gas processing course
TRANSCRIPT
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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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ACIDIC GASES SAFETY PROBLEMS
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.
ACIDIC GASES SAFETY PROBLEMS
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ACIDIC GASES SAFETY PROBLEMS
- 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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ACIDIC GASES CORROSION
PROBLEMS
GAS STREAMS WITH HIGH H2S TO CO2 RATIOS
ARE LESS CORROSIVE THAN THOSE HAVINGLOW H2S TO CO2 RATIOS.
ACIDIC GASES CORROSION
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ACIDIC GASES CORROSION
PROBLEMS
CORROSION IS STRONGLY A FUNCTION OF
TEMPERATURE AND LIQUID VELOCITY.
ACIDIC GASES CORROSION
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ACIDIC GASES CORROSION
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
HYDRATES IN NATURAL GAS
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.
HYDRATES IN NATURAL GAS
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