Agip IRAN – SOUTH PARS GAS FIELD

Iran BV PHASES 4 & 5

GROUP

DOC. N. PLANT :
2017 32 218 R SP SP 20013 ONSHORE FACILITIES
Snamprogetti DOC. N.
JOB. 308700 - DOC. N° 115-ZA-E-03013 DB 2017 115 P312 001

PROCESS DESIGN BASIS

FOR
BUTANE TREATMENT
(SULFREX process licensed by IFP)

2 Issue for EPC M. Poli P. Puzone F. Comodi 15/06/01

Reviewed by the Company’s
1 M. Poli P. Puzone F. Comodi 11/05/01
Representative on 08/05/01
0 IFE M. Poli P. Puzone F. Comodi 27/04/01
REV. REVISION BY CHKD APPR CLIENT DATE

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CONTENTS

1 INTRODUCTION...................................................................................................................... 4

1.1 GENERAL PROJECT DESCRIPTION .......................................................................................... 4

1.2 PURPOSE ............................................................................................................................. 4

2 PROCESS DESIGN SPECIFICATION..................................................................................... 5

2.1 GENERAL ............................................................................................................................. 5

2.2 PROCESS SELECTION: BUTANE TREATMENT UNIT: .................................................................. 5
2.3 PLANT CAPACITY - NUMBER OF TRAINS .................................................................................. 5
2.4 RAW BUTANE FEEDSTOCK CHARACTERISTICS ........................................................................ 6
2.5 TURNDOWN RATIOS .............................................................................................................. 7
2.6 PRODUCTS SPECIFICATIONS .................................................................................................. 8
2.6.1 Sweet Liquefied butane product .............................................................................. 8
2.6.2 By-Products ............................................................................................................... 8
2.7 UTILITIES / SITE CONDITIONS ................................................................................................. 9
2.7.1 Site conditions........................................................................................................... 9
2.7.2 Utilities ....................................................................................................................... 9
2.8 BATTERY LIMITS DEFINITIONS AND CONDITIONS .................................................................... 10
2.8.1 Battery limits definition........................................................................................... 10
2.8.2 Battery limits conditions......................................................................................... 11

3 DESIGN REQUIREMENTS.................................................................................................... 11

3.1 GENERAL ........................................................................................................................... 11

3.2 NUMBER OF TRAINS ............................................................................................................ 12
3.3 METALLURGY ..................................................................................................................... 12
3.4 UTILITIES, CHEMICALS AND CATALYSTS ............................................................................... 12
3.4.1 Utilities ..................................................................................................................... 12
3.4.2 Chemicals and catalysts ......................................................................................... 12
3.5 EQUIPMENT DESIGN REQUIREMENTS .................................................................................... 12
3.6 AVAILABILITY ..................................................................................................................... 13

4 PROCESS GUARANTEES.................................................................................................... 13

4.1 GENERAL ........................................................................................................................... 13

4.2 PERFORMANCES GUARANTEES............................................................................................ 13

5 NUMBERING ......................................................................................................................... 14

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6 REFERENCE DOCUMENTS ................................................................................................. 14

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1 INTRODUCTION

1.1 GENERAL PROJECT DESCRIPTION

Agip Iran BV is developing of the SOUTH PARS Phases 4 & 5 project for National Iranian Oil
Company (NIOC) in IRAN. This project includes offshore facilities (wells, platform and subsea
pipelines) and onshore facilities for the processing of the reservoir fluid.
The new Phases 4 & 5 onshore complex will be located on the Iranian coast of the Persian Gulf
near ASSALUYEH village (approximately 270 km South East of Bandar Busher).
The total capacity of the new Phases 4 & 5 onshore facilities is 2000 MMSCFD of reservoir fluid.
They will include all processing units, utilities, offsites and infrastructure necessary to produce
sales gas, gaseous ethane cut of petrochemical feedstock quality, commercial grade propane and
butane for export and stabilized condensate. The complex is fed by the reservoir fluid delivered to
the onshore plant via two multiphase sealines and consist in:
• Receiving facilities for HP separation of raw gas and condensate/water mixture
• Condensate stabilization producing stabilized condensate for storage and export and light ends
recycled in the HP gas system. One condensate Flashing unit normally not operated is
provided as a back-up of the stabilization facilities.
• Gas treatment facilities producing sales gas, gaseous ethane and NGL’s and consisting in :
• H2S removal from gas / CO2 partial removal from gas
• Dehydration, using molecular sieves technology
• Mercury guard
• Ethane extraction unit producing sales gas, gaseous ethane and NGL’s
• NGL fractionation facilities to produce gaseaous ethane and sour liquid butane and propane
• Gaseous ethane cut treatment for CO2 removal and drying for further export
• Propane and butane treatment for mercaptans removal and drying for further storage and
export
• Export gas compression to export pipeline pressure
• MEG regeneration and injection unit
• Sulphur recovery producing liquid sulphur for further solidification and export
• Utilities, offsites required for operation.

1.2 PURPOSE

This document covers the requirement of Butane Treatment of unit 115, which shall perform the
removal of mercaptans and sulfur compounds before water removal from the liquid propane cut.

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2 PROCESS DESIGN SPECIFICATION

2.1 GENERAL

The butane treatment and drying unit is processing the butane cut recovered in the NGL
fractionation unit to remove the sulfur compounds, mercaptans and water prior to sending the
propane cut to storage.
The butane feed contains mainly ethyl mercaptans as impurities. Maximum sulfur compounds and
mercaptans removal from the butane cut is necessary because the butane needs to comply with
commercial grade butane specification.

2.2 PROCESS SELECTION: BUTANE TREATMENT UNIT:

Extractive technology is required. The design is based on the use of a caustic soda wash process
with caustic soda regeneration by direct oxidation with air in the presence of a proprietary catalyst
(SULFREX process licensed by IFP).
Unit 115 produces Disulphide Oil (DSO) as a by-product. DSO is stored for further export to other
end external users

2.3 PLANT CAPACITY - NUMBER OF TRAINS

The total butane treatment design capacity in the plant is the capacity resulting from the processing
of 2000 MMscfd of reservoir fluid (dry basis).
The corresponding butane capacity is given in § 2.4, together with the feedstock composition.
This capacity is to be treated in 2 parallel identical trains each processing 50% of the total feed.
This corresponds to one butane treatment unit for two gas processing trains.

NGL FRACTIONATION BUTANE TREATMENT BUTANE DRYING

UNIT 107 UNIT 115 BY MOL SIEVE
TRAIN 1 TRAIN 1 UNIT 115 TRAIN 1

NGL FRACTIONATION BUTANE TREATMENT BUTANE DRYING

UNIT 107 UNIT 115 BY MOL SIEVE
TRAIN 2 TRAIN 2 UNIT 115 TRAIN 2

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2.4 RAW BUTANE FEEDSTOCK CHARACTERISTICS

• Table 2.1 provides the characteristics of the sour butane feedstock to the butane treatment Unit
at plant design capacity. The flowrate indicated is the design flowrate, and corresponds to the
total raw butane of the plant, from the two NGL fractionation units.
• The pressure required at the propane unit inlet B.L. has been determined by Engineer
according to the minimum margin required above bubble point at the inlet of butane storage of
the unit, for the maximum operating temperature reached in the process (40°C).

Table 2.1: Raw Butane treatment Unit Feedstock Characteristics Design Capacity (total from all gas
treatment trains)

DESIGN CASE
B.L. Conditions (operating)
• Pressure bar abs 14.1 (3)
• Temperature (°C) 40 (2)
RAW BUTANE DESIGN
FLOWRATE
• tons/h 52.7 (5)
• kmole/h 908
• 3
m /h @ T,P 96
Composition % liq vol % weight
H2S (4) Traces Traces
C3 1.4 1.2
IC4 38.0 37.0
NC4 58.5 59.2
IC5 0.9 0.9
NC5 0.3 0.4
C6+ Traces Traces
COS (4) Traces Traces
Methyl Mercaptan (1) 831 ppm 1258 ppm
Ethyl Mercaptan (1) 0.8 1.13
C3+ Mercaptans Traces Traces
Total 100.0 100.0
C4 Feed Molecular weight 58.1

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Notes:
1. Listed value is the normal content. The design sulphur content expressed as elemental sulfur in
feedstock is as follows:
• Methyl mercaptan: 840 ppm weight
• Ethyl Mercaptan: 8000 ppm weight
2. Butane feedstock inlet temperature takes into account upstream cooling with sea water in the upstream
unit 107 to ensure a caustic temperature of 40 °C within the butane treatment plant.
3. Downstream of the process control valve, at the inlet of unit 115.
4. H2S and COS content is less than 1 ppm weight.
5. The unit is to have a hydraulic margin to pass 10% additional flow.

2.5 TURNDOWN RATIOS

The design capacity of each butane treatment unit is 50% of the capacity defined in Table 2.1 (2
trains in parallel).
Concerning turndown Ratios, each one of the two butane treatment trains shall be designed to
operate at 40% of its normal capacity.
The regeneration section, common to Units 114 and 115, shall be designed in order to work
properly when only Unit 115 is in operation (Unit 114 is out of service) at turndown conditions.

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2.6 PRODUCTS SPECIFICATIONS

2.6.1 Sweet Liquefied butane product

The following specifications apply:

B.L. Conditions (operating)
• Pressure (bar abs) 11.3 (3)
• Temperature (°C)
Description Unit Specification Test method ASTM (2)
Specific gravity @ 60°F To be reported D 2598
Butane content %vol 95.0 min. D 2163
Vap. Pressure @ 100°F Psig 70 max. D 1267 or D 2598
Volatile residue: Pentane and %vol 2.0 max. D 2163 (1)
heavier
Corrosion Copper strip No. 1 strip D 1838
Sulphur content %wt 0.008 max D 1266 (Appendix 1) or D 5453 or
IP 103
Hydrogen sulphide Negative D 2420
Free water (4) None Visual
Notes:
1. When specifically requested in the nomination, results by D 1837 will also be provided.
2. The latest issues of the relevant test methods shall be used (including ASTM-IP joint methods wherever
issued).
3. The total unit pressure drop allowed is 3 bar.
4. The butane from the Sulfrex unit shall contain no free water. The downstream dehydration unit will
remove the water to meet the specification.

2.6.2 By-Products

The characteristics of the butane treating unit by-products (flowrate, composition, impurities
content, B.L. conditions, ...) shall be defined by the Process Licensor. Process Licensor to advise
on the recommended disposal of these by-products.
Ø Process Licensor to give the characteristics of spent caustic and recommend a way of treating
it.
Process Licensor to recommend the frequency and the amount of spent caustic to be removed.
Ø Process Licensor to give the characteristics of spent water.

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Ø The disulfides oil could be sent to storage or to another location (for spiking in crude oil for
example). Process Licensor to give the characteristics of the disulfides oil (NaOH content in
particular) and to specify a disulfide sand filter if required.
Ø Process Licensor to give the characteristics of spent air from the disulfides separator drum and
to specify disposal recommendations.

2.7 UTILITIES / SITE CONDITIONS

2.7.1 Site conditions

The detailed site conditions and utilities that are available in the “Basic Engineering Design Data
for Onshore Facilities” (B.E.D.D.) of the Project (see §6). Should these conditions be modified at a
later stage of the project, then EPC Contractor will be responsible for updating the Butane
Treatment Units design, subject to Process Licensor approval when deemed necessary.

2.7.2 Utilities

Further to the BEDD, some additional remarks concerning the main utilities are as follows
♦ LP saturated steam:
“Saturated” LP steam is slightly superheated to avoid condensing in the header. Pressure let-down
and desuperheating facilities, if required, are within the Butane Treatment Units battery limit.
♦ Plant air, Instrument air, nitrogen
Process Licensor to state the minimum characteristics (in particular required air pressure)
♦ Water distribution networks :
• Chilled Cooling Water (restricted to machinery cooling) : consumption to be minimised
• Sea water for cooling (supply and return) : consumption to be minimised.

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2.8 BATTERY LIMITS DEFINITIONS AND CONDITIONS

The following information is only related to Process battery limits, but does not include all utilities
streams battery limit conditions.

2.8.1 Battery limits definition

The main battery limits are listed in the following Table 2.8.1
The limits are normally after process control.

Table 2.8.1

BATTERY LIMIT DEFINITION

FEED / PRODUCTS
Butane feed Upstream Butane / Caustic exchanger (1)
Treated Butane Downstream Butane Sand Filter
SUPPLIES
Fresh Caustic Make-up caustic solution supply line B/L
Makeup water Make-up water supply line B/L
OTHER STREAMS
Disulfide Oil Downstream Disulfide Oil Sand Filter
Spent Caustic Downstream Spent Caustic Pump
Spent Water Downstream Caustic Settler and Sand Filter
Note
1. Control of butane feed is in the upstream units 107

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2.8.2 Battery limits conditions

The battery limit conditions are listed in the following Table 2.8.2
Table 2.8.2
TEMPERATURE ( °C ) PRESSURE ( barg )
FEED/PRODUCTS Operating Design Operating Design
C4 feed 40 (2) 85 (3) 13.3 24.0 (5)
Treated C4 (1) (1) 10.3 24.0 (5)
SUPPLIES
Fresh Caustic 40 75 23.5 24.0 (5)
Make-up water 60 85 (3) 23.5 24.0 (4)
OTHER STREAMS
Disulfide Oil (1) (1) 5.0 (1)
Spent Caustic (1) (1) 5.0 (1)
Spent Water (1) (1) (1) (1)
Notes
1. By Process Licensor.
2. Normal butane feedstock inlet temperature is 40°C.
3. Maximum temperature in the sunshine.
4. To be confirmed during detailed engineering
5. Pump shut off pressure to be confirmed during detailed engineering

3 DESIGN REQUIREMENTS

The following requirements must be taken into account for the design of the new Butane Treatment
Units.

3.1 GENERAL

The unit is to be designed to remove mercaptans and COS. Process Licensor is to recommend a
system that can meet the total sulphur specification without further treating.
The Process Licensor shall provide a design that meets the guaranteed statements as specified in
Chapter 4 (Process Guarantees).
The process flow diagram shall be optimized by the Process Licensor, in close cooperation with
the Engineering Contractor, with regards to process design, equipment constructibility,
transportation and erection as well as plant operation reliability and availability.
Process Licensor responsibility is limited to the items within the Butane Treatment Units Battery
Limit, taking, however, in consideration the general arrangement of the whole Plant.

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3.2 NUMBER OF TRAINS

The Butane Treatment Units to be implemented shall consist of two parallel and identical trains.

3.3 METALLURGY

The process licensor shall recommend the minimum materials of construction for equipment and
piping. Such recommendations shall be suitable for obtaining mechanical guarantees from
equipment suppliers. The metallurgy selection shall consider corrosive materials and a Plant
service life of 25 years.

3.4 UTILITIES, CHEMICALS AND CATALYSTS

3.4.1 Utilities

Ø Process Licensor to specify the consumption of make-up water for butane water wash. Process
condensate of steam condensate quality will be used.

3.4.2 Chemicals and catalysts

Ø Process Licensor to specify the type of catalyst to be used, the consumption and the frequency
of catalyst injection, the capacity of the catalyst addition pot and the initial fill.
Ø In-line fresh caustic solution tank shall be provided outside the unit for working inventory.
Process Licensor to specify the required concentration of the caustic solution and to
recommend the capacity of this tank and specify the initial fill, the consumption and the
frequency of fresh caustic injection.

3.5 EQUIPMENT DESIGN REQUIREMENTS

Ø Process Licensor to recommend the type of internal for the Butane Extractor: trays or packing
and the requirement for wire mesh for coalescence.
Ø Process Licensor to specify the Lean Caustic Cooler.
Ø The sweet butane is sent to the Settler Drum, Process Licensor to specify the requirement for a
wire mesh or specific coalescing internals
Ø Process Licensor to evaluate the requirement for an additional high performance coalescer
downstream Butane Sand Filter, to achieve the 1000 ppmwt total water content specification.
Ø Process Licensor to recommend the type of internals for the Oxidation Column: trays or
packing
Air compression facilities for butane treatment unit : process air supply shall be specified by
Process Licensor. These compression facilities shall consist of one air compression package

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that will be common to both propane and butane treatment trains. The package will include two
compressors, one operating, one spare.
Ø Process Licensor to optimize the location of the caustic make-up and catalyst injection.
Ø Spent caustic is sent to the waste caustic treatment. Process Licensor to specify a spent
caustic degassing drum and pump to export spent caustic.
Ø The disulfides oil are sent to the Disulfides separator, Process Licensor to recommend the type
of internals and the type and quantity of chemicals if any used to improve separation.
Ø Process Licensor to recommend the equipment and piping design margins, suitable for
mechanical performance guarantee by the equipment vendor. However, the design margin
shall not be lower than the specified margins that are defined in the Process Sizing Criteria of
the Project .

3.6 AVAILABILITY

The unit shall be designed in order to have 95% availability, including time for maintenance.

4 PROCESS GUARANTEES

4.1 GENERAL

The performances shall be guaranteed under the following conditions:

Ø Raw butane Feedstock composition and conditions within the range defined in Table 2.1.
Ø Unit engineered and erected according to the Process Licensor recommendations as provided
in the propane Treatment Units Process Design Package and the Operating Guidelines
Ø Unit under stable and normal operation according to the Process Licensor recommendations
as provided in the butane Treatment Units Process Design Package and the Operating
Guidelines.

4.2 PERFORMANCES GUARANTEES

The performance guarantees for the Butane Treatment Units shall be as detailed in Appendix I to
Process License Agreement (Technology Transfer Agreement No 00/…).
As preliminary figures, the package will be designed in order to meet the following process
guarantees (feedstock characteristics as shown in Table 2.1).
The licensor shall guarantee the following for each phase:
♦ Design capacity: 27 t/h of raw butane feed (for one phase)
Turndown capacity: 10.8 t/h of raw butane feed (for one phase)
♦ For the whole range of operating cases:
Sulphur content: 0.008 %wt max

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Hydrogen sulphide: negative

Moisture content: The butane shall contain no free water
♦ Utility requirements:
Make-up water consumption: To be defined by Licensor
Caustic solution: To be defined by Licensor
Type of catalyst: To be defined by Licensor
Max. power consumption: To be defined by Licensor

5 NUMBERING

Equipment designation is available in “Equipment and Engineering Documents Identification and

Numbering” of the project (see § 6).

6 REFERENCE DOCUMENTS

Basic Engineering Design Data for

Onshore Facilities: Doc N° DB 2017 999 P332 204
Process Sizing Criteria Doc N° DB 2017 999 P312 205
Equipment and Engineering Documents
Identification and Numbering Doc N° DB 2017 999 P332 201
Design Basis for PID Development: Doc N° DB 2017 999 P312 203

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