Hydrocarbon Recovery: Based On Presentation by Prof. Art Kidnay

Hydrocarbon Recovery
Chapter 12
Based on presentation by Prof. Art Kidnay
Reasons for Hydrocarbon Recovery
Field Operations
▪ Reduce liquid content of high GPM gases in gathering systems
▪ Eliminate or reduce potential for condensation (dew-pointing)
▪ Reduce Btu content of gas for use in engines (fuel conditioning)
Plant Operations
▪ Reduce Sales gas Btu content to spec (950 to 1150 Btu/scf)
▪ Eliminate possible condensation
▪ Recover valuable C2+ liquids
Updated: January 4, 2019

2
Copyright © 2019 John Jechura (jjechura@mines.edu)
Plant Block Schematic
Adapted from Figure 7.1,

Fundamentals of Natural Gas Processing, 2nd ed.
Kidnay, Parrish, & McCartney

3
Topics
Fundamentals Recovery Processes
▪ Retrograde Condensation ▪ Dew Point Control and Fuel
Conditioning
Process Components ▪ Low C2+ Recovery
▪ Refrigeration System ▪ High C2+ recovery
▪ Turboexpansion
▪ Heat exchange
▪ Gas-Liquid Separators
▪ Fractionation

4
Fundamentals

Reminder – Liquids Composition
What are Natural Gas Liquids (NGL vs LPG vs LNG)?
Methane
Ethane
Propane
LPG NGL LNG
Butane
Pentanes+
What is the GPM of a gas?

▪ Gallons of NGL components per 1000 scf (Mscf) of gas
▪ Either C2+ GPM or C3+ GPM
6
Retrograde Condensation
1500
B
1250
C
Pressure, Psia
1000
750
A
500
Liquid Vapor
250
0
-300 -250 -200 -150 -100 -50 0 50 100
Temperature, °F

7
Rich Gas Phase Diagram

8
Rich Gas Phase Diagram

9
Operating Conditions Depend on Type of NGL
Recovery

10
Process Components

External Refrigeration
When inlet pressures to Hydrocarbon Recovery are too low to provide
required cooling by expansion we can obtain additional refrigeration by:
▪ Compressing inlet gas to higher pressure
▪ Compressing propane in refrigeration cycle
Compressing propane is usually the best choice

12
Basic Single-Stage Refrigeration System
Compressor Condenser
Suction
Drum
Receiver
J-T Valve
Chiller/ Evaporator

13
Single-Stage Refrigeration cycle
B C
Critical Point
Suction
Drum
Receiver
Pressure
Liquid Vapor J-T Valve

Phase Phase A D
Chiller/ Evaporator
C B
D *
A
Enthalpy

14
1-Stage Propane Refrigeration System
250 Psia
Suction
Drum
Receiver
~120°F
J-T Valve 240 Psia
Chiller/ Evaporator
-40°F, 16 Psia

15
Refrigeration cycle
C B
D
A

16
2 Stage C3 Refrigeration System
Condenser
60 Psia 250 Psia
JT-Valve
- 40°F
16 Psia 25°F
62 Psia
Interstage 25°F
Economizer 62 Psia Receiver
Chiller/ ~120°F
Evaporator 240 Psia
JT-Valve
JT-Valve
Chiller / Evaporator
-40°F, 16 Psia

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2 Stage C3 Refrigeration System
Condenser
60 Psia 250 Psia
JT-Valve
- 40°F
16 Psia 25°F
62 Psia
Interstage
Economizer Receiver
~120°F
240 Psia
JT-Valve
Chiller / Evaporator
-40°F, 16 Psia

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Refrigeration cycle
C B
D A

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Benefits of Staging
Number of Stages 1 2 3
Reduction in Compression Power 0 19% 23%
Reduction in Condenser Duty 0 8% 10%
Condenser Temp = 100oF Chiller Temp = -40oF

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Turboexpanders
Provide
▪ Maximum possible cooling
▪ Work which can drive compressors
Operate
▪ Over wide temperature range
▪ At high speeds, > 15,000 rpm
Require clean gas
Can handle up to 50 wt % liquid formation provided droplet size
less than 20 μm

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Methane Expansion – Isentropic vs. Isenthalpic

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Recovery Processes

Recovery Processes
Dew Point Control and Fuel Conditioning
▪ High recovery not needed
▪ Operating temperatures ~0oF for fractionation
Low C2+ Recovery
▪ < 60% C2+ recovery needed
▪ Operating temperatures ~ -35oF for fractionation
High C2+ recovery
▪ ~ 90% C2+ recovery needed
▪ Operating temperatures ~ -165oF for fractionation

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Dew Point Control and Fuel Conditioning
Traditional technology
▪ Low Temperature Separators (LTS or LTX)
• Standard technology (>60 years old)
Newer technologies
▪ Membrane System
• Newer technology (~10 years old)
▪ Twister
• Newest technology (~5 years old)

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Dew Point Control (No External Refrigeration)
Water
Gas from Knockout J-T
Field Valve
Condensate
Low
Stabilizer
Temperature
Separator
Water Condensate
Glycol Residue Gas

Rich Glycol
Regenerator

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Dew Point Control (With External Refrigeration)
Fig. 16-5, GPSA Engineering Data Book, 14th ed.

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Example Dew Point Control Package
De-Ethanizer Tower
Gas-Gas Heat
Exchanger
Propane Condenser
Gas Chiller
Water Separator
Low Temperature
Separator
http://www.enerflex.com/Oil-and-Gas-Solutions/Gas-Processing/Dew-Point-Control/index.php

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Membrane for Fuel Conditioning
Compressor Cooler
Rich
Gas
C3+ Lean Membrane Fuel Gas

Fuel Gas Slipstream
Compressor
Engine
C3+ Enriched
Gas Permeate

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Twister
Modular, flow dependent
Depends upon pressure ratio, ΔP ~ 20 to 30%
Slip gas is 10 to 15%
Used for dehydration and liquids removal
Is being tested in subsea application
http://twisterbv.com/PDF/resources/Twister_-_How_Does_It_Work.pdf

30
Low C2+ Recovery
Two major processes
▪ Refrigerated Lean Oil
• Lean Oil Absorption first process for liquids recovery
• Existing plants now use refrigerated system
▪ Refrigerated Process
• Simpler than Lean Oil process
• Lower recoveries

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Refrigerated Process
Air Cooler Compressor
Residue
Gas
Cold Separator Fractionator
C3 Chiller
Inlet Gas Reboiler
NGL
Product

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Effect of Composition on C3+ Recovery
90
80
7 GPM
70
C3+ Recovery, %
5 GPM
60
50
40
3 GPM
30
20
-40 -30 -20 -10 0 10 20
Process Temperature, °F

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Recovery Efficiency of C2 and C3
90
7 GPM
80
70 5 GPM
C3
Recovery, %
60
7 GPM 3 GPM
50
40
5 GPM
30
3 GPM C2
20
10
-30 -25 -20 -15 -10 -5 0 5 10
Process Temperature, °F

34
Refrigerated Lean Oil
Fuel Gas
Inlet Gas
NGL
Residue Gas
Cold C3 Vapor
Cold C3 Liquid
Cold C3 Vapor
Cold C3 Liquid
Absorber Rich Oil Low Pressure

Demethanizer Still
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High C2+ Recovery
Requires cryogenic separation
Processes involve:
▪ Propane refrigeration (unless high inlet gas pressure)
▪ Multipass heat exchangers (gas-gas)
▪ Expansion, turbo and JT
▪ Demethanizer column
Two processes:
▪ “1st Generation” – simplest
▪ Gas Subcooled Process (GSP) – more efficient, higher recoveries and
commonly used

36
Considerations for Cryogenic Distillation

37
1st Generation Cryo Process

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Brazed Aluminum Heat Exchanger – “Cold Box”
http://hub.globalccsinstitute.com/publications/co2-liquid-logistics-shipping-concept-llsc-overall-supply-chain-optimization/53-co2

39
GSP Schematic

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Effect of Inerts on Max C2 Recovery
100
90
Maximum Ethane Recovery, %
80
70
60
50
40 1.5 3.0 5.0 8.0

GPM GPM GPM GPM
30
0 2 4 6 8 10 12 14
Nonhydrocarbon Content, mol %

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Propane Recovery Processes
GPSA Engineering Data Book, 14th ed.

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Ethane Recovery Processes

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Summary

Summary
Primary liquids’ production from cold separation
▪ Produced gas at dew point condition at last conditions in contact with
hydrocarbon liquid
Lower liquid content of produced gas has a lower dew point
requiring lower temperatures
Propane refrigeration loop
▪ Typical low temperatures to -40oF
▪ Intermediate pressures reduce compression power & can make chilling
temperatures about 10oF

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Hydrocarbon Recovery: Based On Presentation by Prof. Art Kidnay

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Hydrocarbon Recovery

Updated: January 4, 2019

Adapted from Figure 7.1,

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

What is the GPM of a gas?

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Liquid Vapor J-T Valve

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Condenser Temp = 100oF Chiller Temp = -40oF

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Glycol Residue Gas

Updated: January 4, 2019

Fig. 16-5, GPSA Engineering Data Book, 14th ed.

Updated: January 4, 2019

Updated: January 4, 2019

C3+ Lean Membrane Fuel Gas

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Cold Separator Fractionator

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Absorber Rich Oil Low Pressure

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

40 1.5 3.0 5.0 8.0

Updated: January 4, 2019

GPSA Engineering Data Book, 14th ed.

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

Updated: January 4, 2019

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