United States

Environmental Protection
Agency

Air and Radiation

(6202J)

EPA
October 2001

LESSONS LEARNED

FROM NATURAL GAS STAR

PARTNERS
DESICANT DEHYDRATORS
Executive Summary

There are approximately 150,000 wells producing 90,000 Tcf of high pressure natural gas in the
United States emitting an estimated 90 Tcf of methane from glycol dehydrators to the atmosphere. Producers, traditionally use Triethylene glycol (TEG) dehydrators to remove water from
saturated gas. Glycol dehydrators vent and bleed methane, VOCs, and HAPs to the atmosphere
from the reboiler/regenerator and pneumatic devices, and also require fuel gas to heat the glycol on the reboiler/regenerator and/or the gas if the temperature of the gas is too low for the
glycol to absorb. This process wastes gas, costs money, and contributes to local air quality
problems. Natural Gas STAR Partners have found that replacing these glycol dehydrators with
desiccant dehydrators considerably reduces methane, VOC and HAP emissions and operating
and maintenance costs.
Economics analyses demonstrate that replacing a glycol dehydrator with desiccant dehydrator
can save up to $4,163/yr in gas and O&M cost and 617 Mcf/yr in methane savings for a gas
that is processing 1 MMcfd. This Lessons Learned study describes how Partners can identify
when and where desiccant dehydrators should be implemented to realize these economic and
environmental benefits.
Method for
Reducing Gas Loss1

Annual
Methane
Savings (Mcf)2

Annual volume of
Gas Lost and
Used (Mcf)3

Value of
Gas Saved
($)

Capital and
Installation
Cost ($)4

O&M
Cost
($)5

Payback
(Years)

Replacing A Glycol Dehydrators with two

617
1,146
3,438
20,750
725
5
Desiccant Dehydrators
1
All the values for the gas are based on $3/Mcf and for a 1 MMcfd gas operating at 600 psig and 54 F.
2
Based on the difference between the methane vented or lost from the glycol and desiccant dehydrators.
3
Based on the difference between the gas lost and used from using glycol dehydrator and the gas vented using desiccant dehydrator.
4
Installation cost is based on 75% of the capital cost and also 10% of salvage value is included in the value.
5
Based on the difference between glycol and desiccant dehydrators operation and maintenance costs.
This is one of a series of Lessons Learned Summaries developed by the EPA in cooperation with the natural gas
industry on superior applications of Natural Gas STAR Program Best Management Practices (BMPs) and Partner
Reported Opportunities (PROs). This Lessons Learned Summary focuses on reducing methane emissions from using desiccant dehydrators for gas dehydration and is written for Production Partners.

LESSONS LEARNED

FROM NATURAL GAS STAR PARTNERS

DESICANT DEHYDRATORS
Technology
Background

Produced natural gas normally is saturated with water that can condense
and/or freeze in gathering, transmission and distribution piping causing
pressure surges and corrosion. To avoid this problem, the gas is dehydrated before entering the pipeline or processing equipment. Triethylene
glycol (TEG), less commonly diethylene glycol (DEG) and propylene carbonate have been used the most common dehydrating agents. Recently,
deliquescing salt desiccants are being used in dehydrators by the oil and
gas production sector.

Triethylene glycol (TEG) Dehydrator

In the TEG dehydrator process, or less common diethylene glycol (DEG),
the TEG not only absorbs water, but also methane and other volatile organic compounds (VOCs), such as ethane through pentanes, and hazardous air pollutants (HAPs), such as benzene, toluene, ethylbenzene and
xlyene, or BTEX. When this rich glycol goes through a reboiler/regenerator, methane, VOCs and HAPs are boiled out of solution in
the water and vented to the atmosphere. (See the EPA Lesson Learned
studies: Installation of Flash Tank Separators, Reducing the Glycol Circulation Rates in Dehydrators, and Replacing Gas Assisted Pumps with Electric Pumps).

Desiccant Dehydrator
Natural Gas STAR Partners have reported success using an alternative
method: desiccant dehydrator.

Desiccant
Desiccants have been used to dehydrate natural gas by the oil and gas
industries for over 70 years. Desiccants are made up of hygroscopic salts,
such as calcium chloride, lithium chloride and potassium chloride. Desiccants attract and adsorb moisture, which gradually dissolves the desiccants into brine. This process is called deliquescing. The amount of
moisture removed from the gas depends on the type of desiccant. Calcium chloride, the most common and least expensive desiccant, removes
approximately 67% of moisture in natural gas. Lithium chloride, which is
more expensive desiccant than calcium chloride, removes approximately
87% of moisture in natural gas. Desiccants are usually packed in dehydrator vessels in the form of tablets or pellets. The tablets are package in
25-50lb bags.

Process Description
The desiccant dehydrator is a very simple process; it has no moving parts
and needs no external power so that it can be used in offshore or remote
sites.
As shown in Exhibit 1, wet natural gas enters the dehydrator vessel below the desiccant support grid. The support grid prevents the desiccant
tablets from dropping into the claim area (brine sump). Some vendors
install a mist eliminator below the support grid so that the brine does not
dissolve the packed desiccant tablets. The wet gas flows upward through
the support plate and prebed (which is usually 5-10mm activated alumina and gives additional support to the support plate) in the drying bed,
where it interacts with the desiccant tablets. The moisture from the gas is
adsorbed by the tablets and accumulates on the surface of the tablets.
Exhibit 1: Schematic of Single Vessel Desiccant Dehydrator

Source: Van Air

Gradually the moisture dissolves the desiccants into brine droplets, which
trickle down into the claim area that is connected to a brine storage tank.
When the desiccants reach equilibrium or the maximum amount of moisture they can adsorb, the dry gas exits on the top of the vessel to the
main gas line.

Operating Requirements
The amount of water removed by the desiccant tablets depends on the
quality of the desiccant and the temperature and the pressure of the inlet
gas. High temperature inlet gas will have high moisture content for the
desiccants to remove to the desired moisture content. According to a
Page 2

vendor, the inlet temperature of the gas must be between 35F and 100F
to utilize the desiccant dehydrator. If the inlet temperature of the gas is
too high, the desiccants form hydrates in the solution that cause caking
and drain problems. If the inlet temperature of the gas is too high or too
low, the gas has to be cooled or heated before entering the dehydrator.
Since saturated gas holds more water at low temperatures, high pressure
gas result more moisture removal by the desiccant (the inlet gas pressure
can be as high as 1400 psig). Desiccant tablets work best for a natural
gas processing at high pressure and low temperature. (Appendix 1Table1 provides the outlet water content in the gas at given temperatures and pressures for two types of desiccants). A single commercial dehydrator vessel (Exhibit 1) can dehydrate gas from 0.095 to 5.346 MMcfd
between 35 100 F and 100-1400 psig. The dimensions of the single vessels range from 10-3/4outside diameter (OD) X 73-7/8 over all height of
the vessel (HV) to 37-3/4OD X 85-1/2HV. These vessels can hold 48583 lb of calcium chloride and 57-583 lb for lithium chloride desiccants.

Refilling Desiccants and Draining Brine

As the desiccant tablets adsorb moisture from the gas, the level of the
desiccant tablets in the drying bed slowly decrease to the minimum desiccant tablet level. This level indicates the minimum level at which the
desiccant tablets can dehydrate the gas to its desire outlet moisture content. Some manufacturers place a sight window on the vessel (see Exhibit
1), to show the operator the minimum desiccant level. When the desiccant level is below the sight window (at the minimum desiccant level),
the operator needs to depressurize the vessel; manually open the filler
hatch and refill the desiccants up to the maximum level. To depressurize
the vessel, the inlet and the outlet valves must be closed and the drain
valve has to be open to flash the gas left in the vessel. The brine in the
claim area has to be drained when the brine reaches a certain level to
prevent from flooding. Automatic or manually operated drain valves
drain the brine to the brine storage tank. When the drain valve is operated manually, a liquid level indicator is necessary in order for the operator to know when it is time to drain the brine. The desiccant dehydrators
can be designed (e.g. by using larger size or multiple dehydrators) for
the operator not to refill the desiccant and drain the brine frequently.
Using desiccant dehydrators as alternatives to glycol dehydrators can

Economic and yield significant economic and environmental benefits, including:

Environmental
Reduced capital cost - The capital costs of desiccant dehydrators
Benefits

are low compared to the capital costs of TEG dehydrators. Unlike TEG
dehydrators, desiccant dehydrators do not use pumps, contactors,
and fired reboiler/regenerator. The only capital cost is for the vessel.

Reduced operation and maintenance cost Since most of the

well heads and processing units are located in remote areas, it is important for the dehydrator units to be reliable and continuously accessible and with minimum oversight from operation and mainte-

Page 3

nance personnel. Desiccant dehydrator operation and maintenance

costs are favorable compare to glycol dehydrators. The primary operating and maintenance costs are for desiccants and labor for refilling
the dehydrator. Maintenance costs are labor for draining and disposing the brine. If the drain valve is automatic, no labor is needed to
drain the valve, maintenance cost for services the equipment must be
considered

Decision
Process

Methane or high hydrocarbons are not emitted The desiccant

tablets only adsorb water, therefore, methane and other hydrocarbons will not be vented to the atmosphere as with glycol dehydrators.

Operators can access the economics of

replacing an existing glycol dehydrator
with a desiccant using the
these five steps.

Five Steps for Implementing

A Desiccant Dehydrator
1. Identify possible locations for desiccant dehydrator;
2. Estimate
the
capital
costs;
3. Estimate the operating
costs;
4. Estimate savings;
5. Conduct economic analysis.

Step 1: Identify possible locations

for desiccant dehydrator.
Desiccant dehydrators are an economic
choice for natural gas dehydration
under certain production condition.
Desiccant dehydrators are installed
where gas drying is needed such as
prior to the gas entering transmission
pipelines or processing plants. The wellhead gas temperature and pressure play a major role in determining the appropriate gas drying system.
Glycol dehydrators work best for higher temperature gas. If the temperature of the gas is too low for the TEG to remove the moisture, operators
have to heat the gas prior entering the dehydrator. Heating the gas requires more product burned as fuel. An alternative method is to install a
desiccant dehydrator, which works best at higher pressure and low temperature. In addition, since most desiccant dehydrators are commonly
manufactured for a maximum pressure of 500 psig and expanding the
gas down to this pressure from a higher wellhead pressure will auto refrigerate the gas below wellhead temperature. Exhibit 2 shows the operating conditions of the gas to use either a desiccant or a glycol dehydrator.
Exhibit 2. Optimum Operating Conditions for Dehydration Technologies
Low Pressure

High Pressure

Low Temperature

Desiccant /Glycol1

Desiccant

High Temperature

Glycol

Glycol/ Desiccant2

The gas needs to be heated to apply glycol dehydrators or, the gas has to be compressed
to apply desiccant dehydrators.
2
The gas needs to be cooled to apply desiccant dehydrators

Producers mostly dehydrate the gas up to the maximum pipeline moisture requirement of 7 lb./MMcf of gas processed. Exhibit 7 shows the

Page 4

temperature and pressure requirement of the inlet gas for the calcium
chloride to remove moisture to 7 lb./MMcf. Calcium chloride performance
declines rapidly for the gas above 60 F. For example, if the inlet gas is at
450 psig, the temperature of the gas has to be 47 F or less for calcium
chloride desiccant to remove to pass the pipeline moisture requirement.
Exhibit 3. Calcium Chloride Performance Curves at Maximum Pipeline
Moisture Content Requirement (7 lb. of water/MMcf)
1200

P
r
e
s
s
u
r
e

Calcium Chloride

1000

800

600

P
s 450
I 400
g
200

0
35

37

Source:VanAir

39

41

43

45

47

49

51

53

55

57

59

Temperature (F)

Step 2: Estimate the capital costs.

Capital cost of a single vessel desiccant dehydrator that also include the
initial fill of the desiccant ranges between $2,000 and $46,000 for gas
volume rates from 1 to 20 MMcf/d. The first step in determining the capital cost is based on the gas operating conditions
The first step in determining the capital cost is to calculate how many
desiccants is used to remove the moisture based on the gas operating
conditions. For example, for a gas stream with a flow rate of 1 MMcf/d
flow rate at inlet temperature and pressure of 47 F and 450psig, the
moisture content in the inlet gas is 24.7 lb./MMcf (See Exhibit 4).

Page 5

Exhibit 4: Water content of natural gas at given temperatures

& Pressures

Calcium chloride desiccant removes 17.7 lb./MMcf of the moisture in the

gas to meet the outlet gas moisture content of 7 lb./MMcf as shown in
Exhibit 3. Multiplying the moisture removed Vendors Rule of Thumb
with the pound of moisture removed by the
One pound of desiccant
removes three pounds of
desiccant and the flow rate of the gas, results
moisture from the gas
5.90 lb. of calcium chloride per day is needed
for 1 MMcf of gas. Exhibit 5 summarizes this example.
Exhibit 5: Determine the amount of desiccant needed to remove
the desired water content
Where:
F
I
O
B
D

=Gas flow rate (MMcf/d)

=Inlet water content (lb/MMcf)
=outlet water content (lb/MMcf)
=desiccant-to-water ratio (lb desiccant/lb water)
=the amount of desiccant needed to remove the desired moisture content (lb desiccant/day)

Page 6

Given:
F
I
O
B

=1 MMcf/d
=24.7 lb/MMcf
=7 lb/MMcf
=1 lb desiccant/3 lb water (vendors rule-ofthumb)
D
=the amount of desiccant needed to remove the desired moisture content (lb desiccant/day)
Calculate:
D
=F * (I-O) * B
=1 * (24.7-7) * 1/3
=5.90 lb desiccant/day

After determining the amount of desiccant used to remove the moisture

content to 7 lb./ MMcf, the next step is to size the vessel. To determine
the size of the vessel, the size of the working and minimum beds, the
outside diameter of the vessel, the refilling time of the desiccants and the
bulk density of the desiccant have to be known. The height between the
support bed and the minimum level (the drying bed) and the height between the minimum level and the maximum level (the working bed) are
commercially fixed around 18 and 5, respectively. The bulk density of
the calcium chloride desiccant according to the vendor is around 55 lb/cf
and the refilling time of the desiccants depends on how often the operator wants to change the desiccant (for this example we have assumed
every week). Using these parameters and the equation for volume of a
cylinder, the outside diameter of the vessel has to be 18.18. Exhibit 6
summarizes this example.
Exhibit 6: Determine the out side diameter of the vessel
Where:
D
T
B
OD
H
Given:
D
T
B
H

=The amount of desiccant needed to remove the

desired moisture content (lb desiccant/day)
= Refilling time (day)
= The bulk density (lb/cf3)
= Outside diameter of the vessel (ft)
= the height between the maximum bed level and
maximum bed level (ft)
= 5.90 lb desiccant/day
= 7 days
= 55 (lb/cf3)
= 0.4167 ft ~ 5 in

Calculate:
OD

4 * D *T
H * * B

= 1.515 ft ~ 18.18 in

Now the desired sized of the vessel is determined, the last step in estimating the capital costs is to select the dehydrator from the vendors

Page 7

standardize that is compatible with the examples design. Exhibit 7 shows

different sizes of dehydrators based on the capacity and the pressure of
the gas (more dehydrator specifications are provided in Appendix A. Table 2). If the pressure of gas at the transmission line for the example has
to be 450 psig, the best choice is to pick the dehydrator that has outside
diameter of 20 dehydrator with the capital cost of $6, 500 gives. The
installation cost for this study is assumed to be 75% of the capital cost,
which is about $4,875. Changing the outside diameter to 20 dehydrator
changes the refilling time to every 8.47 days.
Exhibit 7. Cost of Desiccant dehydrators
Maximum Capacity Mscf
Maximum Working Pressure 500 Psig
100
200
300
Outside Diameter

400

450

Psig

Psig

Psig

Psig

Psig

Psig

500
Psig

10

95

177

260

301

342

383

424

12

32

247

362

419

476

533

590

16

214

400

587

680

773

866

959

20

311

620

909

1054

1199

1344

1489

24

481

900

1319

1528

1738

1948

2158

30

760

1422

2085

2416

2747

3078

3409

36

1191

2230

3270

3789

4308

4827

5346

(in)

350

Cost
($)1

6,500

The capital cost includes the initial fill of calcium chloride desiccant tablets.

Source : VanAir

Step 3: Estimate the operating costs.

The operating cost of the desiccant dehydrator is the cost of refilling desiccants. In order to calculate the cost of the refilling desiccants, the
amount of refill desiccants must be determined. A 20 outside diameter
dehydrator holds about 171 lb. calcium chloride desiccant tablets. Based
on Exhibit 5, 5.90 lb. of calcium chloride per day is used to remove moisture from 1 MMcf gas up to the maximum pipeline requirement. The
refilling time is every 8.47 days. By multiplying the refilling time by the
desiccant and the amount of the desiccants used per day and subtracting
the results from the amount of desiccant tablets in maximum level bed,
results the amount of desiccant tablets minimum bed level of 121 lb
desiccant.
Depending on the vendor the cost of calcium chloride can range $0.65 to
$1.2 per lb. Using $1.2 /lb. for the cost of calcium chloride the total cost
for refilling 50 lb. every 8.47 days is $2,586/yr. Exhibit 8 summarizes this
example.

Page 8

Exhibit
and 8: Determine the cost of desiccant refill
Where:
Dmax
Dmin
D

= Amount of desiccant tablets at the maximum bed

level (lb desiccant)
= Amount of desiccant tablets at the minimum bed
level (lb desiccant)
=The amount of desiccant needed to remove the
desired moisture content (lb desiccant/day)
= Refilling time (day)
= Price of the desiccant ($/lb desiccant)
= Total cost per year

T
P
C
Given:
Dmax
= 135 lb desiccant
T
= 8.47 day
D
= 5.9 lb desiccant/day
P
= $1.2/ lb of calcium chloride
Calculate:
Dmin
= Dmax ( D*T)
=(171 (5.90*8.47)
= 121 lb desiccant
C
= (( Dmax - Dmin ) * P * 365 days/yr) / T
= ((171 121) * 1.2 * 365) / 8.47
= $2,586/ yr

Step 4: Estimate savings. Replacing a glycol dehydrator with a desiccant dehydrator significantly saves gas and reduces operating and maintenance costs.
! Gas savings
Desiccant dehydrators have a smaller amount of gas loss that occurs
when depressurizing the vessel to refill the desiccant. The amount of gas
saved is calculated by comparing an existing glycol dehydrator to a desiccant dehydrator. The EPAs previous Lesson Learned studies about glycol
dehydrators, shows that a glycol dehydrator unit has a contactor, an
electric or energy exchange pump, a
reboiler/regenerator, and if necessary,
Determine The Gas savings:
a gas heater, a flash tank separator
1.
G as vented from glycol
and/or a condenser. (See the EPAs
dehydrator;
Lesson Learned studies: Installation of
2.
G as vented from pne uFlash Tank Separators and Glycol Dem atic controllers;
hydrator, Reducing the Glycol Circula3.
G as burner for fuel in
tion Rates in Dehydrators, and Replacglycol reboiler;
4.
G as burner for fuel in
ing Gas Assisted Pumps with Electric
gas heater;
Pumps). Operators can determine the
5.
Less gas vented from
gas savings by following these five
desiccant dehydrator.
steps.
Gas vented from glycol dehydrator
The amount of entrained gas depends on the TEG circulation rate and the
type of pump the dehydrator uses. In this case, an energy exchange
1.

Page 9

pump without a flash tank separator is assumed and the rule of thumb is
for every one gallon of TEG circulated 3 cubic ft of methane is absorbed
and vented from the reboiler/regenerator. The TEG circulation rate of7.2
gal of TEG /hr is aggregated from EPAs Lesson Learned Study. Methane
emission of 189 Mcf/yr is vented from a 1 MMcf/d gas processed in a glycol dehydrator. Exhibit 9 summarizes this example.
Exhibit 9. Gas vented from the reboiler/regenerator
Where:
L
G
GV
Given:
L

= TEG Circulation Rate (gal/ hr) 1

= Methane Entrainment Rate (ft/gal) 1
=Amount of Gas Vented Annually (Mcf/yr)

= 7.2 gal TEG/hr (circulation rate for 1 MMcfd gas

processed)
G
=rule of thumb: 3 cubic ft/gal for energy exchange
pumps; 1 cubic ft/gal for electric pumps
Calculate:
GV
=(L * G * 8,760 (hours per year))/(1000cf/Mcf)
=(7.2 * 3 * 8,760) / 1000
=189 Mcf/yr
1

EPAs Lesson Learned study, Reducing the Glycol Circulation Rates in

Dehydrators, Exhibit 2 and 3.

2.

Gas vented from pneumatic controllers

A glycol dehydrator unit (excluding a flash tank separator and a
condenser) with a gas heater, assume four bleeding pneumatic
controllers: level controllers on the contractor and reboiler, and
temperature controller on the reboiler and gas heater. These
pneumatic devices bleed gas to the atmosphere. Based on
EPAs GRI study, Methane Emissions form the Natural Gas Industry, Volume 3, the annual emission factor for pneumatic devices in the production sector is estimated to be 126
Mcf/device. For the four pneumatic devices, the methane emission is 504 Mcf/yr. Exhibit 10 summarizes this example.
Exhibit 10: Gas vented from pneumatic controllers.
Where:
EF

= Emission Factor (Mcf natural gas leakage/ pneumatic device per year) 1
= Number of pneumatic devices
= Gas Emissions

PD
GE
Given:
EF
= 126 Mcf/device/yr
PD
= 4 Pneumatic device/ dehydrator
Calculate:
GE
= EF * PU
= 126* 4
= 504 Mcf/yr

Page 10

3.

EPAs GRI study, Methane Emissions form the Natural Gas Industry, Volume 3

Gas burner for fuel in glycol reboiler

The glycol dehydrator uses natural gas on the reboiler/regenerator to boil off water from the rich glycol. Assuming that the heat duty is 37,500 Btu/hr with 70% efficiency, the
gas used by the reboiler is 224 Mcf/yr. Exhibit 11 summarizes
this example.
Exhibit 11: Gas burner for fuel in glycol reboiler
Where:
H
= Heat duty (Btu/hr)
HV
= Heating value of natural gas (Btu/cf) 1
E
= Heat Transfer Efficiency
FGR
= Fuel Gas for Reboiler (Mcf/yr)
Given:
H
= 37,500 (Btu/hr)
HV
= 1,027 (Btu/cf)
E
= 70%
Calculate:
MU
= (H * E * 8,760 (hours per year))/ (HV *
1000cf/Mcf)
= (37,500* 0.7*8,760) / (1,027 * 1,000)
=224 Mcf/yr
1

4.

Energy information Administration (EIA), Monthly Energy Review, Table A4.

Gas burner for fuel in gas heater

TEG does not perform well on low temperature gas. Producers
heat the gas prior entering the dehydrator unit when the gas is
below 90 F. Natural gas is used to fuel the gas heater. The
amount of fuel gas used to heat the gas should be include in
the total gas saving. Exhibit 12 shows an example to determine
how much gas is used to heat 1 MMcfd gas from 47 F to 90 F,
which is 237 Mcf/yr.
Exhibit 12: The amount of fuel gas used to heat the gas
Where:
HV
CV
D
T
F
E
MU
Given:
HV
CV
D
T
F

= Heating value of natural gas (Btu/cf)

= Specific heat at constant volume (Btu/lb F) 1
= Density of natural gas (lb/cf) 1
= (T2 T1) change in temperature (F)
= Flow rate (cf/yr)
= Efficiency
= Methane Used (Mcf/yr)
= 1,027 Btu/cf)
= 0.441 (Btu/lb F)
= 0.0502 (lb/cf)
= 43 F (90 47) F
= 41,667 (cf/hr)

Page 11

E
= 70%
Calculate:
MU
= (F *CV * D * T * E* 8,760 (hours per year))
(HV * 1000cf/Mcf)
= (0.441 * 0.0502* 36 * (0.70 * 8,760) / (1,027 *
1,000)
= 237 Mcf/yr

5.

Less gas vented from desiccant dehydrator

The gas loss from a desiccant dehydrator is determined by calculating the

amount of gas flashed out through the brine valve when the vessel is depressurized the vessel during the refilling process. The 20 OD desiccant
dehydrator that was used in Exhibit 7 has an overall height of 76.75.
Based on a vendor, 45% of the volume of the vessel is filled with gas.
Using Bolyes Law, the amount of gas vented to the atmosphere during
depressurizing of the vessel is 8.15 Mcf/yr. Exhibit 13 summarizes this
example.
Exhibit 13: Gas lost from the desiccant dehydrator
Where:
H
= Height of the dehydrator vessel
D
= Outside diameter of the vessel
P1
= Atmospheric pressure (Psig)
P2
= Pressure of the gas (Psig)
PI
= pi
%G
= Percent of gas volume in the vessel
GLD
= Gas loss from the desiccant dehydrator (Scf/yr)
Given:
H
= 76.75 in (6.40 ft)
D
= 20 in (1.67 ft)
P1
= 450 Psig
P2
= 15 Psig
PI
= 3.14
T
= 8.47
%G
= 45%
Calculate:
GLD
= ((H * D2 * PI)/4) * %G* (P1/P2) * 365 days/yr) /
(T)
= 8.15 Mcf/yr

Total Methane Emissions and Gas Savings

Natural gas contain consists 90% methane. The total methane emissions
savings is determined by taking 90% of the summation of the gas loss
from the reboiler/regenerator and of the gas bleed from the pneumatic
devices and subtracting the results by 90% of the gas loss by the dehydrator, which is 624 Mcf/yr. The total fuel gas savings is determined by
adding the fuel gas used in the reboiler and the gas heater, which 461
Mcf/yr. The value of the gas savings is determined by multiplying the
total gas savings (the sum of Exhibit 9, 10, 11 and 12 and minus Exhibit

Page 12

13) by the price of gas (EPA default value of $3.00 per Mcf), which results $3,462 per year. Exhibit 14 summarizes this example.
Exhibit 14: Total Methane Emission and Gas Savings
Calculate:
TME
=Total Methane Emissions (Mcf/yr)
90% *(Exhibit 9+ Exhibit 10 - Exhibit 13)
=(170+454- 7.3) Mcf/year
= 617 Mcf/yr
Calculate:
FGS
=Total Fuel Gas Savings (Mcf/yr)
(Exhibit 11 + Exhibit 12)
=(224 + 237) Mcf/year
= 461 Mcf/yr
Calculate:
TGS
= Total Gas Savings (Mcf/yr)
= GV (Exhibit 9) + GE (Exhibit 10) GLD (Exhibit
13)+FGS
=(189 + 504 8.15 + 461)
=1,146 Mcf/yr
Value of Gas Savings
Calculate:
GVS

= Gas Value Savings

= (TGS * Price of gas)
= (1,146 Mcf/yr)* $ 3/Mcf
= $ 3,438/yr

! Other savings
Other savings include the difference between the operating and maintenance cost (labor cost) of glycol dehydrator and desiccant dehydrator.

Operating and maintenance costs of a glycol dehydrator

The operating costs include the refill cost of the glycol and
from Exhibit 8, to refill the 50 lb. of desiccant every 8.47days
cost $ 2,586/ yr.
Maintenance costs (labor costs) are assumed based on one
hour for one person to close the gas inlet and outlet valves, to
depressurize the vessel, to input 50 lb of desiccant and to
pressurize back the vessel, which is around $300/yr.

Operating and maintenance costs of a glycol dehydrator

The operating costs include the initial and make-up glycol. For
the operation conditions of the example the initial cost is
based on 100 gallons glycol tank that cost $4.50/gal of TEG,
which results $450 According to a vendor, about 0.1 gal /MMcf

Page 13

of glycol is lost in the glycol dehydrator process. The annual

glycol lost will be 37gal and the make up cost will be $164/yr.
Maintenance costs (labor costs) are assumed two people
cleaning and changing the systems, repairing pump and firetube of the reboiler and maintaining of the efficiency glycol,
contactor, reboiler and pump, which is around $3,447/yr.

Step 5: Conduct Economic Analysis. The installation, capital and operating costs of a desiccant dehydrator are favorable compare to glycol
dehydrators. Exhibit 15 shows the cost comparison of the two types of
dehydrators to dehydrate 1 MMcfd natural gas at 450 psig pressure and
47 F temperature.
Exhibit 15: Cost Comparison of Desiccant Dehydrator and Glycol
Dehydrator
1 MMcfd natural gas at operating 450 psig and 47 F
Type of costs and savings
Implementation costs:
Capital Cost
Desiccant1 (includes the initial fill)
Glycol2
Other cost (Installation & Engineering)3

Desiccant
($/yr)

13,000
9,750

Salvage Value4
Total Implementation Costs:
Annual Operating and Maintenance Costs

Glycol
($/yr)

20,000
15,000
2,000

22,750

35,900

Desiccant
Cost of Desiccant refill5 ($1.11/lb)
2,586
Maintenance Cost6
300
Glycol
Cost of Glycol initial and refill6 ($4.5/gal)
614
Maintenance Cost6
3,447
Total Annual O & M Costs
4,061
2,886
Gas Use
Fuel7
1,383
Gas Loss
Pneumatic Devices
1,512
Vents
567
24.45
Total Gas Used and Loss7
3,462
24.45
Methane Emission (Mcf/yr)7
624
8.15
1
The capital of the desiccant dehydrator is based on two desiccant dehydrators that are used alternately, See Exhibit 7.
2
The capital cost of the glycol is only for comparison. The initial fill costs of
glycol $450 for is not included.
3
Estimated installation cost of 75% of the unit cost.
4
Based on 20% of the glycol dehydrator.
5
The values are obtained from Exhibit 8
6
The values are obtain from Step 4 , Section Other Savings. The makeup
glycol is $164/yr.
7
The values are obtained from Exhibit 14, the gas price is assumed to be
$3/Mcf).

Estimated
Savings

Savings achieved by STAR Partners implementing desiccant dehydrators

instead of glycol dehydrators. The analysis of replacing an exiting glycol
dehydrator of 1 MMcf at 450 psig and 75 F gas with a desiccant dehydraPage 14

tor. Exhibit 16 shows the economic analyzes for replacing a glycol dehydrator with a desiccant dehydrator.
Exhibit 16: Economics of Retrofitting a Desiccant Dehydrator
Type of costs and
savings1

Year (0)
($/yr)

Capital & Installation Costs

(22,750)

Avoided O&M
Cost
O&M costs ($/yr)
Value of Gas
Saved
Salvage Value
Total ($)

2,000
(20,750)

Year (1)
($/yr)

Year (2)
($/yr)

Year (3)
($/yr)

Year (4)
($/yr)

Year (5)
($/yr)

3,611

3,611

3,611

3,611

3,611

(2,886)
3,438

(2,886)
3,438

(2,886)
3,438

(2,886)
3,438

(2,886)
3,438

4,163

4,163

4,163
4,163
4,163
NPV (Net Present Value)2 =(6,335)
IRR (Internal Rate of Return)3 = (3%)
Payback Period (yr) = 5
1
All the cost values are obtained from Exhibit 14, the gas price is assumed to be
$3/Mcf).
2
The NPV is calculated based on 10% discount over five years.
3
The IRR is calculated based on 5 years.

Lessons
Learned

Desiccants Dehydrators can cost effectively reduce methane emissions for

gas dehydration. Partners offer the following lessons learned:

Desiccant dehydrators can provide significantly economic benefits,

such as increased operating efficiency, decreased capital and maintenance costs for low flow rate gas at high pressure and low temperature.

Operating costs of desiccant dehydrators are slightly higher than the

cost from glycol dehydrator. The desiccants dissolve in water and
they have to be replaced, while the glycol are recycled/circulated.

Desiccant dehydrators are an effective method for eliminating emissions of methane, VOCs, and HAPs to the atmosphere, resulting in
both economic and environmental benefits.

The brine in the storage tank is often diluted with the produced water
and injected back to the ground or dumped into water disposal pits.

For high temperatures and low pressures and large volume gas, glycol dehydrators are more economical gas drying method.

Page 15

Partners Experiences from Implementing Desiccant Dehydrators

In one of their production fields in Wyoming, Natural Gas STAR partner
BP has installed 12 desiccant dehydrator units for well site dehydration.
As a result of these implementations, BP has reported reducing 8,860
Mcf/yr of methane emissions from these units. Assuming $2 per Mcf, the
gas value savings is approximately $ 17,770 for 12 units. In addition to
the methane emission reduction, desiccant dehydrator reduced all other
emissions, such as VOCs, HAPs and BTEX, from both the glycol dehydrator overhead and the glycol reboiler. The net present value of the desiccant dehydrator is equal to or slightly less than of the glycol dehydrator.

Appendix A
Table 1: Moisture content of natural gas after drying with desiccants in lb./ MMcf

Source: Van Air

Page 16

Table 2: Cost of Desiccant dehydrators

Maximum Capacity Mscf

Source: VanAir

Page 17

Sources
Consulted

Reid Smith
Senior Environmental Specialist
Health, Safety & Environment
BP Amoco Exploration
Western Gas Business Unit
Mail Code 2.4470
501 WestLake Park Blvd.
Houston, TX 77079-2696
Tel: (281) 366-7515 Fax: (281) 366-7922
Duane Zavadil
Health, Safety & Environment Manager
1515 Arapaheo Street
Tower 3, Suite 1000
Denver, Colorado 80202
Tel: (303) 606-4396 Fax: (303) 629-8265
Charles Eskrigge
Air and Vacuum Process inc
5216 Cedar
Bellaire, TX 14.314.3401
Tel: (713) 645-0208 Fax: (713) 645-814.398
Internet: http://www.airvacuumprocess.com
Curt Murray, Sr.
Pride of the Hills MFG., Inc
President-CEO
8140 S.R. 514
Big Priairie, OH 44611-9692
Tel: (330) 567-3108 Fax: (330) 567-3854
Internet: www.prideofthehills.com
The Hanover Compressor Company
12001 N. Houston Rosslyn
Houston, Texas 14.314.3086
Tel: (281) 447-8787, Fax: (281) 447-8781
Paul Gunning, Natural Gas STAR Program
United States Environmental Protection Agency CD (6202J)
1200 Pennsylvania Avenue, NW
Washington, DC 20445
Tel: (202) 564-9736, Fax: (202) 565-2254
Email: [email protected]

End Notes

Murray, Curt. Practical Methods of Dying Natural Gas. Pride of the Hills
MFG., Inc.
Bowman. Bob. Benefits of Using Deliquescing Desiccants for Gas Dehydration. Society of Petroleum Engineers (SPE 45170)
Page 18

U.S. Environmental Protection Agency. Lessons Learned: Reducing the

Glycol Circulation Rates in Dehydrators (EPA430-B-97-014, May 1997).
U.S. Environmental Protection Agency. Lessons Learned: Installation of
Flash Tank Separators (EPA430-B-97-008, October 1997).
U.S. Environmental Protection Agency. Lessons Learned: Replacing Gas
Assisted Glycol Pumps with Electric Pumps. (EPA430-B-00-006, December
2000).

Page 19