Optimize CO, removal What selection criteria should be used when evaluating gas-processing methods to separate bulk CO,? Enhanced investigative techniques pare down technology options to a short-list, Shaw snd P. We Hughes, Cosain Oi, Gan ProtesL, Mancnester England aay technologies efficiently remove carbon oxide (CO,) from nataral gas and other ge stream With co many cholo, there is ‘0 “one size its ll solution. Consequently process ‘esignere mat olign technological bene f arias {uniques with the final produc or downstream last speiieations ‘Chote i always beneficial for any decision. Yo, in thisinstancr, the wast array of potentilopions toremove CO; xn eat enfusion. The presented {uldeliner demonstrate how to generate a short st st appropriate technolo- fice for COy-removal Sapliestion. Many Tae- {ars are inveived in thia ‘xerese. Using an eng roering angultan ea 1) ‘Streamline the evaluation proces and 2) narrow the Sptions to the best ap: proaches that meet feed nd product needs of the fas processor Today many tecinclogies fan be ned ta ffctively Separate CO; from nas ‘alga, fue gas and other Streams, Such methods elude ‘"Solvents—ehemial, phyleal and hybrids Membranes * Caustiewseh + Chregenie separation 3 Sohtbed orden Combined systoms ‘Within each extegor, ‘there are subdivisions af Ticeneare with paricular Fig, Poses asleston ae provesses—ech offering merits and drawbacks. A {onmiadesiger who i familie with he clien’s feeds, the project site and available technologies, fn make a major contribution when electing the fnost appropriate technique. For example, th {heated gus mil be processed bya downstream plant into sales gos and natal gas iguids (NGL), fen procesing methods thst significa warm the gas have a detrimental impact on the cost of ‘ commaltantideaigner ean survey the project as ‘whole ther than a proses package in clation ‘and will have better appreciation af all possible Linpotfatrs, Other infuening condition ee eo Sect location, manning 5 itemenes prevaiting ireomental standards tnd onch-eeonomie fac. fors. The consultant Alesigner eam incorporate this knowledge and opti ‘mlz the application. For xample, Ube develop: ‘ment of C> and Cy rear try processes requires ‘aleing system operating temperatures to avoid GOvireere out. When NGLeand LPG are rane fered, there i choice to raluate between 8p. ‘Stream CO, removal and HRs effect on thane-0Oy ‘soto formation and ‘the downstream separa ton and removel of CO, tolmeet product speeii= note example a gas treatment for export t0 f tranamistion syetem, ‘Treatment afer compres: ‘on expose tig lp ment to higher corrosion potential; wheroas treat ‘ent before compression an reduce the amount ro i St 2 fH 2 ry ] s Hy . 5 eS] a a ai. 2 be pllok apa fs tobe empresa although it ens smal, higher pressure treatment equipment ‘The designer should have broad experience wid diferent processes, whereas the lent ma only ‘efamiliar witha partcaar technology installed at given ste, The right consultantidesigner may have ‘eationships from provious projects with many ai Tent leenaors. They will be abe to rapidly obtain Yeas used during a study Tara major gas-procensing company. This application would remove al CO, fom a natural gas stream that ‘would bo processed ina downstream plant, PROCESS CONSIDERATIONS. Several procen-olated factors alfact the selection ‘otappropriate technology. They are: 60, concentration. The concentration of CO, in the Teed gaa hasan important effec; CO, levels wil deter ‘nine whither egenarsle or noaregenerable processes fre applicable. Ifthe canrnttin of CO, oe ple, nonreenerable process is favored Batt large zave rate la involved, thon rogancrable proces is ‘ecessary. The CO, taceance ofthe downstream gas plant leo an important consideration, Other contaminants. 4 number of other cntami- ‘nants are ound in natural zs tat wll act he tech ‘ology selection, The two mt relevant components are lvdrogensulde (1,5) and water Like CO, His Sin acid species and ia removed by certain solvent. extraction proceeses, Water contamination ofthe fed laffacts the perfrmance of fixed-bed technologies and dilutes aqueaussavents. ‘Other contaminant, such as heavy hydewearbons, organic sulfur compounds (carbonyl cufide, carbon Aislfide and thiols) helium and mercury, may also be resent, but the concentratian uch lower {han the main contaminants, Consideration may be required thay are ound in significant quantities, bat level experienced normally sre nllely affect the selection ofthe CO, removal pros. Pressure. Natural gus, atthe wellhead, is avallable at high pressure, So, a significant pressure drop is Svailable or gas treating. bir ranorta to sal transonasion sytem. However, certain eters ony ‘operate at low’ prstare at which point the presrare ‘top over th treatment plant becomes ance Like ‘wie, the partial pressure of CO, contributes to the Selection process. A high partial pressure makes 8 ‘Pegenerable process attract “As noted previously it important forthe cones: tant/designer to be aware of other prossure effects, ‘throughout the systom, Upstream compression, if reqaied, reduces vessel iz, but increases wall hk ‘eat, Conversely upstream GO, removal reduces coe ‘pressor duty and eorosion prodsctionregurement= ‘Temperature. Most gas processing operations run ‘within 20°C ofthe wellhead temperature, Tempera: {ure 1s normally oul a concern atthe lower end of the range, where ald gas may freeze an aqueass y= tem, Furthermore, operating temperature wil eflct the absorption equilibrium. Other issues with low- temperature gas aot the handling and tranapart of the gas, not the selection ofthe appropriate COs removal technology. Care ia required witha cool gas ‘td aditinalcoling due to Joule Thomsca elects to ‘roll feesing Product considerations. The product may be ‘egured ina dry tate thus,dowastream drying fee- ites are warranted. However, mat natarol gus aw an inherent water conten; co drying ia eal roqure- ‘ont, Bren so, water pickup from an aqueous prostes ‘would pot extra load on aay downstreem water dow= pointing or drying duty, Other considerations. Geographical cation ean be ‘significant connderation wien resting natural gas, fs gas wells ean bo romote, Ths, mintaal operator intervention may be s requirement. Furthermore ‘eatment at remote ses may be necessary to avoid ‘erosion probleme in the transport aystem, Conse- ‘qently, a simple process may be preferred, which x fay to oporata and roquiros low maintanance, Fur- ‘thermore, at rote ites, deliveries of replenishment process chemicals may be difiale. Frum these com vdratons, Fig. 1 illustrates the decision proces AVAILABLE PROCESSES. ‘Some technologies currently available for COs eval are ‘Amine rolvents The most popular solvent is the smine-besd technology Many commodity compounds fave been used for 9 ‘moneathanolamine (MEA), diethanolamine (DEA. ‘hanolamine (TEA) and disopropanolamine (DIPA\, ltr too reactive tbe limited t CO, removed. Those amines may be sultabl to remove other acd specs, Such es H,S, However, current technologies normally feature methyldethanolamine (MDEA) asthe malasolvent, which is aclvaved by mare reactive secondary imines if ther contaminant ae tobe removed. The Uptimined reedvty of MDEA tase processes allowe ‘tational benef rich as reed regeneration energy equirements lower corosvity and higher resistance tedegradatin, Tower vapor presaure wil als allow operation with higher concentrations and thus rice rich amine load {ng Other serially hindered amines such a= d-lyeol sting and DIPA ae ore The Bae proc 8 {Sto-stge astem, with an inital contacting step, fl. lowed by aa indirect regeneration. Most will achieve ‘similar product specfteations, but each process Is Sight dierent end mast be judged on nee rq: ‘nents for regeneration ad waseepublit to fouling ‘om contaminants inthe feed gas. MDEA-based pro- cases wil take advantage ofthe amine’ oaiity and ‘Sean lntarmedate lash to reduc regeneration energy ‘esuiremente, Chesca solvent prosesee are sep ‘ble to foaming problems when the feed Is conta inated with heavy hydrocarbont—an guid or ean. ‘dense formed in the contac Hot caronate solvents he ther main ce cal slvet fer CO, removal is hot potassium ext ‘te soltion. Thi has a similar process lowshect to lamamine system, with acontactar and aregeneratar, “indi especialy aplieablet systems with low a IIH content. andvantage ie thnt nt oly the {tas weld, but also itis warmed. Tis may be cons fred an wnnesesary Wate oes, especialy the gas Ite later cooled foe NOL oF LN separation "Hot potasinm eartnnate ie alae not very reactive so, to stagee may be required ta achiev alowed fencentration Thus, the carbonate process i most ‘ited vo bull CO, vemoval rom high feed emoentra- trons A farther benefit lath eaigent cot compar atively low. ‘Physical solvents. The physical salvent absord (CO, without frming’s new shemieal complex. TY9. tall these processes use methanol procs atibutor {elude mot wetting the process gas and lower regen- tration energy costs With a physeal solvent, CO, is flashed off during the regeneratic phase, and the eam ealvent is purped ack to the contactor Physi. ‘alolvent proceases are eopeilly applicable tolizht ‘aural gees with minimal heavy hydroerbon con: tents. This because the solubility of ethane in ‘uthenol sony 40" ofthe slay of CO, whereas the solubility of propane is similar to COy Conse- ‘quently a reycle system is needed to improve pro- ‘hong recovery. Other pysial solvent processes fire based on anhydrous propylene carbonate oF methyl 2 proline ‘Hybrid solvents, These solvent systems are spe: cially formulated mixtures of chemical end phystal Solvents using a normel eontactouregeneraton sys {am Such processor are rarely eed, but may be ap ‘able under certain creumstance, which te specie process lsnoor Will beable to advise ‘Membranes, The membrane proccss is based on ermecblitydificrenes between component through E'plomeie membrene, Water wor end CO, are highly permeable gases and re easly separated from bulky Rydracerion molecules The diving oes across a mem- a, 3. Conparon tbe ep co ‘anesthe ference between the partial possors of ‘components on either side of the membrane. ‘Withthe membrane procs, Une main penalty ie that significant methane quansites are lotto the perme- fate The methane recovery from the permeate can be ‘rete ia two stage membrane eye installed. However, inthe two-stage system, a compressor is ‘noded ts reyele permeate this raises costs consider “bly: Protetom gina wa and heayy hydrocarbon Is ‘leo needed. “Menbranes ae usually supplied in module; th {natlletio svelativly simple However the modular ‘nature docs nat exh coonomies of sal, and so thoy le more appiable lower flowrate, However, mar ‘anes maybe appropriate at higher lows for several ‘eaten: outside strelyproosseritera Por instance, ‘embrane units may be applicable a remote lations ‘where bw operator ivelvemeat isa requirement, 'Nonregenerable processes ew noaregencrable liguid phase procosees, solely for CO, removal, sre svalable,benuse oho coot othe aborbent, together With high disposal cots for epent solvent. However, ‘hurtiesoda abaorplon may bea viable option for @ Polishing duty, expecially when consdering the sim Bliity af ho proces. fe separation. Ix posible to exjogen cally xtraet CO, from naturel ewe Those process bre cost-ffecive for high eapactes,pertielary in ombinetion with other methods where a specialist rout or aplication is required Bolid-bed nbsorhente Molocslar sieves can be sated when redueing low-concentrations of CO, t9 txtremely low level: They sre mainly used fr poish= {ng die, a8 very large beds Would be equired for bull CO, removal and require an energy-intensive ‘regeneration systam. However, tho beds are regeners= ‘lend ean be used to remove other contaminants st the same Une ‘Combined nyrtems. Vietslly al oUse previously mentioned systems en b eombine to diver the opt ‘al solution toa particular application. Fr instance, ‘membrane or solvent may be used to break a eyo" ffenie saeutrope for enhanced al reevery of CyCO, {sparation. Aiternatvay, for cases where there i @ ‘igh CO, content nthe fecd gas, the optimum may be ‘ cambined aystam, where amembrane removes the bulk ofthe CO, followed by x chemielslvent or meleeFp 4. Conpuron of bet ty conan ‘lasove sytem fr final clean up. ‘Other rect ndvanes include the gub-iquid men brane eotactor whore the solvent is eed on the per smeate ade t improve CO, removal and reduce the ‘ed fara high fed pressure. Othe eensors use the SJosle-Thomaun coling effects onthe gas permeate {hrough the membrane ta prove energy efficiency. EXAMPLE SPECIFICATION ‘Given this information, a sreening for applicable precenees ean be done. For example, an ffaore gas ator prose natural gas with 8-105 CO, ent, and negligible nmounte of F. Production rate tf gas would be reasonably high, and at high preseure ftnd seawater temperature. The gos isto be processed fnahore to achieve pipeline spedfiction and produce NGL. The gas plane hes that procesingebjective: "inlet separation of iqud slugs from the dense ‘ase natural gas fod Gee treat for CO, removal, flowed by farther dlehydrtion to achieve tha dewpeint specication Gas processing and NGL recovery for heating value/ Webbe Index/bydroearbon dewalt contol to ‘moet the sles gus speciation. Selection heuristic. This information canbe used to ‘reen out les aplchle processes and narow tbls for further evaluation. Membranes canbe eliminated {ive tothe plant se, whieh woud reqs igh nm: bor of unis, and the gs loses would bo unaceptabe ‘Noanegenerable proses arent applicable deo the Inge mane of CO, being fod vo the plant ab are sli tod process ds the high enaentaton 0, inthe ‘eed: Crygoniprossse are not applicable bese the and a exmbied proces “Acordia the jeal and hybrid remain, To optimize technology chic, valuation eritria mus be set, and ranked according to their applicability. Tho fcters that are normally ‘oasidred ane = Safeey--material and process Environmental fitare > "Roteasos to air va vent g > Releases toland rom disposal of spent odsor tent > Releases to water due a disposal o knockout water + Gas recovery + Oporating experiance * Gas fod rato, composition inelding trace impo: iis), conditions Treated gus spcifcations—puriy flow, pressure 1 Totoprtion wth downatreatnproceaes ‘Energy reirements 5 Avni wii + Process feibiity > Tuendown expabiiey Range af CO, concentrations that ean be pro- ciation over af the plant. "The level of detail required forth ranking process say belimited by avalable information. However, ‘ange ofmthodzcan be ted or assent Perea Blo, the reliability of ach process may include: °S Experince of sia installations 1 qeipment tem evluston thot assigns an ab trary score to each typeof equipment reflecting its fnheren relist, og, rtating equipments genee- ally ees aiable than veel Detailed reliability stay comparing each pro- “hs the evaluation becomes mare comple, the time talento develop the averall ranking inereses. Capital cost. Esch factor in the ranking can be sselned a relative weighting proportional tits por feived importance. Senay suis can then be done to assess the robustness of the reaul in Teeponse © ‘Sangiog the relative weightings, ‘hcompariaon ofthe verage capital coat for the shar iste technology groups sven in Fig 3 Vendor Information ean be used to generate baste heat and taes balances, and derive a budge capital cot for Sach proers:Te copital ots were calculated bnaed on {COs content at the lower end ofthe seal. “The rosuls ofthe capital cst comparison (Fig. 9) show that an MDEA based chemical solvent process ‘asthe oweet capital cot. Tahould be remembered ‘hat thi igure ie specie or the spetiedepliation ‘he relative costs would be diferent atailferent fed oncentrtons and eons Uuttty costs. Fig. ists the average utility requie- sent of the processes for the shortlisted technalogy {roupe The data for each process was again generated {fom the basic hent and mase balance data applied 1ythe various licencors, The ue requirements were ‘aleulaed ona power equivalent bars, ‘These results demonstrate that fortis appiction physical mavens have the lowest ality requirements, "osly followed by tho potaccum carbonato solvents Ifthe pressure drap between the absorption and ‘regeneration seton fs signfiant then it may be os ‘lfetive to iatall a hydraulic turbine to achive the pressure letdown. The power from the turbine may bh used tooost the pressure of the lean amine slu- tion returaing tthe abeorber. A further evaluation ‘ould be done ta datermine the payback period of tls‘ig 5 Comparison of hyrocaron ease the ver as option, Alo, the spread of the total utility require: ‘ents forthe potassium carbonat solvents was rel atively wide: therefore, euch press may need tbe ‘evaluated individually. Vent losses. A comparison of the average hydrocar bom ose nthe CO, vent eas for the shortlisted tock- ‘ology groups is shown in Fig 6. For this aplication, ‘hyeical solvents had the highest hydrocarbon lacses fom the process; this mada them unacceptable due tothe large amount of absorption of hydrocarbons ‘vith the CO; bythe solvent. The reals ofthe rank Ingmethedology showed the following trends for this appleaton: = An amine solvent procoss has lower capital costs and higher energy requirements than a potassium ea nate solvent proves, 2A potassium esrbonatesalvent process imposed highor nergy requirements onthe downstream gae plant because the treated gas leaving the contactor is 2A physical solvent proceas has lower energy recente or gegeaertios, * Aphyscalclvent precoss genorata higher hyo carbon oe +A physieal solvent process doesnot further wot whee Final process selection. At ths in, the physical felvent process was eliminated due to the very high Toes vate and elatively high eaptal cost. This leaves three proves iypes, which requses a more rigorous felection methodology The factors to be considered at this stage are DA uteeycl cost estimate that takes nto account ‘ein eas ofthe alent pls any makio-up required Der ine and ny ense Toe payable Atafetyenvironmental evaluation > Past experience of mar applications > unity requirements ‘This stage may require mare detailed information from the vendor, and will consume resources during theevalution. Past experiene may have a mar sig- nificant impaet, Dut its important thatthe nesest- Tent be made against the tachnology offered, rather tha historical experience of mila plant. Detaled tamination ofthe vendor reference st and subec ‘quent inquires can pay dividends, ‘Duringatechologyascessment proces, many fae tures must be adoped, ithe project eto haves ‘eat outcome Identifying the key factors that wil inoenc the decision making press Assessing abroad range of technologie and many licensors and process vendors * Contacting te licensor with asestmenteriteria inglevaluation of information to allow the evaluation {to take place with minimsel flr rom all partie. "Tue acer mut he fair withthe tochology so that proces enhancements quoted by one censor ‘an be ineiaded or dseted im the comparative capital fect etimate, to ensure «level paying eld all these factors ean be Drought together, then finding the optimal processing solution i quickly sought . ia shaw eK * ' te rarge eben SIN Sorrento A rar ree aro sero 8 rs