Natural Gas Treatement

Libya
Abdul Karim, Ahmed, Gaddafi, Hamad and Ali

Ministry of Higher Education
Bright Star University – Braga

Faculty Of Technical Engineering
Department of Chemical Engineering
NATURAL GAS TREATEMENT

By
Abdul Karim Abdullah Mohammed 21152887
Ahmed Abdel Qader Mesbah 21142385
qadhafi faraj alqadhdhafii 21142271
Hamad Abdul Salam Ibrahim 21152918
Ali Said Hamad 10165
Supervised By
Dr. Abdel Hamid El Masry
2018-2019
DEGREE OF BACHELOR IN CHEMICAL ENGINEERING

FACULTY OF TECHNICAL ENGINEERING
2018-2019
NATURAL GAS TREATEMENT
By
Abdul Karim Abdullah Mohammed 21152887
Ahmed Abdel Qader Mesbah 21142385
Qadhafi Faraj Alqadhdhafii 21142271
Hamad Abdul Salam Ibrahim 21152918
Ali Said Hamad 10165
Supervised
Project Report Submitted as Partial Fulfillment of the Requirements for the

Degree of Bachelor in Chemical Engineering
2018-2019
i
ABSTRACT
This study was conducted at the SAHL gas plant, where glycol dehydration is used to remove
wet gas from the SAHL Field. In the SAHL glycol - dehydration Unit, Triethylene glycol
(TEG) is used as dehydrating agent. The produced wet gas, from this field is dehydrated
(removal of h2o) by a continues circulation of TEG, in the glycol absorber. The saturated
glycol passes through gas stripper, which regenerates lean glycol for further use in the system.
Tri Ethylene Glycol has been chosen as hydrate inhibitor because of its low volatility, low
toxicity, low flammability, good thermodynamic behavior, and simple proven technology
requirement and availability. But it has common characteristic problem is glycol losses due to
carryover with dehydrated gas and which finally accumulates in pipelines and causes
corrosion.
This paper presents an experimental study of glycol losses. Effort has been made to
investigate the causes and the study suggests some mitigation plans. Current study suggests
the efficiency of the dehydration process depends on a large extent on the cleanliness of the
glycol. Vaporization from reboiler can be minimized by adjusting operating parameters. By
developing monitoring procedure and periodic maintenance, about 90% operating problems of
Glycol Regeneration Plant can be reduced.
Keywords: Glycol Regeneration, glycol loss, and natural gas dehydration
ii
ACKNOWLEDGEMENTS
I give all the love, appreciation and respect to the leading Engineering University of Brega in
the field of chemical engineering, which gave me the opportunity to study in many
engineering departments and all who contributed to the foundation of this university. We
would like to thank all those who contributed to the formation of this university and would
like to thank Dr. Abdul Hamid Al-Masri, who contributed to this pregnancy. We would also
like to thank everyone who helped us from our family, friends and relatives.
iii
APPROVAL
This project report is submitted to the Faculty of Engineering, University of Brega, and has
been accepted as partial fulfillment of the requirement for the degree of bachelor in
Metallurgical and Materials/Petroleum/Civil / Chemical Engineering. The members of the
Examination Committee are as follows:
________________________________________
Supervisor
Chemical Engineering
Faculty of Engineering
____________________________________________
Examiner 1
The examiner name
____________________________________________
Examiner 2
The examiner name
iv
DECLARATION
I hereby declare that the project report is my original work except for quotations and
citations, which have been duly acknowledged. I also declare that it has not been previously,
and is not concurrently, submitted for any other degree at University of Brega or at any other
institution.
Names Signatures
Abdul Karim Abdullah Mohammed 21152887 ‫ـــــــــــــــــــــــــــــــ‬
Ahmed Abdel Qader Mesbah 21142385 ‫ـــــــــــــــــــــــــــــــ‬
Qadhafi Faraj Alqadhdhafii 21142271 ‫ـــــــــــــــــــــــــــــــ‬
Hamad Abdul Salam Ibrahim 21152918 ‫ـــــــــــــــــــــــــــــــ‬
Ali Said Hamad 10165 ‫ـــــــــــــــــــــــــــــــ‬
Date:
v
TABLE OF CONTENTS
ABSTRACT ............................................................................................................................. ii
ACKNOWLEDGEMENTS .................................................................................................. iii
APPROVAL ........................................................................................................................... iv
DECLARATION .................................................................................................................... v
TABLE OF CONTENTS ...................................................................................................... vi
LIST OF FIGURES .................................................................................................................. x
NOMENCLATURES ............................................................................................................. xii
CHAPTER 1 ............................................................................................................................ 1
1. INTRODUCTION .............................................................................................................. 1
1.1Background .......................................................................................................................... 1
1.1.1production manifold ................................................................................................................. 2
1.1.2gas treatments separations ........................................................................................................ 2
1.1.3acid gases absorption:............................................................................................................... 2
1.1.4gas dehydration ........................................................................................................................ 3
1.2 Principles of Dehydration ................................................................................................... 4
1.3 Problem Statement .............................................................................................................. 5

1.3.1 glycol losing problem .............................................................................................................. 5
1.4 Objectives; - ........................................................................................................................ 5
CHAPTER 2 ............................................................................................................................ 7
vi
2. LITERATUREREVIEW ................................................................................................... 7
2.1 Process Simulation of Glycol Regeneration. May 2002. .................................................... 7
2.2 Design of A TEG Dehydration Train Model Using the Glycol Property Package in
HYSYS. May 2013. .................................................................................................................. 7
2.3 Natural Gas Dehydration Process Simulation and Optimization: A Case Study of
Khurmala Field in Iraqi Kurdistan Region R. Abdulrahman and I. Sebastine. June 2013. ...... 8
2.4Improvement of Natural Gas Dehydration Performance by Optimization of Operating

Conditions: A Case Study in Sarkhun Gas. November 2013. .................................................. 8
2.5 Natural Gas Dehydration Process Simulation and Optimization: A Case Study of
Khurmala Field in Iraqi Kurdistan Region. R. Abdulrahman and I. Sebastine 1, January 2014.
.................................................................................................................................................. 9
2.6 Natural Gas Dehydration Using Triethylene Glycol (TEG) C.I.C. Anyadiegwu, Anthony
Kerunwa, Patrick Oviawele. July 28, 2014............................................................................... 9
2.7 Michal Netušil and Pavel Ditl .08 October 2015. ............................................................. 10
CHAPTER 3 .......................................................................................................................... 11
3. METHODOLOGY ........................................................................................................... 11
3.1Types of Dehydration of Natural Gas. ............................................................................... 11
3.2 Dehydration by Using Triethylene Glycol (TEG). ........................................................... 13
3.3 Dehydration Unit. ............................................................................................................. 14
3.4. Process Flow and Components. ....................................................................................... 14

3.4.1 components............................................................................................................................ 14
3.4.2 Process Flow Description .............................................................................................. 26
3.5 Factors Which Affect the Efficiency of a Glycol Dehydration System............................ 30

3.5.1 inlet gas temperature ............................................................................................................. 30
3.5.2 Inlet Gas Pressure .................................................................................................................. 31
3.5.3 Contactor Pressure: ............................................................................................................... 31
3.5.4 gas flow rate: ......................................................................................................................... 31
3.5.5 inlet glycol temperature:........................................................................................................ 31
vii
3.5.6 Glycol Circulation Rate:........................................................................................................ 32
3.6 Operating Problems and Glycol Care: .............................................................................. 32

3.6.1 glycol loss.............................................................................................................................. 32
3.6.2 typical locations for glycol losses ......................................................................................... 33
3.6.3 Conditions affecting glycol losses include -.......................................................................... 33
CHAPTER 4 .......................................................................................................................... 34
4. MATERIAL AND ENERGY BALANCE ...................................................................... 34
4.1 Fundamentals of Material Balances .................................................................................. 34
4.2 Fundamentals of energy balance ....................................................................................... 34
4.3 Material and energy balance by HYSYS .......................................................................... 35

4.3.1 simulation basis manager ...................................................................................................... 35
CHAPTER 5 .......................................................................................................................... 42
5. RESULTS AND DISCUSSION ....................................................................................... 42
5.1 Operation of the Reboiler: ................................................................................................ 43
CHAPTER 6 .......................................................................................................................... 46
6. CONCLUSIONS ANDRECOMMENDATIONS........................................................... 46
6.1 Conclusions ....................................................................................................................... 46
6.2 Recommendations ............................................................................................................. 46
CHAPTER 7 .......................................................................................................................... 48
7. SAFETY ............................................................................................................................. 48
viii
1. Identification and assessment of the hazards ................................................................. 48
2. Control the hazard for example, by containment of flammable and toxic materials. ... 48
3. Control 'of the process. Prevention of hazards deviations in' process variables (pressure,
temperature, flow), by provision of automatic control systems, interlocks, alarms, trips;
together with good operating practices and' management. ..................................................... 48
4. Limitation Of the loss. The damage MIA injury caused if an incident occurs: pressure
relief, plant layout, provision of fire-fighting equipment. ...................................................... 48
7.1 Pressure systems ............................................................................................................... 49
7.3 Control of Toxic Materials ............................................................................................... 50
7.4 Flammability ..................................................................................................................... 51
7.6 Auloignition temperature .................................................................................................. 51
7.7 Flammability 'limits .......................................................................................................... 51
7.8Explosions .......................................................................................................................... 51
7.9. Sources of Ignition ........................................................................................................... 52
7.10 Electrical Equipment ....................................................................................................... 52
7.11 Static-Electricity .............................................................................................................. 52
7.12 Miscellaneous Sources .................................................................................................... 52
7.13 pressure ........................................................................................................................... 53
7.14 Temperature deviations ................................................................................................... 53
7.15 Types of Protection Equipment ....................................................................................... 54

7.15.1 Work Clothing ..................................................................................................................... 54
7.15.2 HEAD PROTECTION ........................................................................................................ 54
7.15.3 HARD HAT ........................................................................................................................ 54
7.15.4 Face Protection ........................................................................................................... 55
REFERENCES...................................................................................................................... 59
ix
LIST OF FIGURES
Figure 1.1 location of Sahl filed ............................................................................................................... 2
Figure 3.1 Basic Glycol Dehydration Unit............................................................................................ 15
Figure 3.2 Tray Contactor Columns ...................................................................................................... 16
Figure 3.3 schematic flow diagram of a typical glycol contact tower.................................................... 17
Figure3.4 Tray with Bubble Caps .......................................................................................................... 18
Figure 3.5 Mist Eliminators ................................................................................................................... 19
Figure 3.6 Gas-Condensate-Glycol Separators ...................................................................................... 20
Figure 3.7 Regenerators ......................................................................................................................... 22
Figure 3.8 Surge Tank ............................................................................................................................ 24
Figure 3.9 Glycol/ Gas Heat Exchanger................................................................................................ 25
Figure 3.10 Glycol/Glycol Heat Exchangers ........................................................................................ 26
Figure 3.11 Contactor Column ............................................................................................................... 27
Figure 3.12 Gas-Condensate-Glycol Separator ...................................................................................... 28
Figure 3.13 Still Column ........................................................................................................................ 29
Figure 3.14 Overflow Tube ................................................................................................................... 30
Figure 4.1 acid gas sweetening with DEA ............................................................................................. 36
Figure 4.2 acid gas sweetening ............................................................................................................. 36
Figure 4.3 MATERIAL BALANCE FOR ACID GAS SWEETENTNING ........................................ 37
Figure 4.4 ENERGY BALANCE FOR ACID GAS SWEETENING ................................................... 37
Figure 4.5 STREAM DATE.................................................................................................................. 38
Figure 4.6 stream data ........................................................................................................................... 39
Figure 4.7 stream date ............................................................................................................................ 39
Figure 4.8 stream data ............................................................................................................................ 40
Figure 4.9 stream date ............................................................................................................................ 40
x
Figure 3.10 stream date .......................................................................................................................... 41
Figure 3.11 stream date .......................................................................................................................... 41
Figure 5.1 Reboiler................................................................................................................................. 42
Figure 7.1 indicate Hard Hat helmet ...................................................................................................... 54
Figure 7.2 Full-Face Splash Shield ....................................................................................................... 54
Figure 7.3 WELDERS SHIELD ............................................................................................................ 56
Figure 7.4 SAFETYGLASSES (Complete with side shields) .............................................................. 57
Figure 7.5 CHEMICAL GOGGLES ...................................................................................................... 57
xi
NOMENCLATURES
Symbol Description Unit
H2S Hydrogen Sulfide
Co2 Carbon Dioxide
H2O Water
MDEA methyl di-ethanol amine
CH4 Methane
Al2O3 aluminum oxide
SiO2 silicon dioxide
TEG Triethylene Glycol
EG ethylene glycol
DEG diethylene glycol
TREG tetra ethylene glycol
MEG monoethylene glycol
Gas-Condensate-Glycol
G-C-G
Separator
xii
1. INTRODUCTION
1.1Background
The Sirte Oil Company, on behalf of the National Oil Company of Libya, has installed a gas
plant including a dehydration unit, for processing and purifying the gas produced from the
ALSAHL gas wells. The SAHL field locates (stands) in the northern east of Breagah seaport
about 120 km far away, in concession”6”. In 1962 first well was drilled (o-1) and in 1982 is
being developed. In 1988 finished well completion and testing. So that in 2003 reached to 14
wells SAHL gas plant SAHL contains 14 gas wells, gas companied with impurities such as:
 Hydrogen Sulfide H2S.

 Carbon Dioxide Co2.
 Water H2O.
 Hydrocarbons -condensed gases.
SAHL plant has two units -trains- the capacity of each train 75mmscf/d SAHL gas plant is
Amine sweetening plant, designed to remove acid gases from the gas by MDEA (methyl di-
ethanol amine) An oil or gas contains h2s known as “sour” (h2s&co2), h2s is deadly-gas,
small quantity of h2s in the atmosphere(1,000ppm) is enough to knock a victim unconscious
and to cause death if rescue doesn’t take place quickly, however, they’re very corrosive in
present of water. SAHL plant consists of Amine Regeneration Unit to regenerate amine for
reusing.
Glycol Dehydration Unit Evaporate water from Glycol to be used again. Heating Medium
System (hot oil system). Oil heaters to heat oil up to limited temp, to boil amine and glycol by
using special heat transfer fluid (thermiol sp oil).Condensate System to remove sour gases
from accumulated condensate from separators by heating up and use sweet gas to bubble the
condensate and release h2s. Fuel Gas System certainly, would be sweet gas otherwise, there
must be problems and corrosion in the equipment's anyway, fuel gas is multiuse in Sahl gas
plant as following:
1
 Fuel gas: - to feed heaters power generator, etc.
 Blanket gas: in storage and surge tanks to prevent contact with oxygen.
 Purging gas: to purge oxygen, carbon monoxide and carbon dioxide in many cases.
 Stripping gas: to bubble liquids and strip gases to liberate them.
 Starting gas: Used as staring for Power Turbine Generator.
 Pilot gas: to make flame as in flare and oil heaters.
Figure 1.1 location of Sahl filed
1.1.1production manifold
All wells collected in the manifold where can be controlled increase, decrease by choke valve
or shut off by ball block valves.
1.1.2gas treatments separations
Gas is being separated in two stages.

A. Production separator: gas mostly separated of condensate and water.
B. Gas scrubber: gas released of remained water and condensate.
1.1.3acid gases absorption:
In the amine absorber. Amine picks up h2s and quantity of co2.
2
1.1.4gas dehydration
In the glycol contactor, glycol removes water from gas, to eliminate corrosion in the pipeline.
In order to prevent corrosion, SAHL inject corrosion inhibitor chemical in regular rate, which
form thin film inside pipeline. Today, natural gas is one of the most important fuels in our life
and one of the principle sources of energy for many of our day-to-day needs and activities. It
is important factor for the development of countries that have strong economies because its
source of energy for household, industrial and commercial use, as well as to generate
electricity. Natural gas, in itself, might be considered a very uninteresting gas - it is colorless,
shapeless, and odorless in its pure form, but it is one of the cleanest, safest, and most useful of
all energy sources. Natural gas is a gaseous fossil fuel. Fossil fuels are essentially, the remains
of plants, animals, and microorganisms that lived millions and millions of years ago.
It consisting primarily of methane but including significant quantities of ethane, propane,

butane, and pentane. Methane is a molecule made up of one carbon atom and four hydrogen
atoms, and is referred to as CH4. Natural gas is considered 'dry' when it is almost pure
methane, having had most of the other commonly associated hydrocarbons removed. When
other hydrocarbons are present, the natural gas is 'wet'. The natural gas used by consumers is
composed almost entirely of methane. However, natural gas found at the wellhead, although
still composed primarily of methane, is by no means as pure. Raw natural gas comes from
three types of wells: oil wells, gas wells, and condensate wells.
Natural gas that comes from oil wells is typically termed 'associated gas'. This gas can exist
separate from oil in the formation (free gas), or dissolved in the crude oil (dissolved gas).
Natural gas from gas and condensate wells, in which there is little or no crude oil, is termed
non-associated gas. Gas wells typically produce raw natural gas by itself, while condensate
wells produce free natural gas along with a semi-liquid hydrocarbon condensate. Whatever the
source of the natural gas, once separated from crude oil it commonly exists in raw natural gas
or sour gas .The raw natural gas contains water vapor, hydrogen sulfide (H2S), carbon
dioxide, helium, nitrogen, and other compounds .In order to meet the requirements for a clean,
dry, wholly gaseous fuel suitable for transmission through pipelines and distribution for
burning by end users, the gas must go through several stages of processing, including
3
The removal of entrained liquids from the gas, followed by drying to reduce water content. In
order to remove water content, dehydration process is used to treat the natural gas.
Dehydration is the removal of water from an object. In Physiologic terms, it entails a relative
deficiency of water molecules in relation to other dissolved solutes. Gas dehydration is one of
the most prominent unit operations in the natural gas industry.
In this operation water, content is removed from natural gas streams to meet sales
specifications or other downstream gas processes such as gas liquid recovery. In particular,
water content level in natural gas must be maintained below a certain threshold so as to
prevent hydrate formation and minimize corrosion in transmission pipelines. The lifetime of a
pipeline is governed by the rate at which corrosion occurs which is directly linked with
presented of water content in gas that causing the formation of hydrates can reduce pipeline
flow capacities, even leading to blockages, and potential damage to process filters, valves and
compressors. That may have prevented by lowered the content of water in natural gas and all
at once save maintenance cost of pipeline.
The types of dehydration process used are absorption, adsorption, gas permeation and
refrigeration. The most widely dehydration processes used are which usually involves one of
two processes: either absorption, or adsorption. Absorption occurs when the water vapor is
taken out by a dehydrating agent. Adsorption occurs when the water vapor is condensed and
collected on the surface. In order to remove these impurities; the processes used in
dehydration are ABSORPTION or ADSORPTION'. [AHM_09]
1.2 Principles of Dehydration

There are two main principles, which are used, in raw gas dehydration these are classified as
follows: -
Absorption: -Absorption dehydration involves the use of a liquid desiccant to remove water
vapor from the gas.
The liquid that is most desirable to use for commercial dehydration purposes should possess
the following properties:
 High absorption efficiency.
 Easy and economic regeneration.
4
 Non-corrosive and non-toxic.
 No operational problems when used in high concentrations.
 No interaction with the hydrocarbon portion of the gas, and no contamination by acid
gases.
Adsorption: - Adsorption is the ability of some solids to hold on the surface of its molecules,
molecules of other substances - Solids, Liquids or Gases In this discussion; we will be dealing
with the process of ' The Dehydration of Natural Gas by Glycol.
1.3 Problem Statement

1.3.1 glycol losing problem
The physical loss of glycol is probably the most important operating problem in the
dehydration system. Most dehydration units are designed for a loss of less than 0.10 gallons of
glycol per million cubic feet of natural gas treated. However, if the system is not operated
properly, the loss might be much higher than this. The glycol contactor (the absorber) and
glycol regenerator are the most common places in the dehydration system where about 90% of
glycol loss occurs. High gas velocity through the glycol contactor will cause carryover of
glycol into the pipeline, and a poor mist eliminator (mist extractor) in the top of the glycol
contactor will pass some glycol even at normal gas velocities.
The glycol losses occurring in the glycol regenerator are usually caused by excessive
reboiler temperature, which causes vaporization or thermal decomposition of glycol (TEG).
Also, excessive top temperature in the still column allows vaporized glycol to escape from the
still column to atmosphere with the water vapor.
1.4 Objectives; -
This study was carried out for finding the causes of glycol loss problem, observed in the
dehydration Plant and to find a permanent solution of this problem, important for smooth
operation of this Plant
At designed performance. The main objectives of this study are outlined below:
5
 Analyzing the basic process of gas dehydration using Triethylene Glycol.
 Studying glycol regeneration process as well as examining the causes of associated glycol
loss during the regeneration process with possible solutions proffered.
 To study the losing characteristics of lean glycol, out-coming from regeneration system.
 To Search for ways and means to enhance the quality of lean glycol necessary for
improving dehydration efficiency.
6
CHAPTER 2
2. LITERATUREREVIEW
2.1 Process Simulation of Glycol Regeneration. May 2002.

Models for the most used glycol regeneration processes have been developed in the process
simulation program HYSYS with the Peng Robinson equation of state. The models can also
be implemented in other process simulation programs and with other vapor/liquid equilibrium
models. Parameters in the models have been adjusted to simulate actual regeneration plant
performance. The models have been used to evaluate alternative regeneration processes.
[Gas -11].
2.2 Design of A TEG Dehydration Train Model Using the Glycol Property
Package in HYSYS. May 2013.
With the help of HYSYS simulation it can be concluded that the water content in natural gas
can be reduced with the help of TEG with high purity content, the simulation also showed that
TEG purity can be increased to about 99.9%wt with the help of the cold finger unit and
stripping gas injection in the reboiler. Peng-Robinson (PR) equation of state (EOS) is
commonly used and mentioned in the oil and gas industry, while the glycol package is only
discussed in relation with HYSYS, keeping in mind the glycol package is not an EOS,
however uses TST EOS. PR EOS is better in predicting the volume of hydrocarbons in a
separation train with oil and gas. The glycol package shows a more ideal behavior when
compared with PR EOS. Due to the low water content in the composition, the project focus on
water removal almost seems unnecessary. However, using the simulation, it shows that it was
possible to remove even more water. The results obtained by using HYSYS for simulating
shows the additional water removal by the use of a TEG regeneration train. This in turn gave a
better process understanding which can be related to real world situations. The entire project
has been an educational experience that allowed out of box thinking along with providing a
real-world aspect to how business projects are conducted. [FIT-87]
7
2.3 Natural Gas Dehydration Process Simulation and Optimization: A Case
Study of Khurmala Field in Iraqi Kurdistan Region R. Abdulrahman and I.
Sebastine. June 2013.
In conclusion, this work-study is achieved Khurmala gas dehydration process simulate and
optimization s by using Aspen HYSYS. It can argue that Khurmala wet gas content some
quintets of water vapor, which it may lead to sever technical problems such as hydrate
formation and pipeline corrosion. However, this problem could solve by installing gas
dehydration unit for Khurmala gas plant. Moreover, simulation work achieved high water
removal. It could be argued that using TEG glycol at 4000 kg/hr. circulation rate can achieve
good gas removal. However, TEG poses high HCs losses for glycol generator at mentioned
circulation rate. Therefore, reducing TEG circulation rate or using DEG at 3500 kg/hr. is also
achieve acceptable water removal result and low HCs losses rate. However, the most
appropriate selection may be taken by the process designers and the process operators.
[Gas -98].
2.4Improvement of Natural Gas Dehydration Performance by Optimization
of Operating Conditions: A Case Study in Sarkhun Gas. November 2013.
In this study, the natural gas dehydration process of the Sarkhun gas plant was simulated by
steady state simulation software and the optimum separation temperature was determined.
According to the simulation results, in order to improve processes performance, the glycol
concentration should be increased from 85% to 92% and also the glycol flow rate should be
increased to 4 m3/h. The experimental results indicated that by these modifications, the water
dew point improved well from 10 C to 26 C and as a result, hydrate formation was prevented.
Thus, the LPG production rate increased from 145 m3/day to more than 160 m3/day.
Moreover, approximately $500 million annual cost saving was observed, dominated by
bringing the product gas into specification for sales. Furthermore, the following modifications
were recognized: Increasing the injection pressure from 75 bars to 80 bars. U Increasing the
glycol concentration from 82 to 92 weight %. U Modifying the glycol injection location from
gasegas heat exchanger to propane chiller. By applying above modifications in Sarkhun, gas
8
refinery. The water dew point temperature decreased well to 26 C. One of the outstanding
achievements of this research was a considerable decrease in greenhouse gas emission to the
atmosphere, mainly due to a remarkable decrease in exchanging of filter elements,
consumption rate of activated carbon, gas burning in flare and fouling in exchangers of glycol
regeneration unit. [NET -11]
2.5 Natural Gas Dehydration Process Simulation and Optimization: A Case

Study of Khurmala Field in Iraqi Kurdistan Region. R. Abdulrahman and
I. Sebastine 1, January 2014.
In conclusion, this study is achieved Khurmala gas dehydration process simulation and
optimization by using Aspen HYSYS It can argue that Khurmala wet gas content some
quintets of water vapor, which may lead to sever technical problems for instance, hydrate
formation and pipeline corrosion. However, this problem could be solved by designing &
installing gas dehydration unit for Khurmala gas plant. Moreover, simulation work achieved
high water removal. It could be argued that using TEG glycol at 4000 kg/hr. circulation rate
can achieve excellent drying results. However, the adopting of high TEG circulation rate may
lead to increase the process operation cost & TEG losses as well. Therefore, the using of TEG
circulation rate about 2000 Kg/hr. could archive acceptable drying results. [BET -07]
2.6 Natural Gas Dehydration Using Triethylene Glycol (TEG) C.I.C.

Anyadiegwu, Anthony Kerunwa, Patrick Oviawele. July 28, 2014.
Natural gas is usually saturated with water from the reservoir, removing this water is a major
task for the process engineers. Natural gas facilities are designed to handle water removal
from the gas stream to meet pipeline specification of water content in the processed gas
stream. With the use of HYSYS software, natural gas dehydration plant was designed; process
conditions and compositions were inputted and simulated. Results obtained show that water
content in natural gas stream from reservoirs can be reduced to the pipeline specification limit.
However, different water contents in the processed gas stream were obtained for different
flow rates of TEG. For the purpose of running the plant economically, the minimum flow rate
of TEG which will reduce the water content to within the limit of pipeline specification, is
very important and the result obtained showed that a minimum of 3.5m3/h of TEG is required
9
to reduce the water content of a gas stream of 10MMSCFD to 6.8lb/MMSCFD, which is
within the limit of 6-7lb/MMSCFD, this value when compare to OVP gas plant which uses
15m3/h for the gas stream of 10MMSCFD to achieve the same water content specification is
far lower. Values below this flow rate (3.5m3/h) may not reduce the water content to the
specified limit. This will pose threat to process facilities because of hydrate formation and
cannot be tolerated when transporting the gas to a region of low temperature. From the result,
the company can run OVP gas plant more economically with a TEG flow rate of 3.5m3/h or
slightly above that. [Ma Q -10].
2.7 Michal Netušil and Pavel Ditl .08 October 2015.
The chapter should help in the selection of a proper dehydration method and in calculating NG
dehydration. The following methods are available as options: absorption, adsorption 20
Natural Gas – Extraction to End Use and condensation. Absorption is used in cases when
emphasis is not placed on the water content of the output stream, and when low operating and
capital investment are required. Adsorption is used in cases when bone dry NG is required.
Low temperature separation employing the JT effect is used in cases where a sufficient
pressure drop is available between the input and the output of the dehydration unit. Supersonic
nozzles are a promising method that will in future displace these three conventional methods.
We have selected for citation here articles and procedures that we consider to provide reliable
results. [TOT-99].
10
CHAPTER 3
3. METHODOLOGY
3.1Types of Dehydration of Natural Gas.
Dehydration of natural gas is the process removal of the water that is associated with natural
gases. The natural gas industry has recognized that dehydration is necessary to ensure smooth
operation of gas transmission lines. Several methods have been developed to dehydrate gases
on an industrial scale. The four major methods of dehydration are absorption, adsorption, gas
permeation and refrigeration. Absorption dehydration involves the use of a liquid desiccant to
remove water content from the gas. Although many liquids possess the ability to absorb water
content from gas, the liquid that is most desirable to use for commercial.
Adsorption (or solid bed) dehydration is the process where a solid desiccant is used for the
removal of water content from a gas stream. The solid desiccants commonly used for gas
dehydration are those that can be regenerated and, consequently, used over several adsorptions
-desorption cycles. The mechanisms of adsorption on a surface are of two types; physical and
chemical. The latter process, involving a chemical reaction, is termed "chemisorption".
Chemical adsorbents find very limited application in gas processing. Adsorbents that allow
physical adsorption hold the adsorbate on their surface-by-surface forces. For physical
adsorbents used in gas dehydration, the following properties are desirable:
 Large surface area for high capacity. Commercial adsorbents have a surface area of 500-
800 m /g.
 Good "activity" for the components to be removed and good activity retention with
time/use.
 High mass transfer rate or high rate of removal.
 Easy, economic regeneration.
 Small resistance to gas flow, so that the pressure drop through the dehydration system is
small.
 Cheap, non-corrosive, non-toxic, chemically inert, high bulk density and small volume
changes upon adsorption and desorption of water.
11
The most widely used adsorbents today are activated alumina, silica gel, molecular sieves
(zeolites). A hydrated form of aluminum oxide (Al2O3), alumina is the least expensive
adsorbent. It is activated by driving off some of the water associated with it in its hydrated
form (Al2 O3.3H2 O) by heating. It produces an excellent dew point depression values as
low as -100 0F, but requires much more heat for regeneration. Gels are granular, amorphous
solids manufactured by chemical reaction. Gels manufactured from sulfuric acid and sodium
silicate reaction are called silica gels, and consist almost solely of silicon dioxide (SiO2). In
chemistry, silica gel is used in chromatography as a stationary phase. In column
chromatography, the stationary phase is most often composed of silica gel particles of 40-63
μm. [Guo _05]
In this application, due to silica gel's polarity, non-polar components tend to elute before
more polar ones, hence the name normal phase chromatography. The advantages of silica gel,
as a desiccant is too much so, this is more important about silica gel. Silica gel has many other
properties that recommend it as a desiccant. It will adsorb up to one third of its own weight of
water content in natural. This adsorption efficiency is approximately 35% greater than typical
desiccant clays, making silica gel the preferred choice where weight or efficiency are
important factors. It also has an almost indefinite shelf life if stored in airtight conditions. It
can be regenerated and reused if required. Gently heating silica gel will drive off the adsorbed
water content and leave it ready for reuse. It is a very inert material, it will not normally attack
or corrode other materials and with the exception of strong alkalis and hydrofluoric acid is
itself resistant to attack. It is non-toxic and non-flammable. It is most frequently and
conveniently used packed in a breathable sachet or bag.
These are available in a wide range of sizes suitable for use with a wide range of
applications. Standard white silica gel is referred to as being non-indicating. As it adsorbs
water content, it remains physically unchanged. Non-indicating silica gel is cheap and
effective, available loose in bulk packs or packed in sachets. Silica gel also as self-indicating
silica gels are colored. Molecular sieves are a crystalline form of alkali metal (calcium or
sodium) alumina-silicates, very similar to natural clays. Molecular sieves are used to obtain
very low water levels in the processed gas (down to 0.03-ppm vol). They are highly porous,
with a very narrow range of pore sizes, and very high surface area.
12
Manufactured by ion exchange, molecular sieves are the most expensive adsorbents and
must be replaced every three years. Thus, for structure A sieves, depending on the
compensation cation, the size of the access cavities maybe about 3A (3A sieves), 4A (4A
sieves) or 5A (5A sieves). They possess highly localized polar charges on their surface that
act as extremely effective adsorption sites for polar compounds such as water and hydrogen
sulfide. Solid desiccants or absorbents are commonly used for dehydrating gases in
cryogenic processes. The use of solid adsorbent has been extended to the dehydration of
liquid. Solid adsorbents remove water from the hydrocarbon stream and release it to another
stream at higher temperatures in a regeneration step. [Guo _07]
3.2 Dehydration by Using Triethylene Glycol (TEG).

There are numbers of liquids that can be used to absorb water from natural gases such as
calcium chloride, lithium chloride and glycols. Glycol dehydration is a liquid desiccant system
for the removal of water from natural gas. It is the most common and economic means of
water removal from these streams Glycol, the principal agent in this process, has a chemical
affinity for water. The liquid glycol will absorb the water content in the natural gas. This
means that, when in contact with a stream of natural gas that contains water, glycol will serve
to 'steal' the water out of the gas stream. This operation is called absorption. There are a few
types of glycol usually used in industry with their advantages and disadvantages like ethylene
glycol (EG), diethylene glycol (DEG), Triethylene glycol (TEG), and tetra ethylene glycol
(TREG). One of the best glycol frequently used in industry is (TEG).
Essentially, glycol dehydration involves using a glycol solution, usually either (DEG or
TEG), which is brought into contact with the wet gas stream in what is called the 'contactor' or
dehydration unit. The process function of glycol is absorbing the water from the wet gas. Once
absorbed, the glycol particles become heavier and sink to the bottom of the contactor where
they are removed. The natural gas, having been stripped of most of its water content, is then
transported out of the dehydrator. Glycols typically seen in industry include monoethylene
glycol (MEG). Usually, TEG is used because it is the most commonly used glycol in industry.
TEG is used as absorber of water content in natural gas. TEG, or triglycol is a colorless,
odorless viscous liquid with molecular formula C6H14O4 and molecular structure Although
13
many liquids possess the ability to absorb water from gas, the liquid that is most desirable to
use for commercial dehydration purposes should possess the following properties: _
 Strong affinity for water

 High boiling points.
 Low cost.
 Noncorrosive
 Low affinity for hydrocarbons and acid gases.
 Thermal stability.
 Easy regeneration
 Low viscosity.
 Low vapor pressure at the contact temperature
 Low solubility in hydrocarbon.
 Low tendency to foam and emulsify.
The rational of using TEG or advantages of TEG is ease of regeneration and operation,
minimal losses of drying agent during operation, high affinity for water, chemical stability,
and high hygroscopic and low vapor pressure at the contact temperature.
3.3 Dehydration Unit.

Generally, in the glycol dehydration process TEG is pumped to the top of a dehydration unit
or contactor tower where it is flow countercurrent with wet gas flowing up the tower. The
TEG adsorbs water from the wet gas and is passed to the glycol regeneration unit where, very
simply, adsorbed gases are flashed off and the water is removed from the reboiler by heating
the wet glycol to around 400ºF at atmospheric conditions gas. The processes are continuous,
that is glycol flow continuously through dehydration unit where they come in contact and the
glycol absorbs the water. The regenerated TEG is then pumped back to the dehydration unit
inlet
3.4. Process Flow and Components.

3.4.1 components.
The efficient operation of a glycol dehydration system requires good understanding of the
dehydration process and process variables as well as frequent monitoring of dew points.
14
Better dehydration results, as well as significant savings, are experienced when systems are
operated properly. The operation of individual components within the system must be
understood to properly operate and troubleshoot the system. A typical glycol dehydration
system is shown in Figure 1. It consists of the following components: contactor column,
reboiler, glycol filter, pump, surge tank, gas-condensate glycol separator and heat
exchangers. [H.K _03]
Figure 3.1 Basic Glycol Dehydration Unit
 Contactor Column
The function of the contactor column (Figure 3.1) sometimes called an absorber, is to
contact natural gas with the glycol, so that the glycol can remove water vapor from the
natural gas. These vessels are designed to accommodate a certain gas volume and
pressure. It should be noted that to exceed design specifications will increase glycol losses
and outlet gas dew point.
15
Figure 3.2 Tray Contactor Columns
For large volumes of gas, the contactor is usually a tray column containing 4 to 12 trays on
which up flowing gas bubbles through down flowing glycol, the number of trays in the
contactor will affect the amount of moisture removed from the gas by the glycol; more trays
mean more moisture removal.
16
Figure 3.3 schematic flow diagram of a typical glycol contact tower.
Rarely does the number of trays exceed ten. Each has a number of openings with bubble caps
bolted over them to disperse gas through the glycol solution as the gas is forced to pass
through these caps and bubble evenly through the glycol. The gas gives up water and becomes
drier as it passes upward through each succeeding tray.
The glycol becomes more saturated with water as it flows downward over each tray. Also
found on the trays are weirs and down comers. Weirs, which are dam-like devices, are used to
maintain the level of glycol above slots in the bubble caps. Down comers carry the glycol to
the trays below.
17
Figure 3.4 Tray with Bubble Caps
Before lean glycol enters the contactor, two things happen:

 The glycol is pumped up to contactor pressure
 The glycol temperature is lowered to 10-15°F (5-7°C) above the inlet gas temperature.
This is done by passing the lean glycol through a heat exchanger where it is cooled by the dry
gas leaving the contactor It is best to have the glycol entering the contactor 10-15°F (5 7°C)
warmer than the inlet gas. Cooler glycol causes condensing of hydrocarbon vapors which
cause foaming, resulting in greater glycol loss. Warmer glycol reduces effectiveness of
absorbing water from the gas. The glycol/gas heat exchanger is sized to give the correct glycol
temperature and usually does not require attention. Incorrect glycol temperatures entering the
contactor indicate an imbalance in the glycol to gas flow rate, a problem in the heat
exchanger, or the reboiler temperature is out of adjustment.
Above the top tray there is usually space for separation where most of the entrained glycol
particles in the gas stream will settle out. Glycol not settling out will be removed by a mist
eliminator (Figure 3.5) in the top of the contactor. This prevents liquid glycol from being
carried out of the contactor and into the gas discharge line, commonly referred to as carryover.
18
Figure 3.5 Mist Eliminators
 Gas-Condensate-Glycol Separator
This separator is also known as the flash tank or Glycol-gas separator (Figure 3.6). It is
used to recover gas which dissolved in the glycol solution in the contactor as well as any
liquid hydrocarbons (condensate) carried out of the contactor by the glycol solution.
The G-C-G separator is simply a three-phase separator in which gas, liquid

hydrocarbons, and glycol are separated. The gas leaves the top of the vessel and is vented or
may be used to supplement the fuel gas required for the reboiler. A pressure control valve
maintains a back pressure on the vessel, usually 50 to 85 psig (345 to 587 kPa). Any excess
gas is discharged through this back-pressure valve. [H.K _03]
19
Figure 3.6 Gas-Condensate-Glycol Separators
Separating liquid hydrocarbons from glycol before they enter the reboiler reduces the load on
the carbon filter and helps prevent carbon from building up on the reboiler fire tube. Problems
caused by hydrocarbons entering the still column are flooding, glycol loss and possible
damage to the still column. Two level control systems are typically installed on gas-
condensate-glycol separators. The upper system regulates flow of liquid hydrocarbon
discharged from the vessel. The lower system regulates the flow of glycol from the vessel.
 Filters
Filters are installed in the glycol stream to remove solids and other contaminants, which may
cause plugging and foaming. There are two types of filters commonly used in gas dehydration
systems: One type is used for solids removal and the other for dissolved contaminants
removal.
 Solids Removal:
Fine screen, sock type or cartridge filters are used for solids removal. Solid particles can cause
erosion of pump pistons, valve seals and discs, plugging of equipment, and foaming. Sock
20
filters are the most commonly used type for solids removal. Sock filters contain cylindrical
elements that are replaced as they become coated. A pressure drops of 3-6 psig (21-41 kPa)
usually occurs as glycol flows through the elements; however, the pressure drops increases as
the elements remove solid material and become plugged. To measure the pressure, drop across
elements, a differential pressure gauge is installed. When the pressure drop rises to 15-20 psig
(104-138 kPa), the elements should be replaced so that collapse of the elements or stoppage of
glycol does not occur.
 Dissolved Contaminants Removal:

Activated carbon filters are recommended for the removal of dissolved contaminants. They
work well until their adsorption capacity is reached. In cases where the glycol contains
appreciable quantities of light hydrocarbons, they must be changed or reactivated frequently.
Most glycol systems cannot be operated successfully without carbon adsorption.
There are two types of activated carbon filters. Most systems use a carbon canister;
however, larger systems use a loose fill carbon vessel. When the loose fill vessel is used, care
must be taken to trap carbon fines and keep them from entering the glycol dehydration system.
This is especially important when a fresh carbon bed is put into service. Routing the glycol
flow through the carbon bed prior to the particle filter is the usual method of trapping carbon
fines. However, care must be taken to reroute the glycol flow to its proper order or the life of
the carbon bed will be shortened. Carbon filters should be replaced anytime the level of
contaminants in the glycol solution goes up. Monthly test should be run to determine the
contamination level.
 Regenerator and Still Column

The regenerator (Figure 3.7) is a combination of the glycol reboiler and the still column. They
operate together to regenerate the rich glycol, making it lean again and ready for use in the
contactor column.
21
Figure 3.7 Regenerators
The reboiler is the vessel, which supplies heat to separate glycol and water by simple
distillation. Glycol is heated to a temperature between 380°F and 400°F (193°C and 204°C)
to remove enough water vapor to regenerate the glycol to 98.5-99%. The temperature of
Triethylene glycol should not exceed 400°F (204°C) because TEG will begin to break down
at higher temperatures, reboilers can be direct fired or heated by steam or hot oil. [POL_90]
The direct-fired type, containing a removable firebox and fire tube, is normally used. The
heating element should be conservatively sized to insure long tube life and prevent glycol
decomposition by overheating the glycol. Glycol level in the reboiler is maintained by an
overflow weir. Excess glycol spills over the weir and flows downward into the surge tank by
gravity. When glycol level is low in the surge tank, fresh glycol is added to the reboiler, so
that it can be dried before going to the surge tank. The still column, sometimes called a
stripper, is the vessel located on top of the reboiler where distillation of glycol and water
actually takes place.
22
Still columns are normally packed columns and have finned condensers or reflux coils in the
top to cool water vapor leaving the column and to recover entrained glycol. The amount of
glycol lost with the water vapor leaving the still column is controlled by the temperature of
the water vapor, normally referred to as still column overhead temperature. This
temperature should be set at the boiling point of pure water for the pressure in the top of the
still column. Normally the pressure will be atmospheric, 14.7 Pisa at sea level, and the
temperature will be 212°F (100°C). Systems with back pressure will require higher
temperatures. Systems operating above sea level will require lower temperatures due to the
lower pressures. If the still overhead temperature is above the boiling point of pure water,
glycol carryover will occur and losses will be higher than normal. [PIM-13]
If the still overhead temperature is below the boiling point of pure water, too much water
will be condensed and the reboiler heat requirements and fuel usage will increase. Column
flooding will result when glycol being fed to the still column has a high concentration of light
hydrocarbons, which will distil out of the glycol and condense in the upper portion of the
column. Flooding will also result if the glycol flow rate exceedsmaximum design limits.
Column flooding does not allow proper glycol/water separation and rich glycol can be lost
through the vent line.
 Surge Tank
This is the vessel (Figure 3.8) used to store regenerated glycol for pump suction. It is
commonly positioned under the reboiler in the glycol dehydration system. The surge tank
should be vented and the vent line kept unplugged. Vapors, which are trapped in the surge
tank, could cause the circulation pump to vapor lock. The vent line should be piped away from
process equipment.
23
Figure 3.8 Surge Tank
 Pumps
Most small dehydration units use a fluid driven pump while larger units generally use an
electrically driven reciprocating pump. In either case, the pump is a critical part of the unit
because it has the only moving parts in the system. Before entering the pump, rich glycol
passes through a strainer to remove large particles. Leaks can be a problem around glycol
pumps. Proper packing gland maintenance and the use of manufacturer's recommended
packing can minimize this problem.
 Heat Exchangers
There are two types of heat exchangers used in a glycol dehydration unit: glycol to gas heat
exchanger and glycol to glycol heat exchanger(s).
 Glycol/Gas Heat Exchanger: -

Dry gas leaving the contactor passes through this heat exchanger, where the temperature of
the gas is raised slightly as it cools the incoming lean glycol. Thus, the final stage of lean
glycol cooling is accomplished here. Incoming glycol is cooled to a temperature about 10-
15°F (5-7°C) above that of the natural gas entering the contactor.
24
Figure 3.9 Glycol/ Gas Heat Exchanger
On small dehydration units, this exchanger is often a double pipe heat exchanger, which is
literally a pipe within a pipe. Lean glycol in the outer pipe flows around the outlet gas in the
inner pipe. Larger units will utilize a shell and tube type of heat exchanger. Heat exchangers
are subject to fouling by salt, coke, or gum deposits which can reduce the heat transfer rate
and increase the lean glycol temperature.
 Glycol/Glycol Heat Exchanger(s):-

Hot, lean glycol leaves the surge tank and passes through a glycol/glycol heat exchanger
(Figure3.10), where the lean glycol is cooled by the rich glycol stream leaving the filters
downstream of the G-C-G separator. a second glycol/glycol heat exchanger heats the rich
glycol which leaves the reflux coil by the lean glycol stream leaving the first glycol/glycol
heat exchanger.
25
Figure 3.10 Glycol/Glycol Heat Exchangers
Lean glycol, which leaves the surge tank at approximately 400°F (204°C), must be cooled
prior to entering the contactor in order for it to absorb the maximum quantity of water from
the gas. These heat exchangers cool the lean glycol to about 212°F (100°C). They are very
important in the overall operating efficiency of the dehydration unit. These heat exchangers
substantially reduce the amount of heat required by the reboiler. [PIM-13]
3.4.2 Process Flow Description

The wet gas enters the contactor through an inlet near the bottom. The gas, travelling upward
in the contactor column, is forced through the openings below the caps and bubbles through
the glycol. During the bubbling process, the gas gives up water vapor to the glycol. As gas
passes, upward through each succeeding tray it becomes drier. Before leaving the contactor,
the dry gas passes through a mist extractor to remove any glycol that may be in vapor form.
As the glycol particles collect and become heavier in the mist extractor, they drop back into
the top tray and rejoin the glycol stream. The dry gas then leaves the contactor and passes
through a heat exchanger where it cools the dry glycol entering the top of the contactor
column. The dry gas is then ready for transmission.
26
Dry glycol enters the contactor tower at an inlet near the top and flows across the top tray,
then downward and across other trays, a level of glycol is maintained on a tray by means of a
dam known as a weir. This level is above the slots in the bubble caps so the gas is forced to
bubble through the glycol. The glycol flows over the weir through an opening known as a
down comer and into the tray below.
Maintaining the level of glycol on the next tray above the bottom of the down comer
prevents gas from bypassing the bubble caps as the glycol spills downward through each
succeeding tray, it becomes saturated with the water it has absorbed from the gas and
collects in the bottom of the contactor, the wet glycol from the contactor then passes
through a filter where any abrasive particles and tarry hydrocarbons are removed before
entering the pump. [SIT-09]
Figure 3.11 Contactor Column
From the pump, the cool wet glycol flows through coils in the surge tank. This allows for a
heat exchange process to occur. The cool wet glycol is warmed by the hot dry glycol before it
enters the gas-condensate-glycol separator. At the same time, the hot dry glycol is cooled
before it enters the contactor column. From the coils in the surge tank, the wet glycol enters
the gas-condensate-glycol separator.
27
Figure 3.12 Gas-Condensate-Glycol Separator
Heat from the surge tank helps separate hydrocarbons from the wet glycol. The hydrocarbon
condensate is skimmed off the glycol and any remaining gas vapors leave from the top. From
the gas-condensate-glycol separator, the wet glycol flows through a tube in the reboiler. Here
the glycol is heated to vaporize the water before entering the still column ("stripper") on the
reboiler. The still column removes the water vapor from the glycol.
Inside the still column is a section, known as a packed column, filled with ceramic,
stainless steel or carbon packing known as saddles or rasching rings. The glycol spreads out
uniformly over the packing and drips down through the lower portion of the packed column.
The water vapor rises to the top of the column. [Gas -11]
28
Figure 3.13 Still Column
From the packed column, the wet glycol drops downward into the bottom of the reboiler. A
source of heat circulated through a tube in the lower section of the reboiler maintains the
temperature of the glycol solution at approximately 370° to 400‫ ؛‬F (188 to 204‫ ؛‬C) which is
just below the boiling and decomposition point of Triethylene Glycol. Waste heat from
compressor or generator exhaust gases can be used as a heat source, but many installations
also use a gas fired heater. The temperature of glycol in the reboiler is critical and must be
controlled within this range. The remaining water boils out of the glycol solution and moves
upward through the still column as vapor.
Some hot glycol vapors also are mixed with the water vapor, as this mixture passes upward
through the still column, it comes in contact with a cooler part of the column and the glycol
vapors are condensed and dropped back down into the reboiler. The water leaves the top of the
still column as vapor. The glycol level in the reboiler is maintained above the heating tube by
the location of the overflow tube. The dried, purified glycol spills into the overflow tube and
flows into the surge tank.
29
Figure 3.14 Overflow Tube
From the surge tank, the dry glycol flows to a pump. The pump raises the pressure of the dry
glycol slightly above that of the contactor column. This dry glycol then passes through a heat
exchanger, which cools the glycol to near the temperature of the natural gas in the contactor.
Proper temperature and pressure must be maintained in this system to prevent foaming. With
the return of the glycol to the contactor column, the dehydration cycle is completed and
another cycle begins.
3.5 Factors Which Affect the Efficiency of a Glycol Dehydration System.

The degree of water removal is determined by several process variables, which include inlet
gas temperature, inlet gas pressure, gas flow rate, inlet glycol temperature, glycol
concentration, and glycol circulation rate.
3.5.1 inlet gas temperature

Incoming gas temperature has a significant effect on the water content of the gas entering the
contactor. At constant pressure, the water content of inlet gas increases as the gas temperature
is increased. If in contact with free water, gas will absorb additional water vapor as the
temperature is increased. If the gas contains more water vapor, the unit is required to remove
more water in order to achieve the desired water content of outlet gas.
30
3.5.2 Inlet Gas Pressure
In the normal operating range of a glycol dehydration unit, pressure is not a critical factor.
However, it is important to note that at constant temperature, gas can hold more water as the
pressure is reduced. Therefore, water content of inlet gas will be high if the gas pressure is
low.
3.5.3 Contactor Pressure:

Operating the contactor below design pressure of the system creates the following
problems:
 At constant temperature, water content of inlet gas increases as pressure decreases,
causing the unit to work harder to dry the gas.
 At constant gas rates, the gas velocity through the contactor increases as the pressure is
lowered, causing carryover problem
3.5.4 gas flow rate:
For a unit to operate efficiently, a specified range for gas flow must be maintained. If flow rate
deviates outside these limits, problems can develop. Falling below the specified range will
result in loss of efficiency and may result in increased dew point for outlet gas, depending on
the design of the trays or packing in the contactor column. If the flow rate rises above the
specified range, reboiler overload occurs resulting in insufficient glycol regeneration and
increased outlet gas dew point. The amount of glycol carried out with the dry gas will also
increase. In fact, all the glycol can be carried out of the contactor column at one time if the gas
flow rate is high enough.
A flow rate without rapid surges or changes is necessary to prevent a loss of seal in the
contactor column down comers. Seal loss allows gas to bypass the trays and results in high
outlet gas dew points and high glycol loss with the outlet gas.
3.5.5 inlet glycol temperature:
Inlet glycol temperature of 10-15°F (5-7°C) above the inlet gas temperature is required to
prevent hydrocarbon condensation in the glycol. Hydrocarbon condensation increases
foaming, reduces carbon filter life, and increases carbon build up on the reboiler fire tube.
31
3.5.6 Glycol Circulation Rate:
If glycol circulation rate is increased without changing other variables, the outlet gas dew
point can be decreased. However, it is desirable to maintain the lowest glycol circulation rate
possible to produce the desired outlet gas dew point.
An excessive glycol circulation rate can result in the following problems:
• Increased fuel consumption
• Exceeded reboiler capacity
• Increased overhead glycol loss due to the higher temperature of lean glycol going to the
contactor column
• Increased pump maintenance.
3.6 Operating Problems and Glycol Care:

Most operating and technical problems usually occur when the circulating glycol solution
gets dirty. In order to get a long, trouble-free life with the glycol system, it is necessary and
very important to recognize these problems and know how to prevent them.
Some of the major problems are -
1. Glycol Loss
2. Foaming
3. Thermal Decomposition of Glycol
4. Dew Point Control
5. Glycol Ph Control
6. Salt Contamination
7. Glycol Oxidation
8. Sludge Formation
We will specifically talk about glycol loss problem that cause many problems.
3.6.1 glycol loss

properly, the loss might be much higher than this.
32
The glycol contactor (the absorber) and glycol regenerator are the most common places in the
dehydration system the glycol losses occurring in the glycol regenerator are usually caused by
excessive reboiler temperature, which causes vaporization or thermal decomposition of glycol
(TEG). Also, excessive top temperature in the still column allows vaporized glycol to escape
from the still column to atmosphere with the water vapor.
3.6.2 typical locations for glycol losses

 Carryover with outlet gas leaving the contactor.
 Vaporization with water vapor leaving the still column.
 Leaks at the pump or pipefittings.
 Removal of liquid hydrocarbons and/or gas from the G-C-G separator.
3.6.3 Conditions affecting glycol losses include -

1. Foaming
Glycol tends to foam when ph. is above 8.5 glycol becomes acidic when ph. goes below 7.0.
Contamination of glycol with salt, liquid hydrocarbons solids or corrosion inhibitors lead to
foaming
2. Contactor column operating at excessive gas rates
Excessive gas flow rates create turbulence, which causes carryover of glycol with the gas
stream Plugged trays, when bubble caps become plugged gas flow velocity increases through
remaining bubble caps resulting in glycol carryover.
3. High still overhead temperature

Liquids entering system, free water and liquid hydrocarbons may flood the still column
resulting in poor glycol/vapor contact. Pressure surges may cause glycol carryover out the top
with the vapor. Still packing plugged resulting in poor glycol/vapor contact. Overhead glycol
carryover from excessive vapor flow
High still overhead temperature results in loss of glycol vapor with the water vapor
increase the flow of cool, rich glycol through the reflux coil, if still column has condenser fins,
clean them to improve heat transfer.
4. Physical leaks
Entire system susceptible to leakage. [FIT-87]
33
CHAPTER 4
4. MATERIAL AND ENERGY BALANCE
4.1 Fundamentals of Material Balances

Material balances are the basis of process design. A. material balance taken over the complete
process will determine the quantities of raw materials required and products produced. Balances
over Individual process units set the process Stream flows and compositions good
understanding of material balance calculations is essential in process Design. Material
balances are also useful tools for the study of plant operation and Trouble, Sheeting They can be
used to check performance against design; to extend the, often-limited date Available from the
plant instrumentation, to check instrument calibrations, and to locate sources of material loss.
One of the basic laws of physical science is the law of conservation of mass.
This law, stated simply, says that mass cannot be created or destroyed (excluding, of course,
nuclear or atomic reactions). Hence, the total mass (or weight) of all materials entering any process
must equal the total mass of all materials leaving plus the mass of any, materials accumulating
or left in the process. In the majority of cases, this will be no accumulation of materials in a
process, and then the input will 'simply equal the output. Stated in other words, "what goes in must
come out". We call this type of process a steady-state process.
Input = output (steady state)

Input = output + accumulation
4.2 Fundamentals of energy balance

As with mass, energy can be considered to be separately conserved in all but nuclear
processes. The conservation of energy, however, differs from that energy can be generated in
a chemical process. Material can change from, new molecular species can be formed by
chemical reaction, but the total mass flow into a process unit must be equal to the flow out at
the steady state. The same is not true of energy. The total enthalpy of the outlet stream will not
equal that of the inlet streams if energy is generated or consumed in the processes; such as that
due to heat of reaction. Energy can exist in several forms: heat mechanical energy, electrical
34
energy, and it is the total energy that is conserved.
In process design, energy balances are made to determine the energy requirements of the
process: the heating, cooling and power required. In plant operation, an energy balance(
energy audit) on the plant will show the pattern of energy usage, and suggest areas for
conservation and savings. As for material a general equation can be written for the
conservation of energy.
Energy out = energy in + generation – consumption – accumulation
4.3 Material and energy balance by HYSYS

4.3.1 simulation basis manager
Aspent HYSYS uses the concept of the fluid package to contain all necessary information for
performing flash and physical property calculation. This approach allows you to define all
information ( property package, components, hypothetical components, interaction
parameters, reactions, tabular data, etc. ) inside a single entity.
There are four key advantages to this approach
 All associated information is defined in a single location, allowing for easy creation
and modification of the information
 Fluid packages can be stored as completely defined entities for use in any simulation
 Component list can be stored out separately from the fluid packages as completely
defined entities for use in any simulation.
 Multiple fluid packages can be used in the same simulation. However, they are defined
inside the common basis manger.
The simulation basis manager is a property view that allows you to create and manipulate
multiple fluid packages or component lists in the simulation.The next figure indicate acid gas
sweetening process with DEA. [BET -07]
35
Figure 4.1 acid gas sweetening with DEA
Figure 4.2 acid gas sweetening
36
Figure 4.3 MATERIAL BALANCE FOR ACID GAS SWEETENTNING
Figure 4.4 ENERGY BALANCE FOR ACID GAS SWEETENING
37
Figure 4.5 STREAM DATE
38
Figure 4.6 stream data
Figure 4.7 stream date
39
Figure 4.8 stream data
40
41
CHAPTER 5
5. RESULTS AND DISCUSSION
properly, the loss might be much higher than this. Since we have identified the problem in the
glycol regeneration unit to be accurate in the reboiler by observing and achieving the
temperature with the loss of the amount that occurs during the process of glycol regeneration.
The temperature of the glycol in the reboiler determines largely the purity to which the glycol
is regenerated. However, there is a limit on the temperature to which the glycol can be heated.
This limit is a few degrees below the decomposition temperature because above this
temperature, the glycol molecule breaks down this is considered one of the reasons for
increasing the loss of glycol and also there are several main reasons including [foam,
excessive flow rate of gas, leakage in pipes and excessive reboiler temperature.] After several
studies into the problems of the loss of glycol, it became clear that the most lost in glycol is
the reboiler. Thus, it is very important to control the reboiler temperature to the range of 390
to 350°F or some other range that provides adequate regeneration of the rich glycol.
Figure 2 5.1 Reboiler
42
5.1 Operation of the Reboiler:
The reboiler is the vessel, which supplies heat to separate glycol and water by simple
distillation. Glycol is heated to a temperature between 350°F and 390°F to remove enough
water vapor to regenerate the glycol to 98.5-99%. The temperature of Triethylene glycol
should not exceed 400°F (204°C) because TEG will begin to break down at higher
temperatures. Reboiler can be direct fired or heated by steam or hot oil. The direct-fired type,
containing a removable firebox and fire tube, is normally used. The heating element should be
conservatively sized to insure long tube life and prevent glycol decomposition by overheating
the glycol. Glycol level in the reboiler is maintained by an overflow weir. [Ma Q -10]
Excess glycol spills over the weir and flows downward into the surge tank by gravity.
When glycol level is low in the surge tank, fresh glycol is added to the reboiler, so that it can
be dried before going to the surge tank. Our study about the reboiler is depending on testing at
24 hr. on the temperature of the glycol that range from 390 FO 380 FO 370 FO 360 FO and 350
FO. The stander of allowed loss is 0.10 gal/mm scf of natural gas treated, so we setting the
reboiler at the temperature that we choose it. The result shown in the following table.
No Temperature F0 Loss gal/day

1 390 2.66
2 380 2.33
3 370 2
4 360 1.66
5 350 1.33
43
T & loss
400
390 390
380 380
370 370
360 360
350 350
340
330
2.66 2.33 2 1.6 1.3
T & loss
As the result, the reading from the side glass at surge tank We can find the quantity of gas
non-treated by divide the value of loss of glycol at that temperature on the stander of allowed
loss that which is 0.10 gal/mmscf of natural gas treated, by the following equation Quantity of
natural gas treated = value of loss of glycol / allowed loss
Q = L / AL
Q1 = 1.33 / 0.10 = 13.3MM SCF / DAY that the natural gas treated
We estimate that the amount of treated gas is 13.3 million. This value is a reference for other
values in the loss, heat and quantity of gas treated. If we can find the amount of untreated gas,
of this value and thus get the value of unhandled gas, which cause operational problems in
terms of the station's capacity and also cause problems in the flow lines.
Q2 = 1.66 / 0.10 = 16.6MM SCF / DAY this value mince from the above equation
Q2-1 = 16.6 – 13.3 = 3.3 MM SCF / DAY natural gas non-treated
Q3 = 2 / 0.10 = 20MM SCF / DAY
Q3-1 = 20 – 13.3 = 6.7 MM SCF / DAY
Q4 = 2.33 / 0.10 = 23.3 MM SCF / DAY
Q4-1 = 23.3 – 13.3 = 10 MM SCF / DAY
Q5 = 2.66 / 0.10 = 26.6 MM SCF / DAY
44
Q5-1 = 26.6 – 13.3 = 13.3 MM SCF / DAY
As we know the stander of allowed loss that which is 0.10 gal/mmscf of natural gas treated
and batter temperature of this process is 350 FO from the result we defined the quantity of
natural gas non-treated at the following table [SOC-98]
No Temperature Fo Loss gal/day Natural gas non-treated

mmscf/day
1. 390 2.66 13.3
2. 380 2.33 10
3. 370 2 6.7
4. 360 1.66 3.3
5. 350 1.33 0
Q&T
400
390
380
370
360
350
340
330
13.3 10 6.7 3.3 0
Q&T
45
CHAPTER 6
6. CONCLUSIONS ANDRECOMMENDATIONS
6.1 Conclusions
We conclude from our study of the kettle containing the TEG glycol in the field of the coast,
as high temperatures affect the recycling process and cause the loss of glycol and turn
negatively affect the process of drying gas and equipment and equipment and even readings
obtained through periodic tests also, And the best temperature in which the process is highly
efficient is 350 Fahrenheit and have the lowest rate of loss of glycol and provide in the
consumption and also economically. In addition, maintain the life of equipment and
operational faults.
6.2 Recommendations
 The temperature of the reboiler should be set at (350 F0) this temperature will usually
give good distillation of the rich glycol and evaporate all water out of it. .
 The glycol should never be heated above 390 F0 as it begins to decompose above that
temperature. When making adjustments to reboiler temperature never increase the
temperature setting by more than five degrees at a time.
 Too great an increase will cause the control system to open the fuel gas valve too wide
giving a large burner flame tube, this will lead to, Hot –spots, and cause damage to the
fire- tube and breakdown of the glycol into corrosive organic acids.
 If coke, salts or tar deposits form on the fire tube, the heat transfer into the glycol is
reduced, the control system will increase the fuel to maintain the glycol temperature
and tube failure can result.
 Localized overheating especially where salt deposits accumulate, will determine the
glycol, Salt deposits can be detected by shutting off the burner on the glycol reboiler
system at night and looking down the fire tube walls where salt deposits have
collected, an analysis of the glycol will determine the degree of these contamination It
is highly recommended that during a plant start-up.
 Make sure the reboiler is up to the desired operating temperature before flowing gas
46
through the contactor ,some fires have been caused by leaks in the gas lines near the
fire-box, The best precaution is to have valves and regulators in the gas line at a
suitable distance of a flame the fire-box, Another very effective measure is the
addition of a flame arrestor around the fire – box, If the flame arrestor is properly
designed, even severe gas leaks in the immediate vicinity of the fire-box will not
ignite.
47
CHAPTER 7
7. SAFETY
Any organization has a legal and moral obligation to safeguard the health and welfare of
its employees and the general public'. Safety is also good business; the good
management practices needed to ensure safe operation will also ensure efficient operation.
The term. "Loss prevention" is an insurance term, the loss being the financial loss caused. By
an accident. This loss will not only be the cost of replacing damaged plant and third party
claims, but also the loss of earnings from lost production and lost sales opportunity.
All manufacturing processes are to some, extent hazardous, but in chemical processes
there are additional, special, hazards associated with the Chemicals used and the process
conditions. The designer must be aware of these hazards, and ensure, through the
application of sound engineering practice, that the risks are reduced to acceptable levels.
In this book, only the particular hazards associated with chemical and allied processes
will be considered. The more general, normal, hazards present in, all manufacturing
process such as, the dangers from rotating machinery, falls, falling objects, use of
Machine tools, and of electrocution will not be considered. Safety and loss prevention in
process design can be considered under the following broad headings:
1. Identification and assessment of the hazards
2. Control the hazard for example, by containment of flammable and toxic materials.
3. Control 'of the process. Prevention of hazards deviations in' process variables (pressure,
temperature, flow), by provision of automatic control systems, interlocks, alarms, trips;
together with good operating practices and' management.
4. Limitation Of the loss. The damage MIA injury caused if an incident occurs: pressure
relief, plant layout, provision of fire-fighting equipment.
In this chapter the discussion of, safety in process design will of necessity be limited: A
more complete treatment of the subject can be found in the books by Wells (1980).and, Lees
(1980) and in. the general literature. The proceedings of the symposia On the Subject, organized
regularly by the American Institute of Chemical Engineers, the, Institution of Chemical
48
Engineers` and the European, Federation of Chemical Engineering, contain many articles
Of interest: on general philosophy; techniques and Organization; and the hazards
associated with specific processes and equipment. [FIT-87]
7.1 Pressure systems

Equipment that operates under pressure is specially designed to withstand that pressure and is fitted
with a safety or pressure release valve or bursting disc to prevent excessive pressure developing
inside it. The safe working pressure (S.W.P.) should be clearly marked on the equipment; and it is
important that this pressure is not exceeded. The gauge pressure must be conserved regularly.
Before pressurizing a system, all valve settings must be checked and all man ways, flanges,
coverers, etc., must be bolted securely using all the clamps or belts provided. [FIT-87]
When opening up a pressure system, ensure that the pressure has been released completely
through the proper vent. This is essential to avoid the risk of being sprayed with its chemical
contents, releasing flammable or noxious vapors or being injured by the blast. Jets of
compressed air may contain dust or grit, which can cause injury when moving at high speed;
the air itself has been known to kill people by injection into the blood stream.
7.2 Precautions to be Taken in Handling Ammonia

At ordinary temperatures, ammonia is a combustible gas and, when mixed with air, it can
explode. Experiments have shown that:-
(a) The range of explosive ammonia air mixture is narrower than for most explosive mixtures,
for example it is (15.5-28%) at 30˚C (fig 6). In pure oxygen, at 18˚C and 760 mmHg, it is (13.
5 -28%).
(b) The velocity of flame propagation is very low.
(c) Ammonia air mixtures are ignited only at relatively high temperatures, such as car. Usually
be reached only with electric sparks or naked flames.
(d) Ammonia air explosives are not very violent and their effects are not usually disastrous.
(e) The explosive power is reduced when the explosion occurs within bloke-lined
surroundings.
(f) The presence of moisture in the ammonia-air mixture markedly reduces its inflammability,
which disappears as soon as the water vapor content is sufficiently high (saturation at about
49
44˚C). Ammonia, gaseous, liquid or in solution, is also a poison. It is an irritant of mucous
membranes and eyes; when inhaled, it causes agitation, dizziness, a sense of choking, vomit
and convulsions. The maximum tolerable concentration for 8 hours is 100 p. p.m., although it
varies according to individuals; 1000 p.p.m. cannot be tolerated for more than half an hour;
5,000p.p.m. Is sufficient to produce, within a few minutes, pulmonary congestion often with a
lethal effect. Thus, the toxic concentration of ammonia is lower than, for example, that of
carbon monoxide. However, a much lower concentration is easily recognizable by smell. And
it is easier, therefore, to avoid (carbon monoxide, on the contrary, is odorless). Ammonia
leakages are easily detectable with a small jet of gaseous chlorine; white ammonium chloride
smoke forms immediately, as chlorine decomposes NH3 into nitrogen and hydrochloric acid,
which in turn reacts with more ammonia.
The use of masks, with a special filter, and of protective clothes to protect the skin is
necessary up to a concentration of 3 % NH3 in the air; a breathing set or a self-contained
respirator is needed for higher concentrations of ammonia in air. Some metals are corroded by
ammonia; at low temperatures and in the presence of moisture and mechanical stress, copper,
nickel, zinc and their alloys cannot be used. All metals can, however, be used with perfectly
dry ammonia. Corrosion of bronze by ammonia solutions can be inhibited by 0.5 percent
hydrofluoric acid. The corrosive power of moist NH3 is greatly increased in the presence of
traces of O2 and CO2. [FIT-87]
7.3 Control of Toxic Materials

Points to consider at the design stage for the control of toxic materials are:
 Containment: sound design of equipment and piping; specify Welded joints: in preference to
flanges (liable to leak).
 Disposal: provision of effective vent stacks to disperse material vented from pressure relief
devices; or use vent scrubbers.
 Ventilation: Use. Open structures, or provide adequate-ventilation. Emergency equipment: escape
routes, rescue equipment, safety showers, eye, and baths. In 'addition, operating practices should
include Regular medical check-ups for employees, to 'cheek for chronic effects, Regular
monitoring of
50
7.4 Flammability
The hazard caused by a flammable material: depends on a number of factors:
1. The flash-point of the material:
2. The auto ignition temperature of the material.
1. The flammability of the material.
2. The. energy released in combustion
7.5 Flash Points

The flash point is a measure of the ease of ignition of the liquid. It is the lowest temperature at
which the material will ignite (room an open flame. The flash point is a function of the vapor
pressure and the flammability limits of the material. It is measured .in standard apparatus,
following standard procedures (BS 2839 and 4688). Both open- and closed-cup apparatus is
used. Closed-cup flash points are lower than. Open cup, and "the type of apparatus used should
be stated clearly when reporting measurements. The flash points of many volatile materials .are
below normal ambient. Temperature; for example, ether - 45°C.
7.6 Auloignition temperature

The 'auto ignition temperature of a substance is the temperature at which it will ignite.
Spontaneously in air, without any external source ignition. It is an indication of the maximum
temperature to which a material can be heated in air; for example, in drying operations.
7.7 Flammability 'limits

The flammability limits of a material are the lowest and highest concentrations in air, at normal
pressure and temperature, at which' a flame will propagate through the mixture they show the
range of concentration over which the material will burn in air if ignited. Flammability limits are
characteristic of the particular material, and differ widely for different materials.
7.8Explosions
An explosion is the sudden, catastrophic, release of energy, causing a pressure wave (blast
wave). An explosion can occur without fire, such as the failure through over pressure of a
steam boiler or an air .receiver. When discussing the explosion of a flammable mixture it is
necessary to distinguish between detonation and 'deflagration. If a mixture detonates, the
51
reaction zone propagates at supersonic velocity (approximately 300 m/s) and the principal
heating mechanism in the mixture is shock compression.
In a deflagration the combustion process is the same as in the formal burning of a gas
mixture; the combustion zone propagates at subsonic velocity, and the pressure build-up is slow.
Whether detonation or deflagration occurs in a gas-air mixture depends one -number of factors;
including the concentration of the mixture and the source-of ignition [PIM-13]
7.9. Sources of Ignition

Though precautions are normally taken to eliminate sources bf ignition on chemical
plants, it is best to work on the principle that a leak of flammable material will
ultimately find an ignition source.
7.10 Electrical Equipment
The sparking of electrical. Equipment, such as motors, is a major potential source of the
Ignition and flameproof equipment is normally specified. In all areas where
flammable gases are likely to be present in flammable concentrations under normal operating
conditions, intrinsically safe equipment should be specified, or the equipment enclosed in a
purged, gas-tight chamber.
In areas where a flammable mixture will only be present under abnormal circumstances,
'non-sparking -equipment can be specified: equipment that does not normally spark but
could; spark if a fault .develops. Some risk is involved, but the-coincident failure of the
equipment and a leak of 'flammable gas would be required to cause 'a fire or explosion.
7.11 Static-Electricity
The movement of any non-conducting the material, powder, liquid or gas, can generate
Static electricity, producing sparks. Precautions must be' taken to ensure that all piping is
properly earthed (grounded) and that electrical continuity is maintained around flanges.
Escaping steam, or other vapours and gases, can generate a static charge.
7.12 Miscellaneous Sources

It is the usual practice on plants handling flammable materials to control the entry, on to the site
,of obvious Sources of ignition; such as matches, cigarette' lighters and battery operated
52
equipment. The use of portable electrical equipment, welding, spark-producing tools and the
movement of petrol-driven vehicles would also be Subject to strict control. [H.K _03]
7.13 pressure
Over-pressure, a pressure exceeding the system design pressure is one of the most serious
hazards in chemical plant operation. Failure of a vessel, or the associated piping, can
precipitate a Sequence of events that culminate in a disaster. Pressure vessel is invariably
fitted with some form of pressure-relif device, set at the design pressure, so that (in
theory).Potential over-pressure is relived in a controlled manner. Here basically different
types of relief device are commonly used. Directly actuated valves: weight or spring-
loaded valves that open at a predetermined pressure and which normally close after the
pressure has been relieved. The system pressure provides the motive power to operate the
valve. Indirectly actuated valves: Pneumatically or electrically operated valves, which are
activated by pressure-sensing instruments. Bursting discs: thin discs of material that are
designed and manufactured to fail at a pressure, giving a full-bore opening for flow.
7.14 Temperature deviations

Excessively high temperature, over and above that for which the for which the equipment
was designed, can cause structural failure and initiate a disaster. High temperature can
arise from loss of control of reactors and heaters; and, externally, from open fires. In the
design of processes where high temperatures are a hazard, protection against high
temperatures is provided:
1. Provision of high-temperature alarms and interlocks to shut down reactor feeds, or

heating systems, if the temperature exceeds critical limits.
2. Provision of emergency cooling systems for reactors, where heat continues to be
generated after shutdown; for instance, in some polymerization system.
3. Structural design of equipment to withstand the worst possible temperature
excursion.
4. The selection of intrinsically safe heating systems for hazardous materials.
53
7.15 Types of Protection Equipment
7.15.1 Work Clothing
Work clothing must be-suitable for protection. Against common hazards expected in
industrial areas in .General. Therefore the following rules apply .Long sleeved shirt and
long trousers/ or coveralls must be worn at all times. In areas with rotating or moving
equipment, loose clothing and wide unbuttoned sleeves are forbidden in order to prevent
injury by being caught in the machine.
Work clothing should be kept as clean as possible. If splashed with Oil or a chemical, it
must be removed as soon as possible. Any Affected part of the body must be washed with
soap and water, and then clean clothing put on. Any contact with an Aggressive chemical,
must be reported to Supervision Immediately. The above rules represent the normal minimal
requirements. Where necessary, additional personal protective clothing and Equipment
specified by the Company must' be worn by employees. Exceptions from the above rules,
which are justified by the nature of work or Special environment, may be permitted if
approved by the Superintendent, Safety and Fire Protection or his substitute. Insulated
clothing may be required for work assignments involving Temperature extremes, such as
welding, the handling of cryogenic liquids, Working in food cold storage facilities etc.
7.15.2 HEAD PROTECTION

An approved hard hat consists of a hard impact shell and an adjustable inside cradle' arid
distributed over the head 'surface area. Wearing of safety hard hats (helmets) is mandatory
for:
 All employees who Work in industrial area.
 Work on a construction site.
 work in a hard-hat use designated area, and
 In any situation where a hazard exists for head injury from a falling object or
bumping against overhead structure or objects.
7.15.3 HARD HAT

Exceptions are the situations where normally no hazard exists for a head injury, such as
working in offices, control rooms, classrooms, etc. A hardhat shell is known to lose its
54
protection value with time it is recommended to change the shell' after 5 years of ', use.
Never drill holes, paint: or. Otherwise, modify the hardhat shell as that also reduces its
protective capabilities. Cracked or damaged hardhats must. Be replaced immediately.
Figure 7.1 indicate Hard Hat helmet
7.15.4 Face Protection
7.15.4.1 face shield

Provides protection from a corrosive or a hot liquid splash, and from small flying particles.
It is not a substitute for eye protection,' and must be used in addition to wearing safety
glasses or chemical goggles. (Example shown below)
7.15.4.2 Acid Suit

Protects face and head from a splash or .mist of corrosive Liquids. Situations which require
use of a hood 'usually also require protection of the body by an acid or chemical suit.
Figure 7.2 Full-Face Splash Shield
Appropriate eye protection is required in these situations
 Where exposure to flying particles may exist.
55
 Where exposure to corrosive liquids exists.
 When disjointing equipment that could be under pressure.
 When specified on- Work Permit, or by a Supervisor.
 In a designated, sign-posted area.
7.15.4.3 types of eye protection equipment
Ordinary safety glasses - These have plain (non-prescription shatter proof glass inside safety
frames and must also have attached side shields. They provide frontal protection from flying
particles or a liquid splash. Protection is satisfactory for many activities where the hazard is
moderate.
Green lens safety glasses with side shields; they provide protection from glare and
sunshine. Special dark-green glasses can also be obtained and are used in some welding
applications chemical safety goggles protects your eyes from liquid splashes, mists or
corrosive chemicals. A face shield is used in addition to eye protection in hazardous, types
[Guo-03]
EXAMPLES OF EYE PROTECTION DEVICES
Figure 7.3 WELDERS SHIELD
56
Figure 7.4 SAFETYGLASSES (Complete with side shields)
Figure 7.5 CHEMICAL GOGGLES
In an industrial environment, there are many situations in which some hazards cannot be
practically eliminated. In such cases, employees are requested to use personal protective
equipment provided by the company. That 'way the probability of personal injury is
reduced.
 It is the employee's duty to use and wear the protective equipment as required:
 As part of a general industrial. Safety standard for working on a site.
 For every specified job with recognized occupational hazard.
By the rules in the area where the work is being performed.
The basic minimum required with regard to personal protection for working
in any industrial area consists of the following
57
 Hard hat
 Work gloves
 Safety shoes or boots
 Safety glasses or goggles
 Hearing protection [POL-92]
58
REFERENCES
Ahmad Syahrul Bin Mohamad (2009); “Natural Gas Dehydration using

Triethylene Glycol
[AHM_09]
(TEG)”, Publication of the University of Malaysia Pahang, April.
Etuk P. (2007); “Total E&P Gas Dehydration Training Manual course EXP-
[ETU_07] PR-PR130”,
Rev.01999.1.
Guo and Ghalambor (2005); “Natural Gas Engineering Handbook”, Gulf

[Guo _05] Publishing
Company, Houston Texas, USA.
Guo, B., Lyons, W.C., and Ghalambor, A. (2007): “Petroleum Production

[Guo _07] Engineering: A
computer Assisted Approach” Elsevier Science & Technology Books.
H.K Abdel Aal, Mohamed Eggour and M. A. Fahim (2003); “Petroleum and
[H.K _03] gas field
processing”, Marcel Dekker Inc., New York, Basel.
Ikoku, Chi. I. (1992); “Natural Gas Production Engineering”, Reprint Edition,

[IKO_92] Krieger
Publishing Company: Boca Raton, FL.
Polk, L. (2009); “Modeling Absorption drying of natural gas”, Norwegian

[POL_90] University of
Science and Technology (Norwegian: Norges Teknisk-Naturvitenskapelige
Universitet i
(NTNU)) Trondheim, Norway, May.
59
Pimchanok Khachonbun (2013); “Membrane Based Triethylene Glycol
[PIM-13] Separation and Reco-
very from Gas Separation Plant Wastewater”, Asian School of Technology,

SitiThailand,
Suhaila Bt Mohd Rohani (2009); “Natural Gas Dehydration Using Silica
May.
[SIT-09] Gel: Fabrication
of Dehydration Unit”, Universiti Malaysia Pahang Publication April.
[TOT-99] Total E&P (1999); “Gas Dehydration Training Manual”
Gas infrastructure Europe (2011) Map Dataset in Excel-format Storage

[Gas -11] map. Available:
http://www.gie.eu/maps_data/storage.html. Accessed 2011 Mar 8.
Fitz, C. W., and Hubbard, R. A., "Quick, Manual Calculation Estimates
[FIT-87] Amount of Benzene Absorbed in Glycol
Dehydrator," Oil & Gas J., p. 72, Nov. 8, 1987
Gas Processors Suppliers Association (GPSA). “Dehydration.” In Engineering
[Gas -98] Data
Book. 1998.
Netusil M, Ditl P (2011) Comparison of three methods for natural gas
[NET -11] dehydration,
Journal of Natural Gas Chemistry 20: 471 - 476
Betting M, Epsom H (2007) High velocities make a unique separator and
[BET -07] dewpointer,
World Oil, 197-200.
Ma Q, Hu D, Jiang J, Qiu Z (2010) Numerical study of the spontaneous
[Ma Q -10] nucleation of
Self-rotational moist gas in a converging–diverging nozzle. International
Journal of
[SOC-98] Siret oil company sahl filed 2017
Computational Fluid Dynamics: 29–36.
60

Natural Gas Treatement

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Natural Gas Treatement

Uploaded by

Copyright:

Available Formats

Libya

Abdul Karim, Ahmed, Gaddafi, Hamad and Ali

Bright Star University – Braga

NATURAL GAS TREATEMENT

DEGREE OF BACHELOR IN CHEMICAL ENGINEERING

Ahmed Abdel Qader Mesbah 21142385

Qadhafi Faraj Alqadhdhafii 21142271

Hamad Abdul Salam Ibrahim 21152918

Ali Said Hamad 10165

Project Report Submitted as Partial Fulfillment of the Requirements for the

Keywords: Glycol Regeneration, glycol loss, and natural gas dehydration

Metallurgical and Materials/Petroleum/Civil / Chemical Engineering. The members of the

Examination Committee are as follows:

Dr. Abdel Hamid El Masry

Abdul Karim Abdullah Mohammed 21152887 ‫ـــــــــــــــــــــــــــــــ‬

Ahmed Abdel Qader Mesbah 21142385 ‫ـــــــــــــــــــــــــــــــ‬

Qadhafi Faraj Alqadhdhafii 21142271 ‫ـــــــــــــــــــــــــــــــ‬

Hamad Abdul Salam Ibrahim 21152918 ‫ـــــــــــــــــــــــــــــــ‬

Ali Said Hamad 10165 ‫ـــــــــــــــــــــــــــــــ‬

ACKNOWLEDGEMENTS .................................................................................................. iii

TABLE OF CONTENTS ...................................................................................................... vi

LIST OF FIGURES .................................................................................................................. x

NOMENCLATURES ............................................................................................................. xii

1.2 Principles of Dehydration ................................................................................................... 4

1.3 Problem Statement .............................................................................................................. 5

1.4 Objectives; - ........................................................................................................................ 5

2.1 Process Simulation of Glycol Regeneration. May 2002. .................................................... 7

2.4Improvement of Natural Gas Dehydration Performance by Optimization of Operating

3.1Types of Dehydration of Natural Gas. ............................................................................... 11

3.2 Dehydration by Using Triethylene Glycol (TEG). ........................................................... 13

3.3 Dehydration Unit. ............................................................................................................. 14

3.4. Process Flow and Components. ....................................................................................... 14

3.4.2 Process Flow Description .............................................................................................. 26

3.5 Factors Which Affect the Efficiency of a Glycol Dehydration System............................ 30

3.6 Operating Problems and Glycol Care: .............................................................................. 32

4. MATERIAL AND ENERGY BALANCE ...................................................................... 34

4.1 Fundamentals of Material Balances .................................................................................. 34

4.2 Fundamentals of energy balance ....................................................................................... 34

4.3 Material and energy balance by HYSYS .......................................................................... 35

5. RESULTS AND DISCUSSION ....................................................................................... 42

5.1 Operation of the Reboiler: ................................................................................................ 43

6.1 Conclusions ....................................................................................................................... 46

6.2 Recommendations ............................................................................................................. 46

7.1 Pressure systems ............................................................................................................... 49

7.3 Control of Toxic Materials ............................................................................................... 50

7.4 Flammability ..................................................................................................................... 51

7.6 Auloignition temperature .................................................................................................. 51

7.7 Flammability 'limits .......................................................................................................... 51

7.9. Sources of Ignition ........................................................................................................... 52

7.10 Electrical Equipment ....................................................................................................... 52

7.11 Static-Electricity .............................................................................................................. 52

7.12 Miscellaneous Sources .................................................................................................... 52

7.13 pressure ........................................................................................................................... 53

7.14 Temperature deviations ................................................................................................... 53

7.15 Types of Protection Equipment ....................................................................................... 54

7.15.4 Face Protection ........................................................................................................... 55

Figure 3.1 Basic Glycol Dehydration Unit............................................................................................ 15

Figure 3.2 Tray Contactor Columns ...................................................................................................... 16

Figure 3.3 schematic flow diagram of a typical glycol contact tower.................................................... 17

Figure3.4 Tray with Bubble Caps .......................................................................................................... 18

Figure 3.5 Mist Eliminators ................................................................................................................... 19

Figure 3.6 Gas-Condensate-Glycol Separators ...................................................................................... 20

Figure 3.7 Regenerators ......................................................................................................................... 22