Design and Operations of Natural Gas Sweetening Facilities

Course prepared for : National Iranian Gas Company Workshop for the 2nd Iranian Gas Forum By: Majid Abedinzadegan Abdi, Ph.D., P.Eng. Faculty of Engineering and Applied Science Memorial University of Newfoundland (MUN) June 2008
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Complete contact info: Majid A. Abdi, Ph.D., P.Eng. Faculty of Engineering and Applied Science Memorial University of Newfoundland (MUN) Office: INCO Innovation Centre (IIC), Room IIC 1009 Tel: 709-737-3965 fax: 709-737-4042 E-mail: [email protected] URL: http://www.engr.mun.ca/people/mabdi.php

NATURAL GAS SWEETENING (Acid Gas Removal)

Purpose and Introduction Process classification
Batch vs. continuous Solvent vs. solid based

Batch Processes
Solid vs. liquid/slurry based

Continuous Processes
Alkanol-Amine based solvents Mixed solvents (enhanced/activated/formulated) Physical solvents Direct conversion Liquid phase oxidation of H2S Adsorption on solids Membranes

Process Selection Guidelines Design Procedures and Guidelines Operations Problems and Troubleshooting

With increasing demand for natural gas, natural gas containing significant amount of acid gases -hydrogen sulfide and carbon dioxide are being tapped for utilization after purification. In most places in the world, H2S, is nearly always limited to 0.25 grains/100 scf (4 ppmv) and the specification may be as low as 1 ppmv. The maximum total sulfur content including mercaptans (RSH), carbonyl sulfide (COS), disulfides (RSSR), etc., is usually to 10 to 20 grains/100 scf. However, some transcontinental pipelines now also require as low as 0.25 grains/100 scf of organic sulfur compounds. Carbon dioxide, CO2, is usually included with nitrogen as an inert gases. The inert gas specifications is within the range of 2 to 3%, therefore, there are occasions where sweetening requires only H2S removal. There are many ways to classify the gas sweetening processes. One would be to classify them as batch vs. continuous. The other would be to categorize them based on the sort of reactant which removes the impurities, which can be either solid or liquid. These processes may be classified as follows: 1. Batch Processes: in these processes the reactants which remove the impurities from gas streams are discarded after they were completely loaded with impurities. The use of these processes is limited to removing very small amounts of sulfur, i.e., low gas flow rate and/or small concentrations of hydrogen sulfide. 2. Aqueous amine (alkanolamine) and chemical solutions: These solution undergo reversible reactions with acid gases and can be regenerated (usually by applying heat) in a cyclic process to remove rather large amounts of sulfur, and CO2 when needed. Several types of amine solutions may be used depending on the sour gas specifications. Potassium carbonate, alone or mixed with amine solutions with other activators, has been used for removal of carbon dioxide from gas streams in petrochemical and crude oil refining industries for many years. 3. Mixed solutions: These solutions are usually a mix of amine solutions with other physical solvents and water, which can also absorb organic sulfur compounds and capable of high acid gas loadings. 4. Physical solvents: Unlike amine solutions these solvents remove the impurities without any chemical reaction involved between the solvent and acid gases. They can be regenerated without heat and simultaneously dry the gas. They are used for bulk removal of large amount of CO2 from high pressure natural gas. 5. Direct conversion or liquid phase oxidation of hydrogen sulfide: These solutions practically remove only hydrogen sulfide and convert (neutralize) it to elemental sulfur in the liquid phase at low temperatures. The solutions are usually regenerated by contacting them with air. 6. Adsorption: The media for acid gas removal is a very porous (large surface area) solid materials, known as molecular sieves. The solids can be regenerated by applying heat or change of pressure in a cyclic process. The use is limited to low acid gas concentrations, and the gas can be simultaneously dried. 7. Membranes: Membrane technology is a rather new technique to remove impurities from gas streams; it has been limited to removal of water from air streams and separation of nitrogen from air. However, its use is expanding to other applications such as acid gas removal and natural gas dehydration. The technology is more suitable for CO2 removal, although Air Products claims that their technology can be used for H2S removal as well. Amine and batch processes are used for over 90% of all onshore wellhead applications. Amine processes are preferred for larger acid gas containing sour gases. The choice between a batch or amine process is related to sulfur and acid gas content of acid gas.

Acid Gas Removal: Batch Processes

Batch Processes specifics and applications Process description
Solid based
Iron sponge SULFATREAT, H2S Scavenger, Natco SulfaTreat, SufaTreat Co., M-I LLC Molecular sieves: MOLSIV, MOLSIV COSMIN 105 A in POLYBEDTM PSA SYSTEMS from UOP sieves, Union Carbide Corp.; SILIPORITE Molecular sieves from TOTAL Caustic soda Formaldehyde-methanol-water mix (Inhibit , Scavinox , Di-Cem ) Zinc based slurries (Chemsweet , Natco) Nitrite solutions (Sulfa-Check , Exxon)

Liquid and slurry Iron oxide slurry

Design guidelines Operations and trouble shooting

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These processes are based on physical or chemical absorption (to liquid media) or adsorption (solid media) of acid gases. Although not as widely used as liquid based continuous processes, they offer advantages such as simplicity, high selectivity (only H2S is generally removed), and process efficiency almost undependable of pressure. These processes are best applied to gases with moderate concentrations of H2S, and where CO2 could be retained in the gas. A fixed bed of solid particles or liquid filled column are generally used to remove acid gases. Typically, in batch processes the gas stream must flow through a vessel filled with solid granules, liquid/slurry that remove the acid gases and hold them in the vessel. When the solid bed or the liquid is saturated with the impurities, the vessel must be removed from service and the solid and/or liquids replaced. Many chemicals can absorb acid gases. The trick is to find an inexpensive, non-hazardous material that has a high capacity for H2S and produces an environmentally acceptable waste. Currently marketed processes are shown on this slide. Iron sponge is the oldest process although it is increasingly being replaced by more efficient processes. Because the bed consists of solid particles, the superficial gas velocity is higher and the tower diameter is smaller than for liquid or slurry processes. The chemical cost is low, however a major drawback is the labor needed to empty the tower and dispose of the pyrophoric spent sponge. Iron sponge consists of wood chips or shavings impregnated with hydrated ferric oxide and sodium carbonate. The technology is being replaced by more efficient SulfaTreat process which is also an iron based process uses a porous form of iron oxide and therefore has much larger capacity per unit volume of the bed. Sulfatreat beds are much smaller for the same gas capacity when compared to iron sponge beds. Iron is a very strong oxidizing element and oxidizes sulfur compounds and neutralize them either to other forms of less harmful sulfur compounds or to the elemental sulfur itself. Molecular sieves which are very high surface area porous materials can be found in nature or made synthetically our of minerals and can be used to remove acid gases. Due to the basic nature of these compounds, acid gases are adsorbed on the very large surface area available within the pore volumes of these compounds. Molecular sieves may be regenerated, therefore, gas sweetening with molecular sieves may be considered as semi batch processes. There are batch liquid based processes to remove sulfur compounds from natural gas streams. These were developed as an alternative to iron sponge. Solutions such as Inhibit, Scavinox, and Dichem are mixtures of formaldehyde, methanol and water. They react with H2S to form cyclic carbon-sulfur compounds known as formthionals. Formaldehyde is a carcinogenic compounds therefore the use of these processes has been restricted in many places of the world. Slurries of iron oxide have been used to selectively absorb H2S, however due to problems including premature H2S break through and foaming were discontinued. Natcos Chemsweet is a zinc oxide-based process. Zinc oxide is also a very strong chemical agent which react with sulfur compounds. The Chemsweet white powder which is a mixture of zinc oxide, zinc acetate and a dispersant is mixed one part in five part of water. The presence of CO2 is not important as the pH is low enough to prevent significance absorption of CO2. Sulfa-Check is an Exxons product (marketed by NALCO). It uses an aqueous solution of sodium nitrite buffered to stabilize the pH above 8. The reaction of nitrite solution with H2S forms elemental sulfur, ammonia, and caustic soda. There are other side reactions and therefore the disposal of the spent solution which is slurry of fine sulfur particles in a solution of sodium and ammonium salt remains a main problem. Caustic soda is the standard base and reacts effectively with acid gases. Again the products of the reactions and disposal of the spent solutions is always a headache that gas processors have to put up with. Caustic wash is recommended to remove very small amount of RSH (mercaptans) and other organic sulfur compounds) from gas streams. The NaSH product cannot be dumped indiscriminately, and injection to deep wells is no longer condoned. The best is to sell it to a nearby paper company for bleaching wood pulp.

Acid Gas Removal: Batch Processes - Design

INLET GAS PIPE

REAGENT

The figures shown in this slide show typical contact tower for batch processes. The vessel is cylindrical with elliptical heads. It is equipped with inlet and outlet gas nozzles, the loading and clean out manways. For liquid service mist eliminator and a gas distributor are needed. The sour gas enters from the top (in a solid-based process) or from the bottom (in liquid-based processes) and passes through the reagent (solid or liquid/slurry). In liquid/slurry services, the rise of gas bubbles through the liquid provides the agitation required to keep the slurry mixed and solid particles in a suspension form. The sweetened gas leaves the vessel from the opposite end. Vessel height must be sufficient to maintain an adequate disengaging space, i.e., the distance between the top of slurry and the mist eliminator. Vessel diameter is a function of the actual gas flow rate at operational conditions. A minimum superficial gas velocity (i.e., actual gas volumetric flow rate divided by the cross section area of the vessel) is needed to provide the agitation that keeps the slurry mixed or the allowable pressure drop in solid beds. Too high a superficial velocity results in excessive expansion of the slurry of frictional pressure drop in solid beds. Vessel height is dictated by the bed life desired between charges. Normal bed life is 30 to 90 days. Design: Operation at a typical superficial velocity of 2 to maximum 10 ft/min results in a favorable working conditions. For iron sponge beds, a velocity of 10 ft/min results in a low loading (0.25 lb Sulfur/ lb sponge). When gas bubbles flow through a liquid or slurry, they quickly reach a constant terminal velocity of about 48 ft/min. The volume of the liquid expands by the volume of gas in the liquid. The expansion factor, f, is the ratio of dynamic volume (or liquid depth in a vessel of constant diameter) to the static volume or depth. The expansion factor should not be less than 1.03 to provide mixing of the solution or above 1.20 where liquid entrainment occurs. The following design parameters are introduced: 1. 2. 3. 4. 5. 6. Gas flow rate, Q, MMscfd Operating pressure, P, psig Operating temperatuer, T, oF H2S inlet concentration, (ppmv), if the H2S concentration is in grains H2S /100scf, multiply by 15.9 to get ppmv) Compressibility factor, Z use Figures 23-3 to 23-5 of the GPSA data book Expansion factor, f (use 1.1 to 1.2) Vs = 48(f-1)/f

When the bubbles rise at 48 ft/min, f is related to the superficial velocity Vs in ft/min as follows:

Acid Gas Removal: Batch Processes Design Procedure

1. Calculate the gas actual flow rate, Qa, at T and P 2. Calculate the internal cross-sectional area, A, and the internal vessel diameter, ID 3. Calculate daily chemical requirement 4. Select a static bed height, L 5. Bed life 6. Charge requirements 7. Check with supplier 8. Check the contact time 9. Check the heat effects

1. 2.

Calculate the gas actual flow rate, Qa, at T and P: Calculate the internal cross-sectional area, A,

Qa =

19.63Q (T + 460) Z ( P + 14.7)

Process Superficial velocity ft/min 10.0 6.5 8.0 8.0 Cross sectional area, ft2 0.1Qa 0.16Qa 0.11Qa 0.13Qa

and the internal vessel diameter, ID: ID= [A/0.7854]0.5 ft,

consider a vessel ID that provides at least this internal diameter after considering the wall thickness.
3. Calculate daily chemical requirement 4. Iron sponge IS=0.013 Q(ppmv H2S) Chemsweet CS=0.248 Q(ppmv H2S) Sulfa-Check SC= 0.0474 Q(ppmv H2S) Caustic soda: depends on the CO2 content NaSH: NS=0.109 Q (ppmv H2S) gal 20% NaOH/day

Iron sponge Chemsweet Sulfa-Check Caustic soda

Select a static bed height, L: typically 10 to 20 ft. The volume, RV, of reactant is: RV=0.7854 (ID)2(L) ft3. Note the bubbling gas into a liquid increases the volume (and the height in the tower) by the volume of the gas bubbles in the liquid at any given time. This increase in bath height up to 20% - must be considered in selecting the shell length of the tower. Bed life, BL, is: for Iron Sponge BL=RV/IS days; for Chemsweet BL=11.7 RV/CS days; for Sulfacheck BL = 7.5 RV/SC days Charge requirements: for Iron Sponge RV bushels; for Chemsweet 11.7 RV lb of solids and 7.0 RV gal water; for Sulfa-Check 7.5 RV gallons. These correspond to a minimum vessel diameters, reactant volume, and bed lives. To increase the bed life, the tower diameter and height can be increased. However reducing the superficial gas velocity below 2 ft/min causes channeling in iron sponge towers. For slurries, operational velocities below 1 ft/min are not recommended because of poor mixing. Check with supplier: Usually supplier provide the information required for design purposes. In most case for batch process they provide the sizing information for the required service. It is recommended to have contact with them and check their sizing information with the above recommended calculations.. For iron sponge beds, make sure the mass velocity is less than 78 (g)0.5 lb/min ft2. This occurs only with liquid hydrocarbons and density over 30 lb/ft3. Check the contact time by determining the space velocity acfh/ft3 of bed. This should be less than 180 acfh/ft3 for low H2S contents and 90 acfh/ft3 for over 50 grains/100scf gas. Check the heat effects: the sulphur deposition or absorption should be less than 15 grains/min ft2 of bed area

5. 6.

7.

8. 9.

Acid Gas Removal: Batch Processes Operations

Operations
General Check the design parameters Condensation and hydrate Damaged reagent Pressurization Daily operations Solid beds Bed support Particle entrainment Excessive pressure drop Before loading inspections After loading inspections Liquid/Slurry baths Water supply pH Foam tests Water make-up Liquid carry over

Trouble shooting
Solid bed - Channeling (low gas velocity) - Hydrate formation/condensation - Check water pH (>8.0, add soda if needed) - Pressure drop (check for damaged solids) - Liquid formation (poor upstream separation Liquid/Slurry beds - Sour gas velocity (<10 ft/min, check liquid carry over) - Inlet gas T (between 50-98 oF, hydrate/drying) - Bath level (anti-foam?, add water if too low) - Outlet H2S conc. (rising rapidly? Check with supplier or add more reagent, zinc oxide/buffer) - Slurry/liquid pH, should be within the range - Hydrocarbon condensation (causes foaming) - Settling solid particles (low or interrupted flow rate - RSH and RSSR and COS in inlet gas (<25%) - Distributor plate (check and clean the plugged holes)
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The keys to trouble free operations are proper installation of the tower and preparation of the reactant. It is important to make sure that superficial velocity of the sour gas is within the design range. For solid-based beds too low a velocity results in poor gas distribution, gas channeling and loss of adsorption efficiency. The high or low velocity effects were already discussed for slurry and liquid-based baths. During cold days, condensation and hydrate formation should be anticipated. A high pressure drop across a solid bed may help the cooling for these phenomena to occur. An inlet separator help to prevent solid reagent damage due to water or liquid hydrocarbon entrance into the bed. The damaged solids may cause increased pressure drop across the bed (as much as 200 psi within a single day). For liquid/slurry system the damage may be even more disastrous: increased bath volume, formation of water/hydrocarbon emulsions, foaming and finally liquid carry over. When the vessel is pressurized it is important to note that too rapid a pressurization from the top, compacts the solid particles and strains the bed support. Too rapid pressurization from the bottom, either lifts the solid and settles them unevenly or bump liquids into the mist eliminator. Start the gas slowly and increase the pressure gradually. It is important to do daily inspection (unless it is impractical) and check the gas flow rate, inlet and outlet H2S and other sulfur compounds concentrations, the liquid height, bath pH and water collected in the bottom of the solid beds. Larger installation may require continuous H2S monitors. Other major operational issues for solid beds and slurries are listed on this slide. For solid beds: a strainer should be provided to remove entrained particles; differential pressure should be checked in case a shut down or bypass is needed due to very high pressure drop incidents; solid reagents conditions should be checked before they are charged to make sure they have the appearance indicated in the specification sheets. When the beds are loaded., care should be taken not to damage the particles by dropping a large quantity at once. For slurry/liquid baths: it is important to check the water supply, drinking water or steam condensate are satisfactory; avoid using produced water or pond water which may induce foaming. The bath pH should be controlled regularly to make sure the pH is within the spec. provided by the supplier. Standard foam test should be performed regularly to make sure if any antifoam is required before foaming becomes out of control. It is important that the inlet gas is saturated with water. A downstream separator with a sight glass will help to warn if there is any liquid carry over. The troubleshooting guidelines are shown on this slide. The major problems are premature H2S breakthrough; rapid buildup of the pressure drop across the solid bed, and foaming with liquid carry over in liquid/slurry systems. The usual cause of these problems is the condition of the inlet gas. If the gas is too close to or at its HC dew point, any cooling condenses hydrocarbons, and if it is unsaturated with respect to water, it dries the charge. It is important to keep the gas a few degrees above its HC dew point (or the bed temperature above the HC dew point of the gas) and nearly saturated with water

Acid Gas Removal: Continuous Processes

Why continuous? Process choices
Chemical solvents
Amine and mixed solvents
MEA, DEA, TEA, MDEA, Shell ADIP DIPA, Flour Econamine DGA

Hot potassium carbonate: Catacarb (Eickmeyer), Benfield (UOP) Formulated/special solutions:UOP Ucarsol, BASF activated MDEA

Physical solvents: Norton Co. Selexol, Flour Flexorb, Shell Sulfinol D&M, Linde Rectisol, Lurgi Purisol, IFP IFPEXOL Direct Conversion of H2S: GTP-Merichem LO-CAT, Shell Sulferox, BG Stretford, Linde Sulfinol Membrane Technologies: Dow CynaraTM, UOP SEPAREXTM, Air Products PRISM membrane, Liqui-Cel Membrane
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Batch processes despite their aforementioned advantages are limited to some particular applications. Uninterrupted operation of these processes requires two or more towers, so that at least one is on stream when another is being recharge or regenerated. For large gas flow rates and when the concentration of acid gases are high the construction and operating costs of batch processes are not justifiable. Continuous processes, in which uninterrupted operations with single equipment is possible, are normally used to remove impurities from natural gas streams. The continuous processes may be classified as shown in this slide. They are mostly based on the use of a solvent which can be regenerated and reused in a cyclic process. Therefore the solvent inventory of the plant is never completely disposed off unless it is severely contaminated with impurities. A continuous flow of the solvent in the gas absorption system continuously removes the impurities from the gas stream. The gas leaves the absorption system incessantly, and the solvent is routed to a regeneration system in which it is stripped off the acid gases and returned to the absorption section. Most gas sweetening processes use aqueous solutions of alkanolamines. The alknolamines of industrial significance are listed in this slide. They are the alcohol derivatives of ammonia. The alkalinity of ammonia is reduced as more hydrogen atoms are replaced by alcohol (ethanol) molecules. Therefore MEA (monethanolamine) is a stronger base and reacts faster with acid gases. A physical solvent may be added to enhance the performance of the amine in special situations. Potassium carbonate is another basic reagent which can react with acid gases. The hot carbonate processes developed by UOP and Unocal are mainly used in petrochemical and refining industries to remove CO2 from gas streams. Formulated amines which are hybrids of amine and physical solvents together with corrosion inhibitors and activators to enhance the ability of the solvents for better removal of carbon dioxide and/or mercaptans and sulfur compounds, or simultaneous removal of acid gases and water have been introduced. In physical solvent-processes the solvent physically absorbs the acid gases as opposed to chemical solutions in which reversible chemical reactions take place between the acid gas and the chemical reagents. Physical solvents dissolve the hydrocarbon constituents of natural gas (especially the larger molecular weight compounds), therefore it is important to note if these components are wanted in the sales gas or not and in what quantities. The most widely used processes are listed in this slide. In direct conversion processes hydrogen sulfide (H2S) is simultaneously removed and chemically converted to sulfur. The solutions are regenerated by air. Therefore the alternative term of Liquid Phase Oxidation is also used for these processes. As explained before, acid gases may be continuously removed from gas stream using the permeation phenomenon. Several technology suppliers offer this technology. Unlike liquid based systems, membranes remove impurities without any chemical or physical dissolution of acid gases. The system is simple and almost maintenance free. Membranes may also be used as gas-liquid contact equipment to contact the aforementioned chemical agents with the gas. New technologies are being developed, especially for offshore and floating facilities, in which the size of equipment is significantly reduced. The membrane base gas-liquid contactors are not sensitive to sea motion and therefore are more recommended for offshore operations

Typical Amine (physico-chemical) Process Flow Diagram

The flow diagram shown on this slide illustrates the arrangement of the equipment needed for amine process. The process flow diagram for formulated amines are almost the same. There are two basic parts: the high pressure process gas contactor and scrubbers, the size of which depends on the sour gas flow rate and pressure, and the low pressure regeneration system that is sized primarily according to the amine circulation rate. The sour gas enters the system through an inlet separator to remove any water or hydrocarbon liquids, Then the gas enters the bottom of the amine absorber and flows counter current to the amine solution. The absorber can be either trayed or packed tower. Conventional packing is used for smaller towers (<20) and trays or structured packing for larger towers. An outlet separator may be included to recover entrained amines from the sweet gas. The amine solution leaves the bottom of the absorber carrying with it the acid gases. This solution containing the CO2 and H2S is referred to as the rich amine. From the absorber the rich amine is flashed to a flash tank to remove almost all the dissolved hydrocarbon gases and entrained hydrocarbon liquids (condensates). A small percentage of the acid gases will also flash to the vapour phase in this vessel. From the flash tank, the rich amine proceeds to the rich/lean amine exchanger. This exchanger recovers some of the sensible heat from the lean amine stream to decrease the heat duty of the amine reboiler. The heated rich amine then enters the amine stripping tower where heat from the reboiler breaks the bonds between the amines and acid gases. The acid gases are removed overhead and lean amine is removed from the bottom of the stripper. The hot lean amine (amine with very little no acid gas content) solution proceeds to the rich/lean exchanger and then additional coolers to lower its temperature to no less than 10oF above the inlet gas temperature. This prevents hydrocarbons from condensing in the amine solution when the amine contacts the sour gas. The cooled lean amine is then pumped up to the absorber pressure and enters the top of the absorber. As the amine solution flows down the absorber it absorbs the acid gases. The rich amine is then removed at the bottom of the tower and the cycle is repeated. Of the amine introduced before, diethanolamine (DEA) is the most common. Methyl-diethanolamine (MDEA) is a very important amine. It is important because it needs less energy to be regenerated and it is selective towards H2S removal. Most modern formulated amines are MDEA based. Figure 21-5 of the GPSA data book summarizes the physical properties of the common gas treating solvents.

A cid Gas R e m oval: A mine processes - A mine U sed

Alcohol derivatives of am m o nia: NH 3 M onoethanola mine (ME A): H O C 2 H 4 N H 2 Diethanolamine (DE A): (H O C 2 H 4 ) 2 N H Diglycola mine (D G A): H(O C H 4 ) 2 N H 2 M ethyldiethanola mine (M D E A): (HO C 2 H 4 ) 2 NC H 3 Triethanolamine (TE A): (H O C 2 H 4 ) 3 N Diisopropanola mine (DIP A): (H O C 3 H 6 ) 2 N H

Monoethanolamine: Gas sweetening with monoethanolamine (MEA) is used where there are low contactor pressures and/or stringent acid gas specifications. MEA removes both H2S and CO2 from gas streams. H2S concentrations well below 0.25 grains/100scf (5.7 mg/m3) can be achieved. CO2 concentrations as low as 100 ppmv can be obtained at low to moderate pressures. COS and CS2 are removed by MEA, but the reactions are irreversible unless a reclaimer is used. Even with a reclaimer, complete reversal of the reactions may not be achieved. The result is solution loss and build-up of degradation products in the system. Total acid gas pick up is traditionally limited to 0.3-0.35 moles of acid gas/mole of MEA and solution concentration is usually limited to 10-20 mass%. Inhibitors can be used to allow much higher solution strengths and acid gas loadings. Because MEA has the highest vapour pressure of the amines used for gas treating, solution losses through vaporization from the contactor and stripper can be high. This problem can be minimized by using a water wash. Diethanolamine: This process employs an aqueous solution of diethanolamine (DEA). DEA will not treat to pipeline quality gas specifications at as low a pressure as will MEA. Although mole/mole loadings as high as 0.8-0.9 have been reported, most conventional DEA plants operate at significantly lower loadings because of corrosion. The process flow scheme for conventional DEA plants resembles the MEA process. The advantages and disadvantages of DEA as compared to MEA are: The mole/mole loadings typically used with DEA (0.35-0.8 mole/mole) are much higher than those normally used (0.30.4) for MEA. Because DEA does not form a significant amount of non re-generable degradation products, a reclaimer is not required. Also, DEA cannot be reclaimed at reboiler temperature as MEA can. DEA is a secondary amine and is chemically weaker than MEA, and less heat is required to strip the amine solution. DEA forms a re-generable compound with COS and CS2 and can be used for the partial removal of COS and CS2 without significant solution losses. Diglycolamine: This process uses Diglycolamine brand [2-(2-aminoethoxy)] ethanol in an aqueous solution. DGA is a primary amine capable of removing not only H2S andCO2, but also COS and mercaptans from gas and liquid streams. Because of this, DGA has been used in both natural and refinery gas applications. DGA has been used to treat natural gas to 0.25 grains/100scf (5.7 mg/m3) at pressures as low as 125 psig (860 kPa, ga). DGA has a greater affinity for the absorption of aromatics, olefins, and heavy hydrocarbons than the MEA and DEA systems. Therefore, adequate carbon filtration should be included in the design of a DGA treating unit. The process flow for the DGA treating process is similar to that of the MEA treating process. The three major differences are: Higher acid gas pick-up per volume of amine can be obtained using 50-70% solution strength rather than 15-20% for MEA (more moles of amine per volume of solution). The required treating circulation rate is lower. This is a direct function of higher amine concentration. Reduced reboiler steam consumption. Typical concentrations of DGA range from 50% to 70% DGA by weight. DGA has an advantage for plants operating in cold climates where freezing of the solution could occur. The freezing point for 50% DGA solution is 30 oF(34C). Because of the high amine degradation rate DGA systems require reclaiming to remove the degradation products. DGA reacts with both CS2 and COS to form non-regenerable products. Methyldiethanolamine: Methyldiethanolamine (MDEA) is a tertiary amine which can be used to selectively remove H2S to pipeline specifications at moderate to high pressure. If increased concentration of CO2 in the residue gas does cause a problem with contract specifications or downstream processing, further treatment will be required. The H2S/CO2 ratio in the acid gas can be 10-15 times as great as the H2S/CO2 ratio in the sour gas. Some of the benefits of selective removal of H2S include: Reduced solution flow rates resulting from a reduction in the amount of acid gas removed; Smaller amine regeneration unit; Higher H2S concentrations in the acid gas resulting in reduced problems in sulfur recovery. CO2 hydrolyzes much slower than H2S. This makes possible significant selectivity of tertiary amines for H2S. This fact is used by several companies who provide process designs using MDEA for selective removal of H2S from gases containing both H2S and CO2. Because the reaction between CO2 and tertiary amines forms the acid-base adduct, tertiary amines are ideally suited for bulk removal of CO2 from natural gas streams. The bulk removal of CO2 requires only a modest heat input for regeneration. The combination results in economic bulk removal of CO2 from high CO2 content gas streams. Triethanolamine: Triethanolamine (TEA) is a tertiary amine and has exhibited selectivity for H2S over CO2 at low pressures. TEA was the first amine commercially used for gas sweetening. It was replaced by MEA and DEA because of its inability to remove H2S and CO2 to low outlet specifications. TEA has potential for the bulk removal of CO2 from gasstreams. It has been used in many ammonia plants for CO2 removal. Diisopropanolamine Diisopropanolamine (DIPA) is a secondary amine which exhibits, though not as great as tertiary amines, selectivity for H2S. This selectivity is attributed to the steric hindrance of the chemical.

Acid Gas Removal: Hot Potassium Processes

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The basic process was developed by the U.S. Bureau of Mines and employs an aqueous solution of potassium carbonate (K2CO3). The contactor and stripper both operate at temperatures in the range of 230-240oF (110116C). The process is not suitable for gas streams containing only H2S. If H2S is to be removed to pipeline specifications or there are low CO2 outlet specifications, special designs or a two-stage system may have to be used. Potassium carbonate processes are somewhat effective in removing carbonyl sulfide and carbon disulfide. There are three basic process flow variations for the potassium carbonate process. The flow scheme required depends on the outlet specifications of the natural gas. These are: Single Stage Process: The single stage process is shown in the figure on the right side of the above slide. Potassium carbonate is pumped to the top of a packed or trayed contactor where it contacts the gas stream. The rich solution flows to the stripper where the acid gases are stripped with steam. The lean solution is then pumped back to the contactor to complete the cycle. Split Flow Process: In this process scheme (see left in the above slide), the lean solution stream is split. Hot solution is fed to the middle of the contactor for bulk removal. The remainder is cooled to improve equilibrium and is fed to the top of the contactor for trim acid gas removal. Two Stage Process: In this process scheme (not shown here) the contactor is like that of the split flow process. In addition, the stripper is in two sections. A major portion of the solution is removed at the mid point of the stripper and pumped to the lower section of the contactor. The remainder is further stripped with steam and then cooled prior to entering the top of the contactor. Numerous improvements have been made to the potassium carbonate process resulting in significant reduction in capital and operating costs. At the same time, lower acid gas concentration in the treated gas can now be achieved. The most popular of the carbonate processes are: Benfield Process: The Benfield Process is licensed by UOP. Several activators are used to enhance the performance of the potassium carbonate solution. Catacarb Process:The Catacarb Process is licensed by Eickmeyer and Associates. Activators, corrosion inhibitors, potassium salts, and water are contained in the solution. This process is mostly used in the ammonia industry.

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Acid Gas Removal: Physical Solvent Processes

11

These processes are based on physical absorption and operate with a flow scheme as shown in this slide. In general, a physical solvent process should be considered when: the partial pressure of the acid gas in the feed is greater than 50 psi (345 kPa); the heavy hydrocarbon concentration in the feed gas is low; bulk removal of the acid gas is desired; and selective removal of H2S is desired. These processes are economically attractive because little or no energy is required for regeneration. The solvents are regenerated by: multi-stage flashing to low pressures; regeneration at low temperatures with an inert stripping gas; and heating and stripping of solution with steam/solvent vapours. In general, physical solvents are capable of removing COS, CS2, and mercaptans. In certain instances, physical absorption processes are capable of simultaneously dehydrating and treating the gas although additional equipment and higher energy requirements may be needed to dry the solvent. The processes operate at ambient or sub ambient temperature to enhance the solubility of the acid gases. The solvents are relatively non-corrosive so carbon steel can be used. Chemical losses are low due to low solvent vapour pressure. Physical solvents will absorb heavy hydrocarbons from the gas stream resulting in high hydrocarbon content in the acid gas stream as well as possibly significant hydrocarbon losses. Some of the physical absorption processes are summarized below: Selexol: This process uses a polyethylene glycol derivative as a solvent. The solvent is selective for RSH, CS2, H2S, and other sulfur compounds. The process can be used to selectively or simultaneously remove sulfur compounds, carbon dioxide, water, as well as paraffinic, olefinic, aromatic and chlorinated hydrocarbons from a gas or air stream. Because water and heavy hydrocarbons are highly soluble in Selexol, the treated gas from a Selexol unit normally meets both water and hydrocarbon dew point specifications. The vendor states that the solvent is very stable, no degradation products are formed or disposed of, and no solvent reclaiming is required. Depending on the applications, the operating pressure could be as low as ambient though higher pressure is preferred. Operating temperature varies from 0oF ( 18oC) to ambient. Selexol was developed by Union Carbide Corporation and now is a UOP technology. Fluor Solvent: This process patented by the Fluor Corporation, is based on the use of anhydrous propylene carbonate. The temperature of the lean solution to the absorber is usually well below ambient, and some method of refrigerating the solvent is usually necessary. Rectisol Process: This process uses methanol as a solvent, and was developed by the German Lurgi Company and Linde A. G. Because of the vapour pressure of methanol, the process is normally applied at temperatures of -30 to 100oF (35C to 73C) for the Rectisol solution. It has been applied for the purification of natural gas for LNG production. The process is best suited where there are limited quantities of ethane and heavier components and has been used more in Europe than the U.S and Canada. Ifpexol: Ifpexol also uses refrigerated methanol for the complete treatment (dehydration, NGL recovery and sweetening) of natural gas. The Ifpexol process is based on two independent steps : Ifpex-1 : methanol is used as hydrate inhibitor in a cold process for NGL extraction. The mixture of methanol and water recovered at the low temperature separator is regenerated by simple stripping with a fraction of the feed gas and pure water is produced. Ifpex-2 : refrigerated methanol/water mixture is used as a solvent for the extraction of acid gases (CO2/H2S). Being a physical solvent process, Ifpex-2 fits best for bulk acid gas removal and also allows the removal of the organic sulphur species. A key feature of Ifpex-2 is that acid gases are obtained dry and under some pressure which brings important savings for acid gas re-injection. Ifpexol was developed by the Institut Franais du Ptrole (IFP) Purisol: This process was developed by Lurgi and has been licensed by the Ralph M. Parsons Company. The solvent used in this process is N-methyl-2-pyrrolidone (NMP), a high boiling point liquid. Like Selexol, Purisol exhibits a selectivity for H2S. Purisol has not been used much in the U.S and Canada. Catasol: This process is licensed by Eickmeyer and Associates. Catasol solvents are reported to have selectivity for H2S/CO2, CO2/propane, and COS/CO2

11

Acid Gas Removal: Formulated Solutions (Special/hybrid or mixed Solvents) Formulated Solutions
Dow GAS/SPECTM UOP UcarsolTM series

Huntsman EXTREATTM BASF activated MDEA or aMDEA Sterically hindered amines, Exxon FLEXSORB Hybrid (mixed solutions)
Shell Sulfinol M & D UOP Hi-Pure
12

Formulated Solvents: Formulated Solvents is the name given to a new family of amine-based solvents. Their popularity is primarily due to equipment size reduction and energy savings over most of the other amines. All the advantages of MDEA are valid for the Formulated Solvents, usually to a greater degree. Some formulations are capable of slipping larger portions of inlet CO2 (than MDEA) to the outlet gas and at the same time removing H2S to less than 4 ppmv. For example, under ideal conditions of low absorber pressure and high CO2/H2S ratios, such as Claus (sulphur recovery units) tail gas clean-up units, certain solvent formulations can slip upwards to 90 percent of the incoming CO2 to the incinerator. While at the other extreme, certain formulations remove CO2 to a level suitable for cryogenic plant feed. Formulations are also available for CO2 removal in ammonia plants. Finally, there are solvent formulations which produce H2S to 4 ppmv pipeline specifications while reducing high inlet CO2 concentrations to 2% for delivery to a pipeline. This case is sometimes referred to as bulk CO2 removal. This need for a wide performance spectrum has led Formulated Solvent suppliers to develop a large stable of different MDEAbased solvent formulations. Most Formulated Solvents are enhancements to MDEA discussed above. Thus, they are referred to as MDEA-based solvents or formulations. Benefits claimed by suppliers are: For New Plants: reduced corrosion; reduced circulation rate; lower energy requirements; smaller equipment due to reduced circulation rates. For Existing Plants; increase in capacity, i.e., gas through-put or higher inlet acid gas composition; reduced corrosion; lower energy requirements and reduced circulation rates Formulated Solvents are proprietary to the specific supplier offering the product. Companies offering these solvents are Dow Chemical Company (offering Formulated Solvents under the name GAS/SPECTM, Huntsman Corporation (marketing Formulated gas treating solvents under the TEXTREATTM name), Union Carbide Corporation (marketing the UCARSOLTM family of Formulated Solvents), and German BASF (marketing the activated MDEA or aMDEA formulated) solvents. These companies offer their Formulated Solvents on an "as is" sale basis. This means there is no technology (process) license fee involved to use the solvent; therefore, no process warranty is included. Some suppliers do offer free services such as process/performance simulation, on-site technical service, solvent analysis, etc. Check with the current suppliers for their present warranty and service policy as these items are subject to change. Sterically Hindered Amines: Other amines have been used to treat sour gases. One specialty amine has been constructed by a process defined as steric hindrance (hindered amines are amines containing a bulky substitute group to the nitrogen atom in the ammonia molecule to lower the stability of carbamate ion (a transient combination of CO2 and the amine). The actual structure of the amine has been formed to accommodate a specific process requirement. This type of amine and the associated technology is different than Formulated Solvents, which create the desired formulations by blending different components with a standard amine such as MDEA. An example of this technology is FLEXSORB solvents, marketed by Exxon Research and Engineering Company. Sulfinol Process: The Sulfinol Process, licensed by Shell E&P Technology Company, is used to remove H2S, CO2, COS, CS2, mercaptans and polysulfides from natural and synthetic gases. Sulfinol is a mixture of Sulfolane (a physical solvent), water and either DIPA or MDEA (both chemical solvents). It is this dual capacity as both a physical and a chemical solvent that gives Sulfinol its advantages. Sulfinol with DIPA (Sulfinol-D) is used when complete removal of H2S, CO2, and COS is desired. Sulfinol with MDEA (Sulfinol-M) is used for the selective removal of H2S in the presence of CO2, with partial removal of COS. Both Sulfinols can reduce the total sulfur content of treated gas down to low ppm levels. The advantages of Sulfinol are: low energy requirements; low foaming and non-corrosive nature; high acid gas loadings; some removal of trace sulfur compounds. The disadvantages of Sulfinol are; higher heavy hydrocarbon co-absorption; reclaimer sometimes required when removing CO2. Hi-Pure Process: The Hi-Pure process is a combination conventional Benfield potassium carbonate process and alkanolamine process. The gas stream is first contacted with potassium carbonate followed by contacting with an amine. The process can achieve outlet CO2 concentrations as low as 30 ppmv and H2S concentrations of 1 ppmv.

12

Acid Gas Removal: Direct Conversion-Liquid Phase Oxidation of H2S (Liquid-Redox Processes)
A. Sour Gas Treatment B. Acid Gas Treatment/Sulfur Production

13

Iron chelate processes belong to a process group referred to as liquid redox sulfur recovery. Processes in this group absorb H2S from gas streams and produce elemental sulfur by reacting oxygen with the H2S to form elemental sulfur and water. Liquid redox sulfur recovery processes all share the following major operations: sour gas cleaning by absorption of H2S into a circulating alkaline solution; conversion of the formed HS- to elemental sulfur via the action of an auxiliary redox reagent (iron and vanadium are two most important reagents); separation and recovery of solid sulfur; regeneration of the spent auxiliary reagent via reaction with oxygen dissolved in the solution. The addition of an auxiliary redox reagent increases the rate of reaction and directs the oxidation to elemental sulfur. Because they share major process operations and are based on similar process chemistries, the process flow sheets and equipment requirements for liquid redox systems are rather similar. The processes which are members of the ironbased subgroup of redox processes are LO-CAT (now marketed by Merichem), IFP Sulfint and Shell SulFerox all work based on chelated iron liquid redox processes. Vanadium based processes are very similar to iron-chelate processes. Vanadium is a heavy metal and the processes involve environmental and health issues. The two most widely used processes are British Gas Stretford, and German Linde Sulfolin. The liquid redox processes are more suitable for low sulfur production applications (<10-12 ton/day sulfur). They are very efficient in reducing the sulfur emissions of gas processing facilities to environmentally acceptable levels. They are also very suitable when the sulfur concentration varies with time or the low sulfur concentration where the Claus sulfur recovery process is not capable of handling.

13

Acid Gas Removal: Membrane Gas Permeation Processes

14

MEMBRANE SEPARATION PROCESS Gas permeation is the transport of gas molecules through a thin polymeric film from a region of high pressure to one of low pressure. Gas permeation is based on the principle that different gases permeate through polymeric films at different rates due to differences in diffusivity and solubility. Separation efficiency is affected by the gas composition, pressure differential, pressure ratio, separation factor, and temperature. Pressure drop through the membrane is high, so the gas which permeates is available only at lower pressure. For the natural gas not permeating the membrane, the pressure drop will be similar to that through any other process unit. membrane systems are used primarily for bulk CO2 removal from natural gas streams. The systems are modular, skid mounted units containing either spiral wound or hollow fiber membrane elements. The elements are housed in pressure tubes in various configurations depending on system requirements. The advantages of membrane systems over conventional processes are site specific, but may include: lower capital and energy costs; reduced space requirements, faster delivery time and lower installation costs due to smaller, lighter modular design; lower operating costs and limited manpower requirements due to simplified operation and maintenance; increased adaptability to changing feed flow and composition; elimination of dehydration equipment; faster, easier start-up and shutdown. Membranes however suffer, in some cases, from poor separation efficiency due to close permeation rates for various constituents of natural gas. For instance methane and some heavier hydrocarbon constituents of natural gas have very close permeation rates with those of acid gases and water for common polymeric membranes, therefore a significant amount of methane and heavier hydrocarbons may be lost when this technology is used for acid gas and water removal from natural gas streams. APPLICATIONS membrane systems are typically used in the following applications and markets: Natural Gas Upgrading: membrane systems remove carbon dioxide and water vapour to pipeline specifications and lower the H2S level. Systems can be installed either onshore or offshore, at the wellhead or at gathered facilities Enhanced Oil Recovery (EOR) Operation: membrane systems are used to recover carbon dioxide from EOR floods for recycle injection. Systems can be used as a base load system, designed as part of the recovery plant, or as a de-bottlenecking unit upstream of the existing recovery plant. OPERATING RANGE Commercial applications have demonstrated the versatility of membrane systems. Typical feed conditions range between 400 and 1400 psig with CO2 levels from 3 to ~70%. Commercial systems have been designed and operated at feed flow rates ranging from 5 MSCFD to over 700 MMSCF. Technology suppliers usually offer complete membrane system design including comprehensive feed pretreatment schemes to extend membrane life. Major players in membrane technology are: Dow CynaraTM now marketted by Natco, UOP SEPAREXTM, Air Products PRISM membrane, Liqui-Cel Membranes

14

Acid Gas Removal: Process Selection

1. 2. 3. 4. 5. 6. 7. 8. The types and concentrations of impurities in the gas, and the degree of removal desired Concentration of non-H2S Sulfur compounds (COS, RSH, RSSR, CS2, COS, polysulfide, etc.) Selectivity of acid gas removal required, if any. Temperature and pressure at which the sour gas is available, and at which the sweet gas is to be delivered Volume of gas to be treated CO2/H2S ratio in the gas The presence and amount of heavy hydrocarbons and aromatics in the gas Economics of the process
15

There are many variables in gas treating, which makes the precise definition of the area of application of a given process very difficult. Among several factors, the factor shown on this slide are the most significant that need to be considered. The concentration of acid gas components are important to consider. Some processes effectively remove large amounts of acid gases, but not to low enough levels (e.g., physical solvents). Other remove to ultra-low values, but cannot handle large amounts of acid components in the incoming gas economically (e.g., liquid-redox). The presence of non-H2S sulfur compounds (e.g., mercaptans) may eliminate some of the sweetening processes (for instance MDEA alone cannot remove mercaptans effectively) . Selectivity of a process implies the degree of removal of one acid gas component relative to another. Some processes remove both H2S and CO2 (most alkanolamines), while others are designed to selectively remove only H2S (MDEA and DIPA blends). Generally, it is important to consider the selectivity of a process for H2S versus CO2 to ensure desired extent of removal of these components. For this reason, CO2 to H2S ratio in the gas is also an important parameter. Operating conditions affect the performance of several sweetening processes. Also, different processes discharge the sweetened gas stream at different pressure and temperature levels relative to the conditions of the incoming gas (i.e., pressure drop is a definite result of any gas processing process, however some process have inherently larger pressure drops such as solid bed adsorption processes). Thus, the inlet and outlet conditions desired are significant variables to consider. It may be economical in some cases to alter inflow conditions to suit process, and out flow conditions to meet pipeline requirements. Usually for physical solvent processes, a high pressure inlet gas with high concentration of acid gases are required, therefore if we are dealing with a natural gas stream containing a large concentration of CO2 and a low pressure, the gas should be pressurized to a level suitable for the selected process. Some processes are economical for large gas volumes (e.g., most amine and formulated amine processes), while others lose their economic advantages when large volumes of gas are to be treated (e.g., membrane, liquid-redox and batch processes). Gas composition should also be considered, since some processes are adversely affected by the presence of heavier fractions, while others may strip the gas of some of its hydrocarbon constituents (Shell sulfinol, and most physical solvent processes). The desirability of recovering sulphur as elemental sulphur reduces the choices considerably. Processes with sulfur recovery options have become very important in recent years, and will further become so in the future due to environmental problems caused by sulphur emissions. Sulphur is a by-product, generally in demand in some part of the world by fertilizer and chemicals industry. Therefore sulfur recovery may be attractive from an economical point of view, although in some places there is no demand and it is preferred to inject the sulfur compounds to depleted hydrocarbon reserves.

15

Acid Gas Removal: Process Selection Charts

1000
Physical solvents plus amine, membranes

CO2 Removal, no H2S

Physical solvents and/or with amine or carbonate, membranes Fluor DGA, Selexol, Sulfinol, high loading DEA

H2S Removal, no CO2

Physical solvents

Physical solvents

Partial pressure CO2 in Feed, psia

100
Physical solvents or carbonate Phy. Solv. or Sulfinol

Carbonate or concentrated amines Membrane, carbonate or amine

es su re

Fluor DGA, DIPA (ADIP), Sulfinol or high loading DEA

an d

ou tle t

10
Membrane, amines
of eq ua l in le t

LO-CAT, Sulfa-Check, amnes, liquid-redox, Sulfinol LO-CAT, Sulfa-Check, Liquid-redox

0.1

1.0

Li ne

10.0

100.0

0.10

1.0

16

10.0

Partial Pressure of CO2 in Product, psia

Partial Pressure of H2S in Product, psia

Decisions in selecting a gas treating process can many times be simplified by gas composition and operating conditions. High partial pressures , usually above 50 psi (345 kPa) of acid gases enhance the probability of using a physical solvent. The presence of significant quantities of heavy hydrocarbons in the feed discourages using physical solvents. Low partial pressures of acid gases and low outlet specifications generally require the use of amines for adequate treating. Process selection is not easy and a number of variables must be weighed prior to making a process selection. The graphs shown on this and the next slide can be used as screening tools to make an initial selection of potential process choices. Graphs should be used only for an initial guide to select a number of good candidates and should never replace good engineering judgment. A comprehensive feasibility study and cost-benefit analysis will determine which process is more economical. To select the process, determine flow rate, temperature, pressure, concentration of the acid gases in the inlet gas, and allowed concentration of acid gases in the outlet stream. With this information, calculate the partial pressure of acid gases as follows: Pi=yi.Pt , where, Pi is partial pressure of component i, psia, Pt system pressure, psia, and yi is the mole fraction of component i. Next, determine if one of the four following situation is required and use the appropriate guide: Removal of H2S with no CO2 present Removal of H2S and CO2 Removal of CO2 with no H2S present Selective removal of H2S with CO2 present

Partial pressure H2S in Feed, psia

pr

16

Acid Gas Removal: Process Selection Charts

1000 CO2 and H2S Removal
Selexol, high loadign amine

Selective Removal of H2S in presence of CO2

Physical solvents

100
Partial pressure Acid Gas in Feed, psia
Physical solvents or carbonate

Sulfinol, carbonate or amine

es su re

DIPA or hindered amne processes

es su re

ou tle t

an d

in le t

Amines or Sulfinol
of

eq ua l

Li ne

0.1

1.0

10.0

100.0

1.0

Li ne

Liquid redox, DIPA

of

eq ua l

in le t

an d

10.0

ou tle t

10

100.0

Partial Pressure of acid gas in Product, psia

17 Partial Pressure of H2S in Product, psia

Partial pressure H2S in Feed, psia

Rectisol or Selexol

pr

pr

17

Acid Gas Removal: Amine Plant Design

Process simulation using ASPEN/HYSYS, TSWEET, etc.

Feed P, T, flow rate and composition Amine type and conc. Amine loading and circulation rate Number of stages (theoretical vs. real) Reflux ratio/regenerator steam rate Amine flow rate (gpm)

Key design parameters

LMEA= 2.01 (MMscfd) (mole percent of acid gas in feed) LDEA = 1.26 (MMscfd) (mole percent of acid gas in feed).

18

The type of equipment and design procedure for MEA and DEA systems are similar. Process simulators such as Hyprotech HYSYS, ASPEN and BR&E TSWEET are extensively used to simulate and analyze amine processes. Very reliable simulation can be obtained using these simulators and the material and energy balance information can be used to design the processes. The simulators are equipped with tower and separator design and heat exchanger hydraulic and thermal design modules or can be linked to exchanger design packages such Hyprotech HTFS or Heat Transfer Consultants (HTC) STX to design heat exchangers (shell and tubes and air coolers). Typically, these programs require considerable input. For example: 1. The type and concentration of the amine solution 2. The lean amine loading or amine circulation rate 3. The residence time of the amine solution in contactor or the percent approach to equilibrium or the efficiency of trays (sometimes based on acid gas components) 4. The number of theoretical stages in the contactor and regenerator 5. The reflux ratio 6. Or steam required per gallon of circulation Often some of the input data must be calculated, e.g., acid gas loadings. These programs allow the user to: compare amine solutions type and concentration quickly; optimize the number of stages in the contactor and regenerator; obtain the heat duties and size equipment; get the physical properties of the amine solutions; re-rate an existing plant for a different amine solution. For special formulations such as Shell Sulfinol, UOP Ucarsol and BASF activated MDEA, the licensee should be contacted. These companies usually provide the basic design information and perform simulation free of charge for evaluation purposes. The important design parameters in amine systems are shown on this and the following slides. One the most important parameters which determines the size and therefore the final cost of the gas sweetening plant is the amine or solvent circulation rate. Amine plants are sometimes referred to by the amine flow rate (e.g., a 2,500 gpm plant). The amine flow rate is generally a good indication of the size of process equipment. The circulation rate for amine systems can be determined from the acid gas flow rates by selecting a solution concentration and an acid gas loading. The following simple formulas can be used to determine the amine flow rates: LMEA= 2.01 (MMscfd) (mole percent of acid gas in feed); and LDEA=1.26 (MMscfd) (mole percent of acid gas in feed), where LMEA and LDEA are in gallons per minute or gpm. For design purposes, the following solution strengths and loading are recommended to provide an effective system without excessive corrosion: for MEA, amine weight fraction is about 20% and acid gas loading is 0.33 mole acid gas/mole MEA; for DEA the amine strength is 35 wt.% and acid gas loading is 0.5 mole acid gas/mole DEA. In the modern plant designs, especially when the concentration of CO2 required be removed is very high (>5-6%), lower acid gas loadings are considered for DEA (~0.35-max. 0.4). For the above recommended concentration the densities at 60oF fro the MEA and DEA are: 20% MEA = 8.41 lb/gal (1,046 kg/m3), and 35% DEA = 8.71 lb/gal (1,083 kg/m3). For high loaded DEA system (especially when H2S concentrations are high, acid gas loadings up to 0.7 have been chosen for design purposes. This high acid gas loadings are not recommended for modern gas sweetening plant design practices. The above simple flow rate calculation equations are obtained by straight forward mass balance around the absorption tower.

18

Acid Gas Removal: Amine Plant Design (cont.)

Key design parameters (cont.) - Absorption system

Inlet separator (std. design, SoudersBrown, etc.) Contactor tower (amine absorber) Number of trays (20-24 valve trays, ~30% efficiency) Packing height (see suppliers charts) Cross section area (flooding calcs., 100-micron liquid particles separation, std vertical separator calcs.) Water wash requirement (water make-up, reduced amine loss) Hydrocarbon dew point, and retrograde condensation (foaming reduction) Outlet separator (amine loss/down stream contamination prevention) 19

The high pressure process gas system consists of an inlet separator, contact tower, and outlet separator. The inlet separator (scrubber), removes of slugs and drops of condensed hydrocarbon, produced water, corrosion inhibitors, and well treating chemicals from the inlet sour gas stream. It should be located as close as possible to the amine contactor. It can be complemented, but not replaced, by any integral scrubber in the contactor tower. Removal of contaminants from the inlet gas may be enhanced by washing the gas with water. This is an additional processing step and is needed only when the sour gas contains droplets or particles too small to be effectively removed by conventional filter separators. Entrained liquids, most commonly slugs of produced water (often saline), must be removed because they quickly contaminate the amine solution and cause problems such as foaming, equipment fouling, high corrosion rates, solvent loss, and sour effluent gas. Entrained liquids are the most frequent contamination source for all sweetening processes. Amine absorbers use counter-current flow through a trayed or packed tower to provide intimate mixing between the amine solution and the sour gas. Typically, small diameter towers use stainless steel packing, while larger towers use stainless steel trays. For normal acid gas concentrations (>2-3 % total acid gas), number of standard trays are between 20 to 24 (equivalent to approximately 7 to 8 theoretical stages). Variation in solution concentration or acid gas content or loading may require further investigation to determine the number of trays. Valve-type trays are the most common and efficient contacting internals. In a trayed tower the amine falls from one tray to the one below. It flows across the tray and over a weir before flowing into the next downcomer. The gas bubbles up through the liquid and creates a froth that must be separated from the gas before it reaches the underside of the next tray. For preliminary design a minimum diameter capable of separating 150-200 micron droplets can be assumed. The gas velocity should be reduced by 25 to 35% from the above calculations, to avoid jet flooding and by 15 to 20% to allow for foaming. The size of packed towers must be obtained from manufacturers published literature. Structured packing, (e.g., supplied by Koch-Glitch) present very efficient gas-liquid contact and produce very little pressure drop compared to tray towers and conventional packing. The standard design requires the inclusion of a mist pad above the top tray. The typical tray spacing is 18 to 24 inches and the distance between the top tray and the mist pad is 3 to 4 feet. Some contactors have a water wash consisting of two to five trays above the lean amine feed tray. This eliminates amine carry over and conveniently add make-up water. Most of MEA units at low pressures should have wash water trays as the vapour pressure of MEA is such that the water wash may be useful in reducing MEA losses in the overhead sweet gas. DEA systems normally do not need this as the vapour pressure of DEA is rather lower. The best way to monitor the performance of the contactor and detect foaming is with a differential pressure (DP) cell connected to the gas inlet and outlet. Accordingly connections for a DP cell should be provided. Hydrocarbon dew-point in the contactor at both the inlet and outlet conditions should be checked. It is important to note that the dew-point increases as the acid gases are removed, and hydrocarbon condensation is one of the most common causes for excessive foaming. Retrograde condensation should also be checked as hydrocarbon condensation can result from a temperature rise or a pressure drop in the contactor. Note that due to heat of reaction between the acid gases and amine the solution gradually is warmed up as it flows down the contactor. The gas pressure drops due to friction as it flows up the amine absorber (contactor). The outlet gas separator removes any liquid carry over from the sweet gas and prevents contamination of down stream equipment. It also signals excessive foaming in the contactor.

19

Acid Gas Removal: Amine Plant Design (cont.)

Various Tower Gas-Liquid Contact Internals

20

Various gas-liquid contact devices are shown on this slides.

20

Acid Gas Removal: Amine Plant Design (cont.)

A gas-Liquid Contactor 21 Source: Koch-Glitch

A typical (generally includes all types of internals in one column; not representing a working tower) gas-liquid contact device is illustrated on this slide. Structured packing materials are also shown.

21

Acid Gas Removal: Amine Plant Design (cont.)

Structured Packing Valve Trays

Random Packing Tower Internals

22 Source: Koch-Glitch

A closer look at the tower internals may be taken here. High performance structured and packing as well as valve trays and other tower internals are shown on this slide.

22

Acid Gas Removal: Amine Plant Design (cont.)

23

Typical performance charts for structured packing are shown on this slide. Typically a height between 10 to 15 inches can act as one theoretical tray as compared with 3 x (18-24)=54-72 inches in trayed towers (it should be noted that typical tray spacing is between 18-24 and three trays act as one theoretical tray). The pressure drops are much lower in structured packing due to a more streamlined flow of gas and liquid.

23

Acid Gas Removal: Amine Plant Design (cont.)

Key design parameters (cont.) Regeneration system

Flash tank: 2 scf/gal of flashed gas, 20-30 min. liquid amine residence time Lean/rich exchanger Stripping tower
Number of stages: ~20 V-Grid (fixed valve) or traditional valve trays, 40-50% efficiency Lean cooler and reflux condenser types and heat duties: see table below Reboiler types and heat duty: kettle vs. thermosyphon
Heat Exchanger Reboiler Solution Exchangers Aerial Cooler Reflux Condenser Duty (Btu/hr) 72,000 x gpm 45,000 x gpm 15,000 x gpm 30,000 x gpm Area (ft2) 11.30 x gpm 11.25 x gpm 10.20 x gpm 5.20 x gpm 24

The regeneration system consists of a flash tank, rich/lean amine heat exchanger, stripping tower and its auxiliaries, filters, and aerial coolers. There are also reflux, booster and circulation pumps. Primary amines require reclaimer as well. The amine solution absorbs hydrocarbons (HC) as well as acid gases in the contact tower. These flash out when the pressure is reduced. The flash tank provides the residence time for this degassing of the rich amine solution. HC absorption depends on the inlet gas composition and pressure. For lean sour gas the rule of thumb is 2 scf/gal. Recommended residence times are 20-30 minutes for two-phase vessels. When the flash gas is used for fuel it is needed that the gas be treated with lean amine in an integrated small column attached to the flash separator. HC contamination often promotes foaming and equipment fouling. Down stream facilities such as sulfur plants will be troubled if HCs are stripped off the amine solution in the stripping tower. Flash tank reduces the heat duty of the stripper reboiler. Standard gas-liquid separator design procedure should be followed to design the flash tank. The lean/rich heat exchanger preheats the rich amine solution and reduces the duty of the reboiler. It also cools the lean amine and reduces the duty of the aerial lean amine cooler. Both shell and tube and plate and frame heat exchangers are used . The rich amine usually passed through the tube side with a low inlet velocity (typically 2 to 4 ft/sec.) to reduce corrosion. This low velocity sometimes cause fouling in the tube side of the exchanger when solid particulates are present. Typically the temperature change for both streams is 70 to 100oF and the pressure drops 2 to 5 psi. Using two or more exchangers in series is common practice to accommodate a temperature cross; for example the exit rich amine stream is hotter than the exit lean amine stream. Again standard heat exchanger design procedures are followed. Software packages such as HTFS and HTC-STX are very effective in designing new exchangers and rating the existing ones. The reflux condenser and lean amine cooler are air-cooled, forced draft fin-fan heat exchangers with automatic louvers for temperature control. A 10% safety factor should be considered for heat duty. For small facilities (<200 gpm) the two exchangers may be combined on one structure with a common fan. Air circulation is advisable when the ambient temperature is expected below 10oF. Sometimes a trim cooler, using water, is needed for the lean amine systems. The summer ambient air temperature is a very critical factor when the air-coolers are designed and affects the size and cost of manufacturing of these important process devices. A design summer air temperature of 110oF is chosen for most North American and European designs while an air temperature of 130-135oF is not unusual for the Middle Eastern gas sweetening plants. Typical regenerator or stripping tower (sometimes it is called still as well) is comprised a trayed or packed tower operating at 10-20 psig. The same sizing procedure as explained for the contactor can be used. A standard design consists of 20 (Nutter V-grid or valve) trays spaced 24 inches apart working in . This is equivalent to 7 to 10 theoretical plates when the tray efficiency is 40 to 50%. The trays are designed for liquid and jet flood rates of 65 to 75% with a foam factor a 0.75. Small amine reboilers are direct fired heaters that use natural gas. The fire tube surface is based on a heat flux of 6,500 to 8,500 Btu/hr. ft2 to keep the tube wall temperature below 300o. Larger reboilers use a stream or hot oil bundle. There is usually more corrosion with thermosyphon than kettle type designs. Forced circulated, oil medium heated, vertical (non-kettled) reboliers are recommended for heat sensitive amines including both MEA and DEA as the heat exchanger tube wall temperature can be maintained well below degradation temperatures. Sending the amine in the tube side also provides the condition to use tube insert inside the tubes to further reduce the risk of amine thermal degradation in amine reboilers. A number of good references are available for design of amine reboilers (see for instance this recent article Optimize reboiler design by Chen Edward Foster Wheeler USA), Hydrocarbon Processing, v 80, n 7, July, 2001, p 61-67 and Effectively design and simulate thermosyphon reboiler systems, part 1 and 2 by Martin G.R. et al. Hydrocarbon Processing, v 74, n 7, Jul, 1995, p 67. The reboiler duty is: (1) the heat to bring the acid amine solution to the boiling point, (2) the heat to break the chemical bonds between the amine and acid gases, (3) the heat to vaporize the reflux, and (5) the heat losses from the reboiler and still. A safety factor of 15 to 20% is needed for start up. The heat duties and transfer areas of the regeneration equipment can be estimated from the amine circulation rate as shown in the table on this slide.

24

Acid Gas Removal: Amine Plant Design (cont.)

Key design parameters (cont.)

Regeneration system (cont.)

Lean amine loading (0.001 -0.01) Reflux accumulator (reflux ratios:1.2 to 3) Surge tank (10-15 min holding time) Amine reclaimer (MEA, DGA, and DEA)

25

Lean amine loading is a major factor in determining the reboiler duty and the performance of the amine contactor. Too much of acid gas in the lean amine results in off-spec acid gas (particularly H2S) in the product (sweetened gas). It is very important to carefully monitor the acid gas loading by occasional analyses. The lean loading may be adjusted by fine adjustment of steam flow rate (heat duty) to the rebiler. Measurement of lean amine loadings is not as accurate as it is for that of rich amine (due to lower acid gas concentrations), however, using chromatography or other analytical techniques, it can be measured even on-line. Lean loadings within the range 0.001-0.01 mole acid gas/mole of amine are recommended for typical operations. The condensate formed in the reflux air-cooler (typically 130-145oF) is routed to an accumulator. The reflux accumulator separates the reflux or condensed water from the water-saturated acid gases. The water is returned to the still and the acid gases are sent to sulfur recovery or flared. Flaring is not a very acceptable practice these days and is being replaced by incineration or other sulfur treatment options. A mist pad is usually included. A means of measuring the reflux rate is most helpful and recommended. The reflux rate (moles of water returned to the still mole of acid gases leaving the reflux condenser) varies from 3.0 for primary amines and low CO2/H2S ratio (< 0.01-0.1 mole ratio) to 1.2 for tertiary amine and high CO2/H2S ratios (>0.3-3). A surge tank holding about 10-15 minutes of flow is needed in most amine circulation loops. This is usually an extension of the firetube-type reboiler for smaller units (<20-100 gpm) and a separate vessel for large systems (>300 gpm). The vessel provides some surge capacity and a means to charge the amine when the system is shut down or during the start-up operations. Reclaimer. It was believed that only primary amines required additional regeneration to remove several impurities accumulated in them during the long term operation of the gas sweetening plants. MEA and DGA plants are designed with a semi-continuous distillation kettle attached to the stripper reboiler. It has been shown that DEA and other amines including MDEA, also undergo degradation reactions and require regular reclaiming or purification exercises. Heat distills the amine and water under stripper pressure conditions, leaving the contaminants in the reclaimer. A slip stream of 1 to 3% of the lean amine flow rate is fed continuously to the reclaimer. Alkaline solutions such as sodium hydroxide or carbonate are injected to reverse the non-reversible amine salts with stronger acid gases (e.g., formic and acetic acids) and sulfur compounds, especially COS and CS2, present in the gas. Other contaminants are amine degradation products, iron sulfide, and high boiling hydrocarbons. These are removed as a sludge at the end of each cycle. Reclaiming helps to have fewer operational problems as most of the operational problems in amine plants stem from contaminated solutions.

25

Acid Gas Removal: Amine Plant Design (cont.) Key design parameters (cont.)

Filters

Pumps

Mechanical (for particulates) Carbon (for dissolved hydrocarbons, surfactants, well treating chemicals, compressor lube oil - NOT RECOMMENDED FOR AMINE DEGRADATION PRODUCTS!) Split flow requirements (10-25% of circ. rate) Amine charge Amine booster Reflux Aerial cooler
Pump
Amine Charge/Circulation Booster Reflux Lean cooler

Horsepower
gpmxpsigx0.00065 gpm x 0.06 gpm x 0.06 gpm x 0.36
26

Filters: Both mechanical filters for particulates and activated carbon filters for heavy hydrocarbons are needed. Installing filters in both rich and lean amine lines is the preferred but most costly approach. For H2S services, installing filters in rich amine line is more troublesome. Cleaning and replacement of filter cartridge requires careful purge and release of H2S containing rich amine , therefore most filters in sulfur services are installed on the lean amine line. A mechanical filter in the rich amine line just after the flash tank prevents fouling of heat transfer surfaces and plugging in the rich/lean heat exchanger and amine stripper internals. Including a carbon filter reduces the tendency to foam by adsorbing hydrocarbons that would otherwise be removed in the amine regenerator (stripper). For small units, the mechanical filter should be full flow and remove 95% of 10 microns or larger particles. For large units with high circulation rates (>300-500 gpm range), a slip stream is more practical. Carbon filter is often installed in the lean line before the lean amine cooler to improve the quality of the amine feed stream. Activated carbons were wrongly believed to remove amine degradation products. There are compelling scientific evidence that carbon filters are not able to remove amine degradation products very efficiently. Activated carbon is very effective in removing dissolved higher HCs, surfactants, well treating chemicals, compressor lube oils, and all organic (hydrocarbons) chemicals from amine streams. For design purposes carbon filter vessels stream containing granular carbon in the range of 4-30 mesh, a flow rate of 2-10 gpm/ft2 of bed area, and a retention time of 5 to 10 minutes are recommended. The carbon particles mesh size should be preferably about 5-10. The carbon filter is usually sized for 10-25 percent of the circulation rate. Several different carbon materials are used for amine systems supplied by major suppliers such as Norit in Europe, Calgon in United States, Takeda in Japan and many others all over the world especially in China. Pumps: The amine booster and reflux pumps are centrifugal, preferably in-line or horizontal, with TEFC (Totally Enclosed Fan Cooled) motors. One hundred percent stand by capacity is recommended. Selection of the circulation pump depends on the contactor pressure and the amine circulation rate. A 50% or 100% standby capacity is normally considered for these pumps. For high pressure low capacity services, reciprocating pumps are used for charge amine pumps, however, centrifugal pumps are widely used for low pressure (~100 psig) and multistage horizontal centrifugal pumps for high pressure (>700 psig) or high circulation rates (> 300 gpm). In sizing and rating pumps a low positive suction pressure (NPSH) of 3-10 psig is used. Motor sizes can be estimated from the amine circulation rate as shown in the table on this slide.

26

Acid Gas Removal: Amine Plant Design (cont.) Key design parameters (cont.)
Control systems
Alarm and shut downs Gas and liquid flow rate, temperature, level, pressure, and differential pressure monitoring and control

Materials of construction
CO2 and degraded-amine corrosion Other corrosion routes (galvanic, crevice, pitting, intergranular, selective leaching, erosion, and stress corrosion cracking-SCC) Oxidation
27

The alarm and shutdown panel can be electronic or pneumatic. In either case a process or safety malfunction shuts the unit down, sounds the alarm horn, and indicates the condition responsible. As a minimum, the following should trigger a plant shutdown: Emergency manual shutdown Treated gas Off spec. Inlet separator High level Lean amine cooler High temperature Reflux condenser High temperature Surge tank Low level Amine reboiler High pressure, High temperature, Flame failure Cooler fans High vibration Amine treating is a proven technology and no special considerations should be taken into account for amine plant process control systems and conventional gas and liquid flow rate, temperature, level, pressure and differential pressure and monitoring and control system can be used. Control Systems: Amine plants manufacturers have extensive experience with Distributed Control Systems (DCS) and Programmable Logic Controller (PLC) and can design, supply and configure the control system to suit each clients control and operating philosophy. The DCS and PLC systems may include major control system suppliers such as Foxboro I/A, Fisher-Rosemount, Moore, Allen-Bradley, Modicon, etc. Human Machine Interface (HMI) systems are also included which may have Wonderware In Touch for PLC systems. The graphical operator interfaces that are supplied with the control systems by these manufacturers allow operators to view and control the process unit(s). All control systems supplied usually have the following capabilities: Control and Alarm Setpoint Adjustments; PID Control Loop Adjustments; Analog Input (4-20 mA); Analog Outputs (4-20 mA); Digital Input (24 VDC); Digital Output (24 VDC); RTD / Thermocouple Input . HMI systems and DCS have the following additional capabilities: Multiply security levels; process data trending; process reports; alarm generation and reports. Construction Materials: A large number of literature reviews exist concerning the types of corrosion that occur in amine plants (see for instance: Understanding corrosion in alkanolamine gas treating plants; DuPart, M.S. (Dow Chemical USA); Bacon, T.R.; Edwards, D.J., Source: Hydrocarbon Processing, v 72, n 4, Apr, 1993, p 75-80; and Reduce corrosion in amine gas absorption columns, Mogul, M.G (Belzona Inc), Source: Hydrocarbon Processing, v 78, n 10, Oct, 1999, 7 pp. Typical corrosion types can be summarizes as: general, galvanic, crevice, pitting, intergranular, selective leaching, erosion, and stress corrosion cracking (SCC). SCC is very important because gas stream containing H2S cause metals to sulfide stress crack. Carbon steel (CS) becomes susceptible when the H2S partial pressure exceeds 0.05 psia at system pressures above 65 psia. Corrosion problems are more severe in MEA systems due to the inherent more corrosive nature of MEA. In considering the susceptibility of steel to SCC the key property is hardness. National Association of Corrosion Engineers (N.A.C.E.) publication MR-01-75 is the leading guideline for specifying the appropriate metal hardness. The two most important procedures used are Brinell Hardness to determine the hardness as BHN and Rockwell C/B number (RC). There are standard ASTM or NACE techniques to measure the hardness based on these procedures. In addition to H2S corrosion, the following factors must be considered: CO2 Corrosion, especially when the rich amine temperature exceeds 150oF. Amine degradation products especially ethylene-diamine and oxazolidone compounds are very corrosive, they will form in high CO2 loading conditions. Limiting CO2 loading (<0.25-0.30) and corrosion inhibitors for high loadings are recommended.; Electrolytic (galvanic) corrosion due to presence of unlike metals in aqueous environment; Oxidation corrosion due to free oxygen in the make up water and feed gas stream; inert gas blanketing in amine storage and surge tanks and de-aerated (boiler feed) water are recommended. Oxygen also causes a different form of amine degradation whose products form heat stable salts which contribute to enhanced corrosion in amine plants.

27

Acid Gas Removal: Amine Plant Design (cont.)

Key design parameters (cont.)
Material of construction (cont.)
Stress relieve all pressure vessels and HXs, piping in sour gas and rich amine service Corrosion allowance: 0.0625 ASME vessels and 0.05 for pipes (CS only) CS (RC-22 or 241 BHN) for shell heads and externals CS for baffles, lugs and clips and other internals SS 300 or 400 series for demister, and tower internals (valves, caps, bolts, etc.) CS (<150oF) SS 300 series (> 150oF) for tube and tube sheets of HXs CS for fire tubes CS for case and SS (300/400) for fluid ends and internals of HP pumps (>200 psig) Ductile iron case and SS (300/400) for fluid ends and internals for LP pumps (<200 psig) Ductile iron impellers for centrifugal pumps, SS 300 impellers for rich amine and temperatures > 150oF CS for general valves and tubing; SS 300 for T> 150oF; SS for feed lines to stripper, stripper overhead, condenser tubes and upper stripper trays Low velocity line sizing (<2-5 ft/sec) Avoid slip-on flanges and cavities in manufacturing DP for amine flow and SS 316 and 316L for most transducers and control instruments and valves
28

For most application the guidelines shown on this slide, for material selection will provide adequate life and good corrosion resistance. Amine systems are extremely corrosive due to acid gas concentrations and relatively high temperatures. It is critically important that all carbon steel (CS) exposed to the amine be stress relieved after the completion of welding on the particular piece including all pressure vessels, heat exchangers if shell and tube, reboilers, coolers, headers and piping in sour gas or rich amine service. A system fabricated from stress-relieved carbon steel for DEA solutions, as per the recommendation in this slide, will not suffer excessive corrosion. For MEA systems, corrosionresistant metals (stainless steel 304) should be used in some particular areas indicated on this slide. Corrosion prone areas in an amine systems are presented here and it is recommended to use SS 304, even for DEA systems, in the following areas: absorber and stripper trays or packing; lean/rich exchanger and reflux condenser tubes; any part of the reboiler tube bundle exposed to vapour phase, reclaimer tubes; pressure reduction valves and pipes leading to flash tank; pipe from the rich/lean exchanger to the stripper inlet. SS cladding is sometimes provided in the lower part of amine contactor and flash tank, especially if the system is designed for high rich amine acid gas loadings. Corrosion allowances indicated are strongly recommended; no corrosion allowance is required for stainless steel parts. Carbon steel with an as welded condition maximum hardness RC-22 is recommended for shells, head, and all externals. Steels of fine grain manufacture are least susceptible to corrosion and should be specified for all pressure containing parts. For internals the material should be compatible with the shell and head material. For wetted part tower internals subject to high velocities, low carbon stainless steel series 300 (e.g., 304L) or 400 series (e.g., AL410S). For heat exchanger and fire-tubes, and pump parts the guidelines shown should be followed. For ordinary (sweet gas and utility lines) valves and piping, carbon steel should be used. It is highly recommended to avoid using ductile or cast iron valves because of lack of impact resistance and tensile strength. When only CO2 is removed, 300 series SS (e.g., 304) for services above 150oF should be used. SS should be used as discussed before for the feed line to stripper, stripper overhead, reflux condenser tubes, and stripper trays, specially the upper ones. All amine lines should be sized for low fluid velocity, e.g., 2 to 5 ft/sec. It is recommended to avoid using slip-on flanges, or other fabrication techniques that provide cavities which collect the corrosive amine solutions. Seal welds should be used to fill in all gaps, e.g., tray support rings. Differential Pressure (DP) cell with SS 316 nozzle or venturi restriction elements are preferred due to lower solid deposition and crevice/pitting corrosion incidents.

28

Acid Gas Removal: Amine Gas Sweetening Plants - Operations

Plant Check Out Clean Out Of Amine Unit Start Up Performance Amine Analyses Amine Loss Make-up Water MakeOptimization
29

Amine plants are far more difficult to operate compared to batch and membrane based units. Accordingly it is important to follow the assembly, start up, and operation procedures. A thorough understanding of the system, function and operation of all equipment should be attained by the operators. For this reason, it is recommended that each operator make a completeness check of the plant and mark off on the Mechanical Flowsheets or P&IDs. Each system should be checked for the following: Plant Completeness Check. (1) before assembly, all received materials should be checked and order placed for damaged items; (2) after the assembly, make sure that the piping begins and terminates at the proper locations, valves are properly located and operable, drains and vents are installed and either valved or plugged, strainers, blinds and spectacle blinds are installed properly, flanges are rated properly, bolted correctly and have gaskets, control valves and relief valves are installed as tagged, Check that valves have been installed properly. Some valves allow flow in only one direction; (3) to prepare the plant for clean ups, blinds should be installed on the inlet gas line to prevent accidental or premature pressurization of the system; (4) Piping and Instrumentation Diagrams (P&IDs) are used to assure that all vessels, valves, instruments, etc. are tagged; interconnecting pipes, tubing, and wiring are clean and correctly installed; and all leads to control panel are functioning; (5) all mechanical equipment should be checked for lubrication, alignment, rotation, etc. Pumps should be packed and filter elements put into filters; ensure that there is sufficient oil present in the engines, compressors, force feed lubrication systems, lubricators and pumps. ensure that sufficient coolant is present in the engine/compressor cooling systems. (6) Pressure, flow, temperature and level instruments should be checked for calibration; (7) Check relief valve settings; ensure that floats or displacers have been installed for all level controls and switches; (8) Vessels, pipes, and pressure containers should be pressure tested using water or clean gas and leaks be repaired; (9) alarms, shutdown systems and safety devices should be checked and understood and assurance be made that settings conform to process design; carefully review the operating instructions for all pieces of equipment and carry out the recommended pre-startup checks (10) location and use of breathing apparatus, fire extinguishers, hose carts, first aid kits, etc. should be reviewed; location of emergency shutdown facilities and their use should be reviewed. Now, blinds can be removed and fuel gas, instrument air, and power supply be established. Cleaning of Equipment and Piping. When the plant was hydrostatically tested by the construction personnel, it should have also been flushed and blown out. Cleaning removes protective oils, valve grease, mill scale, rust, and other contaminants which foul amine solution. The wash-out procedure is very similar to actual start-up and operation. New units should be washed using a soda ash (5 wt.%) or caustic solution (1%) with de-ionized rinse. Used units may need an acid wash to remove rust and sulfide scale (circulation of 9% sulfamic acid plus 1% citric acid plus 6% degreaser in hot water). The cleaning procedure is as follows: (1) the unit is charged with 5% sodium carbonate (soda ash) (or 0.2% caustic soda) solution. Heat up the reboiler to 200oF. (2 Check plunger pumps may leak slowly for lubrication; piston pumps should not leak.); (3) start the reflux condenser fan, increase heating to establish a reflux; (4) Pressurize contactor tower slowly. By pass all filters. Start amine cooler fan and booster and charge pumps (5) vent trapped air from valves at high points; (6) Establish an operating level in the contactor; (7) circulate for six hours; periodically open vessel bottom and piping drains and flush for one minute. Add soda ash as required. (8) shutoff the reboiler, fans and pumps when systems has cooled to 180oF. (9) drain system; use blanket gas to keep air out.; (10) refill the system with de-ionized water; (11) repeat the wash-out procedure; circulate for about eight hours, flushing low points every two hours and observe the cleanliness; (12) if clean, drain sufficient water to add enough amine to obtain the desired solution strength. If water is too dirty, flush completely and fill with proper strength of amine solution; (13) circulate for two hours to mix thoroughly; (14) open the block valves on filters and close by-pass valves. The plant is now ready for start up.

29

Acid Gas Removal: Amine Gas Sweetening Plants - Operations (cont.) Plant Check Out Clean Out Of Amine Unit Start Up Performance Amine Analyses Amine Loss Make-up Water Optimization
30

Plant start up. Before any of the equipment is placed in operation, ensure that the steps described in previous slide, Plant Check Out and Clean Out of Amine Unit, have been carried out. Following the checkout of plant control and shutdown logic, plant electrical system, instrument air system, purging and leak check of all equipment components and piping systems, and charging of all chemicals and lubricants, the plant facilities are now ready to commence startup. Start up procedures are usually provided by the designers and manufacturers of the process equipment. A brief start up procedure may be presented as follows: (1) block valves on process gas flows should be initially closed; (2) Turn on power to electrical panels; make sure all alarms and shutdown signals are operational; (3) start reboiler, fans, reflux pumps, booster and charge (circulation) pumps as described previously in wash out cycles; (4) open the inlet gas valve slowly to pressurize the contactor; keep the flow rate about half of the design flow rate and leave the sales gas line valve closed; (5) check amine solution concentration; (6) circulate until the still overhead temperature at the condenser inlet reaches the minimum operating temperature (usually 190-200oF); (7) open the sales gas valve and increase the gas flow rate to the desired operating rate. Operation may have been manual so far. If every thing is under control and all the parameters are within the range specified by design and operating manuals, switch to the fully automatic mode. None of the safety shut downs should activate. Amine units are usually part of larger plants which may include gas dehydration and dew-point control, sales gas recompression, refrigeration systems, safety and flare systems, utility supply facilities, etc.. Therefore the start-up and commissioning of the amine unit should be synchronized with other processes and units within the entire gas processing facility. Normal Operation/Performance Routine Checks. Daily duties and routine checks including: prepare a daily check list; some of the checks would be as follows: record all pressure and temperature readings and compare to expected operational conditions as well as readings for previous daily reports; check inlet filter/separator, amine contactor, and regenerator P readings. As well, observe lean/rich exchanger pressure drops on both sides of the plate/frame or shell and tube exchanger; look for sudden increases in differential pressure; check all fluid levels: inlet filter separator bottom section, amine contactor, sweet gas scrubber, flash tank, reboiler surge section; check and record temperatures and pressures in all equipment; record ambient temperature; check the steam rate, amine reboiler temperature, and pressure; check amine reflux condenser temperatures, lean amine cooler temperatures; check amine concentration; check carbon and mechanical filter P readings; check additives (e.g., antifoam) injection pump discharge pressure, pulsation, observe for vibration, and check lubrication of gearbox and packing; check booster and reflux pump discharge pressures; check operation of lean amine cooler/condenser air-coolers louvers; check H2S analyzer, check acid level, tape supply; check and record amine flow; add make-up water as required; add amine with the appropriate strength as required. Weekly Checks including: check operations of amine reboiler controls and shutdowns and adjust accordingly; check all recorders and calibrate if required; check all underground drain tank levels. check amine concentration; acid gas in feed and sales gas should be checked daily during the first two weeks and thereafter weekly checks should be performed; perform amine foam test as required.

30

Acid Gas Removal: Amine Gas Sweetening Plants - Operations (cont.) Plant Check Out Clean Out Of Amine Unit Start Up Performance Amine Analyses Amine Loss Make-up Water Optimization
31

Typical operating ranges are as follows: (1) rich amine upstream of stripper: P= 40-80 psig, T= 100-180oF; (2) amine exchanger, rich side :Tin=100-180oF, Tout=190-220oF, lean side Tin=240-250oF, Tout=170-190oF; (3) amine cooler: Tin=170-190oF, Tout=100-130oF; (4) reflux condenser: Tin=190-225oF, Tout=100-130oF; (5) reflux pump: Ps= 4-6 psig, Pd= 30-40 psig; (6) booster pump: Ps= 4-6 psig, Pd= 50-65 psig; (7) amine charge pump: Ps= 5-40 psig, Pd= 50 psig over contactor operating pressure. Amine Analysis. The colour of the regenerated solution can be most informative: light brown: good condition and well regenerated; green: very fine FeS particles (<1micron) larger FeS particles are black and will settle; blue, green: copper or nickel, copper oxide reacts with MEA to form a light blue complex (very unlikely in DEA plants); orange and dark red: iron compounds complexed with amine; red, brown: either oxidation or thermal degradation. Primary amine may smell like ammonia; secondary amine smell like a wet ash-tray. The following analysis may be used to determine the condition of the amine. For procedures and interpretation consult the Dow Gas Conditioning Fact Book (1962). Alkalinity titration for amine concentration; gas chromatography (GC) for free amine and degradation products, acid gas content; total and primary nitrogen; acid gas loading; Karl Fischer for water content; Elemental analysis by atomic absorption (AA) or iron, chlorine, aluminum, copper, sodium, etc.; foam test for extent and strength and stability of foam. Amine Loss. There are two types of day-to-day losses: those that are an integral part of the process and those due to leaks, spills, and mishandling. Sometimes the mishandling is much larger than the process losses. There are also upsets (e.g., foaming in the contactor) and contamination (e.g. inlet separator dumps produced water into the contactor). Process losses include the following: (1) sweet gas from the contactor: MEA is volatile enough to result 0.45 lb/MMscf of process gas; DEA, DGA, DIPA and MDEA are much less volatile and the losses are 0.02 to 0.03 lb/MMscf (2) Entrainment from the contactor: this averages 0.5 to 3.0 lb/MMscf. Entrainment losses can be reduced by operating at 70% of the flooding velocity and installing a demister in the top of the tower. Water wash trays above the top tray are the most effective solution. (3) gas from the flash tank and liquids from a three phase tank: these losses are very small (4) reflux overhead gas: these are very small because the vapour and liquid do not contain much amine. Reclaiming: this loss depends on how often the primary or secondary amines are reclaimed. Usually between 5-15% of the total amine inventory in the plant is lost in every reclaiming exercise. Amine consumption for a well designed and operated with few upsets averages 2 lb/MMscf for DEA, DIPA, and MDEA. Losses for MEA are about 3 lb/MMscf because of the volatility and reclaiming. DGA losses are intermediate. Makeup Water. This replaces operating losses from the contactor the sweet gas is hotter and therefore more humid than the sour gas and the off gas from the reflux condenser. Periodic additions suffice for small units. Continuous addition is recommended for larger units especially when acid gas rate is high. The makeup water may be combined with the reflux to the stripper or fed to wash trays in the top of contactor tower. Makeup water may contain contaminants that accumulate in the unit and so cause foaming, corrosion , plugging, and fouling. Makeup water should meet the following specifications: 20 ppm chloride, 100 ppm TDS (total dissolved solids), 50 ppm total hardness, 10 ppm sodium/potassium and 10 ppm iron.

31

Acid Gas Removal: Amine Gas Sweetening Plants - Operations (cont.) Plant Check Out Clean Out Of Amine Unit Start Up Performance Amine Analyses Amine Loss Make-up Water Optimization and Trouble shooting
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A very good articles published by Abry and DuPart (Dow Gas/Spec Technology group) gives guidelines for optimizing an amine plant based on historical plant data and how to cut costs, use less amine and reduce corrosion see Amine Plants Troubleshooting and Optimization; Abry R.G.F. and DuPart, R.S.; Source: Hydrocarbon Processing, v 74, n 4, Apr, 1995, p 41-50). Authors report how the process information is designed to circumvent upsets and to facilitate control. The authors also show how this plant data can be used to optimize the facility if operated away from design conditions. The optimization presented in this reference considered a decrease in inlet gas flow rate with the same concentration of acid gas components. Most operating companies usually exceed design inlet gas flow rates with higher concentration of acid gas components, therefore their analyses are somewhat unrealistic and perhaps overly optimistic. Note that the larger the unit, the greater is the need for optimization. The weekly amine analysis is most informative as most amine problems are triggered by contaminated solutions. Amine concentration should be closely watched too high (>35% for DEA, 30 % for MEA and 50% for MDEA and DGA) increases the corrosion rate, and too low (<25% for MEA and DEA and <35-40% for MDEA and DGA) increases the circulation rate and wastes fuel. Acid gas loading is also very important rich stream too high (>0.35 for most amines) increases the corrosion rate, and too low indicates (<0.2) inefficient use of amine and too high a circulation rate. Lean stream too high indicates (>0.1) poor regeneration and too high a circulation rate, and too low (<0.001) means unnecessary regeneration and fuel usage. pH should also be checked too low add soda ash. Makeup water quality should be checked regularly, as it is a major source of contaminant introduction to amine solutions. The reflux ratio is usually not measured. However, it should be checked and monitored carefully. The optimum values depend on the amine system. Keeping the regenerator overhead temperature below 225oF and the reflux condenser effluent near 130oF is recommended. Check also the temperature approach of the lean/rich amine heat exchanger. Departure from design and/or startup condition denotes fouling. Once again, amine solution quality is very important as most amine plants work fairly well hardly with any problems with clean solutions. Amine degradation products (both DEA and MEA) play a major role in amine plants problems. They increase viscosity of the solution and therefore affect the power requirement to transport the liquid, most of them are corrosive and hence are a precursor to particle formation and fouling. Amine degradation reduces amine concentration (strength) and therefore causes a rise in amine circulation rate. The reduction of amine strength by formation of degradation products is not detectable by simple alkali titration techniques or nitrogen content tests as amine degradation products are amine themselves. Accurate gas chromatography is the only way by which these compounds may be identified and measured. Amine solutions should have identification chart in which weekly amine regular test results are carefully recorded and examined. Continuous increase in amine degradation products, heat stable salts, dangerous ions (e.g., Na, Cl, etc.), and foaming behavior are symptoms of an ill solution. Sources of contaminants should be identified and the problem should be treated accordingly. Sometimes, there is no solution to the problems and the solvent should be changed or reclaimed completely. Large gas sweetening plants are recommended to reclaimed their solutions regularly (e.g., once in one or two year continuous operation). Some plants may need more frequent reclamation depending on the nature of the gas entering to the plant and choices of equipment and other operational parameters including rich amine acid gas loading, lean/rich amine exchanger effluent temperatures, and reboiler performance.

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Acid Gas Removal: Amine Gas Sweetening Plants - Operations (cont.)

Troubleshooting
Gas is not sweet Amine solution not regenerated Dirty, degraded amine Excessive corrosion Foaming of amine solution Sulfur is present in amine loop Too much solid accumulation Amine changes color continuously
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1.

2.

3.

Gas is not sweet Amine solution conc. is too low Amine flow rate is too low Insufficient amine regeneration; increase steam rate Reflux rate and temp. are too low; increase steam rate Too high stripper pressure Foaming in contactor and liquid carry over to outlet separator Amine solution not regenerated Reboiler temp., pressure and reflux ratio not are at design Leaks in amine lean/rich HX Foaming in stripper Too high stripper pressure broken trays and packing (due to sever corrosion) Dirty, degraded amine Gas contain oxygen Faulty inert blanketing in amine surge and storage tanks Contaminated makeup water (free oxygen); sparge amine with sweet gas to strip oxygen. Oxygen can enter when the fed gas contains vapour recovered from stock tanks, and can oxidize H2S to elemental sulfur. Too high rich amine acid gas loading (especially CO2) Inadequate circulation in reboiler (thermosyphone, due to reboiler inlet/outlet plugging)

4.

5.

Excessive corrosion Amine concentration is too high Amine is highly degraded; replace or reclaim Makeup water is contaminated (check chlorine and oxygen content) Insufficient amine regeneration Insufficient amine filtration; increase filter rate or change filter elements Oxygen is present; eliminate Fluid velocities are too high Temperature to stripper too high Foaming of amine solution Dirty amine (too much solids) Degraded amine Liquid HC in gas or amine Inlet gas temperature too low (HC cond.) Lean amine temp. too low(>10oF above inlet gas) Wrong or off spec. chemicals (amine, antifoam, etc.) Surfactants and corrosion inhibitors Very fine particles in gas and amine Inadequate cleaning before startup Too much or too little antifoam Contaminated makeup water Add antifoam always downstream of carbon filters Cotton-sizing chemicals or small carbon particles being washed off a newly installed cloths and/or carbon filter Incoming gas contains salt or produced water and very fine particles

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Acid Gas Removal: Amine Gas Sweetening Plants (cont.) - Operations Case Studies Troubleshooting
Gas is not sweet Amine solution not regenerated Dirty, degraded amine Excessive corrosion Foaming of amine solution Sulfur is present in amine loop Too much solid accumulation Amine changes color continuously

Climate adjustment (winterization, heat and humidity consideration)

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6.

7.

8.

9.

Sulfur is present in amine loop (Khangiran - Hashemi Nejad gas plant, Iran) Polysulfide and fine sulfur in the gas (better inlet filtration, amine reclamation, and sulfur wash at wellhead with sulfur solvents) Dissolved oxygen in amine Too much solid accumulation (Kangan- Valieasr gas plant, Iran) Corrosion rate is high - corrosion product accumulation: reduce rich amine loading, degradation products high; reclaim solution Inlet gas contains very fine particles; better inlet filter cartridge (<0.1 micron, inlet gas water wash) Amine changes color continuously (Bandar Imam - new amine unit, Iran) Troubled thermosyphone reboiler Sever corrosion, plugged stripper line to reboiler Plugged reboiler inlet /outlet lines High acid gas loading (>0.7) Insufficient stripping (broken trays; carbon steel trays were used Reclamation is required Sulphate depositing in reboiler (South Pars Gas Facilities) Check make up water quality Check inlet separator (produced water or MEG mix to the contactor)

Amine units should also be adjusted for different climates. For cold climates they are winterized which includes: (1) extra insulation for already insulated equipment and insulation of equipment not normally insulated (e.g., contactor tower); (2) air-recirculation louvers on air-coolers; (3) Heat tracing of the amine piping and stagnant ports, e.g., level gauges, external float gages, switches and controllers. Heat may be electric, steam ,hot oil, etc.; (4) frost protection in foundation design to prevent movement; and (5) some manufacturers prefer to erect a building around the equipment, then only uncovered equipment needs special protection. This of course would be very difficult for very large plants. In very hot areas (Southern US or the Middle East, the air coolers in the very hot and humid summer days are the major problem makers. High design air temperatures and higher design factors are usually used for these heat exchangers. Humidity creates major corrosion problems on the exterior of process equipment. High quality coatings are needed for most process equipment. Cooling and lubricating systems on prime movers and electrical motors need extra attention during hot summer days. Therefore the designer should always keep an eye on the climate when the design phase is completed. * There are a number of very good technical papers at Brian Research and Engineering (BR&E) web site (http://www.bre.com/technicalpapers/technicalpaper-home.asp) concerning the design and simulation of gas conditioning processes.

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