Gas Processing and Value Added Products

V.S.N.P. KAVITHA, Chief Chemist, ONGC, Sivasagar

1.0 Natural Gas

Natural gas is a gaseous fossil fuel, consisting of combustible mixture of hydrocarbon gases,
primarily methane but including significant quantities of ethane, propane, butane, pentane,
traces of hexane and higher. It also contains some non-hydrocarbon components like
carbon dioxide, nitrogen, helium and hydrogen sulfide. It is found in oil fields, natural gas
fields and in coal beds (as coal bed methane). (When methane-rich gases are produced by
the anaerobic decay of non-fossil organic material, these are referred to as biogas.)

The exact composition of natural gas varies widely, but below is given a typical makeup of
natural gas. Natural gas may be associated gas (from oil/condensate reservoirs) or non-
associated gas (from pure gas reservoirs).

Typical Composition of Natural Gas

Methane CH4 70-90%
Ethane C2H6
Propane C3H8 0-20%
Butane C4H10
Pentane C5H12
C6H14 and 0-2%
Hexane+
Highers
Carbon Dioxide CO2 0-8%
Oxygen O2 0-0.2%
Nitrogen N2 0-5%
Hydrogen Sulphide/ Organo
H2S 0-5%
sulphur compounds
Helium He 0-5%
Other Rare gases A, Ne, Xe Trace(<0.01%)

2.0 Uses

Natural gas is primarily used as a fuel for residential domestic, transport purposes. Natural
gas is a major source for electricity generation through the use of gas turbines and steam
turbines. Natural gas can be used to produce hydrogen, with one common method being the
hydrogen reformer. Hydrogen has various applications: it is a primary feedstock for the
chemical industry, a hydrogenating agent, an important commodity for oil refineries, and a
fuel source in hydrogen vehicles. Natural gas is a major feedstock for the production of
ammonia, via the Haber process, for use in fertilizer production. Natural gas is also used in
the manufacture of fabrics, glass, steel, plastics, paint, and other products like Heavy water.

Supply of natural gas is done, after processing, through pipelines generally within the
country boundaries. It is also supplied as CNG (compressed natural gas) through tankers
which are used mainly as transport fuel. Natural gas is transported intercontinental as LNG
(liquefied natural gas).

CNG (compressed natural gas) is natural gas compressed to high pressures at ambient
temperatures. LNG (Liquefied natural gas) is natural gas liquefied at -161 OC at atmospheric
pressure which contains mainly methane, ethane and propane and minor C4. It does not
contain CO2 (<1 ppm)

Typical Composition of refined Natural Gas

Refined NG CNG LNG

Pressure 35-40 KSC 220-270 KSC 1.0 KSC
Temp Ambient Ambient <-161OC
Methane CH4 70-100 % 82-94 89.7
Ethane C2H6 3-6 6.1
Propane C3H8 0.1-2.0 2.35
0-20%
Butane C4H10 0.1-0.7 1.49
Pentane C5H12 0.1.0.2 0.06
C6H14 and
Hexane+ Traces-0.2% 0-0.2 Traces
Higher

Carbon Dioxide CO2 0-8% <10 1-100 ppm

Nitrogen N2 0-1% <15 0.22
Hydrogen Sulphide/
Organo H2S/RSH <5 ppm < 5ppm
sulphurcompounds

3.0 PROCESSING AND EXTRACTION OF VALUE ADDED PRODUCTS

Before natural gas can be used as a fuel, it must undergo extensive processing even to an
ultimate level of removing almost all materials other than methane. The by-products of that
processing include ethane, propane, butanes, pentanes, Liquefied Petroleum Gas, VAP
products containing higher molecular weight hydrocarbons viz. Aromatic Rich Naphtha,
Kerosene/Aviation Turbine Fuel, Diesel, elemental sulfur, and sometimes helium and
nitrogen. After refining, the clean natural gas is transmitted through a network of pipelines,
to thousands of miles away country wide. Through these pipelines, natural gas is delivered
to its point of use.

What is processing? A mechanism through which contaminants are removed and

components of interest (VAP) are recovered.

Why processing? Required to make the gas compatible with the requirements of pipe line
transportation as well as conforming to the specifications of end user.

How is processed? By subjecting the gas to various Physico-Chemical treatments.

 Examples:

ƒ Refrigeration (External or Expander/compression) – to liquefy the condensable

components (All components of a Natural Gas)

ƒ Fractionation (Stripping alone or Stripping + rectification) – to recover the desired

boiling fractions (C2, C3, LPG, ARN, ATF, HSD etc)

ƒ PSA (Pressure Swing Absorption) – to remove generally non-hydrocarbons like

H2S, CO2, H2O, O2 etc (MS driers)

ƒ Chemical treatment -Ex: to remove CO2,H2S, (MDEA / Caustic) / - solvent

extraction (:to recover FG Hexane)/ - Sulfur recovery through catalytic oxidation of
H2S

Fig. 1 Schematic flow diagram of a typical natural gas processing plant

The figure 1 given above is a very general schematic block flow diagram of a typical natural
gas processing plant. It shows the various unit processes used to convert raw natural gas
into sales gas pipelined to the end user markets. Oil and Natural Gas Corporation Limited
(ONGC) produces both associated and non-associated natural gas, again sweet as well as
sour in nature, from a variety of fields spread out across the country. Depending upon the
demand for utility and logistics, natural gas is supplied to various local consumers after
effecting minor processing to remove water and solid impurities.
However, over the times, processing plants at various places have been established to
produce LPG, ethane, propane, and other value added products like Sulphur, ARN, ATF,
HSD. As on to-day ONGC has LPG extraction plants at Ankleswar, Gandhar and Hazira in
Gujarat, Uran in Maharashtra.

Asia’s largest sour gas treatment plant of ONGC at Hazira is a massive state–of–art
technology plant where around 45 million M3/ day sour gas and 9,000 M3/day sour (gas)
condensate are processed to remove H2S and extract C3, LPG, ARN, Kerosene/ATF, and
HSD. After sweetening, around 40 million M3 per day gas is supplied through HBJ pipe line
to cater to the needs of various consumers across the country. Hazira plants supplies lean
gas to local customers like KHRIBHCO which produces fertilizers and heavy water.

4.0 A typical process flow diagram for Sour Gas.

Sour H2S/CO2 Dehydration Dew point Lean gas

Natural K absorber, Sweetened (Glycol Depression, To supply
O treatment) External
Gas (Amine Natural gas Moisture DP= trunk line
D treat 0OC at line
refrigeration
H2S= H2S < 4
ment) pressure
4-1500 ppm DP=0OC at
ppm Residual line
H2S < 4 pressure Sulphur
ppm Recove
Amine Acid gas H2S+CO2
regeneration ry unit

Dehydration Cold Box Seperator GAS Expander/

External 1 Compressor Sulphur
(Molecular Seive) Product
Moisture < 1ppmv refregiration Cooling
Liquid
Liquid + gas
LPG (C3+C4) product Lean gas Liquid
Liquid
Seperator 2
C3 LPG Liquid
extraction De-
Extra Lean gas to
column methaniser /
ction De-ethaniser consumers
column column
(C1,C2,C3,Tr. C4)
ARN (C5+) product
C1 gas
C2 + C3
Naphtha Cracker Plant
Extraction

C2+C3 liq product

ONGC’s first gas process plant at Uran produces C2, C3, LPG and ARN. ONGC has also
mini refinery plants at Tatipaka in Andhra Pradesh and Karaikal in Tamil Nadu which
produces ARN, Kerosene and HSD. Plans are on anvil to construct a Gas - Naphtha dual
feed cracker plant at Dahej in Gujarat using the ARN produced at Hazira Plant. ONGC
constructed a C2 and C3 extraction plant at Dahej which uses LNG as feed stock using
Linde’s process in which advantage is taken of the cryogenic temperature of LNG (~160OC)
in receipt.

5.0 (GAS) CONDENSATE

ƒ Condensate is a liquid mixture of hydrocarbon compounds - API gravity >50 Deg

(0.7793 g/ml at 15OC).

ƒ Gas Condensate formed through condensation of gaseous hydrocarbon components

inside the reservoir and in dynamic equilibrium with the gas under saturated
conditions, or formed while transportation of gas from a reservoir through the well
bore (retrograde condensation)

Typical Gas Condensate composition

GAS CONDENSATE
COMPONENT % MOLE
C1 21.06
C2 7.35
C3 10.59
C4 12.26
C5 9.13
C6 11.66
C7 8.81
C8 4.37
C9 2.17
C10 1.39
C11 0.49
A-C6 - A-C10 7.01
BP>200 0.85
CO2 2.86
H2S 0.030
6.0 A typical process flow diagram for Sour (Gas) Condensate.

Sour OFF gas to LPG; H2S>20 ppm

sweetening unit
Sour
Condensate Liquid (C3+) LPG Caustic
Stripper
column Fractiona Wash
H2S= 5-1000 (Heating) H2S < 4 ppm tion unit
Ppm
column

ARN Natural LPG (C3+C4)

ARN product Fractiona Gasoline Product
tion Liquid H2S<5 ppm
column (NGL)

ATF/
Kerosene
product
ATF / Kerosene
Fractionation
column

HSD/Heavy Cut product

LPG
(C3+C4)

HSD NATURAL
C2+ C3
GAS &
CONDENS

ATF/
KEROSEN ARN
E
 PLACE PROCESSING PRODUCTS
ANKLESWAR External / internal Refrigeration/ Lean gas, LPG & ARN
Fractionation (Gas feed)
GANDHAR Stripping / Fractionation Off gas, LPG & ARN
(Stabilised Condensate feed)
URAN Gas sweetening-Dehydration- External / Lean gas, C2+ C3,
internal Refrigeration/ Fractionation LPG (C3+C4), ARN
(Gas feed)
HAZIRA Gas sweetening-Dehydration- External Lean gas, C3, LPG, ARN,
(DPD)/ internal Refrigeration/ Fractionation ATF /Kerosene, HSD,
(Sour gas & Sour gas condensate feed) Sulphur
TATIPAKA / Fractionation ARN, Kerosene, Heavy
KARAIKAL (Stabilized condensate feed) cut (HSD)
DAHEJ Linde’s method C2 + C3
(LNG Feed)
DAHEJ Naphta & Gas - dual feed cracker plant Ethylene, Propylene
(Feed: C2+C3 from Dahej + ARN from Hazira Benzene, Butadiene
& Uran Plants)

In respect of all these value added products, continuous in process (line) sample analysis is
done to keep a strict vigil on the fluctuations in the QUALITY parameters like density, flash
point, distillation parameters, smoke point, kinematic viscosity etc., which are easily affected
by the slightest changes in the process parameters and feed characteristics.

There are several established standards and procedures to guide the analytical procedures
and maintain specifications:

1. AGA (American Gas association)

2. ASTM(American standards and testing methods)
3. API (American Petroleum Institute)
4. IP (Institute of Petroleum)
5. BIS (bureau of Indian standards)
6. ISO (organization for International Standards)

ATF specifications and testing lab standards are specially governed by rules and regulations
of “Civil Aviation Authority” and their certification is very much ESSENTIAL.