NGL Recovery Techonolgy at KBR

NGL RECOVERY TECHNOLOGIES

Irfan Hussain March 29 - 2011

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AGENDA

What is Gas Processing Introduction to NGL Recovery NGL Recovery Technologies

Joule Thomson Process

Turbo Expansion Process How Turbo Expander Works

Licensed Technologies for C2 & C3 Recovery Process Economics for C2 and C3 Recovery Shaybah NGL Recovery Unit Critical Equipment (BAHE)

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NGL Recovery

Dehydration

Condensate Stabilisation

Condensate ProductNGL Product

Sulphur Recovery

Sulphur Product

Gas / LNG Product

Feed from Wellhead

Inlet Separation

Introduction to Gas Processing

Acid Gas Removal

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Introduction to NGL RecoveryWhat is NGL:• C2 + C3 + C4 mixture (liquefied from gaseous phase)

LPG = C3+C4; CNG = C1; LNG = C1

NGL Recovery – Why? • Meet Hydrocarbon Dew Point of sales gas• Extract expansive product (C2/C3) from sales gas

NGL Use • Petrochemical Plants – Polypropylene & Ethylene• Domestic (fuel)

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NGL Recovery (basic schemes)

J-T Cooling System

Low Temperature Separator

De-Methanizer Column

Reboiler

NGL Product

Gas / Gas Exchanger

J.T Valve

Sales Gas

Treated Feed gas

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J-T Cooling System – Advantages: - Low Capital Cost- Simplicity of design & operation (no rotating equipment)• Broad range of flow (valves have high turndown capacity)- Can achieve gas dew point by condensate recovery (high revenue)

J-T Cooling System – Disadvantages: - NGL recovery may not be feasible if large ΔP is not available- Effectiveness lost as field pressure declines (may require additional

equipment)

Mechanical Refrigeration can also be used with J-T valve

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Turbo Expander Cooling System

Low Temperature Separator


Reboiler

NGL Product

Gas / Gas Exchanger

Sales Gas

Treated Feed gas

Turbo Expander

Brake Compressor

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Turbo Expander Cooling System – Advantages: - Can be used with medium to high feed gas pressure- Produces work useable as power for sales gas compression - Low gas dew point achievable when low ΔP is available- High revenue with higher NGL recovery

Turbo Expander Cooling System – Disadvantages: - Higher capital cost- Extensive gas pre-treatment required to prevent water freezing and

solid CO2 formation- Variation in feed gas pressure & composition can reduce efficiency- Special metal alloys in cryogenic area

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How Turbo Expander Works

Basic Parts:- Outer housing to contain the gas - Expander wheel connected with a shaft to spin

Function:- High pressure (high temp) gas exerts pressure on wheel causing it

to turn- Gas exits through a hole in the housing- As gas energy is used to turn the shaft, gas leaves at low

temperature & low pressure- NGL is recovered from cold gas- Lean gas is recompressed by the same work (brake compressor)

First Law of ThermodynamicsInternal Energy can be converted into heat and mechanical work

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How Turbo Expander WorksIsentropic Expansion through Turbo Expander

Point (1) is Inlet gas (after treating)

Point (2) is After cooling by gas/gas exchanger/De-Methanizer side draw coolers

Dotted Line is new 2 phase diagram after separation of heavier components in LTS

Point (2) – (3) is Expansion via T.E (work is done by gas i.e. Isentropic Expansion)

Point (2) – (4) is Expansion via J.T

Gas can be expanded to lower pressure by T.E than J.T (will recover via B.C)

At same DP, Lower Temp. is achieved via T.E

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Licensed Technologies

LICENSOR PROCESS NAME

Gas Subcooled Process (GSP) Single Column Overhead Recycle (SCORE) Overhead Recycle Process (OHR) Cold Residue reflux Process (CRR) Recycle Split-Vapour Process (RSV) Recycle Split-Vapour with Enrichment Process Split Flow reflux Process (SFR) Improved Overhead Recycle Process Enhanced NGL Recovery Process Split Feed Gas Compression Process High Ethane Recovery Process High Pressure Absorber (HPA)

Shell Global Solutions Shell Deep LPG (SHDL)

ABB Lummus

IPSI LLC

Ortloff Engineering Ltd.

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Licensed Technologies – C2 & C3 Recovery

C3 Recovery Technologies: Single Column Overhead Recycle (SCORE)Shell Deep LPG Process (SHDL)

C2 Recovery Technologies: Gas Subcooled Process (GSP)Cold Residue Reflux Process (CRR)

C2 & C3 Recovery using Licensed Technologies

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25

45

85

97

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95 96 99 100

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10

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30

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60

70

80

90

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BTC Shell SHDL SCORE GSP CRR

Rec

over

y, %

C2 Recovery C3 Recovery

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Licensed Technologies – C3 Recovery

Shell Deep LPG

Low Temp. Separator De-Methanizer

Column

Reboiler

NGL Product

Gas / Gas Exchanger

Sales Gas

Treated Feed gas

Turbo Expander Brake Compressor

Low Temp. Separator

Gas / Gas Exchanger

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Single Column Overhead REcycle (SCORE)


Reboiler

NGL Product

Condenser

Sales Gas

Treated Feed gas


Low Temp. Separator

Gas / Gas Exchanger

Reflux Drum

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Gas Subcooled Process (GSP)


Reboiler

NGL Product

Sub Cooler

Sales Gas

Treated Feed gas


Gas / Gas Exchanger

Low Temp.Separator

Flow Split

Side Draw Coolers

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Cold Residue Reflux Process (CRR)


NGL Product

Sub Coolers

Sales Gas

Treated Feed gas


Gas / Gas Exchanger

Low Temp.Separator

Flow Split

Side Draw Cooler

Flow Split

O/H Compressor

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Process Economics for C2 and C3 Recovery

Propane Recovery Processes: SHDL & SCORE

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80

85

90

95

100

1000 1500 2000 2500 3000 3500 4000

Column Pressure, kPa

Prop

ane

Rec

over

y, %

SHDLSCORE

Propane Recovery Processes: SHDL & SCORE

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80

85

90

95

100

20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000

Booster Compressor Power, kW

Prop

ane

Rec

over

y, %

SHDLSCORE

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Process Economics for C2 and C3 Recovery

Ethane Recovery Processes: GSP and CRR

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20

40

60

80

100

40,000 50,000 60,000 70,000 80,000 90,000

Refrigeration Compression Power, kW

Etha

ne R

ecov

ery,

%

CRR

GSP


60

70

80

90

100

1500 2000 2500 3000 3500 4000

Column Pressure, kPa

Etha

ne R

ecov

ery,

%

CRRGSP


60

70

80

90

100

100,000 110,000 120,000 130,000 140,000 150,000Total Compression Power, kPa

Etha

ne R

ecov

ery,

%

CRRGSP

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Economics – Higher NGL Recovery

IS HIGH NGL RECOVERY ALWAYS THE BEST SOLUTION?

High NGL Recovery means:

Lower sales gas flow Lower gas heating valueHigher capital investment Higher operating cost (residue gas compression, refrigeration compressor ) Extra gas treatment required i.e. CO2, moisture removal, Hg removal etc.

Recommendation:

Detailed life cycle cost analysis to generate maximum revenue Sensitivity analysis for selected process: operating pressures, refrigeration

requirement, flow split etc.

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NGL Fractionation

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Open Art NGL Recovery Unit (Pre-Treatment Section)

Sweet RichGas

Dehydrated Condensate to Demethaniser

Liquid Molecular Sieve Dehydrators

Gas Mercury Removal Units

Dehydrated Gas to NGL

Free Water to Drain

Regen Gas Compressor Regeneration Gas

Separator

Gas Molecular Sieve Dehydrators

Regen Gas Hot Oil Heater

Condensate Mercury Removal Units

Feed Gas Chiller

Water Degassing Drum

Feed Gas ChillerSeparators

Gas FilterSeparators

Condensate FilterSeparator

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Open Art NGL Recovery Unit (NGL Recovery Section)

Feed/Residue BAHE

Feed/Residue BAHE 1

Gas Chiller 1

Condensate Chiller 1

Feed/Side draw BAHE 2

Feed/Residue BAHE 3

Condensate Chiller 2 & Gas Chiller 2

Demethanizer Overhead BAHE

Expander Feed Separator

Turbo Expander /Brake Compressors A/B

Demethanizer

Demethanizer Trim Reboiler

Demethanizer Bottoms Pumps

Chiller Separator

JT ValveJT Valve

FEED GAS

From Condensate Mercury Removal Beds

To Residue Gas Compressor

To NGL Surge Spheres

heat in

heat out

To BAHE 1

To BAHE 2

To BAHE 3

C3 in

C3 out

C3 out

C3 in

C3 in

C3 out

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NGL Recovery Technologies

Shoaib is on Fire ! QUESTIONS?

NGL Recovery Techonolgy at KBR

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