DESIGN OF A 100MMSCFD ACID GAS REMOVAL

PLANT FOR NATURAL GAS PROCESSING

Atiya Khalid B21108006005

Misbah Ibrahim B21108006012
Ruba Tarique B21108006024

Group 05

SUBMITTED TO:

DR AHSAN

DEPARTMENT OF CHEMICAL ENGINEERING

UNIVERSITY OF KARACHI
KARACHI, PAKISTAN
2025

1
 ABSTRACT

This report presents the detailed design of a 100 MMSCFD acid gas removal unit
(AGRU) for natural gas processing, focusing on the removal of hydrogen sulfide (H₂S)
and carbon dioxide (CO₂) using amine-based solvent technology. The process design
includes absorber column, a flash separator, and a lean/rich amine heat exchanger,
with both tray and packed column configurations evaluated. The report outlines key
design parameters such as column diameter, stage numbers, pressure drops, and
equipment specifications, aligning with industrial standards and safety requirements.
Optimization strategies such as lean amine polishing filters and oxygen scavenger
dosing are proposed to address solvent degradation and corrosion in the regeneration
section. Furthermore, the design incorporates future-ready features including modular
equipment layout, integration potential for carbon capture utilization and storage
(CCUS), and Industry 4.0 technologies for predictive maintenance. Overall, this
design ensures operational efficiency, environmental compliance, and scalability for
future demands in gas treatment facilities.
.

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 Table of Contents
ABSTRACT ...................................................................................................................... 2

INTRODUCTION ............................................................................................................. 5

PROCESS DESCRIPTION ............................................................................................... 6

2.1 Process Flow Diagram ................................................................................................... 7

Abbreviation Sheet of PFD .............................................................................................. 8

EQUIPMENT DESIGN .................................................................................................... 9

3.1 Absorber ......................................................................................................................... 9

3.1.1 Operating Principle ................................................................................................. 9

3.1.2 Factors affecting the absorption Column ................................................................ 9

3.1.3 Standard Design steps: .......................................................................................... 10

3.1.4 Absorber Design Calculation of Tray Column ..................................................... 11

3.1.5 Key Findings from Absorber Tray Column Design .............................................. 18

3.1.6 Calculation for Packed Column Absorber ............................................................ 19

2. Packing Type .................................................................................................................. 19

3.1.7 Tray vs. Packed Column Comparison for Amine-Based Acid Gas Removal....... 20

3.2 FLASH SEPARATOR ................................................................................................. 21

3.2.1 Purpose and Importance ........................................................................................ 21

3.2.2 Operating Principle ............................................................................................... 21

3.2.3 Comparison: Vertical vs. Horizontal Flash Separator in AGRU .......................... 22

3.2.4 Design Calculation of Horizontal Separator ......................................................... 23

3.3 Lean Amine Heat Excahnger ....................................................................................... 25

3.3.1 Applications in Acid Gas Removal Systems ........................................................ 25

3.3.2 Operating Principle ............................................................................................... 26

3.3.3 Comparison: Shell and Tube vs. Plate and Frame Heat Exchangers .................... 26

3.3.4 HTRI Report for Shell and Tube Heat Exchanger ................................................ 27

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 CREATIVE OPTIMIZATION ........................................................................................ 29

4.1 Optimization of Regeneration System ......................................................................... 29

4.1.1 Lean Amine Polishing Filter System .................................................................... 29

4.1.2 Oxygen Scavenger Dosing in the Rich Amine Circuit ......................................... 30

FUTURE-READY PLANT DESIGN ............................................................................. 32

5.1 Modularity: Equipment Layout for Easy Expansion ................................................... 32

5.2 Decarbonization: Utilization Potential of Acid Gases in Future Plant Designs ........... 32

5.2.1 Potential Utilization Pathways .............................................................................. 33

5.2.2 Benefits of Acid Gas Utilization and Value Addition .......................................... 33

5.3 Industry 4.0: IoT Sensors for Predictive Maintenance................................................. 34

CONCLUSION ............................................................................................................... 35

REFERENCE .................................................................................................................. 36

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 INTRODUCTION
Acid gas refers to any gas mixture that contains significant amounts of acidic components,
primarily hydrogen sulfide (H₂S) and carbon dioxide (CO₂). These gases are commonly
found in natural gas reservoirs, refinery off-gases, biogas, and various industrial
processes. H₂S is particularly hazardous due to its high toxicity , while CO₂, though non-
toxic, contributes to corrosion and lowers the heating value of fuel gases. Other minor
acidic components like carbonyl sulfide (COS), carbon disulfide (CS₂), and sulfur dioxide
(SO₂) may also be present in trace quantities. [1]

The presence of acid gases poses several challenges. They are corrosive, especially when
moisture is present, as they form weak acids that attack pipelines, compressors, and
process equipment. H₂S is highly toxic; exposure to even small concentrations can cause
serious health risks or be fatal. Additionally, acid gases contribute to environmental
pollution, including acid rain and greenhouse gas emissions, making their removal from
gas streams both a safety and environmental necessity. [1]

To remove acid gases from process streams, several technologies are employed. The most
common is amine treating, where chemical solvents like monoethanolamine (MEA),
diethanolamine (DEA), or methyldiethanolamine (MDEA) absorb H₂S and CO₂. Other
methods include physical solvents like the Selexol process, membrane separation for
selective removal, cryogenic processes for CO₂ removal, and solid bed adsorption using
materials such as activated carbon or molecular sieves. [2]

Globally, environmental agencies such as the EPA and occupational health organizations
like OSHA have set strict limits on the emissions and workplace exposure levels of H₂S
and CO₂. Compliance with these regulations, along with the use of advanced treatment
technologies, ensures that acid gas is managed in a way that protects both human health
and the environment.

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 PROCESS DESCRIPTION
The process begins with the sour gas feed entering the absorber column from the bottom.
Inside the absorber, the sour gas flows upward in counter-current contact with a lean
amine solvent entering from the top. As they interact, the acid gases are absorbed into
the solvent. The treated sweet gas exits from the top of the absorber

The rich solvent, now loaded with absorbed acid gases, exits from the bottom of the
absorber. It is depressurized through a valve and sent to a flash drum, where light
hydrocarbons and flash gases are separated and removed from the system as flash gas.
The liquid phase, referred to as the regen feed, continues to a lean/rich heat exchanger,
where it is preheated by exchanging heat with the hot regenerated solvent stream.

The preheated rich solvent enters the stripper column. At the bottom of the stripper, a
reboiler supplies heat (with steam input) to strip the acid gases from the solvent. The acid
gases rise to the top of the stripper and pass through a condenser, where vapors are
partially condensed. The mixture enters a reflux drum, where the condensed liquid is
separated and returned to the stripper as reflux, while the uncondensed acid gas exits the
system.
The regenerated lean amine leaves the bottom of the stripper. It is pressurized by a booster
pump, passes through the lean/rich heat exchanger (providing heat to the incoming rich
solvent), and is then cooled in a lean solvent cooler. The cooled lean amine is pumped
by a lean amine pump back into the absorber, completing the continuous loop. Make-up
solvent is introduced before the solvent returns to the absorber to maintain the system's
solvent balance and compensate for any losses.

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2.1 Process Flow Diagram

V-101
8

7
T-101

P-100
6
MIX-100

E-100
9
10
P-101

5
V-100
11

4
E-101

3
T-100

VLV-100
2

Figure 2.1 Process Flow Diagram of Acid Gas Removal Unit Using Chemical Solvent

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Abbreviation Sheet of PFD

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 EQUIPMENT DESIGN
3.1 Absorber

An absorber is a key piece of mass transfer equipment utilized in gas–liquid systems,

where one or more components are selectively removed from a gas stream by dissolution
into a liquid solvent. In the context of natural gas processing and chemical industries, the
absorber plays a vital role in ensuring that gas products meet required specifications,
environmental standards, and process efficiency.

3.1.1 Operating Principle

The absorber operates based on the principle of mass transfer, facilitated by the
difference in partial pressure of the target gas component between the gas and
liquid phases. Typically, the gas stream enters the bottom of a vertical absorption
column, while the liquid solvent commonly an amine solution enters from the top.
This creates a counter-current flow, maximizing contact time and driving force for
mass transfer.

3.1.2 Factors affecting the absorption Column

Several operational challenges can impact the efficiency and stability of an
absorption column. Key factors include:
1. Foaming: The formation of stable foam or bubbles within the column can
significantly reduce gas–liquid contact area, hindering mass transfer. Severe
foaming may also cause liquid carryover and operational instability.
2. Entrainment: High vapor velocities can carry liquid droplets upward with the gas
stream. This reduces absorption efficiency and can contaminate the overhead gas
product.
3. Weeping and Dumping: When vapor flow is too low, liquid may leak through
tray perforations (weeping) or even fall through completely (dumping), reducing
the interfacial area for mass transfer and overall column performance.

4. Flooding: Excessively high vapor flow rates can push the liquid upward, causing
a buildup of liquid within the column. This results in a sharp pressure drop, loss
of separation efficiency, and potential equipment damage.
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3.1.3 Standard Design steps:

1) Calculation of theoretical number of stages.

2) Calculation of actual number of stages.
3) Calculation of diameter of column.
4) Calculation of weeping point.
5) Calculation of pressure drop.
6) Downcomer design.
7) Entrainment calculations.
8) Calculation of height of column. [1]

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3.1.4 Absorber Design Calculation of Tray Column [3],[4]

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13
14
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3.1.5 Key Findings from Absorber Tray Column Design

Table 3.1 Results of absorber design calculation

Design Calculated Value Standard Range Comments

Parameter (RC Vol. 6)
Theoretical Stages 19 Based on Valid calculation
absorption factor using absorption
factor.
Actual Stages 27 25–35 Within expected
range for
absorbers.
Column Diameter 3.21 m 1.5–5 m Appropriate for
flow rate.
Operating Vapor 0.38 m/s 60–85% of 80% of flooding
Velocity flooding velocity used
appropriately.
Downcomer Area 12% 10–15% Well within
standard design
range.
Hole Diameter 5 mm 3–10 mm Standard tray
holes size.
Vapor Velocity 3.09 m/s > 2.55 m/s Satisfies anti-
Through Holes weeping criteria.
Pressure Drop per 0.26 psia 0.1–0.5 psia Acceptable
Tray pressure drop.
Tray Spacing 0.7 m 0.5–0.7 m Within
recommended
limits.
Total Column 20 m 15–30 m Reasonable for
Height design scale.

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 3.1.6 Calculation for Packed Column Absorber

1. Key Input Data from Tray Column Design

Table 3.2 Data for Packed column calculation

Parameter Value

Theoretical stages (N) 19

Gas flow (V) 32.73 kg/s (10980 lbmol/hr)

Liquid flow (L) 183.86 kg/s (23170 lbmol/hr)

Column diameter (D) 3.21 m

ρL (liquid density) 1023 kg/m³

ρG (gas density) 12.03 kg/m³

μL (liquid viscosity) 0.8 cP = 0.0008 Pa·s

DL (liquid diffusivity) 2×10⁻⁹ m²/s

2. Packing Type

Choice: Mellapak 250Y (structured packing)

 Packing factor (F_p): 20 m⁻¹

 Surface area (a): 250 m²/m³
 Void fraction (ε): 0.95

3. Summary of Results

Table 3.3 Results Comparison of tray vs packed column design

Parameter Tray Column Packed Column

Height 20 m 10.1 m

HETP 70% tray efficiency 0.4 m

Pressure Drop 0.26 psia 0.16 psia

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3.1.7 Tray vs. Packed Column Comparison for Amine-Based Acid Gas
Removal

Table 3.4 Tray vs Packed Column Design

Parameter Tray Column Packed Column Comments

Height 20 m 10.1 m Packed columns

typically require
less height due to
higher surface
area.
HETP / Efficiency 70% tray ~0.4 m HETP Packed columns
efficiency (~0.7 m are more efficient
HETP) per meter height.
Pressure Drop 0.26 psia 0.16 psia Packed columns
generally have
lower pressure
drop — beneficial
in gas systems.
Cost (Capital) Higher Lower Packed columns
are often cheaper
for smaller to
medium gas flows.
Operating Cost Moderate Lower Lower energy
consumption in
packed columns.
Foaming Higher Lower Packed columns
Sensitivity are preferred
when foaming is a
concern (amines
prone to foam).
Maintenance Easier Harder Tray columns
easier to clean and
inspect, especially
for fouling
systems.

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3.2 FLASH SEPARATOR

A flash separator, also known as a rich amine flash tank, is an essential unit operation
within Acid Gas Removal Units (AGRUs). It functions as a gravity-based phase separator,
primarily used to remove light hydrocarbons and flash gases from the rich amine stream
before it enters the regenerator.

3.2.1 Purpose and Importance

The flash separator serves as a critical intermediate step between the absorber and
the regenerator in an acid gas removal unit (AGRU). Its primary functions and
benefits include:
 Removal of Light Hydrocarbons: Prevents the carryover of volatile
hydrocarbons into the regenerator, which could otherwise lead to increased vapor
load, foaming, and safety concerns.
 Degassing of Rich Amine: Facilitates the release of dissolved acid gases (e.g.,
H₂S, CO₂) from the rich amine stream, reducing the burden on the regenerator and
enhancing separation efficiency.
 Corrosion and Foaming Prevention: By removing entrained gases and
hydrocarbons, the flash separator minimizes the risk of corrosion and foaming in
downstream equipment.

 Improved Lean Amine Quality: Reducing contamination in the rich amine

stream leads to a higher quality regenerated (lean) amine, which improves overall
system performance and longevity.

3.2.2 Operating Principle

The rich amine stream exiting the absorber enters the flash separator, where it
undergoes a pressure reduction. This pressure drop causes partial vaporization
(flashing) of light hydrocarbons and dissolved gases. The vapor phase, containing
flash gases and hydrocarbons, exits from the top of the vessel and is typically
routed to a flare or recovery system. The degassed rich amine is withdrawn from
the bottom of the separator and pumped to the regenerator for acid gas removal.

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3.2.3 Comparison: Vertical vs. Horizontal Flash Separator in AGRU

Table 3.5 Vertical vs Horizontal Separator

Aspect Vertical Separator Horizontal Separator

L/D Ratio 2–4 2.5–5

Suitability Used when gas load is Preferred when liquid

high or space is limited. volume is large, such as
in amine systems.

Retention Time Shorter liquid retention Longer retention time

time. allows more complete
flash gas removal.

Foaming Handling Less effective. Handles foaming liquids

better (important for
amine systems).

Response to Level Quick response due to Slower level change;

Changes low liquid volume. steady downstream flow.

Space Requirement Occupies less vertical Requires more horizontal

space. space.

Typical Use in AGRU Less common for amine Most common for amine
flash tanks. flash tanks.

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3.2.4 Design Calculation of Horizontal Separator [3], [5]

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3.3 Lean Amine Heat Excahnger

The shell and tube heat exchanger is a widely utilized type of indirect heat exchanger,
designed to facilitate heat transfer between two fluid streams without direct contact. One
fluid flows through a bundle of tubes, while the other flows across the shell side, enabling
efficient thermal exchange. Due to its robust design, ease of maintenance, and high
thermal efficiency, it is extensively used in industrial gas processing applications,
including acid gas removal units (AGRUs).

3.3.1 Applications in Acid Gas Removal Systems

In AGR systems employing amine-based solvents such as MEA, DEA, or MDEA,
shell and tube heat exchangers play a critical role in thermal energy integration.
Their primary applications include:
 Preheating Rich Amine: Utilizing thermal energy from hot lean amine to raise
the temperature of the rich amine stream before it enters the stripper.
 Energy Recovery: Capturing waste heat from the hot lean amine stream exiting
the regenerator, thereby improving overall energy efficiency.
 Steam Consumption Reduction: By preheating the rich amine, the exchanger
reduces the thermal duty required in the reboiler, lowering steam demand and
operating costs

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 3.3.2 Operating Principle
The exchanger typically operates with hot lean amine (from the regenerator)
flowing through the tube side, while the cold rich amine (from the absorber) flows
through the shell side. As the two streams pass in counter-current or cross-flow
configuration, heat is transferred from the lean to the rich amine:
 The rich amine stream increases in temperature, enhancing desorption efficiency
in the stripper.
 The lean amine stream is cooled before re-entering the absorber, improving
absorption performance.
This heat recovery step is essential for maximizing thermal efficiency and
maintaining the economic and operational sustainability of the AGRU.

3.3.3 Comparison: Shell and Tube vs. Plate and Frame Heat Exchangers

Table 3.5 Comparison between shell and tube heat exchanger

Criteria Shell and Tube Plate and Frame

Fouling Resistance Better suited for fouling Narrow passages foul
fluids like amine easily
Cleanability Can be mechanically Requires chemical
cleaned (tubes) cleaning or disassembly
Pressure & Temperature Handles high Limited to moderate
Ratings temp/pressure conditions
Thermal Efficiency Lower U-values Higher U-values
Footprint Larger and heavier Compact
Flexibility Wide range of Limited for dirty or
configurations viscous fluids
Industrial Use in Amine Standard design Rare, mostly for clean
AGR fluids

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3.3.4 HTRI Report for Shell and Tube Heat Exchanger

2.1
5.0

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28
 CREATIVE OPTIMIZATION
4.1 Optimization of Regeneration System

One of the primary operational challenges in amine-based acid gas treatment systems is
corrosion and chemical degradation in the regeneration section, particularly in the
stripper column, reboiler, and heat exchangers. These issues not only affect the longevity
of the equipment but also lead to excessive amine losses, increased operating costs, and
unexpected shutdowns. Corrosion in this section is primarily driven by degraded amine
products, heat-stable salts (HSS), organic acids, and dissolved metal ions—many of
which accumulate as the solvent ages and cycles through the process.
To mitigate these issues without modifying the core acid gas removal process, two
complementary and innovative solutions are proposed for integration:
1. Lean Amine Polishing Filter System
2. Oxygen Scavenger Dosing in the Rich Amine Line

These solutions aim to break the degradation-corrosion cycle at its root, thereby reducing
regeneration energy consumption indirectly (by maintaining a healthier solvent) and
significantly lowering corrosion and fouling rates in the hot parts of the plant.

4.1.1 Lean Amine Polishing Filter System

While corrosion occurs primarily in the regeneration section (due to heat and acidic
conditions), the causes of corrosion originate from chemical contaminants that
circulate throughout the entire amine loop. Over time, the solvent accumulates
degradation products such as organic acids, heat-stable salts, metallic ions (e.g.,
Fe²⁺, Cu²⁺), and fine particulates that enter from upstream gas or form in situ due
to oxidation or thermal breakdown.

The lean amine polishing filter system, although physically installed on the lean
amine line before it re-enters the absorber, plays a key role in preventing this
damage in the stripper and reboiler. This is because the filtered lean amine, once
injected into the absorber, becomes the rich amine that flows into the regeneration
section. Therefore, if the lean amine is clean, the rich amine entering the stripper

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 will also be clean, thus carrying fewer corrosive impurities into the high-
temperature zone.

The filtration system typically consists of two stages:

1. Activated Carbon Filter – Removes dissolved organic degradation products,
surfactants, and complex hydrocarbons.
2. Ion-Exchange Resin or Coalescing Filter – Captures heat-stable salts (which
cannot be thermally regenerated), dissolved metal ions, and fine solids.
By continuously filtering these corrosive and degradation-promoting species from
the lean solvent, the system:
 Prevents fouling in reboiler tubes and heat exchangers.
 Reduces formation of corrosive compounds under high-temperature conditions in
the stripper.
 Extends the amine solvent life by up to 30%.
 Reduces the frequency of solvent reclamation and unplanned maintenance.

Thus, even though the polishing filter is physically upstream of the absorber, its
benefit is directly realized downstream in the regeneration section, where the
thermal degradation reactions are most severe. This proactive solvent
conditioning helps maintain a chemically stable, less corrosive rich amine that
greatly reduces corrosion risk in the stripper and associated equipment.

4.1.2 Oxygen Scavenger Dosing in the Rich Amine Circuit

Another major contributor to amine degradation and corrosion is dissolved

oxygen, which can enter the system from air ingress at the absorber top,
mechanical leaks, or during gas-liquid contact in upstream units. Oxygen catalyzes
the formation of peroxides and organic acids, especially in the hot environment of
the regeneration section, leading to significant oxidative degradation of the amine.
These degradation products then act as precursors to heat-stable salts and further
lower the pH, increasing corrosivity.

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 To eliminate this threat, the proposed design includes controlled injection of
oxygen scavengers, such as sodium sulfite (Na₂SO₃) or hydrazine (N₂H₄), into the
rich amine stream ideally after the flash drum and just before the lean/rich amine
exchanger. These scavengers chemically react with and neutralize dissolved
oxygen, preventing it from reaching the high-temperature regeneration zone.
The reaction between oxygen and sodium sulfite, for instance, proceeds as:

This process converts a corrosive component (O₂) into a stable and non-corrosive
sulfate salt. In practice, oxygen scavenger dosing systems are compact,
inexpensive, and easily controlled through inline sensors that monitor dissolved
oxygen concentration. They require no modification to existing process piping and
can be installed as skid-mounted units during plant construction or added as
retrofits.

Implementing oxygen scavenger dosing ensures that oxidation-driven degradation

reactions are arrested at the source, thereby reducing:
 Heat-stable salt formation.
 Organic acid production.
 Foaming and solvent discoloration.
 Corrosion rates in reboilers and exchangers.
The benefit is a more stable and chemically resilient solvent, which requires less
energy for regeneration (since degraded amine is harder to regenerate effectively),
fewer reclaimer cycles, and extended equipment life.

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 FUTURE-READY PLANT DESIGN
To ensure long-term efficiency, scalability, and compliance with evolving industry
standards, the 100 MMSCFD natural gas treatment plant has been designed with a future-
ready approach. Key considerations include modularity for expansion, potential utilization
of acid gases in decarbonization strategies, and integration of Industry 4.0 technologies
for advanced operations and maintenance.

5.1 Modularity: Equipment Layout for Easy Expansion

The plant layout is developed with a modular design philosophy, in which critical
processing units such as absorbers, regenerators, and heat exchangers are configured as
skid-mounted modules. These modules are self-contained units that can be prefabricated,
easily installed, and replaced or duplicated to scale up capacity.

To facilitate future expansion or technology upgrades, the layout provides sufficient

spacing between equipment. This allows for safe and efficient maintenance activities as
well as the installation of additional units with minimal disruption. Piping systems are
designed with flanged connections and reserved tie-in points, enabling seamless
integration of new modules. Similarly, utility systems (power, steam, cooling water) are
designed with spare capacity to accommodate potential future loads.

This modular approach ensures that future capacity increases can be implemented with
reduced capital expenditure, minimized downtime, and enhanced operational flexibility.

5.2 Decarbonization: Utilization Potential of Acid Gases in Future Plant

Designs

In conventional natural gas treatment facilities, acid gases—primarily carbon dioxide

(CO₂) and hydrogen sulfide (H₂S)—are typically viewed as waste byproducts requiring
safe disposal. However, in modern and future-ready plant designs, these streams can be
strategically utilized to add significant value, both economically and environmentally.
Rather than being treated solely as liabilities, acid gases can serve as feedstocks for
processes that support decarbonization and generate marketable products.

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 5.2.1 Potential Utilization Pathways

1. CO₂ Capture and Utilization

Captured CO₂ can be purified and compressed for deployment in:
 Enhanced Oil Recovery (EOR): Increasing oil production while sequestering
CO₂ underground, thus creating dual value from energy recovery and carbon
management.
 Geological Storage: Permanent CO₂ sequestration helps reduce the plant’s overall
carbon footprint, adding environmental value by contributing to emissions
reduction targets.
2. Chemical Conversion into Value-Added Products
CO₂ can be chemically converted into a range of commercially valuable products,
contributing to a circular carbon economy:
 Methanol: A widely used chemical feedstock and fuel component.
 Urea: Used extensively in fertilizer production.
 Synthetic Fuels and Chemicals: Supporting cleaner energy transitions and
reducing reliance on fossil-derived feedstocks.
3. Sulfur Recovery from H₂S
The H₂S stream can be directed to a Sulfur Recovery Unit (SRU), where it is
converted into elemental sulfur using the Claus process. Elemental sulfur is a
valuable industrial commodity used in:
 Fertilizer production (e.g., sulfuric acid)
 Rubber and chemical manufacturing
 Metal refining

5.2.2 Benefits of Acid Gas Utilization and Value Addition

1. Economic Value Creation: Converts what would otherwise be waste streams into
saleable products, diversifying revenue sources.
2. Environmental Compliance and Decarbonization: Enhances the plant’s
sustainability by reducing emissions and supporting global climate objectives.

33
 3. Integration with CCUS Strategies: Aligns with emerging trends in carbon
management through Carbon Capture, Utilization, and Storage (CCUS).
4. Operational Flexibility and Future-readiness: Prepares the plant for integration
with low-carbon technologies and evolving market demands.
5. Reduction of Environmental Liabilities: Minimizes risks associated with flaring
or venting of acid gases, improving the plant’s environmental performance.

5.3 Industry 4.0: IoT Sensors for Predictive Maintenance

The plant incorporates Industry 4.0 principles by integrating IoT-enabled sensors for
continuous monitoring of critical process and mechanical equipment. Sensors are
installed on assets such as compressors, pumps, and heat exchangers to measure key
parameters including vibration, temperature, pressure, and flow rate.

This real-time data is analyzed using predictive maintenance software that detects
anomalies and anticipates equipment failures before they occur. Maintenance activities
can therefore be scheduled proactively, reducing the risk of unplanned shutdowns and
improving overall plant reliability. Additionally, remote monitoring capabilities enhance
operator safety and operational transparency, especially for remote or offshore
installations.

The use of IoT and predictive analytics reduces maintenance costs, extends equipment
life, and ensures consistent, safe, and efficient plant operation.

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 CONCLUSION

The design of the 100 MMSCFD acid gas removal plant successfully addresses the
technical, operational, and environmental challenges associated with treating sour
natural gas. By employing amine-based absorption and regeneration systems, the plant
achieves effective removal of CO₂ and H₂S, ensuring that the treated gas meets
pipeline and environmental specifications. Detailed equipment sizing and
performance evaluation for both tray and packed columns confirm that the design falls
within industry-recommended parameters, offering flexibility for implementation
based on operational priorities. Creative optimization through lean amine filtration
and oxygen scavenging significantly enhances system reliability and solvent
longevity, while reducing corrosion risks and maintenance costs. The integration of
modular design elements and smart sensor technologies ensures the plant is adaptable
to future expansion, decarbonization goals, and digital operational strategies. This
forward-thinking design not only fulfills current processing needs but also aligns with
the evolving landscape of sustainable and intelligent natural gas treatment.

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 REFERENCE
[1] R. M. R. S. S. M. L. A. S. F. M. Z. S. S. M. W. u. H. N. e. H. a. B. A. Abid Salam
Farooqi, "Removal of Carbon Dioxide and Hydrogen Sulfide from Natural Gas
Using a Hybrid Solvent of Monoethanolamine and N-Methyl 2-Pyrrolidone,"
ACS Omega , vol. 9, p. 25704−25714, 2024.

[2] H. G. R. S. B. W. L. D. Z. D. a. X. J. Yulei Ma, " Hydrogen sulfide removal from

natural gas using membrane technology: a review," Journal of Material
Chemistry A, 2021.

[3] R. K. Sinnott, Chemical Engineering Design: Chemical Engineering Volume 6, 4th

ed. Butterworth-Heinemann, 2005

[4] E. E. Ludwig, Applied Process Design for Chemical and Petrochemical Plants, vol.
2, 3rd ed. Butterworth-Heinemann, 1997.

[5] Gas Processors Suppliers Association, GPSA Engineering Data Book, 12th ed. Tulsa,
OK: Gas Processors Suppliers Association, 2004

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