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T
he processes gas plant owners/operators use to source of the reflux stream was either a portion of the
recover hydrocarbon liquids from natural gas streams separator vapour or the separator liquids or a combination
have undergone continual improvements over many of the two. The higher product recovery levels and lower
decades. Gas plants today are required to maximise profits power requirements quickly made this the next ‘standard’
by optimising both the recovery of natural gas liquids (NGL) process technology, commonly known as the gas sub-
based on market prices and plant throughput to satisfy their cooled process, or GSP (see Figure 1).
delivery contracts. Given recent market volatility, the ability Compared to the simple expander plant, the key fea-
to vary plant operation has become increasingly important. ture of GSP was the addition of a reflux stream created by
NGL recovery plants designed with built-in flexibility can condensing and subcooling a portion of the feed gas. This
maximise plant throughput, even above nameplate capac- reflux stream captured more of the valuable ethane and
ity, while maintaining maximum product recovery. This heavier hydrocarbons that were otherwise lost to the res-
gives them an economic advantage over standard designs. idue gas stream from the top of the fractionation column.
Unfortunately, many standard cryogenic NGL recovery Although the GSP technology required an additional heat
plants were constructed using technologies with limited exchanger and an additional fractionation section at the
product recovery capabilities and flexibility. These plants top of the column, the product recoveries were significantly
are unable to effectively achieve maximum ethane and pro- improved without requiring more compression power. This
pane recovery or adjust operations without losing valuable allowed operators to recover ethane and heavier hydrocar-
product, in particular propane, into the residue gas stream. bon components as the NGL product while also producing
To stay competitive, owners/operators of older plants often a mostly methane residue gas stream. The process could
need to retrofit their plants. also be configured to reject the ethane into the residue
Several new process technologies are available to effec- gas stream while recovering only the propane and heavier
tively upgrade standard plants. These recent advances can components as a liquid product. The latter ‘ethane rejection
provide higher ethane and propane recoveries, and many mode’ of operation was useful in locations without a destina-
offer fully flexible ethane recovery levels, ranging from tion for an ethane product or where market conditions made
ultra-high recovery to almost full rejection while maintain- ethane more valuable for its heating value in the residue gas.
ing high propane recovery. Other technologies include the
ability to process higher feed gas flow rates with minimal
modifications to existing equipment. Identifying the key Subcooler
a turboexpander, with the expanded feed gas providing Inlet gas Expander
Demethaniser
top reflux to a fractionation column. This became known
as a ‘simple expander plant’. The integration of the turbo-
expander was a significant improvement over the previous
standard, the ‘refrigerated J-T plant’, providing higher prod-
uct recovery with less compression power.
In the 1970s, The Ortloff Corporation improved on the Bottom product
Retro-Flex retrofit
The proprietary UOP Retro-Flex technology6 was co-devel-
Bottom product
oped in partnership with SME Products, LP specifically to
increase the recoveries of propane and heavier components
from GSP plants. It is applicable to both ethane recovery Figure 3 Retro-Flex retrofit
and ethane rejection modes of operation and does not
require additional compression. Retro-Flex is considered a condensing it in the CRM. The additional cooling and rec-
‘bolt-on’ retrofit, with all new equipment located on a skid tification of this stream allows Retro-Flex Plus to capture
adjacent to the existing plant. This minimises the number of more of the unrecovered ethane. In ethane rejection oper-
tie-in points and downtime. ation, the reflux compressor is shut down, and the retrofit
Figure 3 shows a Retro-Flex retrofit for a GSP system design reverts to the Retro-Flex technology.
operating in ethane rejection mode. The cold flashed A Retro-Flex retrofit offers a convenient upgrade option
stream from the GSP subcooler, which normally feeds the for GSP plant operators who want to improve their propane
top of the column (shown dashed), is instead routed to the recovery levels, either in ethane recovery or rejection modes
cold refluxing module (CRM) for processing. The residue of operation. Moreover, with only four tie-in points, it requires
gas stream that normally flows from the column overhead minimal downtime and has small plot space requirements.
directly to the subcooler (shown dashed) is instead routed
to the CRM and then subsequently routed to the subcooler. GSP2 retrofit
The resulting condensed liquids are pumped to the top of The standard RSV and Retro-Flex retrofits rely on existing
the existing column as top reflux. equipment for all the feed gas processing. When through-
For a standard GSP plant, the Retro-Flex installation put greater than nameplate capacity is desired, special con-
requires only four tie-in points, shown with circles in Figure sideration must be given to processing the additional feed
3. By installing appropriate isolation valves, the installation gas without exceeding the existing equipment limitations.
downtime can be minimised, and the CRM module can be One such technology is the proprietary UOP Ortloff
easily bypassed if desired, allowing the plant to revert to GSP2 process⁸ shown in Figure 4. With GSP2, the feed
the original GSP section. Typically, no modifications to the gas is split into two streams, usually with the existing plant
column or other existing equipment are required. The CRM
and pumps are mounted on a single module for easy instal-
lation, and all equipment is accessible for monitoring and New heat
exchanger
maintenance.
In ethane rejection mode, a Retro-Flex retrofitted GSP
plant provides a significant propane recovery improvement Subcooler Absorber
compared to the original plant performance. Retro-Flex can Residue
gas
achieve greater than 99% propane recovery even when
rejecting almost all the ethane, whereas the GSP process is Pump
typically limited to 85-94% propane recovery while reject- Residue gas
ing ethane. In ethane recovery mode, Retro-Flex achieves compressor
Expander
nearly 100% propane recovery, while GSP is typically lim- Inlet gas
ited to less than 99% propane recovery. It is important to Demethaniser
Table 2
Case study 2
The Comanche III Gas Processing Plant, owned by Brazos
Midstream, was commissioned in January 2018. It was
designed as a standard skid-mounted plant using GSP with
a design capacity of 200 MMSCFD. At start-up, the recov-
ery levels were approximately 93% ethane and slightly less
than 99% propane.
Although this was a relatively new modular NGL recov-
ery plant, Brazos Midstream quickly developed a desire to
achieve higher propane recoveries, both in ethane recov-
ery and ethane rejection modes of operation. Based on the
Figure 7 Absorber, left, and new heat exchanger seen market needs, the goals of the retrofit were identified as
during installation follows:
• Improve product recoveries, particularly increasing the
drops and poor thermal performance. It was replaced as propane recovery level to essentially 100% in ethane recov-
part of the retrofit ery mode and greater than 99.5% while rejecting ethane at
• The expander/compressor was refurbished and fitted a 55% recovery level. Ethane recovery of greater than 99%
with new expander and compressor wheels to handle the was also desired
retrofit conditions • Provide an option to increase plant throughput in the
• The demethaniser internals were replaced to improve future.
packing efficiency and handle higher vapour and liquid flows. To provide the desired ultra-high ethane recovery and
New equipment for the GSP/Retro-Flex retrofit included essentially 100% propane recovery, a process like RSV
the following, along with associated piping and controls: was clearly required. However, the RSV2 option was cho-
• Absorber column sen because of the potential to process additional gas. It
• Absorber bottoms pumps was also attractive because of the ability to connect the
• Reflux condenser/subcooler new equipment with minimal downtime, requiring only six
• Cold refluxing module (CRM) tie-ins.
• Demethaniser hot oil reboiler Given the young age of the original GSP plant and the
• Air-cooled product cooler (for ethane rejection mode) application of the RSV2 feed gas bypass, the retrofit did not
• Supplemental refrigeration compression. require any modifications to the existing equipment. New
For this project, the CRM was constructed on top of the equipment for the RSV2 retrofit included the following,
absorber, eliminating the need for additional pumps typi- along with associated piping and controls:
cally required for a Retro-Flex retrofit. The new absorber • Absorber column
(with the CRM attached on top) can be seen next to the • Absorber bottoms pumps
existing column in Figure 6. • Recycle gas exchanger/reflux condenser.
The addition of the new equipment required five tie-in Figure 7 shows the new equipment during construction.
points, which were completed during a planned plant The absorber appears on the left, while the new recycle gas