II.

Gas processing plant

Gas-oil
separators

Condensate
separator

Dehydration

Sweetening

Fractionation
1/169

1. Gas-oil separators
Many cases pressure relief at the wellhead will cause a natural
separation of gas from oil (using a conventional closed tank, where gravity
separates the gas HC from the heavier oil)
Some cases a
multi-stage

gas-oil

separation process
is

needed

separate
stream

to

the

gas

from

the

crude oil.

Multi-stage gasoil separation

3/169

Horizontal Separator

Vertical Separator

Spherical Separator

2 Condensate separator

Condensates are most often removed from the gas stream at the
wellhead through the use of mechanical separators.
In most cases, the gas flow into the separator comes directly from

the wellhead, since the gas-oil separation process is not needed

The condensate obtained on compression or refrigeration of
wet gas is termed as Natural gasoline
7/169

3. Dehydration

Introduction

Necessity for gas dehydration

Preventative dehydration processes

Gas dehydrate methods

Operating Considerations

8/169

3. Dehydration

Introduction

Nearly all gas streams contain (or saturate) water vapor

The amount of water vapor depends on:

The temperature and pressure of the gas in the formation
The composition (or the density) of gas

A dehydration process is needed to eliminate water which may

cause the formation of hydrates

Sale gas is dehydrated because it must be dry enough to meet

contract specifications

The most important specs of sales gas (for pipeline transmission) is

water content
9/169

WATER CONTENT
OF NATURAL GAS

10/33

Example 1
Determine the water content of a natural gas which
has the density (compare with air) 0,6 at T= 50oC
and P = 20 bar?
Solution:
P = 20 bar = 2000 kPa
T = 50oC

P = 2000 kPa

Wo = 4,6 g/Sm3 kh

11/33

Example 2
Determine the water content of a natural gas which
has the density d = 0,8 at T= 50oC and P = 20 bar
and the salinity of Brine = 3,5%.
Gii: P = 20 bar = 2000 kPa
T = 50oC
W0cb = 4,6 g/Sm3 kh
P = 2000 kPa
d = 0,8

CG = 0,99
Salinity= 3,5% Cs = 0,92
Vy :
W
= W0 x CG x CS = 4,6 0,99 0,92
= 4,19 g/Sm3 of gas
12/33

3. Dehydration

Necessity for gas dehydration

Water present in the residue gas gas transmission difficulties:

Formation of hydrates
Plugging the lines
Pressure control devices

Hydrate are ice-like mixtures

of water and hydrocarbons
which form at low temperature

Corrosion - Erosion
Expensive service disruptions
Expensive line repairs
Condense in the pipeline and
accumulate at low points
Reducing the flow capacity of the lines

13/169

Structure of Hydrates
Nature of Hydrates
solid solution
They have 2 types of
structure: I and II
The structure of all
both types are based
on the Unit cell,
which is pentagonal
dodecahedron (D)
512

14/33

 2 main gas hydrate structures are:

- Type I: unit cell consists of 2D cages and 6T

(the 14-hedra) cages (46 water molecules).
- Type II: unit cell consists of 16D and 8H (16hedra) cages (136 water molecules).
Photos of 2 types of hydrate:
TYPE I

TYPE II

15/27

Hydrate condition formation

The stable formation region of Hydrates is above these lines

Example 3
A natural gas has d = 0,6 at P = 1,5MPa Hydrate
forming temperature?
3,2oC
A natural gas has d = 0,6, if we increase P from 1,5
Mpa to 2,5 Mpa Hydrate forming temperature will
rise from 3,2oC to
8,9oC
If the gas density increase from 0,6 to 0,8
Hydrate forming temperature will rise from 3,2oC to
9,3oC

3. Dehydration

For preventing hydrate formation:

1. Reduction of line P to permit the evaporation of the ice forming

particles.
2. Use of line heaters to elevate the gas T above that which would allow
hydrate formation.

3. Injection of certain inhibitors or chemicals (ammonia, alcohol, glycols)

into it to lower the freezing point of the water

For dehydrating: Removal of enough water from the gas to achieve a

dewpoint lower than any T the gas may encounter during transmission or
distribution.

18/169

3. Dehydration

Preventative dehydration processes

Alcohol:
Methanol and ethanol (methanol more effective than ethanol)
They are pumped into the system or forced in by means of
pressure chambers connected in the line.
Dewpoint depression is in direct ratio to the quantity of inhibitors
added
Injection of the chemical at controlled rates is important for its
uniform distribution and evaporation into the gas stream.

19/169

3. Dehydration

Preventative dehydration processes

Ammonia:

Combination with the CO2 in the gas forming ammonium carbonate

lower the transmission efficiency of the pipeline and system

Glycol:
Excellent anti-ice agent
Very difficult to recover especially when used in the field.

20/169

3. Dehydration

Gas dehydrate methods

Dehydration by refrigeration with an inhibitor

Dehydration by absorption

Dehydration by adsorption

Dehydration by osmosis

Very popular for use

21/169

3. Dehydration

Gas dehydrate methods

Absorption By Liquid Desiccants

Desiccants must fulfill certain requirements:

High affinity for water
Ability to be regenerated and yield the absorbed water
Non-corrosiveness
Low vapor pressure
Low viscosity
Low cost
Ease of regeneration

22/169

3. Dehydration

Gas dehydrate methods

Absorption By Liquid Desiccants

Absorption By Liquid Desiccants:

The most prominent physical dehydrating methods
Used extensively in Western Canada
Accomplished with many types of liquid desiccants (sulphuric
acid, calcium and lithium chloride solutions, glycerine and
others)

23/169

3. Dehydration

Gas dehydrate methods

Absorption By Liquid Desiccants

Desiccants: glycols (ethylene, diethylene and triethylene)

Used in solution with water in varying ratios according to the
drying design on hand.

MEG (ethylene or monoethylene glycol), DEG (diethylene

glycol), and TEG (triethylene glycol)
DEG and TEG are the glycols most commonly used in the plant.

In low temperature separation plants, a dilute ethylene glycol

solution of 60 - 80% glycol is used

24/169

3. Dehydration
Gas dehydrate methods

Absorption By Liquid Desiccants

Desiccants: glycols (EG, DEG and TEG the most common glycol used )
The solutions employed in plant dehydration processes are based on:

The contact temperature

Glycol concentration

Dewpoint temperature requirements

25/169

Effect of the TEG

concentration and
the contact
temperature on the
Dew point of gas

A greater dew point

depression can be
achieved by Increasing
glycol purity

Diethylene Glycol Dehydration Plant

27/169

Triethylene Glycol Dehydration Plant

28/169

Flow Diagram of a Triethylene-Dessicant Unit

29/169

Triethylene Glycol Dehydration Plant

5.5 8.3oC

Tinlet glycol should be 10 15oF warmer than Tinlet gas

Triethylene Glycol Dehydration Plant

A high sale gas dew point is

usually caused by both Poor
glycol regeneration and
Inadequate glycol circulation

glycol concentration (lean glycol and rich glycol) 3

glycol circulation rate is probably just right

3. Dehydration Operating Considerations

In general, the absorbers run most efficiently at high pressure and low
temperature

The absorption of water vapor by TEG is fovarized at low T (10 40oC):

Lower 10oC glycol viscosity difficult to column operation
Upper 40oC dehydration effect + vaporization losses of TEG

The regeneration is fovarized at:

high T (but lower than the decomposition temperature of Glycols: (EG:
165oC, DEG: 164oC, TEG: 206oC, T4EG: 238oC)

Low P (but higher than the atmospheric pressure for preventing of leak
air into the regenerator flammable risk

3. Dehydration

Operating Considerations

A glycol circulation rate of 30 - 50 l/kg water removed is considered

adequate
Reconcentrate a dilute glycol solution (Regeneration) by heating it Glycol
purity is primarily determined by T of reboiler

Water and TEG have widely varying boiling points (100C and 287C
respectively) Separated easily by fractional distillation (use the packed
tower or stripper)

33/169

3. Dehydration

The cause(s) of reducing glycol purities:

A leak in a heat exchanger

The packing in the still column is partially plugged

Steam from the reboiler black-flows into the accumulator

34/169

3. Dehydration

Dehydration by adsorption

The essential components of installation:

A regeneration gas cooler for condensing water from the hot

regeneration gas.

A regeneration gas separator to remove water from the regeneration

gas stream.

Piping, manifolds, switching valves and controls to direct and control

the flow of gases according to process requirements.

35/169

3. Dehydration

Operating Considerations

Solid Desiccant Dehydrators

The following terms apply to the technology:

Wet gas (gas containing water vapor)

Dry gas (dehydrated gas)

Regeneration gas (wet gas that has been heated in the

regeneration)

Desiccant is a solid (A typical desiccant might have as much as

0.82 m of surface area /mg)

36/169

Two Tower Solid Desiccant Dehydration Unit

37/169

3. Dehydration

Operating Considerations

Solid Desiccant Dehydrators

Zeolite (Molecular sieve), Activated alumina (bauxite) or a silica gel type

desiccant is used in most dehydration systems

They can reduce effectively the water content:

< 10 ppm with silica gel
< 0.1 ppm with Activated alumina
< 0.03 ppm with Zeolite

The degree of adsorption is a function of operating T and P:

Adsorption increases with pressure increases
Adsorption decreases with a temperature increase

38/169

3. Dehydration

Operating Considerations
Solid Desiccant Dehydrators

A bed may be regenerated by:

Decreasing its pressure

Or increasing its temperature by hot gas (practice)

The hot natural gas:

Supplies heat

Carrier to remove the water vapor from the bed

39/169

Two Tower Solid Desiccant Dehydration Unit

40/169

Three Drum Solid Desiccant Unit

41/169

Regeneration Gas Temperature Versus Desiccant Bed

Temperature in a Dry Desiccant Dehydrator

42/169

3. Dehydration
Dehydration by adsorption

When the bed is completely saturated with water vapor, the outlet gas
would be just as wet as the inlet gas
the towers must be switched from adsorb cycle to regeneration

cycle before the bed has become completely saturated with water.

The usable life of a desiccant may range from one to four years in
normal service.

Abnormally fast degradation occurs through blockage of the small

pores and capillary openings

43/169

3. Dehydration
Dehydration by adsorption

Lubricating oils, amines, glycols, corrosion inhibitors, and other

contaminants (CANNOT be removed during the regeneration cycle)

eventually win the bed

H2S poisons the desiccant and reduces its capacity

Light liquid hydrocarbons may accumulate if adequate regeneration

temperatures are not attained

The cause of desiccant breakage:

High gas velocities

Slugs of free water reaching the desiccant

Sudden pressure surges

Install a special filter in the main gas stream behind the desiccant beds

44/169

3. Dehydration
Dehydration by adsorption

Severe fouling of the dry desiccant bed may occur in a very short time

when treating a gas stream containing both H2S and CO2

If CO2 and H2S are present, corrosion may occur in the regeneration
gas heat exchanger

Occasionally corrosion is combatted by the injection of ammonia

ahead of the regeneration gas cooler

Help to control the pH

Ammonia and CO2 react to form an unstable white solid plugs

up the pores of the desiccant

45/169

Flowsheet of a basic two-tower dry desiccant unit

46/32

4. Acid gas removal

H2S

Acid
gas
CO2

47/169

4. Acid gas removal

Corrosive
material

Captures
solar
radiation

CO2

Noncombustible

Catalyst
poisoning

48/169

4. Acid gas removal

Highly
toxic

1.18 times
heavier
than air

May accumulate
in
dangerous
concentrations in
drains, valve pits,
vessels and tanks
H2S concentration
must be less than
6 mg/m3 (43 ppm)

Flammable
gas

H2S
An auto-ignition
temperature of 292oC

Catalyst
poisoning

Corrosive
material

49/169

4. Acid gas removal

Introduction

Typical acid gas

and sour gas
constituents

Component

Mole percent
Sour gas

Acid gas

CO2

8.50

18.60

H 2S

13.54

78.71

CH4

77.26

1.47

C 2H 6

0.21

0.09

C3+

0.23

0.11

COS

0.02

0.05

RSH

0.01

0.04

H 2O

0.01

0.04

N2

0.34

0.00

50/169

4. Acid gas removal

4 methods:
Absorption
Adsorption

Permeability

Very popular for use

Limited for use caused by the very

high selectivity of the membrane

Distillation at low T

For CO2 removing

51/169

Acid gas removal by adsorption

Chemical adsorption
Process

Solvent

With Alkanolamine:

Physical adsorption
Process
Selexol

Solvent
Dimethylether

MEA

Monoethanolamine

polyethylene

DEA

Diethanolamine

(DMEPEG)

DIPA

Diisopropanolamine

DGA

Diglycolamine

With K2CO3 :

Sulfinol

Normal

Hot K2CO3 solution

Bentild

Hot K2CO3 solution + 1,8%

of

glycol

Solution of sulfolane and

DiIsoPropanolAmine (DIPA)

Rectisol

Methanol at low temperature

Purisol

N - methyl - 2 - pirrolidone

DEA
Vetrocokk

K3AsO3 solution

(NMP)
Stretford

2,6 - 2,7 antraquinonsulfonic Fluor

acid

Carbonate of propylene

4. Acid gas removal

Absorption of Acid Gases Chemical Solvents

Carbonate Process

Hot potassium carbonate is used to remove both CO2, H2S and also COS
The reactions:
K2CO3 + CO2 + H2O 2KHCO3
K2CO3 + H2S KHS + KHCO3
High CO2 partial pressure (the range of 26 bar) and temperature between
110116oC, are required to keep KHCO3, KHS in solution.

This process CANNOT be used for streams that contain H2S only
Because: KHS is very hard to regenerate unless a considerable amount of
KHCO3 is present.

53/169

4. Acid gas removal

Absorption of Acid Gas Physical Solvents

Physical solvent properties

Solvent

Selexol

Sulphinol

Fluor

Dimethyl ether of

Sulpholane

Propylene

120

102

polyethylene glycol
Molecular weight

134

Solubility (cm3 gas/cm3 solvent)

H 2S

25.5

13.3

CO2

3.6

3.3

COS

9.8

6.0

54/169

4. Acid gas removal

Absorption of Acid Gase Physical Solvents

The difference in H2S and CO2 physical solubility gives the solvents their

selectivity.

Organic solvents are used in these processes to absorb H2S more than
CO2 at high pressures and low temperatures.

Regeneration is carried out by releasing the pressure step by step

Selexol Process

Not rely on a chemical reaction with the acid gases

Use the dimethyl ether of polyethylene glycol (DMEPEG)

Requires less energy than the amine-based processes

It has high selectivity for H2S over CO2 that equals to 910

55/169

Selexol Process

56/39

4. Acid gas removal by permeability

Inlet gas

Membrane

Treated gas

Impurities

Selective permeation for gases occurs depending on the solubility at

the surface contact between the gas and the membrane.

The acid gas basically diffuses through the membrane if high

pressure is maintained to ensure a high permeation rate.

57/169

4. Acid gas removal

Absorption of Acid Gases

Membrane Absorption

The rate of permeation of the gas depends on the partial

pressure gradient as follows:

where PA: the gas permeability

Am : the membrane surface area
t : the membrane thickness
PA : the partial pressure gradient of gas A above and
below the membrane.

58/169

Spiral-Wound Membrane

59/39

Hollow fiber membrane

60/39

5. Fractionation
Cryogenic processing and absorption methods are some of
the ways to separate methane from natural gas liquids (NGLs).
The cryogenic method is better at extraction of the lighter liquids,
such as ethane, than is the alternative absorption method.
Essentially, cryogenic processing consists of lowering the
temperature of the gas stream to around -120oF (-84.4oC)

While there are several ways to perform this function, the turbo
expander process is most effective, using external refrigerants to
chill the gas stream.
The quick drop in temperature that the expander is capable of
producing, condenses the hydrocarbons in the gas stream, but
maintains methane in its gaseous form.

61/169

5. Fractionation
The absorption method uses a lean absorbing oil to separate the C1
from the NGLs. While the gas stream is passed through an
absorption tower, the absorption oil soaks up a large amount of the
NGLs.
The enriched absorption oil, now containing NGLs, exits the tower
at the bottom.
The enriched oil is fed into distillers where the blend is heated to
above the boiling point of the NGLs, while the oil remains fluid.
The oil is recycled while the NGLs are cooled and directed to a

fractionator tower.
Another absorption method that is often used is the refrigerated
absorption method where the lean oil is chilled rather than heated, a
feature that enhances recovery rates somewhat.

62/169

5. Fractionation
The stripper bottom product from the LPG extraction plant
consists of propane, butane and natural gasoline with some

associated ethane and lighter components.

This is the feed to the LPG fractionation plant where it is
separated into a gas product, propane, butane and NGL.

63/169