Processing of Natural Gas Sweeting Dehyd

Alexandria University
Faculty of Engineering
Mechanical Engineering Department
PROCESSING OF NATURAL GAS

(Sweeting, Dehydration, Fractionation & Liquefaction)
Supplementary Thesis
submitted to the mechanical engineering department
Faculty of Engineering, Alexandria University

In registration of the degree of

Doctor of Philosophy
In
Mechanical Engineering
By
Eng/ Sameh Tawfik Abdel Fattah Mahmoud
2012
Alexandria University
Faculty of Engineering
Mechanical Engineering Department
PROCESSING OF NATURAL GAS

(Sweeting, Dehydration, Fractionation & Liquefaction)
By
Eng/ Sameh Tawfik Abdel Fattah Mahmoud
Examiner's committee Approved
Prof Dr/Abdel Hamid Attia Elsaid ……………………
Prof Dr/Samy Morsy Elsherbiny ……………………
Vice Dean for Graduated Studies and Research
Prof. Dr/ Heba Wael Leheta ……………

Advisor's committe Approved
Prof Dr/Abdel Hamid Attia El-said ……………………

Professor Doctor in Mechanical Engineering Department
Faculty of Engineering- Alexandria University
ABSRACT

-This research is considered as an introduction for designing a Natural Gas
processing plant
- It concerns with natural gas processing systems (sweeting, dehydration,
fractionation, liquefaction and recovery)
- As an example for natural gas processing systems we have studied and
designed a processing system for Egyptian natural gas
- Firstly we get the Egyptian natural gas composition and we have studied
the methods of processing by using ( Cryogenic refrigeration cycles ) like
Cascade, Linde and Claude cycles.
- After making an evaluation and studying the advantages and disadvantages of
these systems we get that Cascade and Linde cycles are the most suitable
systems in natural gas processing plant.
- We made two different designs for separation and liquefaction plants ( as
mentioned in chapter 3 and chapter 4 )
- In our design process , we have used basic rules of thermo dynamics and
refrigeration charts
- Also we have used computer skills and software for calculation and
simulation as Microsoft Excel , EES, and mainly HYSYS 7
- This design only contains general plant design without equipment detail
design or sizing
- so the next step after this research is a complete prototype design for
Linde oxygen production plant (containing equipment design)

i
ACKNOWLEDGMENTS
Thank Allah, Most Merciful and Most Compassionate. I wish to express my appreciation to
all those who contributed practically and morally to the achievement of this research. No
words can adequately express my sincere gratitude and extreme appreciation to:
Prof. Dr. Abd El Hamid Attia El-Sayed
Prof. Dr. Samy Morsy Elsherbiny
Prof. Dr. Mahamed Abdel-Fattah Tiaema
n, personal attention and continuous encouragement throughout this work. I feel greatly honored to
have been working under his supervision.
My grateful appreciation and deepest thanks are further extended to:
Eng. Mahmoud Elzouka
for his helpful advice, constant support and generous effort and assistance during various
phases of this work.
I would like to acknowledgment all our professors and staff members of Mechanical
Engineering Department, Faculty of Engineering, University of Alexandria, and everyone
who cooperate with me in this work.

ii
NOMENCLATURE
1 C1……………………………………………………………...Methane
2 C2……………………………………………………………... Ethan
3 C3……………………………………………………………... Propane
4 C3MR………………………………………………..………...Propane mixed refrigerant
5 C4……………………………………………………………... Butane
6 C5+……………………………………………………………..Pentane
7 CO2…………………………………………………..………...Carbon dioxide
8 COS…………………………………………………………….Carbon sulphide
9 CS2……………………………………………………………..Carbon disulphide
10 DEA…………………………………………………………… Diethanol amine
11 DGA……………………………………………………………Diglycol amine
12 H2O……………………………………………………………Water
13 H2S…………………………………………………………….hydrogen sulphide
14 Hg……………………………………………………………...mercury
15 HTEX…………………………………………………………..Heat exchanger
16 LIC……………………………………………………………..level control
17 LNG……………………………………………………………Liquefied Natural Gas
18 MC……………………………………………………………..drier precooler
19 MD……………………………………………………………..separator
20 MEA……………………………………………………………Monoethanolamine
21 MR……………………………………………………………..mixed refrigerant
22 N2………………………………………………………………Nitrogen
23 NGL…………………………………………………………....Natural Gas Liquids
24 PIC……………………………………………………………..pressure control
25 SRU……………………………………………………………Sulpher Recovery Unit

iii
TERMINOLOGY
1 horse power …………………………………………………………….. hp
2 mega Pascal ……………………………………………………………. Mpa
3 mille gram …………………………………………………………….... mg
4 million tones per annum ……………………………………………….. MTPA
5 part per million………………………………………………………......ppm
6 single mixed refrigerant ………………………………………………...SMR

iv
List of Contents

CHAPTER I
INTRODUCTION AND LITERATURE SURVEY
1.1. Introduction…………………………………………………………………….…….… 1
1.2. Natural Gas
1.2.1. How these once living organisms become natural gas………….……….……...2
1.2.2. Natural Gas composition………………………………………………………..2
1.2.3. LNG…………………………………………………………………………….4
1.2.4. LNG Storage & transportation………………………………...………………..5
1.3. Objective…………………………………………………………………………………6
CHAPTER 2
EQUIPMENT & CYCLES

2.1. Separators…………………………………………………………………………....….7
2.1.1. Separator Function………………………………………………………….….7
2.1.2. Separation Types……………………………………………………………….7
2.1.3. Separation principle…………………………………………………...……….8
2.1.4. Separator Procedure…………………………………………………..………..9
2.1.5.Further analysis of separator (Phases of separator)………………….………...10
2.1.5.1. Primary Separation section ………………………………………....11
2.1.5.2. Secondary Separation section……………………………..………...11
2.2.5.3. Mist Extraction section ………………………………...………...…12
2.1.5.4. Liquid Accumulation section……………………………...……...…12
2.2. Distillation columns…………………………………………………………..…...……13
2.2.1. Components……………………………………………...……………………13
2.2.1.1. Trays……………………………………………………………...…14
2.2.2. Bottom Strainer………………………………………………………………..22
2.2.3. Reflux distributor…………………………………………………………...…23
2.2.4. Top Tower Demister………………………...…………………………………23
2.3. Cold box…………………………………………………………………………………24
2.3.1. What is the cold box…………………………………………………………...24
2.3.2. Cold box insulation……………………….……………………………………25
2.3.3. Cryogenic heat exchanger ………………………………………..……………26
2.3.3.1. Coil-wound heat exchanger……………………………………...…..26
2.3.3.2. Plate-finned heat exchanger…………………………...……………..27
2.4. CYCLES……………………………………………..…………….…………….29
2.4.1. Simple Cycle……………………………………………………………..…….29
2.4.1.1 Simple Cycle Explanation………………………………………...…..33
2.4.2 Dual Cycle……………………………………………………………...……….32
2.4.2.1 Dual Cycle Explanation……………………………………...……….33
2.4.2.2 Dual Intermediate Pressure optimization…………………………….35
2.4.3 Linde cycle………………………………………………………..…………….43
2.4.4 Claude cycle………………………………………………………….…………45
2.4.4.1 The effect of expander mass flow rate on Kw.hr/Kg…………...…….46
2.4.4.2The maximum allowable temperature for T-1 to make a liquid yield...47
2.4.4.3 How to optimize Claude cycle…………………………………...…...47
2.4.4. 4 Effect of T_1 on mass flow rate of expander and Kw.hr/kg……...….48
2.4.4.5 Effect of maximum pressure on Kw.hr/Kg and mass flow rate of Expander….50
v
CHAPTER ( 3)
SWEETING, DEHYDRATION & FRACTIONATION

3.1. Acid gas remover (Sweetening processes and sulfur recovery) …………………..……52
3.1.1. Gas Sweetening………………………………………………………….…….52
3.1.2. Introduction………………………………………………………...………….53
3.1.3.Basic Flow Diagram of Amine Treating Process for CO2 and H2S Removal…53
3.1.4.Reasons for Sweetening…………………………………………...……………54
3.1.5. Process Flow……………………………………………………….…………..55
3.1.5.1 Inlet Separator…………………………………………………...……55
3.1.5.2 Contactor…………………………………………………...…………56
3.1.5.3 Outlet Separator………………………………………………………56
3.1.5.4 Flash Drum………………………………………………………..…..56
3.1.5.5 Heat Exchanger (HTEX) ……………………………………………..56
3.1.5.6 Stripper………………………………………………….…………….57
3.1.5.7 Reboiler…………………………………………...…………………..57
3.1.5.8 Condenser………………………………………………….…………57
3.1.5.9 Reclaimer……………………………………………………………..57
3.1.5.10 Rich Amine………………………………………………...………..58
3.1.5.11 Lean Amine………………………………………………...………..58
3.1.6 Gas Sweetening Cycle Explanation………………………...…………………..59
3.1.6.1 Procedures…………………………………………………………….59
3.1.6.2. (DEA) amine regeneration……………………...……………………59
3.2. Dehydration………………………………………………………………….………….60
3.2.1. Introduction………………………………………………………..…………...60
3.2.2. Purpose of dehydration………………...………………………………………60
3.2.3. Water content can affect……………………………………………………….61
3.2.4. Hydrates may be prevented in one of the following ways…………...……….62
3.2.5. Other purposes of dehydration…………………………………………………62
3.2.6. methods of dehydration……………………………….………………………..63
3.2.6.1. Absorption Dehydration……………………………………….……..63
3.2.6.2. Adsorption units (Ex. SEGAS Circuit)……………….……………..66
3.2.7. Dehydration cycle………………………………………………….…………..71
3.2.7.1. Procedures……………………………………………………………71
3.2.7.2. (E glycol) regeneration……………………….………………………72
3.3. Fractionation……………...…………………………………………………………….91
3.3.1. De-methanizer………………………………………………………………….91
3.3.2. De-ethanizer……………………………………………………………………93
3.3.3. Depropanizer…………………………………………….……………………..93
3.3.4. Debutanizer……………………………………….……………………………94
3.3.4.1. Butane Splitter or De-isobutanizer………………….………………..95
3.3.5. De-pentanizer………………………………………………………..…………96
3.3.6 Fractionation cycle…………………………………………..………………….96
3.3.6.1 Demethanizer…………………………………………………………97
3.3.6.2 Deethanizer………………………………….………………………..97
3.3.6.3 Depropanizer………………………………………………...………..98
3.3.6.4 Debutanizer………………………………………………….………..98
vi
CHAPTER ( 4)
LIQUEFACTION & RECOVERY

4.1 Liquefaction…………………………………………………………..……………….99
4.1.1. Liquefaction cycle development…………………………………………….99
4.1.2. Liquefaction cycle…………………………………………….……………..99
4.1.3. C3MR process……………….……………………..………………………105
4.1.4. Design for larger train capacity…………………………...………………..107
4.1.5. The AP-XTM Process………………………………………………………107
4.2 Heat Recovery…………………………………………………………..……………109
4.2.1 Liquefaction of methane (E-113) & condenser of Demethanizer (E-111)………………109
4.2.2 Refrigeration of treated gas (E-114), condenser of Deethanizer (E-115), refrigeration of
methane (LNG-1)…………………………………………………………………...110
4.2.3 Refrigeration of Ethylene (LNG-2)……………………………………….…………..112
4.2.4 Refrigeration of Propane (LNG-3) and condenser of Depropanizer(E106) ………….…113
4.2.5 Condensers of debutanizer (E-107), Regeneration column (E-110) and Reboiler of
Demethanizer column (E-104)………………………………………………114
4.2.6 Reboiler of debutanizer (E-101),Reboiler of Regeneration column (E100),Reboiler of
Depropanizer(E-102)and Reboiler of Dethanizer (E103)…………………...…….…114
4.2.7. Optimization……………………………………………………….……...…115
CHAPTER ( 5)
CONCLUSIONS & RECOMMENDATIONS

5.1 Conclusions……………………………………………………………………118
5.1.1 For heat load (1MW) , at the same conditions ( pressure & temp )….118
5.1.2 for Claude cycle……………………………………………………..118
5.1.3 Comparison on between simple cycle & linde cycle…………………118
5.1.4 for cascade cycle…………………………………………………,….119
5.2 Recommendations…………………………………………………………….119
REFERANCES
Referances…………………………………………………….………………….120
APPENDIX
Complete cycle drawing

vii
List of Figures
Page
Figure No Figure title
NO
Figure No 1-1 The order of the well compositions………………………. 3
Figure No 2-1 2-phase separator………………………………………… 7
Figure No 2-2 3-phase separator…………………………………………… 8
Figure No 2-3 Procedure of separation ……………………………….… 9
Figure No 2-4 Separation sectors ..…………………………………..….. 10
Figure No 2-5 Straightening vanes ……………………………………...... 12
Figure No 2-6 Large bubble splits ……………………………………..... 13
Figure No 2-7 Bubble cap tray…………………………………………..... 14
Figure No 2-8 Cap layout…………………………………….....………… 15
Figure No 2-9 Down comers………………………………….....……....... 16
Figure No 2-10 Weep holes…………………………………….....……....... 16
Figure No 2-11 Inlet wires……………………………….……........…....... 17
Figure No 2-12 Outlet wires………………………………...…………....... 17
Figure No 2-13 flow passes (One, two & three passes) ………….……....... 18
Figure No 2-14 Trap out pans…………………………………………....... 19
Figure No 2-15 Sieve deck tray………………………………….……....... 20
Figure No 2-16 Section tray………………………..……………….…....... 20
Figure No 2-17 Valve tray……………………………………………........ 21
Figure No 2-18 Bottom strainer………………………………………........ 22
Figure No 2-19 Reflux distributor……………………….……………....... 23
Figure No 2-20 Top tower demister…………………….…..…………....... 24
Figure No 2-21 Cold box………………………………………………....... 25
Figure No 2-22 Coil wound heat exch……….……………..…………....... 27
Figure No 2-23 Plate finned heat exchanger…………………………….... 28
Figure No 2-24 Simple cycle………………………….………………....... 29
Figure No 2-25 P-h diagram of Simple cycle………………………..…..... 30
Figure No 2-26 Dual cycle……………………………….……………....... 32
Figure No 2-27 P-h diagram of dual cycle……………………………....... 33
Figure No2-28 Dual cycle……………………………….……………....... 35
Figure No 2-29 Importing data in spread sheet………………………....... 36
Figure No2-30-A Importing data in spread sheet………………………....... 36
Figure No 2-30-B Importing data in spread sheet………………………....... 36
Figure No2-31-A Exporting data from spread sheet……………………....... 37
viii
List of Figures (Continue)
Page
NO
Figure No 2-31-B Exporting data from spread sheet…………………............ 37
Figure No 2-32-C Exporting data from spread sheet………………………..... 38
Figure No 2-32-A Importing variables into data book spread sheet…….…..... 38
Figure No 2-32-B Importing variables into data book spread sheet……........... 39
Figure No2-32-C Importing variables into data book spread sheet………….. 39
Figure No 2-33 Importing variables into data book…………………........... 40
Figure No 2-34 Detecting the range of Independent………………............. 40
Figure No 2-35 Results of power W.R.T pressure changing …...…………. 41
Figure No 2-36 Results of power W.R.T pressure changing 42
Figure No 2-37 Linde cycle………………………………………..…......... 43
Figure No 2-38 Max Temp V.S KW.hr\Kg……………………………........ 44
Figure No 2-39 Max Presseure V.S KW.hr\Kg……………………............. 44
Figure No 2-40 Claude cycle………………..…….........…..……...…..….. 45
Figure No 2-41 Expander flow rate V.S KW.hr\Kg…………………......... 46
Figure No 2-42 Max temp of linde ……………………………..……......... 47
Figure No 2-43 Effect of T1 on mass flow of expander at const P1 = 40 bar 48
Effect of maximum pressure on Kw.hr /Kg and mass flow
Figure No 2-46
rate of expander At constant T1 = 150ok……………......… 50
Effect of maximum pressure on Kw.hr /Kg and mass flow
Figure No 2-47 51
rate of expander At constant T1 = 160ok……………......…
Effect of maximum pressure on Kw.hr/Kg and mass flow
Figure No 2-48
rate of expander At constant T1 = 170ok……………......… 51
Figure No 3-1 Sweeting schematic diagram…………………..................... 52
Figure No 3-2 Sweeting schematic diagram…………..………..……......... 53
Figure No 3-3 Amine sweeting process……………………....……......... 55
Figure No 3-4 Acid Gas Removal (Gas Sweetening) ……….…….......... 59
Figure No 3-5 Natural gas schematic ………………………................... 60
Figure No 3-6 Natural gas and contamination …………………......... 61
Figure No 3-7 Hydrates formation……………………………..……….. 62
Figure No 3-8 schematic diagram of glycol dehydration……..……......... 64
Figure No 3-9 segas dehydration schematic diagram ………………......... 67
Figure No 3-10 Precooling zone……………………………..……......... 68
Figure No 3-11 Dehydration beds……………………………..……......... 69
Figure No 3-12 Dehydration beds……………………………..……......... 70
Figure No 3-13 Regeneration gas reheater……………………..……......... 70
ix
Page
NO
Figure No 3-14 Dehydration……………………………..……………......... 71
Figure No 3-15 Distillation Columns…………………………………......... 73
Figure No 3-16-A Cooling the condensers………………………..……......... 75
Figure No 3-16-B Cooling the condensers………..……………………..….... 75
Figure No 3-17 Ethylene Cycle: (Dual Cycle)…………………………...… 77
Figure No 3-18 Debutanizer……………………………..……………....... 78
Figure No 3-19-A Heating the Reboilers……………………………..…........ 79
Figure No 3-19-B Heating the Reboilers………………………………......... 79
Figure No 3-20 Simple PROPANE Rankine cycle………………………… 81
Figure No 3-21 Propane cooling cycles) Dual Stage…………………….. 83
Figure No 3-22 Propane cooling cycles in 15-MC01 ……………………… 84
Figure No 3-23 Propane cooling cycles in 15-MC02 …………………….... 85
Figure No 3-24 cooling the ETHYLENE in LNG-1………………………. 86
Figure No 3-25 Cooling the Condenser of the deethanizer column……...... 87
Figure No 3-26 Nitrogen cooling cycle…………………………………...... 88
Figure No 3-27 Nitrogen cooling cycle………………...………..……......... 89
Figure No 3-28 Etheyelene cycle……………………………….……......... 90
Figure No 3-29 Demethanizer………………………………....……......... 91
Figure No 3-30 NGL fractionation……………………………..……......... 92
Figure No 3-31 De-ethanizer…………………………………..…..…......... 93
Figure No 3-32 Depropanizer…………………………………..……......... 94
Figure No 3-33 Debutanizer……………………………..……………......... 94
Figure No 3-34 Butane splitter……………………………..…….…......... 95
Figure No 3-35 De-pentanizer……………………………..………........... 96
Figure No 3-36 Fractionation……………………………..…….................. 97
Figure No 4- 1-A Liquefaction cycle……………………………..……......... 101
Figure No 4- 1-B Liquefaction cycle……………………………..……......... 103
Figure No 4- 2 Simplified cascade process…………………….……......... 104
Figure No 4- 3 C3MR process……………………………..…….............. 106
Figure No 4- 4 Cooling curves of pure and mixed refrigerants vs. NG….... 106
Figure No 4- 5 The AP-XTM Process………………………….……......... 108
Figure No 4- 6 Liquefaction of methane E-113………………..……......... 109
Figure No 4- 7 Refrigeration of treated gas E-114……………………....... 110
Figure No 4- 8 Refrigeration of Ethylene LNG-2……………………......... 112
Figure No 4- 9 Refrigeration of Propane LNG-3……………………......... 113
x
Page
NO
Figure No 4- 10 Condensers of debutanizer (E-107) ……………………..... 114
Figure No 4- 11 Reboilers……………………………………….……......... 114
Figure No 4- 12-A Total work……………………………………...……......... 115
Figure No 4- 12-B Total work………………..……………………..……......... 116
Figure No 4- 12-C Total work……………………………..…………..…......... 117
Appendix Complete cycle
xi
List of Tables
Table No Table title Page NO

Table NO1-1 Natural Gas compositions (hydrocarbons)..................... 4
Table NO 1-2 Contaminants Compositions in Natural Gas.................. 4
Table NO 2-1 Heat load for simple cycle.............................................. ١
Table NO 2-2 Compressor specification for simple cycle……………. ١
Table NO 2-3 Heat load for dual cycle................................................
Table NO 2-4 Compressor specification for dual cycle.......................
Table NO 2-5 Comparison between simple & linde cycle..................... 44
Table NO 5-1 Comparison between simple & linde cycle..................... 118
xii
CHAPTER 1
INTRODUCTION AND LITERATURE SURVEY
1.1Introduction
The Chinese are reputed to have been the first to use natural gas
commercially, some 2,400 years ago. The gas was obtained from shallow
wells, transported in bamboo pipes, and used to produce salt from brine in
gas-fired evaporators.
Manufactured, or town, gas (gas manufactured from coal) was used in both
Britain and the United States in the late 17th and early 18th centuries for
streetlights and house lighting The next recorded commercial use of natural
gas occurred in 1821.
William Hart drilled a shallow 30-foot (9-meter) well in Fredonia, New
York, and, by use of wooden pipes, transported the gas to local houses and
stores (Natural Gas Suppliers Association, 2004).
During the following years, a number of small, local programs involved
natural gas, but large-scale activity began in the early years of the 20th
century. The major boom in gas usage occurred after World War II, when
engineering advances allowed the construction of safe, reliable, long-
distance pipelines for gas transportation. At the end of 2004, the United
States had more than 297,000 miles (479,000 kilometers) of gas pipelines,
both interstate and intrastate.
In 2004 the U.S. was the world’s second largest producer of natural gas
(19.2 trillion cubic feet [Tcf]*, 543 BSm3) and the leading world consumer
(22.9 Tcf, 647 BSm3). (Energy Information Administration, 2005h and BP
Statistical Review of World Energy, 2005)
Although the primary use of natural gas is as a fuel, it is also a source of
hydrocarbons for petrochemical feedstocks and a major source of elemental
sulfur, an important industrial chemical. Its popularity as an energy source
-١-
1.2. Natural Gas
 Natural gas comes from reservoirs beneath the earth’s surface.
 Sometimes it occurs naturally and is produced by itself (non-
associated gas)
 Sometimes it comes to the surface with crude oil (associated gas)
 Sometimes it is produced constantly such as in landfill gas
Natural gas is a fossil fuel, meaning that it is derived from organic material
deposited and buried in the earth millions of years ago.
Other fossil fuels are coal and crude oil.
Together crude oil and gas constitute a type of fossil fuel known as
“hydrocarbons” because the molecules in these fuels are combinations of
hydrogen and carbon atoms.

1.2.1. How these once living organisms become natural gas
The origins of fossil fuels are formed when organic matter (such as the
remains of a plant or animal) is compressed under the earth, at very high
pressure for a very long time. Natural gas is formed from organic particles
that are covered in mud and other sediment. Over time, more and more
sediment and mud and other debris are piled on top of the organic matter.
This sediment and debris puts a great deal of pressure on the organic
matter, which compresses it. As one gets deeper and deeper under the
earth’s crust, the temperature gets higher and higher. At higher
temperatures more natural gas is created.
1.2.2. Natural Gas composition

The main component of natural gas ismethane. Methane is composed of
one carbon and four hydrogen atoms (CH4). When natural gas is produced
from the earth, it includes many other molecules, like ethane (used for
manufacturing), propane (which we commonly use for bbq’s) and butane
- -
Hydrocarbon
 Methane (C1)
 Ethane (C2)
 Propane (C3)
 Butane (C4)
 Pentane (C5+)
Non Hydrocarbon
 Carbon Dioxide (CO2)
 Hydrogen Sulphide (H2S)
 Water (H2O)
 Mercury (Hg)
 Nitrogen (N2)
We can find natural gas around the world by exploring for it in the earth’s
crust and then drilling wells to produce it.
( Figure 1-1) : The order of the well compositions

wikipedia, the free encyclopedia.mht

Natural gas can be transported over long distances in pipelines or as LNG

transported in ships across oceans. Natural gas can be stored until needed in
underground caverns and reservoirs or as LNG in atmospheric tank.
- -

(Table1-1): Natural Gas compositions (hydrocarbons)

SYMBOL TYPICAL NATURAL GAS STREAM
For home and industrial use as a fuel ( stove, water

Methane (C1 )
heater, etc.)
Ethane (C2 ) Makes glycol, anti-freeze ,plastics, etc.
Propane (C3 ) Used as a commercial fuel .

Isobutane (C4 ) Used in making plastics, and as a gasoline
Normal Butane Products Used as a fuel, also for making plastics and, certain
(NC4) rubber product.
Pentane plus anything “heavier” (containing more than
Pentane(C5+)
five carbon atoms) is basically gasoline.

(Table 1-2): Contaminants Compositions in Natural Gas

SYMBOL CONTAMINANTS
Nitrogen ( N2 ) Has no BTU value, just takes up space in the gas stream.
Carbon Dioxide (CO2) Reduces the BTU rating of the gas, and is also corrosive.
Hydrogen Sulphide
Is corrosive and toxic.
(H2S)
Is corrosive to pipeline, and can lead to the formation of
Water (H2O)
hydrates
1.2.3. LNG
Liquefied natural gas (LNG) is natural gas that has been cooled to the point
that it condenses to a liquid, which occurs at a temperature of
approximately -256°F (-161°c) and at atmospheric pressure . Liquefaction
reduces the volume by approximately 600 times, making it more
economical to transport between countries in specially designed ocean
- -
vessels. LNG technology makes natural gas available throughout the world.
LNG is a cryogenic liquid. The term “cryogenic” means low temperature,
generally below( -100°F ).
LNG is clear liquid, with a density of about 45 percent the density of water.
It’s also:
 Odorless
 Colorless
 Non Corrosive
 Flammable
 Cold burn when in contact
 Liquefied at -161 ºC at 1.0 bar
 LNG vapor heavier than air < -130 ºC
However, as with any gaseous material besides air and oxygen, the natural
gas vaporized from LNG can cause asphyxiation in an unventilated
confinement
1.2.4. LNG Storage & transportation
The LNG is stored in double-walled tanks at atmospheric pressure. The
storage tank is really a tank within a tank that is filled with insulation
The inner tank, in contact with the LNG, is made of materials suitable for
cryogenic service and structural loading of LNG. These materials include
9 percent nickel steel, aluminum and pre- stressed concrete
The outer tank is generally made of carbon steel or pre-stressed concrete.
To make LNG available for use, energy companies must invest in a number
of different operations that are highly linked and dependent upon one
another. The major stages of the LNG value chain, excluding pipeline
operations between the stages, consist of the following:
 Exploration to find natural gas in the earth’s crust and production of
the gas for delivery to gas users. Most of the time natural gas is
discovered during the search for oil.
- -
 Liquefaction to convert natural gas into a liquid state so that it can be
transported in ships.
 Shipping the LNG in special purpose vessels.
 Storage and regasification , to convert the LNG stored in specially
made storage tanks, from the liquefied phase to the gaseous phase,
ready to be moved to the final destination through the natural gas
pipeline system
1.3. Objective
The goal of this research is: optimization of energy required for
liquefaction and recovery of LPG

- -
CHAPTER 2
EQUIPMENT & CYCLES
2.1. Separators:
2.1.1. Separator Function:
In an oilfield separation system, the substances to be separated are oil,
water and gas. It depends on the difference of densities between oil
containments.
2.1.2. Separator Types:
There are two main types of separators according to phases of fluid
present, they are:
1- (2 – phase) liquid separation.
Depends on separating gas from total liquid.

Gas

Liquid

(Figure 2-1): 2-phase separator

Applied process design for chemical and petrochemica1 plants,Ernest e.
Ludwig. volume 2, third edition by gulf professional publishing

- -
2- (3- phase) separation.
Depends on separating oil, gas & water of each other.
Gas
Oil
Water
(Figure 2-2): 3-phase separator

2.1.3. Separation principle:

The gas and liquid reach a state of equilibrium at the existing conditions
(within the vessel) of Pressure and Temperature; this then is the basis of
gas liquid separation.
Two factors are necessary for separators function:
1- The fluids to be separated must be insoluble in each other.
2- One fluid must be lighter than the other. Separation depends upon the
effect of gravity to separate fluids. If they are soluble in each other, no
separation is possible with gravity alone. So we can summarize all the
previous factors in one phrase:
“The separator depends on difference between densities of the separated
fluid”.

- -
Separation takes place in two stages:

(Figure 2-3): Procedure of separation

Applied process design for chemical and petrochemica1 plants,Ernest e. Ludwig. volume
2, third edition by gulf professional publishing and francis group, llc

1- Separate liquid mist from the gas phase.
2- Separate gas in the form of foam from the liquid phase.
2.1.4. Separation Procedure:
1- Droplets of liquid mist will settle out from gas, provided.

2- The gas remains in the separator long enough for mist to drop out.
3- The flow of the gas through the separator is slow enough (no
turbulence) which will
keep the gas stream stirred up so that the liquid has chance to drop out.
- -
2.1.5.Further analysis of separator (Phases of separator):
Separator is divided into four major sectors:

1- Primary Separation section
2- Secondary Separation section
3- Mist Extraction section
4- Liquide Accumulation section

(Figure 2-4): Separation sectors

Applied process design for chemical and petrochemica1 plants,Ernest e. Ludwig.
volume 2, third edition by gulf professional publishing
-١ -
2.1.5.1. Primary Separation section:
As the fluids enter the vessel an initial separation of gas and
liquid takes place.This happens because of:
1-Reduction in velocity.
The velocity of the inlet stream is reduced as the fluids flow
from a relatively small diameter pipeline into the large volume
separator.
2- Reduction in pressure.
The pressure is reduced by maintaining a controlled pressure
on the vessel lower than that of the inlet stream
3- Change in flow direction.
The change in flow direction is accomplished by placing
some form of deflector at the inlet to the separator
2.1.5.2. Secondary Separation section :
In the secondary separation process liquid droplets are removed from the
gas stream. Liquid droplets which are suspended in the gas stream will
tend to fall or 'settle' towards the bottom of the vessel.This is simply due
to the force of gravity.
The ease with which the droplets will settle out of the gas stream and fall
into the liquid accumulation section of the separator depends on a number
of factors, these include:
1-The size of the droplets, which determined by the composition of the inlet
fluid streams.
2-The density of the liquid droplet, compared to the density of the gas
3-The velocity at which the gas stream is traveling through the separator,
which is determined by the size of the separator and its throughput.
- ١١ -
4-The turbulence which exists in the flowing gas stream, we can be reduced by
having devices called straightening vanes built into the separator to make
the gas flow more streamlined.
(Figure 2-5): Straightening vanes

2.2.5.3. Mist Extraction section:
The secondary separation of liquid droplets from the gas by gravity settling
will not usually remove very small particles. These particles tend to remain in
the gas stream in the form of a mist.
In order that the gas leaving a separator as free as possible from liquid, a
final mist extraction section is built into the vessel.
2.1.5.4. Liquid Accumulation section:
The lowermost section of a separator is where the liquids from the other
three sections accumulate before being discharged from the vessel.
Initially, this liquid will have gas bubbles entrained within it which must be
removed.
Just as liquid droplets tend to fall through a gas stream, gas bubbles tend to
rise to the surface of liquids due to density difference.
-١ -
2.2. Distillation columns
2.2.1. Components:
1- Trays
2- Bottom Strainer
3- Reflux distributor
4- Top Tower Demister
In order for good separation (or fractionation) to occur in a distillation
column, the vapors must have good contact with the liquid on each tray.
When the large bubble is broken into several smaller bubbles, The smaller
bubbles expose more surface area for vapor liquid contact.
(Figure 2-6): Large bubble splits

-١ -
2.2.1.1. Trays
A. Bubble Cap Tray
The vapor is broken into small bubbles which increases the surface area for
vapor-liquid contact. The bubble cap sits on top of a riser. The riser
channels vapors into the bubble cap.
Orier gap
Water vapor
Glycol

Wet gas
(Figure 2-7): Bubble cap tray

1) Cap Layout
Caps should be arranged on the tray in 60° equilateral layout, with the
liquid flowing into the apex (top) of the triangle rather than parallel to the
base.
The liquid flows normal to each raw of caps.
Liquid Bypass Baffles Also known as redistribution baffles, these short
stub baffles guide the liquid flow path to prevent excessive by-passing of
the bubble-cap field or active area.

-١ -
(Figure 2-8): Cap layout
-١ -
2) Down comers

(b) inclined

(c) inlet wire

(Figure 2-9): Down comers

Reflux flows down from one tray to the next through down comers. Down
comers must be large enough to allow for drainage from one tray to the next or
flooding might occur on some of the trays.
Down comers can be designed in several different ways to provide smooth flow
from tray to tray.
3) Inlet Weirs

(Figure 2-10): Weep holes
-١ -

(Figure 2-11): Inlet wires
Applied process design for chemical and petrochemica1
plants,Ernest e. Ludwig. volume 2, third edition by gulf
professional publishing

(Figure 2-12): Outlet wires

Applied process design for chemical and petrochemica1
plants,Ernest e. Ludwig. volume 2, third edition by gulf
These contribute to the uniform distribution of liquid as it enters the tray

from the down comer. It is not recommended for fluids that are dirty or
tend to foul surfaces. If a more positive seal is required at the down comer
at the outlet, an inlet weir can be fitted or a recessed seal pan used.
-١ -
4) Outlet Weirs
These are necessary to maintain seal on the tray, thus insuring bubbling of
vapors through liquid.
5) Weep Holes
Holes for drainage must be adequate to drain the tower in a reasonable time, yet
not too large to interfere with tray action.
Draining of the tower through the trays is necessary before any internal
maintenance can be started.
The majority of the holes are placed adjacent to the outlet or downcomer weir.

6) Flow Pass

(Figure 2-13): flow passes
(One, two & three passes)

In a one-pass system, liquid flows completely across each tray. In the two-
and three-pass systems, liquid flows across the trays in different directions.
7) Draw off Pan (trap out pans)

Most trays in the tower are level, but trays where a side stream is being
drawn off have a low place at the middle of the tray. These low areas on
trays are called trap out pans.

-١ -
(Figure 2-14): Trap out pans
The risers on a tray where a side stream is being drawn off are much taller
than normal to prevent vapor-liquid contact on this tray.
Because the tall risers and caps look something like a "top hat", this type of
tray is often called a hat tray.
B. Sieve Deck Tray
This tray is a sheet of light metal with a large number of holes drilled
through it.Vapor rising through the holes keeps the liquid on the tray and
bubbles up through it. The overflow weir keeps a constant depth of liquid
on the tray.
A sieve deck tray is:
1- Inexpensive,
2- Easy to clean, and
3- Maintains good liquid and vapor contact as long as it is operated at
its design load.

-١ -
(Figure 2-15): Sieve deck tray
Because the sieve deck tray has fixed openings and does not have covers
over the holes, it does not perform well if tower loads are constantly
changing.
C. S‐section tray :

(Figure 2-16): Section tray


The S-section tray is also inexpensive to construct. It is made of
overlapping S-shaped sections which form:
1- Long,
2- Continuous bubble caps, and
3 - Troughs for the liquid and the vapor.
- -
Each long cap has slots cut in its lower edge which act like bubble cap
teeth, forcing vapor to bubble, or flow through the liquid on the
troughs.The S-section tray must be put together exactly in order to work
well. Small differences in the position or leveling of the S-sections affect
the efficiency of vapor-liquid contact.
D. Valve Tray:
(Figure 2-17): Valve tray

A valve tray has a variable opening for vapors to flow through.The hole has
a cover that consists of a cap held in place by guides which go down
through the plate, or tray and hook underneath it.
When there is no vapor flow, the caps sits over the hole and close it.Under
low pressure the cap start to rise.As the flow of vapors increases, the cap
rise until it is stopped by the guide tabs. The valve tray is similar to the
babble cap tray. Both are more adaptable to variations in tower loads than a
sieve deck tray. The valve trays and bubble cap trays are designed to
perform well with variable tower loads.

- ١-
2.2.2. Bottom Strainer

Strainer

(Figure 2-18): Bottom strainer
During the operation of a tower:

1- The bubble caps,
2- Bolts, and
3- Other foreign objects
may be dislodged and carried along with bottom stream.
To prevent these objects leaving the tower and damaging pumps, a strainer
is installed in the bottom outlet line.
Strainers must have openings small enough to catch small objects, but large
enough not to hinder the flow of liquid, or product, or oil out of the tower.
The holes in the strainers must be kept open so that the flow of liquid out of
the tower will not be stopped, or hindered.
- -
2.2.3. Reflux distributor

(Figure 2-19): Reflux distributor
Applied process design for chemical and petrochemica1 plants,Ernest
e. Ludwig. volume 2, third edition by gulf professional publishing
Reflux entering the top of the tower should be spread evenly across the top tray
to avoid dead spots.
One way to disperse reflux is to place a reflux distributor in front of the inlet
line.
A reflux distributor is simply a plate or baffle that prevents liquid from spraying
across the tray.
Reflux entering the tower is forced to flow under the baffle so that the liquid is
distributed evenly across the tray.
2.2.4. Top Tower Demister
Sometimes small drops of liquid suspended in vapor are carried up from
one tray to the next or into the overhead vapor line.
This is called entrainment. When the overhead product must be a dry vapor
or gas, entrainment is a more serious problem.
Entrainment between trays can usually be prevented by controlling vapor
velocity. Entrainment at the top of a tower can be cut down by placing a
demister on the vapor outlet line. Demisters are constructed of fine-gauge
wire knitted into mesh.Demisters must be kept clean of dirt and foreign
matter, or the flow of vapor will be restricted, or stopped.
- -

Demister
(Figure 2-20): Top tower demister

2.3. Cold box:

2.3.1. What is the cold box
Normal industrial practice is to arrange processing equipment such as heat
exchangers, distillation columns, and process piping as tightly as possible
within limits of casing (cold box). The casing is then filled with the
specified insulation. Sometimes several cold boxes of different dimensions
may be involved. These may have one common interface or be completely
separate, in which case they will be connected to external process piping
also housed in its own insulated casings. While the foregoing may sound
simple enough, the design engineer must consider the following factors:
1-Temperature differential between the process equipment and the outside
ambient conditions
throughout the year.
2-Heat transfer rates of the insulating material.
3-Resistance to fracturing (dusting) of the insulating material.
4-Moisture permeation and its effect on the insulating properties of the
material.
5-Settling and its effect on process piping and instrumentation.
- -
6-Optimum compactness or density in terms of weight per unit volume.
7-Fire hazards from the insulating material in the presence of oxygen.
8-Facility of filling or emptying the cold box to execute repairs within the
box.
9-Ease of storage or disposal of the insulating material once removed.
2.3.2. Cold box insulation

(Figure 2-21): Cold box

With the exception of liquid hydrogen and liquid helium plants, cryogenic
process equipment can be satisfactorily insulated with either fibrous or
porous material. As noted with a few exceptions, the majority of cryogenic
plants have been insulated either with mineral wool or with expanded
perlite. The latter material is getting the larger share in the market because
of its ease of handling, and overall lower cost on an in situ basis.
This material does not work well at helium temperatures, so it is necessary
to use vacuum insulation. The components are therefore mounted in a steel
box -the cold box -in which the pressure is kept at a level of 0.00001 mbar
by means of special pumps. This eliminates heat transfer due to gas
conduction and convection, while heat transfer by radiation is minimized
by wrapping each component in superinsulation. This material, which
- -
reflects the radiant heat, is similar to the aluminum foil used in the kitchen.
Some insulation materials are:
- mineral wool
-rock wool,
-expanded perlite,
-glass wool (fiberglass),
-glass blocks (foam glass),
-silica aerogel
-magnesium carbonate.
2.3.3. Cryogenic heat exchanger
There are many types of cryogenic heat exchangers, but mainly the used
types can be reduced to two major types:
2.3.3.1. Coil-wound heat exchanger.
The practically unrestricted range of usable materials allows coil-wound
heat exchangers to be used for a wide range of applications in cold as well
as warm applications. The coil-wound heat exchanger is the core
equipment in large base-load LNG plants.

- -
Benefits:
Providing a large heating surface per shell.

(Figure 2-22): Coil wound heat exchanger

2.3.3.2. Plate-finned heat exchanger:

This type Is the most common type used in industry. In cryogenic
applications, heat exchangers are normally the plate-fin type, and are made
of aluminum. The advantages of this type of heat exchangers are a compact
rectangular design, good mechanical stability at low temperatures and an
ability to withstand high pressure. Specialist manufacturers offer them as
standard catalogue items. The following types are available: parallel,
counter flow, parallel and counter flow, or cross and/or counter flow. The
process engineer decides which type best fits the particular application.
Plate-fin heat exchangers can treat many process streams in only one unit
thus avoiding expensive interconnecting piping of different units.
- -
Applications:
Plate-fn heat exchangers can be used for a wide range of applications,
especially for low temperature services and treatment of clean fluids.
Beside others the main applications are:
1-Petrochemical plants
2- Gas treatment plants
3- Natural gas liquefaction plants
4- Air separation plants
5- Helium liquefaction plants

(Figure 2-23): Plate finned heat exchanger

- -
2.4. CYCLES:
2.4.1. Simple Cycle:

The simple cycle consists of the following components:
1-A Compressor
2-An Expansion Valve or an Expander
3-An Evaporator
4-A Condenser
They may be arranged as follows in the shown diagram:
(Figure 2-24): Simple cycle

- -
P

(Figure 2-25):P-h diagram of Simple cycle

Ashrae Handbook
2.4.1.1 Simple Cycle Explanation:
1- The refrigerant at PT (1) is saturated vapor at 1 bar.

2-It will be compressed to reach a pressure of 20 bars PT (2).
3- Then it will enter the condenser and cools down until it becomes saturated
liquid PT (3).
4- The liquid will then be expanded to reach the 1 bar pressure PT (4).
5-The cold refrigerant will enter the evaporator to cool the air thus
achieving the cooling required from this cycle. The hot refrigerant will be
saturated vapor PT (1) and start the cycle again.
- -
For a Heat Load of 1 MW

(Table 2-1): Heat load for simple cycle

Point 1 2 3 4
Pressure(bar) 1 20 20 1
Temperature(oC) - 33.25 269.56 49.58 -33.25
Mass flow rate(Kg/s) 1.01 1.01 1.01 1.01
Std ideal liquid volume
5.9 5.9 5.9 5.9
flow rate(m3/s)
Vapor /phase fraction 1 1 0 0.29
Molar enthalpy(kJ/Kg mole) - 47830.76 - 36587.33 -64683.1 -64683.1
(Table 2-2): Compressor specification for simple cycle
Power (MW) 0.67

capacity(act m3 /h) 4197.1
Adiabatic efficiency 75
Power needed for compressor = 0.67 MW

- ١-
2.4.2 Dual Cycle:
The simple cycle consists of the following components:
1-Two Compressors:
2-An Expansion Valve or an Expander
3-An Evaporator
4-A Condenser
5-A Flash/Inter-stage Intercooler
They may be arranged as follows in the shown diagram:

(Figure 2-26): Dual cycle

- -
P

h
(Figure 2-27): P‐h diagram of dual cycle
Ashrae Handbook
2.4.2.1 Dual Cycle Explanation:
1-The refrigerant at PT (1) is saturated vapor at 1 bar.

2-It will be compressed to reach a pressure of 5.42 bars PT (2) (calculated
to achieve lowest power by HYSYS Data Book)
3-The refrigerant will enter the intercooler and reach saturated vapor at
5.42 bars PT (3).
4-It will be compressed to reach a pressure of 20 bars.
5-Then it will enter the condenser and cools down until it becomes
saturated liquid.
6-The liquid will then be expanded to reach the 5.42 bars pressure.
7-The refrigerant will enter the intercooler and saturated liquid exits at 5.42
bars PT (7).
8-The liquid will then be expanded to reach 1 bar pressure PT (8).
9-The cold refrigerant will enter the evap. to cool the air thus achieving the
cooling required from this cycle. The hot refrigerant will be sat.vapor at
PT (1) and start the cycle again.
- -
For a Heat Load of 1 MW
(Table 2-3): Heat load for dual cycle
Point 1 2 3 4
Pressure (bar) 1 1 5.42 5.42
Temperature (oC) -33.25 -33.25 120.1 6.69
Mass flow rate (Kg/s) 0.823 0.83 0.83 1.2
liquid volume flow rate (m3/s) 4.84 4.84 4.84 7
Vapor /phase fraction 0.13 1 1 1
Molar enthalpy (kJ/Kg mole) -68409.42 - 47830.76 -42406.6 4.67
Point 5 6 7 8
Pressure (bar) 5.42 20 5.42 20
Temperature (oC) 6.69 49.58 6.69 137
Mass flow rate (Kg/s) 0.83 1.2 1.2 1.2
liquid volume flow rate (m3/s) 4.84 7 7 7
Vapor /phase fraction 0 0.171 1
Molar enthalpy (kJ/Kg mole) -68409.42 64683.1 - 64683.1 42277.95

(Table 2-4): Compressor specification for dual cycle
LP HP
Name
Compressor Compressor
Power (MW) 0.26 0.31
capacity(act m3 /h) 3437.1 1026.2
Adiabatic efficiency
Total Power= 0.57 MW

NOTE:
When using the Simple cycle for the same load as used in the Dual cycle of 1MW to
be cooled,
- -
And for the same cycle conditions such as pressures, temperatures………
The SIMPLE cycle compressor needed 0.68 MW The DUAL cycle
compressors needed 0.57 MW By using the DUAL cycle 0.1 MW will be
saved (Dual cycles need less power for the same refrigeration effect)
(Figure 2-28): Dual cycle
2.4.2.2 Dual Intermediate Pressure optimization:

Hysys can optimize dual cycle intermediate pressure by iteration
method to find minimum possible power by compressor.
In our college courses we studied an equation gives an approximate value
the correct value will be known as the following explanation shows.
Draw the dual cycle on Hysys and check the ability of its solving.
Note;
To solve the dual cycle you must supply the following data:
1-Evaporator, Condenser & intermediate pressures.
2- Vapor status after the evaporator and condenser.
3-Heating load applied on the evaporator, or temperature difference in
case of heat exchanger (you can substitute it by mass flow rate of the
circuit).
- -
(Figure 2-29): Importing data in spread sheet
Using spreadsheets insert power of compressors and sum them in

spreadsheet.
(Figure 2-30-A): Importing data in spread sheet
(Figure 2-30-B): Importing data in spread sheet
- -

(Figure 2-31-A): Exporting data from spread sheet

(Figure 2-31-B): Exporting data from spread sheet

- -

(Figure 2-31-C): Exporting data from spread sheet
(Figure 2-32-A): Importing variables into data book spread sheet
- -

Then using data book, insert the dependent & independent variables
(Figure 2-32-B): Importing variables into data book spread sheet

(Figure 2-32-C): Importing variables into data book spread sheet

- -

(Figure 2-33): Importing variables into data book spread sheet
Detect the range of iteration of the dependent variable.
(Figure 2-34): Detect the range of iteration
- -
Then Run iteration and find the result
(Figure 2-35): Results of power W.R.T pressure changing
- ١-
From the tables and figures you can detect the intermediate pressure that gives you
minimum power.
(Figure 2-36): Results of power W.R.T pressure changing

Graduation project gas separation & liquefaction, Eng : M.Elzoka , Alex university
- -
2.4.3 Linde cycle
It is like a simple cycle but the only difference is the introduction of a heat
exchanger.
It is used for the purpose of liquefaction or refrigeration.
In this study, we will use Ammonia for demonstration.
To take the best efficiency from the cycle, minimum temperature approach
in the cycle should be kept minimum.
(Figure 2-37): Linde cycle


- -
(Table 2-5 ): comparison between simple & linde cycle

Simple cycle Linde

Compressor capacity smaller Larger
Compressor power larger Smaller
Maximum cycle pressure larger Smaller
(Figure 2-38): Max Temp V.S KW.hr\Kg


(Figure 2-39): Max Presseure V.S KW.hr\Kg

- -
To make Kw.hr/Kg as less as possible, we should
1-Decrease T_1 as much as possible.
2-Increase P_1 as much as possible till we notice no change
in the value Kw.hr/Kg
2.4.4 Claude cycle

It is used to reject heat to a very high heat reservoir with respect to the
liquefaction temperature.
It makes use of isenthalpic expansion plus isentropic expansion.
It is composed of Linde cycle in addition to expander and 2 heat
exchangers to decrease temperature to a limit of Linde cycle.
EES program for determining max allowable T_1
In this study, we will use Nitrogen for demonstration.

(Figure 2-40): Claude Cycle

- -
2.4.4.1 The effect of expander mass flow rate on
Kw.hr/Kg
Absolute min temperature approach (0K)
Kw.hr / Kg

Mass flow rate (Kg/ hr)

(Figure 2-41): Expander flow rate V.S KW.hr\Kg
So, expander mass flow rate should kept to minimum

But, what is the minimum limit for expander mass flow rate?
It is heat exchanger # 2 & heat exchanger # 3, the mass flow rate should
o
keep both at minimum approach above 5 C.
As mass flow rate increases, minimum temperature approach increases. So
we should choose expander mass flow rate which set the minimum
approach of the exchanger # 3 to minimum.
- -
2.4.4.2The maximum allowable temperature for T-1 to make
a liquid yield

This is the same analysis made for linde cycle

Temperature (oK)
Pressure (bar)
(Figure 2-42): Max temp of linde

2.4.4.3 How to optimize Claude cycle
We gain the maximum performance “least Kw.hr/kg” when all exchangers

o
works at the minimum temperature approach = 5 C “minimum allowable
for heat exchanger”.
So we use HYSYS to control cycle parameters to achieve minimum
o
approach in all exchangers = 5 C.
- -
2.4.4. 4 Effect of T_1 on mass flow rate of expander and
Kw.hr/kg
At P_1=40 bar

Mass flow rate (Kg/hr)
Kw.hr / Kg

Temperature (0K)
(Figure 2-43): Effect of T1 on mass low of expander at const P1 = 40 bar

At P_1=50 bar


Kw.hr / Kg
Temperature (0K)

- -
At P_1=60 bar

Kw.hr / Kg

Temperature (0K)


We notice that as T_1 decrease, we need more expander mass flow rate to
the required cooling.
So, it is preferable to make T_1 as low as possible to achieve less Kw.hr/kg
But the minimum temperature of T_1 is limited by saturation temperature
at the high pressure

- -
2.4.4.5 Effect of maximum pressure on Kw.hr/Kg and mass flow
rate of expander

@ T_1 =150K
Kg
Kw.hr// Kg
Kw.hr
Pressure (bar)
(Figure 2‐46): Effect of maximum pressure on Kw.hr/Kg and mass flow rate of expander
At constant T1 = 150ok
We notice that a great difference between Kw.hr/kg at low pressure and

high pressure.
To take a clearer look at change in high pressure, we will repeat the
investigation and begin from P_1=50 bar.
We notice that increasing P_1 leads to decrease in Kw.hr/kg to a certain
limit then further increase in pressure causes increase in Kw.hr/kg, this
pressure is around 130 bar and it is also close to inversion line.

- -
@ T_1 =160K

@ T_1 =170K
Kw.hr / Kg

Pressure (bar)
Kw.hr / Kg
Pressure (bar)
- ١-
CHAPTER ( 3)
SWEETING, DEHYDRATION &
FRACTIONATION
3.1. Acid gas remover (Sweetening processes and sulfur
recovery)
(Figure 3-1): Sweeting schematic diagram

Natural gas engineering hand book, Dr. Boyun guo & Dr.Ali Ghalmbour, university of
louisiana at Lafayette,© 2005 by gulf publishing company, Houston
3.1.1. Gas Sweetening

Sour Gas contains either components H2S or CO2. H2S is by far the most
dangerous but CO2 can cause problems with solids formation in
compression and cooling. Both these components are acid gases and are
removed by similar “sweetening” processes
- -
3.1.2. Introduction
Quality requirements for gas entering LNG plants include:

3
Shall not contain more than 23 mg of H2S per m . (16 ppmv)

3
Shall not contain more than 115 mg of total Sulphur per m
 Shall not contain more than 2% by volume of CO2. sweetening processes
remove sour and undesirable gases from the gas stream:
 H2S -Hydrogen Sulphide
 CO2 -Carbon Dioxide
 COS -Carbonyl Sulphide
 CS2 -Carbon Disulphide
3.1.3.Basic Flow Diagram of Amine Treating Process for
CO2 and H2S Removal
(Figure 3-2): Sweeting schematic diagram

- -
3.1.4. Reasons for Sweetening
 Safety and Environmental Protection

 Product Specification (see above)
 Corrosion Prevention
 Improved Heating Values
 CO2 Solid formation (cryogenic operations)
 Economics (sometimes)
Sour gas is supplied to the sweetening system from the inlet separator and
the condensate stabilizer.
Sour products recovered in this process are further processed in a sulphur
recovery unit (SRU)
If the volume is low enough (less than 1 tonne of sulphur per day in the
inlet gas), the gases are incinerated and released to atmosphere as CO2 and
SO2.
Various types of sweetening processes are employed in industry today. All
processes utilize a solid or liquid desiccant to recover the sour component.
After the desiccant has recovered the sour component it must be
regenerated to release the sour components so it can be reused.
The most common liquid desiccants in use are “amines”.
- -
3.1.5. Process Flow
Amine systems tend to be located in a central plant to service the entire
sour gas production for a field. A typical amine sweetening process is
shown in the following diagram.
(Figure 3-3):Amine sweeting process

3.1.5.1. Inlet Separator

 Removal of liquids and/or solids
 Separator should be sized to handle surge capacity. Poor separator
design can cause problems in the treating facilities.
- -
3.1.5.2. Contactor
 Sour gas enters the bottom of the tower and moves upward through
the trays
 H2S and CO2 in the gas react with the liquid amine solution and are
removed from the gas stream.
 The reaction is often assisted by placing fresh lean amine on various
trays down the tower. This ensures that the gas will contact lean
amine a few times as it moves up the tower.(This is not shown on the
diagram).
As the sweet gas leaves the tower, it is often contacted with water to
remove any amine that has vaporized and is travelling with the gas.
The top 2 or 3 trays may be used for this function. This is considered
a “water wash” section of the tower.
 The water wash is often used if the contactor temperature is
especially high or if MEA is used as the amine.
3.1.5.3. Outlet Separator

 The sweetened gas is passed through a separator to remove any
amine solution (or liquid water) that may be travelling with the gas
flow
 The gas is now saturated with water and must proceed through
dehydration facilities to lower the water dew point before sale.
3.1.5.4. Flash Drum
 From the contactor, the amine may enter a flash drum to allow any
hydrocarbon an opportunity to leave the amine solution.
3.1.5.5. Heat Exchanger (HTEX)
 The rich amine passes through a heat exchanger where it picks up
heat from the hotter lean amine on its way to the contactor.
 Since this service is clean, plate and frame exchangers can be used,
but often a more common shell and tube exchanger is put in service.
- -
3.1.5.6. Stripper
 The rich amine enters the stripper, where hot acid gas and steam heat
the rich amine, removing the H2S and CO2 that is bound into the
product.
3.1.5.7. Reboiler
 The amine at the bottom of the stripper tower is heated to 105 C –
o
o
140 C (depending on the type of amine being used).
 This causes the acid gas/amine reaction to reverse and the acid gas
vaporizes with steam from the amine solution.
 The acid gas/steam vapour re-enters the stripper and contacts new
rich amine on its way out the top. Amine carried with the acid
gas/steam vapour tends to reunite with the rich liquid amine thereby
removing it from the vapour flow.
3.1.5.8. Condenser
 After leaving the top of the stripper tower, the acid gas/steam vapour
is cooled to remove heat and condense out the water from the flow.
 The water is separated in a reflux drum and returned to the stripper
tower as a liquid.
 The acid gas vapour is sent downstream to a Sulphur Recovery Unit
(SRU).
 If the plant has a gas sulphur inlet rate of less than 1 tonne/day (this
is a very small pollutant amount), the acid gas may be incinerated.
Burning the H2S creates SO2 which is a monitored.
3.1.5.9. Reclaimer
 A reclaimer may be used in MEA or DGA service.
 A reclaimer heats a slipstream of the amine from the reboiler to
higher temperatures. In MEA service, a caustic solution is added to
increase the pH of the mixture.
- -
 This higher temperature (and higher pH) cleans out some products of
“side reactions” and an
 amine sludge is created. This must be disposed of properly.
3.1.5.10. Rich Amine
The amine picks up H2S and CO2 in the contactor tower.
3.1.5.11. Lean Amine
 A lean amine stream from the bottom of the reboiler (or bottom of
the tower) is pumped back to the contactor.
 The lean amine is often passed through a charcoal filtration system to
remove entrained solids
 If anti-foam additives are added to the system, the charcoal filters
will remove them, so they should be taken off-line during addition.
 The lean amine must be cooled to approximately 6 C warmer than
o
the inlet gas.
- -
3.1.6 Gas Sweetening Cycle Explanation
(Figure 3-4): Acid Gas Removal (Gas Sweetening)
3.1.6.1. Procedures:
Feed enters Absorber at conditions of (32.23 , 69.96 bar, 10000 kg/hr)
from the bottom of the column and the amine (DEA) enter at the top of the
column. Amine absorbs co2 from the feed gas.
The sweet feed gas exit from the top of column and the rich amine exit
from the bottom.
3.1.6.2. (DEA) amine regeneration:
Rich amine pass through expansion valve to reach to (6.2 bar& 38.49 ) to
enter Heat exchanger transfers the heat between rich amine and lean amine.
Rich amine will heat and lean amine will be cold and rich amine enters
Regeneration column to extract CO2 from the rich amine to be lean amine
and use it again.
Lean amine exit from Heat exchanger at (71.070C & 1.47 bar) then pump it
to (70.06 bar & 73.34 0C) and cooled it to be warmer than feed at (40) by
air cooler .finally, sweet gas exit with amount of water.
- -
3.2. Dehydration
3.2.1. Introduction
The natural gas is dehydrated twice; once at the field, other at
procedure of natural gas liquefaction & fractionation systems.
 What I will discuss in this part is the process of dehydration in
natural gas liquefaction & fractionation procedures.
(Figure 3-5):Natural gas dehydration schematic
3.2.2. Purpose of dehydration:

 The term dehydration means removal of water vapor.
 All natural gas downstream from the separators still contains
water vapor to some degree. Water vapor is probably the most
common undesirable impurity found in untreated natural gas.
 The main reason for removing water vapor from natural gas is
- -
that water vapor becomes liquid water under low temperature
and/or high-pressure conditions (causing the formation
Hydrates).
3.2.3. Water content can affect
long distance transmission of natural gas due to the following
facts:
Hydrate crystals
Pipe
Corrosion
Natural Gas
(Figure 3-6):Natural gas and contamination

 Liquid water and natural gas can form hydrates that may plug the
pipeline and other equipment.
 Natural gas containing CO2, H2S is corrosive when liquid water is
present.
 Liquid water in a natural gas pipeline potentially causes slugging
flow conditions resulting in lower flow efficiency of the pipeline.
 Water content decreases the heating value of natural gas being
transported.
- ١-
3.2.4.Hydrates may be prevented in one of the
following ways:
 remove the water phase
 increase the temperature
 decrease the pressure
 addition of chemicals (inhibitors)

(Figure 3-7): Hydrates formation

3.2.5. Other purposes of dehydration:

 Drying the gas to a water content of less than 0.5 ppmv to prevent
water freezing in cryogenic section of unit 15.
 Water content in untreated gas is equal few hundred of Ibm/MMscf.
 Water content in treated gas is in range 6-8 of Ibm/MMscf.
Note:
Water content is stated in a number of ways:
 Mass of water per volume of gas, Ibm/MMscf (mg/Cm ) [used with

3
gasses].
- -
 Dew point temperature, °F (°C), which is the point that liquid water, real
or hypothetically subcooled, will condense out of the hydrocarbon phase
[used with gasses].
 Concentration, parts per million by volume (ppmv) [used with
gasses].
 Concentration, parts per million by mass (ppmw) [used with liquid].
3.2.6. Methods of dehydration:
 Absorption dehydration.
 Adsorption dehydration.
 Dehydration by cooling
3.2.6.1. Absorption Dehydration:
 Water levels in natural gas can be reduced to the 10 pmm.

 The procedure of absorption is passing another fluid which has high

affinity for water towards the non dehydrated natural gas so it
absorbs water then regenerated in a separated circuit ,while the
natural gas is dehydrated towards 10 pmm.

A. Properties of absorbent:
 A high affinity for water and a low affinity for hydrocarbons
 A low volatility at the absorption temperature to reduce vaporization
losses.
 A low viscosity for ease of pumping and good contact between the gas
and liquid phases.
 A good thermal stability to prevent decomposition during
regeneration.
 A low potential for corros
- -
B. Procedure of the circuit:
1) Inside the bid:
 The wet gas passes through an inlet scrubber to remove solids and
free liquids, and then enters the bottom of the glycol contactor.
 Gas flows upward in the contactor, while lean glycol solution
(glycol with little or no water) flows down over the trays.
 Rich glycol absorbs water and leaves at the bottom of the column
while dry gas exits at the top.
(Figure 3-8): schematic diagram of glycol dehydration
2) Inside the Regeneration unit:

Heat exchanger unit:
 The rich glycol flows through a heat exchanger at the top of the
still where it is
heated and provides the coolant for the still condenser.
Flash separator unit
 Then the warm solution goes to a flash tank,
where dissolved gas is removed.
- -
The rich glycol from the flash tank is further
heated by heat exchange with the still
bottoms, and then becomes the feed to the
still. The still produces water at the top and tank before being
returned to the contactor
C. Advantages of absorption:
 Low initial cost
 Low pressure drop across absorption towers
 Recharging of towers present no problems
 Materials that would cause fouling of some solid adsorbents can be
tolerated in the contactor
D. Disadvantages of absorption:
 Suspended matter, such as dirt, scale, and iron oxide may
contaminate glycol solutions.
 Over heating of solutions may produce both low and high boiling
decomposition products
 The resultant sludge may collect on heating surfaces, causing some
loss in efficiency, or, in severe cases, complete flow stoppage
 When both oxygen and hydrogen sulfide is present, corrosion may
become a problem because of the formation of acid material in the
glycol solution.
 Liquids such as water, light hydrocarbons or lubrication oils in inlet
gas may require installation of an efficient separator ahead of the
absorber. Highly mineralized water entering the system with inlet
gas may, over long periods crystallize and fill the re-boiler with solid
salts.
Foaming of solution may occur with a resultant carry-over of liquid.
The addition of a small quantity of antifoam compound usually
remedies this problem.
- -
3.2.6.2. Adsorption units (Ex. SEGAS Circuit)
The purpose of the Dehydration Unit is to remove water from the treating
gas leaving the Acid Gas Removal Unit. Drying is required to prevent ice
and hydrate formation in the Liquefaction Unit, which would cause
blockage of lines and equipment
The Dehydration Unit is based on three beds molecular sieve configuration
with two beds operated in parallel in adsorption mode while the third one is
in regeneration mode. The system operates on a 24 hours cycle, consisting
in 16 hours of adsorption, 15 minutes for depressurizing, 6 hours and 15
minutes for heating, 1 hour and 15 minutes for cooling and 15 minutes for
repressurizing, ready for next adsorption

The dehydration Process is proceeded on the following
sequence:
 Cooling.
 Separation.
 Adsorption.
 Regeneration.

- -
(Figure 3-9): segas dehydration schematic diagram
A. Drier pre cooler:
 The feed gas is coming from unit (14 &12) after removing acids &
Mercury.
 Where sweet gas is cooled under constant pressure.
 Although pressure is constant there is pressure drop
 0.8 bar inside the heat exchanger resulted from the tube
staggering.
 The cooling fluid is C3 (propane) liquid state coming from liquefying unit
(ex. 16-MC10).
 The vapor C3 is then delivered to unit 16-MD05 for
reliquefication.
- -
Drier pre cooler Control
 13-LIC-1003 Level control.

 13-PIC-1005 pressure control.
 The level control & pressure control of the heat exchanger is
controlled by the valves at the entrance & exit of the refrigerant.
(Figure 3-10): precooling zone
B. Water s separated:
 Water then condensates from separator MD01 and gas flashes

carrying the rest of the water vapor.Water condensated is routed back
to the Acid Gas Removal Unit. The temperature of the feed gas
exiting the Drier Precooler (13-MC01) is 64.5 bar and is maintained
at 22 0C, a temperature high enough to avoid Hydrate formation but
low enough to condense a significant amount of water.

- -
(Figure 3-11): Dehydration beds
C. Adsorption Process
 The feed gas from the Drier Inlet Separator (13-MD01) flows
vertically down to two of the Molecular Sieve Driers (13-
MD02A/B/C). Dried gas from the Molecular Sieve Drier is filtered
in the Dried Gas Filter (13-MD04) prior to flowing to Liquefaction
unit. The treated gas from the adsorption beds must meet a moisture
content of 0.5 ppmv maximum
D. Regeneration process:
 In the regeneration, the molecular sieve beds are regenerated one at a

time using regeneration gas, which is normally supplied from the HP
End Flash Gas Compressor aftercooler (15-MC10) at 29 bar and
35 0C, flowing vertically upwards through the beds.
 Prior to the heating phase of the regeneration cycle, the heating drier
is depressurized to 27 bar to HP fuel gas system. The regeneration
gas is heated in the Regeneration Gas Heater (13-MC02) to 168 0C,
flows upwards through the heating bed
- -

(Figure 3-12): Dehydration beds

(Figure 3-13): Regeneration
- -
Gas reheater
 The wet regeneration gas leaves the top of the heating bed is cooled
in the Regeneration Gas Cooler (13-MC03), which results in
condensation of water vapor contained in the wet regeneration gas.
The condensed water is separated in the Regeneration Gas Knockout
drum (13-MD03) and is routed back to the Acid Gas Removal Unit
3.2.7. Dehydration cycle

3.2.7.1. Procedures:
The feed gas coming from sweetening (at p=69.96 bar, T=40.2c) and flow
rate=9945 kg/hr, throttling to(36.22 0C & 60bar & x =0.9) then enters the
separator , then the vapor enter absorber column from bottom with
(e glycol) from above (at p=60 bar, T=20.15C)to absorb the water from the
sweet gas.
- ١-
3.2.7.2. (E glycol) regeneration:
(E glycol) exit the absorber at (60bar, T=24.79C) then throttling to (1.1 bar
& 27.45c) then enter the absorber with air from the bottom at (P=1.1bar,
T=20c) to absorb the water from (e glycol) and regenerate it.
Sector ONE:
(Sweetened and Dehumidified NG until first Distillation Column)
The treated NG is now sweet (No acid gases) and dehumidified.
1-The NG is now at 21 °C and 50 bars.
2-The NG will enter 15-MC01 to exit at 0.6 °C and 50 bars. It is cooled by
one of the propane cycles.
3-Then it will enter 15-MC02 to exit at -17 °C and 50 bars. It is cooled by
one of the propane cycles.
4-The NG will then enter the Flash separator.
- The Vapor and Liquid phases will both enter the distillation
column T-100.
- The liquid will enter from the top stage inlet.
- The vapor will enter from the middle.

- -

Sector TWO:
(Distillation Columns)
(Figure 3-15): Distillation Columns

Column T-100
The condenser and reboiler pressures are 35 bars.
Condenser line components: LNG at 99.45% METHANE (CH4) and the
rest is NITROGEN
Reboiler line components: Various comp. such as PROPANE & BUTANE
& ETHANE & HEPTANE & HEXANE…….
The Condenser line from T-100 is at -91 °C and 35 bars.
It is cooled in 15-MC03 to reach -98.5 °C
It is cooled again in 15-MC04 to reach -165 °C.
Then it will be expanded to reach 5 bars pressure and -163 °C. This is
considered as LNG product.
The reboiler line will be expanded to reach 29 bars thus its temperature will
be -31 °C. Then it will enter the DEMETHANIZER.
- -
Column DEMETHANIZER
Condenser line components: Pure METHANE so it is considered as final
product.
Reboiler line components: Components that are heavier than METHANE.
The Reboiler line will enter the DEETHANIZER column at 29 bars and 25 °C.
Column DEETHANIZER
Condenser line components: Pure ETHANE so it is considered as final
product.
Reboiler line components: Components that are heavier than ETHANE.
The Reboiler line will enter the DEPROPANIZER column at 28 bars and
87 °C.
Column DEPROPANIZER

Condenser line components: Pure PROPANE so it is considered as final
product.
Reboiler line components: Components that are heavier than PROPANE.
The Reboiler line will enter the DEBUTANIZER column at 20 bars and
134 °C.
Column DEBUTANIZER
The condenser and reboiler pressures are 4.9 bars.
Condenser line components: Pure BUTANE so it is considered as final
product.
Reboiler line components: Components that are heavier than BUTANE.
The Reboiler line will exit the DEBUTANIZER column at 4.9 bars and 117
°C as heavy products.
- -
Sector THREE:
(Cooling the Condensers)

(Figure 3-16-A): Cooling the condensers

(Figure 3-16-B): Cooling the condensers
- -
Columns (T-100 and DEMETHANIZER) Condensers:
The heat rejected from these columns will be considered as heat addition to
the ETHYLENE cycle.
ETHYLENE CYCLE: (DUAL CYCLE)
1-ETHYLENE exits from compressor 1 at 4.7 bars and -17 °C.
2-Then it will enter the flash separator.
3-Vapor will be compressed in compressor no.2 to reach 20 bars and 25 °C.
Then it will be cooled in LNG-1 to reach -28.8 °C by PROPANE cycle
no.3.
4-It will be expanded to reach 4.7 bars making it temperature -72.4 °C.
The cooled Ethylene will return to the flash separator.
5-The liquid is expanded to 1.1 bars making its temperature -102.5 °C.
Then it will be divided into 4 portions;
 1 portion is used to cool the NITROGEN in the closed NITROGEN cycle.
It will come out vapor.
 1 portion is used to cool the LNG in the 15-MC03 cycle. It will come
out vapor.
 1 portion is used to cool the Condenser of column T-100. It will
come out vapor.
 1 portion is used to cool the Condenser of column DEMETHANIZER
cycle It will come out vapor.
6-The vapor from the 4 portions will be collected and sent to Compressor No.1 to
restart the cycle.
- -
(Figure 3-17): Ethylene Cycle: (Dual Cycle)
Column
(DEETHANIZER) Condenser:
The heat rejected from this column will be considered as heat addition to
PROPANE cycle no. 4.
- -
Column (DEBUTANIZER) Condenser:

The heat rejected from this column will be considered as heat addition to the
cooling water cycle.

(Figure 3-18): Debutanizer
- -
Column (DEPROPANIZER) Condenser:
The heat rejected from this column will be considered as heat addition to the
Sector FOUR:(Heating the Reboilers)
(Figure 3-19-A): Heating the Reboilers
(Figure 3-19-B): Heating the Reboilers
- -
Column (T-100) Reboiler:
The reboiler line temperature is -27 °C so AIR will be efficient enough to
heat it.
Ambient AIR at 25°C will heat the reboiler to reach 15 °C at exit.
Column (DEMETHANIZER) Reboiler:
The reboiler line temperature is 25 °C so a simple PROPANE Rankine
cycle will be used.
The condenser of the rankine cycle is the reboiler of the
DEMETHANIZER column.
So the heat rejected from the rankine cycle is the heat added to the reboiler
of the column.
Simple PROPANE Rankine cycle
PROPANE is expanded to 10.4 bars and its temperature will be 28 .5 °C.

Then it will be cooled in the cycle condenser to become completely liquid.
The pump will increase PROPANE liquid pressure to 18.7 bars and the
temperature will be 29.5 °C.
The reboiler of the rankine cycle receives its heat from the condenser of the
DEPROPANIZER column.
This is because the condenser of the DEPROPANIZER line is at 57 °C and it is
rejecting heat to PROPANE at 29.5 °C.
- -
The PROPANE will exit the heater at 54 °C and 18.7 bars to enter the expander
to restart the cycle.
(Figure 3-20): Simple PROPANE Rankine cycle
- ١-
Columns (DEETHANIZER , DEPROPANIZER & DEBUTANIZER)
Reboilers:
All three reboilers act as coolers in the steam cycle as shown in the
figure
STEAM cycle:
Steam is heated in the boiler to reach 151 °C at 5 bars. The steam will be
divided into 2 portions.
Portion 1 will be cooled in cooler A (DEETHANIZER Reboiler) to reach
90 °C. This is possible because the column reboiler line is at 87 °C. The
steam then returns to be mixed with portion 2 and enters the circulating
pump.
Then the steam enters the boiler to restart the cycle again.
Portion 2 will be cooled in cooler B (DEPROPANIZER Reboiler) to reach
137 °C. This is possible because the column reboiler line is at 134 °C. Then
it will be further cooled in cooler C (DEBUTANIZER Reboiler) to reach
121 °C. This is possible because the column reboiler line is at 117 °C.
Portion 2 will enter the mixer and be mixed with portion 1.
- -
Sector FOUR:(PROPANE cooling cycles)Dual Stage
(Figure 3-21):(Propane cooling cycles)Dual
- -
PROPANE cycle no.1:for cooling the NG in 15-MC01
(Figure 3-22):(Propane cooling cycles in 15-MC01)
PROPANE Cycle no.1 explanation:

PROPANE exits from compressor no.1 at 16 bars and 47 °C.
It enters the air cooled condenser to become liquid completely.
It is expanded to reach 8.29 bars so its temperature becomes 19.68 °C.
Then it will enter the flash separator.
The liquid is expanded to 4.3 bars so its temperature becomes -3 °C.
It will cool the NG in 15-MC01 and exit in vapor phase. It will enter
compressor no.2 to reach 8.29 bars. And reenter the flash separator.The
vapor will enter compressor no.1 to restart the cycle
- -
PROPANE cycle no.2:for cooling the NG in 15-MC02
(Figure 3-23):(Propane cooling cycles in 15-MC02)
PROPANE exits from compressor no.1 at 16 bars and 56 °C.

It enters the air cooled condenser to become liquid completely.
It is expanded to reach 6.19 bars so its temperature becomes 9 °C. Then it
will enter the flash separator.
The liquid is expanded to 2.4 bars so its temperature becomes -20.4 °C.
It will cool the NG in 15-MC02 and exits in vapor phase. It will enter
compressor no.2 to reach 6.19 bars. And reenter the flash separator.
The vapor will enter compressor no.1 to restart the cycle
- -
PROPANE cycle no.3:for cooling the ETHYLENE in LNG-1

(Figure 3-24):( cooling the ETHYLENE in LNG-1)

PROPANE exits from compressor no.1 at 16 bars and 58.9 °C.
It enters the water cooled condenser to become liquid completely at 16 bars
and 45 °C.
It is expanded to reach 5.01 bars so its temperature becomes 1.8 °C. Then it
It will cool the ETHYLENE in LNG-1 and exits in vapor phase. It will
enter compressor no.2 to reach 5.01 bars. And reenter the flash separator.
- -
PROPANE cycle no.4:for cooling the Condenser of the
DEETHANIZER column.
(Figure 3-25):( Cooling the Condenser of the deethanizer column)

PROPANE exits from compressor no.1 at 16 bars and 53.3 °C.
It enters the air cooled condenser to become liquid completely at 16 bars
and 46 °C.
It is expanded to reach 8.29 bars so its temperature becomes 1.8 °C. Then it
It will cool the Condenser line of the DEETHANIZER column and exits in
vapor phase. This is possible because the condenser line is at 6 °C. It will
enter compressor no.2 to reach 8.29 bars. And reenter the flash separator.
- -
Sector FIVE:(NITROGEN cooling cycle) for cooling LNG in
15-MC04

(Figure 3-26):( Nitrogen cooling cycle)
This is a closed cycle.
The NITROGEN exits the compressor at 6.3 bars and 21.5°C.
It will be cooled by the top heat exchanger by ETHYLENE from the
ETHYLENE cycle to reach -95 °C.
It will be expanded to reach 1.103 bars so its temperature becomes -170 °C.
It will cool the LNG in 15-MC04 exiting in vapor phase and -100 °C to
enter the compressor and restart the cycle.
- -
Nitrogen Cycle
Nitrogen cycle parameters 1 nit 2 nit 3 nit 4 nit

Temp (0C ) ‐100 215.4 ‐95 ‐170
Pressure ( bar ) 1.013 6.331 6.331 1.013
Vapor fraction 1 1 1 1
(Figure 3-27):( Nitrogen cooling cycle)

Ashrae Handbook 2000
- -
Etheyelene Cycle:

Ethylene cycle 1eth 5eth
1eth 2 eth 3eth 4eth 5eth
parameters vap liq
Temp (0C ) -102.5 -16.75 -72.41 25.16 -28.89 -72.41 -72.41
Pressure ( bar ) 1.110 4.7 4.7 20 4.7 4.7
Mass flow ( kg/h) 2645e+004 4.454e+004 2645e+004
Ethylene feed
Temp (0C ) -102.5
Pressure ( bar ) 1.110
Vapor fraction 0.1525

Mass flow ( kg/hr) Ethylene

812.1 kw
To nitrogen cycle 98004 compressor (1) work
To methane condenser 4992 Ethylene
1475 kw
To liquefy NG 5625 compressor (2) work
To (T-100) condenser 6032
(Figure 3-28):( Etheyelene cycle)

Ashrae Handbook 2000
- -
3.3. Fractionation

3.3.1. De-methanizer:
After natural gas sweetening contains all hydrocarbons components
(methane, ethane, propane, butane, pentane, C5+)
The first step is to separate methane from the natural gas stream leaving the
other components (, propane, butane, pentane, C5+).
Natural Gas Liquids
Natural gas liquids (NGL) include all hydrocarbons liquefied in the field or
in processing plants, including ethane, propane, butanes, and natural
gasoline.
This process is called de-methanization
(Figure 3-29): Demethanizer
- ١-
NGL fractionation:
The process of separating a stream of NGLs into its components is called
fractionation. At the fractionation plant, liquids will be separated into
commercial quality products and then delivered to the market by tankers
(exports) and tank trucks (domestic consumption). NGLs are fractionated
by heating mixed NGL streams and passing them through a series of
distillation towers. Fractionation takes advantage of the differing boiling
Points of the various NGL products. As the temperature of the NGL stream
is increased, the lightest (lowest boiling point) NGL product boils off the
top of the tower as a gas where it is then condensed into a purity liquid that
is routed to storage. The heavier liquid mixture at the bottom of the first
tower is routed to the second tower where the process is repeated and a
different NGL product is separated and stored. This process is repeated
until the NGLs have been separated into their components.

(Figure 3-30): NGL fractionation
- -
Natural gas liquids are normally fractionated by boiling the lighter products
from the heavier products in the following order:
3.3.2. De-ethanizer:
The first step in the NGL fractionating sequence is to separate the ethane
and propane, with the ethane going overhead and the propane and heavier
components passing from the bottom of the fractionators.

(Figure 3-31): De-ethanizer
3.3.3. Depropanizer:
The next step in the processing sequence is to separate the propane and the
isobutene, with the propane going overhead and the isobutene and heavier
components passing from the bottom of the depropanizer.
- -
(Figure 3-32): Depropanizer
3.3.4. Debutanizer:

The next fractionating step is separation of butanes from pentanes plus
(C+ 5) stream. The butanes (both iso and normal) pass overhead and the
pentanes plus from the bottom of the fractionators.
(Figure 3-33): Debutanizer
- -
3.3.4.1. Butane Splitter or De-isobutanizer:
When it is desirable to do so, the butanes that pass overhead from the
debutanizer may be separated into iso-and normal butanes. The isobutene
goes overhead and the normal butane is drawn from the bottom of the
tower.
(Figure 3-34): Butane splitter
- -
3.3.5. De-pentanizer:
(Figure 3-35): De-pentanizer
For feed gas compositions containing approximately less than 80% Rich
Gas, Depentanizer column is in operation.
For feed gas compositions containing approximately greater than 80% Rich
Gas, the Depentaniser column is not in operation and the LPG products
from Debutanizer are re injected into the LNG product at the Main
Cryogenic Heat Exchanger.
3.3.6 Fractionation cycle
Treated gas exit from the dehydration unit at (20.07 c & 60 bar) then enter
the Heat exchanger and exit at (-46c& 60 bar) , throttling to (20 bar&-
78.49c&x=0.9)
- -
(Figure 3-36): Fractionation
3.3.6.1 Demethanizer:
Distillation column (40 trays, pc=18.9 bar, Pr=19.9 bar)

Separating Methane to (p=18.9bar, T=-109.8C, Mass fraction=0.99, flow
rate=8470 kg/hr) then throttling to (5 bar,-138.3, x=0.2677) then sub cooled
to (-143).
3.3.6.2 Deethanizer:
Distillation column (26 trays, pc=9 bar, Pr=11 bar).

Hydrocarbons (C2+) leaves Demethanizer column at (p=19.9 bar, T=7.4c,
x=0) throttled to
(10.2 bar,-16.9c) enter Deethanizer column to separate ethane at (p=9bar,
T=-35.5C, flow rate=797.9 kg/h).
- -
3.3.6.3 Depropanizer:
Distillation column (42 trays, pc=8.8 bar, Pr=8.9 bar).
Hydrocarbons (C3+) leaves Deethanizer column at (p=11 bar, T=40.06,
x=0) enter Depropanizer column to separate propane at (p=8.8bar,
T=21.94c, flow rate=399.6 kg/h, Mass fraction=0.9997)
3.3.6.4 Debutanizer:
Distillation column (54 trays, pc=8.5 bar, Pr=8.6 bar)
Hydrocarbons (C4+) leaves Depropanizer column at (p=8.9 bar, T=90,x=0)
enter debutanizer column to separate butane at (p=8.5bar,T=72.19℃, flow
rate=99.99 kg/h, Mass fraction=0.9999)
Then C5+ leaves the column at (8.6 bar, 151.2c, 69.98 kg/hr, x=0) Chapter
5 LNG

- -
CHAPTER ( 4)
LIQUEFACTION & RECOVERY
4.1. Liquefaction
4.1.1. Liquefaction cycle development
 LNG production for baseload consumption now has over 40 years of

history starting with permanent operations of the Camel plant in
Algeria in 1964.
 The earliest plants consisted of fairly simple liquefaction processes
based either on cascaded refrigeration or single mixed refrigerant
(SMR) processes with train capacities less than one million tonnes
per annum (MTPA).
 These were quickly replaced by the two-cycle propane pre-cooled
mixed refrigerant (C3MR) process developed by Air Products and
Chemicals Inc. (APCI). This process became the dominant
liquefaction process technology by the late 1970s and remains
competitive in many cases today.
 The number of cycles is a key factor in the success of liquefaction
process.
4.1.2. Liquefaction cycle
 This cycle takes warm, pretreated feed gas and cools and condenses
it into an LNG product.
 To make the cold temperatures required for the LNG, work must be
put into the cycle through a refrigerant compressor, and heat must be
rejected from the cycle through air or water coolers.
 The amount of work (size of refrigerant compressors, drivers and
refrigerant flowrate) is a strong function of liquefaction process, feed
- -
gas conditions (liquefaction temperature), and cooler temperature.
 In the single cycle process, there is a single working fluid that can be
compressed in a single set of compressors driven by a single driver.
An example of a single cycle process is a propane refrigeration
system.
 All modern baseload liquefaction facilities use either two or three
cycles. The workhorse of the industry is the two-cycle C3MR.
 The first cycle is the propane cooling that precool the mixed
refrigerant and feed gas process.
 The second cycle is the mixed refrigerant that condenses and
subcools the natural gas to very low temperatures. Because it is a two
cycle process, it requires two separate refrigerants each with their
own dedicated compressors, drivers, inter and aftercoolers, heat
exchanger, etc.
 Many of the liquefaction trains currently under development
including RasGas, NLNG, Snøhvit, and Darwin feature three-cycle
processes. Three-cycle processes include AP-X™, Shell PMR, Linde
Mixed Fluid Cascade, and the ConocoPhillips Optimized Cascade.
The third cycle on the AP-X™ process allows onshore train
capacities to increase to approximately 7.5-10+ MTPA (5) and have
thus circumvented the typical C3MR process bottlenecks, namely the
main cryogenic heat exchanger diameter and propane refrigerant
compressor capacity
 Generally speaking, economies-of-scale within the liquefaction train
are realized when capacity can be increased without an increase in
the number of cycles. When the required number of cycles increases,
the equipment count, plot space, and complexity also increase such
that liquefaction process cost savings are reduced or lost. LNG value
chain economies-of-scale within other gas processing blocks,
-١ -
product storage, port facilities, utilities, and shipping remain so there
is still a strong motivation to go to larger trains if sufficient gas is
available.
(Figure 4-1-A): Liquefaction cycle

 In the liquefaction cycle, the heat is removed from the natural gas in
four distinct stages: cooling and condensation, expansion and
flashing, evaporation, and compression.
 The efficiency of the liquefaction process can be improved by using
multi-stage refrigeration, either with the cascade cycle or the mixed-
refrigerant cycle.
 In the first method, the liquefaction involves refrigerants such as
-١ ١-
butane, propane, ethane, methane, nitrogen, or their mixtures. The
gas is thus cooled in successive steps. It is a rather costly cycle
depending on the number of stages with a compressor, heat
exchanger, storage tank and other components required for each
stage of the cycle. Although both systems provide similar
efficiencies, the mixed-refrigerant cycle requires a lower initial
investment. In that process, the working fluid is expanded at
different pressure levels and the liquid and gas are separated after
each expansion. The gas is then compressed while the liquid passes
onto the next refrigeration stage.
 The power for all of these operations can be provided by steam
turbines, gas turbines, combined gas and steam turbines, or electric
motors.
 Steam turbines are typically more flexible and have a characteristic
thermal efficiency of 25%.
 Gas turbines have higher efficiencies of about 30-35%, although they
are less flexible than steam turbines in regard to power control. Gas
turbines are also more sensitive to
 changes in ambient temperatures
-١ -
(Figure 4-1-B): Liquefaction cycle
The ConocoPhillips Optimized Cascade LNG Process showing the gas

treatment phase (top, starting from the right), and the liquefaction cycle
with three cascaded refrigerants (propane, ethylene, and methane) , The
-١ -
compressors are driven by gas turbines and the heat removal is
accomplished through air fin heat exchangers rather than by cooling
towers, reducing the need for cooling water.
(Figure 4-2): Simplified cascade process
-١ -
4.1.3. C3MR process
A basic schematic of the C3MR process is shown in (Figure 1).
Natural gas from the acid gas removal unit is dried and pre-cooled to about
-35 C by propane.
After pre-cooling, it passes up through a tube circuit in the main cryogenic
heat exchanger where it is liquefied and sub-cooled to between -150 C to -
162 C by mixed refrigerant (MR) flowing down on the shell-side.
Liquid propane is then let down in pressure in a series of stages, further
reducing its temperature and allowing it to provide refrigeration to the
natural gas.
The propane is also used to pre-cool the mixed refrigerant which has been
compressed after exiting the bottom of the MCHE. After pre-cooling, the
partially condensed mixed refrigerant is separated in a high pressure
separator. The vapor and liquid streams pass through separate tube circuits
in the MCHE where they are further cooled, liquefied, and sub-cooled.
The two sub-cooled streams are let down in pressure, further reducing their
temperatures. As the mixed refrigerant vaporizes and flows downward on
the shell side of the MCHE, it provides refrigeration for liquefying and sub-
cooling the natural gas. The vaporized mixed refrigerant is then
recompressed.
The C3MR cycle minimizes the number of equipment items and control
loops while maintaining the highest efficiency on the market. These
advantages lead to minimal plant complexity, easier operation, and high
availability.
-١ -
(Figure 4-3): C3MR process
(Figure 4-4): Cooling curves of pure and mixed refrigerants vs. NG
-١ -
4.1.4. Design for larger train capacity
From the 1960’s until about 2000, train capacities increased from less than 0.5
MTA to about 3 MTA. Since 2000, train capacity has increased to about 5
MTA.
The industry is about to take a very substantial step towards increasing
train capacity with the implementation of the AP-XTM process in Qatar in
early 2008. Six trains are currently under construction, each with a
nameplate capacity of 7.8 MTA. The AP-XTM process is an extension of
the C3MR process, maintaining its advantages as well as allowing for a
substantial increase in train capacity.
Other technological developments have been made which allow the C3MR
cycle to be extended beyond 5 MTA and the AP-XTM cycle beyond 8
MTA. These improvements include main exchanger enhancements as well
as process/machinery integration advancements.
4.1.5. The AP-XTM Process
Propane is used for pre-cooling natural gas, while natural gas is liquefied
and partially sub-cooled in the MCHE with a mixed refrigerant. However,
final sub-cooling is not done in the MCHE and the temperature exiting the
exchanger is about -1150C rather than -150 0C to -162 0C.
The final stage of sub-cooling is done using a nitrogen expander loop.
Nitrogen is compressed to a high pressure and then cooled to near ambient
temperature. The high pressure nitrogen is then cooled with low pressure
nitrogen returning to the compressor, after which it is expanded to a lower
pressure further reducing its temperature. The nitrogen provides
refrigeration for sub-cooling LNG. By using nitrogen to sub-cool LNG, the
percentage of the total refrigeration load on the upstream C3MR section is
reduced, allowing for greatly increased capacity in a single train without
having to parallel major equipment (e.g. refrigerant compressors and the
-١ -
main exchanger). By not having to parallel the major equipment,
difficulties in balancing flows are avoided, and economies of scale on
individual equipment are realized. Furthermore, nitrogen expander cycles
are easy to operate since they utilize a single component in a single phase.
Although the nitrogen expander system has not been used in baseload LNG
liquefaction, it has been used extensively in other cryogenic processes,
including LNG peak-shaving facilities. This experience has provided a
basis for developing confidence in operability, flexibility, reliability,
minimizing risk while maintaining efficiency similar to that for the C3MR
cycle.
(Figure 4-5): The AP-XTM Process

-١ -
4.2 Heat Recovery

4.2.1 Liquefaction of methane (E-113) & condenser of
Demethanizer(E-111):
(Figure 4-6) :( Liquefaction of methane E-113)
-١ -
Procedures:
Methane enter (E-113) at (-1500C, 2.399 bar, x=0.297) to liquefied it by

latent heat(x=1) then compressed by two stage compressor with flash
intercooler (6.112 bar) and enter sep-1
(15.57 bar) the exit vapor compressed to (28.26 bar,-79.06c) and
condensate to (-98c) by Ethylene cycle (Cascade)
Liquid from separator divide in (tee-2) one to (E-111), the other enters (tee-
1) and divide. One to flash intercooler, the other to (E-113).
Chapter 5 LNG
4.2.2 Refrigeration of treated gas (E-114), condenser of
Deethanizer (E-115), refrigeration of methane (LNG-1)

(Figure 4 -7) :( Refrigeration of treated gas E-114)

- ١١ -
Procedures:
Ethylene enter (LNG-1) at (-103c, 1.079 bar, x=0.344) to liquefied

Methane by latent heat(x=1) then compressed to (sep-2) at (14.53 bar) the
exit vapor compressed to (16.35 bar,-31.72) and condensate to (-36c) by
Ethylene cycle (Cascade)
Liquid from separator divide in (tee-3) the first to (E-115), the second
enters (E-114).the third enters (LNG-1).
- ١١١ -
4.2.3 Refrigeration of Ethylene (LNG-2):
(Figure 4 - 8) :( Refrigeration of Ethylene LNG-2)
Procedures:
Propane enter (LNG-2) at (-39c, 1.163bar, x=0.1152) to liquefied Ethylene by

latent heat(x=1) then compressed to (sep-3) at (2.642 bar) the exit vapor
compressed to (6 bar, 19.16c) and condensate to (8c)by R134a cycle (Cascade)
Liquid from separator enters (LNG2).

- ١١ -
4.2.4 Refrigeration of Propane (LNG-3)
(Figure 4 - 9) :( Refrigeration of Propane (LNG-3)
Depropanizer(E106) :
Procedures:

R134a enter (LNG-3) at (3.99, 3.374bar, x=0.0608) to liquefied Propane by
latent heat(x=1) then compressed to (sep-4) at (4.528 bar) the exit vapor
compressed to (6.077 bar, 24.84c) and condensate to (22c)by Water .Liquid
from separator divided in (tee-4) the first enters (E-106) and the second
enters (LNG-3).
- ١١ -
4.2.5 Condensers of debutanizer (E-107), Regeneration column
(E-110) and Reboiler of Demethanizer column (E-104):

(Figure 4 -10) :( Condensers of debutanizer (E-107)
Procedures:
Water at (25c, 1.2 bar, 4504 kg/hr) enter (E-107) and heated to (39.94c,
1.15bar) .then enter (E-110) and heated to (71.87c, 1.1bar).then enters (E-
104) cooled to (32.09c, 1.05 bar)

4.2.6 Reboiler of debutanizer (E-101),Reboiler of Regeneration
column (E100),Reboiler of Depropanizer(E-102)and Reboiler of
Dethanizer (E103):
- ١١
(Figure 4 -11)- :( Reboilers)
Water at (58.54c, 5.719 bar, 2900 kg/hr) heated to (157c, x=1) and heated
(E-101) by latent (x=0.95) then heated (E-100) by latent
heat(x=0.3721).Enters (E-102) and cooled to (120.3c, x=0) and enters (E-
103) and cooled to (58.54c) and recycle it to be closed lope.
4.2.7. Optimization:
1-The temperature of Methane cycle which exit from LNG-1

2-The temperature of Ethylene cycle which exit from LNG-2
3-The temperature of Propane cycle which exit from LNG-3
4-The temperature of R134a cycle which exit from LNG-4
(Figure 4 -12-A) :( Total work)
- ١١ -
(Figure 4 – 12 -B) :( Total work)
- ١١ -
(Figure 4 – 12 -C) :( Total work)
Total power of Cascade cycles=4044 kW

Heating power of E-105 =2055 kW
Pumping power =134.35 kW
Total power =6233 kW
Kw/ (Kg/hr) Methane = 0.723
- ١١ -
CHAPTER ( 5)
CONCLUSIONS & RECOMMENDATIONS
5.1 Conclusions
5.1.1- For heat load (1MW) , at the same conditions ( pressure &
temp )
The SIMPLE cycle compressor needed 0.67 MW
The DUAL cycle compressors needed 0.58 MW
Then By using the DUAL cycle 0.1 MW will be saved
5.1.2- for Claude cycle
- We gain the maximum performance “least Kw.hr/kg” when all
o
exchangers works at the minimum temperature approach = 5 C
“minimum allowable for heat exchanger”.
So we use HYSYS to control cycle parameters to achieve minimum
o
approach in all exchangers = 5 C.
- increasing P_1 leads to decrease in Kw.hr/kg to a certain limit
then further increase in pressure causes increase in Kw.hr/kg, this
pressure is around 130 bar and it is also close to inversion line.

5.1.3 Comparison on between simple cycle & linde cycle

Simple cycle Linde
Compressor capacity smaller Larger
Compressor power larger Smaller
Maximum cycle pressure larger Smaller
- ١١ -
5.1.4- for cascade cycle
Total power of Cascade cycles=4044 kW
Heating power of E-105 =2055 kW
Pumping power =134.35 kW
Total power =6233 kW
Kw/ (Kg/hr) Methane = 0.723
5.2 Recommendations
1- Using cascade cycle to achieve minimum consumed power
- ١١ -
REFERANCES
1- Ashrae Handbook 1997
3- Ashrae Handbook1999
5- Applied process design for chemical and petrochemica1 plants,Ernest e. Ludwig. volume 2, third
edition by gulf professional publishing
6- Aspen hysys property packages,© 2006 by aspen process engineering webinar2008
7- Aspen simulation workbook, by aspen technology, inc.©2008
8- Cryogenic engineering second edition,Thomas m. Flynn,Cryoco, inc.louisville, colorado, u.s.a.
© 2005 by marcel dekker
9- Fundamentals of natural gas processing,L. L.Faulkner,the ohio state university,© 2006 by taylor
and francis group, llc
10- Graduation project gas separation & liquefaction, Eng : M.Elzoka , Alex university
11- Natural gas engineering hand book, Dr. Boyun guo & Dr.Ali Ghalmbour, university of louisiana
at Lafayette,© 2005 by gulf publishing company, Houston
12- Removal of carbon dioxide from natural gas for lng production, Salako abiodun Ebenezer,
institute of petroleum technology norwegian university of science and technology© 2005 by
Trondheim
13-Simultaneous production of, LNG and NGL ,Philip Hagyard, Henri Paradowski & Dominique
Gadelle
14-wikipedia, the free encyclopedia.mht
15-www.airliquide.ca
16-www.dlib.eul.edu.eg
17-www.eulc.edu.eg
‫ال اص‬
‫م احل معالج الغاز الطبيعى‬
‫) التحلي ( ‪Gas sweeting‬‬ ‫إزال اأحما‬
‫ية م ل الـ )‪ (CO2 , H2S , COS‬يجب الت لص م ھا‬ ‫عاد ما يحتو الغا الطبيعى على بعض الشوائب الح‬
‫حيث تتتسبب ھ الشوائب فى تكو مواد صلبة تعيق اإن غاط أث اء ع ليا التبري ‪.‬‬
‫ياد نسبة ھ الشوائب عن ح ود معي ة‬ ‫ك ا تشترط جود الغا الطبيعى على ع‬
‫) التحلية ( لأسبا التالية )مراعا عوامل اأما ‪ ،‬تقليل نسب الت كل‪ ،‬ياد‬ ‫ويتم إجراء ع لية إ الة اأح ا‬
‫تحسين ع لية اإن غاط ‪ ،‬العوامل اإقت ادية ‪،‬‬ ‫القي ة الحرارية للغا ‪ ،‬تقليل نسبة ال كونا ال لبة بغر‬
‫تحسين الجود ‪،‬‬
‫إجراء ع ليا‬ ‫ما يس ى وح الت لص من الكبريت ) ‪ SRU ( Sulpher Recovery Unit‬بغر‬ ‫و يست‬
‫التحلية ويعتبر الـ حلو اأمي ى ) ‪ ( amine solution‬ھو أشھر الـ ركبا الكي يائية ‪Desiccants‬‬
‫ال ست مة فى ع ليا التحلية‪.‬‬
‫) التحلي (‬ ‫م احل إزال اأحما‬
‫‪ -‬ال اصل الداخلي ) ‪( Inlet separator‬‬
‫ي ه مائ ا لس عة ال حط ة حت ى‬ ‫وھى ال س ولة عن ف ل كل من ال كونا الس ائلة وال لبة واب أ يك و ت‬

‫يم‬ ‫نتافى ح و ال شكا ال اج ة عن أخطاء الت‬
‫‪ -‬المامسا ) ‪( contactors‬‬
‫ثم ي ع إلى أعلى مارا ب ج وعة صوانى ‪Trays‬‬ ‫‪ -‬ي خل الـغا ال ا من أسفل الـبر‬
‫‪١‬‬
‫‪ -‬يتفاع ل ك ل م ن ث انى أكس ي الكرب و وث انى أكس ي الكبري ت )‪ (CO2 , H2S‬م ع ال حل و اأمي ى ‪amine‬‬
‫‪ solution‬حيث يقو بانتزاعھ ا من الغا ال ار‬
‫‪ -‬يتم التأكي على ات ا التفاعل ب ضافة محلو أمي ى على ال وانى من فتر أخر‬
‫نق و ب الت لص م ه‬ ‫‪ -‬بع انتزاع ثانى أكسي الكربو وثانى أكسي الكبريت من الغا يتبقى ال حتو ال ائى ال‬
‫فى مرحة الغسيل‬
‫بال اء‬
‫الغسيل بال اء ف ى حال ة ارتف اع درج ة ح رار ال ـ ‪ contactor‬أو ف ى حال ة اس ت ا ال ـ ‪MEA‬‬ ‫‪ -‬عاد ما يست‬
‫ك حلو أمي ى‬
‫‪ -‬ال اصل ال ارجي )‪( outlet separator‬‬
‫من‬ ‫بع ال راحل السابقة اص بح ال ـغا بع التحلي ة مش بعا ب ال حتو ال ائى ل لك اب م ن إ ال ة ھ ا ال حت و‬

‫خا الفواصل ال ارجية لتجھيز الغا لع ليا التسويق‬
‫‪ -‬إسط ان ال ميض ) ‪( flash drum‬‬
‫وھى ال رحلة التى تلى ال امسا وھى مس ولة عن إ الى الـھي روكربونا من ال حلو اأمي ى‬
‫الح ار )‪( HTEX‬‬ ‫‪ -‬المبا‬
‫وھو ال س و عن خفض حرار ال حلو اأمي ى وھو فى طريقه إلى ال امس ا وھ ى ع اد م ا تك و م ن ن وع‬
‫غاف ومواسير أو مبردا لوحية‬
‫‪ -‬الفاصل ال ھائي ‪Stripper‬‬
‫ي خل ال حل و اأمي ى ‪ reach amine‬إل ى الفاص ل ال ھ ائى إ ال ة ك ل م ن ث انى أكس ي الكرب و وكبريتي‬

‫الھي روجين )‪(H2S‬‬
‫‪ -‬إعا الغليا ) ‪( Reboiler‬‬
‫‪ ١‬درج ة م وي ة ( م ا‬ ‫‪ ١‬إل ى‬ ‫درج ة ح رار م ن )‬ ‫ال ـ حلو اأمي ى ال وج ود ف ى أس فل الب ر‬ ‫يس ت‬

‫ى‬ ‫ى والـ حلو اأمي ى م ا ي د إلى تب ر الـغا الح‬ ‫يتسبب فى تفاعل كي يائى بين الـ غا الح‬
‫ى إلى الفاصل ال ھائى وھك ا‬ ‫وبع لك يعاد إدخا الـغا الح‬
‫‪-‬المكثف ) ‪( condenser‬‬
‫بع تر الغا أعلى الب ر ي تم إج راء ع لي ة تبري إ ال ة الح رار وتك ي ف ال حت و ال ائى حي ث ي تم نزع ه‬
‫احقا وإعادته فى حالة سائلة ويتم إرسالب الغا إلى وح الت لص من الكبريت‬
‫‪ -‬المست لص ) ‪( reclaimer‬‬
‫الـ ‪ reclaimer‬مع الـ ‪MEA , DGA‬‬ ‫يست‬
‫اأمينى ‪Reach amine‬‬ ‫‪ -‬المحل‬
‫وھو ال س و عن إ الة ثانى أكسي الكربو و كبريتي الھي روجين‬
‫المائى ‪Dehydration‬‬ ‫إزال المحت‬
‫ي تم إ ال ة ال حت و ال ا م رتين لل ـغا الطبيع ى ال ر اأول ى ف ى الحق ل وال ر اأخ ر أث اء ع لي ة اإس الة‬

‫وف ل ال كونا‬
‫المائى ‪:‬‬ ‫من إزال المحت‬ ‫الغ‬
‫ب ه ال ت لص م ن ب ار ال اء ال وج ود ف ى الغ ا و ل ك ل ع تك ف ب ار وتحول ه إل ى س ائل ع درج ا‬ ‫يق‬

‫الت ى ب ورھا ت د إل ى انس اد انابي ب ال ق ل‬ ‫ف ة وال غوط العالي ة م ا يس بب تك و الھي را‬ ‫الحرار ال‬
‫أث اء ع ليا نقل الغا‬
‫ية ت د إل ى الت ك ل باتحادھ ا م ع ث انى أكس ي الكرب و و كبريتي الھي روجين ‪ -‬خف ض‬ ‫‪ -‬تك و م واد ح‬
‫القي ة الحرارية للغا‬
‫الھيدرا‬ ‫تافى تك‬ ‫ط‬
‫‪ -١‬إ الة ال اء‬

‫‪ -‬رفع درجة الحرار‬
‫‪ -‬خفض ال غط‬
‫‪ -‬إضافة بعض ال واد الكي اوية ‪inhibitors‬‬
‫‪ -‬م ع تج ال حتو ال ائى‬
‫المائى‬ ‫إزال المحت‬ ‫ط‬
‫‪ -١‬اإمت ا‬
‫‪ -‬اإدم ا‬
‫‪ -‬التبري‬
‫ف ل المك نا ‪fractionation‬‬
‫مراحل ف ل ال كونا ‪- :‬‬

‫‪ -١‬ف ل اإي ا ‪De –ethanization‬‬
‫‪ -‬ف ل البروبا ‪De – propanization‬‬
‫‪ -‬ف ل البيوتا ‪De – botanization‬‬
‫‪ -‬ف ل الب تا ‪De – pentanization‬‬
‫اإسال واست اص المك نا ‪liquefaction & recovery‬‬

‫وتتم ك ا ھو موضح بال ائر ال رسومة فى نھاية البحث‬
‫موافق‬ ‫لج ة اإشراف‬
‫أ‪.‬د ‪ /‬عب الح ي عطية السي‬

‫‪......................................‬‬ ‫اأستا ال كتور بقسم الھ سة ال يكانيكية‬
‫كلية الھ سة ‪ -‬جامعة اإسك رية‬
‫جامعة اإسك رية‬
‫كلية الھ سة‬
‫قسم الھ سة ال يكانيكية‬
‫معالج الغاز الطبيعى‬
‫المائى‪ -‬ف ل المك نا‬ ‫) التحلي (‪ -‬إزال المحت‬ ‫إزال اأحما‬
‫مق مة من‬
‫مھ س ‪ /‬سامح توفيق عب الفتا مح ود‬
‫ماجستير الھ سة ال يكانيكية – كلية الھ سة – جامعة اإسك رية‬
‫موافقو‬ ‫لج ة ال اقشة والحكم‬
‫‪......................................‬‬ ‫أ‪.‬د ‪ /‬عب الح ي عطية السي‬
‫‪......................................‬‬ ‫أ‪.‬د ‪ /‬سامى مرسى الشربي ى‬
‫‪......................................‬‬ ‫أ‪.‬د ‪ /‬مح عب الفتا طعي ة‬
‫‪١‬‬
‫جامعة اإسك رية‬
‫كلية الھ سة‬
‫قسم الھ سة ال يكانيكية‬
‫معالج الغاز الطبيعى‬
‫المائى‪ -‬ف ل المك نا‬ ‫) التحلي (‪ -‬إزال المحت‬ ‫إزال اأحما‬
‫رسالة تك يلية‬
‫مق مة إلى قسم الھ سة ال يكانيكية ‪ -‬كلية الھ سة – جامعة اإسك رية‬
‫للتسجيل فى درجة‬
‫دكتورا الفلسفة فى الھ سة ال يكانيكية‬
‫مق مة من‬
‫مھ س ‪ /‬سامح توفيق عب الفتا مح ود‬

‫ماجستير الھ سة ال يكانيكية – كلية الھ سة – جامعة اإسك رية‬
‫‪١‬‬

Processing of Natural Gas Sweeting Dehyd

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Processing of Natural Gas Sweeting Dehyd

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Alexandria University

PROCESSING OF NATURAL GAS

submitted to the mechanical engineering department

Faculty of Engineering, Alexandria University

Eng/ Sameh Tawfik Abdel Fattah Mahmoud

PROCESSING OF NATURAL GAS

Examiner's committee Approved

Prof Dr/Abdel Hamid Attia Elsaid ……………………

Prof Dr/Samy Morsy Elsherbiny ……………………

Vice Dean for Graduated Studies and Research

Prof. Dr/ Heba Wael Leheta ……………

Prof Dr/Abdel Hamid Attia El-said ……………………

Complete cycle drawing

Table No Table title Page NO

1.2.2. Natural Gas composition

( Figure 1-1) : The order of the well compositions

Natural gas can be transported over long distances in pipelines or as LNG

SYMBOL TYPICAL NATURAL GAS STREAM

For home and industrial use as a fuel ( stove, water

Propane (C3 ) Used as a commercial fuel .

(Table 1-2): Contaminants Compositions in Natural Gas

(Figure 2-1): 2-phase separator

(Figure 2-2): 3-phase separator

2.1.3. Separation principle:

(Figure 2-3): Procedure of separation

1- Droplets of liquid mist will settle out from gas, provided.

Separator is divided into four major sectors:

(Figure 2-4): Separation sectors

(Figure 2-5): Straightening vanes

2.2.5.3. Mist Extraction section:

(Figure 2-6): Large bubble splits

(Figure 2-7): Bubble cap tray

(Figure 2-12): Outlet wires

These contribute to the uniform distribution of liquid as it enters the tray

7) Draw off Pan (trap out pans)

(Figure 2-17): Valve tray

During the operation of a tower:

(Figure 2-20): Top tower demister

2.3. Cold box:

(Figure 2-22): Coil wound heat exchanger

2.3.3.2. Plate-finned heat exchanger:

(Figure 2-23): Plate finned heat exchanger

2.4.1. Simple Cycle:

(Figure 2-24): Simple cycle

(Figure 2-25):P-h diagram of Simple cycle

2.4.1.1 Simple Cycle Explanation:

1- The refrigerant at PT (1) is saturated vapor at 1 bar.

(Table 2-2): Compressor specification for simple cycle

Power (MW) 0.67

Power needed for compressor = 0.67 MW

2.4.2.1 Dual Cycle Explanation:

1-The refrigerant at PT (1) is saturated vapor at 1 bar.

(Table 2-3): Heat load for dual cycle

Total Power= 0.57 MW

(Figure 2-28): Dual cycle

2.4.2.2 Dual Intermediate Pressure optimization:

Using spreadsheets insert power of compressors and sum them in

(Figure 2-30-A): Importing data in spread sheet

(Figure 2-30-B): Importing data in spread sheet

(Figure 2-31-B): Exporting data from spread sheet

(Figure 2-32-A): Importing variables into data book spread sheet

(Figure 2-32-B): Importing variables into data book spread sheet

(Figure 2-32-C): Importing variables into data book spread sheet

(Figure 2-33): Importing variables into data book spread sheet