day2 01 nicola mondelli

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Gas Flaring Recovery:

Our recent experience

in

Gas Fieldsand

Petroleum Refineries

February 20, 2013 Rev.0

Gas Flare Reduction Conference



2

Confidential Information

1. Introduction

2. Case Study 1 – Gas Field in North Africa

3. Our experiences in fast track projects and plant operation

4. Case Study 2 – Petroleum Refinery in North Africa

5. Our experiences in revamping and fast track projects

6. Questions & Answers

7. Conclusions

Agenda



3


Approximately 150 bcm (3,5 bcf) of gas are flared to the atmosphere in

the world. This huge quantity is equivalent to 5% of the world gas

production

Tecnimont KT S.p.A. (TKT) and GEA signed a Cooperation Agreement

to collaborate together in the field of Gas Flaring Recovery

The mission of the Cooperation Agreement is to manage the complexity

of our customer’s needs by providing innovative products andcustomized solutions.

TKT and GEA can work for you to solve this issue with the purpose to

recover valuable products in Gas Fields, Petroleum Refinery and

Chemical & Petrochemical complex

Introduction



4


Our Range of Services

R&D/IPL

Full Plant Life CycleSupport

EPCTrainingServices

After SalesServices

Op. & Maint.Services

FEEDBasic

DesignConceptual

DesignFeasibility

Study

Decom.

PMCServices

CMSServices

PlantOptimization

RevampingStudies



5


Our Value

TECHNOLOGY & KNOW-HOW

KNOWLEDGE

EXPERTISE

REFERENCES

“We know how to define, design, built and operate Industrial Plants”

Full Plant Life CycleSupport

44

AMINEREGENERATION AMINEREGENERATIONSECTIONSECTION

33

22

CLAUS TAILGAS

H2RICH GAS

SOURWATERSOUR WATER

SWEET TAIL GASSWEETTAIL GAS

ACID GAS TOCLAUS ACID GASTOCLAUSLEANAMINELEAN AMINE

RICHAMINE

RReductioneduction

Typical 10Typical 10--250 ppm Vol. H250ppm Vol. H22SS

COOL PROCESSGAS

A Absorptionbsorption RRecycleecycle

11

HEATING / COOLINGHEATING /COOLING

SECTIONSECTION

“From White Paper ” … through Process Scheme … up to Plant in operation



6


In a North Africa Country, the wells overhead associated gas were flared

to the atmosphere with a significant pollution to the atmosphere due to

the presence of heavy hydrocarbons and important economic loss

The basic idea of Client was to identify the best and fast technological

solution to be implemented within 24 months from the contract award,

including also the time for a conceptual study

Introduction to Case Study 1

Fast Track Project



7


Fast track project to be implemented within 24 months from contractaward (from white paper up to the plant in operation)

Plant design parameters:

Raw Gas flow rate…………………………………51,000 Nm3/h

Raw Hydrocarbon liquid flow rate……………..25 m3/h

Min Butane production (97% purity)…………...5,9 t/h

Min Gasoline production (99,5% purity)……....4,2 t/h

ROI max 2 years (preferred 1 year!)

Utilise an existing pipeline from wells to site

Minimise emissions

3 years of continuous operation executed by EPC Contractor after 1st

plant start-up

Case Study 1 – Main Constrains



8


Assignment of a dedicated project task force lead by a project manager ful l empowered to execute the project

Combined team work between technology provider (EPC Contractor) andClient (Owner)

Selection of the best scheme selected during the proposal phase

Execution of basic design overlapped with engineering activit ies

Identification and selection of LLI within 2 weeks from the contractaward (CA). Management of the procurement with a fast track approach

First si te activi ties after 3 months from CA

Completion of detailed engineering within 14 months from CA

Optimisation of construction and precomissioning through a detailedstudy of systems and sub-systems

Start of commissioning activities at month 22, plant full in operation atmonth 24

3 years of continuous operation and Training on e Job of Client'soperators

Case Study 1 – Project Execution Strategy



9


Dehydration at wells and preliminary gas-liquid separation

Gas phase: from C1 to C3

Liquid phase: gasol ine with a portion of C3 and C4

The gas separation is achieved by a simple refrigeration system, propylene fluid

based, utilising an Oil Flooded Screw Compressor. The aim of the separation was

to set a volumetric flow rate capable to uti lise the exist ing pipeline connecting the

wells with the plant site, no hydrocarbon fractionation at wells

The liquid stream and the gas stream are processed at plant site to obtain:

Gasol ine stream

Butane stream

Propane stream

Propane, Ethane Rich Stream

Main goal was to minimise gas flaring of incondensable gas

Case Study 1 – Process Description



10


The selected scheme is quite simple: dehydration of the gas followed byrefrigeration. The subcooled liquid is fed to rectifying section of the De-Ethanizer, while the liquid stream, after dehydration is fed to thestr ipping section of the De-Ethanizer

Dehydration is achieved with molecular sieves, treated gas is utilized for the regeneration

The fractionating section consists of:

De-Ethanizer

De-Propanizer

De-Butanizer

Hot oil is used as heating medium

The plant is also equipped with ut ili ties and off-sites section

Case Study 1 – Selection of the Process Scheme



11


Case Study 1 – Process Flow Scheme

EXP. GAS

Condensate

RICH GAS

Hot Oil

Dehyd.

Dehyd.

Refrig.

Sections

DEETHANIZER

DEPROPANIZER

DEBUTANIZER

FLARE SYSTEM

BUTANE

PROPANE

BUTANE

GASOLINE



12


Case Study 1 – “ The Plant”

GAS

IN

TreatedGAS

Condesate

IN

Hot

Oil

System

Fractionating

System

Refrigeration

System



13


Fast Track Project

Plant in operation within 24 months from the contract award

Plant in operation with full satisfaction of the Client since 2010???

ROI less then 1,5 years

Deep reduction of CO2

emissions

Case Study 1 – Conclusions



14


In north Africa, a Refinery experienced pressure instability and oscillation

problems in the fuel gas network.

The pressure in the Fuel Gas Drum was subject to large fluctuations causing

disturbances to the fuel gas users, reducing the steady performance of heaters,increasing the risk of process shut down, causing instability in burner’s pilots

operation and large quantity of fuel gas flaring was experienced.

As consequence of this instability, all the refinery boilers were operated with fuel

oil only and continuous fuel gas flaring leads to a Refinery emission issue in

addition to a valuable fuel gas loss.

Fuel Gas pressure stabilization and recovery of flared Fuel Gas became a vital

requirements for the Refinery

the main goal was to minimize OPEX, to increase reliability and safety and mostimportant to be in compliance with new stringent environmental regulations

reducing as much as possible the use of fuel oil

Introduction to Case Study 2



15


The following graph represents fuel gas flow rate, fuel gas pressure and gas flaring flow rateduring one month of operation

Refinery is subject to a fluctuation of fuel gas request that produces fuel gas pressureinstability, frequent and prolonged fuel gas flaring.

Case Study 2 – operating data from Refinery

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

5

6/30 7/1 7/2 7/3 7/4 7/5 7/6 7/7 7/8 7/9 7/10 7/11 7/12 7/13 7/14 7/15 7/16 7/17 7/18 7/19 7/20 7/21 7/22 7/23 7/24 7/25 7/26 7/27 7/28 7/29 7/30

One month trend

FG flow rate [T/h] P FG-drum [kg/cm2] gas to flare [T/h]



16


Phase (1) assessment of the original design (Design Basis, ProcessFlow Scheme, Util ities Consumption Summary, flare loadsummary, P&ID’s, plot plan, burner and furnaces design,etc.);

Phase (2) analysis of the current operation (DCS data, trends, logbook, lab analysis, etc.;

Phase (3) identification of the causes of fluctuations

Phase (4) definitions of several corrective actions

Phase (5) selection of the best solution capable to minimize OPEXand CAPEX in full compliance with the environmentalregulation in force in that Country

Phase (6) Value Engineering and Constructability Analysis

performed with a joint team of Refinery and Contractors toidentify further possibility of optimization as well asconstrains during construction and operation

Case Study 2 – Process Study



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The source of instability has been identified in the dimensions of the fuel gas KO drum thatwas not properly designed to cover the possible operating scenarios of the Refinery

The following figure shows the effect of fuel gas pressure and fuel gas demand duringtransient conditions

The analysis of the design of the KO drum has demonstrated that the current gas drumvolume is not suffic ient to cover such quick gas flow rate variations. In addition the location of such drum is not symmetrical in respect of the major users.

Case Study 2 – Results of the assessment

5

3

bar

hour1 2

2

4

1



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Necessity to install an additional Collection Balance Drum to better

compensate for the fluctuations of the Fuel Gas network

Identify a stable source of fuel gas make-up (vaporization of LPG), to

cover unexpected and rapid shortage of fuel gas

New fuel gas pressure control philosophy integrated with a Flare Gas

Recovery System (FGRS)

Identification of “ driven users” which can handle some fuel gas

fluctuations without affecting the process units

Constrain the fuel gas network within operating limits (min and max

pressure) through adjustment of FG fired in dedicated special users

Split-range control for fuel gas minimization to flare

Minimization of fuel oil consumption through proper design of the burner

system

Case Study 2 – Corrective actions



19


Case Study 2 – Pressure ControlConceptual Scheme

Flare Gas

Compressor

Capacity

FGRS

LPG

make-up

to FG

network

FG to

“driven”

users

LPG make-up

to “driven”

users

Max FG Pressure………. 4 barg

Normal FG Pressure……3 barg

Min FG Pressure………...2 barg

FG KO

Drum

FG pressure

“driven”

users

Flow rate

LPG

vaporized

Split Range

PTPT

PV PV PV PV

FT

PYP=maxopen

PY PYP=minopen

PYP=normopen

PY PY

TI

PI

FV

PIC FIC

Compensation.

Overpressure Contro l

PIC



20


Fluctuations of fuel gas network can be controlled with the proper

design of the Fuel Gas network system (hardware and software)

Flare Gas Recovery Systems is a key factor to minimize emissions and

fuel gas consumptions

It was possible to recover up to 2,5 t/h of Fuel Gas from the flare

All the corrective actions have been implemented through a fast track

project

ROI was less than 1,5 years.

Case Study 2 – Conclusions



21


Questions & Answers



22


CONCLUSION

WE HAVE KNOW-HOW, KNOWLEDGE, EXPERTISE AND

REFERENCES

WE ARE ABLE TO DELIVER A CORRECT AND TROUBLE FREE

SUPPLY

WE CAN ASSURE AND GUARANTEE THE SUCCESS OF THE

PROJECT WITH FULL SATISFACTION OF THE CLIENT



23


Stop to Gas Flaring!

Thank you!



24Confidential Information

Contacts

Tecnimont KT S.p.A.

Mr. Michele Colozzi

[email protected].: +39 348 2250034

KT ARABIA

Mr. Nicola Mondell i

[email protected]

Mob.: 0500654266

GEA

Mr. Giuseppe Falsiroli

[email protected].: +39 347 4559294

day2 01 nicola mondelli

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