IJISET - International Journal of Innovative Science, Engineering & Technology, Vol.

3 Issue 8, August 2016

ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
www.ijiset.com

Energy Recovery Opportunity at Natural Gas Regulating

Station by replacing Pressure Control Valve with Turbo
Expander using Aspen HYSYS: A case study of WAH
SMS (Sale Metering Station)
Saif Ul Islam ( Khattak.saif@gmail.com), Iftikhar Ahmed (miftikhar74@gmail.com), Zaki Ud Din
(zaki.ee@suit.edu.pk)
University of Engineering and Technology Peshawar / Peshawar/ Pakistan

Abstract In this research work, a case study of a gas regulating

World energy crisis make it essential to recover the energy station / city gate station located at WAH, Pakistan
which is normally wasted in the industrial process [1]. We within the gas transmission network of Pakistan’s
can refer to the gas transportation, the process in which largest natural gas transmission and distribution
energy is wasted during pressure reduction in city or power
company namely Sui Northern Gas Pipelines,
plant. Gas pressure reduction is accomplished through
Limited (SNGPL) has been presented and it has been
regulators or throttle valves. In this research work, a model
proposed that this pressure reduction of gas can do
for turbo expander is presented for achieving pressure
reduction as well as energy recovery goals. In this regards, ‘useful ‘work if passed through turbo expanders
WAH SMS (Sale Metering Station) is consider as case coupled with electric generators.
study for Energy Recovery option at Natural Gas Pressure It has been observed that as the power extracted from
Letdown station. turbo expander is increased (using oil brakes or
electric generator), the gas temperature is reduced
1. Introduction sharply for a constant gas flow and gas pressure
A natural gas transmission company (or a pipeline reduction. The maximum extractable power from
operator) has several natural gas regulating stations turbo expander therefore depends on the minimum
or city gate stations or sales metering stations (SMSs) allowable temperature of gas at outlet of turbo
within its pipeline network which are used for expander which is the hydrocarbon dew point
pressure reduction and custody transfer / selling of temperature. Using dynamic simulation in Aspen
natural gas to distribution companies. These HYSYS, the maximum extractable power has also
regulating stations are sometimes used to transfer been calculated.
large volumes of natural gas ranging from 1 MMscfd
to 500 MMscfd while the gas pressure is reduced to The temperature of gas at outlet of turbo expander
about 50 to 100 Psig at these stations as per demand should be kept above the hydrocarbon dew point
of gas distribution companies, from an inlet pressure temperature in order to eliminate fiscal loss through
of about 500 to 1000 psig. conversion of the sale gas into NGL.

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ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
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The gas distribution network have several “Town inlet and outlet temperature are assumed 3 deg C for
Border Stations” (TBS) at various localities within simulation. The preheated gas temperature at inlet of
the city where the gas pressure is also reduced to turbine is 71.3 deg C and its output power is 1367
about 10 to 20 psig from 100 to 150 psig. However, Kw[4].
the volume of gas is usually very small usually less Ramin Taheri Seresht et.al, focus on the waste
than 1 MMscfd, so, it is not feasible to produce recovery in oil, gas and petrochemical industries in
useful work using turbo expanders. which large amount of energy is wasted. In this
paper, it has been suggested to use expansion Turbine
2. Literature Review for achieving pressure reduction, as well as energy

Previously work done in this field has recovery goals. In this regard, Tehran City Gate

mainly emphasized on the recovery of wasted energy Station No.2 which is one of the large natural gas

at the regulating stations / city gate stations / sale pressure reducing stations in Iran (both from capacity

metering stations. Here, the summary of the different and inlet pressure perspectives), has been selected as

researchers is elaborated in detail. a case study. In first step waste of energy was
calculated by using energy analysis and in second
Mehdi Taleshian et.al presents a model for turbo-
step, by using expansion turbines that are used
expander to reduce the gas pressure and recover the
parallel in the station for achieving the goals of gas
wasted energy. They proposed a model which utilizes
reduction pressure and power recovery was simulated
an online calculation method is more efficient and
in four scenarios by Thermoflow1 software. The
simpler than the older offline model which surmounts
results show undeniable fact that the Energy loss at
the need for making complicated lookup tables prior
this station has been 38,443,578 KWh for a year. As
to calculation. Because of instantaneous varying of
a result of using turbo expander , the energy recovery
domestic consumptions, environment temperature
will be 96% [5].
and other effective parameters, turbo-expander inlet
Bryan Lehman and Ernst Worrell, Give an overview
gas pressure and mass flow-rate vary with time and
of expansion turbines and their use. In this paper,
consequently the extracted power has time variant
three cases were analyzed and estimate the potential
specification. and causes some power quality issues
for expansion turbine use in the U.S. and find that
such as voltage flicker, voltage sag, etc. So, this
expansion turbines have the potential to generate a
system is simulated and power quality issues are
theoretical maximum of 21 TWh in industrial and
investigated for a fault occurring at the point of
utility settings, recovering 11% of natural gas
common coupling (PCC)[3].
transport energy as electricity. Two case studies
Jaroslav Pozivil , use the expansion turbine in place
were performed in the Netherlands, and one in Japan.
of throttle valve for the recovery of wasted energy. In
One of the projects in the Netherlands uses a gas
this paper Velke Nimcice transmitting station data is
pressure drop to generate power for the utility grid,
used for simulation and to avoid the hydrate zone and
while the other generates power for onsite use. The
dew point inlet gas to turbine is preheated. Gas
project in Japan utilizes the pressure and temperature
condition, flow rate 51 MMscfd (60000 Nm3/h), the

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ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
www.ijiset.com

drop of expanding gas in a district heating and place of the throttle valve. The energy in the gas can
cooling facility both to generate power and to cool be used to produce electricity. The work the gas
water [6]. performs is gained from its enthalpy and the gas
Shoaib Khan Mohammadi et.al, This paper deals with cools rapidly in the turbine. From thermodynamics
thermodynamic modeling, parametric analysis and relations involving enthalpy, entropy and also by
optimization of a novel integrated system to recover using the first law of thermodynamic [8].
energy from pressure reduction in city gate station Sepehr Sanaye and Amir Mohammadi Nasab ,
(CGS). This research cover thermodynamic modeling present in their paper that, for longer distances,
of a hybrid system includes a turbo expander, an natural gas is transported through transit pipeline at
organic Rankine cycle (ORC) and a Proton Exchange high pressures. In a place of consumption or at
Membrane (PEM) electrolyzer to produce electricity passing into a lower pressure pipeline, the pressure of
and hydrogen. The pressure of natural gas in the gas must be reduced. In Iran, the common
transmission pipeline in Iran gas system is high about procedure of reducing pressure in natural gas station
7MPa. Since, near the cities pipeline pressure should is using expansion valves, which causes the waste of
be reducing to 1.7 MPa, there is a great potential to large amount of energy. Combined heat and power
recover energy to produce electricity and other (CHP) systems have many economic and
energy products. In the proposed integrated system in environmental benefits. In this paper a CHP system
this paper, a comprehensive parametric analysis which its prime components are boiler, expander,
include the effect of main parameters such as natural pump, heat exchanger and gas engine, is used in a
gas preheat temperature, the natural gas pressure inlet pressure reduction station to produce electricity. A
to turbo expander, the heater mass fuel flue rate and new and relatively quick method for selecting the
high temperature of ORC on the system performance number of each type of prime component, and
is investigated [7]. determining their nominal power and their efficiency
Ebrahim Khalili Ardali and Esmaeil Heybatian, in is also presented [9].
this research paper city gas station of Iran is consider Bronicki et.al present in their paper that,An energy
for the potential of electrical energy recovery through recovery, pressure reducing system for reducing high
expansion turbine. Gas pressure reduction is pressure gas in a transmission pipeline to a low
accomplish through throttle valves, where the pressure gas in a consumer pipeline includes an
isenthalpic expansion takes place without producing expander system having at least one expander for
any energy. A non-negligible amount of pressure expanding the high pressure gas and producing work
energy is wasted in that irreversible process and and low pressure gas that is supplied to the consumer
throttling of natural gas lowers its potential energy. In pipeline, and a generator coupled to said expander for
this paper we have evaluated this work. One converting the work to electricity which is supplied
computer simulation was developed to study and to an electrical load. The system further includes
calculate the exact values of some parameters when apparatus including an on/off valve serially
an expansion turbine driving a generator is used in connected to a pressure regulating valve, the

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ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
www.ijiset.com

apparatus being connected in parallel with the remainder of gas fuel for combustion in a steam
expander system. The on/off valve has an open state generator[11].
for effecting transmission of gas through the pressure
regulating valve which has an adjustable flow control 3. Turbo Expander
opening for throttling high pressure gas and Turbo expanders are expansion turbines, rotating
producing low pressure gas when the on/off valve is machines similar to steam turbines. Commonly the
in its open state; and a closed state for preventing terms “Expansion turbines” and “turbo expanders”
transmission of gas through the pressure regulating specifically exclude steam turbines and combustion
valve. A control system is provided which is gas turbines. Turbo expanders can also characterized
responsive to flow through the expander system for as modern rotating devices that convert the pressure
controlling the size of the flow control opening and energy of a gas or vapor stream into mechanical work
the state of the on/off valve[10]. as the gas or vapor expands through the turbine. If
Bloom et.al, This paper deals with a gas expander chilling the gas or vapor stream is the main objective,
based power plant system for generating electricity at the mechanical work so produced if often considered
a pressure reducing station of a gas transmission a byproduct. If pressure reduction is the main
pipeline is disclosed where gas at high pressure is objective, then the heat recovery from the expanded
being delivered to the distribution or gas utilization gas is considered a beneficial byproduct.
system; by means of pressure reduction with a gas In each case, the primary objective is the turbo
expander system capable of accommodating expander is to conserve the energy by recovering
fluctuating high pressure gas conditions and from cold gas or hot gases at temperature above 1000
maintaining desired lower pressure gas conditions, degrees.
which comprise the steps of generating steam,
condensing the steam in a heat exchanger and using 4. Turbo Expander for Energy
the heat of condensation of the steam to heat a Conservation
portion of high pressure gas in a controlled manner to
A considerable amount of energy can be recovered
maintain the required gas conditions of the lower
by using low grade waste heat, process gas or waste
pressure line throughout the range of operation, and
gas pressure letdown. Centrifugal turbo expanders are
passing the high pressure gas through a gas expander
well adapted to such energy conservation scheme.
to drive an electrical generator. In one embodiment of
For many years turbo expanders has been used in the
the system, a portion of the gas fuel supplied to a
cryogenic processing plants to provide low
steam generator is utilized as a motive gas supply for
temperature refrigeration. Power recovery has been
a gas ejector which creates a vacuum in the shaft
second importance. Turbo Expander are mainly used
sealing chamber of the gas expander, evacuates the
in low pressure air separation plants, expanding
leakage gas thereby preventing the release of gas to
down from 5 bar, and in hydrocarbon processing
the surrounding, and combines evacuated gas with
plants, expanding natural gas from as high as 200 bar.
The air separation expanders are roughly divided into

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ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
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two types. The first type ranges from a few

horsepower up to 100 hp. Here, the expander power
is too small to be recovered and is, therefore, 5. Average Natural Gas
absorbed by an oil brake or similar device. The Composition at SMS WAH
second type ranges from 100 hp to over 2000 hp,
where the power is used to drive electric generator or
process booster compressor.
The turbo expander used in the power recovery has
very simple cycle as shown in the figures below. The
cycle configuration involves the removal of solids or
liquids ahead of the expander, and often the incoming
stream is heated so its temperature will not reach its
frost point at the discharge. This addition of heat also
increases the amount of available power.
Figure 3 Average Natural Gas Composition at WAH SMS

The figure 3 shows the composition of gas stream of

WAH SMS.

6. Hydrocarbon Dew Point Curve of

Natural Gas

Figure 1 Power recovery cycle using turbo expander

Figure 4 Hydrocarbon Dew Point Curve of Natural Gas

The figure 4 helps us identify the

minimum temperature that should be at
the outlet of turbo expander in order to
avoid condensation of heavier
hydrocarbons (and hence minimize
fiscal loss).
The gas pressure at the outlet of SMS at
Figure 2 Simplified binary geothermal cycle using power WAH is to be kept at 78 psig due to
expansion turbine

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ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
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operational requirement for time period table below shows the minimum flow rate of 10
under study. At this pressure, the MMscfd at night, 20 MMscfd at day time and 25
condensation temperature is about 4 MMscfd during the peak hours.
Deg. F. Therefore, the temperature at Table 2 Average Natural Gas Pressure at SMS WAH
the outlet of turbo expander should be
above 4 Deg. F. In this case study, it has Avg Gas Pressure Pressure (PSIG)
been found that, for the constant gas
flow and pressure reduction at the SMS, Average gas pressure at 75 - 80

the gas temperature reduces in d/s of SMS WAH

proportion to the power extracted from

Average gas pressure at 400 - 500
the turbo expander. Details of this
u/s of SMS WAH
calculation along with the simulation
snapshots have been mentioned at a
later part in this report. The table below shows the average upstream and
downstream pressure of gas at WAH SMS. The
7. Average Natural Gas Flow rate at average upstream pressure at WAH SMS remains in
SMS WAH the range of 400 ~ 500 Psig, and the downstream
pressure remains in the range of 75 ~ 80 Psig.
Table 1 Natural gas flow rate at SMS WAH

Avg/Min/Max Flow Rate of Flow rate of gas 8. Present Operational Scheme

Gas (MMSCFD)

Average gas flow during 24

20
hours

Minimum gas flow (in the

10
night)

Maximum gas flow (in the

25
peak hours)
Figure 5 Present Operational Scheme at WAH SMS

The table below shows the average, minimum and

maximum flow rates of gas at WAH SMS during
day, night and during peak demand time. The flow
rates variants with the demand of consumer. At day
time the demand of the consumer is high while at the
demand became decrease. Also, there are certain
hours where the gas supply demand increases. The

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ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
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1.1 Proposed Operational Scheme 1.2.1 Scenario-1

- For power extracted = 100 hp,
- Gas temperature at turbo expander outlet =
32.5 Deg. F

Figure 4-1 Proposed Operational Scheme for Scenario - 1

Figure 6 Proposed Operational Scheme at WAH SMS
1.2.2 Scenario-2
1.2 Effect of Increasing the Power
In the below simulation a scenario is discussed in
Extracted from Turbo Expander (using which 200 hp power is recovered at 18.7 deg F outlet
oil brakes or electric generator load) temperature. The inlet parameters are; temperature,

As the power extracted from turbo 73.68 Deg F, Pressure, 466.8 Psig and flow rate is

expander is increased using oil brakes 19.0 MMscfd.

or electric generator load, the pressure Table 4-3 Inlet Parameters for Scenario -
drop (and hence temperature drop)
2
across the turbo expander is increased.
Whereas the gas flow rate across the Inlet Parameters Readings
turbo expander remains the same (as it Temperature 73.68 deg F
depends on the consumer requirement Pressure 466.8 Psig
in the distribution network and it varies Flow 19.0 MMscfd
throughout the day and becomes
minimum at night at few SMSs).The
Table 4-4 Output Parameters for
isentropic efficiency of the turbo Scenario-2
expander has been considered as 75 %
Output Parameters Readings
in the simulation.
Turbo Expander outlet 18.7 Deg F
temperature
Below are few snapshots of the
Recovered Power 200 Hp
simulation in Aspen HYSYS Dynamics,
showing effect of increasing power
extracted on inlet/outlet conditions
across the turbo expander,

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Table 4-7 Inlet Parameters for Scenario-4

Inlet Parameters Readings

Figure 4-2 Proposed Operational Scheme for Scenario-2 Temperature 73.68 deg F
Pressure 466.8 Psig
1.2.3 Scenario-3 Flow 19 MMscfd
In the below simulation a scenario is discussed in
Table 4-8 Output Parameters for Scenario-4
which 300 hp power is recovered at 4.8 deg F outlet
Output Parameters Readings
temperature. The inlet parameters are; temperature,
Turbo Expander Outlet -8.2 deg F
73.68 Deg F, Pressure, 466.8 Psig and flow rate is
Temperature
19.0 MMscfd.
Recovered Power 400 Hp
Table 4-5 Inlet Parameters for Scenario-3

Inlet Parameters Readings

Temperature 73.68 deg F
Pressure 466.8 Psig
Flow 19.0 MMscfd

Table 4-6 Output Parameters for Scenario-3

Output Parameters Readings

Figure 4-4 Proposed Operational Scheme for Scenario-4
Turbo Expander outlet 4.8 deg F
Temperature 1.2.5 Scenario-5
Recovered Pressure 300 Hp In the below simulation a scenario is discussed in
which 500 hp power is recovered at -21.6 deg F
outlet temperature. The inlet parameters are;
temperature, 73.68 deg F, Pressure, 466.8 Psig and
flow rate is 19.0 MMscfd.

Table 4-9 Inlet Parameters for Scenario-5

Inlet Parameters Readings

Temperature 73.68 deg F
Figure 4-3 Proposed Operational Scheme for Scenario-3
Pressure 466.8 Psig

1.2.4 Scenario-4 Flow 19.0 MMscfd

In the below simulation a scenario is discussed in Table 4-10 Output Parameters for Scenario-5

which 400 hp power is recovered at -8.2 deg F outlet Output Parameters Readings
temperature. The inlet parameters are; temperature, Turbo Expander outlet 500 Hp
73.68 deg F, Pressure, 466.8 Psig and flow rate is Temperature
19.0 MMscfd.

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Recovered Power -21.6 Deg F 1.3 PCV in operation at SMS WAH

In the below screenshot, the part of a slightly
modified simulation (through addition of pipe
segments) between inlet and outlet of SMS has been
shown. Moreover, only the operation of PCV has
been shown in it.

Figure 4-5 Proposed Operational Scheme for Scenario-5

1.2.6 Scenario-6
In the below simulation a scenario is discussed in
which 600 hp power is recovered at -35.0 deg F
outlet temperature. The inlet parameters are; Figure 4-7 PCV in Operation at WAH SMS
temperature, 73.68 deg F, Pressure, 466.8 Psig and
1.1. Turbo expander in
flow rate is 19.0 MMscfd.
parallel operation with
Table 4-11 Inlet Parameters for Scenario-6
PCV at SMS Wah
Inlet Parameters Readings During normal operation, the turbo expander cannot

Temperature 73.68 deg F be used independently because the gas flow keeps on

Pressure 466.8 Psig changing throughout the day with maximum gas flow

Flow 19.0 in the afternoon and minimum gas flow at mid night.
At SMS WAH, the average gas flow is 20 MMSCFD
Table 4-12 Output Parameters for Scenario-6
and the simulation of turbo expander in parallel
Output Parameters Readings operation with PCV, has been performed at the
Turbo Expander Outlet 600 Hp average gas load using Aspen HYSYS.
temperature 1.1.1. For 300 hp extracted from
Recovered Power -35.0 deg F Turbo expander
The gas temperature at outlet of turbo expander = 4.9
Deg. F

Figure 4-6 Proposed Operational Scheme for Scenario-6

Figure 4-8 Turbo Expander in Parallel with PCV

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1.1.2. For 250 hp extracted from Figure 4-11 Throttling valve at suction of Turbo Expander

Turbo expander The HYSYS simulation was therefore, modified to

The gas temperature at outlet of turbo expander =
include the speed controller and the turbo expander’s
12.0 Deg. F
operating curve generated using HYSYS. Below is
the snapshot of the simulation before generating the
performance curves of the expander in HYSYS,

Figure 4-9 Turbo Expander in Parallel with PCV for 250 hp

1.1.3. For 200 hp extracted from

Turbo expander
The gas temperature at outlet of turbo expander =
19.0 Deg. F.

Figure 4-12 Speed Control of Turbo Expander

In this HYSYS simulation, keeping the expander

speed constant at 10000 rpm, the power extracted is
increased and the performance of the speed controller
Figure 4-10 Turbo Expander in Parallel with PCV 200 hp is assessed. The flow coefficient or conductance of
the suction throttle valve of the expander has been
1.4 Speed Control of Turbo Expander
assumed to be 100 (USGPM of water at 60 Deg. F
The simulations of turbo expander above are very with 1 psi dP across the valve). Below are the
simplified ones. In actual practice, a control valve is simulation snapshots,
installed at suction of turbo expander which restricts
gas flow rate in order to control gas flow rate and 1.4.1 For 26 hp Power extracted from
hence speed (rpm) of turbo expander. Turbo expander
Table 4-13 26 Hp Power Extracting from Turbo Expander at
20.11 % Opening of Suction Valve

Description Readings
Suction Valve Opening 20.11 %
Suction Gas Actual Flow 448.1 ACFM

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rate 1.4.3 For 40 hp Power extracted from

Suction Gas Molar Flow 5.68 MMscfd Turbo expander
Rate
Table 4-15 40 Hp Power Extracting from Turbo
Discharge Gas 13.3 deg F
Expander at 24.15 % Opening of Suction Valve
Temperature
Description Readings
Suction Valve Opening 24.15 %
Suction Gas Actual Flow rate 527.1 ACFM
Suction Gas Molar Flow Rate 6.82 MMscfd
Discharge Gas Temperature 10.6 deg F

Figure 4-13 Suction Valve opening at 20.11 %

1.4.2 For 30 hp Power extracted from

Turbo expander
Table 4-14 30 Hp Power Extracting from Turbo Expander at
21.34 % Opening of Suction Valve

Description Readings
Suction Valve Opening 21.34 %
Figure 4-15 Suction Valve Opening at 24.15 %
Suction Gas Actual Flow 472.9 ACFM
rate 1.5 Conclusion
Suction Gas Molar Flow 6.03 MMscfd In this report, a preliminary study has been
Rate carried out to assess the potential of energy
Discharge Gas 12.4 deg F recovery at a city gate station of SNGPL
Temperature using dynamic simulation in Aspen HYSYS.
It has been observed that an electric power
of up to 180 kW (300hp
x0.746x0.80=180kW) based on 80 %
conversion efficiency can be produced by
installing a turbo expander at the city gate
station without any fiscal loss through
condensation of natural gas at the outlet of
Figure 4-14 Suction Valve opening at 21.34 %
turbo expander.

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no. 1, pp. 62–70.

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[11] D. M. Bloom, M. Park, and M. Hill, “United
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[3] M. Taleshian, H. Rastegar, and H. Askarian

Abyaneh, “Modeling and Power Quality
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[4] J. Poživil, “Use of Expansion Turbines in

Natural Gas Pressure Reduction Stations,”
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[5] R. T. Seresht, H. K. Jalalabadi, and B.

Rashidian, “Retrofit of Tehran City Gate
Station ( C . G . S . No . 2 ) By Using,” no. 2,
2010.

[6] B. Lehman and E. Worrell, “Electricity

production from natural gas pressure
recovery using expansion turbines,” Proc.
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[7] S. Khanmohammadi, P. Ahmadi, and A.

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[8] E. K. Ardali, E. Heybatian, B. Province, and

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[9] A. M. Nasab, “Modeling and optimization of

a natural gas pressure reduction station to
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