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New Gas Separation Process
Presented by Andrea Tran & Conner Cruson
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Outline
Conventional processingMembrane technologyAmine vs. MembraneIntroduction of the new
technologyAdvantages/Disadvantages of
new process
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Conventional processing
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Overview of Gas plant processing
Field operations/Inlet receivingInlet compressionGas treatingDehydrationHydrocarbon recoveryOutlet compression
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Conventional Process
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Demethanizer unit
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1
20DEETHANIZER
1
2
3
Stream NameStream Description
Phase
TemperaturePressure
Flowrate
Composition ETHANE PROPANE BUTANE PENTANE METHANE
FPSIG
LB-MOL/HR
1FEED
Mixed
144.653440.000
975.838
0.5290.1390.0200.2990.013
2OVERHEAD
Vapor
47.385425.000
526.904
0.9730.0030.0000.0000.024
3BOTTOMS
Liquid
293.592440.000
448.934
0.0070.2990.0430.6500.000
Stream NameStream Description
Phase
Total Stream
Rate Std. Liq. RateTemperaturePressureMolecular WeightEnthalpy Mole Fraction LiquidReduced TemperatureReduced PressureAcentric FactorUOP K factorStd. Liquid Density Sp. Gravity API Gravity
Vapor
Rate Vapor Std Vol FlowMolecular WeightZ (from K)EnthalpyCPDensityTh. ConductivityViscosity
Liquid
Rate Liquid Std Vol FlowMolecular WeightZ (from K)EnthalpyCPDensitySurface TensionTh. ConductivityViscosity
LB-MOL/HRLB/HRGAL/HRFPSIG
MM BTU/HRBTU/LB
LB/GAL
LB-MOL/HRLB/HRFT3/HRFT3/HR
BTU/LBBTU/LB-FLB/GALBTU/HR-FT-FCP
LB-MOL/HRLB/HRGAL/HRGAL/HR
BTU/LBBTU/LB-FLB/GALDYNE/CMBTU/HR-FT-FCP
1FEED
Mixed
975.83843893.87910953.073
144.653440.00044.9814.203
95.7460.70000.92140.72610.152515.5674.007
0.4807162.879
292.75110198.9973111.202
111094.31334.838
0.74512181.545
0.5970.438
0.015470.00998
683.08733694.8718445.0217927.746
49.3270.1316269.7760.7493.990
5.10090.054210.08071
2OVERHEAD
Vapor
526.90415685.0725285.611
47.385425.00029.7682.041
130.0980.00000.93020.62180.096619.4142.968
0.3559266.043
526.90415685.0724154.898
199951.15629.768
0.63718130.098
0.7460.505
0.012660.00887
n/an/an/an/an/an/an/an/an/an/an/an/a
3BOTTOMS
Liquid
448.93428208.8075667.461293.592440.00062.8355.001
177.2791.00000.95840.85600.218113.4284.977
0.5970105.517
n/an/an/an/an/an/an/an/an/an/an/a
448.93428208.8078253.7785667.462
62.8350.17150177.279
1.0643.418
2.42640.044450.06222
Column NameColumn Description
Condenser DutyReboiler Duty
MM BTU/HRMM BTU/HR
DEETHANIZERDEETHANIZER
-5.92488.7636
De-ethanizer unit
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Amine sweetening unit
ACID GAS
RECYCLE AMINESOURGAS
SWEETGAS
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High capacity processing unitHigh reactivity of gas and amine efficient
removal of acid gasesHigh recovery of hydrocarbon gases
Amine unit
High energy consumptionLoss of solvent during processing
Advantages
Disadvantages
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Other alternatives
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Membrane technology
PERMEABILITY OF GASES
Driving force:
• Partial pressure• Gas permeability (determined by membrane material)
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To increase the recovery of methane, a multistage membrane unit is desired:
Membrane technology
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Limitation of Membrane
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Low capital investmentEase of operationNo chemicals needed
Membrane
Advantages
DisadvantagesRequirement of feed gas pretreatmentGas compressionGenerally higher loss of hydrocarbon
gasesLow capacity
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Our new technology
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Replace the amine treatmentReduce the overall cost of gas
processingReduce green house gas emissions
Objective
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Process design
Technical information cannot be disclosed at this time due to IP protection issue.
Only results and economics will be compared.
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Design 1_CO2 removal
New technology63,030 lb-mole/hr
89.7% C1
0.7% C2
0.1% C3
0.02% iC4
9.4% CO2
58067 lb-mole/hr
97.2% C1
0.8% C2
0.1% C3
0.01 % iC4
1.9% CO2
4964 lb-mole/hr
2.4% C1
0.1% C2
0.5% C3
0.24% iC4
96.8% CO2
CLEAN GAS:
ACID GAS:
FEED GAS:
Amine treatment unit63,030 lb-mole/hr
89.7% C1
0.7% C2
0.1% C3
0.02% iC4
9.4% CO2
58150 lb-mole/hr
97% C1
0.8% C2
0.1% C3
0.02% iC4
2% CO2
4880 lb-mole/hr
2.6% C1
0.04% C2
0% C3
0.06% iC4
97.2% CO2
FEED GAS:
CLEAN GAS:
ACID GAS:
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Feed gas
Product gas
Acid gas % loss
C1 0.897 0.972 0.024 0.2%
C2 0.007 0.008 0.001 1.4%
C3 0.001 0.001 0.005 29.8%
i-C4 0.0002 0.0001 0.0024 79.3%
CO2 0.094 0.019 0.968
CO2 removal result
Feed gas
Product gas
Acid gas % loss
C1 0.897 0.97 0.026 0.25%
C2 0.007 0.008 0.0004 0.38%
C3 0.001 0.001 0.000 0.12%
i-C4 0.0002 0.0002 0.0006 22%
CO2 0.094 0.02 0.972
Conventional method(Amine unit)
New technology
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Williams Milagro plant capacity: 576 MMCF/ day
FCI Operating cost
Annualized cost
$2,838,000 $31,969,000 $32,158,000
*Operating costs are per year**Annualized costs based on lifetime of 15 years
Cost comparison
FCI Operatingcost
AnnualizedCost
$1,914,000 $13,674,000 $13,802,000
Conventional method(Amine unit)
New technology
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Design 2 _CO2/H2S removal
New technology63,030 lb-mole/hr
85% C1
0.8% C2
0.2% C3
5% H2S9% CO2
54500 lb-mole/hr
97.7% C1
0.9% C2
0.2% C3
0.04 % H2S1.1% CO2
8530 lb-mole/hr
3.9% C1
0.1% C2
0.1% C3
36.7% H2S59.3% CO2
CLEAN GAS:
ACID GAS:
FEED GAS:
Amine treatment unit63,030 lb-mole/hr
85% C1
0.8% C2
0.2% C3
5% H2S9% CO2
55263 lb-mole/hr
96.8% C1
0.9% C2
0.2% C3
0.0% H2S2% CO2
7676 lb-mole/hr
0.11% C1
0.0% C2
0.0% C3
39.8% H2S60% CO2
FEED GAS: CLEAN GAS:
ACID GAS:
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Feed gas
Product gas
Acid gas % loss
C1 0.85 0.977 0.039 0.6%
C2 0.008 0.009 0.001 1.6%
C3 0.002 0.002 0.001 6%
H2S 0.05 0.0004 0.367
CO2 0.09 0.011 0.593
CO2/H2S removal result
Feed gas
Product gas
Acid gas % loss
C1 0.85 0.968 0.001 0.06%
C2 0.008 0.009 0.000 0.87%
C3 0.002 0.002 0.000 11.88%
H2S 0.05 0.00 0.398
CO2 0.09 0.02 0.600
Conventional method(Amine unit)
New technology
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Williams Milagro plant capacity: 576 MMCF/ day
FCI Operating cost
Annualized cost
$3,043,000 $39,495,000 $39,698,000
*Operating costs are per year**Annualized costs based on lifetime of 15 years
Cost comparison
FCI Operatingcost
Annualizedcost
$1,987,000 $15,656,000 $15,789,000
Conventional method(Amine unit)
New technology
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Low operation cost Energy efficient process Reduction of green house
gas emissions Recyclable solvent No chemicals required
New TechnologyAdvantages
Disadvantages Loss of some
ethane, propane and iso-butane
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The new process design significantly reduces the energy consumption.
The new process conditioning efficiency is comparable to the amine process, some loss of propane and butane.
The new process is environmentally friendly.
Conclusion
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Q & A