February 2011, Volume 2, No.

1
International Journal of Chemical and Environmental Engineering


Flowsheet Development and Simulation of Off-
Shore Carbon Dioxide Removal System at Natural
Gas Reserves

Tigabwa Yosef Ahmed, Murni M Ahmad
a
Chemical Engineering Department, Universiti Teknologi PETRONAS,
Bandar Sri Iskandar, 31750 Tronoh, Malaysia.
a
Corresponding author: murnim@petronas.com.my

Abstract
Carbon dioxide content in natural gas can cause corrosion and environmental issues. Most natural gas reserves in Malaysia contain 50
to 74 mol% of CO2. However, the capability of most existing acid gas treatment systems is limited to treat natural gas with CO2
content of 30 to 40 mol%. The purpose of this paper is to present preliminary study on the potential of an off-shore application of an
adsorption system using aminated resin to capture CO2 at the natural gas reserves. This system is intended to reduce the CO2 content
down to the capability of existing acid gas treatment. The flowsheet simulation based approach implemented in PETRONAS iCON
and HYSYS process simulators is used to study the effect of temperature, pressure, adsorbent concentration and flow rate on the CO2
removal performance using the proposed system. For the assumed CO2 content of 70 mol% in the natural gas from reserves, the
developed iCON and HYSYS models predict reduction to 11.8 mol% and 14 mol% of CO2 in the treated gas stream, respectively. The
preliminary economic study indicates positive economic potential. Thus, the results showed that the aminated resin can be used for
effective and efficient CO2 removal process using the proposed off-shore system from the natural gas stream.

Keywords: CO
2
, Adsorption, Simulation, MDEA, Resin, Aminated Resin

1. Introduction
When CO2 exists in natural gas prior to combustion, it
introduces several disadvantages: the heating value of the
natural gas is lowered, the gas volume to be handled and
transported is increased and the greenhouse gasses are
released.
Many technologies have been used to remove CO2
from natural gas such as, membrane, absorption and
adsorption. Some specially designed membranes such as
aromat ic polyimide separation membranes are proved
effective to remove CO2 in concentration between 5 and
40 mol% [1]. However, in the majority of membrane
separation techniques, membrane saturation might lead to
gas losses. Furthermore, the technology requires a
regulated and extensive pretreatment of the feed gas to
maintain the life time of the membrane which contributes
to the increase in operating cost of the membrane capture
system. Membranes are also sensitive to thermal and
pressure variation in feed gas conditions [2]. On the other
hand, in absorption process aqueous amines are the most
common and widely used for CO2 removal from natural
gas. However, recently there is a need to utilize solid
sorbents for CO2 removal due to the issues observed in
aqueous amine utilization i.e. its lifetime, susceptibility to
degradation through oxidation and corrosion problems
[3].
Much has been done on the development of novel
adsorbents for CO2. Adsorption of CO2 on phenolic resin-
based carbon spheres [4], act ivated carbons [5], amine
surface-bonded silica gel [6], amine-
functionalized mesoporous silica [7] and amine-enriched
fly ash carbon sorbents [8] are some of the adsorption
processes used for CO2 removal. The use of amine
surface-bonded solid materials has proved the valuable
contribution of the porous supports in the solid structures
for providing the amine with structural integrity and a
surface for gas/solid contact [7]. However, instead of
surface area or pore volume, amine content of
the materials is the governing factor to achieve high
CO2 removal capacity. To date, designing sorbents with
high CO2 removal capacity and favorable kinetics is an
ongoing process.
The use of process simulators to evaluate the
performance of various CO2 removal processes is
justifiable as testing at industrial scale is very expensive.
In process simulat ions choosing an appropriate fluid
package is one of the crucial steps. The process
simulators such as HYSYS [9], Aspen HYSYS [10],
Aspen Plus [11] and TSWEET

[12] have been used for

simulation of CO2 absorption with various amine
solutions. Most of the simulation systems for fluid

21

processes offer some basic support for simulation of
solid processes as well.
This work focuses on designing and simulating a
system for CO2 adsorption with aminated resin which is
proposed to be installed at natural gas reserves. Two
commercial process simulators i.e. HYSYS and iCON are
used. iCON, a simulator based on Sim42, is jointly
developed by PETRONAS, the Malaysias national oil
corporation in collaboration with Virtual Materials Group
(VMG) Inc.

2. Process Development
The natural gas received from the reserves contains
some hydrocarbon condensates and water. Hence, the gas
is usually passed through field separators to remove those
components. The two known separators used for this
purpose are slug catcher and stabilizer [13]. The natural
gas is resent to gas treating plants at refineries for further
processing. In this work, an off-shore CO2 removal unit at
natural gas reserves is proposed to be introduced before
the gas is sent to gas treating plants. This unit is
developed due to the alarming of high concentration of
CO2 in natural gas reserves. Fig.1 illustrates the general
flow diagram for natural gas treatment system with the
inclusion of the newly designed off-shore CO2 removal
unit.

Natural Gas
Reserves
Off-shore Unit Gas Treatment Plant
Table 1
< 30 mol% CO
2

Fi g.1. Outline of the overall process for natural gas processing
system

The conditions of the natural gas stream coming from
the reserves are listed in Table 1. To design the process,
the commonly known heuristic-based design approach by
[14] has been adopted. This method helped to make
various design-based decisions in a hierarchical manner
by decomposing the design into a serious of sub-
problems.














Table 1. Natural gas feed conditi ons [15]
Nat ural Gas
Component s Mole fract ion Mass fract ion
N2 0.0016 0.001
CO2 0.70* 0.813
H2S 0.0172 0.015
C1 0.2105 0.089
C2 0.0393 0.031
C3 0.0093 0.011
iC4 0.0026 0.004
nC4 0.0029 0.004
iC5 0.0014 0.003
nC5 0.0012 0.002
nC6 0.0018 0.004
nC7 0.0072 0.019
H2O 0.005 0.002
Temperat ure (F) 86
Pressure (psia) 1000.0
* Concentrat ion of CO
2
in nat ural gas reserves in Malaysia [16]

1.1.1 3. Process Description
In this work, the CO
2
removal process in the off-shore
unit is developed based on counter current flow operation
to achieve optimum contact time between the natural gas
and aminated resin. The aminated resinwater mixture
enters the top of the adsorber and flows to the bottom
while the natural gas heavy in CO2 enters from the bottom
of the adsorber column. The treated natural gas leaves
from the top of the column while the exhausted aminated
resin-water mixture leaves the column from the bottom.
The exhausted resinwater mixture then is flowed into a
flash tank to remove the hydrocarbon components carried
over. The flashed overhead product containing the
hydrocarbons can be used as a fuel. To make the resin
ready for reuse a regeneration section using a distillation
column, which acts as CO2 stripping column, is used to
remove the adsorbed CO2 from the resin. Some water
vapor also removed together with the CO2 and water can
be separated from the mixture via condensation. Fig.2
shows the flow diagram of the off-shore unit for CO2
removal.

Sweet gas
Aminated resin-water
mixture
Sour Natural gas
Acid gas
Cond.Q
Reboiler.Q
Regenerator
Adsorber
Makeup
water
Regeneration
bottoms
Regeneration
feed
Flash vapor
Bottom products
Reflux
Pump Q
Flash tank
Cooler Q

Fi g.2. Flow di agram of the off-shore unit for CO2 removal [12]

Due to the slow reaction rate of MDEA with CO2, it is
necessary to use tray column to give more time for the
reaction to occur. Moreover, since the solid resin presents
in the towers the tray column is preferred for easier
cleaning. Heat stable salts [17] and other solid process

22

contaminants which might be accumulated over some
run times are assumed to be removed from the cycle by
filtration process as appropriate.
4. Chemical Reaction Analysis
Aminated resin is an amine functionalized resin in
which the active sites on the resin are amines capable of
capturing CO2. The amine group selected is
methyldethanolamine (MDEA) known for its bulk CO2
removal capacity. The tertiary amine, MDEA, has two
ethanol groups attached to the nitrogen atom along with a
methyl group [18]. Fig.3 illustrates the simple structures
of the aminated resin.
Resin
Active sites
N
..
HOCH2 CH2
HOCH2CH2
CH3
N
..
HOCH2 CH2
HOCH2CH2
CH3

Fi g.3. Simple structure of the Aminated Resin

Since the resin is functionalized with
methyldethanolamine, the resin itself is considered as a
simple inert solid. Hence, the reaction mechanis m of CO2
with the MDEA on the resins active sites is assumed to
be similar to CO2 with liquid MDEA. The reaction
mechanis m of CO2 with liquid MDEA is readily available
in various literatures [19] and [20].
Three overall react ions, given in equations 1-3 are
assumed to occur during the adsorption process. MDEA is
a tertiary amine and does not have hydrogen atom
attached to the nitrogen, thus the reaction with CO2 can
only occur after the CO2 dissolves in the water to form a
bicarbonate ion [21].
+
+ + H HCO O H CO
3 2 2

(1)
The bicarbonate ion format ion is slow and only occurs
in the liquid phase [20]. The bicarbonate ion then
involves in an acid-base reaction with the amine to yield
an overall CO2 adsorption reaction.
+
+ + +
3 2 2
HCO MDEAH MDEA O H CO (2)









Hence, the generalized equation governing the
reaction mechanism of CO2 with the aminated resin can
be summarized as follows:
+
+ + +
3 2 2
HCO MDEAH R MDEA R O H CO
(3)
where R represents the resin (Fig.3).

As H2S is among the contaminant gases in natural gas,
it also undergoes reaction with the MDEA on the resin
instantaneously with infinite reaction rate. In this work, its
concentration is assumed to be constant. The overall
reaction of H2S with the MDEA is summarized as
follows:
+
+ + HS MDEAH R MDEA R S H
2
(4)
The resulting anions from the overall reaction
equations 3 and 4 i.e.

3
HCO and

HS , would give off
CO2 and H2S when heated, respectively [22].
1.1.2
5. Process Simulation
In the simulat ion using iCON, the MDEA fluid
package that supports a simple inert solid is used.
Meanwhile, in HYSYS a generalized package for amines
called amine fluid package is used instead as the
simulator does not have a fluid package designed
explicit ly meant for MDEA.
The concentration of MDEA assumed is 38 wt% as
the tertiary amine, MDEA, is found to be efficient and
effective for CO2 removal between the concentration
range of 2050 wt% [23]. Another assumption made is
that the tray efficiency of the adsorption column is
assumed as 15% and 80% for CO
2
and H2S [24]
respectively. This is because H2S can instantly react with
MDEA, and CO2 reacts more slowly. The number of trays
for the adsorption column is assumed to be 20.
The simulations of the system implemented in ICON
and HYSYS process simulators are given in Figs.4 and 5,
respectively.

















SEPARATOR
SOUR_GAS
BOTTOMS_LIQUIDS
ADSORBER
MDEA_TO_CONT
GAS_TO_CONTACTOR
SWEET_GAS
FLASH_TANK
Vlv-1
RICH_MDEA
MDEA_TO_FLASH_TK
FLASH_VAP
DISTILLATION_COLUMN
M-1
MAKEUP_WATER
E-2
MDEA_TO_COOL
P-1
MDEA_TO_PUMP
ACID_GAS
M-2
MDEA_TO_RECY
MDEA_TO_CONTACTOR
RICH_TO_REGEN
REGEN_BTTMS

Fig.4. Simulati on model for the off-shore CO2 removal system using iCON process simulator.


23














Table 2. Mat erial balance for the off-shore CO2 removal syst em using Icon process simulator

Fi g.5. Simulation model the off-shore CO2removal system using HYSYS process simulator.
Table 3. Mat erial balance for the off-shore CO2 removal syst em using HYSYS process simulator

24

Based on simulations, the concentration of CO2 in
the treated natural gas stream labeled as sweet gas in
the process flow diagrams (Fig.4 and Fig.5) is predicted
to be 11.8 mol% and 14 mol% from iCON and HYSYS
models respectively i.e. less than 30 mol%.

6. Results and Discussion
The simulation models are next used to study effect of
some parameters on the CO2 removal performance. The
most important parameters for the design of CO
2
removal
system are the adsorbent circulation rate and its
concentration, temperature of the adsorbent and pressure
of the sour gas [12] and [24]. The effect of each
parameter is studied while holding all other process
variables constant. Moreover, the identification of best
operating parameters were done in a two

dimensional search i.e. not identifying the best
performance with respect to all parameters
simultaneously.

6.1 Effect of Resin Flow Rate
Fig.6 compares the CO2 removal performance for the
system at different adsorbent concentration of 38 wt%
MDEA and 48 wt% MDEA when increasing the MDEA
flow rate. A similar trend to Fig.6 was also reported [12]:
when the circulation rate is increased for any given
column, the CO2 adsorption increases in a column of
fixed diameter. Another observation is that high
concentration of MDEA favors the CO2 removal in the
developed unit. The higher the quantity of reactive amine
present, the higher the quantity of CO2 removed.



485.00, 0.24
605.00, 0.22
765.00, 0.21
485.00, 0.22
605.00, 0.21
765.00, 0.21
0.2
0.22
0.24
0.26
400 500 600 700 800
MDEA-resin flow rate [m
3
/hr]

C
O
2

m
a
s
s

f
r
a
c
t
i
o
n

i
n

S
w
e
e
t

G
a
s

38 wt% MDEA
48 wt% MDEA

Fi g.6. Effect of MDEA-resin flow rate on CO2 amount using 38
wt% and 48 wt% MDEA using HYSYS process simulator (T=35C
and P=6860.28 kPa)



550.00, 0.26
580.00, 0.29
370.00, 0.25
130.00, 0.24
40.00, 0.27
0.2
0.25
0.3
0.35
0 100 200 300 400 500 600
MDEA-resin Temperature [F]
C
O
2

m
a
s
s

f
r
a
c
t
i
o
n

i
n

S
w
e
e
t

G
a
s

Fig.7. Effect of the MDEA-resin t emperat ure on CO2 amount at 38
wt % MDEA using HYSYS process simulator
(P = 6860.283 kPa)
6.2 Effect of Temperature
Fig.7 shows the acid gas concentration in the sweet gas
in relation to the MDEA-resin temperature at 38 wt%
MDEA. Based on Fig.7, below 130 F, the increase in
temperature enhances CO2 removal in the system. This is
because high temperature improves the reaction kinetics
to a greater extent and less viscosity i.e. higher
diffusivity. However, beyond 130 F, the decrease in
solubility of the CO2 becomes the overriding factor
leading to less CO2 removal. A similar trend is also
reported in the work by [24] and [26]. Based on the trend
plotted in Fig.7 it can be concluded that the system
removes the highest amount of CO2 at 130 F.
6.3 Effect of Sour Gas Pressure
Fig.8 illustrates that both simulat ion models generate
similar trends of sour gas pressure effect on CO2 removal.
Up to 1500 kPa, the increase in pressure shows
insignificant effect on the CO2 adsorption capacity of the
aminated resin. That is because the CO2 reaction is driven
by kinetics and it is less affected by lowered pressure.
However, Fig.8 indicates that high pressure, more than
4500 kPa, enhances CO2 removal. This can be explained
as with the increase of pressure carbon dioxide seems to
interact stronger with the adsorbent [1].

7300.00, 0.21
4500.00, 0.21
1100.00, 0.20
1900.00, 0.25 1150.00, 0.24
0.2
0.22
0.24
0.26
0 1000 2000 3000 4000 5000 6000 7000 8000
Sour Gas Pressure [kPa]
C
O
2
M
a
s
s

F
r
a
c
t
i
o
n

i
n

S
w
e
e
t

G
a
s


Using ICON
Using HYSYS

Fig.8. Effect of the sour nat ural gas pressure on CO2 amount at 38 wt %
MDEA using HYSYS and ICON process simulat ors (T = 30C)


25

Deviation analysis for results for the effect of pressure
was performed using equations 5, 6 and 7 [27]. Table 4
shows the detail of the calculat ion.
2
1

|
|
.
|

\
|
=
=
N
i iCON
HYSYS iCON
x
x x
RSS

(5)
N
RSS
MRSS =

(6)
MRSS error Mean =

(7)

Table 4. Deviat ion bet ween the result s
D
ata
P
oint
P
(kP
a)
CO2 (wt %)
in treat ed gas
Deviat ion
HYS
YS
IC
ON
RS
S
M
RSS
Mean
error
1 100 0.24 0.2
05

0.1
05

0.0
35

0.187
2 130
0
0.24 0.2
06
3 190
0
0.25 0.2
11

The deviation is calculated as 18.7% (Table 4). Possible
factors contributing to the deviation include; one, the
different fluid packages used for simulat ion models and
two, the difference in the sour gas pressure used in the
simulations. Each simulat ion models developed for this
work has advantages and limitat ions as discussed in
Table 5.



Table 5. Observat ion on simulat ors performance during paramet ric
st udy

Paramet er
Simulat or
HYSYS ICON
Fluid
package
- Amine
fluid package
- MDEA
fluid package
Pressure - Simulator
converged for each
P att empted and
produced consist ent
result s
- However,
the simulator did not
converge for
P > 2000 kPa
-
Simulat or converged
for each P
attempt ed

Temperat
ure
- Simulator
converged for each
T attempt ed and
produced consist ent
-
Simulat or did not
converge for various
T att empted
result s
MDEA-
Resin
circulat ion
rat e
- Simulator
converged
-
Simulat ion did not
converge for various
t ries
7. Preliminary Cost Analysis
A preliminary cost analysis is performed to evaluate
economic potential level 1 of the system, given in
equation 8.
Economic Potential 1 = Profit from Product Cost of
Reactant
(8)
The calculation is performed based on the basis given
in Table 6. The price of the aminated resin is assumed to
be 40 % and 16 % higher than the price of the solvent
MDEA and a resin [28] and [29], respectively (Table 6).
A total of 330 operational days in a year is considered to
obtain the estimate for the economic potential level 1.

Table 6. Price of Raw mat erials and product s
Mat erial Price Amount
consumed/
produced
(m
3
/hr)
Tot al price
($ per year)
Aminat ed
resin
$0.70 per
lb
*


273


26,872,673
Wat er
$0.337 per
m
3 **

Nat ural gas $154.47 per
m
3 ***
206 252,020,89
4
*
The price for t he aminated resin is considered t o be 40 % and 16
% higher than the price of the react ant s i.e. solvent MDEA [28] and
Polyet hylene [29] respect ively, to produce the aminated resin
**
Industrial wat er t ariff for Terengganu as of 2008 is taken for t he
calculat ion [30]
***
http://www.indexmundi.com/commodit ies/?commodity=nat ural-
gas
The economic potential is calculated to RM
697,959,485 per year. The positive value indicates the
economic viability of the off-shore CO2 removal system.
8. Conclusion
In this paper the use of MDEA functionalized resin
based CO2 removal system for off-shore application was
investigated according to the two simulation models
created using iCON and HYSYS process simulators. The
features and capabilit ies of the simulat ion softwares are
also reported. From the simulat ion conducted, it was
observed that the increase in temperature of the MDEA-
resin of 38 wt% up to 130 F enhances the CO
2
removal
and the 130 F is spotted being the best operating
condition. Moreover, introducing the sour gas at a
pressure higher than 4.5 MPa is identified to bring better
performance to the system. Needless to say, the increase

26

in flow rate of the MDEA-resin improved the CO
2

removal performance of the unit as the quantity of
reactive amine present for CO
2
removal is high. Hence,
we concluded that the use of MDEA functionalized resin
is effective and economical for CO
2
removal for off-shore
application where the resin allows the amine to withs tand
high pressure. The work can further be improved by
considering heat integration to make the system more
energy efficient.

ACKNOWLEDGMENT
The authors are thankful to Universit i Teknologi
PETRONAS for providing research facilit ies to
accomplish the task.

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[30] www.span.gov.my/index.php?opt ion=com_cont ent&t ask=view&i
d=161&It emid=614