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Chemical Engineering Research and Design 1 4 2 ( 2 0 1 9 ) 257–267

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Chemical Engineering Research and Design

journal homepage: www.elsevier.com/locate/cherd

Subsea natural gas dehydration with membrane


processes: Simulation and process optimization

Kristin Dalane, Magne Hillestad ∗ , Liyuan Deng ∗


Department of Chemical Engineering, Norwegian University of Science and Technology (NTNU), Sem Sœlandsvei 4,
N-7491 Trondehim, Norway

a r t i c l e i n f o a b s t r a c t

Article history: Subsea processing enables broader exploration of oil and gas reservoir, giving an increased
Received 27 September 2018 focus on developing alternative processes for subsea oil and gas treatment. This work pro-
Received in revised form 30 vides a first evaluation of a new proposed subsea natural gas dehydration process with the
November 2018 use of a membrane contactor with triethylene glycol (TEG) for dehydration of the natural gas
Accepted 24 December 2018 in combination with thermopervaporation for regeneration of the TEG. Simulation models
Available online 1 January 2019 are developed in Aspen HYSYS V8.6 and process optimization is performed on three different
process designs with respect to staging of the regeneration. By introducing two thermop-
Keywords: ervaporation units in series the TEG flow rate is reduced by 55%, the membrane volume by
Subsea natural gas dehydration 14.6% and the energy demands by 37.8%, compared to a design with one thermopervapora-
Membrane Contactor tion unit. However, increasing the number of regeneration stages increases the complexity
Thermopevaporation as additional heaters are introduced.
Process optimization © 2018 Published by Elsevier B.V. on behalf of Institution of Chemical Engineers.
Triethylene glycol

1. Introduction as lean TEG in the glycol contactor. In addition to the top-


side dehydration facility, injection of hydrate inhibitor such
Natural gas from the reservoir is normally saturated with as monoethylene glycol (MEG) or methanol is commonly used
water, which may condense during transportation causing to prevent hydrate formation from the reservoir to the topside
flow assurance problems such as hydrate formation, corro- treatment facility (GPSA, 2014).
sion and erosion (Netusil and Ditl, 2012). Removal of the water With increasing focus on subsea processing and the
can prevent these challenges and dehydration of natural gas ultimate vision of directly exporting of the produced hydro-
is therefore one of the main processing steps in natural gas carbons from the reservoir to the market (Ruud et al., 2015),
treatment. Several methods can be used for dehydration of alternative technologies for subsea dehydration of natural gas
natural gas, such as absorption into a solvent or adsorption should be investigated. Subsea dehydration can reduce the
onto a solid (Campbell, 1998). The most common technology water content in downstream processing steps to acceptable
used in the oil and gas industry today is the absorption pro- levels, and eliminate the need for continuously injection of
cess with the use of glycols, typically triethylene glycol (TEG), hydrate inhibitor. In addition, subsea dehydration can provide
as illustrated in Fig. 1. The inlet scrubber is applied to remove subsea to shore production, as the gas will be processed subsea
hydrocarbon liquids and/or free water from the wet gas before and directly exported (Fredheim et al., 2016). When consider-
it enters the glycol contactor. In the glycol contactor the nat- ing a technology for subsea installation several design criteria
ural gas meets the glycol in a counter-current flow and the should be considered. Unmanned operation is required as the
dry gas leaves from the top of the column. The rich TEG (TEG process is placed at a remote location and limiting moving
with the absorbed water) is regenerated before it is reused parts is favorable to reduce the need for maintenance (Jahnsen


Corresponding author.
E-mail addresses: magne.hillstad@ntnu.no (M. Hillestad), liyuan.deng@ntnu.no (L. Deng).
https://doi.org/10.1016/j.cherd.2018.12.027
0263-8762/© 2018 Published by Elsevier B.V. on behalf of Institution of Chemical Engineers.
258 Chemical Engineering Research and Design 1 4 2 ( 2 0 1 9 ) 257–267

Table 1 – Properties of the wet natural gas for the


membrane contactor inlet.
Parameter Value

Temperature [◦ C] 30
Pressure [bar] 80
Flow [Sm3 /d] 24.9
Molar flow [kmol/h] 4.4×104
H2 O content [ppm] 600

perature differences. The access to large amount of cooling


water on the seabed, makes thermopervaporation an interest-
ing technology for subsea operation. Several researchers (Wu
et al., 2016; Hu et al., 2007a,b; Guo et al., 2007, 2006; Burshe
et al., 1998; Wang et al., 2011; Ong and Tan, 2015; Rao et al.,
Fig. 1 – Process design for commonly used natural gas 2007; Xu et al., 2010; Hua et al., 2012; Won Yim and Kong,
dehydration process with glycol (Netusil and Ditl, 2011). 2013; Yu et al., 2012; Dogan and Durmaz Hilmioglu, 2010; Jafari
et al., 2013; Akberov et al., 2014; Hyder and Chen, 2009; Hyder
et al., 2011). With respect to high accessibility and retriev- et al., 2009; Sun et al., 2015) have investigated dehydration of
ability, high modularity is preferred. Depending on the water monoethylene glycol (MEG) with vacuum pervaporation. Little
depth of the installation, compact design is favorable due to information is found on research for dehydration of TEG with
the limitations in size and weight for the installation cranes vacuum pervaporation (van Veen et al., 2001; Josefsen, 2017;
(Albuquerque et al., 2013; Orlowski et al., 2012). The complex- Dalane et al., 2018a), and no data for thermopervaporation.
ity of the system should be kept low and the number of process Due to the limited investigation of membrane contactor for
equipment to a minimum. To avoid leakage and minimize the dehydration of natural gas and TEG regeneration with ther-
potential of failure, the number of subsea connection points mopervaporation, more research is needed to evaluate the
should be low, which makes it important to consider how the potential for subsea operation.
process design should be installed in subsea modules. In this work, a natural gas dehydration process with the
Membrane technology being compact with no moving use of membrane technology is evaluated through modelling
parts, in addition to flexible operation due to high modularity and simulation. Compared to the commonly used absorption
make membranes and membrane contactors to interest- process in Fig. 1, the conventional packed absorption column
ing technologies for subsea operation (Dalane et al., 2017). is replaced with a hollow fiber membrane contactor unit. In
Membrane contactor is a hybrid technology combining the addition, the regeneration part is replaced with a thermop-
advantages of both absorption and membrane technology. ervaporation unit. The models of the membrane contactor
One of the advantages compared to conventional adsorption (Dalane et al., 2018b) and thermopervaporation unit (Dalane
columns is the higher surface area per unit contactor volume, et al., 2018a) are already published and will not be described
providing increased contact area in a smaller module. During here. They are written in MATLAB and implemented in Aspen
the last decade, membrane contactors have been intensively HYSYS V8.6 with the use of MATLAB CAPE-OPEN (version
studied, especially for CO2 capture (Boributh et al., 2012, 2011; 1) AmsterChem. (2017). Here, process design with different
Rongwong et al., 2013; Rode et al., 2012; Albarracin Zaidiza number of regeneration stages are evaluated, in addition to
et al., 2014, 2015, 2016; Zhang et al., 2006, 2014; Hoff, 2003; Hoff optimization of the operation conditions for the system with
et al., 2004; Boucif et al., 2012; Eslami et al., 2011; Faiz and Al- respect to TEG flow rate and membrane module sizes. More-
Marzouqi, 2010, 2009; Yan et al., 2014; Rezakazemi et al., 2011; over, the different designs are compared based on subsea
Razavi et al., 2013; Chabanon et al., 2013; Farjami et al., 2015; feasibility with respect to sizes, number of stages and energy
Dai et al., 2016; Usman et al., 2017, 2018). Promising result have demands. This is the first and an important step in the feasi-
been reported from one pilot test of natural gas dehydration bility evaluation of the new proposed dehydration process.
with membrane contactor, showing dehydration to pipeline
specification and stable operation (Falk-Pedersen et al., 2005; 2. The proposed process concept
Meyer et al., 2002; King et al., 2002).
Regeneration of TEG is commonly achieved with distil- The proposed subsea natural gas dehydration process is illus-
lation technology, but the system complexity and energy trated in Fig. 2 and the selected capacity is a natural gas feed of
demand make the process less feasible for subsea operation. 25 MSm3 /d, saturated with H2 O at reservoir conditions. Åsgard
This encourage the research for alternative technologies for transport condition is selected as the dehydration require-
subsea regeneration of TEG. Wijmans et al. (2004) patented ments, with a water dew point of −18 ◦ C at 69 barg (Gassco,
a natural gas dehydration process where the regeneration 2018; Ruud et al., 2015). The pressure and the temperature of
step is replaced with vacuum pervaporation. Pervaporation the natural gas from the reservoir are reduced to 80 bar and
combines permeation through a membrane with evapora- 25 ◦ C and a scrubber is applied to remove the liquid hydrocar-
tion, leading to a possibly higher recovery of the TEG. In bon and/or free water. The natural gas from the scrubber is
vacuum pervaporation, a vacuum pump is applied on the saturated with water, which may condense if the temperature
permeate side to achieve a low vapor pressure and improve in the pipeline is reduced. Therefore, to prevent condensing
the separation performance. An alternative to the vacuum of the water before the membrane contactor inlet, the natural
pervaporation; i.e. driving force by vacuum pump, is thermop- gas is heated to 30 ◦ C. The properties of the wet natural gas
ervaporation where the low vapor pressure is maintained by feed to the membrane contactor are as given in Table 1. The
condensing the permeate; i.e. driving force created by tem- wet natural gas enters the membrane contactor on the shell
Chemical Engineering Research and Design 1 4 2 ( 2 0 1 9 ) 257–267 259

Fig. 2 – Simplified illustration of the proposed subsea natural gas dehydration system.

side and the triethylene glycol (TEG) flows counter-current


Table 2 – Specifications of membrane contactor.
inside the fibers. The H2 O is transported over the membrane
Parameter Value Unit
and absorbed into the TEG, providing a dry natural gas ready
to be exported. The rich TEG is reduced in pressure to 1 bar Fiber inner diameter 600 ␮m
and heated before it enters the thermopervaporation unit for Membrane length 1 m
regeneration by removal of the water. The regenerated TEG Packing density 1500 m2m /m3t
Membrane thickness (porous, PP) 200 ␮m
is reused in the membrane contactor for absorption of H2 O.
Membrane porosity 0.71
Prior to the membrane contactor inlet the temperature and
Membrane thickness (dense, AF2400) 1 ␮m
pressure of the TEG is adjusted to the same conditions as the Membrane permeability (dense, AF2400) 3000 Barrer
membrane contactor gas inlet. Operation pressure 80 bar

Operation temperature 30 C

2.1. Simulation assumptions


tion in the MATLAB library can be used within the simulation
Simulations are carried out using Aspen HYSYS V8.6 pro- software. In addition to simple implementation of MATLAB
cess simulator. Modelling of the membrane contactor and models as unit operations.
thermopervaporation unit are performed in MATLAB and
implemented into Aspen HYSYS with the use of MATLAB 2.3. Membrane contactor
CAPE-OPEN (version 1). The other units in the design (scrubber,
heaters, coolers, pumps and pressure relief valves) are stan- The membrane contactor model is based on a hollow fiber
dard units in Aspen HYSYS. The design pressure drop in the module configuration with counter-current flow. On the shell
scrubber, heaters and coolers are assumed to be negligible. side a one-dimensional model is used for the gas flow. For
The thermodynamic models used to calculated the thermody- the liquid in the lumen side, a two-dimensional model is
namic properties in the simulations are Peng-Robins (PR) for developed to describe the temperature and the concentration
the natural gas and the non-random two-liquid model (NRTL) profiles in axial and radial directions. The partial differen-
for the liquid phase. With the use of MATLAB CAPE-OPEN it is tial equations describing mass, temperature and pressure
possible to choose if the physical properties of the gas and liq- changes are discritized by orthogonal collocation. Conse-
uid should be retrieved from Aspen HYSYS properties or from quently this results in nonlinear algebraic equations solved
defined correlations inside the model. In the developed mod- in MATLAB by Newton–Raphson type iteration. In a previ-
els, all the physical properties required for the TEG and the ous work, the model was validated against high pressure
natural gas are calculated based on defined correlation inside experimental data and a sensitivity study with respect to
the model. The HYSYS flow sheet gives the feed conditions membrane and module properties was performed (Dalane
to the membrane modules such as the temperature, the pres- et al., 2018b). The result from this evaluation provides the
sure, the composition and the total flow rate, and the outlet selection of membrane and module properties used for the
conditions are provided by the model. Only water is assumed membrane contactor in this simulation, as listed in Table 2.
to be transported over the membrane in the membrane units. To meet the subsea requirements of long-term stable opera-
tion, a thin composite membrane has been selected to avoid
2.2. MATLAB CAPE-OPEN unit operation in Aspen pore wetting, which significantly reduces the separation per-
HYSYS formance. The selected membrane for this process evaluation
consist of a porous polypropylene (PP) support coated with a
CAPE-OPEN is a standard for communication between dense layer of Teflon® AF2400.
chemical engineering software components, facilitating inter-
operability between process simulators. Most simulation 2.4. Thermopervaporation unit
software are CAPE-OPEN compliant, including Aspen HYSYS,
which means that a CAPE-OPEN unit operation and property The thermopervaporation model is based on the plate-and-
package can be included in the simulation (van Baten and frame module configuration, with alternated channels for the
Pons, 2014). CO-LaN is a non-profit organization responsible TEG, air gap and the cooling water. The TEG and the cool-
for the management of the CAPE-OPEN standard (CO-LaN, ing water are modelled as two-dimensional laminar flow,
2017). “MATLAB CAPE-OPEN unit operation” developed by while the air gap is considered as a stagnant phase. The
AmsterChem (AmsterChem., 2017) is a software for develop- model consist of a temperature dependent permeability cor-
ing unit operation models to be implemented in CAPE-OPEN relation for the dense Teflon® AF2400 layer, developed based
compliant software. This give the advantage that all the func- on results from vacuum pervaporation experiments (Dalane
260 Chemical Engineering Research and Design 1 4 2 ( 2 0 1 9 ) 257–267

mance. It is possible to improve the separation performance


Table 3 – Specifications of thermopervaporation.
by using several stages of the regeneration in series with heat-
Parameter Value Unit
ing between the stages. Three different process designs with
Feed channel thickness 4 mm respect to number of stages for the regeneration were inves-
Air gap 1 cm tigated, including one (Design 1), two (Design 2) and three
Membrane length 1 m (Design 3) stages. A simplified illustration of the three process
Membrane width 1 m designs are given in Fig. 3. The remaining variables are then
Membrane thickness (porous, PP) 25 ␮m
used in the optimization of each process design.
Membrane porosity 0.41
Membrane thickness (dense, AF2400) 1 ␮m
The optimization is performed in MATLAB. Aspen HYSYS
Cooling water channel thickness 5 mm is accessed from MATLAB via activeX/COM interface. Aspen
◦ HYSYS is used for the process simulation as different process
Cooling water operation temperature 4 C
Cooling water velocity 0.05 m/s configurations can easily be simulated, in addition stan-
Operation pressure 1 bar dard unit operations, flash calculations and thermodynamic
properties can be used. The optimization problem solved in
et al., 2018a). The same solving methods is used for the ther- MATLAB with the fmincon function can be written as:
mopervaportion model as for the membrane contactor. In a
previous work a sensitivity study was performed for the ther- min f (x) (1)
x
mopervaporation unit with respect to membrane and module
properties (Dalane et al., 2018a). The selected specifications
s.t. c(x) ≤ 0 (2)
used for this evaluation are based on the results from the
sensitivity study, as given in Table 3. In the thermopervapora-
tion unit, the permeate is condensed on the cooling wall and ceq (x) = 0 (3)
removed from the module as condensed water by the gravity
force. To successfully operate a gravity dependent thermoper- where f is the objective function to be minimized, c is the
vaporation unit a vertical module orientation is required. inequality constraints, ceq is the equality constraints and x
is the optimization variables. The main equality constraint is
3. System optimization the dehydration pipeline specification for the natural gas. The
other constraints are mainly for simulation purposes to avoid
There are several design variables that can be adjusted to infeasible operation conditions. Every time Aspen HYSYS is
obtain the optimum process design. The goal for the process called by the optimization routine it return values with a given
is to meet the dehydration specifications for the dry natural accuracy based on the solver tolerance for the membrane
gas, which is a water dew point of −18 ◦ C at 69 barg. In all the modules. To assure accurate results from the optimization
cases the dehydration criteria must be fulfilled. As mentioned routine, the calculation tolerance of the membrane modules
above, based on the sensitivity analysis of the membrane units are given a much stricter requirements than for the opti-
the membrane and module parameters are given specific val- mization. In addition, to avoid iterations in Aspen HYSYS the
ues. In addition, a given natural gas feed is used with the recycle block is removed and equality constraints are added on
conditions as given in Table 1. This leaves us with five vari- the component molar flow of TEG and H2 O to ensure that the
able for the optimization of the process design, including TEG recycle loop is closed. The optimization variables (x), which are
flow rate, TEG regeneration temperature, membrane contactor equal to the design variables are: molar flow of TEG (fTEG) and
size (number of fibers), size of the thermopervaporation unit(s) H2 O (fH2 O) in the regeneration loop at the membrane contac-
(number of feed channels) and the number of regeneration tor inlet, number of fibers in the membrane contactor (Nf) and
stages in series. number of feed channels in the thermopervaporation unit(s)
The liquid temperature in the thermopervaporation unit (Nc). The regeneration temperature of the TEG is also eval-
will decrease along the module due to heat of evaporation uated as an optimization variable. However, during the first
and heat transfer between hot and cold fluid. A reduction in evaluation it is found that the temperature always reached the
the liquid temperature results in reduced separation perfor- upper limit for the variable which is decided based on material

Fig. 3 – Simplified illustration of the three different design configurations of the dehydration process with one, two or three
stages of regeneration. The illustration only shows the main differences between the designs, as the rest of the process is
the same. MC indicates the membrane contactor, TPV is a thermopervaporation unit and H indicates an electrical heater.
Chemical Engineering Research and Design 1 4 2 ( 2 0 1 9 ) 257–267 261

limitations. Therefore, the temperature is fixed to 100◦ C in the


Table 4 – Cost values and parameters used in the
optimization to reduce the computational time. objective function.
Category Parameter Value
3.1. Objective function
Capital Expenditure Membrane contactor 45 $/m2
The objective function to be minimized is a function based on (CAPEX) cost (Ce,MC )
investment and operating costs. The investment cost includes Thermopervapoartion 75 $/m2
unit cost (Ce,TPV )
the main equipment in the regeneration loop, such as the
Recirculation pump Eq. (7)
membrane contactor, the thermopervaporation unit(s), the cost(Ce,P )
heater(s) and the TEG recirculation pump. The operating cost Electrical heater cost Eq. (8)
includes the electrical power required for the heater(s) and the (Ce,H )
pump in the TEG regeneration loop. The size of the membrane Total fixed capital Eq. (5)
unit(s) and the energy demand are parameters of interest. cost (CI )
Annual capital Eq.(6)
These are included in the objective function as the investment
charge ratio (ACCR)
cost of the membrane unit is proportional to the membrane
Annual Operating Electricity cost (CEL ) 0.0627 $/kWh
area and the energy consumption is included in the operating Expenditure
cost. The objective function is given in Eq. (4). (OPEX)
Other assumptions Equipment lifetime 5 years
f = CI · ACCR + QEL · CEL (4) (n)
Interest rate (i) 5%
where CI is the total capital cost, ACCR is the annual capital
charge ratio, QEL is the annual electrical power demands and HYSYS V9 provides easy cost estimation possibilities and was
CEL is the electricity price. therefore used for the development of the cost correlations
A typical installation factor of six is used to estimate the for the TEG circulation pump and the electrical heater. How-
total capital cost for fluid processes (Towler and Sinnott, 2008), ever, for the rest of the simulation work Aspen HYSYS V8.6
but to adjust for the subsea conditions this factor is increased was used.
with 50%. Based on this, the total capital cost can be calculated
with Eq. (5). However, this does not include the cost of the Ce,P = 1.5 (0.3872 · S + 153, 691) (7)
ships for the subsea installation, which is not considered in
this evaluation. Ce,H = 1.5 (2.0993 · S + 8240.7) (8)

CI = 9 (Ce,MC + Ce,TPV + Ce,P + Ce,H ) (5) Here, S is the size parameter, which for the recirculation
pump is the liquid flow rate [L/s] and the for the electrical
Ce,MC is the cost of the membrane contactor, Ce,TPV is the heater(s) is the energy demands [kW].
cost of the thermopervaporation unit(s), Ce,P is the cost of the
TEG recirculation pump and Ce,H is the cost of the electrical 4. Results and discussion
heater(s).
To include the capital cost in the objective function, it With the use of the fmincon function in MATLAB the optimum
should be transformed to annual cost, which is achieved with point with respect to the selected variables are found. Three
the use of the annual capital charge ratio (ACCR). different process designs are evaluated with different num-
  bers of regeneration stages in the range from one to three,
i(1 + i)n as illustrated in Fig. 3. The results from the optimization for
ACCR =  n
 (6)
(1 + i) − 1 the different process designs, including the values of the opti-
mization variables are given in Table 5.
where i is the interest rate and n is the number of years (life- The temperature drop in the thermopervaporation unit
time of investment). affects the separation performance, due to the reduced driv-
One uncertainty in this evaluation is the limitation in ing force over the membrane. By introducing staging of the
cost estimations for subsea processing equipment. Therefore, regeneration with heating between each thermopervapora-
onshore cost values are used with adjustment to include for tion unit it is expected that the separation performance would
subsea operation conditions. The cost for the membrane con- be increased and provide a higher purity of the lean TEG. When
tactor and thermopervaporation unit are assumed based on the purity of the lean TEG is increased the required mem-
reported onshore prices for membrane modules (Haider et al., brane area in the membrane contactor and the TEG flow rate
2018; Merkel et al., 2010; He et al., 2015), with an increase by is reduced. Reducing the TEG flow rate will also have an effect
50% to provide the more robust module shell for subsea opera- on the energy demand from the heaters and the pump. It is
tion. The price of the thermopervaporation unit is assumed to therefore expected that staging of the regeneration will pro-
be higher than the membrane contactor based on more com- vide a better design with respect to membrane sizes, TEG flow
plexed module preparation with a lower packing density of rate and energy demands. However, it is important to remem-
the module. An overview of the cost values and parameters in ber that increasing the number of stages introduces additional
the objective function are given in Table 4. heaters, which increase the complexity. As expected, increas-
The equipment cost of the TEG circulation pump (Ce,P ) ing the number of regeneration stages gives a decreased TEG
and the electrical heater(s) (Ce,H ) are found based on a linear flow rate as the purity of the lean TEG is increased. By increas-
approximation from cost estimation in Aspen HYSYS V9 given ing from one stage (Design 1) to two stages (Design 2) a larger
in Eq. (7) and Eq. (8) respectively. A factor of 50% is added to benefit is provided compared to further increaseing from two
the equipment cost to adjust for the subsea conditions. Aspen to three stages (Design 3). The TEG flow rate is reduced by
262 Chemical Engineering Research and Design 1 4 2 ( 2 0 1 9 ) 257–267

Table 5 – Values of the optimization variables and the result for the optimum point of the different process designs with
respect to membrane sizes and energy demands. The volume calculation is based on only the active membrane area and
a cooling wall thickness of 1 mm.
Parameter Design 1 Design 2 Design 3 Unit

Optimization variables
Molar flow TEG (fTEG) 590.6 267.1 160.0 [kmol/h]
Molar flow H2 O (fH2 O) 52.2 22.0 12.4 [kmol/h]
Number of MC fibers (Nf) 21.271 19.941 19.560 [x106 ]
Number of TPV feed channels
1 (Nc1) 8.206 3.374 1.915 [x103 ]
2 (Nc2) 3.651 1.830 [x103 ]
3 (Nc3) 2.105 [x103 ]
Results
Lean TEG flow rate 642.8 289.1 172.4 [kmol/h]
TEG circulation rate 197.8 89.4 53.5 [LTEG /kgH2 Oremoved ]
Lean TEG purity 98.95 99.02 99.08 [wt%TEG]
MC area 40,095 37,588 36,869 [m2 ]
MC volum 27 25 24.6 [m3 ]
TPV area
1 16,412 6784 3829 [m2 ]
2 7123 3660 [m2 ]
3 4209 [m2 ]
TPV volum
1 255 105 59 [m3 ]
2 111 57 [m3 ]
3 65 [m3 ]
Total membrane volume 282 240 206 [m3 ]
Heater duty
1 4509 2048 1234 [kW]
2 797 471 [kW]
3 437 [kW]
Recirculation pump duty 243 110 66 [kW]
Total energy demand 4752 2955 2208 [kW]
Objective function value 9.45 7.85 7.06 [mill$]

55.0% (353.6 kmol/h) for Design 2 compared to Design 1. Going volume and the energy demand. Comparing the result of
from Design 2 to Design 3, a further reduction of 40.4% (116.7 Design 1 and Design 2 shows that the total membrane vol-
kmol/h) is obtained. In conventional absorption dehydration ume is reduced by 14.6% (41 m3 ) and the total energy demand
processes a TEG circulation rate of 15-40 LTEG /kgH2 Oremoved is is reduced by 37.8% (1796 kW). Going from Design 2 to Design
commonly reported Bahadori (2014), Mokhatab et al. (2006), 3 gives a further decrease of the membrane volume by 14.3%
Netusil and Ditl (2012). This value is based on optimization of (34 m3 ) and 25.3% (747 kW) in the energy requirements. The
the conventional dehydration process, and it is important to complexity of the system is increased with the additional
note that when new technologies are used for both the absorp- heaters when the number of regeneration stages is increased.
tion and the regeneration step, this value might not be an In addition, the largest benefits are given when going from
optimum for the new process. The results in Table 5 show that Design 1 to Design 2. Therefore, a further increase in number
the TEG circulation rate for all the evaluated designs are higher of regeneration stages might not be favorable. Compact design
than the reported TEG circulation rate for the conventional is important due to installation and retrieval cost, in addition
absorption process, but the value is reduced as the number of to limitations in weight for the installation cranes. It is found
regeneration stages are increased. that increasing the number of thermopervaporation stages is
Increasing the number of regeneration stages also reduces preferred from a separation point of view. However, a next step
the value of the objective function. Fig. 4 illustrates the con- for the practical evaluation of subsea installation is to evalu-
tribution from the different parts of the objective function. ate how the system should be designed in subsea installation
From these results it can be seen that the main contribu- modules. Big subsea modules would require a large ship for
tion to the objective function is the cost of the membrane the installation, while smaller modules would lead to more
units and the electricity. This explain why the value of the subsea connection points which have a larger potential for
objective function is reduced with increased staging, even leakages and failures. All these factors make it favorable to
though additional heaters are added. However, the contribu- find the most compact design of the process.
tion from the heater(s) to the objective function is increased The results reveals that the low packing density of the ther-
with the number of regeneration stages. Increasing the num- mopervaporation membrane module gives large volumes for
ber of regeneration stages reduces the contribution from this units. Even thought the membrane area in the membrane
the regeneration part (thermopervaporation unit(s), heater(s), contactor is more than the double of the thermopervapora-
recirculation pump and electricity) of the objective function, tion unit, the volume is much larger. The low packing density
while the membrane contactor percentage is increased. of the thermopervaporation unit (64.4 m2 /m3 ) is based on the
Important factors for subsea operation are the size of the selected plate-and-frame module configuration, in addition to
system and the energy demand. As for the TEG flow rate, the air gap and the cooling water channel which increases
increasing the number of stages reduces the total membrane the size of the unit. From a practical point of view, it could
Chemical Engineering Research and Design 1 4 2 ( 2 0 1 9 ) 257–267 263

Fig. 4 – Contribution of the different parts on the cost function for the different process designs with respect to stages of
regeneration; (a) Design 1 (one stage), (b) Design 2 (two stages) and (c) Design 3 (three stages). MC is an abbreviation for
membrane contactor and TPV for thermopervaporation.

Fig. 5 – a) The number of feed channels in the thermopervaporation unit as a function of numbers of fibers in the
membrane contactor, when the dehydration criteria for the natural gas is received. b)The value of the objective function and
the total membrane volume (membrane contactor and thermopervaporation unit) as function of changing the number of
fibers in the membrane contactor simultaneously as the number of feed channels in the thermopervaoration is adjusted.

be favorable to reduce the size of the thermopervaporation module parameters are needed to evaluate the exact benefit
unit and increase the membrane contactor size to reduce the on the packing density.
total membrane volume. An analysis is performed for Design The temperature drop and the low packing density of the
1, where the number of fibers in the membrane contactor is thermopervaporation unit are two limiting factors for the pro-
changed simultaneously as the number of feed channels in posed process. Adding spacers in the feed channels could
the thermopervaporation unit is adjusted to meet the dehy- increase the separation performance, as the introduction of
dration criteria for the natural gas (Fig. 5a). In this analysis mixing or turbulence might prevent or reduce the tempera-
the TEG flow rate is kept constant at the value found at the ture and concentration polarization. This was proven by Krish
optimum point for Design 1 (Table 5). From the result given et al. Kirsh et al. (2013), for the butanol-water mixture and it is
in Fig. 5b, it can be seen that the objective function has a expected that the same effect might be seen for TEG-water
minimum point as reported above, however with respect to mixtures. Another alternative that could be interesting to
the total membrane volume, another minimum point can be analyse is to introduce a heating channel or an electrical wire
found (MC fibers 32x106 ) with a higher value of the objective inside the feed channel to maintain the liquid temperature
function. along the membrane module. However, if heating is placed
The low packing density of the thermopervaporation mod- close to the membrane material it is important to remem-
ule is related to the selection of membrane module, another ber the temperature limitations for the membrane material.
module configuration, for instance tubular membrane mod- Avoiding the temperature drop could increase the separation
ules, could provide a higher packing density and reduce the performance and maybe a system as suggested in Design 1
volume. The need for the air gap and the cooling water would without staging of the regeneration could be sufficient. This
still limit the packing density, but it is expected that the alternative moves the heating previously used between the
packing density would be higher. However, when changing regeneration stages to inside the membrane module, which
the module configuration new models and evaluations of the means that the complexity of the system is moved to the
264 Chemical Engineering Research and Design 1 4 2 ( 2 0 1 9 ) 257–267

Fig. 6 – (a) The effect of the thermopervaporation cost on the total number of feed channels in the thermopervaporation
units (TPV) and the total membrane volume (thermopervaporation units and membrane contactor). (b) The sizes of the
membrane units with number of fibers in the membrane contactor (MC) and the lean TEG flow rate as function of the
thermopervaporation cost.

membrane module and it is therefore a trade-off between sys- penalty on the volume. In this sensitivity study four different
tem complexity or membrane module complexity. prices were used for the thermopervaporation unit; 75 (base
case), 100, 150 and 200 $/m2 .
4.1. Price sensitivity study The results given in Fig. 6 shows that increasing the price
from 75 to 100$/m2 do not change the optimum point. But, as
As the cost values are based on assumptions and are uncer- expected, with a further increase of the price the size of the
tain values a sensitivity study for some of the parameters thermopervaporation unit is reduced. As the size of the ther-
in the objective function was performed to evaluate how the mopervaporation units are decreased, the total membrane
optimum point is changed for Design 2. volume is reduced as the largest contribution is given by the
thermopervaporation units (Fig. 6a). A decrease in the regen-
4.1.1. Price of thermopervaporation eration size, results in a decreased purity of the lean TEG and
The price of the membrane units are related to the membrane hence an increase in the membrane area in the membrane
area and therefore also to the size of the units. However, the contactor, as illustrated in Fig. 6b. The lean TEG flow rate is
thermopervaporation unit has a much lower packing density increased when the price is increased to 150 $/m2 . However,
compared to the membrane contactor resulting in a much when the thermopervaporation price is further increased to
higher volume, even if the membrane area is much lower. In 200 $/m2 a small reduction in the TEG flow rate can be seen,
the objective function there is no penalty on the volume of with a larger increase of the membrane area in the membrane
the units, as the price is only related to the membrane area. contactor.
As shown from the investigation for Design 1 (Fig. 5b) it was
found that with respect to the total membrane volume another 4.1.2. Electricity price
minimum could be found. It is therefore of interest to evalu- In the base case, the electricity price is set to 0.0627 $/kWh,
ate how the optimum conditions for the system are changing for the sensitivity evaluation the price are increased by 50%
when the price of the thermopervaporation unit is increased, (0.0941$/kWh) and 100% (0.1254$/kWh). The results (Fig. 7)
while keeping all other cost values constant. Increasing the show that changing the electricity price give some changes
price difference between the membrane units will introduce a in the membrane sizes and TEG flow rate with respect to

Fig. 7 – (a) The effect of the electricity cost on the lean TEG flow rate and the total energy demands. (b) The sizes of the
membrane units with number of fibers in the membrane contactor (MC) and the total number of feed channels in the
thermopervaporation units (TPV) as function of electricity cost.
Chemical Engineering Research and Design 1 4 2 ( 2 0 1 9 ) 257–267 265

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within Subsea Production and Processing. The authors grate- http://dx.doi.org/10.1016/j.gee.2016.11.006.
fully acknowledge the financial support from SUBPRO, which Dalane, K., Dai, Z., Mogseth, G., Hillestad, M., Deng, L., 2017.
is financed by the Research Council of Norway (237893), major Potential applications of membrane separation for subsea
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