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SUMMARIZED OVERVIEW TO
NATURAL GAS PROCESSING
2009
formula abbrev
CH4 C1
C2H8 C2
C3H12 C3
C4H16 C4
C4H16 C4
C5H20 C5
C5H20 C5
C5H20 C5
---- C6
The main upstream process executed to the gas aim to prepare the gas
to be used as final fuel source if it is a natural gas or to be delivered to
the down stream plants for further process to obtain high economic
.value products and residue gas which will be used as final source fuel
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I. GAS PROCESSING
NGL- C2+
LNG
LPG & C5+
Hydrate .
Sales Gas
Sour &sweet gas.
Dry & wet gas .
Associated & free gas.
Rich & lean gas .
GTL
DRY ICE
JT
Early start
Upgrade unit
API unit-Oily water
Closed &open drain
Hot &cold flare
Cold box
Surge Vessel
K.O.DRUM
LTS
Blow down P/L
Back Pressure &pressurizing .
Battery limit
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2- Up-stream(Field) processes in Natural gas
processing:
Purification(Slug removal)---------treatment
Sweetening(de-souring) ---------treatment
Compressing
purification:
the purification process performed after gas generated from the well to eliminate
all accompanied substances impeded with the gas such as sand , mud which is
normally present with the gas as natural surround in the well or liquids either
hydrocarbon liquids such as oil in case of associated gas or condensed heavy
saturated hydrocarbon chains or free water as accompanied present originally in
the well or from water injection to left the gas from the naturally in well. This
operation performed using sand removal units and slug catchers to separate three
phase gas liquids hydrocarbons above water by utilizing the difference in specific
gravity.
Dehydration:
This operation is performed to reduce the water vapors in gas phase to prevent the
hydrate formation during transportation via the pipelines at the different pressure
and temperature conditions causing blocking to the lines and lead to corrosion in
case of presence of acid gases such as CO2 or H2S.
This process carried out using injection as in methanol or glycol techniques or
adsorption process using solid or liquid absorbent material such as glycol
contactors or molecular sieves beds.
Sweetening:
The sour gases or acid gases is not recommended to be maintained in the gas due
to its harmful effect to the pipes and equipments generally on the other hand its
harmful to health.
This operation generally executed using adsorption techniques by solid descants
or by absorption by liquid as in amine process.
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.
Compression:
The gas which is almost treated is then fed to booster compression unit to be
delivered directly to gas plant via P/L network.
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EXAMPLE FOR RAW NATURAL GAS COMPOSITION AS RICH
AND LEAN FEED STOCKS:
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The following are the some specifications of the feed natural gas
which undergoes processing :
In order to produce these products ,the feed gas from fields must
undergo some subsequent processes that performed in gas plant which
is mainly to produce NGL(natural gas liquids)which is then
fractionated to the desired products .
The wet, sweet ,free gas from fields (gas production plant) undergo
the following processes :
Fractionation
Storage
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Gas dehydration :
Hydrates:
A Single Hydrate
Crystal
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Molecular sieve dehydrators are commonly used ahead of NGL
recovery plants designed to recover ethane. These plants typically
operate at very cold temperatures and require very dry feed gas to
prevent formation of hydrates. Dehydration to a 150F dew point is
possible with molecular sieves. Water dew points less than 150F can
be accomplished with special design and strict operating parameters.
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Cryogenic process (Production of NGL):
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removal and nitrogen rejection may also be carried out depending on
composition of the inlet gas. Method for the separation of NGL can
generally be divided into cryogenic and non-cryogenic systems. Early
attempts at recovery of these liquids were made using lean oil
absorption (non-cryogenic) and mechanical refrigeration. The
absorption process was later developed into refrigerated absorption
process and in recent years, enhanced absorption processes involving
both refrigeration and pre-saturation have been developed. The
introduction of Joule Thompson valves and turbo expanders in 1960s
made significant contributions to the achievement of cryogenic
conditions. The schemes using these technology were initially
designed with minimal heat integration and no or little column reflux.
These were later developed into schemes that generated column reflux
and maximize the heat integration for high NGL recoveries and
optimize the plant profitability.
The cryogenic process has application as the most economical means
for recovering a high percentage of all hydrocarbons heavier than
methane. Specifically, the cryogenic process aims to recover ethane
and heavier hydrocarbons, such as propane, butane and gasoline
components. Different
variations of this process are capable of removing more than 85% of
the ethane and essentially all of the heavier hydrocarbons found in
produced natural gas. By contrast, other processes may be more
appropriate when the goal is to recover just propane and heavier
components. The main advantage of the cryogenic plant, in terms of
recovered product, is therefore its ability to recover ethane or high
propane recoveries.
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demethanizer; these include the capital cost of the equipment and its
operating cost, which includes several factors. Since methane must be
rejected from the NGL, it stands to reason that the cost of
demethanizing will be less if the amount of methane condensed is less.
Thus, one criteria in the design and operation of the turboexpander
plant is to minimize the amount of methane that liquefies while still
maximizing the recovery of ethane and heavier hydrocarbons. The
quantity of methane that can be removed in the demethanizer depends
upon its design. It will have been designed for some maximum case,
where the maximum amount of methane condensed and rejected
corresponds to the maximum recovery of ethane. Turboexpander plants
can usually recover 98+% of the propane and 100% of the butane and
heavier hydrocarbons from the feed gas stream. NGL recoveries vary
according to the design of the plant and its operational objectives, but
one thing is certain: as ethane recovery targets go higher, so does the
difficulty in preventing excessive methane condensation.
There are three general methods which can be used to achieve the
conditions necessary to attain high ethane recovery levels.
1. J-T Expansion
2. Turboexpander
3. Mechanical refrigeration
Each of these processes has been used successfully, with the
turboexpander being the predominant process of choice for
ethane recovery facilities.
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Fig( ) : Tubular heat exchanger including all components
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FIG.( ): J.T.VALVE.
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Fractionation
Fractionation is based on the fact that the vapor of a boiling mixture will be
richer in the components that have lower boiling points. Therefore, when
this vapor is cooled and condensed, the condensate will contain more
volatile components. At the same time, the original mixture will contain
more of the less volatile material.
Although many people have a fair idea what fractionation means, the
important aspects that seem to be missed from the manufacturing point of
view are that:
The best way to reduce operating costs of existing units is to improve their
efficiency and operation via process optimization and control. To achieve
this improvement, a thorough understanding of fractionation principles and
how fractionation systems are designed is essential.
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Main Components of Fractionation Columns:
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References
1. R. N. MADDOX , H. ERBAR , GAS CONDITIONING AND
PROCESSING , Campbell Petroleum Series (Jan. 1982).
2. "GPSA Engineering Data Book" Eleventh Edition.
Wobbe no -1
Astm hg -2
abbreviattion -3
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