Fundamentals of Gas Dehydration
C. Richard Sivalls, Mark Ferguson, Paul Carmody, Adam Baxter, Mike Sheilan, & Mike Schneider
The fundamentals session, marking the 75th conference anniversary, focuses on gas dehydration with Triethylene Glycol and Molecular Sieve Systems. A respected industry leader will discuss hydrate prevention history. The session will also cover fundamental design, operation, and considerations for dehydrating CO2. The session aims at engineers and operators new to the industry and serves as a refresher for experienced attendees.
Emissions Reduction with Electric Motor Driven Dehydration Pumps
Kyle Benning, Kyle Baker, & Jeremy McCurdy
This paper will evaluate and quantify the cost in emissions and revenue associated with wasting sales gas to drive energy-exchange dehydration pumps. These energy-exchange or pneumatic pumps driven by natural gas were a brilliant innovation for remote gas processing locations in the 1950s when this technology was invented. But now with more electrical infrastructure and power available, as well as an eye to creating more eco-friendly natural gas, an electric motor driven pump will result in less wasted gas and less emissions tied to venting and flaring. This paper will quantify those emissions savings at typical pipeline pressures, on a gallon of glycol pumped basis.
The Formation and Disposition of Cyanide Ion Degradation Products in Refinery DEA Solutions
Al Keller
Hydrogen cyanide (HCN), a byproduct from the coking and fluid catalytic cracking of nitrogen-containing heavy oils, accelerates corrosion in refinery gas processing equipment. Although water washes are employed to mitigate localized cyanide buildup, their effectiveness is limited due to insufficient fresh water supply. Consequently, HCN often persists into the amine system, where alkanolamines like Diethanolamine (DEA) remove it alongside hydrogen sulfide (H2S) and carbon dioxide (CO2), as HCN acts as an acid gas, forming cyanide ions (CN-) in solution. Research examining 16 months of data from five DEA systems indicates a relationship between cyanide ion presence and the formation of DEA degradation products such as DEA-Formate Salt, DEA formamide, and THEED; this paper will explore this relationship and the equilibrium boundaries governing the accumulation of these degradation species.
Shell Turbo Technologies: Achieve Solvent Performance and Gas Capacity Improvement Compared to Traditional Column Internals
Anh Do, Ton Schlief, & Karl Stephenne
The oil and gas industry faces increasing challenges, including handling more contaminated resources, meeting stricter product specifications, maximizing asset efficiency, and minimizing costs. Shell Turbo Technologies (STT), featuring the patented Shell Turbo Trays deployed in 2021, effectively addresses these issues by allowing operators to revamp existing units for increased capacity, as demonstrated by a 21% gas rate increase in a Middle Eastern AGRU and a nearly 60% improvement in a TEG dehydration facility. For greenfield projects, STT can reduce absorber/contactor capital expenditure by 30–50%, offering a powerful solution for enhancing operational efficiency and cutting costs. This presentation will highlight STT's benefits for gas processors and refiners, covering its development, design fundamentals, data from commercial applications, and how it helps increase processing capacity, tackle operational issues, and reduce both operating and capital expenses.
Amine System Challenges - Pipestone Sour Gas Plant
Loni van der Lee & Michael Sheilan
The AltaGas Pipestone Sour Gas Plant located approximately 40 km west of Grande Prairie, Alberta, and operational since September 2019, processes 100 MMSCFD of sour natural gas from the Montney Shale play, utilizing separation, DGA sweetening, molecular sieve dehydration, deep-cut processing, liquids handling, and acid gas injection. Despite its design to handle up to 5 mol%, the plant has faced significant challenges in its first five years, including frequent foaming, severe corrosion in the amine regeneration tower and rich amine piping, substantial fouling in exchangers, and high operating costs due to frequent amine additions, filter changeouts, and equipment maintenance. Through collaboration with internal and external experts, the team has progressively identified and addressed these issues, implementing design and operational changes—such as separation improvements, increased filtration capacity, media changes, antifoam assessments, inlet gas testing, enhanced temperature management, heat transfer monitoring, and amine regenerator upgrades—to enhance unit performance and apply these lessons to future expansions.
Mercaptan Removal Options
Jon Lewis
Raw natural gas often contains impurities like hydrogen sulfide (H2S), carbon dioxide (CO2), and mercaptans, which require extensive removal for pipeline or LNG specifications. Amine-based chemical solvents have long been the preferred method for removing via acid/base reactions, with Methyldiethanolamine (MDEA), often in proprietary formulations, being a common choice. For achieving deep CO2 removal (e.g., to 40 ppmv for LNG), activators like piperazine are frequently added to MDEA, also facilitating carbonyl sulfide (COS) removal through hydrolysis. Mercaptan removal, however, poses a greater challenge, necessitating a holistic design approach to determine the optimal removal point within the flow scheme. This paper will evaluate three primary options for mercaptan removal—within the Acid Gas Removal Unit (AGRU) using a physical solvent, in the Dehydration Unit, or from liquids condensed in the ‘cold’ plant (NGL Recovery Unit) discussing their respective merits and drawbacks, recent operational experiences, and their impact on downstream units such as Acid Gas Enrichment and Sulfur Recovery Units.
Dry-Out Practices and Design Considerations for Cryogenic Gas Plants
Scott A. Miller, David A. Jelf, J A. Anguiano, & Joe T. Lynch
Efficient dry-out is crucial for successful cryogenic gas plant startups, yet inadequate planning and execution frequently cause significant delays. This paper emphasizes the importance of incorporating dry-out provisions into the original design and adhering to best practices during the dry-out period to prevent such losses. It will cover the rationale behind thorough dry-outs, common pitfalls that extend dry-out times, and fundamental requirements for eliminating free water from the system. Additionally, guidelines will be provided for EPC contractors on necessary design details for monitoring and executing proper closed-loop dry-out procedures, an outline of which is included to significantly reduce pre-cool down drying time. Applicable to any turbo-expander cryogenic plant, the paper will conclude with examples of real-world dry-outs, illustrating the impact of following or neglecting these crucial procedures.
Field Results from the Recovery of Hydrogen from Hydrogen Sulfide by an Iodine Thermochemical Cycle
Ryan J. Gillis, Rachid Taha, Te-Chun Chu, & Alex Sanchez
Building on the 2022 LRGCC paper, "Hydrogen from Hydrogen Sulfide in Natural Gas Production and Processing," this work presents the successful piloting of a novel, two-step chemical cycle for hydrogen sulfide processing in the Permian Basin. Hundreds of hours of pilot plant operation demonstrate the technical feasibility and potential economic viability of this unique approach, which recovers hydrogen gas from the hydrogen sulfide stream. This paper will detail the system design, operational insights, hydrogen recovery rates, hydrogen sulfide removal efficiency, and process integration. We'll also share results from tests with higher hydrogen sulfide concentrations and conclude with a techno-economic evaluation, identifying ideal installation sites for this innovative technology.
A Catalyst- Sorbent Hybrid Process for Organic Sulfur Removalfrom Natural Gas, Lighthydrocarbons, Biogas and Co2
Gökhan Alptekin, Freya Kugler, Matthew Schaefer
While conventional amine scrubbing and solid/liquid scavengers effectively remove hydrogen sulfide (H2S) from natural gas and natural gas liquids, they are not cost-effective for removing organic sulfur compounds like mercaptans, carbonyl sulfide (COS), and carbon disulfide (CS2). To address this, a new hybrid process is being developed that utilizes a metal oxide catalyst and an advanced sorbent. This process first dimerizes mercaptans into less volatile disulfides using a specialized catalyst, which are then easily removed by a low-cost, high-capacity mesoporous carbon adsorbent with optimized pore sizes. The carbon sorbent's surface is also modified to effectively remove COS and CS2. This innovative, cost-effective, and expendable system, capable of operating in both wet and dry gas streams, has the potential to remove all organic sulfur compounds to ultra-low concentrations, as supported by laboratory and commercial-scale tests across various feedstocks.
Saudi Aramco “Sulfur Deposition Recovery Technology”
John P. O’Connell
The conventional Claus process, the long-standing method for sulfur recovery from hydrogen sulfide (H2S) in the petroleum industry, typically achieves 95-98% efficiency. However, stringent environmental regulations now necessitate tail gas treatment (TGT) technologies, like the common two-stage Claus followed by a reduction absorption amine-based TGT, to reach over 99.9% overall sulfur recovery. Given the prohibitive capital and operating expenses of traditional Claus/TGT configurations, a new sub-freezing sulfur recovery technology developed by Aramco offers a more attractive and simpler solution. This innovative process leverages the Claus reaction, without requiring a TGT, by maximizing the reaction efficiency through sub-freezing catalytic bed temperatures. By indirectly removing heat in the catalytic converter beds, the sulfur produced can be cooled below its freezing point, achieving greater than 99.9% recovery efficiency. This technology is adaptable for both small (10 TPD) and very large (over 1000 TPD) applications, producing high-quality elemental sulfur, unlike traditional low-tonnage recovery methods that often yield impure sulfur destined for landfills. This paper, authored by renowned sulfur recovery expert John O’Connell, will detail the configuration and capabilities of this new technology.
Solids Influx Prediction Tracking in Gas Inlet Facilities Using Computational Fluid Dynamics Modelling
Megat A. Rithauddeen, Ahmad Fadzil, & Turki Al-Ghamdi
While aiming for solids-free production in gas processing plants, especially onshore facilities with closed-loop hydrate inhibition systems for sour gas, recent experiences indicate that complete solids exclusion isn't always achievable, necessitating robust solids handling. Drawing on Saudi Aramco's experience with offshore sour gas fields utilizing closed loop monoethylene glycol (MEG) systems, this paper details a pioneering approach using Computational Fluid Dynamics (CFD) modeling to predict and track drilling mud and solids influx across a new gas inlet facility. The analysis covers solids distribution during normal and scraping operations across critical equipment, including the liquid manifold, slug catcher, MEG flash drum, rich MEG tank, condensate reception vessel, condensate flash drum, and heat exchangers. By evaluating particle loading and size distribution, the study assesses the adequacy of proposed designs to handle expected solids, identifies gaps to prevent buildup, and establishes the basis for system upgrades. This novel CFD-based method successfully identified and incorporated design enhancements during the execution phase, significantly improving system robustness against solids influx and minimizing the risk of unscheduled downtime, with plans for real-time monitoring validation.
Considerations When Specifying Filtration Equipment with a Focus on Amine Solvent Units
Chris Wallace & John Worrell
While often overshadowed by core process reactors, filtration and separation equipment are critical for the stability, reliability, and economics of industrial fluid processes, particularly in the gas processing industry for maintaining amine solvent system health. Current industry’s best practices offer minimal and vague details on liquid filtration, leading to subjective interpretations and undersized or inefficient equipment installations. This paper aims to bridge the communication gap between the filtration and gas processing industries by providing a concise overview of particle filtration equipment goals, optimization strategies, and a detailed review of critical process design data parameters on equipment data sheets. By clarifying design conditions such as fluid/solids composition, flow rate, properties, temperature, pressure drop, particle size, and removal efficiency, and by explaining how filtration application engineers interpret common information, the authors hope to establish better-defined specifications and industry standards, ultimately leading to more effective filtration solutions aligned with end-user objectives.
Aerosols In Residue Gas and Orifice Plate Meters
Matt Thundyil & Carl Hahn
Accurate metering is crucial for the natural gas industry, as measurement errors can lead to significant commercial, legal, and engineering issues, often stemming from process stream contamination. This paper addresses a specific challenge at a North American gas plant where an orifice plate metering system experienced inaccuracies due to fouling by viscous oil, likely from the residue gas compressor. Investigation revealed design flaws in the compressor's discharge coalescer elements and housing. An improved coalescer design and housing adaptation were implemented, successfully resolving the metering problems. Beyond the direct cost of oil loss, the study highlights the substantial commercial impact of oil carryover on metering accuracy, underscoring the immense financial implications associated with such challenges.
Bechtel Sulfur Adsorbent Technology (Bsat) Field Results at a Recompression Station
Richard Fink, Arnab Baksi, Charles Kimtantas, & Martin Taylor
Elemental sulfur is soluble in natural gas in the parts per billion range, and the natural gas pipeline industry is more and more frequently discovering the effects of Elemental Sulfur Deposition (ESD). After encountering a change in temperature or pressure, elemental sulfur can desublimate and form a yellow or off-yellow deposit. These deposits are frequently found in locations that require a pressure drop, such as orifices, regulators, control valves, meter stations, filter separators, etc. These deposits can interrupt flows that disrupt the required throughput of gas and oftentimes mandate shutdowns of various systems to manage cleanup. Bechtel Energy Technologies and Solutions, Inc. (BETS) has developed and patented advanced adsorbent material to remove elemental sulfur from the vapor phase before these troublesome deposits can occur. Valley Crossing Pipeline, LLC an Enbridge – Gas Transmission & Midstream company hosted a field trial in 2024 at a selected South Texas facility. The methods used and the results observed during the field test will be discussed.
Troubleshooting Rich Amine Filter Short-Life Issues in an Amine Unit
Steven Kong & Mike Cundall
This paper describes the unusually short life (as short as 2 hours) of the filters in the rich amine service of a sour gas processing plant and the measures taken to improve the filter life to more acceptable levels. Corrosion in the amine regenerator system due to lower acid gas flows and operation below the tray turndown was the main cause leading to short filter life and most of the corrosion was mitigated through process parameter changes. Even though all the typical amine unit setpoints such as lean amine loading, heat stable salts and overhead temperature were in line with recommended targets.
Innovative Separation Technologies in Enhanced Oil Recovery Operations
Byron Griffin, Ryan Duncan, Tim Rollenhagen, & Bas Hakenberg
As a prominent Permian Basin operator specializing in Enhanced Oil Recovery (EOR) and unconventional resources, Occidental Petroleum (Oxy) is revolutionizing its Water Alternating Gas (WAG) injection processes. Traditionally, WAG operations lead to significant CO2 gas flashing from water in conventional low-pressure tank batteries, incurring high costs associated with vapor recovery units (VRUs) and water pressurization for reinjection. Oxy is addressing this by piloting a tankless design that utilizes separators and compact hydrocyclones to achieve reinjection-quality water at higher pressures. This innovative approach substantially reduces CO2 gas volumes and VRU demand, thereby lowering water injection pump requirements, decreasing capital intensity, and unlocking new investment opportunities. This paper will detail the design, key findings, and lessons learned from the 2023 commissioning of this technology in a mature EOR field near Denver City, Texas.
Hysweet™ A Step Further in Mercaptan and Acid Gas Removal for Natural Gas Processing
D. Rakotoalimanana, R.Cadours, M. Scala, C. Volpi, E. Cloarec, C. Alfano, G. Dalary, & G. Parer
The oil and gas industry continually seeks to optimize production amidst stringent specifications and competitive pressures. Conventional amine solvents for H2S and CO2 removal have limited mercaptan (RSH) removal capabilities. In response, TotalEnergies developed a novel hybrid solvent formulation that simultaneously removes mercaptans and acid gases with minimal hydrocarbon co-absorption, leading to more competitive process configurations and solving operational issues with sour gas. First implemented at the Lacq plant in 2007 by adding a physical component to DEA solvent, this technology has been continuously enhanced, culminating in a 2018 industrial-scale MDEA-PZ-hybrid solvent achieving deep mercaptan elimination (below 5 ppmv for various mercaptans) even at low pressure. Now part of Axens' technology portfolio, this HySWEET™ hybrid solvent has seen several licenses granted, with the first two units successfully starting up in early 2024, demonstrating its ability to meet acid gas and mercaptan specifications while ensuring trouble-free downstream sulfur recovery. This paper presents operational records from the Lacq plant and new industrial units, providing insights into the benefits, limitations, and field of application for this advanced hybrid solvent technology.
Realtime Photoacoustic Molecular Detection using Tunable Diode Lasers
Carvel Jasmin
To fully understand the impact of Tunable Diode Lasers (TDL) technology on our industry, it is important to take a step back and look at the evolution of when and how this technology started, how it is being used and its benefits. Photoacoustic Tunable Diode Lasers (PA) TDL in the next step in the utilization of lasers. Photoacoustic Spectroscopy (PAS) is based on the photoacoustic effect. In 1880 Alexander Graham Bell showed that thin discs emitted sound when exposed to a beam of sunlight that was rapidly interrupted with a rotating slotted disk. In 1938 Viengerov measured gas absorption spectra with a blackbody IR source. And now we are at the next level of PA-TDL measurement where the power of technology is fully utilized to measure contaminants in the Oil & Gas industry.
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