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SEPTEMBER, 2014.
TABLE OF CONTENTS
LIST OF FIGURES..........................................................................................iii
LIST OF TABLES............................................................................................iv
ACRONYMS AND ABBREVIATIONS.................................................................v
CHAPTER 1: INTRODUCTION........................................................................1
CHAPTER 2: LITERATURE REVIEW................................................................4
2.1. NATURAL GAS LIQUID RECOVERY........................................................4
2.2. LICENSORS OF NATURAL GAS LIQUID RECOVERY TECHNOLOGIES.........6
2.3. ORTLOFF NATURAL GAS RECOVERY PROCESSES...................................6
2.3.1. RESIDUE SPLIT-VAPOUR PROCESS......................................................6
2.3.2. SUPPLEMENTAL RECTIFICATION PROCESS..........................................8
2.3.3. OVERHEAD RECYCLE PROCESS..........................................................9
2.3.4. IMPROVED OVERHEAD RECYCLE PROCESS......................................10
2.3.5. SINGLE COLUMN OVERHEAD RECYCLE PROCESS.............................11
2.4. IPSI LLC NATURAL GAS RECOVERY PROCESSES...................................13
2.4.1. ENHANCED NGL RECOVERY PROCESS..............................................13
2.4.2. SPLIT FEED COMPRESSION PROCESS................................................15
2.5. ABB LUMMUS NGL RECOVERY PROCESSES.........................................16
2.5.1. HIGH ETHANE RECOVERY PROCESS.................................................16
2.5.2. HIGH PRESSURE ABSORBER.............................................................17
CHAPTER 3: CONCLUSION..........................................................................20
REFERENCES..............................................................................................21
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LIST OF FIGURES
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LIST OF TABLES
Table 1: Some uses of Natural Gas Liquids (U.S. Energy Information Administration, 2012).....2
4
ACRONYMS AND ABBREVIATIONS
JT Joule Thomson
Refrig. Refrigeration
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CHAPTER 1: INTRODUCTION
Natural gas is a mixture of hydrocarbon gases which consists primarily of methane, but
commonly includes varying amounts of other higher alkanes (C 2 C4/5) and an even
lesser percentage of carbon dioxide, nitrogen, hydrogen sulphide, etc. Natural gas exists
in the earths crust; it is found and brought to the surface through several complex
processes. Among the major uses, natural gas is used as fuel by burning it directly; it is
used as a petrochemical feedstock to make other products e.g. fertilizer; and it is also
After Natural gas is brought out of the earths crust, it has to be processed so as to
remove unwanted components that may reduce its usefulness. If possible, it is preferred
that the resulting processed gas is purely methane (CH 4). The impurities which are
Water: This can be in the form of water vapour and liquid water. The water may
radon, and the produced water may contain dissolved traces of radium, which
can accumulate within piping and processing equipment. This can render piping
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pentanes and even higher molecular weight hydrocarbons. When these heavier
hydrocarbons are processed and purified into finished by-products, they are
The presence of natural gas liquids in natural gas is undesirable because they cause the
formation of a liquid phase during transportation of natural gas which is unsafe and as
such they must be removed. On the other hand however, natural gas liquids are not
useless. Natural gas liquids consist of useful compounds that have numerous important
uses; these compounds have greater value as separate products than as part of the
natural gas stream. Table 1 below shows some of the uses of some of the components of
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Gas Chemical End Use
Applications Primary Sectors
Liquid formula Products
Natural gasoline; Gasoline;
Pentane C5H12 blowing agent for polystyrene; Transportation
polystyrene foam solvent
Blending with vehicle Gasoline;
Mix of C5H12
Pentanes fuel; exported for ethanol blends;
and heavier Transportation
Plus* bitumen production in oil sands
hydrocarbons
oil sands production
*Pentanes plus is also known as natural gasoline. It contains pentane and heavier
hydrocarbons.
Because of the great usefulness of natural gas liquids, they have to be removed from the
natural gas in such a way that they are not lost. Hence, the process of removal of natural
gas liquids from natural gas is called natural gas liquids recovery. There are several
available licensed processes used to recover natural gas liquids from natural gas. The
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CHAPTER 2: LITERATURE REVIEW
The industrial recovery of natural gas liquids from natural gas is predominantly
achieved in one of four ways, these are: low temperature distillation, lean oil absorption,
solid bed adsorption and membrane separation processes. Of these four, low
cooling the natural gas to temperatures low enough to cause ethane, propane and heavier
hydrocarbons that are present in the natural gas to condense after which they are
distilled.
The low temperatures required in low temperature distillation methods of NGL recovery
refrigerant (usually propane) to cool the inlet gas; self refrigeration is achieved by
causing the gas to expand, usually by passing the gas through a Joule-Thomson (JT)
valve thereby causing the gas temperature to drop. Cryogenic refrigeration is similar to
self refrigeration just that instead of a JT valve, the gas is passed through a turbo
expander which results in a greater temperature drop. Figure 1 shows the phase
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Figure 1: Thermodynamic pathways of different NGL recovery technologies (From
Mokhatab et al., 2006, pg. 366)
When the natural gas is cooled outside the retrograde condensation zone, condensation
of NGL will be induced. Line from A to B indicates gas-to-gas heat exchange; while the
Most modern gas processing plants employ the cryogenic refrigeration method which
demethanizing fractionating column. The expander reduces the inlet gas pressure (with
value of about 600 to 900 psia) to the demethanizer operating pressure, which varies
from 100 to 450 psia. The turbo expander simultaneously produces cooling/condensing
of the gas and useful work, which may be used to recompress the sales gas.
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The demethanizer is a low temperature distillation column that makes a separation
between methane and ethane. Methane and components lighter than methane, such as
nitrogen, are the principal products in the vapour near the top of the column, whereas
ethane and heavier components, such as propane, butanes, and heavier hydrocarbons,
comprise the principal components in the bottom product of the column. Typical inlet
gas temperatures to the demethanizer are 90 to 100 oC, sufficiently low that a great
TECHNOLOGIES
As mentioned earlier, there are several licensed processes that are employed in gas
plants for NGL recovery. The licensors of these processes include ORTLOFF
and others. Some of these processes will be discussed in the subsequent sections.
PROCESSES
This process is also called the Recycle Split Vapour (RSV) process. It is a cryogenic
process and was developed by Ortloff in the late 1990s as an enhancement of the
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Figure 2: Schematic of Ortloff residue split-vapour process (From Mokhatab et.
al., 2006, pg. 375)
The inlet gas is cooled in a gas-to-gas heat exchanger by passing the cold gas coming
from the demethanizer in counter-current flow with the warm inlet gas which causes
partial condensation of the inlet gas. After that, the inlet gas stream is passed through a
cold separator which separates the condensed liquids from the gas. The liquid from the
cold separator is fed to the demethanizer with part of it mixed with the gas from the cold
separator and passed through the subcooler where it is totally condensed with the
overhead stream from the demethanizer. The condensed liquid stream is then flashed to
the top of demethanizer, providing reflux to the demethanizer. The greater portion of the
gas stream from the cold separator expands through the expansion turbine to the
demethanizer pressure.
The main differentiating feature of the RSV process is the presence of an additional
reflux stream produced by recycling a portion of the residue gas, after recompression,
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back to the top of the column. The stream is passed through the overhead heat
exchanger or subcooler, which effectively condenses the gas totally, after which it is
flashed to the top of the demethanizer to provide reflux. Because of this extra reflux
stream, the subcooled inlet gas split and the expander outlet stream are sent lower down
in the tower rather than to the top of the column. The reflux provides more refrigeration
The RSV process is CO2 tolerant and the recovery can be adjusted by the quantity of
recycle used. The RSV process can be used for very high ethane recoveries limited only
Like the Recycle Split Vapour (RSV) process, this process is also an enhancement of the
Gas Subcooled Process (GSP). The Supplemental Rectification Process (SRP) has the
advantage of ultra-high propane and heavier recovery at all times coupled with being a
flexible process for ethane recovery; it is suitable where ethane production needs to be
The SRP design incorporates a vapour draw from the demethanizer column that is used
to generate two reflux streams for the column. A rectification section is added above the
typical top feed point of the GSP process. A portion of the condensed side draw vapour
is fed to the top of this new section. The remainder provides reflux below the expander
feed when needed, depending on the ethane recovery level. These additional SRP reflux
points allow the process to maintain ultra-high recovery of the propane and heavier
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Subcooler
the absorber is the composite tower and the deethanizer is the composite distillation
tower. The inlet gas is cooled in an inlet gas-to-gas heat exchanger after which it goes to
a low temperature separator which separates the partly condensed liquid from the
vapour. The liquid from the cold separator is used to cool the inlet gas at the front-end
heat exchanger before taken to the deethanizer. The vapour from the cold separator is
passed through an expander and then to the absorber. The residue gas leaving the
absorber is used to cool and condense the vapour stream from the deethanizer before
being fed to the top of the absorber as reflux. The bottom product from the absorber is
fed to the top of the deethanizer where the final liquid NGL is collected as the bottom
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product. The OHR process provides more efficient recovery of propane and heavier
hydrocarbons than the GSP design, but is not suitable for high ethane recovery.
Figure 4: Schematic of the Ortloff Overhead Recycle process (From Hudson et. al.,
1998, pg. 3)
better use of the refrigeration available in its feed streams. In the OHR design, the cold
absorber bottoms liquid is supplied directly to the deethanizer as its top feed; in the IOR
process however, this stream is first used to supply part of the feed gas cooling, which
reduces the cooling load on the inlet gas and also reduces the deethanizer reboiler duty
by the same amount. A small portion of the cold reflux produced by the overhead
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condenser is used to rectify the vapours flowing up the deethanizer, allowing the
Figure 5: Schematic of the Improved Overhead Recycle process (From Hudson et.
al., 1998, pg. 7)
processing technology suited to the recovery of propane and heavier hydrocarbons from
recovery with high efficiency. Unlike the OHR and IOR designs, it uses a single
composite column.
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Reflux for the column is generated by condensing a vapour side draw stream. A liquid
side draw is utilized for process cooling to optimize heat integration. While the basic
working principle of the SCORE process is the same as the IOR process, it can lead to
considerable advantage in terms of the investment cost for the plant. The single, larger
column and small reflux drum are generally cheaper than the two columns used in the
IOR process, and one less set of cryogenic pumps is required. Its single column design
With appropriate design features, a plant using the SCORE process can also be switched
to operate in an ethane recovery mode utilizing Ortloffs Gas Subcooled Process (GSP).
Condenser
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2.4. IPSI LLC NATURAL GAS LIQUIDS RECOVERY PROCESSES
Developed by IPSI LLC, the Enhanced NGL Recovery Process focuses more on the
enhancement of the bottom of the demethanizer column unlike the other Ortloff
processes discussed earlier which focus more on introducing reflux at the top of the
demethanizer to enhance ethane recovery. The Enhanced NGL Recovery Process (also
known as IPSI-1) uses a slip stream from or near the bottom of the distillation column
vaporized at the inlet gas-to-gas heat exchanger thereby cooling the inlet gas further.
This refrigeration step increases the efficiency of the recovery process by enhancing
efficiency, then is recompressed and recycled back to the bottom of the tower where it
Lowering the temperature profile in the tower, thereby permitting better energy
integration for inlet gas cooling via reboilers, resulting in reduced heating and
refrigeration requirements.
Reducing and/or eliminating the need for external reboiler heat, thereby saving
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This process can be incorporated as a modification to an existing NGL recovery process
regardless of the original licensor. One of its limitations is that as the plant capacity
increases and the feed gets richer, it may require additional refrigeration to maintain
The Split Feed Compression (SFC) process was developed in 2002 by IPSI LLC. This
process is particularly suitable when the feed gas is supplied at a relatively low pressure.
In order to achieve high NGL recovery, modern expansion processes require that the
turbo expander be operated at high expansion ratios combined with an enhanced reflux
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generated for the top rectification section of the demethanizer. The implication of this is
that when the feed gas pressure is low, provisions have to be made to increase it.
Conventionally, the way out has been either to raise the feed gas pressure or operate the
demethanizer at a lower than normal pressure. These call for an additional (usually
expensive) application of compression power to the total gas flow either at the front-end
(i.e. feed gas) or at the back-end (i.e. residue gas) to gain the desirable expansion ratio
and to promote partial condensation of feed gas for the reflux stream.
To solve the problem of application of additional compression, the SFC process applies
compression to a small portion of the total feed gas, typically ranging from 25 to 35
percent, that portion necessary to facilitate condensation for use in the demethanizer as a
top reflux stream. This way, the reflux stream has sufficient pressure to function. This
lower design pressure for the front-end equipment processing the main portion of feed
gas. Like the Enhanced NGL Recovery Process, it can also be adapted in retrofitting
plants where the front-end equipment does not have a high enough design pressure. Any
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Compressor
feed gas, or inlet feed split. That is, the inlet feed gas is split into two: one stream goes
into the inlet gas-to-gas heat exchanger to be cooled and the second one is used to
provide reboiler heat to the demethanizer(s). Afterwards, the two streams are mixed
before being sent to the cold separator. If the two mixed streams are not at the same
temperature, some work is lost due to the mixing operation. The High Ethane Recovery
process provides loss work prevention by reboiling the demethanizer with part of the
residue gas, or residue gas split. The entire inlet gas is sent to the inlet gas-to-gas heat
exchanger while the recycle-reflux stream circulates through the reboilers. After
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providing the necessary heat to reboil the column, the recycle-reflux stream is further
cooled and liquefied or condensed in the reflux subcooler. The condensed recycle-
reflux stream is then expanded isenthalpically in a valve and sent to the top of the
demethanizer column as reflux. This scheme is also known as open heat pump.
This process can be adapted to existing NGL recovery processes in retrofit situations.
Figure 9: Schematic of the High Ethane Recovery Process (Google Patents, 1999)
of about 100 to 450 psia while the pipeline gas is required to be supplied at above 1000
psia. This implies that recompression of the sales gas is necessary after the NGL
recovery process; in most plants, gas processing capacity is generally limited by the
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horsepower available for recompression of the pipeline sales gas stream. The High
Pressure Absorber (HPA) process was developed to minimise the pressure difference
between the NGL recovery process operating pressure and the sales gas pipeline
increased plant capacity of existing gas processing plants. The HPA process employs a
at a lower pressure. The pressure difference between the absorber and the fractionating
Pump
Figure 10: Simplified Schematic of the High Pressure Absorber process (From
Foglietta et. al., 2004)
Treated inlet gas stream is cooled in the front end heat exchanger and passed to a cold
separator which separates the partially condensed liquid components of the cooled feed
gas from the vapour stream. The vapour stream from the cold separator is supplied to an
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expander where this stream is isentropically expanded to the operating pressure of the
absorber. The absorber overhead stream contains substantially all of the methane, C 2
compounds and lighter compounds in the expanded vapour stream. The condensed
liquids descend down the column and are removed as absorber bottom stream, which
The feed into the fractionating column are the liquid streams from the cold separator
(part of which is passed through the front end exchanger and the other part through the
overhead condenser to absorb heat) and the liquid bottom stream from the absorber. The
overhead gas stream from the fractionating column is partially condensed in the
overhead separator; the liquid from this partial condensation is re-introduced into the
fractionating column as reflux and the vapour stream (which contains a major portion of
fed into the absorber. The liquid component of this compressed stream serves as reflux
in the absorber.
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CHAPTER 3: CONCLUSION
Even though there are up to four different methods of natural gas recovery from natural
gas, namely low temperature distillation, lean oil absorption, solid bed adsorption and
membrane separation processes this study reveals that most of the licensed technologies
are based on the low temperature distillation method; or more precisely cryogenic
distillation. All the processes discussed in this study are based on cryogenic distillation
of natural gas.
This study also shows that the newer processes basically seek to improve on the older
ones. An example is seen in the case of the Ortloffs Improved Overhead Recycle
process which was an improvement of the Overhead Recycle process in terms of the
reflux streams (thereby improving ethane recovery). The Single Column Overhead
Recycle was again invented and it served as an improvement of the Improved Overhead
With the constantly increasing usefulness and demand for natural gas and also
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REFERENCES
www.bechtel.com/3904.html
Foglietta, J.H. (1999). Hydrocarbon gas separation process. Google Patents. Retrieved
Foglietta, Jorge H. (1999). NEW RECYCLE PROCESS SCHEME FOR HIGH ETHANE
Foglietta, Jorge H., Haddad, Hazem, Mowrey, Earle R., Patel, Sanjiv N. and Sangave
Hudson, Hank M., Pitman, Richard N., Wilkinson, John D. and Cuellar, Kyle T. (1998).
from: http://www.ou.edu/class/che-design/che5480-07/Next%20Generation
%20NGL-LPG(Hudson%20et%20al)-98.pdf
representative natural gas liquid (NGL) recovery processes under various feed
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Engineering (PSE ASIA) (pp. 732-738) Kuala Lumpur. Retrieved from:
http://www.sps.utm.my/download/PSEAsia2013-119.pdf
Elsevier Inc.
document=ortloffs-single-column-overhead-recycle-score-process&download=1
U.S. Energy Information Administration (2012). What are natural gas liquids and how
http://www.eia.gov/todayinenergy/detail.cfm?id=5930
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