temperature
Fig 4-56
SLIDE 202
Table 4-6
Determine Theoretical Trays Number
4Step off by Triangulation on the Two McCable-Thiele Diagram Lines.
4Actual Tray Number = No. Of Theoretical Trays
Tray Efficiency
Contactor Bubble Cap Tray Efficiency = 25%
Valve Tray Efficiency = 33.5%
Tray Spacing = 24
* Always Round Up Trays Number.
4/16/2013
102
SLIDE 203
Packed Contactor Special Consideration. Fig 4-53
4Depth of Packing = No. of Theoretical Trays.
4Depth Footage is Normally Rounded up to Whole Number
Glycol Reconcentrator
4Glycol Circulation Rate(L).
gal/hr
L
w
Teg/H
2
O Conc. Ratio
gal(Teg)/lb (H
2
O)
Wi Inlet Gas Water Content.
lbH
2
O/mm Scf (Gas)
q
o
Gas Flow Rate at Operating
Conditions(mm Scf/day)
24
o i w
q W L
L =
SLIDE 204
Reboiler
4Total Heat Load(H
t
)
By Estimation
H
t
= 2000 L
Normally Enough for HP Requirement of Glycol Dehydrator Sizing.
Detail Determination
H
t
= H
L
+ H
w
+ H
r
+ H
h
H
L
= TEG Heat Requirement(Btu/hr)
=
i
= TEG Density at Reboiler Average Temp. lb/gal
C = TEG Specific Heat at Reboiler Avg. Temp. btu/lb/
0
F
T
2
= TEG Outlet Temp.
0
F
T
1
= TEG Inlet Temp.
0
F
= 1200 for High Pressure TEG Dehydrator
( )
1 2
T T C L
i

( )
1 2
T T C
i

4/16/2013
103
SLIDE 205
H
w
= Water Heat of Vaporization Btu/hr
= 970.3 (W
i
- W
o
) q
o
24
970.3 = Water Heat of Vaporization at 212
0
Fand 14.7 psia in btu/lbm
H
R
= Heat Needed to Vaporize Reflux Water in the Still
= 0.25 H
w
Btu/hr
H
H
= Heat Losses From Reboiler and Stripping Still Surfaces(Btu/hr)
4 H
H
By Estimation
H
H
= 5000 to 20,000 Btu/hr Depending on Size.
4 H
H
By Detail Determination
H
H
= 0.24 A
s
(T
2
- T
1
); A
s
Total Reboiler and Still Exposed Surface Area Ft
2
T
2
Vessel Fluid Temp.
0
F
T
1
Min. Ambient Temp.
0
F
0.24 Heat Load Constant For Large Insulated Surfaces btu/hr/ft
2
.
0
F
SLIDE 206
Fire Box Surface Area
4Required Info.
Heat Flux of About 7000 Btu/
0
F
A
F
= H
t
= Total Surface Area of Fire Box (ft
2
)
7000
= Fire Box Diameter x Overall U-tube Length
= D
F
X L
F
4 Table 4-7 Consists of Specs of Glycol Concentrator Components.
4/16/2013
104
SLIDE 207
SLIDE 208
Types of Pumps
4Glycol Pumps
Uses Rich Glycol to Pump Lean Glycol.(Table 4-8 for Selection)
4Positive Displacement and Centrifugal Pumps
Glycol Flash Separator
4Sized by Retention Time
4 Flash Separator Retention = 5 mins.
V
L
= LT Settling Vol.(gals)
60
V
L
= Settling Volume gal
T = Retention time - 5 mins
L = Glycol Circulation Rate- Gal/hr
4/16/2013
105
SLIDE 209
Sivalls Stripping Still Chart
SLIDE 210
TEG Reconcentrator Specifications
.
4/16/2013
106
SLIDE 211
TEG Dehydration Design Example
Example
Size a TEG Dehydrator System for a Gas Stream to be dehydrated to meet the following requirements.
Gas flow Rate 10.0 mm sfc/day
Gas specific Gravity 0.70
Operating Line Pressure 1000. 0 psig
Contactor Max. Working Pressure 1440.0 psig
Gas Inlet Temperature 100
0
F
Outlet Gas Water Content 7.0 lb H2O/mm scf
Selected Design Criteria:
TEG to Water Circulation Rate 3.0 galTEG/lb H2O
Lean TEG Concentration 99.5 % TEG
Use Trayed-Type Contactor With Valve Trays
Contactor Sizing
a. With Gas Flow Rate of 10.0 mm scf/day and 1000 psig Operating Pressure, From Fig 4-51a Select 24 Diameter.
b. Approx. Gas Capacity at 24 Diameter and 000 psig = 11.3 mm scf/day
c. From Table 4- 6, C
t
= 1 and C
g
= 1
qo = qs . Ct . Cg = 11.3 x 1.0 x 1.0 = 11.3 mm scf/day
SLIDE 212
Dew point Depression and Water Removed.
From Fig. 4-53
Dew Point Temp. Water Co lb. H
2
O/mm cf ntent
Inlet 100
0
F 61
Outlet 33
0
F 7
67
0
F 50 lb. H2O/mm cf
3. Required Number of Trays
1. Using Sivalls Chart Fig 4-54
With Dew Point Depression - 67
0
F
TEG to Water Circulation Rate(L
w
) - 3.0 gal. TEG/lb. H2O
No. of Trays = 4.5
.2. Using McCabe-Thiele
i. Lean TEG Density = 1.11 x 8.34 = 9.266 lbm/gal.
ii. Rich TEG Conc. =
= 0.995 x 9.266 = 0.96 = 96%
9.266 + 1/3
w
i
i
L
Conc TEG Lean
1
.) (
+

4/16/2013
107
SLIDE 213
iii. Operating Line Points.
Column Top 7.0 lb. H
2
O/mm cf and 99.5 % TEG
Column Bottom 61 lb H
2
O/mm cf and 96.0 % TEG
iv. Equilibrium Line Points
Percentage TEG Equilibrium dew Point Water Content of Gas
Temperature at 100
0
F at Dew Point Temperature
And 1000 psig
______________ _________________ ___________________
99 12 3.2 lb. H2O/mm cf
98 30 6.3
97 40 9.0
96 47 11.7
95 51 13.3
v. Construct McCabe-Thiele Diagram See Fig 4-55
Number of Theoretical trays = 1.48
Number of Actual trays = 1.48 = 4.44 = 5
0.33
SLIDE 214
McCabe-Thiele Diagram
4/16/2013
108
NNPC FSTP Engineers
Transmission
Course Code:
Lesson 5
Lesson 5
LNG and GTL Processes
4/16/2013
109
Lesson 5 Contents
LNG Process
GTL Process
Lesson 5
LNG Process
4/16/2013
110
SLIDE 219
Liquefied Natural
Gas (LNG)
Definition of LNG
4Natural gas is cooled through cryogenic refrigeration to - 260
0
F (-162
0
C) to
form Liquefied Natural Gas.
4The LNG is 1/600
th
the volume the natural gas, which makes it feasible to
transport it over long distances.
4It is Flammable in 5-15% concentration
4It is a Cleaner burning gas
4Special LNG vessels load LNG at the liquefaction facility and transport it to
regasify at import terminals in remote demand and offshore locations
4At these import terminals, LNG is warmed back to natural gas, and nally
pumped into pipelines and sent to market.
LNG Process
Customers
Shipping Regasification Production Liquefaction
4/16/2013
111
SLIDE 221
Liquefied Natural Gas
Process
4Basic LGN Train
4
Vaporization
Industry Users
Residential
Commercial
& Industry
Vaporization Storage
Shipping
Road Transport
Storage at Plant LNG Processing Plant
Gas Supply
from Field
Loading LNG Containers
Supply Station
SLIDE 222
Process
Basic Processes involved in LNG
4Transportation
4Pressure Equalization
4Condensate Removal
4CO
2
, H
2
S and Mercury Removal
4Dehydration
4Refrigeration
4Liquefaction
4Storage and Loading
4Transportation and Marketing
4/16/2013
112
SLIDE 223
Process
4Raw material to LNG
SLIDE 224
Nigerian Liquefied Natural
Gas
NLNG Natural Gas Liquefaction Process
4Bonny LNG Simplified Process Flow Diagram
4/16/2013
113
SLIDE 225
Gas
Gas Inlet Facilities
4Natural gas received from suppliers is scrubbed for hydrocarbon liquids (C5 +) and
undergoes pressure control at the Pressure Control Station which ensures plant has
stable supply pressure of 70-90b(g) reduced to 54b(g).
4Further resultant condensate generated from this process is separated out. Other
facilities include pigging of transmission lines from suppliers.
Acid Gas Removal Process
4This removes acid gasses of CO2 & H2S by absorption using circulating amine
solution to prevent corrosion & freezing at low temperatures
Dehydration Process
4Drying of the gas is ensured by using molecular sieve beds to adsorb water to
prevent ice & hydrate formation at low temperatures
SLIDE 226
Gas
Mercury Removal Process
4In the NLNG, Gas from Soku contains traces of mercury. Activated carbon bed process
is employed to remove trace quantities of mercury to prevent attack on aluminium
tubing found in the Main Cryogenic Heat Exchanger
4of a combined cycle power plant.
Liquefaction Process
4The refrigeration system employed in the cooling of the gas to liquid state is Propane
Pre-cooled Mixed Refrigerant System.
4The gas is pre-cooled by propane mechanical compression refrigeration system to -
17oC to remove C5, aromatics & some LPG is routed to the fractionation section.
4The sweet natural gas (C1,C2,C3 & C4 ) is now liquefied in 2 stages involving initial
cooling with propane refrigeration to -38oC followed by further cooling against mixed
refrigerant in the MCHE to -161oC.
4The mixed refrigerant comprises of Nitrogen, Methane, Ethane & Propane
4/16/2013
114
SLIDE 227
Gas
Liquefaction Process
SLIDE 228
Gas
Fractionation Process
4Distillation columns are used to separate LPG into fractions to be used for make
up propane & mixed refrigerants or re-injection into LNG.
4The functions of the Fractionation Unit are:
To produce an acceptable ethane and propane make-up to the refrigerant
cycles.
To reject methane into the HP Fuel Gas system.
To recover LPG for re-injection into the LNG product.
To produce a condensate product with a specified vapor pressure.
Fractionation (Liquid Handling Unit)
LPG from all trains, separates Propane & Butane for storage & exportof a
combined cycle power plant.
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SLIDE 229
LNG Storage & Loading
4The LNG from the main heat exchanger is stored in three 84,000m3 full
containment above ground cryogenic storage tanks. Each tank is fitted with 3 loading
pumps capable of a combined loading rate of 10,000m3/hr through 2 loading arms, a
third arm is provided for vapour return during loading. The returned vapour is
compressed and routed to the plant fuel gas system. LNG Carriers are of both
membrane and spherical tank type and have a capacity of 122,000 - 132,000m3
4LPG Storage & Loading
4Propane and butane from the fractionating tower are stored separately in two
refrigerated tanks each with a capacity of 65,000m3 . Propane being stored at -45oC
and Butane at -5oC. Each tank is provided with three pumps designed to load
refrigerated LPG ships a a rate of 3000m3 /hr. Chilling of the Propane & Butane as
well as re-liquefaction of tank boil off is done in a propane refrigeration unit.
LNG Loading &
Transportation
SLIDE 230
LNG Loading &
Transportation
Condensate Storage & Loading
4Condensate from the inlet gas processing plant is stored in two 36,000m3 floating
roof tanks. Five loading pumps (+ 1 spare) rated at 800m3 provide the ability to load a
typical 60,000m cargo in approximately 16 hours through two loading arms.
The sphere tank The membrane tank
Shipping Tank Configurations
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Land-based Terminal Platform Terminal
Floating Storage & Regasification Unit
LNG Loading &
Transportation
SLIDE 232
Regasification is the physical process whereby liquefied natural gas (LNG) is heated to its
gaseous state.
The regasification process entails pumping the LNG, under high pressure
through various receiving terminal piping components where it is heated by direct-fired in
a controlled environment.
The re-vaporized natural gas is regulated for pressure and enters the sales pipeline
system for delivery to consumers
LNG import (regasication) terminals can be onshore-terminal or oshore-onboard.
At an onshore terminal, a conventional LNG carrier (LNGC) unloads its LNG cargo to the
storage tanks and the LNG in then regasied at the regasication unit and pumped into the
local natural gas pipeline.
At an oshore terminal, LNG is regasied onboard specialized transport vessels that
connect directly to pipeline.
LNG Regasification
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SLIDE 233
LNG Regasification
Lesson 5
GTL Process
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118
4Gas to Liquids describes Technology that carries out a chemical transformation process
which converts natural gas(CH
4
) into products such as fertilizers, methanol or liquid
hydrocarbons such as diesel, kerosene and waxes, which are readily transported to any
location.
4It is a chemical process involving the polymerization of methane molecule to form
chain and cyclic hydrocarbons
Basic Process of GTL Technology
Gas to Liquid Process
Basic Process Blocks of GTL Technology
4Three Basic Steps are involved in the GTL Technology converting natural
gas to GTL
Step 1
Step 3
Step 2
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Process Block 1
4Steam Reforming of natural gas into
synthesis gas (a mixture of hydrogen and
carbon monoxide) also called syngas for
short
4It can be produced from other sources
than natural gas: biomass, coal or even
heavy oil residue are all possible.
4Natural gas is particularly convenient for
several reasons
4Synthesis Gas need to undergo
sweetening to remove contaminants before
FT process
Process Block 1
Two processes may be used to convert methane into syngas:
Natural gas autothermal reforming (ATR).
CH
4
may be converted into syngas via a reaction with water (steam) and oxygen O
2
:
2CH
4
+ O
2
+ H
2
O 5H
2
+ 2CO
OR
with water (steam) and carbon dioxide CO
2
:
2CH
4
+ O
2
+ CO
2
3H
2
+ 3CO + H
2
O
Both reactions are exothermic (they produce heat), and the temperature of the syngas
produced is around 1000
O
C.
Steam methane reforming (SMR).
CH
4
may also be converted to syngas using only water. It requires a high temperature
(700-1000
O
C) and occurs in presence of a Nickel based catalyst.
CH
4
+ H
2
O CO + 3 H
2
This method is most used produce syngas (also used to produce ammonia-based
fertilizers).
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120
Process Block 2 - Fisher-Tropsh Synthesis
4It uses a catalyst(mostly iron or cobalt base) to convert
hydrogen (H2) and carbon monoxide (CO) into higher
hydrocarbons, mostly normal paraffins (alkanes C
n
H
2n+2
)
4The chosen catalyst and process conditions will
determine the composition of products, ranging from
gasoline to diesel and waxes.
The Main reaction at Fischer Tropsch Reactor
1. (2n+1) H2 + n CO -> C
n
H
2n+2
+ n H
2
O
It's an exothermic reaction (it liberates heat: 39.4
kcal / mole of CO).
Consequently, the reactor has to be cooled down.
Other products are created are alkenes C
n
H
2n
and alcohols C
n
H
(2n+1)
OH:
Syncrude
Process Block 3
4Upgrading of product s through hydrocracking to adjust the final their properties and
required specification.
4The components are separated. Heavier components (if any) may be cracked, and
lighter components are reformed.
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Summary of GTL Processes
Summary of GTL Products
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NNPC FSTP Engineers
Transmission
Course Code:
Lesson 5
Lesson 6
Pipeline Operations
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123
Lesson 6 Contents
Nigeria Pipeline Network
Pipeline Operations and Management
Ono 246
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124
Ono 247
Petroleum Crude oil & Product Pipeline System
Oil Terminal
Refinery
Product Deport
Product Deport
Product Deport
Product
Deport
Product Main Line
well
well
Gathering Lines
well
well
well
MARKET
FIELD
SBM
Tanker
Offshore Oil Export
Flow Station
Ono 248
Nigeria Pipelines: Crude Oil (petroleum)- Natural Gas - Products Pipelines
Label
Number
on Map
Project
Name
Start
Point
End
Point
Diameter
(inches)
Length
(Km)
Capacity
(1000b/d
or bn cm)
--------- --------------------- ------------ ------------ ------------ ---------- -------------
F33 - - - Escravos Kaduna 16, 24 674 -
F34
1
- - - Kwale
Brass
(offshore)
10, 14, 24,
36
206 -
F35 - - - Ramuekpe Bonny 24, 28, 48 134 -
F36
Trans-Nigeria
Pipeline
Warri Ramuekpe 16 - -
F39
2
Offshore Gas
Gathering System
[OGGS]
Banga field
Bonny
Terminal
32 268 -
F40
Escravas-Lagos
Pipeline System
[ELPS]
Escravos Lagos 36 340 -
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Ono 249
Label
Number
on Map
Project
Name
Start
Point
End
Point
Diameter
(inches)
Length
(Km)
Capacity
(1000b/d
or bn cm)
F42
Aladja System
Pipeline
Oben Ajaokuta 24 294 -
F43
Greater Ughelli
System
Ughelli Warri - - -
F10 - - - Enugu Auchi - - -
F11
3
- - - Kaduna Gasau 6, 10 356 -
F12
4
- - - Kaduna Maiduguri 4, 6, 12 1050 -
F13 - - - Kaduna Warri 16 - -
F14 - - - Lagos Ilorin 6, 12, 16 259 -
F15
5
- - -
Port
Harcourt
Yola 6, 12 333 -
F16
6
- - - Warri Lagos 12, 16 312 -
Ono 250
Cross Border Pipelines
Nigeria - Algeria
Project Name Start End Length (km)
F44
7
Trans-Saharan Warri Arzew 4400
Nigeria - Ghana
F41
8
West Africa
Gas Pipeline
[WAGP]
Lagos
Takoradi
1033
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Ono 251
West African Gas Pipeline Project
600 km pipeline to supply 200 mmscf/day to neighbouring
Benin, Togo and Ghana at the cost of $260m.
Layout of the West African Gas Pipeline - WAPCo
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Trans Saharan Gas Pipeline to Europe
4128 kilometers
Equatorial Guinea Gas Supply Line.
600 mmscf/day
Ono 254
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Ono 255
Pipeline Management
Ono 256
All Activities executed during pipeline operationto ensure and guarantee pipeline
delivers efficiently, effectively and safely while ensuring pipeline competence and
integrity, Health & Safety of Personnel, environmental integrity and project
economy
What is Pipeline Management
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Ono 257
Basic Elements of Pipeline Management
Pipeline
Management
Pipeline Field
Operations
Pipeline
Construction
Maintenance
Pipeline
Economics
Operations
Control
People
&
Organization
Community
Relation
Security
Health safety
&
Environment
Ono 258
Pipeline networks consists of several equipment and systems that operate
together to move products from location to location.
Pipeline Equipment and Accessories
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Ono 259
4Initial injection station
Supply or inlet station
The beginning of the pipeline system, where the product is injected into the line.
Consists of
The well
Storage facilities,
Pumps or Compressors
4Compressor/Pump Stations
Location normally defined by the length of pipeline, topography of the terrain, the type
of product being transported, and operational conditions of the network.
4Partial Delivery Station or Depots
Intermediatestations
These allow the pipeline operator to deliver part of the product being transported to
customers.
Ono 260
4Block Valve Station
First line of protection for pipelines.
These are employed to isolate any segment of the line for maintenance work or
isolate a rupture or leak.
Block valve stations are usually located every 20 to 30 miles (48 km), depending
on the type of pipeline.
Location also depends exclusively on the nature of the product being transported,
the trajectory of the pipeline and/or the operational conditions of the line.
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Ono 261
4Regulator Station
Special type of valve station, where the operator can release some of the pressure
from the line.
Regulators are usually located at the downhill side of a peak.
4Transmission System
Pipelines,
valve assemblies,
Cathodic Protection Stations
Pumping Stations or Compressor Stations
4Final Delivery Station
The outlet stations or terminals or depot
Product distributed to the consumers.
It could be a tank terminal for liquid pipelines or a connection to a distribution
network for gas pipelines.
Ono 262
4Distribution network
Consumer Metering Stations
Town Border Stations (TBSs),
District regulatory Stations (DRSs)
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Ono 263
Pipeline Commissioning
Dry up pipeline Before Commissioning
4Method for Pipeline Drying up :
Use dry air (compressor) to push a series of foam pigs through the
pipeline to collect water/liquids until the required dryness is achieved.
Purge pipeline before the admission of the gas to be transmitted
Use inert gas to purge of air.
4Pipeline can be commissioned straight to gas after drying up
Pipeline Field Operations
Ono 264
Fluid Movement
4Fluid is released from Tank or Reservoir and kept in motion by Pump or
Compression stations along the pipeline.
4Multi-product pipelines are used to transport two or more different
products in sequence or in discrete batches in the same pipeline.
4Flow is normally kept at a speed of about 1 to 6 metres per second (3.3
to 20 ft/s); about 4 - 8 km/hr for liquids and this helps the liquid not to mix
as they are always in motion
4Natural gas flows at about 40 km/hr and volumes are not
batched(mixed).
4Flow in multi-product pipelines is either without physical separation
between the different products OR with Piston pigs being used as a
separation medium
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Ono 265
Fluid Movement
4Multi-product flow without separation normally results in Interface
consisting of some mixing of adjacent products
4The Interface is either absorbed in one of the product based or Directed
to a separating vessel
Petroleum Products
in Batching
Ono 266
Fluid Movement
4Compressors or Pumps are strategically located on the pipeline
for increase the pressure for onward movement as the pressure
decrease along the line due to frictional losses
Field Personnel Operations
4Inspecting the pipeline and pipeline safety measures such as
cathodic protection
4Maintaining and repairing the pipeline, pumps, compressors,
valves, metering equipment, safety measures and electronic
equipment.
4Calibrating instruments.
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Ono 267
Control Centre Operations
4Monitoring the pipeline system 24 hours per day,
4Scheduling batch receipt and delivery,
4Controlling batch movement, and
4Responding to emergencies
Pipeline Monitoring
4Operator at Control centre monitors;
Pressure,
Temperature
Flow rates and
Look for any inconsistencies which may indicate a potential leak or
equipment failure.
4Information is fed to the control centre through SCADA systems.
4Sudden, large pressure drops will trigger automatic emergency systems
that close valves to isolate the section of the pipeline in question
Ono 268
Pigging Operation
4Pigs are devices launched from pig-launcher stations and travel through
the pipeline to be received at any other station down-stream, in order to
effect a desired maintenance job
4Maintenance Executed with Pigging include
Cleaning wax deposits
Cleaning material accumulation inside the line
Grinding of Weld Bumps
Washing of Pipeline of Undesired Chemicals
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135
Different Types of Pigs
Cup Pig Disc Pig
Sphere Pig
Foam Pig
Ono 270
Pig Lunching Station
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136
Pipeline Accessories
Valves
Insulation Joints
Scratchers Or Pigs
Meters
Operator at Pig Receiver Station
Ono
SLIDE 272
Pigging Station
Operation
1. Arrival Line
2. Trap
3. By-pass
4. Reception Line
5. Drain
1. Arrival Line
2. By-pass Line
3. Departure Line
4. Reception Barrel
5. Device for Closing at Quick
Manoeuvring
Barrel Receiving Station
Barrel Lunching Station
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Ono 273
Pipeline Operational Problems
4Wax or Paraffin Accumulation
Results in pressure loss due to frictional losses during fluid flow.
Very common and severe in colder climates
Pipelines should be inspected and cleaned often using pigs, also known as
scrapers or Go-devils.
4Dents, cracking or other mechanical damage.
Due to operational recklessness and handling of equipment
Sabotage can also caused these.
Smart pigs (also known as intelligent or intelligence pigs)
Pipe section should be changed.
Ono 274
Pipeline Operational Problems
4Corrosion
Results in metal loss
Reduces the integrity of pipe
Smart pigs (also known as intelligent or intelligence pigs)
Pipe section should be changed
Corrosion protection devices should be put in place.
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Ono 275
4Pipeline Operation Control and Monitoring Systems support the remote operation of the
pipeline system
4They include:
Instrumentation system
Data gathering units
Communication systems.
4Field Instrumentation/Data Gathering Units
Flow Meters
Pressure gauges
Temperature gauges/transmitters,
Other devices to measure the relevant data required.
Normally installed along the pipeline on some specific locations, such as injection or
delivery stations, pump stations (liquid pipelines) or compressor stations (gas
pipelines), and block valve stations.
Pipeline Operation Control & Monitoring
Ono 276
4SCADA System for Pipelines.
SCADA is an industrial control systems that stands for Supervisory Control and
Data Acquisition.
It is a computer systems that monitor and control industrial, infrastructure, or
facility-based processes.
Pipeline Operation
Control and Monitoring
Communication Structure
Main Control Room
Field Gathering Structures
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Ono 277
Components of SCADA System
1. Remote Terminal Units (RTU)
This is a local unit where all information measured by these field
instruments is gathered
The RTU transfers the field data to a Main Control Room in real
time using communication systems, such as satellite channels,
microwave links, or cellular phone connections.
RTUs can be installed at every station along the pipeline.
It is connected to sensors in the process, and it converts sensor
signals to digital data and sending digital data to the supervisory
system.
Pipeline Operation
Ono 278
2. Human-Machine Interface (HMI)
This is the apparatus which presents process data to a human
operator, and the medium through which, he monitors and controls
the process.
It shows the operational conditions of the pipeline
It is the Supervisory (computer) System, gathering (acquiring) data on
the process and sending commands (control) to the process.
Operator can monitor the hydraulic conditions of the line, as well as
send operational commands (open/close valves, turn on/off
compressors or pumps, change setpoints, etc.) through the SCADA
system to the field.
Pipeline Operation
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Ono 279
3. Main Control Room
The Pipeline System is controlled and operated remotely, from the
Main Control Room.
All the data related to field measurement received from multiple
RTUs along the pipeline is consolidated in one central database.
2. Communication Infrastructure connecting the supervisory system to
the RTU.
Pipeline Operation
Ono 280
SCADA Optimization Components
To achieve Optimum operational performance Advanced Pipeline Applications,
software tools can be installed on top of the SCADA system as well as personnel
competence improvement programme to provide extended functionality to perform
Some of these Applications are Listed below
Leak detection
Leak location
Batch tracking (liquid lines)
Composition tracking
Predictive modeling (if scenario)
Look ahead modeling
Operator training
Stress cycle calculation
Pipeline Operation
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141
SLIDE 281
Compression & Pumping
Stations
Compression & Pumping Stations
4Types of Compression or Pumping Stations.
Field Gathering Station
Boost Well Fluid Press to Transmission Line
Relay or Mainline Gathering Station
Boost Transmission Line Pressure
Re-pressuring or Recycling Station
Used to Boost Processing or Secondary Recovery Projects Pressure
Storage Field Station
Compresses or Pumps Injection Line Fluids into Storage.
Used to Suck out Storage Fluid into Trunk Lines
Distribution Plant Station
Boost Distribution Line Pressure
282
Pipeline Maintenance Programmes
Scheduled inspections of valves and other components
Regular Pipeline Integrity Tests
4Potential Failures and Wall Thickness & MAWP Reduction
4Pipeline Internal Maintenance and Chemical Injection
4Pipeline External Maintenance and the Cathodic Protection
4Piping & Pipeline Inspection Techniques
4Hydro test
After mechanical completion or Maintenance of pipeline, it must be
tested for minimum test pressure should of 1.5 times of design
pressure
Pipeline Maintenance
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Ono 283
Pipeline Maintenance Programmes
Pipeline Monitoring
Pipelines are monitored 24 hours per day, seven days per week from
central control centres
This guarantees and ensures the integrity and safety of pipelines and
early detection of vandalism, leaks, etc.
Chemical Injection:
4Chemical Inhibitor
4Scale Inhibitor and
4Biocide Materials
Fluid Sampling:
Ono 284
Corrosion Control
Pipeline corrosion prevention methods applied in the Industry include
Coating with tar or asphalt as they were being installed (early times).
Coating with epoxy and polyethylene at the manufacturing plant.
Cathodic Protection.
It involves applying a weak direct current of electricity to the pipeline to
prevent corrosion.
The current flows into the pipe through breaks in the outer coating and
protects the bare metal from water and other corrosive agents.
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Ono 285
Modern Infrastructure
New Technologies
Environmental Competence
Vibrant Skills Development & Improvement Programme
Clear Priorities
Diversity of Options
Customer Satisfaction
Planning
Drivers of Successful
Pipeline Management
Ono 286
The Big Posers
Pipeline Vandalism
Kidnapping
Illegal Bunkering
Unemployment
Derivation Issues
Local Content
DEVE
Pipeline Security & Community
Issues in Nigeria

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