Natural Gas Dehydration Process Simulation and Optimisation A Case Study of Jubilee Field
Natural Gas Dehydration Process Simulation and Optimisation A Case Study of Jubilee Field
Marfo, S.A., Opoku Appau, P., Morkli, C. and Issah, S. (2020), “Natural Gas Dehydration Process Simulation
and Optimisation - A Case Study of Jubilee Field”, Proceedings of 6th UMaT Biennial International Mining and
Mineral Conference, Tarkwa, Ghana, pp. 127-136.
Abstract
Natural gas, a naturally occurring fossil fuel has become a popular energy source in recent years due to its environmental
merit over alternate fossil energy sources. However, a challenge associated with produced natural gas is saturated water
vapour among other impurities. These must be removed by gas treatment processes to prevent problems such as hydrate
formation, corrosion and other threats to process facilities. Employing Triethylene glycol (TEG) as a liquid desiccant, a
dehydrating plant for natural gas obtained from Jubilee Field was designed and simulated using Aspen HYSYS software.
The model of the plant was used to investigate the effect of varying TEG flow rate, reboiler temperature and number of
stages of the packing column in the contactor on dry gas water content. The study revealed that a TEG flow rate of 0.5 m³/hr
was sufficient to dehydrate a 240 MMSCFD from 37.98 lb/MMSCFD water content to 4.84 lb/MMSCF of water in the dry
gas stream with 8 contacting stages at reboiler temperature of 204.4 °C.
Keywords: Natural Gas, Jubilee Field, Simulation, Aspen HYSYS, Triethylene glycol (TEG)
1 Introduction market, the demand for natural gas has created the
need for more facilities for the production,
Natural gas is a naturally occurring fossil fuel used
processing and transportation of natural gas.
as a source of energy for electricity generation,
heating and domestic purposes. It has application in Ghana discovered oil in the Jubilee Field offshore
the petrochemical, fertilizer and plastic industry as Cape Three Points in the Western Region in 2007.
a feedstock, and as a precursor for production of Over the years, oil and gas exploration have
materials such as nylon. Natural gas is touted as the continued with more discoveries of crude oil and
cleanest, safest and most useful fossil fuel (Arubi natural gas. By the end of 2016, Ghana had begun
and Duru, 2008). When natural gas is combusted, work on the Sankofa Gas Project which
its emissions of sulphur dioxide are negligible and encompasses the development of the Sankofa and
the levels of carbon dioxide and nitrous oxide are Gye Nyame gas fields located 60 km offshore of
about 50% less compared to other fossil fuels Western Ghana in water depths ranging from 520
(Marques et al., 2014). These facts and an m to 1,014 m in the Tano Basin. These fields are
increasing interest in environmental advocacy have estimated to hold 1.45 Tcf of non-associated gas. It
led to an increase in the demand for natural gas is expected that gas obtained from this project will
worldwide in recent years. account for 40% of the nation’s domestic power
generation (Kuukyee, 2015). A pipeline network
Until the 21st century, a great quantity of natural
construction is underway to link the offshore fields
gas produced at oil and gas fields were flared,
to the onshore receiving facilities.
especially in areas lacking pipelines and other gas
transportation infrastructure (Elvidge et al., 2009). In view of these, it is imperative to note that, the
Although natural gas is still being flared worldwide produced natural gas has to meet certain quality
due to problems of storage and lack of a ready specifications before being fed into any pipeline
127
transportation system in order for the pipeline grid 600 MMbbl with upside. The production from the
to operate efficiently (Roy and Amin, 2011). This field averaged approximately 102 000 bopd. The
is because natural gas produced at the well head, as field underlies portions of the West Cape Three
pointed out by Bhran et al. (2011), is a mixture of Point and Deep-water Tano License Blocks. The
many hydrocarbon gases and some non- field start-up occurred on November 28, 2010 and
hydrocarbon gases, mainly hydrogen sulphide, production has continued to ramp up as additional
carbon dioxide, nitrogen, and water vapour. These phase one wells has been brought online. The phase
impurities if not processed can cause corrosion, 1 development program consists of 17 wells, 9
reduction in heating value of the gas, producers, 6 water injectors, and 2 gas injectors
environmental pollution and several problems to which target the lower and upper Mahogany
the pipeline during transportation. Water vapour in reservoirs (McLaughlin, 2012). Figure 1 shows the
particular increases natural gas corrosivity location of the Jubilee Field.
especially when acid gases are present (Mawgoud
and Khalil, 2014). It also causes hydrate formation
at low temperature conditions which may plug the
system. Dehydration is therefore vital in gas
processing prior to transportation through
pipelines. The industrial pipeline specification of
water content in a processed natural gas stream is
between the range of 4 to 7 lb/MMSCFD (Arubi
and Duru, 2008) and therefore natural gas must be
dehydrated to meet these specifications.
The basic parameters required for simulation of The Aspen HYSYS software was utilised in the
TEG dehydration of natural gas in Aspen HYSYS simulation of the TEG dehydration process. Aspen
are: HYSYS is a user friendly, industry-standard
simulation program used by researchers, process
Composition and feed stream conditions of
raw natural gas coming from the well;
For the purposes of this study, a steady state The design of the process flow diagram was based
simulation of the dehydration plant was carried out. on the typical TEG dehydration plant described in
The software requires the input of the pure gas Figure 2. The various equipment needed for the
components. Therefore, in the first step of the dehydration process, including the scrubber,
simulation process, the main components of the gas absorber, flash separator, heat exchanger, reboiler,
were defined by adding the data on gas stream regenerator and pump were selected from the
compositions of this case study. palette and connected by their respective material
streams. It is important to define the composition
2.3.3 Selection of fluid package and conditions of the feed stream. In this paper, the
feed stream is named inlet gas and its molar
Following the selection of gas components, a fluid composition and conditions are based on the data
package was selected. The fluid package is the obtained. The input conditions required are the
equation of state used by the software to calculate flow rate, temperature and pressure. HYSYS
gas stream properties and it is carefully selected calculates all other conditions using the selected
depending on the process type and its pressure and property package.
temperature range. The fluid package selected in
this case is the Glycol Package because it is It is also necessary to specify certain operating
applicable over the range of temperatures, conditions of the various equipment. With this
pressures and component concentrations information, HYSYS solves all the mass and
encountered in a typical TEG dehydration system. energy equilibrium equations taking into
The Glycol Package is based on the Twu-Sim- consideration the specified design parameters for
Tasson (TST) equation of state and according to the unit to produce a product stream. The
Aspen Technologies, the TST equation of state is converged sign indicates that the absorber has been
suitable for TEG dehydration systems and can simulated successfully. Figure 3 shows the menu
accurately predict; for the absorber unit specified with eight contacting
stages. The converged sign indicates that the
Activity coefficients of the TEG-water absorber has been simulated successfully. Figure 4
solutions within the absolute deviation of shows the complete process flow diagram.
2%.
Dew point temperatures within an average
error of positive or negative 1 °C.
Water content of gas within the average
absolute deviation of 1%.
0.2 9.778
3.0
0.5 4.521 175 180 185 190 195 200 205
10 1.0 3.599 Reboiler Temperature (°C)
3.0 3.617
5.0 3.659 Figure 6 Outlet Gas Water Content against
0.2 9.537 Reboiler Temperature at 8 Contactor Stages
0.5 4.324 and TEG Flow Rate of 1m³/hr
12 1.0 3.584
3.0 3.617
100.00
5.0 3.659
99.98
99.96
Lean TEG (wt %)
99.94
7.5
Water Content in Gas Out (lb/MMSCFD)
99.92
7.0 99.90
99.88
6.5
99.86
6.0 99.84
99.82
5.5 0.4 0.6 0.8 1.0 1.2 1.4 1.6
Stripping Gas Rate (MMSCFD)
5.0
From Table 3, it can be observed that outlet gas for effective transfer of water from the gas to the
water content reduces with high TEG flow rate and glycol. Also, a greater number of trays indicates
increases with low flow rates. However, between a that the gas would have a higher contacting time in
TEG flow rate of 0.5 m³/hr and 3 m³/hr, water the vessel and would as such lead to more effective
content is well within pipeline specifications. It can dehydration. These results are corroborated by
also be recognised that high TEG flow rates of 5 researches conducted by other authors
m³/hr and above do not further decrease water (Anyadiegwu et al., 2014; Arubi and Duru, 2008).
content in the outlet gas stream significantly. It can also be noticed that a TEG flow rate of above
Anyadiegwu et al. (2014) reported that flooding the 3 m³/hr is uneconomical and leads to liquid loading
contactor with such high amounts of TEG could in the gas because of excessive TEG in the
rather result in a phenomenon called liquid contactor.
carryover where the excess TEG becomes entrained
in the gas stream causing an increase in the hydrate From Figures 5 and 6, it can be realised that
formation temperature. It would therefore not be although the TEG flow rate also determines the
economical to flow TEG beyond 1 m³/hr given the extent of dehydration, water content of outlet gas
processing conditions obtained from the Jubilee reduces with increasing reboiler temperature. This
Field. Similarly, a low TEG flow rate of 0.2 m³/hr is because the reboiler temperature largely
would result in water content which do not fall determines the purity to which the glycol is
within the range for pipeline quality natural gas and regenerated. However, reboiler temperature must
therefore cannot be used. not be raised beyond 204 °C to prevent breakdown
of glycol molecules. This temperature limit also
Table 4 indicates that, increasing numbers of affects the purity of glycol that can be regenerated
theoretical equilibrium stages of the contactor to less than 98.5%. For this simulation, a glycol
results in reduced water content of outlet gas temperature of 180 °C resulted in a TEG purity of
regardless of the TEG flow rate. A TEG flow rate 96.02%. Operating the reboiler temperature at 190
of 1 m³/hr for example, results in 4.351 °C led to a TEG regeneration of 96.96%. Finally,
lb/MMSCFD of water in the outlet gas stream at 4 97.64 and 97.88% of lean TEG were obtained for
contacting stages, 3.644 lb/MMSCFD at 8 reboiler temperatures of 200 °C and 204.4 °C
contacting stages (Table 3), 3.599 lb/MMSCFD respectively.
and 3.584 lb/MMSCFD at 10 and 12 stages
respectively. Thus, as expected, a greater number
of contactor stages indicates a larger surface area
Authors
Solomon Adjei Marfo is a
Lecturer at the Petroleum
Engineering Department of
University of Mines and
Technology, Tarkwa, Ghana.
He holds PhD in Petroleum
Engineering from the University of Port Harcourt,
Nigeria, MEng Degree in Mining (Petroleum
Engineering) from the University of Belgrade,
Serbia and BSc in Chemical Engineering from the
Kwame Nkrumah University of Science and
Technology, KNUST, Kumasi, Ghana. He is a
member of the Society of Petroleum Engineers
(SPE), a Registered Environmental Specialist
(RES) with the National Registry of Environmental
Professionals (NREP) of USA. His research
interests include sand and water control in oilfields
using chemicals, agro-waste and local materials
evaluation for oilfields application.