A Study on

Processing of Natural Gas &

It’s Transmission

A Minor Project report submitted

In partial fulfillment of the requirement for the award of degree of

Bachelor of Technology

By

Adarsh Mangal
Chandrakant
Nikhil Verma
Shashwat Jha
Saurabh Barman

Under the supervision of

DR. Anil Kumar Poonia

(Associate Professor)

DEPARTMENT OF CHEMICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR
RAIPUR, CHHATTISGARH
(DECEMBER, 2021)
 NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR
DEPARTMENT OF CHEMICAL ENGINEERING
G.E. Road, Raipur - 492010 (C.G)

DECLARATION

We hereby declare that in the minor project work report entitled, “Processing of Natural Gas
& It’s Transmission” which is being submitted to National Institute of Technology Raipur for
the award of the degree of Bachelor of Technology in Chemical Engineering is a bonafide
report of the work carried out by us under the guidance of Associate Professor Dr. Anil
Kumar Poonia, Department of Chemical Engineering, National Institute of Technology
Raipur.

The material contained in this project report has not been submitted to any university/institution
for the award of any degree.

Adarsh Mangal
Chandrakant
Nikhil Verma
Shashwat Jha
Saurabh Barman

1
 NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR
DEPARTMENT OF CHEMICAL ENGINEERING
G.E. Road, Raipur - 492010 (C.G)

CERTIFICATE

This is to certify that the minor project report entitled “Processing of Natural Gas & It’s
Transmission” which is submitted by below listed students in partial fulfillment of the
requirements for the award of degree of Bachelor of Technology, is a record of the candidates
own work carried out by them under my supervision. The matter embodied in this project report
is original and has not been submitted elsewhere for the award of any other degree.

S.No Name of Student Roll No.

1 Adarsh Mangal 18113004

2 Chandrakant 18113019

3 Nikhil Verma 18113036

4. Shashwat Jha 18113049

5. Saurabh Barman 18113903

Dr. Anil Kumar Poonia

Associate Professor
Department of Chemical Engineering
National Institute of Technology Raipur

2
ACKNOWLEDGEMENT

The success and final outcome of this minor project work required a lot of guidance and
assistance from many people and we are extremely privileged to have got this all along the
completion of our project work. All that we have done is only due to such supervision and
assistance and we would not forget to thank them.

We are deeply indebted to our mentor Dr. Anil Kumar Poonia, Associate Professor, Department
of Chemical Engineering, National Institute of Technology Raipur who gave us the golden
opportunity to do this wonderful project on the topic “Processing of Natural Gas & It’s
Transmission” which also helped us in doing a lot of Research and we came to know about so
many new things, we are really thankful to him.

We are very thankful and fortunate enough that we build and work like a team to get constant
encouragement, providing all the necessary information and materials for developing a good
system, support and guide each other which helped us in successfully completing this project
work.

Adarsh Mangal
Chandrakant
Nikhil Verma
Shashwat Jha
Saurabh Barman

3
ABSTRACT

The objective of a natural gas processing plant is to produce a methane-rich gas by removing the
acid gases, heavy hydrocarbons, nitrogen, water, and other impurities. This chapter gives an
overview of the design and function of the different process units within a natural gas processing
plant.
Raw natural gas from production wells contains a full range of hydrocarbons, carbon dioxide,
hydrogen sulfide, nitrogen, water, and other impurities. They can originate from any one of
three types of production wells: crude oil wells, gas wells, and condensate wells. Natural gas
that comes from crude oil wells is the associated gas. Gas can exist as a gas cap over the crude
oil reservoirs, or can be dissolved by the crude oil under pressure. Natural gas from gas wells
or from condensate wells, in which there is little or no crude oil, is the non-associated gas. Gas
wells generally produce sour natural gas, while condensate wells produce natural gas
condensate or gasoline that is saturated with natural gas. Raw natural gas can also come from
unconventional sources. Natural gas can be found in coal seam, as the coal-bed methane gas.
It can be the associated gas from shale oil production. Natural gas from offshore wells is
another source. The unconventional sources typically contain a high level of Carbon dioxide
and nitrogen, which can be found in different parts of the world. These gas reservoirs are
believed to be much larger than previous predictions. As technology in exploration and drilling
advances, the unconventional reserves are becoming economically attractive and will become
an important source of energy supply.
Extraction of natural gas is very crucial in our life because it is a clean source of energy and
contains lighter paraffins i.e. methane, ethane, propane, butane, etc. and other constituents and
it can be utilized as precious chemical feedstock to generate products like CNG, LPG and NGL
and used as a raw material for fertilizers.
However, natural gas has many impurities in its raw state so it undergoes into various
processing steps which includes pretreatment of feed (i.e. mercury removal, sour gas removal
and dehydration of natural gas etc) and the extraction of natural gas with its separation of other
byproducts which can be utilized for commercial purposes.
The optimum production of natural gas in a safer way is the main concern of various chemical
industries which have a potential risk of hazard. There are many different kinds of unit
operations and unit processes employed for the transmission of natural gas which leads to
sustainable development required for social, economic development and has a harmful effect
on the environment or global climate.

4
 TABLE OF CONTENTS

Sr No. TITLE Page No.

DECLARATION i

CERTIFICATE ii

ACKNOWLEDGEMENT iii

ABSTRACT iv

1 INTRODUCTION 1-2

1.1 Context of Study

1.2 Natural gas origin and sources

1.3 Natural gas composition and classification

2 Natural gas properties 3-5

2.1 Chemical and physical composition

2.2 Thermodynamic properties

3 Natural gas processing 6-14

3.1 Chapter Overview

3.2 Gas processing plant configuration

3.3 Sulfur recovery and handling unit

3.4 Gas dehydration unit

3.5 Hydrocarbon dew pointing

3.6 Nitrogen rejection

3.7 Gas compression and Transmission

4 Gas plant for NGL production 15-16

4.1 Chapter Overview

4.2 Carbon dioxide removal

5
 4.3 Mercury Removal
5 CONCLUSION 17
References 18-20

6
CHAPTER 1
INTRODUCTION

This chapter provides the insights of this study. The first chapter covers the context of the study
or information, the objectives of the proposed study.
1.1 Context of Study
Natural gas is the most commonly used highly efficient fossil fuel because it is a clean source
of energy and contains lighter paraffins i.e. methane, ethane, propane, butane, etc. and other
constituents. Natural gas can primarily be used as fuel and also it can be utilized as a source
of hydrocarbons for petrochemical feedstock to generate products like CNG, LPG and NGL
and used as a raw material for fertilizers.
1.2 Natural Gas origin and sources
Different theory was proposed for the origins of fossil fuels but the most broadly acceptable
theory for the origin of natural gas imagines that natural gas hydrocarbons obtained from
organic material (like land and aquatic animals, plants and microbes) which was carried within
sediments such that they were accumulated and converted over many million years into its
current form. Biogenic and thermogenic are two important mechanisms involving
disintegration of fossil organic matter in the sediments. Biogenic gas is developed at shallow
depths and less temperatures through bacterial action on the organic debris depositing in the
sediments while thermogenic gas is developed at deeper depths by disintegration of organic
matter, called kerogen, deposited in fine-grained sediments, particularly for clays and shales.
This disintegration happens through the multiple effects of temperature and pressure.
Thermogenic gas is mainly supposed to be evolved by two mechanisms: direct thermal cracking
of sedimentary organic material and secondary thermal cracking of oil which is developed in
the first stage. Thermal cracking of sedimentary organic material resulting into primary
thermogenic gas which accompany oil and secondary thermogenic gas is accompanied with
insoluble solid material known as pyrobitumen which is developed from secondary thermal
cracking of oil.

Both mechanisms require thermal cracking with some quantity of sustained pressure mostly
due to the weight of the sedimentary development. Less information is accessible on the time
needed to produce thermogenic gas than the normal presumption that it is a long time. Natural
gas derives from both “conventional” (simpler to generate) and “unconventional” (tougher to
generate) geological structures. Conventional gas is generally “free gas” carried in multiple,
comparatively small, porous regions in different naturally appearing rock transformations such
as carbonates, sandstones, and siltstones. Conventional natural gas typically happens in deep
reservoirs, either related with crude oil (associated gas1) or in reservoirs that hold little or no
crude oil (nonassociated gas2).

Natural gas from coal also called as coal-bed methane, geopressured aquifers, tight gas sands,
gas shales and gas hydrates are termed as unconventional gas resources. The general properties
of the various types of unconventional gas resources is such that they contain huge amounts of
natural gas, but it is typically more hard to liberate this gas as correlated with conventional
reservoir rocks. New advanced methods are consistently being formed to ensure more accurate

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approximations of the quantity of gas in these unconventional reservoirs and to activate these
rocks to liberate the gas.

1.3 Natural Gas composition and classification

Natural gas generally contains hydrocarbons and non-hydrocarbon components associated in a
complex mixture and exhibits a gaseous state under atmospheric situations. Natural gas
typically contains hundreds or more than hundreds of various compounds in different
proportions. However, it is unbelievable but it happens when two wells connected from
identical reservoirs can also liberate gases of non-identical composition when the reservoir is
exhausted. Primary components of natural gas is methane and it also contains considerable
amount of ethane , propane , butane , pentane , also has some traces of hexane and heavier
hydrocarbons. Many natural gases generally contain carbon dioxide , nitrogen, hydrogen
sulfide and other different sulfur compounds like carbonyl sulfide, carbon disulfide and
mercaptans (R-SH) and also present some traces of helium, argon and hydrogen. Natural gas
also contains some traces of mercury, arsenic, uranium and selenium. Various types of natural
gas can be classified into dry, wet and condensate form relying upon the composition of
hydrocarbons heavier than methane .

If natural gas is in dry form then it only contains methane in its purest form because all ordinary
related hydrocarbons are removed. But if other hydrocarbons exist in the natural gas it forms a
wet phase because liquid phase can be seen in wet form during production at surface situations.
If natural gas contains a large amount of hydrocarbon liquids and after then develops a liquid
phase in the reservoir during production of exhaust operation and hence it transforms into its
condensate form. Classification of natural gases is based on its liquid content as either rich or
lean words define the quantity of surely recoverably liquids and these words also employ ethane
and heavier constituents but sometimes utilized for propane and heavier constituents when
ethane is not considered as a valuable or desired product. Natural gas can also classify on the
basis of sulfur content either as sour or sweet. If natural gas has less sulfur content then it is
called sweet gas which is desirable but when natural gas has high sulfur content then it is termed
as sour gas which goes for treatment to meet the desired specifications given by environmental
laws. The sour and sweet words define both acid gases (Carbon dioxide and Hydrogen sulfide).
Sweet natural gas holds only less than 4ppmv of Hydrogen sulfide but Carbon dioxide can be
accepted upto higher levels like 3-4 mol%, as long as heating value of sales gas is acceptable.

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CHAPTER 2 Natural Gas Properties

Natural gas is colourless, odourless, tasteless, odourless, tasteless, odourless, tasteless,

shapeless, and lighter than air. The natural gas would then be sold within stipulated pressure,
heating value, and maybe Wobbe Index restrictions after suitable treatment for acid gas
reduction and moisture and hydrocarbon dew point correction (often referred to as the Wobbe
Number). Because one of the most common applications of natural gas is as a fuel, pipeline gas
is typically bought and sold based on the amount of heat it can create when burned. Natural
gas's heating value varies depending on its accumulations, which are impacted by the amount
and type of gases it contains. In custody transfer, the gas sector always employs the gross
heating value (also known as greater heating value). Obviously, the heat of condensation of
water at the defined conditions is the numerical difference between the two net and gross
heating values. Direct measurement, such as calorimetry, or computation of the value based on
gas analysis are both used to estimate heating values for custody transfer. Natural gas's heating
value is measured in British thermal units (Btu). The energy required to raise the temperature
of one pound of water by one degree Fahrenheit is measured in British thermal units. The
acronyms MBtu (1000 Btu) or MMBtu (1 million Btu) are more typically used for larger
industrial customers. Because metres measure volume rather than energy content, gas
companies generally use a conversion factor of 1000 Btu/ft3 to convert the volume of gas
consumed to its heat equivalent and so determine the actual energy use. The Wobbe Index is a
measurement of the heat input to an appliance through a particular aperture at a given gas
pressure (defined as the gross heating value of the gas divided by the square root of the specific
gravity). A combustion diagram for an application may be produced using this as the vertical
coordinate and the flame speed factor as the horizontal coordinate appliances, with the aid of
appropriate test gases. This diagram depicts the range of variations in the Wobbe Index and
flame speed factor of gases that can occur without causing incomplete combustion, flame lift,
or the lighting back of pre-aerated flames for the provided range of appliances. This method of
predicting combustion properties is not accurate enough to completely eliminate the
requirement for practical testing of new gases. Because natural gas transported to pipelines has
virtually no odour, most rules mandate the addition of an odorant so that the existence of the
gas can be identified quickly in the event of an accident or a leak. The addition of trace amounts
of organic sulphur compounds to the gas before it reaches the user provides this odorization.
The sulphur compound is added to natural gas as a chemical odorant (a mercaptan, also known
as a thiol, with the general formula R-SH and the odour of rotten eggs) so that it can be smelled
if there is a gas leak. When the concentration of gas in air reaches 1%, a user must be able to
recognise the presence of the gas by odour. Because natural gas has a lower limit of
flammability of about 5%, this criterion is equivalent to one-fifth of the lower limit of
flammability. The combustion of these minute amounts of odorant does not result in any
significant sulphur content or toxicity issues. We'll go over crucial gas parameters like specific
gravity, compressibility factor, formation volume factor, density, isothermal compressibility,
viscocity.
.

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 [1]

2.2 Thermodynamic properties

The laws of thermodynamics can be used to anticipate the behaviour of hydrocarbons in a
variety of situations. The most interesting properties of natural gas are its specific heats and
Joule–Thomson coefficient.

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CHAPTER 3 Natural Gas Processing

3.1 Chapter Overview

Raw natural gas streams must be treated to comply with emissions regulations and pipeline gas
specifications. Typical pipeline gas specifications. Specifications are necessary to ensure the
quality of gas and to ensure consumers are provided with clean and safe fuel gas.The product
gas must meet the heating values or Wobbe Indexes specifications, which are required to ensure
optimum operation of gas turbines and combustion equipment to minimize emissions.In
addition, pipeline operators require that the product gas be interchangeable with existing
pipeline gas.When the gas is high in heavy hydrocarbon contents, they must be removed to
meet the heating value specification.
The liquid removed from the process can often be sold at a higher price than natural gas.
Propane and butane can generally be sold as liquefied petroleum gas (LPG).. Ethane can be
used as feedstock to petrochemical plants. The components can be exported to refineries as a
blending stock for gasoline. The characteristics of various types of natural gas liquid (NGL)
products can be found in GPSA Engineering Data Book (2004). It is important to recognize the
definitions and specifications of the treated gas and product specifications. Theproduct
specifications for condensate and NGL. Small changes to the specifications may have
significant impacts on the treatment and processing options, affecting the cost and complexity
of the gas plant.

3.2 Gas processing plant configurations

The configuration and complexity of a gas processing plant are determined by the feed gas
compositions and the levels of treatment and processing necessary to achieve product standards
and emission restrictions. Liquid values can also be the drivers for process complexity, which
determines the levels of NGL components to be recovered two schematics of a gas processing
plant that have been simplified. To fulfil sales gas criteria, the initial strategy is to remove
condensate, sulphur, and the heavier components. The second scheme is to process the feed gas
for recovery of the NGL components to increase plant revenues. Typically, the leftover gas is
recompressed and sent to a sales gas pipeline. It can also be sent to a natural gas liquefaction
plant for liquefied natural gas (LNG) production, used as fuel gas to power plants, or as a
feedstock to petrochemical plants. The gas processing facility must be designed to be "fit-
forpurpose," matching the project's economic and environmental requirements. While
pollutants and sulphur must be removed to fulfil emissions regulations in the first scheme, the
level of processing in the second scheme depends on the project. It is determined by the
commercial agreements reached between upstream producers and downstream distributors and
customers.

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3.3 Sulfur recovery and handling unit

Since the acid gas from the amine regenerator includes concentrated Hydrogen sulfide, it cannot
be vented or flared for safety reasons. Acid gas can be reinjected back into reservoirs for
sequestration if reinjection wells are available, avoiding the need for a sulphur recovery plant.
If reinjection wells are available, acid gas can be reinjected back to the reservoirs for
sequestration, which would avoid the investment of a sulfur recovery unit. Hydrogen sulfide is
treated in a sulphur recovery unit in most cases when a reinjection facility is not available. To
satisfy today's emission target, the sulphur recovery unit can be combined with a tail gas
treatment unit to achieve 99.9% sulphur removal.
• Approximately 25% of natural gas produced from new sources must be treated in some
way to eliminate hydrogen sulphide and recover elemental sulphur from acid gas
streams.
.
• Hydrogen sulfide is a highly flammable gas and has a wide limit of flammability, and
unlike elemental sulfur, it is highly toxic.

• Venting or flaring Hydrogen sulfide into the environment is prohibited for

environmental and safety reasons; consequently, it must be converted to the harmless
elemental sulphur.

• Technically, chemical conversion of Hydrogen sulfide for disposal as solid waste (such
as calcium sulphate) is possible, but it is neither cost-effective nor practical. Acid gas
injection is an alternative to sulphur recovery in distant regions or when there is no
market for sulphur.

Modified Claus process

◈ The entire reaction is carried out in two phases in the modified Claus sulphur recovery
method. Only enough air is introduced in the first stage (thermal section) to oxidise
onethird of the entering Hydrogen sulfide to Sulphur dioxide. This reaction is extremely
exothermic and does not have an equilibrium limit.

𝐻2𝑆 + 𝑂2 → 𝑆𝑂2 + 𝐻2𝑂

◈ In the reaction furnace, the unburned Hydrogen sulfide in the acid gas reacts with the
produced to Sulphur dioxide yield elemental sulfur vapor. This reaction is referred to
as the Claus reaction and is shown by
𝑆𝑂2 + 𝐻2𝑆 ↔ 𝑆2 + 2𝐻2𝑂

◈ Usually, 60–70% of the total conversion of 𝐻2𝑆 elemental sulfur is achieved in the
thermal stage.

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 [2]

Thermal section
The reaction furnace's hot products of combustion travel through the tubes of the waste heat
boiler (WHB), where they are partially cooled to 600–800 degrees Fahrenheit by creating
highpressure or medium-pressure steam. The sulphur vapour species shifts through a variety of
exothermic processes when the gases from the reaction furnace cool in the WHB, resulting in
various sulphur species. In the first Sulphur condenser, the cooled gases from the WHB are
further chilled (to 340–375 F) by generating low-pressure or medium-pressure steam, where
the majority of the sulphur vapour generated in the reaction furnace is condensed. The
condensed sulphur is separated from the gas and drained from the condenser to the sulphur
collection pit via a hydraulic seal and rundown line.

Catalytic section
There are three processing steps in the catalytic portion. The first step is the reheater, which
boosts the temperature of the gas from the sulphur condenser to prevent sulphur vapour
condensation, as sulfur continues to form by the Claus reaction. Typically, the first reheater is
required to raise the temperature to around 600 degrees Fahrenheit, which is essential to
promote COS and CS2 destruction. In the second step, the hydrogen sulfide and sulfur dioxide
are reacted over an activated alumina catalyst in a series of catalytic reactors (1– 3).The first
reheater will raise the temperature to roughly 600 degrees Fahrenheit, which is necessary for
COS and CS2 destruction. These reactions are both exothermic and are represented as:

2𝐻2𝑆 + 𝑆𝑂2 ↔ 𝑆6 + 2𝐻2𝑂

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 2𝐻2𝑆 + 𝑆𝑂2 ↔ 𝑆8 + 2𝐻2𝑂

In the third step, the sulfur condenser is used to remove liquid sulfur, the product of reaction.
This changes the equilibrium, allowing for more reactions in the following catalytic converter
(reactor).The final sulfur condenser is typically at 270 F to minimize sulfur vapor losses in the
vent gas. The effluent (tail) gas, which still contains significant amounts of sulphur compounds
as well as a small amount of sulphur as vapour and entrained liquid, is either routed to a tail gas
treating unit or discharged into the atmosphere (TGTU) for further sulfur recovery and
minimizing impacts on the environment or to a thermal oxidizer to incinerate all the sulfur
compounds in the tail gas to sulfur dioxide before dispersing the effluent to the atmosphere.
The sulfur recovery depends on such things as feed composition, age of the catalyst, and
number of reactor stages. Standard Claus units have sulphur recovery efficiencies of 90–96%
for a two-stage catalytic conversion and 95–98% for a three-stage catalytic conversion. Because
of equilibrium limitations and other sulfur losses, overall sulfur recovery efficiency in a general
Claus unit is typically limited to 98%.

3.4 Gas dehydration unit

After the acid gas has been removed, the gas is sent into a gas dehydration plant where it is
treated to meet the appropriate water dew point criteria for pipeline propagation or
transmission, generally 7 lbs water/ MMscf. Water dew point limits for frigid climates might
be as low as -40 degrees Fahrenheit to avoid hydrate formation in pipelines. Different types of
dehydration technologies are available for the dehydration process including glycol
dehydration and solid desiccant (i.e., molecular sieves, silica gels, activated alumina)
dehydration which relies on capacity of plant and verge of drying.

🞂 Natural gas fluid from production tanks or wells is saturated with water vapours, it
condenses and creates gas hydrates, which are solids, which can gather and jam
pipelines with appliances, disrupting operations and preventing gas flow production.
🞂 Dehydrating natural gas methods involves wet gas absorption, adsorption, and cooling
When a low dew point gas is required for pipeline gas or NGL recovery, liquid glycol
solvent is frequently utilised for absorption and solid desiccants for adsorption. Cooling
of wet gas allows expansion and refrigeration of natural gas with inhibitors injected is
normally used for low dew point fall in generation of pipeline gas for light weather
places.
🞂 Water vapours in the gas phase can be absorbed in a liquid solvent solution, which is
used in the dehydration of natural gas. However many liquids have a tendency to
absorb water from gas and these liquids having certain desirable characteristics for
dehydration process which are as follows: . Highly efficient solvent (liquid) for
absorption.
2. Simple and economic revival.
3. Non-corrosive and non-toxic.
4. Not facing any operational issues like high viscosity when used in large
concentrations.

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 5. Least amount of hydrocarbons should be absorbed in the gas and not capable of
contamination by acid gases.
DRIZO DEHYDRATION SYSTEM
🞂 The DRIZO dehydration system is responsible for partition operation in the regenerator
overhead where the oil is split from the aqueous phase. Entrained glycol in aqueous
phase is refluxed back to the regenerator. The hydrocarbon phase is first removed then
heated and now filtered, and employed as the stripping gas for TEG regeneration.
Purity and quality of lean glycol can be maintained by manipulating the quantity of
stripping gas recycle and its regeneration temperature.
🞂 The important benefits of the DRIZO process are that all BTEX [benzene, toluene, ethyl
benzene, and xylenes are a volatile organic compound (VOC), which must be burnt
according to meet desired emissions specifications] compounds are covered again from
the regenerator before expose into the environment and no external stripping gas is
mandatory.

The DRIZO Existing dehydration units, which must be improved to meet desired criteria of
higher glycol quality and purity for better BTEX emission control, are often preferred.
However, as compared to traditional gas stripping, the DRIZO method can regenerate greater
purity TEG while also allowing for a large water dew point drop of upto 150 F.
The quantify of the degree of gaseous compound adsorbed to some extent of partial pressures
at a constant temperature shows in a graph known as an adsorption isotherm, depending on the
type of adsorbent, the type of adsorbate, and intermolecular interactions between the adsorbate
and the adsorbent surface, which can have a variety of configurations.
ADSORPTION
🞂 The most commonly used adsorbents for natural gas drying are activated alumina, silica
gel, and molecular sieves. For natural gas drying up to –70°C, activated alumina is the
least expensive adsorbent material. But activated alumina have many limitations such
as coadsorption of hydrocarbons which affects a low water duty and ruin in production
and rehydration touch with wet gas at large temperature during its regeneration process.
🞂 Silica gel has a high water adsorption capacity and also adsorbs some C5+ components,
hence it was developed for the aim of removing water and gasoline from natural gas at
the same time. The water dew point obtainable by using silica gel is near about –55°C
to –60°C.
🞂 Molecular sieves are synthetic zeolites (i.e., metal aluminosilicates) with 3D crystalline
structures having interlinking cavities of equal size, split by equally uniform, narrower
apertures. Molecular sieves can dry natural gas to a dew point lesser than –100°C.
🞂 As a result, these chemicals can be used to dry natural gas in its raw state for cryogenic
hydrocarbon recovery.

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 [3]

3.5 Hydrocarbon dew pointing

The hydrocarbon dew point temperature must be reduced to a lower temperature that is below
the coldest ambient temperature during transmission. This is to avoid hydrocarbon liquid
condensation in the pipeline, which is a safety hazard. Depending on the phase envelope of the
pipeline gas, the hydrocarbon dew point can actually increase when the pressure is lowered,
which must be considered in the design of the unit.

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 [4]
3.6 Nitrogen rejection
Nitrogen content in natural gas varies depending on the gas reservoirs. Nitrogen can be naturally
occurring in high concentration in some gas fields, such as in the South China Sea where 30–
50% nitrogen content gas can be found. For onshore facilities where nitrogen injection is
employed for enhanced oil recovery, nitrogen content can also be very high. When nitrogen is
present in high concentrations, it should be removed downstream of the NGL recovery unit.
Heavy hydrocarbons (BTEX aromatics) must be removed in the NGL recovery unit, as these
hydrocarbons will solidify in the cryogenic section of the nitrogen rejection unit. If the gas is
used for LNG production, the nitrogen content must be removed to below 1 mol% to meet LNG
specification. Nitrogen is not desirable in LNG products, as it will lower the liquefaction
temperature, which would increase the power consumption. Nitrogen removal by cryogenic
separation is more efficient than other alternatives. Membrane separators and molecular sieves
can be used for nitrogen rejection, but their processing capacity is relatively limited. They are
suitable for bulk separation, and are not economical to meet stringent specifications. The
rejected nitrogen would contain a significant amount of hydrocarbons, which may be an
environmental issue.
Nitrogen rejection methods can be classified into cryogenic and non cryogenic processes-
1. Cryogenic processes
Cryogenic nitrogen rejection technology, which is the most common method of
removing nitrogen from natural gas, uses the difference of boiling points between
nitrogen and methane for separation. Cryogenic processes use Joule–Thomson (JT)
cooling of the high-pressure gas, and separation in a distillation column to produce a
nitrogen overhead product and a methane-rich bottom. The nitrogen product contains
less than 1 mol% methane, which can be safely dischargedto the atmosphere. The
methane-rich bottom contains less than 1 mol% nitrogen that can be sent to the pipeline
or natural gas liquefaction plant. Cryogenic processes are typically used to treat natural
gas containing more than 10 mol% nitrogen and are proven to be economical in
processing gas flow rate ranging from 30 MMscfd up to 900 MMscfd.
2. Non Cryogenic processes
Noncryogenic nitrogen separation processes include mainly pressure swing adsorption
(PSA) and membrane separation. PSA uses a zeolite adsorbent to selectively separate
nitrogen from methane in a cyclic process. The process includes adsorption of methane
at high pressure, during which nitrogen is separated at pressure. Natural gas with
lownitrogen content is produced at low pressure. The adsorbent can be regenerated with
a combination of pressure and thermal changes. PSA technology is limited in capacity
and can typically handle 2–15 MMscfd gas flow rate. The drawback of this process is
that natural gas is produced at low pressure requiring recompression to pipeline
pressure. Also, the hydrocarbon content in the rejected nitrogen is significant which
represents a production loss. The losses can be somewhat reduced by recompression to
the feed section, which is seldom justified because of the high compression cost. For
coal bed methane applications where there are few impurities, the Molecular Gate
adsorption-based technology (developed by Engelhard) can be used to handle small gas
flow of 0.5 MMscfd. The Molecular Gate technology traps nitrogen in a unique
adsorbent material while letting methane flow through. The Molecular Gate adsorbent
is a titanium silicate molecular sieve designed with a 3.7-A˚ pore size. Because nitrogen
has a smaller molecular diameter (3.6 A˚ ) than methane (3.8 A˚ ), nitrogen can enter

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 the pore and be adsorbed while methane passes through the fixed bed of adsorbent with
minimal pressure losses.

[5]

3.7 Gas compression and transmission

A reciprocating compressor is a positive displacement machine in which the compressing and displacing
element is a piston moving linearly within a cylinder. The reciprocating compressor uses automatic

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spring-loaded valves that open when the proper differential pressure exists across the valve describes
the action of a reciprocating compressor using a theoretical pressure–volume (PV) diagram. In position
A, the suction valve is open and gas will flow into the cylinder (from point 1 to point 2 on the PV
diagram) until the end of the reverse stroke at point 2, which is the start of compression. At position B,
the piston has traveled the full stroke within the cylinder and the cylinder is full of gas at suction pressure.
Valves remain closed. The piston begins to move to the left, closing the suction valve. In moving from
position B to position C, the piston moves toward the cylinder head, reducing the volume of gas with an
accompanying rise in pressure. The PV diagram shows compression from point 2 to point 3. The piston
continues to move to the end of the stroke (near the cylinder head) until the cylinder pressure is equal to
the discharge pressure and the discharge valve opens (just beyond point 3). After the piston reaches
point 4, the discharge valve will close, leaving the clearance space filled with gas at discharge pressure
(moving from position C to position D). As the piston reverses its
travel, the gas remaining within the cylinder expands (from point 4 to point 1) until it equals suction
pressure and the piston is again in position A.

Centrifugal compressors
A centrifugal compressor achieves the compression task by converting the mechanical energy from the
driver to kinetic energy in the gas, using the forces that moving and stationary airfoils exert on this gas.

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We want to introduce now the essential components of a centrifugal compressor that accomplish the
tasks specified above. The gas entering the inlet nozzle of the compressor is guided to the inlet of the
impeller. An impeller consists of a number of rotating vanes that impart the mechanical energy to the
gas. The gas will leave the impeller with an increased velocity and increased static pressure. In the
diffuser, part of the velocity is converted into static pressure. Diffusers can be vaned, vaneless, or volute
type. If the compressor has more than one impeller, the gas will be again brought in front of the next
impeller through the return channel and the return vanes. If the compressor has only one impeller, or
after the diffuser of the last impeller in a multistage compressor, the gas enters the discharge system.

[7]

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 CHAPTER 4
Gas plant for NGL production

4.1 Chapter Overview

There are economic incentives to create LPG and sometimes ethane liquid as byproducts when
the feed gas contains a considerable proportion of liquids, the hydrocarbons. Storage, piping,
metering, and custody transfer are all common components of a liquid facility, which must also
contain a safety mechanism to prevent liquid leakage or spillage. This plant is more complicated
and expensive than a simple hydrocarbon dew point plant.

[8]

4.2 Carbon dioxide removal

Carbon dioxide removal is necessary to achieve the Carbon dioxide criteria for sales gas, which
is normally limited to 2–3 mol%. To avoid Carbon dioxide freezing in the cold part of the NGL
recovery unit, Carbon dioxide may need to be reduced to even lower levels. 2 mol% of carbon
dioxide may usually be tolerated in the propane recovery process since the NGL column
operates at a warmer temperature. Unless the gas is transported to a liquefaction machine,
which would necessitate Carbon dioxide removal down to 50 ppmv, deep Carbon dioxide
removal may not be necessary. If the NGL recovery unit is used for ethane recovery, the
demethanizer column will run at a much lower temperature, increasing the risk of Carbon
dioxide freezing. Even if Carbon dioxide does not freeze, a significant amount of Carbon
dioxide will condense with the ethane product, which may not meet the Carbon dioxide criteria

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in the ethane product (typical Y-Grade NGL limits Carbon dioxide content in ethane to 500
ppmv). When ethane recovery is required, the design must guarantee that Carbon dioxide in the
feed gas is reduced sufficiently to avoid Carbon dioxide freezing while still meeting the ethane
product's Carbon dioxide requirements.

4.3 Mercury removal

Mercury is always present in ppm quantities in the feed gas. To avoid mercury damage on the
brazed aluminium heat exchangers, mercury must be removed using carbon beds or catalytic
beds. To obtain high NGL recovery, brazed aluminium exchangers are often employed in the
NGL recovery process. Aluminum is highly reactive to mercury and can quickly corrode,
resulting in the failure of the exchangers. The mercury removal bed is normally designed to
remove mercury at a concentration of less than 0.01 mg/Nm3. The mercury removal step can
be placed either upstream or downstream of the acid gas removal unit and the dehydration unit.
Installing a mercury removal unit upstream can prevent mercury from migrating to downstream
equipment, providing mercury-free sales gas and liquid goods. For NGL recovery, there are
various patents and private technologies. Unlike acid gas removal units, the selection of an
NGL recovery method must be based on NGL recovery levels, feed gas pressure, temperature,
gas compositions, and product criteria, as well as NGL recovery flexibility. The NGL process
must be able to manage both rich and lean gas scenarios. If nitrogen injection is considered in
the same formation, the design must take into account the higher nitrogen feed gas case. The
rich gas case controls the design of the front part of the NGL recovery unit in the summer since
the refrigeration duty is higher. However, because the gas flow is higher, the lean gas and high
nitrogen gas would govern the design of the demethanizer and residue gas compressor. The
NGL recovery machine can be configured to recover either propane or ethane. When ethane
margins are low, the NGL process can be designed for ethane recovery and operated on ethane
rejection for operating flexibility. Another option is to build a propane recovery plant that can
also be used for ethane recovery.

The desired propane and ethane recovery determines the composition of NGL products.
Because the NGL flow rate and pipeline pressure are higher, the NGL product pump and
pipeline must be constructed for ethane recovery. NGL is often transported to an NGL
fractionation centre, where the final liquid products are created. To achieve product criteria,
NGL products may require extra treatment and processing.

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CHAPTER 5
CONCLUSION

Natural gas is the most popular utilized fossil fuel because it not only gives clean energy but
is also employed as a raw material for petrochemical products like CNG, LPG and NGL and
also for fertilizers. Different theory was given by scientists for the origin of fossil fuels but
the most widely acceptable theory is that fossil fuels is made up of organic material like land
and aquatic plants, animals and microbes was hold by sediments such that it accumulated and
transformations take many million years such that it involves two mechanisms are biogenic
and thermogenic through disintegration of organic matter in the sediments. Biogenic occurs
at shallow depths and less temperature through bacterial behaviour on the organic debris
depositing in the sediments while thermogenic is caused due to disintegration of organic
matter at deeper depths concentrated in fine-grain sediments. Natural gas derives from both
conventional and unconventional geological structures. Conventional gas is typically free gas
held in multiple, relatively small, porous regions in different naturally appearing rock
geological structures. Natural gas from coal also called coal-bed methane, geopressured
aquifers, tight gas sands, gas shales and gas hydrates come under unconventional gas
resources. Natural gas normally contains a complex mixture of hydrocarbons and
nonhydrocarbons exhibit gaseous state under atmospheric situations which includes hundreds
of compounds in non-uniform proportions. Natural gas consists of methane as main
component and other components are ethane, propane, butane , pentane , also has some traces
of hexane and heavier hydrocarbons. Many natural gases generally contain carbon dioxide ,
nitrogen , hydrogen sulfide and other different sulfur compounds like carbonyl sulfide ,
carbon disulfide and mercaptans (R-SH) and also present some traces of helium, argon and
hydrogen. Natural gas also contains some traces of mercury, arsenic, uranium and selenium.
Classification of natural gas is based upon composition of hydrocarbons heavier than methane
into dry, wet and condensate form and also natural gas can classified on the basis of sulfur
content into sweet and sour and also classified on its liquid content into rich and lean.

Natural gas must undergo treatment to meet desired emission specification by environmental
laws to assure gas standards and give safe and clean fuel gas to its customers.
The product gas necessarily fulfills the heating values or Wobbe Index parameters which
needs to assure optimum performance of gas turbines and combustion appliances to reduce
emissions.
Amine regenerator comprises acid gas of concentrated which do not expose into atmosphere
for safety accounts and also due to acid gas pollution. If reinjection wells are operable then
acid gas can reinjected back to reservoirs which cancel investment in sulfur recovery unit.
Nowadays this unit combined with tail gas operating unit to attain 99.9% sulfur removal.
Modified Claus process consists of two reactors are burner and convertor reactor. In burner
reactor. Main parameters related with burner reactor are ratio and its temperature. Operating
temperature in burner reactor is 1850F to assure that all ammonia content in the feed gas is
perfectly finished to safeguard the catalysts in convertor reactor. The exit gas from burner
reactor is chilled to 450F in the waste heat reboiler then it goes to the convertor reactor for
catalytic transformation into elemental sulfur and water. The convertor exit product is
supplied in condenser unit to obtain elemental sulfur as a liquid product. Less quantities of S

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developed in the burner reactor also recovered later the waste heat boiler. Generally, 3 sets of
condenser-convertor units connected in series are required to attain 95% recovery of S.
Natural gas fluid from production tanks is saturated with water fumes and if gas is cooler than
its hydrate structure temperature then it condenses and develops gas hydrateswhich are solids
so they can accumulate and plug pipelines with appliances, disturbing operations and halting
gas production. Dehydrating natural gas methods includes absorption, adsorption and by
cooling of wet gas. Liquid glycol solvent employed for absorption and solid desiccants for
adsorption are commonly used when small dew point gas is needed for pipeline gas and NGL
recovery.
The DRIZO technology is generally preferred to existing dehydration units which require to
be advanced for achieving desired specifications of higher glycol quality and purity for better
emission regulation of BTEX. However, DRIZO process can able to give higher purity of
TEG by regeneration as compared with conventional gas stripping process and also permits
attaining a huge water dew point fall upto 150 F.
The quantify of the degree of gaseous compound adsorbed to some extent of partial pressures
at a constant temperature shows in a graph known as an adsorption isotherm, which can have
various structures relying on the type of adsorbent, the type of adsorbate, and intermolecular
interactions between the adsorbate and the adsorbent surface. Activated alumina, silica gel
and molecular sieves are the most commonly employed adsorbents of natural gas for its
drying. When high concentrations of nitrogen is available then it need to remove downstream
of NGL recovery unit like heavy BTEX aromatic compounds and then solidify in cryogenic
portion of nitrogen rejection unit and this gas needs to remove nitrogen content lower than
1mol% to attain LNG extent for its production because nitrogen is not advisable in LNG
product so it reduces the liquefaction temperature and enhances its power consumption.
Removal of Nitrogen through cryogenic separation is highly efficient than other methods.
Cryogenic methods remove nitrogen from natural gas by utilizing the difference in boiling
points between methane and nitrogen for separation. The final nitrogen product is below 1
mol% methane and safely expose to environment. The methane-rich bottom is below 1 mol%
nitrogen goes to the pipeline or natural gas liquefaction plant. This proves to be economical
in gas flow rate operated within the limit of 30 MMscfd up to 900 MMscfd.
Noncryogenic methods separate nitrogen mostly by membrane separation and pressure swing
adsorption (PSA). PSA employs zeolites adsorbent to separate nitrogen selectively from
methane at high pressure because methane adsorbs on zeolites at high pressure and low
nitrogen content is developed at low pressure such that regeneration of adsorbent occurs with
combined manipulation of temperature and pressure. But the process need recompression to
pipeline pressure due to production of natural gas at low pressure and the hydrocarbon amount
in nitrogen rejection is considerable indicates a production loss. The Molecular Gate
adsorption method given by Engelhard can be employed for handling small gas flow rate of
0.5 MMscfd.
Removal of Carbon dioxide is necessary for sales gas Carbon dioxide prescribed limits of 2–3
mol% and sometimes Carbon dioxide can removed even to a smaller value to abolish Carbon
dioxide freezing in the cold portion of NGL recovery unit. If the recovery of ethane is needed
then design assures Carbon dioxide in the feed gas must be removed enough for abolish of
Carbon dioxide freezing and attain Carbon dioxide extent of the ethane product. Normally
mercury content in feed gas should be in ppm. However its removal is necessary because
mercury in feedstocks of petrochemical plants can occur poisoning of precious metal
catalysts. Using carbon beds and catalytic beds is needed to resist the chances of mercury

Page | 18
attack in brazed aluminium heat exchangers which normally used for attaining high NGL
recovery. Mercury is very reactive with aluminium metal so it can be corroded rapidly causes
in collapse of heat exchangers. Hence, the NGL plant is designed appropriately for removal of
mercury to levels less than 0.01 mg/Nm3.

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