Dehydration and Phase Envelope (Full Paper)
Dehydration and Phase Envelope (Full Paper)
Dehydration and Phase Envelope (Full Paper)
A. Esmaeili 1, F. Golozari 2
1. Islamic Azad University, Tehran-South Branch, Chemical Engineering Dept., Ahang Blvd.,
Tehran, Iran, Tel.: +989125130090, e-mail: [email protected]
2. PFI consultant company, Chemical Engineering Dept., Tehran, Iran, Tel.: +989128158694,
e-mail: [email protected]
Abstract
Water and hydrocarbons are natural companions. Hydrocarbons are formed in a water
environment and are in equilibrium with water at reservoir conditions. Water is a conspicuous
component of gas in all steps of gas handling from its initial production to its ultimate
consumption. Presence of water vapour in compressed gas is especially troublesome because
the solubility of water in the gas is diminished by decreased temperature; Pressure favours the
combination of condensed water with natural gas to form solid hydrates even though the
temperature is above the freezing point of water. Three conditions have to be fulfilled for
hydrates to form:
The presence of water (“free”, dissolved or emulsified)
The presence of light hydrocarbons (from C1 to C4), or acid gas (CO2, H2S) or
Nitrogen
Meet the P, T conditions (depending on the nature and composition of gas)
Thermodynamic predicts that hydrates can form even when the gas phase is unsaturated
with water. This problem has occurred in several instances in pipelines in which the gas
residence time was usually long, but it is extremely rare. The formation of hydrate is avoided
since it can cause blockages through local plugs. Dehydration is the process used to remove
water from natural gas and natural gas liquids (NGLs) and is required to:
Prevent formation of hydrate and condensation of free water in processing and
transportation facilities,
Meet a water content specification,
Prevent corrosion
Techniques for dehydration of natural gas, associated gas condensate and NGLs include:
absorption using liquid desiccants, adsorption by using solid desiccants, dehydration with
calcium chloride, dehydration by refrigeration, dehydration by gas stripping, dehydration by
membrane permeation, dehydration by distillation.
The main purpose of this paper is to research about effects of hydrate formers
components such as nitrogen, hydrogen sulphide and water on gas phase envelope curve of
South Pars Gas Field (Iran) as well as two main methods of gas dehydration. In recent study,
some cases are investigated by using PIPESIM simulator (licensed by Schlumberger) and
equation of state of Peng-Robinson so that each one has considerable result. Our simulation
illustrates present or absence of some non-hydrocarbon components such as water and
nitrogen and also composition of hydrocarbon components have remarkable effects on gas
envelope curve so that high amount of nitrogen changes hydrocarbon dew point curve
sensitively.
Introduction
Gas Hydrates
At a given pressure, pure methane forms hydrates at the lowest temperature, adding
ethane through butane, hydrogen sulphide, or carbon dioxide raises the formation temperature
significantly. However, addition of carbon dioxide and nitrogen to typical natural gas mixture
will lower the hydrate formation temperature of the mixture. Heavier compounds, C5+, are
too large to fit into the cages formed by natural gas and have insignificant effect as a diluent
because their concentration is so low [5]. From a practical viewpoint, the structure type does
not affect the properties, or problem caused by the hydrate but the type (in fact the
composition) has 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 form hydrates at higher temperatures than similar gas mixtures which do not
contain these components.
Hydrate Inhibition
The formation of hydrates can be prevented by dehydrating the gas or liquid to eliminate
the formation of a condensed water (liquid or solid) phase. In some cases, however,
dehydration may not be practical or economically feasible. In these cases, chemical inhibition
can be an effective method of preventing hydrate formation [4]. Use of chemical inhibitors is
the least attractive hydrate inhibition method for several reasons [5]:
The proper inhibitor dosage must be known to avoid plugging or needless chemical
costs, but oftentimes it is determined empirically.
The chemical cost, although it is usually a small fraction of overall operating costs.
The reliability of inhibitor injection can be a problem because of malfunctioning
injection pumps and depleted inhibitor reservoirs, especially at remote sites.
The possible interaction between hydrate inhibitors and other additives reduces the
effectiveness of some of additives, an effect that is usually determined empirically.
Gas Dehydration
The term dehydration means removal of water vapour, all natural gas downstream from
the separators still contains water vapour to some degree. Water vapour is probably the most
common undesirable impurity found in untreated natural gas. The main reason for removing
water vapour from natural gas is that water vapour becomes liquid water under low
temperature and or high pressure conditions and would be highly likely to form hydrate while
solubility of water in natural gas increases with temperature rise and decreases with pressure
rise; thus, liquid water formation condition is against on water solubility in natural gas. There
are three different behaviours between gas hydrate curve and water dew point curves that is
made by High water content gases which in water dew point curve is on the right side the
hydrate curve (like gas from wellhead), Medium water content gas that both curve are close to
each other and may have cross (i.e. gas from high pressure separators) and low water content
gas which water dew point curve is located higher than hydrate curve (like dehydrated gas)
respectively. Specifically, water content can affect long-distance transmission of natural gas
due to the following facts [2]:
Liquid water and natural gas can form hydrates that may plug the pipeline and other
equipment
Natural gas containing CO2 and or H2S is corrosive when liquid water is present.
Liquid water in a natural gas pipeline potentially causes slugging flow conditions
resulting in lower flow efficiency of the pipeline.
Water content decreases the heating value of natural gas being transported.
Absorption
In the situations where inhibition is not feasible or practical, dehydration must be used.
Both liquid and solid desiccants may be utilized but economics frequently favour liquid
desiccant dehydration when it will meet the required dehydration specification. Liquid
dehydration equipment is simple to operate and maintain. It can easily be automated for
unattended operation like glycol dehydration at a remote production well. Liquid desiccants
can be used for sour gases, but additional precautions in the design are needed due to the
solubility of the acid gases in the desiccant solution. At very high acid gas content and
relatively higher pressures the glycols can also be soluble in the gas [4]. Water level in natural
gas can be reduced to 10 ppmv range in a physical absorption process in which the gas is
contacted with a liquid that preferentially adsorbs the water vapour. Operating conditions for
glycol units are governed principally by the degree of dehydration required, the physical
properties of the glycol solutions and the inlet pressure of the gas to the processing unit. The
solvent used for the adsorption should have the following properties [5]:
A high affinity for water and a low affinity for hydrocarbons
A low volatility at the absorption temperature to reduce vaporization losses
A low viscosity for ease of pumping and good contact between the gas and liquid
phases
A good thermal stability to prevent decomposition during regeneration
A low potential for corrosion
Glycols are typically used for applications where dew point depressions of the order of
60ºF to 120ºF are required. In practice, ethylene glycol (EG), diethylene glycol (DEG),
triethylene glycol (TEG), tetraethylene glycol (TREG) and propylene glycol are the most
commonly used adsorbents; triethylene glycol is the most useful one in gas plants, although
some operations in colder climates will use diethylene glycol because of its lower viscosity.
For operations which frequent brine carryover into the contactor occurs, operators use EG
because it can hold more salt than the other glycols. The solubility of sodium chloride in EG
water mixtures is around 20% wt, whereas it is only around 5% wt in TEG. Tetraethylene
glycol has a lower vapour pressure and withstands higher regeneration temperatures than does
TEG, but the additional cost outweighs the marginal increased benefits. Glycol dehydration
units in the typical gas plant are downstream of the amine absorbers; amine carryover is the
main concern in these situations. Water soluble components increase the regenerator duty, and
hydrocarbon impurities can cause foaming in the system. Proper sizing of inlet scrubbers is
critical in these situations so that separators or coalescing filters are required to prevent fine
mists from entering the absorber [5].
Good practice dictates installing an inlet gas scrubber, even if the dehydrator is near a
production separator. The inlet gas scrubber will prevent accidental dumping of large
quantities of water (fresh or salty), hydrocarbons, treating chemicals or corrosion inhibitors
into the glycol contactor. Even small quantities of these materials can result in excessive
glycol losses due to foaming, reduced efficiency and increased maintenance. Integral
separators at the bottom of the contractor are common. Glycol dehydrators have several
advantages including [2]:
1. low initial equipment cost
2. low pressure drop across absorption towers
3. makeup requirements may be added readily
4. recharching of towers presents no problems
5. the plant may be used satisfactorily in the presence of materials that would cause
fouling of some solid adsorbents
Adsorption
Solid desiccant units generally cost more to buy and operate than glycol units. Therefore,
their use is typically limited to applications such as high H2S content gases, very low water
dew point requirements, simultaneous control of water and hydrocarbon dew points, and
special cases such as oxygen containing gases, etc. [4]
Because adsorbate concentrations are usually low, generally only a few layers of
molecules will build up on the surface. Thus, adsorption processes use solids with extremely
high surface to volume ratios. Commercially used synthetic zeolites (such as molecular sieve)
have surface to volume ratios in range of 750cm2/cm3, with most of the surface for adsorption
inside of the adsorbent. In the case of molecular sieves, the adsorbent consists of extremely
fine zeolite particles held together by a binder. Therefore, adsorbing species travel through the
macropores of the binder into the micropores of the zeolite. Molecular sieves have an
extremely narrow pore distribution, whereas silica gel and alumina have wide distributions.
However, a molecular sieve binder, which is usually about 20% of the weight of the
adsorbent, has large pores capable of adsorbing heavier components. Two steps are involved
in adsorbing a trace gas component; the first step is to have the component contact the surface
and the second step is to have it travel through the pathway inside the adsorbent. In
commercial practice, adsorption is carried out in a vertical, fixed bed of adsorbent, with the
feed gas flowing down through the bed. There are three separate zones in the beds [5]:
The equilibrium zone, where the adsorbate on the adsorbent is in equilibrium with
the adsorbate in the inlet gas phase and no additional adsorption occurs.
The mass transfer zone (MTZ), the volume where mass transfer and adsorption take
place and water content of the gas is reduced to less than 1 ppm.
The active (bottom) zone, where no adsorption has yet taken place.
If the bed operates too long in adsorption, the mass transfer begins to move out the
bottom the bed causing a “breakthrough”. At breakthrough, the water content of the outlet gas
begins to increase and will eventually reach feed gas water content when the MTZ is
completely displaced. In the saturation zone, molecular sieve is expected to hold
approximately 13 pounds water per 100 pounds of sieve which represents the capacity of a
3-5 year old adsorbent while new molecular sieves have an equilibrium capacity near 20%.
The advantages of solid desiccant dehydration include [2]:
Lower dew point, essentially dry gas (water content less than 0.1 lb/MMSCF) can
be produced
Higher contact temperatures can be tolerated with some adsorbents
Higher tolerance to sudden load changes, especially on start up
Quick start up after a shutdown
High adaptability for recovery of certain liquid hydrocarbons in addition to
dehydration functions
Although this type of dehydrator has high adaptability to sudden load changes, sudden
pressure surges should be avoided because they may upset the desiccant bed and channel the
gas stream resulting in poor dehydration. If a plant is operated above its rated capacity, high
pressure loss may cause some attrition to occur. Attrition causes fines, which may in turn
cause excessive pressure loss and result in loss of capacity. In order to maintain continuous
operation, this may require discarding the desiccant before its normal operating life is reached.
For cost reduction, the inlet part of the bed can only be recharged and rest of them retained.
Theory
Figure1 shows estimated gas phase envelope of the mentioned field by using
Peng-Robinson equation of state so that amount of water has been considered 1.55 mole
percent, methane 80.96% mole, ethane 5.17% mole and other its components are followed as
wellhead gas mole fraction in table1. For these compositions, maximum hydrate temperature
and cricondenbar are 29.5°C and 300 Bara respectively. When there is no water within gas
components as is seen in figure 2, the curves of ice, hydrate and aqueous are omitted. As is
illustrated in this figure just hydrocarbon curve is existence, therefore there is no possibility to
be created hydrate, ice and aqueous curves even with changes of temperature and pressure.
Therefore, if one of three mentioned conditions in hydrate formation is ignored even with
existence of two others, hydrate would not be created. The something that is common in both
curves is the shape of phase envelope curve and value of cricondenbar as well as
cricondentherm.
Figure 1. Phase Envelope and Hydrate formation Curves of South Pars Gas Field
Figure 2. Phase Envelope Curve of South Pars Gas Field without Water content
Table1. Gas component of South Pars Gas Field as mole fraction in different assumed cases
Figure 3. Phase Envelope Curve of South Pars Gas Field without carbon dioxide content
Figure 4 discusses about effect of nitrogen content in natural gas mixture so that if this
value is assumed as nil, dew point pressure will be decreased up to 280 Bara. In fact, phase
envelope curve would be thicker in comparison with the normal case that there is nitrogen in
gas composition while remarkable effect is not seen on hydrate formation curve. The presence
of nitrogen somehow decreases the aqueous phase temperature formation compared with
former case.
Figure 4. Phase Envelope Curve of South Pars Gas Field without nitrogen content
Because rise in CO2 and H2S content has two different behaviour on hydrate formation
temperature as fall and rise respectively, no change can be seen in the hydrate and phase
envelope curves in figure 5.
Figure 5. Phase Envelope Curve of South Pars Gas Field without CO2 and H2S content
References:
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envelope curce, In 13th Asia Pacific confederation of chemical engineering congress
(APCCHE 2010), Taiwan
[2] B. Guo, A. Ghalambor, Natural Gas Engineering Handbook, Gulf publishing company,
Houston, Texas, 2005
[3] J. M. Campbell, Gas Conditioning and Processing, Seventh Edition, Campbell Petroleum
Series, 1992
[4] Gas Processors Suppliers Association, Engineering data book, Twelefth Edition,
Oklahoma
[5] J. Kidney, R. Parrish, Fundamentals of Natural Gas Processing, Taylor and Francis
Group, 2006