SWEETENING (Chemical Absorption) Presentation
SWEETENING (Chemical Absorption) Presentation
Z By Dr.Vatani Y
TSP-POGC-NIGC (١)
GAS SWEETENING
PROCESSES
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1. GENERAL
Natural gas is the most sought after fuel source because of its
clean combustion (reduction of the atmosphere pollution). It
is also a base for LPG (propane, butane) manufacture. It can
be used also as a feedstock to petrochemical plants.
Production and distribution of natural gas are non-negligeable
agents of the world economy. The gas is a mixture of
hydrocarbon components, which can be produced from a
reservoir rock (original natural gas designation) or from a
crude production (associated gas).
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Natural gas or associated gas produced with crude oil-contain
acid components, mainly carbon dioxide (CO2) and hydrogen
sulfide (H2S) and sometimes traces of other compounds:
Carbonyl sulfide (COS) carbon disulfide (CS2) and
mercaptans.
Gas or oil produced from a well that contains hydrogen
sulfide (H2S) or other obnoxious sulfur compounds is called
“sour” gas or oil.
oil The process used to remove the H2S or
sulfur compounds is called “Sweetening”.
H2S must be removed from the gas before it can be used for
fuel. It is highly corrosive, and deadly toxic.
toxic The products
formed when it burns are also highly toxic.
toxic Other sulfur
compounds are also corrosive and toxic, but not to the degree
of H2S.
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In order to obtain a commercial product, gaseous or liquefied,
the gas shall be treated to eliminate these sour components
for safety or process reasons:
- Safety:
Safety H2S is a very toxic gas .
- Process:
Process Risk of plugging mainly with CO2 .
Another aspect of gas sweetening is linked with the
development of the CO2 injection to improve oil recovery. In
this case CO2 is extracted by a selective process.
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1.1. Natural Gas
A natural gas (original term) is a hydrocarbon gas, which is
produced from a gas reservoir. It means that at reservoir
conditions the hydrocarbon mixture is gaseous or at its
hydrocarbon dew point.
Table 1 shows the compositional analysis of several natural
gases.
Natural gas often contains hydrogen sulfide and carbon
dioxide in concentrations, which make the gas unsuitable for
use as fuel. The gas may also contain other sulfur materials,
which must be removed before the gas can be utilized as fuel.
Gas, which is produced during the refining of crude oil often
contains complex sulfur compounds which must be removed
before the gas can be used for fuel.
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TABLE 1
COMPOSITIONAL ANALYSIS
OF NATURAL GASES
(From Natural Reservoirs)
Country Iran
Field Kangan Nar Khangiran Assaluyeh Sarkhon
Components Mole% Mole% Mole% Mole% Mole%
N2 5.95 4.61 0.55 3.474 4.89
CO2 1.83 1.46 6.41 1.860 0.65
H2S 681ppm 59.6ppm 3.85 0.555 0.02
COS --- --- 17ppm 3.1ppm ---
C1 85.29 87.98 88.35 85.086 87.76
C2 4.14 3.65 0.56 5.448 3.75
C3 1.32 1.09 0.09 1.991 1.39
IC4 0.29 0.24 0.02 0.379 0.32
NC4 0.40 0.32 0.03 0.573 0.48
IC5 0.20 0.16 0.02 0.178 0.19
NC5 0.14 0.11 0.02 0.159 0.15
C6+ 0.44 0.38 0.01 0.273 0.21
RS 59.6ppm 17.1ppm --- 159.4ppm ---
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1.2. Gas Transportation
Natural gas from gas well is a raw product which in almost
generally for satisfying given specifications (transportation
specifications, commercial specifications), as shown in
Table 2. COMPONENT PROBLEMS
Water Vapor Hydrates
Solidification
CO2
(At low temperatures)
Acid Gases
H2S Toxicity
CO2
Corrosion
And /or
(With free water)
H2S
TABLE 2 Condensation
RAW GAS Heavy Ends Solidification
CONTAMINANTS (At low temperatures)
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Natural gas generally is saturated with water at its reservoir
conditions. When the gas is produced, its temperature and
pressure will decrease. Temperature decrease will promote
the condensation of the water. Once water under liquid form
is present in the gas transportation line two problems can
arise:
• If the gas contains acid gases (CO2 and /or H2S)
corrosion will occur.
occur
• If the gas temperature is low,
low light hydrocarbon of
the gas with free water can form hydrates (solids)
which when present in the line, can block the
production system.
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In addition to the problems linked with the presence of free
water in the pipeline, additional operating problems can arise
due to the condensation of heavy hydrocarbons from the gas
flowing through the line. Two-phase flow (gas and
hydrocarbon liquids) regime can induce intermittent flow in
the pipeline and then operating problems in downstream
processing facilities.
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1.3. Sales Gas
Natural gas from wells is a raw product, which is generally
far from satisfying commercial specifications.
Processing facilities to be provided to allow a raw feed gas
to meet the required specifications are as follows:
a) Water dew points : Gas dehydration will be
mandatory ( physica absorption or gas
refrigeration ) . Physical absorption generally
uses TEG ( triethylene glycol ) as solvent.
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Physical absorption process (which use dry solvents) can
be also envisaged depending upon the gas pressure and the
acid gas partial pressures. Moreover they are generally
suited to H2S removal (CO2 removal is more difficult to
achieve with these processes).
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for a sales gas contact, he can be led also to look for a
hydrocarbon liquid contract to get rid of the treated gas
associated condensate.
TABLE 3
IRAN SALES GAS SPECIFICATIONS
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2.GAS SWEETENING PROCESSES
The different Gas Sweetening Processes to be applied
depend on the quality and quantity of acid gas contaminants
to be removed:
z CO2 when this is the sole contaminant of the gas
z H2S when this is the sole contaminant of the gas
z CO2 and H2S simultaneously
z Selective removal of H2S when both CO2 and H2S
are present in the gas
The existing processes are as follows:
z Chemical Absorption
z Physical Absorption
z Physico-chemical Absorption
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z Physical Adsorption
z Cryogenic Fractionation
z Permeation (membrane)
z Direct conversion to sulfur
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z Diisopropanolamine or DIPA
z Methyldiethanolamine or MDEA
As an alternative to alkanolamine products, an alkaline salt
is also used :
z Hot Potassium Carbonate or HPC or Hot Pot
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Chemical absorption process is based on a contact between
the gas to be treated (feed gas) and an aqueous solution
containing one of the above solvents.
solvents Acid gas in the feed
gas is a weak acid which reacts with the alkanolamine
(alkaline product) or alkaline salt (in the case of
potassiumcarbonate) to give bisulfide (with H2S) and
bicarbonate (with CO2).
The chemical reaction (chemical absorption) takes place in a
fractionation column (absorber or contactor) which is
equipped with trays or packing. The gas enters the column at
the bottom tray (or at the bottom part of the packing). The
aqueous solution enters the column at the top tray (or at the
top section of the packing).
There is a heat of reaction between the solvent and the acid
gas during this absorption, which is exothermic.
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The treated gas exits the unit at a higher temperature than
the feed gas.
gas This implies that the treated gas water content
will be higher than the feed gas water content. As a
consequence should a dehydration of the gas be also
required, this unit will be always installed downstream of the
sweetening unit.
The alkanolamine salt is then re-transformed into alkaline
solution in a regeneration section and the cycle is repeated
again.
2.1.1. Description of an Amine process
This process flow scheme varies little, regardless of the
aqueous amine solution used as the sweetening agent.
Slight modifications can appear linked to the type of amine
which is selected and to the optimization of the scheme for
specific purposes.
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The feed gas (sour gas) containing H2S and/or CO2 always
must enter the plant through an Inlet Separator (or feed gas
knock-out drum) to remove free liquids and/or entrained
solids.
Inlet Separator
Objective
Catch liquid entrainments (water and hydrocarbon
condensate and mist) to prevent entries of
contaminants in the amine system
Characteristics
Generally vertical drum equipped with Demister pad to
prevent liquid droplets carry-over
Alternatives
Cartridge filter-separator
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The gas from this separator enters the bottom of the
Absorber and flows upward trough the column in intimate
counter-current contact with the aqueous amine solution
(lean solution). In the column the chemical reaction between
the amine and the feed gas acid gas occurs and the amine
solution absorbs the acid gas. The chemical reaction (due to
the heat of reaction between the amine and the acid gas) is
exothermic.
exothermic It will raise the temperature of the gas.
Treated gas (lean gas or sweet gas) leaves the top of the
column and the amine solution loaded with acid gas (rich
solution) leaves the bottom of the column.
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Absorber
Objective
Acid gas removal from feed
Characteristics
- Fractionation column equipped with trays (generally
around 20) or packing beds (generally 2 or 3 beds).
- The column must be equipped with pressure
differential instrument to monitor the differential
pressure across the trays (or beds)
- sharp UP increase indicated foaming
- slow U P indicated tray (or bed) fouling
- The column generally is fitted with three (3) level
glasses at bottom to detect the real level in the bottom
where there is foaming or oil layer .
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- Lean solution inlet temperature = at least feed gas
temperature + 5 deg.C to avoid hydrocarbon
condensation. Higher lean solution inlet
temperatures will result in lower acid gas pickup up
by the solution and higher water losses (treated
higher temperatures).
The absorber column operates at the feed gas pressure.
pressure A
minimum pressure of 4/5 b.a is required to make the process
feasible and operable. There is no limitation on high
pressure as far as the process is concerned. The only
limitation relates to the thickness of the still plates to form
the body of the column (anticipated construction problems
for thickness above 150 mm).
Feed gas temperature must be positive (high freezing point
of the amine solutions).
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However high temperatures will affect the performances of
the unit. Should the feed gas be at high temperature, an inlet
cooler (using air or water) or a gas/gas exchanger (using the
hot treated gas as heating medium) will be provided. This
equipment will be installed upstream of the inlet separator.
The top of the absorber can be equipped with additional
trays (2 to 4) to accommodate a water wash section. The
injected water will remove the amine carried over with the
treated gas. It is injected at the top tray and completely
withdrawn at last tray of the water wash section.
The treated gas is then handled by a separator (or Treated
Gas KO Drum)
Drum to collect entrained liquid before being routed
to the downstream facilities.
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Treated Gas KO Drum
Objective
Dry the treated gas by removing entrained amine
Characteristics
Vertical drum equipped with Demister pad
Alternatives
Cartridge filter-separator
The rich solution from the Absorber is then let down and
generally routed to the Amine Flash Drum.
Drum This drum (which
operating pressure is between 7 and 15 b.a) allows to remove
a portion of acid gas which evolves from the solution by the
pressure let-down effect. The acid gas stream from the
Amine Flash Drum is routed either to the fuel gas pool of the
facilities or to the acid gas disposal system.
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Amine Flash Drum
Objective
Removal of dissolved gas and entrained liquid
hydrocarbons upstream the amine/amine heat
exchanger and the regenerator
Characteristics
- Generally horizontal three-phase drum (liquid
hydrocarbons skimming system is required
- Should be operated at minimum pressure (for a better
degassing of the solution)
- Liquid retention of 10 to 20 minutes have been used
The rich solution from the Amine Flash Drum then passes
through an Amine/Amine Heat Exchanger.
Exchanger
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This heat exchanger serves as a heat conservation device
and lowers the total heat requirements for the process. The
rich solution is heated by the regenerated solution (lean
solution) coming from the regenerator.
Amine/Amine Heat Exchanger
Objective
Preheat the rich solution to the regenerator
Characteristics
- Shell and tube exchanger with rich solution tube
side/lean solution shell side
- Minimum vaporization should take place in the
exchanger (tube side) to prevent erosion/corrosion
due to mixed flow
- Velocity must be limited to 1 m/s
- Should several exchanger be required, they will be
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removed in the upward flow of amine solution
- Lean solution inlet temperature between 110 to 130
deg.C
- Rich solution outlet temperature between 90 and 110
deg.C
Alternatives
Plate frame exchanger. This type of exchanger
offers larger surface areas and higher heat transfer
rates in a small volume. It is however more
susceptible to fouling
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Regenerator
Objective
Regenerate the rich amine by stripping of the acid gas
Characteristics
- Fractionation column equipped with trays (generally
around 20) or packing beds (generally 2 or 3 beds).
- The column must be equipped with pressure
differential instrument to monitor the differential
pressure across the trays (or beds)
. sharp U P increase indicated foaming
. slow U P indicated tray (or bed) fouling/plugging
- Demister pad can be installed at the top to reduce
amine loss caused by physical entrainments
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The Regenerator trapout product feeds the Reboiler which is
a shell and tube exchanger (using hot oil or steam as heating
medium).
Reboiler
Objective
Heat up the rich solution to produce the energy to
reverse the chemical reaction to free acid gas from the
amine solution and to generate steam to strip acid gas
from solution. The stripping efficiency is controlled by
the overhead reflux ratio.
Characteristics
- Generally kettle type reboiler. Square tube pitch
pattern is recommended
- Regenerated solution outlet temperature is only
function of operating pressure and amine strength
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- Reboiler duty controlled by heating medium rate
(steam or hot oil)
- Tube skin temperature <145 deg.C to avoid amine
degradation
- Space to be provided below the bundle to have a
good natural circulation and leave room for sludge
deposit
- Liquid layer above the bundle high enough to
prevent localized drying and overheating (150 to 200
mm height)
- Sufficient vapor volume above the liquid level to
have no solution entrainments
Reflux drum
Objective
- Recover as stripper reflux the water condensed in the
condenser
- Catch possible condensed hydrocarbons
Characteristics
- Vertical or horizontal drum equipped with Demister
pad
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- Temperature as low as possible to minimize amine
concentration and water entrainments to
downstream facilities (for example Sulfur recovery
unit)
- Oil skimming facilities to be provided
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An Activated Carbon Filter can be added downstream of the
main filter to remove products not stopped by the main filter
(hydrocarbon, water soluble compounds, unknown foam
contributors). The flow rate to the Activated Carbon Filter
can be less than the flow to the main filter.
Activated Carbon Filter
Characteristics
- Liquid velocity through the activated carbon bed
would be less than 1cm/s.
- Height of the bed would be above 1.5 m
- Diameter of carbon particles would be 1/8² to 1/4²
(4x10 mesh)
- Density of about 300 kg/m3
- Pressure drop : 1 b maximum
- The life of the activated carbon bed is at least 1 year.
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Should a Carbon Filter be provided, a downstream additional
filter (Polishing Filter) must be installed to remove particles
of carbon.
An amine Storage Tank (surge tank) is provided. Pumping
facilities are provided to route the stored solution to the unit.
Surge Tank
Objective
Spare capacity equivalent to amine solution hold-up
(inventory of the unit) for emergency or maintenance
unloading
Characteristics
- Atmospheric classical storage tank (fixed roof or cone
roof)
- Blanketing with nitrogen or treated gas to avoid amine
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degradation with oxygen (always avoid amine
contact with air)
- Oil recovery : skimming facilities
- Operating temperature above the freezing point of
the solution
2.1.2. Monoethanolamine
MEA is a primary amine. It is the oldest solvent used in
modern Gas Sweetening plants. Gas sweetening process
using MEA is in the public domain. Figure XI-B.3 is a process
flow diagram of a MEA unit.
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2.1.3. Diglycolamine
This is not the proper chemical name for this product: The
actual name is 2-2 Aminoethoxyethanol. This is a primary
amine which then shows a high reactivity with acid gases.
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2.1.4. Diethanolamine
This amine is a secondary amine.
The processing scheme of DEA is similar to MEA processing
scheme with the exception of the reclaimer which is not
required.
2.1.5. Diisopropanolamine
DIPA is a secondary amine. Whilst the product is available
from manufacturers of chemical products, SHELL is the
licenser for two (2) processes using DIPA :
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2.1.6. Methyldiethanolamine
MDEA is a tertiary amine. It is a newcomer to the group of
ethanolamines used for natural gas sweetening and has
received a great deal of attention recently because of its
capability for selective reaction with H2S in the presence of
CO2. When MDEA is used as the sole pure solvent in the
aqueous solution, it is the main reason of its selection.
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The End.
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