gas processing course

8/9/2019 Gas Processing Course

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INTRODUCTION


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PROVEN EGYPTIAN GAS RESERVES IS 62 TCF

(AT THE END OF 2003)


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CUMULATIVE GAS PRODUCTION IN EGYPT IS

13.5 TCF ( TILL 30/6/2003)


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NATURAL GAS CONSUMPTION IN EGYPT IS AROUND 28.3 BILLIONS CUBIC METERS (AT THE

END OF 2003) REPRESENTING ABOUT 47 % OF

THE PRIMAREY ENERGY CONSUMPTION IN THECOUNTRY


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MAJOR GAS FIELDS IN EGYPT ARE :

- ABU MADI

- SHUKHEIR

- BADREDDIN

- ABU QIR


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(EASTERN EUOROPE

/ FORMER SOVIET UNION)


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NATURAL GAS CONSUMPTION

- HOMES (26%).

- COMMERCIAL APPLICATIONS (15%).

- INDUSTRIAL APPLICATIONS(43%).

- GENERATING ELECTRICITY (16%).


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USE OF NATURAL GAS

- FERTILIZERS

- METHANOL

- BLENDING AGENTS

- PREMIUM GASOLINE

- PETROCHEMICAL DERIVATIVES


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NATURAL GAS INDUSTRIAL APPLICATION

- PULP AND PAPER

- METALS

- CHEMICALS.

- GLASS

- CLAY

- WASTE TREATMENT (INCENIRATOR)

- FUEL IN VEHICLES

- HEATING, COOLING, DEHUMIDIFICATION AND DRYING


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NATURAL GAS COMPANIES INEGYPT

- BRITISH GAS (B.G)- B.P AMOCO.

- ENI-AGIP.

- SHELL.- RESOL

- APACHE

- INTERNATIONAL EGYPTIAN OIL COMPANY( IEOC )

- EDISON


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TYPES OF NATURAL GAS

- ASSOCIATED GAS (OIL WELL GAS)

- NON-ASSOCIATED GAS (GAS WELL GAS)

- GAS CONDENSATE


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NATURAL GAS COMPOSITION


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NATURAL GAS COMPONENTS


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NATURAL GAS COMPONENTS

PROPERTIES


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PIPELINE SPECIFICATIONS


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DEFINITIONS


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Gas processing

The separation of constituents from natural gas for the

purpose of making salable products and also for treating the

residue gas to meet required specifications .

Gas processing plant

A plant which processes natural gas for recovery of natural

gas liquids and sometimes other substances such as sulfur.

Gas-well gas

The gas produced or separated at surface condit ions from the

full well stream produced from a gas reservoir.


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Gas-well liquids

The liquid separated at surface condit ions from the ful l well stream

produced from a gas reservoir.

Natural gas

Gaseous form of petroleum, consisting of mixtures of hydrocarbon gases.

Associated gas

Natural gas which over lies and is in contact with crude oil in the reservoir.

Wet gas

Gas containing water, or a gas which has not been dehydrated.


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Dry gas

Gas whose water content has been reduced / removed by

dehydration process.

Lean gas

Gas containing little or no hydrocarbon commerciallyrecoverable as natural gas liquid product.

Rich gas

Gas containing many hydrocarbons commercially recoverable asnatural gas liquid product.


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Synthetic gas (SNG)

The gas product resulting from the gasification of coal and or gas

liquids or heavier hydrocarbons.

Acid gas

The hydrogen sulfide and or carbon dioxide contained in, or

extracted from gas or other streams.

Dew point

The temperature at any given pressure at which liquid init ially

condenses from gas or vapor.


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Raw gas

Unprocessed gas or the inlet gas to gas processing plant.

Sour gas

Gas containing undesirable quantities of hydrogen sulfide,

mercaptans, and or carbon dioxide.

Sweet gas

Gas which has no more than the maximum sulfur content defined by

the specifications for the sales gas from a plant.


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Water Dew point

The temperature at which water vapor start to condense from a gas

mixture.

Hydrocarbon Dew point

The temperature at which hydrocarbons start to condense from a

gas mixture.

Bubble point

The temperature at any given pressure at which the first vapor form

above a liquid.


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Hydrate

A solid material resulting from the combination of a hydrocarbon with

water under pressure.

Desiccant

A substance used in a dehydrator to remove water and moisture form

gases or air.

Dehydration

The process of removing the water form gases or liquid.


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Recovery

That percent or fraction of a given component in the plant feed whichis recovered as plant product.

Light ends

The low-boiling, easily evaporated components of a hydrocarbon

liquid mixture.

Heavy ends

The portion of a hydrocarbon mixture having the highest boiling

points.

Distillation

The process of separating a multiple components feed of dif fering

boiling points into two or more products.


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Absorber

A tower or column that provides contact between natural gas being

processed and a liquid solvent.

Absorption

The operation in which one or more components in the gas phase

are transferred to (absorbed into) a liquid solvent.

Adsorption

The process by which gaseous components are adsorbed on

solids because of their molecular attraction to the solid surface.


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Debutanizer

A fractionator designed to separate butane (and more volatilecomponents if present) from a hydrocarbon mixture.

Demethanizer

A fractionator designed to separate methane (and more volatile

components if present) from a hydrocarbon mixture.

Depropanizer

A fractionator designed to separate propane (and more volatile

components if present) from a hydrocarbon mixture.

Stripper

A column wherein absorbed constituents are stripped from the

absorption oil. The term is applicable to columns using a strip-ping

medium, such as steam or gas.


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Stripping factor

An expression used to describe the degree of stripping.

Mathematically, it is KV/L, the reciprocal of the absorption factor.

Stripping medium

As stated under "stripper" , the medium may be steam, gas, or other

material that wi ll increase the driving force for strip-ping.

Trayed column

A vessel wherein gas and liquid, or two partially miscible liquids, are

contacted, usually concurrently on trays.

Partial Pressure

The pressure due to one of the several components in the gaseous

mixture. Partial pressure of a gas in a perfect gaseous mixture is

equal to its mole fraction in the mixture multiplied by total pressure.


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COMPONENT

C6+IC5IC5NC4IC4C3C2C1N2H2SCO2

XXXXXXXXXXXNATURAL GAS

XXINERT GAS

XX ACID GAS

XXXLNG

XXXXXXXNGL

XXXXXXLPG

XXXXXCONDENSATE

COMPOSITION OF NATURAL GAS PRODUCTS


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NATURAL GAS TREATING


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TYPES OF CONTAMINANTS

- AMMONIA (NH3).

- HYDROGEN SULFIDE (H2S).

- HYDROGEN CYANIDE (HCN).

- CARBON DIOXIDE (CO2).

- CARBONYL SULFIDE (COS).- CARBON DISULFIDE (CS2).

- MERCAPTANS (RSH).

- NITROGEN (N2).- WATER (H2O).

- SULFER DIOXIDE (SO2).


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REASONS FOR CONTAMINANT

REMOVAL

- SAFETY- CORROSION CONTROL

- GAS AND/OR LIQUID PRODUCT SPECIFICATIONS

- PREVENT FREEZE-OUT AT LOW TEMPERATURES- DECREASE COMPRESSION COSTS

- FOAMING

-

PREVENT POISONING OF CATALYSTS INDOWNSTREAM FACILITIES

- MEET ENVIROMENTAL REQUIREMENTS

ACIDIC GASES SAFETY PROBLEMS


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HYDROGEN SULFIDE

HYDROGEN SULFIDE IS A HIGHLY TOXIC GAS, ATVERY LOW CONCENTRATIONS IRRITATION OF THEEYES, NOSE, AND THROAT IS POSSIBLE.

HYDROGEN SULFIDE IS A HIGHLY FLAMMABLE GAS

AND WILL SUPPORT COMBUSTION IN AIR AT

CONCENTRATIONS FROM 4.3 TO 46 VOLUMEPERCENT.



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- CARBON DIOXIDE

CARBON DIOXIDE WILL DISPLACE OXYGEN ANDCAN CREATE AN OXYGEN-DEFICIENT ATMOSPHERE

RESULTING IN SUFFOCATION.

THE ATMOSPHERIC CONCENTRATION IMMEDIATELY

HAZARDS TO LIFE IS 10 %(VOL.)

ACIDIC GASES CORROSION


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PROBLEMS

GAS STREAMS WITH HIGH H2S TO CO2 RATIOS

ARE LESS CORROSIVE THAN THOSE HAVINGLOW H2S TO CO2 RATIOS.



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PROBLEMS

CORROSION IS STRONGLY A FUNCTION OF

TEMPERATURE AND LIQUID VELOCITY.



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PROBLEMS

REBOILER, RICH SIDE OF AMINE-AMINE

EXCHANGER, STRIPPER OVHD CONDENSING

LOOP TEND TO EXPERIENCE HIGH CORROSION

RATES.


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FOAMING PROBLEMS

A SUDDEN INCREASE IN DIFFERENTIAL PRESSURE ACROSS A CONTACTOR OFTEN INDICATES SEVERE

FOAMING

FOAMING RESULT IN REDUCING THE TREATING

CAPACITY AND SWEETNING EFFECIENCY.

FOAMING REASONS


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FOAMING REASONS

- SUSPENDED SOLIDS

- ORGANIC ACIDS

- CORROSION INHIBITOR

- CONDENSED HYDROCARBONS

- MAKE-UP WATER IMPURITIES

- LUBE OIL


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NATURAL GAS TREATING PLANT

MATERIAL OF CONSTRUCTION

TREATING PLANTS NORMALY USE CARBON

STEEL AS THE PRINCIPAL MATERIAL OF

CONSTRUCTION.


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NATURAL GAS TREATING PLANT

MATERIAL OF CONSTRUCTION

STAINLESS STEEL 304, 316, OR 410 MAY BE USED IN

THE FOLLOWING CRITICAL AREAS:

- REFLUX CONDENSER

- REBOILER TUBE BUNDLE- RICH / LEAN EXCHANGER TUBES

- BOTTOM 5 TRAYS OF THE CONTACTOR AND TOP 5

TRAYS OF THE STRIPPER- PIPING FROM RICH/LEAN EXCHANGER TO THESTRIPPER

GAS TREATMENT PROCESS


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SELECTION- CONTAMINANTS TYPES AND CONCENTRATION.

- ACID GAS SPECIFICATIONS.

- TREATED GAS SPECIFICATIONS.

- VOLUME OF GAS TO BE PROCESSED.

- TEMPERATURE AND PRESSURE AT WHICH SOUR GAS IS

AVAILABLE.- HYDROCARBON COMPOSITION OF THE SOUR GAS.

- LIQUID PRODUCT SPECIFICATIONS.

- DISPOSAL OF BY-PRODUCTS CONSIDERED HAZARDOUSCHEMICALS.

- OPERATING AND CAPITAL COST.

- SELECTIVITY REQUIRED FOR ACID GAS REMOVAL.


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CHEMICAL REACTION PROCESS

(CHEMICAL SWEETNING)


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CHEMICAL REACTION PROCESSES REMOVE THE H2S

AND/OR CO2 FROM THE GAS STREAM BY CHEMICAL

REACTION WITH A MATERIAL IN THE SOLVENT

SOLUTION.


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THE REACTION MAY BE REVERSIBLE OR

IRREVERSBLE , THE REACTION IS REVERSED

AT LOW PRESSURE AND HIGH TEMPERATURE.


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CHEMICAL SWEETNING SOLVENT


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EQUEOUS ALKANOLAMINES

- TRIETHANOL AMINE (TEA)

- DIETHANOL AMINE (DEA)

- MONOETHANOL AMINE (MEA)- DIISOPROPANOLAMINE (DIPA)

- DIGLYCOL AMINE (DGA)

- METHYLDIETHANOLAMINE (MDEA)

CHEMICAL SWEETNING PROCESS FLOW DIAGRAM


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CHEMICAL SWEETNING MAIN

PROCESS EQUIPMENT


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INLET SEPARATOR

THE INLET SEPARATOR SHOULD BE SIZED NOT

ONLY ON THE BASIS OF INLET FLUID VOLUMES,

BUT ALSO ON SURGE CAPACITY TO HANDLESLUGS OF LIQUID HYDROCARBONS


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FILTERATION

FILTERATION IS ESSENTIAL TO REMOVE

PARTICLES DOWN TO 5 MICRONS.


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TWO STAGE OF FILTERATION MAY BE REQUIRED.

THE FIRST STAGE, A CARTRIDGE-TYPE FILTER, TOREMOVE PARTICLES DOWN TO 10 MICRONS.

THE SECOND STAGE OF FILTERATION TYPICALLY AN

ACTIVATED CARBON FILTERS REMOVE

HYDROCARBON AND OTHER CONTAMINANTS DOWN

TO 5 MICRONS.


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THE CARRYOVER OF CARBON FINES CAN

BE CONTROLLED BY EITHER LOCATING A

SECOND CARTRIDGE-TYPE FILTER

IMMEDIATELY DOWNSTREAM OF THE

CARBON FILTER OR USING A GRADED

CARBON BED.


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DURING PERIODS OF ANTIFOAM INJECTION, THE

CARBON FILTER SHOULD BE TAKEN OUT OF

SERVICE . CARBON WILL REMOVE MOST

ANTIFOAMS AND WILL BE DEACTIVATED BY

THEM.

FLASH TANK


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FLASH TANK

- REDUCE ERROSION IN RICH / LEAN EXCHANGERS.

- MINIMIZE THE HYDROCARBON CONTENT IN THE

ACID GAS.

- REDUCE THE VAPOR LOAD ON THE STRIPPER

- ALLOW USING THE OFF-GASES AS FUEL

RECLAIMER


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RECLAIMER

RECLAIMER IS USUALY REQUIRED FOR MEA AND

DGA SYSTEMS TO REMOVE THE FOLLOWING:

- SUSPENDED SOLIDS

- ACIDS AND IRON COMPOUNDS

- HEAT STABLE SALTS

- DEGRADATION PRODUCTS

GAS TREATING USING CAUSTIC WASH (NAOH)


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THE PROCESS EMPLOYS COUNTER-CURRENT CONTACTING

OF THE GAS STREAM WITH A CAUSTIC SOLUTION IN A

PACKED OR TRAYED COLUMN.

THE SPENT SOLUTION IS EITHER REGENERATED OR

DISCARDED DEPENDING ON WHAT ACID COMPONENTS AREPRESENT IN THE SOUR GAS.

IF ONLY MERCAPTANS ARE PRESENTED, THE CAUSTICSOLUTION IS REGENERATED WITH STEAM


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NAOH CAN BE USED TO TREAT NATURAL GAS

STREAMS TO REMOVE CO2,CS2, H2S AND

MERCAPTANS

H2S + 2 NAOH NA2S + 2 H2O

CO2 + 2 NAOH NA2CO3 +2H2O

RSH + NAOH RSNA + H2O


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PHYSICAL SOLVENT PROCESSES

(PHYSICAL SWEETNING)

SOLVENTS USED IN PHYSICAL


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SOLVENTS USED IN PHYSICAL

ABSORPTION

- POLYETHYLENE GLYCOL DERIVATIVES

- ANHYDROUS PROPYLENE CARBONATE

USES OF PHYSICAL SOLVENT


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PROCESSES

- THE PARTIAL PRESSURE OF THE ACID GASES IN THEFEED IS GREATER THAN 50 PSI

- THE HEAVY HYDROCARBON CONCENTRATION IN THEFEED GAS IS LOW.

- SELECTIVE REMOVAL OF H2S IS DESIRED

- LITTLE OR NO ENERGY IS REQUIRED.

MAIN FEATURES OF


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- PHYSICAL SOLVENT PROCESS IS CAPABLE OF

SIMULTINEOUSLY DEHYDRATING AND SWEETNING

THE GAS.

- THE PROCESS OPERATE AT AMBIENT OR

SUBAMBIENT TEMPERATURE.

- THE SOLVENTS ARE RELATIVELY NONCORROSIVE

SO CARBON STEEL CAN BE USED.

PHYSICAL SWEETNING

PHYSICAL SOLVENT PROCESS FLOW DIAGRAM


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GAS TREATING BY ADSORPTION

MOLECULAR SIEVE


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THE SIEVE BED CAN BE DESIGNED TO DEHYDRATE

AND SWEETEN SIMULTANEOUSLY.

PROCESS CYCLE TIMES ARE IN THE ORDER OF 6-8

HOURS

TO OPERATE PROPERLY THE SIEVES MUST BE

REGENERATED AT A TEMPERATURE CLOSE TO 600OF

TO A LONG ENOUGH TIME TO REMOVE ALL

ADSORBED MATERIALS, USUALY ONE HOUR OR

MORE.

MOLECULAR SIEVE


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MOLECULAR SIEVE


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MEMBRANE TECHNOLOGY

MEMBRANE TECHNOLOGY FOR CO2


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REMOVAL

MEMBRANES ARE SEMIPERMEABLE BARRIERS

THAT SELECTIVELY SEPARATE SOME COMPOUNDS

FROM OTHERS

MEMBRANE MATERIALS FOR CO2


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MEMBRANE MATERIALS FOR CO2

REMOVAL

- CELLULOSE ACETATE

- POLYIMIDES

- POLYAMIDES- POLYSULFONE

- POLYCARBONATES

- POLYETHERIMIDE

MEMBRANE PERMEATION


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MEMBRANE DOESN’T WORK AS FILTER, WHERE SMALL MOLECULES ARE

SEPARATED FROM THE LARGER ONES. INSTEAD, THEY OPERATE ON

THE PRINCIPLE OF SOLUTION-DIFFUSION THROUGH A NON POROUS

MEMBRANE.

MEMBRANE SEPARATE BASED ON HOW WELL DIFFERENT COMPOUNDS

DISSOLVE INTO THE MEMBRANE AND THEN DIFFUSE THROUGH IT.

FAST GASES SUCH AS CO2, H2, HE, H2S, AND WATER VAPOR PERMEATE

QUICKLY. CO, N2, C1, C2,OTHER HYDROCARBONS PERMEATE LESS

QUICKLY, AND SO ARE CALLED SLOW GASES.


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MEMBRANE PERMEATION


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ONE STAGE FLOW SCHEME


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RESIDUE (CO2 REDUCED)

PERMEATE (CO2 ENRICHED)

MEMBRANE UNIT FEED

TWO STEP FLOW SCHEME


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RESIDUE (CO2 REDUCED

PERMEATE (CO2 ENRICHED)

FEED

TWO STAGE FLOW SCHEME


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RESIDUE (CO2 REDUCED)

PERMEATE (CO2 ENRICHEDFEED

MEMBRANE DESIGN CONSIDERATIONS


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LOW COST

HIGH RELIABILITY HIGH ON-STREAM TIME

EASY OPERATION

HIGH HYDROCARBON RECOVERY LOW MAINTENANCE

LOW ENERGY CONSUMPTION

LOW WEIGHT AND SPACE REQUIREMENT

MEMBRANE PERFORMANCE


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THE MEMBRANE PERFORMANCE IS LOWERED

DUE TO

LIQUIDS

HEAVY HYDROCARBONS(>C15)

CERTAIN CORROSION INHIBITOR

MEMBRANE SYSTEM PRETREATMENT


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COALESCING FILTER FOR LIQUID AND MISTELIMINATION

NON-REGENERABLE ADSORBENT GUARD BEDFOR TRACE CONTAMINANT REMOVAL

PARTICLE FILTER FOR DUST REMOVAL AFTERTHE ADSORBENT BED

HEATER FOR PROVIDING SUFFICIENTSUPERHEAT TO THE GAS

MEMBRANE SYSTEM PRETREATMENT


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COALESCINGFILTER

ADSORBENTGUARD BED

PARTICLEFILTER

HEATER

FEED

MEMBRANE


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NATURAL GAS DEHYDRATION


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DEFINITION

DEHYDRATION IS THE PROCESS USED TO REMOVE

WATER FROM NATURAL GAS AND NATURAL GAS

LIQUIDS.

IMPORTANCE


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- MEET A WATER CONTENT SPECIFICATION

- PREVENT CORROSION

- PREVENT DECREASE IN THE GAS HEATING

VALUE

- PREVENT HYDRATE FORMATION

- REDUCE TRANSFER COST

MAIN FEATURES OF GAS DEHYDRATION


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THE SATURATED WATER CONTENT OF A GAS DEPENDSON PRESSURE, TEMPERATURE AND COMPOSITION.

SATURATED WATER CONTENT INCREASES AT HIGHERTEMPERATURE,LOWER PRESSURE AND LOW SPECIFICGRAVITY.

THE PRESENCE OF ACID GASES (i.e. CO2 & H2S)INCREASE THE WATER CONTENT IN THE NATURALGAS

NATURAL GAS

WATER CONTENT


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WATER CONTENT

SAT. WATER CONTENT =

1060 kg/106 SM3 @ 40ºC AND 7 MPa

Water Content

of Natural Gas


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of Natural Gas

SAT. WATER CONTENT =

61 Ib/M

3

@ 100ºF AND 1000 PSIA


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HYDRATES IN NATURAL GAS

DEFINITION


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A HYDRATE IS A PHYSICAL COMBINATION OF

WATER AND OTHER SMALL HYDROCARBONMOLECULES TO FORM A SOLID CRYSTALLINE

COMPOUND WHICH HAS AN “ ICE-LIKE ”

APPERENCE, BUT WITH A DIFFERENT STUCTURE

THAN ICE AND MUCH MORE DENSE THAN ICE.


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HYDRATE FORMATION


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NATURAL GAS HYDRATES ARE FORMED WHEN NATURAL

GAS COMPONENTS, NOTABLY METHANE, ETHANE,

PROPANE, ISOBUTANE, HYDROGEN SULFIDE, CARBONDISULFIDE AND NITROGEN ENTER THE WATER LATTICE

POSITIONS AND OCCUPY THE VACANT LATTICE

POSITIONS, CAUSING THE WATER TO SOLIDIFY ATTEMPERATURE CONSIDERABLY HIGHER THAN THE WATER

FREEZING POINT. ENOUGH GASEOUS MOLECULES MUST

ENTER THE LATTICE AND OCCUPY THE VOIDS TO FORM A

STABILIZED HYDRATE

HYDRATE TYPES

SMALLER MOLECULES (CH4, C2H6, CO2, H2S) STABILIZE A


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( , , , )BODY-CENTERED CUBIC CALLED STRUCTURE I.

LARGER MOLECULES (C3H8, I- C4H10, N-C4H10) FORM ADIAMOND-LATTICE CALLED STRUCTURE II.

NORMAL PARAFFIN MOLECULES LARGER THANN-C4H10

DO NOT FORM STRUCTURE I AND II HYDRATES AS THEY

ARE TOO LARGE TO STABILIZE THE LATTICE. HOWEVER,

SOME ISOPARAFFINS AND CYCLOALKANES LARGER

THAN PENTANE ARE KNOWN TO FORM STRUCTURE HHYDRATES.

HYDRATE TYPES


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NITROGEN : N 2 .6 H 2 O

CARBON DIOXIDE: CO2 .6 H 2 O

HYDROGEN SULFIDE : H 2 S. 6 H 2 O

METHANE : CH 4 .6 H 2 O

ETHANE : C2 H 6 .8 H 2 O

PROPANE : C3 H 8 .1 7 H 2 O

ISO-BUTANE : I - C4 H 1 0 .1 7 H 2 O


HYDRATE STRUCTURE TYPE


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HYDRATE STRUCTURE TYPE

FROM A PRACTICAL VIEWPOINT, THE STRUCTURE TYPE DOES NOT

AFFECT THE APPEARANCE, PROPERTIES, OR PROBLEMS CAUSED BYTHE HYDRATE.

IT DOES, HOWEVER, HAVE A SIGNIFICANT EFFECT ON THE

PRESSURE AND TEMPERATURE AT WHICH HYDRATES FORM.STRUCTURE II HYDRATES ARE MORE STABLE THAN STRUCTURE I.THIS IS WHY GASES CONTAINING C3H8 AND I-C4H10 WILL FORMHYDRATES AT HIGHER TEMPERATURES THAN SIMILAR GASMIXTURES WHICH DO NOT CONTAIN THESE COMPONENTS.


FACTORS THAT AFFECT HYDRATE FORMATION


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FACTORS THAT AFFECT HYDRATE FORMATION

THE CONDITIONS WHICH AFFECT HYDRATE FORMATION ARE:

TEMPERATURE

PRESSURE

COMPOSITION

IN GENERAL, HYDRATE FORMATION WILL OCCUR AS PRESSURE INCREASES AND/OR

TEMPERATURE DECREASES TO THE FORMATION CONDITION.

THE PRESENCE OF H2S IN NATURAL GAS MIXTURES RESULTS IN A SUBSTANTIALLY

WARMER HYDRATE FORMATION TEMPERATURE AT A GIVEN PRESSURE. CO2, IN

GENERAL, HAS A MUCH SMALLER IMPACT AND OFTEN REDUCES THE HYDRATE

FORMATION TEMPERATURE AT FIXED PRESSURE FOR A HYDROCARBON GAS MIXTURE.

Simple

Hydrate Prediction

Correlation


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Ref. GPSA Data Book

What is the hydrate temperature

of a 0.7 specif ic gravity natural

gas at 7000 kPa?

Hydrate temperature = 18º C

Simple

Hydrate Prediction

Correlation


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Ref. GPSA Data Book

What is the hydrate temperature

of a 0.7 specif ic gravity natural

gas at 1000 psia?

Hydrate temperature = 65º F


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HYDRATE INHIBITION

THE FORMATION OF HYDRATES CAN BE PREVENTED BY


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DEHYDRATING THE GAS OR LIQUID TO ELIMINATE THEFORMATION OF A CONDENSED WATER (LIQUID OR

SOLID) PHASE.

IN SOME CASES, HOWEVER, DEHYDRATION MAY NOT BE

PRACTICAL OR ECONOMICALLY FEASIBLE. IN THESECASES, INHIBITION CAN BE AN EFFECTIVE METHOD OFPREVENTING HYDRATE FORMATION.

DEHYDRATION ADDITIVES


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THE FOLLOWING ADDITIVES ARE USED TO LOWER THE

HYDRATE TEMPERATURE AT A CERTAIN PRESSURE

- METHANOL (CH3 OH )

- ETHYLENE GLYCOL (C2H6O2)

- DIETHYLENE GLYCOL (C4H10O3)

- TRIETHYLENE GLYCOL (C6H14O4)

- TETRAETHYLENE GLYCOL (C8H18O5 )

DEHYDRATION ADDITIVES PROPERTIES

HIGH ABSORPTION EFFICIENCY


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- HIGH ABSORPTION EFFICIENCY.

- EASY AND ECONOMIC REGENERATION

- NON CORROSIVE AND NON TOXIC

- NO INTERACTION WITH THE HYDROCARBON PORTION

OF THE GAS

- NO OPERATIONAL PROBLEMS WHEN USED IN HIGHCONCENTRATIONS

DEHYDRATION FEATURES

HYDRATE INHIBITION UTILIZES INJECTION OF ONE OF THE GLYCOLS OR


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METHANOL INTO A PROCESS STREAM

FOR CONTINUOUS INJECTION IN SERVICES DOWN TO – 40°F, ONE OF THE

GLYCOLS USUALLY OFFERS AN ECONOMIC ADVANTAGE VERSUS METHANOL

RECOVERED BY DISTILLATION.

ETHYLENE GLYCOL IS THE MOST POPULAR BECAUSE OF ITS LOWER

COST, LOWER VISCOSITY AND SOLUBILITY IN LIQUID HYDROCARBONS.

FOR LOW GAS VOLUMES , INFREQUENT OPERATION AND AT CRYOGENIC

CONDITIONS (BELOW – 40°F) METHANOL USUALLY IS PREFERRED.


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GLYCOL LOSSES

- FOAMING


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- HIGH GAS FLOW RATE IN THE CONTACTOR

- RAPID CHANGES IN THE GAS FLOW RATES

- PUMP LEAKAGE

- GLYCOL CARRY OVER WITH THE GAS LEAVING THECONTACTOR

- LOW PH (< 3)

GLYCOL INJECTION PROCESS


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GLYCOL INJECTION PROCESS


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DEHYDRATION USING SOLID DESICANTS


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SOLID DESICANT PROPERTIES


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-Calcium chloride (CaCl2) can be used as aconsumable desiccant to dehydrate natural gas.

CALCIUM DI CLORIDE


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- 3/8” to 3/4 “ CaCl2 pellets are installed in a

fixed bed much like a dry desiccant tower.

- Outlet water contents of 1 lb/MMscf have been

achieved with CaCl2 dehydrators. Typical

CaCl2 capacity is 0.3 lb CaCl2 per lb H20.

- CaCl2 dehydrators may offer a viable

alternative to glycol units on low rate, remotedry gas wells.

- The CaCl2 must be changed out periodically.

In low capacity – high rate units this may be as

often as every 2-3 weeks.

- Brine disposal raises environmental issues.


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MERCURY REMOVAL

VARIOUS FORMS OF MERCURY

ELEMENTAL MERCURY (HG.)


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- ELEMENTAL MERCURY (HG.)

- ORGANIC FORM (HG (CH3)2 ,HG (C2H5)2 )

- INORGANIC FORM (HG CL2)

- SUSPENDED MERCURY COMPOUNDS (MERCURIC SULFIDE)

DIFFERENCE BETWEEN VARIOUS FORMS

OF MERCURY


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- VAPOR PRESSURE

- SOLUBILITY

- PHASE

- ADSORPTION PROPERTIES

REASONS FOR MERCURY

REMOVAL

- DEPOSITS IN CRYOGENIC EQUIPMENT


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Q

- CAUSE CRACKING OF WELDED ALUMINUM HEAT EXCHANGER

- REDUCE PRODUCTS (C1, C2, C3, C4, C5+) QUALITY

- CORROSION

- DEPOSITS IN THE MOLECULAR SIEVE, GLYCOL UNITS AND ACID GAS REMOVAL UNITS. (DIFFICULT DISPOSAL ANDREGENERATION)

- POISON THE DOWN STREAM CATALYST IN ETHYLENE, MTBE, AROMATICS AND OLEFINE PLANTS.

- SAFETY AND HEALTH PROBLEMS DURING EQUIPMENTMAINTENANCE AND INSPECTION

MERCURY CONTENT


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MERCURY CONTENT IN N.G SHOULD BE NILOR LESS THAN 0.01 MICROGRAM PER NORMALCUBIC METER


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Hg Removal Without Treatment Of The Spent

Regeneration Gas


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NATURAL GAS REFRIGERATION


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PURE COMPONENT PHASE BEHAVIOR


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PHASE BEHAVIOR OF C2-NC7 SYSTEM


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REFRIGERATION CYCLE PROCESS FLOW DIAGRAM


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COMPRESSOR

EVAPORATOR

EXPANSION VALVE

CONDENSER

A

CD

B

REFRIGERATION CYCLE PRESSURE-ENTHALPY DIAGRAM

CRITICAL POINTI

)


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P R E S S U R E ( P S

ENTHALPY (Btu / Ib)

A

C

D

B

REFRIGERATION SYSTEM PRESSURE DROP

- CONDENSER PRESSURE DROP : 3.0 TO 7.0 PSI


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CONDENSER PRESSURE DROP : 3.0 TO 7.0 PSI

- LINE HYDRAULIC LOSSES

EVAPORATOR TO COMPRESSOR : 0.1 TO 1.5 PSI

COMPRESSOR TO CONDENSER : 1.0 TO 2.0 PSI

CONDENSER TO RECEIVER : 0.5 TO 1 PSI

Refrigeration Mechanical


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ONE STAGE REFRIGERATION SYSTEM

COMPRESSOR


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EVAPORATOR OR CHILLAR

RECEIVER

SUCTIONDRUM

Air Cooler

Q= 35 MMBTU/HR

120 oF240 psia

P1 = 10 psi

-40 oF16 psia

14.5 psia

250 psia

P1 = 1.5 psi

COMPRESSOR

TWO STAGES REFRIGERATION SYSTEM


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SUCTIONDRUM

Q= 25 MMBTU/HR

120 oF240 psia

P1 = 10 psi

-40 oF16 psia

14.5 psia

250 psia

P1 = 1.5 psi P = 60 psi

Q= 10 MMBTU/HR

25 oF62 psia

120 oF240 psia

P1 = 2 psi

THREE STAGES REFRIGERATION SYSTEM


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Q= 23 MMBTU/HR

120 oF240 psia

P1 = 10 psi

-40 oF

16 psia

14.5 psia

82 psia

P1 = 1.5 psi P = 34 psi

Q= 10 MMBTU/HR

-4 oF36 psia

120 oF190 psia

200 psia

44 oF

84 psia

Q= 7 MMBTU/HR

Q= 3 MMBTU/HR

CASCADE REFRIGERATION SYSTEM

Q= 15 MMBTU/HR

120 oF240 psia

-120 oF18.5 psia

17 psia153 psia

P = 51 psi

-78.5 oF52 5 i

-25 oF148 psia

Q= 30.71 MMBTU/HR

-40 oF16 psia21


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141

Q= 23 MMBTU/HR

120 oF240 psia

-40 oF

16 psia

14.5 psia 82 psiaP = 34 psi

Q= 10 MMBTU/HR

-4 oF

36 psia

100 oF190 psia

200 psia

44 oF

84 psia

Q= 7 MMBTU/HR

Q= 3 MMBTU/HR

Q= 10 MMBTU/HR

52.5 psia

ETHANE SYSTEM

PROPANESYSTEM

Q= 3 MMBTU/HR

1 2 3

REFRIGERANTS PHYSICAL PROPERTIES


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TURBO EXPANDERS


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TERBO EXPANDERS


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FRACTIONATION


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FRACTIONATORS PRODUCTS

- DEMETHANIZED PRODUCT (C2+)

- DEETHANIZED PRODUCT (C3+)


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( )

- ETHANE/PROPANE MIXTURES (EP )- COMMERCIAL PROPANE

- PROPANE/BUTANE MIXTURE (LPG)

- BUTANE(S)

- BUTANE/GASOLINE MIXTURES

- NATURAL GASOLINE- MIXTURES WITH A VAPOR PRESSURE

SPECIFICATION

FRACTIONATOR TRAIN


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What are those?

- NGL ?


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G

- LPG ?

- LNG ?

NGL


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NATURAL GAS LIQUIDSITS COMPOSITION IS MAINLY

ETHANE+

LPG


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LIQUIFIED PETROLEUMGAS

ITS COMPOSITION IS MAINLY

PROPANE & BUTANES

LNG


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LIQUIFIED NATURALGAS

ITS COMPOSITION IS MAINLY

METHANE & ETHANE


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Gas Conditioning

To meet sales gas specifications only


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– No further processing

–Water removal–CO2 /H2S removal

–Hydrocarbon dew point control


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NGL Extraction

Pr o ce s s Ty p e s


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Adsorption: Hydrocarbon RecoveryUnits

Absorption: Lean Oil

Condensation: Mechanical RefrigerationExpander Valve

(LTS, LTX, JT)

Adsorption


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Absorption Process(Refrigerated Lean Oil Plant)


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Refrigeration Mechanical


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Expander Process


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Valve Expansion Process


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LNG


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LIQUIFIED NATURALGAS

Why LNG ???

Pipelines can not be used for gas exportbecause of:

– Geography


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• Distance – no local gas market• Physical terrain – mountain ranges• Water depth

– Politics• International agreements required• Political risk

– Economics• Size• distance

Why LNG?

• 600:1 volume reduction


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Typical LNG Properties

• Boiling point -160 to -162 °C

• Molecular weight 16 to 19


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• Odor none• Color none

• Density 425 – 485 kg/m3

• Calorific value 1030 – 1180 Btu/scf

• Specific heat capacity 2.2 – 3.7 kJ/kg/°C

• Viscosity 0.11 – 0.18 cP• Thermal conductivity 0.19 – 0.22 W/m/°C


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LNG PROCESS FACILTIES


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FEED

PREPARATION

FACILITIES

STORAGE AND

SHIPPING

FACILITIES

NGL

RECOVERY

FACILITIES

LIQUIFICTION

FACILITIES

LNG Process Facilities


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Typical Gas Processing Stages

• Gas Compression

• Phase Separation


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• Acid Gas Removal

• Sulphur Recovery

• Dehydration• Mercury Removal

• NGL recovery

Acid Gas Removal

• CO Removal – Solidification in liquefaction plant

– Reduce corrosion issues

H2S R l


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• H2S Removal – Hazardous compound

– To meet LNG specification

– Reduce corrosion issues• Organic Sulphur Removal

– To meet LNG specification

• Amine processes are the industrystandard

– Hybrid solvents gaining in popularity

Typical Amine Plant Layout


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Dehydration

• Water removal to prevent solidificationin the liquefaction plant

Mi i i i i


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• Minimizes corrosion issues

• Specification < 1 ppmv

• Adsorption on Molecular Sieve is theindustry standard


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Mercury Removal

• Trace contaminant but accumulates in plant

• Mercury will cause failure of aluminum

equipment


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equipment – Must be removed prior to liquefaction plant

• Contamination of liquid streams

– Beneficial to remove upstream of processingunits

• Removal by Sacrificial Beds

– Sulphided activated carbon

– Metal sulphide

NGL Recovery system

Demethanizer•Separates CH4 from heavier components

•Cryogenic cooling followed by fractionation

•Methane to sales or LNG plant


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•Methane to sales or LNG plant•Residue to de-ethanizer

De-ethanizer

•Separates Ethane from heavier hydrocarbons

•Fractionation column•Ethane to sales or mixed with methane

NGL Recovery System

•Depropanizer

• Separates Propane from heavier

hydrocarbons


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hydrocarbons

• Fractionation column

Debutanizer• LPG for sale

• Residual condensate to oil

NGL Recovery System


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LNG LIQUIFICATION TECHNOLOGY


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LNG LIQUIFICATION TECHNOLOGY

COMPARISON

LIQUIFICATION PROCESSES

CASCADE CYCLE (PHILLIPS,AIR PRODUCT)

C3/ C C ( C )


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C3/MR CYCLE (APCI)

MRCYCLE (APCI , PRICHARD)

MR/MR CYCLE (APCI, TECHNIP/SNAM)

LNG PRODUCTION WITH DIFFERENTREFRIGERATION CYCLES

TYPE LICENSOR PLANTSTOTAL

MMTA%

CASCADE PHILLIPS PET Co


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CASCADE

SINGLE PRESSURE

MIXED REFRIGERANT(MR)

PROPANE PRE-

COOLED/MIXEDREFRIGERANT(C3/MR)

MIXED REFRIGERANT

PRECOOLED/MIXEDREFRIGERANT

9

2

84

5

4

1

25

3 6.6

109.3

2.4

11.5

APCI &(TEARLAC) by

TECHNIP /SNAMPROJETTI

APCI

APCI & PRITCHARD

PHILLIPS PET. Co.

& APCI

COMPARISION BETWEEN THETWO MAIN TECHNOLOGIES FOR

LNG LIQUEFACTION PROCESS

AIR PRODUCTS AND CHEMICALS INC(APCI)


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AIR PRODUCTS AND CHEMICALS INC(APCI)

THE PHILLIPS OPTIMIZEED CASCADEPROCESS

APCI PROCESS

The APCI process utilizes a propane pre-cooled / mixed

LIQUEFACTION PROCESS


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The APCI process utilizes a propane pre cooled / mixedcomponent refrigerant (MCR) system .

PHILLIPS PROCESS

The Phillips optimized cascade process utilizes three cascade

pure component refrigeration system . (Propane - Ethylene -Methane)

FLEXIBILITY FOR FEED STOCK

CHANGES

APCI process can accommodate varying feed


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APCI process can accommodate varying feedstock better by allowing for adjustment of MRcomposition


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NGL RECOVERY CAPABILITY

There is no difference between the two


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technologies for the NGL Fractionation Section.

APCI PROCESS

The key to optimizing the design ,is optimization of theMCR blend and selection of press re le els for the chillers

PROCESS DESIGN COMPLEXITY


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y p g g , pMCR blend and selection of pressure levels for the chillers.

PHILLIPS PROCESS

Optimization of chiller pressures is the main factor for

process design

Both technologies are similar in complexity level .

THERMODYNAMIC CYCLEEFFICIENCY

APCI PROCESS

42-45%


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PHILLIPS PROCESS

39-42%

Theoretical minimum workEFFICIENCY =

Total work

COMPRESSOR DRIVERS

APCI PROCESS

Utilize larger sized refrigeration compressordrivers (Frame 6&7)


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g g pdrivers.(Frame 6&7)

PHILLIPS PROCESS

Utilize six frame 5C for 3.6 MTPA plant.

RELIABILITY / AVAILABILITY OF THECRYOGENIC HEAT EXCHANGER

APCI PROCESS

The main heat exchanger used in the APCI

process has been utilized in numerous LNGapplications


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applications.

PHILLIPS PROCESS

The brazed aluminum heat exchangers and

equipment used in PHILLIPS process are utilizedin several LNG plants as well as numerous gasprocessing facilities worldwide.

PLANT INFRASTRUCTURE

The remainder of the plant and marine facilitiesill b i il f b th t h l i i


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will be similar for both process technologies .i.e.LNG storage tanks, loading system, jetty and

marine facilities, fire protection equipment, utilitysystems, etc.

APCI Propane Pre-Cooled Mixed

Refrigerant


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Phillips Optimized Cascade


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Egyptian LNG Plants

• Egypt LNG (SE-GAS)

- Located at Damietta


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Located at Damietta

- Union Fenosa

- APCI Propane Pre-cooled

- Mixed Refrigerant process

- 1 x 4.5 mtpa train

Egyptian LNG Plants

• Egyptian LNG

– Located at Idku

– BG Group, Edison, Gaz de France,


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BG Group, Edison, Gaz de France,EGPC, Egas

– Phillips Optimized Cascade

– Under construction by Bechtel

- 1 x 3.6 mtpa train

LNG storage

• LNG Storage Tanks realizes on average45% to 65% of total Import terminalcosts(£10s millions).

– Metallurgy – Cryogenic


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– Insulation – Cold seals – Limited vendors – Seismic considerations

• Construction of the order 2 to 4 years for

tanks.

GTL TECHNOLOLOGY


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GTL TECHNOLOLOGY

NATURAL GAS

APPLICATION

LIQUIFIED NATURALGAS (LNG)

NATURAL GAS LIQUIDRECOVERY (NGL)


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APPLICATION

GAS TO LIQUID FUEL

(GTL)PETROCHEMICAL

INDUSTRIES

WHAT IS GTL??

• “ GTL” IS LOOSELY DEFINED TERM THAT IS GENERALLYUSED TO DESCRIBE CHEMICAL CONVERSION OF NATURAL


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USED TO DESCRIBE CHEMICAL CONVERSION OF NATURAL

GAS TO SOME OF LIQUID PRODUCTS USING FISCHER -

TROPSCH TECHNOLOGY.

CONVERSION OF NATURAL

GAS TO LIQUID FUEL

DIRECT APPROACH INDIRECT APPROACH


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(UNDER RESEARCH)

CONVERSION OFN.G TO SYNTHESIS

CONVERSION OFSYNTHESIS TO LIQUID FUEL

GTL UNIT100 MMSCFD

N.G

10,000 BPSD

LIQUID FUEL


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50 MWHELECTRICITY

15,000BBL/DAYWATER

GTL UNIT• THE LIQUID FUEL PRODUCED FROM GTL UNITS CAN BE DISTILLATED

TO NAPHTHA, KEROSENE, GAS OIL ,DIESEL OIL.

• WAXES AND LUBE OIL FEED STOCKS AND DETERGENT CAN ALSO BE

PRODUCED FROM GTL UNITS.

THE PRODUCED WATER CAN BE USED AS BOILER FEED WATER


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• THE PRODUCED WATER CAN BE USED AS BOILER FEED WATER,

POTABLE WATER (AFTER TREATMENT),IRRIGATION

• THE GENERATED EXOTHEMIC HEAT ARE USED TO GENERATE

ELECTRICAL HEAT WHICH IS ENOUGH TO OPERATE THE UNIT AND

CAN EXPORT THE SURPLUS .

GTL TECHNOLOGY

NATURALGAS

REFORMING

FISHER-TROPSCHCONVERSION

PRODUCTWORK UP

NATURAL

GAS

SYNTHESIS

GAS

WAXY SYNCRUDE

(HYDROCARBON)


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( )

• MIDDLE DISTILLATE FUEL

• NAPHTHA

• GASOLINE

GTL TECHNOLOGY HAS THREE MAJOR

PROCESS STEPS

• STEP-1

NATURAL GAS REFORMING , CONVERTS NATURAL GAS INTO

SYNTHESIS GAS, (A MIXTURE OF CARBON MONO OXIDE (CO), AND HYDROGEN (H2)).


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CH4 + H2O CO + 3H2

THIS PROCESS TECHNOLOGY IS A CONVENTIONAL PROCESS

TECHNOLOGY HAS BEEN USED IN MANY COMMERCIAL

FACILITIES IN PETROLEUM REFINERIES ,METHANOL, AMMONIA AND UREA PLANTS AND OTHER RELATED INDUSTRIES

FOR EXAMPLE H2 PLANT.


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• STEP-3

THE HYDRACARBON ARE UPGRADED TO HIGH QUALITY

MIDDLE DISTILLATE FUEL (KEROSENE,DIESEL OIL AND SOME

NAPHTHA) BY USING STANDARD MILD HYDROCRACKING OR

THERMAL CRACKING , HYDROISOMERIZATION PROCESS FOR


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THE PRODUCED WAX AND DISTILLATION FOR PRODUCT

SEPARATION .

PRODUCTION

OF

SYNTHESIS GAS


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PARTIAL OXIDATIONSTEAM REFORMING AUTOTHERMAL REFORMING

• STEAM REFORMING PROCESS CAN PRODUCE SYNTHESISGAS FROM NATURAL GAS USING STEAM REFORMER OVER ANICKLE CATALYST LOADED IN THE REFORMER TUBES . THE

H2 / CO PRODUCT RATIO IS 1 : 3 .

CH4 + H2O CO +3H2

• STEAM REFORMING PROCESS IS OFFERED BY :

- HALDOR TOPSOE.

20 BAR

800-900 ° C


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- FOSTER WHEELER COPORATION .

- KTI B.V.- LURGI AG .

- UHDE GMBH .

• ADVANCED STEAM REFORMING CAN PRODUCE A

SYNTHESIS WITH H2 / CO PRODUCT RATIO < 1 .

• PARTIAL OXIDATION PROCESS

CAN PRODUCE SYNTHESIS GAS FROM ENTIRE RANGE OFGASEOUS AND LIQUID HYDROCARBON AS WELL AS SOLIDS(COAL , COKE ) .THE PROCESS IS CONTINOUS NON

CATALYTIC PARTIAL OXIDATION USING OXYGEN OR AIR ASAN OXIDANT AND WAS DONE IN A REFRACTORY -LINEDPRESSURE VESSEL . THE H2 / CO PRODUCT RATIO IS 1.7 :1 .


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/

2CH4 + O2 2CO + 4H2 .

• PARTIAL OXIDATION PROCESSIS IS OFFERED BY

- TEXACO INC .

- ROYAL DUTCH .

140+ BAR

1200-1500 °C


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SYNTROLEUM GTL PROCESS TECHNOLOGY

AUTOTHERMAL

REFORMING

N.GSYNTROLEUM

REACTOR

SYNTHESIS

GAS

SYNTHESIS


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REFORMING REACTORGAS CRUDE OIL

SYNTROLEUM MAIN FEATURES

• SYNTROLEUM PROCESS USED THE AUTO THERMAL REFORMERREACTOR TO PRODUCE A NITROGEN DILUTED SYNTHESIS GASCONSISTING PRIMARILY OF CARBON MONO OXIDE AND HYDROGEN .

• SYNTROLEUM GAS IS CONVERTED INTO SYNTHESIS CRUDE IN AREACTOR CONTAINING CATALYST DEVELOPED BY SYNTROLEUM .


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• SYNTROLEUM PROCESS ALSO PLANS TO BUILD GTL PLANTS THAT

CONVERTS N.G INTO A MARGIN OF PRODUCTS SUCH AS SYNTHETICLUBRICANTS , SOLVENTS AND CHEMICAL FEED STOCKS .

• GAS TURBINES OR HEATERS MIGHT BE USED IN THE PROCESS TO

BURN THE LOW HEATING VALUE OF TAIL GAS THAT IS PRODUCED BYTHE PROCESS WHICH WOULD RESULT IN THE NEED TOINCORPORATE OTHER METHOD TO GENERATE HORSEPOWER FORTHE COMPRESSION PROCESS .

23

SHELL MIDDLE DISTILLATE SYNTHESIS (SMDS)

GTL PROCESS TECHNOLOGY

SHELLGASIFICATION

PROCESS (SGP)

PRODUCT

WORK UP

N.GHEAVY

PARAFFINS

SYNTHESIS (HPS)

REACTOR

SYNTHESIS

GAS

WAXY

SYNCRUDE


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• PARAFFINIC SOLVENT

• MIDDLE DISTILLATES• WAXY RAFINATE

• PARAFFINS

• WAX

SHELL MIDDLE DISTILLATE SYNTHESIS

(SMDS) MAIN FEATURES

• SMDS USES PARTIAL OXIDATION PROCESSTECHNOLOGY FOR THE SHELL GASIFICATIONPROCESS (SGP)TO PRODUCE SYNTHESIS GAS FROMNATURAL GAS .


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• SHELL MDS UTILIZES THE HEAVY PARAFFINSSYNTHESIS REACTOR (HPSR) IN WHICH SYNTHESISGAS IS CONVERTED TO PARRAFINS .


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SASOL MAIN FEATURES

• SASOL USED AUTO THERMAL REACTOR (ATR ) TO PRODUCESYNTHESIS GAS FROM NATURAL GAS .

• BY SASOL PROCESS THE HYDROCARBONS ARE SYNTHESIS BY ACHAIN GROWTH PROCESS. THE LENGTH OF THE CHAIN BEINGDETERMINED BY THE CATALYST SELECTIVITY.


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• SASOL HAS DEVELOPED HIGH PERFORMANCE COBALT - BASED

AND IRON - BASED CATALYST .

• SASOL HAS DEVELOPED THE TWO TYPES OF FISCHER - TROPSCHCONVERSION TECHNOLOGY BY USING TWO TYPES OF REACTORS;SLURRY PHASE REACTOR & SASOL ADVANCED SYNTHOLREACTOR.

SASOL MAIN FEATURES CONTINUED

• SASOL UTILIZES THE SLURRY PHASE REACTOR TO PRODUCE WAXESAND MIDDLE DISTILLATE FUELS . THIS TECHNOLOGY WASDEVELOPED FROM THE CONVENTIONAL TUBULAR FIXED REACTOR

• SASOL UTILIZES THE ADVANCED SYNTHOL REACTOR TO PRODUCEMAINLY LIGHT OLEFIN AND GASOLINE FRACTION.


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• PRODUCT UPGRADED MAKE USE OF A STANDARD HYDROCRACKING

AND HYDROISOMERIZATION PROCESS AND DISTILLATION PROCESS.

• SASOL’S SLURRY PHASE DISTILLATE PROCESS (SSPD) CAN PRODUCETHE DIESEL OIL WITH CETANE NUMBER >70, AROMATIC CONTENT <3 %VOL.AND WITH NO SULFUR .


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RENTECH INC. GTL PROCESS

TECHNOLOGY

PARTIALOXIDATION

PRODUCTUPGRADING

UNITS

N.GSLURRY

SYNTHESIS

REACTOR

SYNTHESIS

GAS

WAXY

HYDROCARBON


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LIQUID FUEL

( NAPHTHA,KEROSENE &

DIESEL )

RENTECH MAIN FEATURES

• RENTECH USED PARTIAL OXIDATION REACTOR (POX) TOPRODUCE SYNTHESIS GAS FROM NATURAL GAS .

• BY RENTECH PROCESS, THE HYDROCARBON ARE SYNTHESISBY FORMING LONG AND SHORT STRAIGHT CHAINHYDROCARBONS .

• RENTECH HAS DEVELOPED HIGH PERFORMANCE IRON -

BASED CATALYST POWDER .


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• RENTECH HAS DEVELOPED THE FISCHER - TROPSCH

CONVERSION TECHNOLOGY BY USING VERTICAL SYNTHESISREACTOR.

• PRODUCT UPGRADED MAKE USE OF A STANDARDHYDROCRACKING OR THERMAL CRACKING,HYDROISOMERIZATION PROCESS ,VACUUM SEPARATION ANDDISTILLATION PROCESS .

RENTECH VERTICAL SYNTHESISREACTOR

1- PREHEATED SYNTHESIS GAS IS FED TO THE BOTTOM OF THEREACTOR WHERE THE IRON BASED CATALYST POWDER ISSUSPENDED IN A MOLTEN WAX SLURRY .

2- THE SYNTHESIS GAS BUBBLES UPWARD THROUGH THE SLURRY, CONTACTS THE CATALYST PARTICALS AND FORMS THESTRAIGHT CHAIN HYDROCARBONS .


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3- THE LONG STRAIGHT CHAIN HYDROCARBONS ARE DRAWNOFF AS A LIQUID HEAVY WAX . THE SHORT CHAINHYDROCARBONS ARE WITHDRAWN AS OVERHEAD VAPORS ANDCONDENSED TO SOFT WAX , DIESEL AND NAPHTHA. ANYHYDROCARBONS NOT CONDENSED ARE RECYCLED TO THE PLANTINLET OR ARE USED AS FUEL GAS FOR NECESSARY POWERGENERATION.

COMMERCIAL APPLICATIONS OF “ GTL”

TECHNOLOGY

• IN GERMANY :

THIS TECHNOLOGY WAS ORIGANILLY DEVELOPED

DURING WORLD WAR II WHEN IT WAS USED TOPRODUCE LIQUID FUELS FROM COALS . SOMEFACTORIES ARE STILL USING IT.


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• IN NEW ZELAND :

MOBIL COMPANY USED THIS TECHNOLOGY IN1986 TO PRODUCE 14,500 BARREL / DAY

GASOLINE FROM NATURAL GAS.


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COMMERCIAL APPLICATIONS OF “GTL”TECHNOLOGY CONTINUED

• IN MALAYSIA :

SHELL MIDDLE DISTILLATE SYNTHESIS (SMDS)

PROCESS WAS APPLIED AT PLANT IN MALAYSIA

“BINTULU PLANT “ ,WHICH WENT ON STREAM IN

1993 THE PLANT CONVERTS 10MMSCFD OF


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1993 . THE PLANT CONVERTS 10MMSCFD OF

NATURAL GAS TO 12,000 BPSD OF LIQUID

PRODUCTS.

COMMERCIAL APPLICATIONS OF “GTL”TECHNOLOGY CONTINUED

• IN QATAR :

SASOL ,PHILIPS AND QATAR GENERAL PETROLEUMCOMPANY “QGPC ”HAVE SIGNED A JOIN VENTURE FORGTL PROJECTS USING N.G TO PRODUCE 20,000 BPSDOF MIDDLE DISTILLASTE AT RASLAFFAN. THIS


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PROJECT IS SCHEDULED TO START YEAR 2002.

EXXON NEGOTIATES WITH QGPC TO BUILD GTL PLANTTO CONVERT 500 - 1000 MMSCFD NATURAL GAS TO

50,000 - 100,000 BPSD MIDDLE DISTILLATE ANDOTHER LIQUID PRODUCT .


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DIESEL OIL

PROPERTIES CONVENTIONAL GTL

FLASH POINT

SPECIFIC GRAVITY

SULPHUR

CETANE NUMBER

71

0.84

350 PPM

4

81

0.78

< 5 PPM *

4


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CETANE NUMBER

CLOUD POINT

AROMATICS

45

- 17

74

- 12


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NITROGEN

CETANE NUMBER

-

48-51

NA

58 (MIN)

NIL

70

• THE ABOVE TABLES SHOW THAT GTL SUPER CLEAN PRODUCTS

COULD BE BLENDED WITH CONVENTIONAL PETROLEUM REFININGPRODUCTS FOR BOTH LOCAL ENVIRONMENTAL IMPROVEMENT ANDEXPORT .

GTL ECONOMICS

• PAY BACK TIME IS 7.5 YEARS

• IRR IS 11 % .

BASED ON PETROLEUM RESEARCH INSTITUTE FEASIBILITY STUDYWHICH IS BASED ON THE FOLLOWING :

- SASOL TECHNOLOGY .

- PLANT CAPACITY IS 100,000 .


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,

- TOTAL COST IS MM$ 300 .- PLANT LIFE TIME IS 25 YEAR .

- NATURAL GAS PRICE IS $ / MMBTU 1.1.

- PRICE OF PRODUCTS IS 143 % FROM THE CRUDE OIL PRICE .

- PRICE OF CRUDE OIL BARREL IS $ 18 .

- ELECTRICITY PRICE IS $ / KWH 0.02 .

- WATER PRICE IS $ / M3 0.245

gas processing course

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