1. Chris, Stephanie, Kyle, Mariam Mentor: Jerry Palmer
Gas Treatment Plant
Chris, Stephanie, Kyle, Mariam
Mentor: Jerry Palmer

2. Outline 1. Block Flow diagram 2. Mass Balance 2. Liquid Knockout
3. Sour Gas Treatments
4. Gas Dehydration
5. NGL Recovery and CO2 Removal
6. NGL Stabilization
7. Inert Removal-N2
8. Equipment Cost
9. Capital Cost
10. Revenues
11. Sample Calculations
12. Question & Answer

3. Block Flow Diagram

4. Mass Balance

5. Liquid Knockout
3- Horizontal Tanks and decreasing temperature and pressure.
In a dynamic refinery environment it is important to have the capability to compensate for a surge of liquids and take out any non-volatile components which will cause issues in the future separation processes.
3 tanks are used because its the most efficient setup for large scale processes.

7. Sour Gas Treatment

8. Sour Gas Treatments Liquid Scavenger Solid Scavenger Liquid Redox
Amine+Claus+Tailgas
Gases treated
Acid Gas
Yes
Natural Gas No
Turndown
Sensitive
Not Sensitive
Products Streams
Biodegradable Liquid
Non-Hazardous Solid
Sulfur Cake for Fertilizer
Pure Sulfur
Operating Costs
$10/lb. of S
$3.50/lb. Sulfur
$0.15/lb. of S
Small
Equipment Costs
Low
Moderate
High
General Application Guidlines
100 lb. of sulfur per day
300 lb. of sulfur per day
Less than 20 tons of sulfur per day
Greater than 15 tons of sulfur perday and greater than 15% H2S

9. Why LO-CAT II? -System Stability
-Ease of operation and Catalyst consumption
-Chemical Cost is roughly 1/2 to 1/3 of a
Sulferox Unit
-Uses a Patented chelate system that is more
resistant to Oxidation

11. Gas Dehydration

12. Gas Dehydration & CO2 Rejection
The methods of dehydration looked into are lean gas absorption, adsorption and membrane separation.
Absorption
Adsorption
TEG dehydration
Mole sieve dehydration
Glycol is cost effective
Adsorbent like silica gel is expensive
For removing large quantities of water
Required for cryogenic systems which need low moisture content
Glycol can be replaced continuously
Multiple adsorption beds are required for
continuous use.
Does not remove CO2
Removes CO2

13. PFD-003 Gas dehydration

14. NGL Recovery + CO2 Removal

15. NGL Recovery Mechanical Refrigeration Plant: - limited to -24 to -40 F
- only 60% propane
Lean oil absorption:
- 40% ethane
- 90% propane
- 100% heavier hydrocarbons
- Heating and cooling required
- High operating cost
Turboexpander:
% ethane
% propane
-100% of heavier hydrocarbons
- Since high percent ethane recovery is needed, this is the most economical way 90

17. NGL Stabilization

18. NGL Stabilization
NGL's need to be stabilized to a point that it can be stored and transported in non- pressurized vessels.
Enhances the safety in handling, and improving the liquid's marketability.
Stabilizing the liquid reduces the volatility.

20. Inert Removal-N2

21. Inert Removal-N2
Available options are cryogenic distillation, membrane separation and PSA.
Cryogenic distillation has been selected on the basis that is very efficient for large scale separation facilities.
Additionally because LNG is being produced in the following stage its worthwhile to expend the energy to process the methane.

23. LNG Production

24. LNG Production LNG is produced under very low temperatures.
Effective for transportation of natural gas over long distances.
Safer than transporting compressed natural gas in vehicles because LNG is comparably low in pressure.

26. Equipment Cost Estimates
pump
$20,000 to $85,000
distillation column
$600,000
compressor
$20,000 to $1,500,000
cryo distillation column
$700,000
heat exchanger
$50,000 to $100,000
primary LNG cryo heat exchanger
$3,000,000

27. Estimated Capital Cost
Amine Treating cost for 5% acid gas removal $10.0MM
Dehydration cost $1.0MM
Compression cost (7000hp x $1400/hp) $9.8MM
Cryogenic NGL recovery cost $23.0MM
Liquid-Redox Sulfur Recovery at 5 T/d $4.0MM
Total cost of components $47.88MM
Other costs and 30% $14.3MM
Total Estimate Plant Cost $62.1MM
-Based on a Natural Gas Treatment Facility that processes 100 MMscfd.
-Prices based in 2008 and do not account for inflation.
Employee payroll with fringe benefits $3.5MM/year

28. Revenues Natural Gas: 300 Million $/year NGL: 110 Million $/year
LNG: 50 Million $/year
Elemental Sulfur: 50,000 $/year

29. Sample Calculations SCFD to Lb/Hr conversion:
X Lb/hr = ( Y SCFD) / [ ( 24 hr/1d)*(1 lbmol/ Z Lb)*( SCF /lbmol) ]
V/n = RT/P = 60F
X : lb/hr
Y : SCFD
Z: MW
X bbl = ( Y lbmol * MW lb/lbmol) / (5.615 ft^3/bbl*Z lb/ft^3)
X= volume
Y= n moles
Z = density

30. Q & A