fuel gas ngl (c3+) recovery by twister jtx process
DESCRIPTION
Evaluation of Condensate Recovery & dehydration, de-watering by Twister, Joule & Joule Thompson Coefficients, uses in Real Gas Calculations for Applied Gas Machinery & Equipment, Valves, Nozzles, Compressors, Expanders, pipeline, flare relief devices, gas expanders, two-phase power recovery, Friction Heat by Joule Effect in Gas Flow, Flow Coefficient, Kd, Cv, Crane TP410TRANSCRIPT
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NGL recovery from fuel gas
at Safaniya + Tanajib
by JT Expansion Valve
Otis Armstrong– 02 Nov. 2009
(analysis by Twister BV & P&CSD)
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• Background & Technical –SA interest in JT expansion for Economics to apply to
Fuel Gas of TPD & SONPD
• Why? Apply to Saf & Tan Fuel Gas – no deep recovery of condensate in gas
55F dew point vs -32F dew Point by JT
• Design approach -Use PFD Composition + sensitivity from Labs results
• Tanajib vs. Safaniyah – same fuel composition with new FG line, diff P&T
• Economic analysis –Results SONPD higher IRR due to bigger gas use & no line dp
Agenda
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HOW? JT Valve = Min stages to Max Vena Cava +meet noise dB
Single stage
deviceMulti stage device
Expansion at ~S=C
Recovery at ~P=C
Intersection ~= max JT
Twister technology
Reduces valve
friction heating to
increase cooling &
NGL recovery.
H-S valve analysis
does not account
for friction heating
in gas flow
OP Armstrong 2009
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Condensate Recovery module = Goal for our application- LSTK
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• Objective : Recover valuable C3+ hydrocarbon NGL’s from boilers & furnaces fuel gas at Tanajib &Safaniya by LTX gas expansion using Twister Technology
• Sweet fuel gas for Tanajib originates from Safaniya- identical composition, but flow rate, inlet P & T are not identical- system drawing
• Sufficient pressure drop available for expansion (~90%) in both Twister LTX application’s
• Gas is dehydrated to 7 lb/MMSCF
• Cool gas in gas-gas heat exchanger(s) to increase condensate recovery
• Configuration with only 1 JTX valve or Twister selected at both location
• Apply maximum heat integration; use MEG when Low T Separator temperature is below Hydrate Forming Temperature
• Hydrocarbon Condensate goes into condensate line by independent pump
Design approach for Tanajib & Safaniyah JT LTX Application
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PFD – Safaniya EXISTING FUEL SYSTEM w/o JT bypass
12”FG-4 to SEC
8“-P-222 (FG frm Refrig)
P/L Comp’s
PCV107 A/B
12“-FG-5
Hot oil furnace
Flare, Purge &Misc. users
Glycol Heater &Purge
Boilers
Sweet gas from Refr
PCV104 A/B
Co
nd
ensa
te 1
0”P
25
3
36“-P-230 (FG frm P/L K’s)
6“-FG-3/4
Point A
Point C
Point B
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PFD – Safaniya F/G w/ JT By-Pass System INSTALLED
12”FG-4 to SEC
8“-P-222 (FG frm Refrig)
P/L Comp’s
PCV107 A/B
12“-FG-5
Hot oil furnace
Flare, Purge &Misc. users
Glycol Heater &Purge
Boilers
Sweet gas from Refr
PCV104 A/B
36“-P-230 (FG frm P/L K’s)
6“-FG-3/4
JT Unit
Hea
vy F
uel
Gas
Ligh
t Fu
el G
asCondensate out
Point A
Point B
Co
nd
ensa
te 1
0”P
25
3
Point C
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JT
PFD – Safaniya Twister LTX PFD Internal Configuration
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PFD – Tanajib EXISTING Fuel Gas System w/o LTX bypass
Sour gas from Offshore gas pipeline 8“-FG-600-9A2L
ZV1507
G82-D-090
PCV1512 A/B
G82-D-091
PCV1516 A/B
12“-FG-610-3A1L
Hot oil furnaceG80-F010/011
Flare, Purge &
Misc. users (G80)
Glycol Heater &Purge (G54)
BoilersG80-F007/008
Sweet gas fromSafaniya (new)
NC
Co
nd
ensa
te
Point C
Point B
Point A
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PFD – Tanajib F/G with LTX Twister By-Pass INSTALLED
Sour gas from Offshore gas pipeline
Sweet gas fromSafaniya (new)
8“-FG-600-9A2L
ZV1507
G82-D-090
PCV1512 A/B
G82-D-091
PCV1516 A/B
12“-FG-610-3A1L
Hot oil furnaceG80-F010/011
Flare, Purge &Misc. users (G80)
Glycol Heater &Purge (G54)
BoilersG80-F007/008
LTX Unit
He
avy
Fuel
Gas
Light Fu
el Gas
Co
nd
ensa
te
Condensate out
Existing
New
NC
Point A
Point B
Point C
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PFD – Tanajib Twister LTX Internal PFD
JT
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C3+ recovery
summer winter
Safaniya 875 bpd 1032 bpd
Tanajib: 535 bpd 475 bpd
Total 1410 bpd 1507 bpd
Liquid recoveries by Twister using PFD Compositions
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• LPG 25 US$/bbl
• C5+ 35 US$/bbl
• Fuel gas 3.3 US$/MMBTU
• Electricity 3 ct/kWhr
• MEG 5,000 US$/metric tonne
• Inflation 5% per year
• NPV discount rate 15% per year
• Maintenance 250,000 per 3 years
• Operating days 350 days per year
• Lifetime 20 years
• Apply gas shrinkage for constant BTU to gas system
Economic analysis - parameters
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Safaniya: MMBTU/d constant
Total installed cost US$ 10,000,000
NPV net profits US$ 24,260,000
IRR 49.1%
Tanajib:
Total installed cost US$ 9,000,000
NPV net profits US$ 9,500,000
IRR 31.3%
Economic analysis – results (nearly identical CAPX but SONPD higher gas demand)
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1. Some Gas analysis have indicated that the gas is much
dryer than 7 lb/MMSCF. This means possible operation w/o
chemicals thus reducing OPEX.
2. Black powder in Gas line also indicates intermittent off-spec
operation
3. Chemical free operation is possible by maintaining the LTS
temperature above the hydrate formation temperature
4. Chemical free operation is also possible by using a hydrate
separator (Twister BV proprietary technology) which uses
hot oil/hot water to melt hydrates inside the vessel
4. Conservative gas shrinkage case taken as base case
Economic Analysis - sensitivities
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• ___________________ Conclusion______________________
• OP Armstrong’s claim is substantiated by P&CSD review to extract
substantial amounts of NGL ’s from fuel gas at both Safaniya and
Tanajib by LTX Twister with Gas to Gas LTX cooling
• Economic analysis indicates both locations provide a positive
income & high IRR
• Maximum profits can be obtained by maximising heat integration
and using MEG only when required
__________________Action Recommended__________________
• Install 1st Unit at SONPD due to higher IRR, but also for Tanajib
• Submittal was made to P&CSD and Concurred for Application
• Make Request to Facility Planning for Formal DBSP, pending
Management approval. FPD to review economic alternatives.
Conclusions & Recommendations
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Salient Points of P&CSD Evaluation, emails dated 10/3&7 of ‘09
The LTS liquids from the Twister and J-T systems are compared as follows:
SUMMER CONDITIONS Proposed Twister System
Conventional J-T Expansion
Raw Fuel Gas, MMSCFD 27.98 27.98Inlet Pressure, psia 997 997Inlet Temperature, °F 140 140
Fuel Gas Pressure, psig 85 85
LTS Liquids Flow, Std BPD 1292 1295
addition of Twister technology does not offer any significant advantage ... Therefore, for the Safaniyah application, addition of
proprietary Twister system to recover heavier condensate from rich fuel gases cannot be recommended.
Regarding
the need to
recover
higher-value
hydrocarbon
s from fuel
gas, yes that
should be
considered
on its own
economics.
Perhaps that
should have
been done
long time
ago, and that
remains true
wherever
rich gases
are
consumed
as fuel.
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Overview of Safaniyah area Flow Lines
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Overview of Twister LTX Swirl ValveTwister’s field experience with Swirl Valve as JT Choke for LTX shows :
HC dew-point reduced by 7°C at design capacity.
Flow rate increases 20% from capacity with conventional JT choke
Cold separator temperature increases by 5°C,
Pressure drop over conventional JT valve is reduced by 20%
A safe Noise level of 70dB(A) at design capacity.
It Provides linear control characteristic like other traditional cage valves
Swirl Valve Working Principle :
Compared to a traditional valve, the SWIRL Valve enlarges the mean diameter of droplets
and bubbles by at least a factor of 5. Only droplets with a diameter smaller than 0.2 micron
will not be separated by the SWIRL Valve. A SWIRL Valve works using Tangential slots in the
cage valve trim to force the liquid flow into a strong rotational motion, causing small droplets
to concentrate and agglomerate along the perimeter of the pipe wall. Free pressure energy is
dissipated through dampening of vortex along the extended pipe length downstream of the
valve. Advantage of creating a swirling flow in the valve is twofold: 1. Regular velocity
pattern provides less interfacial shear meaning less droplet break-up resulting in larger
drops, then concentrating the droplets in circumference of the flow area to increased number
density giving improved coalescence from larger drops. The flow is normally throttled over a
perforated cylinder (cage). These perforations, either slots or holes have a radial orientation
perpendicular to the cylinder surface. Dissipation of energy by centrifugal forces produces
useful work as opposed to conventional valve energy dissipation via eddy currents which
produce no useful work.
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Overview of Twister LTX Swirl Valve
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Overview of Twister
ProcessTwister Supersonic Separator works by taking
in a feed of saturated ('dirty') gas, and then
using available pressure drop to expand pre-
swirled gas via a Laval nozzle (contracting and
then widening pipe throat) which accelerates
the gas to supersonic velocities . The cooling
effect of this expansion forces the water and
hydrocarbons to condense forming tiny droplets
which are then efficiently separated from the
gas using the high centrifugal forces(500,000g)
caused by the rotating vortex (conservation of
angular momentum – angular velocities
increase in direct proportion to the reducing
diameter of the tube inner body - like a figure
skater spinning). The Static inlet guide vanes
twist the gas, and it moves through the Twister
tube at over Mach 1, while swirling around in a
vortex fashion.
Droplets are thrown to the outside of the tube,
where they are removed from the processed
gas using a simple pipe-in-pipe separator and
some of the process gas (slip gas) as a carrier
The gas that flows straight through the tube is
conditioned, with impurities removed
Detailed
Engineering
should review
merits of a
conventional
Twister Tube as
opposed to the
JT Twister valve.
The Twister
personnel claim
deeper recovery
is possible in a
twister tube due
to the
supersonic
effect imposed
on a gas by a
true Twister
tube. The issue
is does the
additional cost
justify use of the
twister tube as
opposed to
Twister JTX
valve?