Flowsheet for CNG Manufacturing

Recovery of CNG from Natural gas:

Natural gas processing includes the following steps:

 Condensate and Water Removal
 Acid Gas Removal
 Dehydration – moisture removal
 Mercury Removal
 Nitrogen Rejection
 NGL Recovery, Separation, Fractionation, and Treatment of Natural Gas
Liquids

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In addition to these processes, it is often necessary to install scrubbers and
heaters at or near the wellhead. The scrubbers remove sand and other large-
particle impurities. The heaters ensure that the temperature of the natural gas
does not drop too low and form a hydrate with the water in the gas stream.
Natural gas hydrates are crystalline ice-like solids or semi-solids that can
impede the passage of natural gas through valves and pipes.

A generalized natural gas flow diagram is shown above. After initial scrubbing
to remove particles, the first step in natural gas processing is the removal of
condensate (oil) and water that is achieved by controlling the temperature and
pressure of the inlet stream from the well, as shown in Flowsheet. Gas separated
in this unit is sent to acid gas recovery; the condensate or the oil recovered is
usually sent to a refinery for processing, while water is disposed, or treated as
wastewater.

Acid gases (H2S and CO2) are separated usually by absorption in an amine
solution, as discussed for H2S recovery in a petroleum refinery in Lesson 10.
The recovered H2S is sent to a combined Claus-SCOT (Tail Gas Treating) unit
to be converted to elemental sulphur. After removing the acid gases, the natural
gas stream is sent to a dehydration unit to remove water typically by absorption
in a glycol unit, followed by mercury removal (by adsorption on activated
carbons or other sorbents), and nitrogen rejection either cryogenically, or by
adsorption, or absorption depending on the nitrogen concentration. The last step
in the processing sequence is the Natural Gas Liquids (NGL) extraction,
fractionation, and treatment, as described in Flowsheet.

Separation and Fractionation of Natural Gas Liquids:

Natural gas liquids (NGLs) have a higher value as separate products.
Two basic steps: 1) Extraction, 2) Fractionation
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 1. NGL Extraction
Absorption Method
o Similar to using absorption for dehydration, using a different
absorbing oil for hydrocarbons.
Cryogenic Expansion Process
o Dropping the temperature of the gas stream to around -120°F by
expansion and external refrigeration
2. Natural Gas Liquid Fractionation - works like Light Ends Unit
o Deethanizer - separates ethane from the NGL stream
o Depropanizer - separates propane.
o Debutanizer - boils off the butanes
o Butane Splitter or Deisobutanizer - separates iso and n-butanes.

NGL extraction can be carried out by absorption in oil that selectively absorbs
hydrocarbons heavier than methane, or by a cryogenic expansion and external
refrigeration to condense NGL.

Following the NGL extraction, the treated natural gas stream that is, now,
mostly methane, or a gas compliant with the natural gas specifications is sent to
the pipeline for transmission to the point of use.

The extracted NGL, on the other hand, is sent to a fractionation unit that
operates like Light Ends Unit in a refinery, separating ethane, propane, butane,
and naphtha (>C5, natural gasoline). Note that the fractionation unit may also
include a butane splitter or deisobutanizer to separate n-butane and iso-butane.

Now, following the fractionation unit, the treated gas is compressed to get
CNG.

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 4.1 MATERIAL BALANCE

The overall mass balance, yield, and operating mode of each processing unit are
presented starting with the stabilization unit. As mentioned earlier the purpose
of stabilization is to maximize the recovery of C5+ from natural gas feedstock.
The product is called field condensate, 𝐹𝑓𝑖𝑒𝑙𝑑𝐶5+ , since it is recovered early from
field feedstock.

Overall mass balance around Condensate and water removal unit (A) is given in
following equation,

𝐹𝑁𝑎𝑡𝑔𝑎𝑠𝑗, = 𝐹𝑟𝑒𝑠𝑔𝑎𝑠𝑗, + 𝐹𝑓𝑖𝑒𝑙𝑑𝐶5+𝑗,

Where j indicates technology and m is a set of operating mode for example

different pressure and temperature as operating conditions.

The acid gas stream, , that is mainly H2S and CO2 is separated from residual
gas and overall mass balance around Acid Gas Removal Unit (B) is given in
following equation,

𝐹𝑟𝑒𝑠𝑔𝑎𝑠𝑗,𝑚 = 𝐹𝑠𝑤𝑒𝑒𝑡𝑔𝑎𝑠𝑗,𝑚 +𝐹𝑎𝑐𝑖𝑑𝑔𝑎𝑠𝑗,𝑚

CO2 mass balance around unit (A) is given in following equation,

𝐹𝑁𝑎𝑡𝑔𝑎𝑠𝑗,2 = 𝐹𝑟𝑒𝑠𝑔𝑎𝑠𝑗,𝑚𝐶𝑂2 + 𝐹𝑓𝑖𝑒𝑙𝑑𝐶5+𝑗,𝑚𝐶𝑂2

H2S mass balance around unit (B) is given in following equation,

𝐹𝑟𝑒𝑠𝑔𝑎𝑠𝑗,2𝑆 = 𝐹𝑎𝑐𝑖𝑑𝑔𝑎𝑠𝑗,𝑚𝐻2𝑆 +𝐹𝑠𝑤𝑒𝑒𝑡𝑔𝑎𝑠𝑗,𝑚𝐻2𝑆

Since the CO2 and H2S concentration levels will be in ppm level after acid gas
removal unit, then material balance, and yield equations would be sufficient up
to Acid Gas Removal unit (B).

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The acid gases stream, 𝐹𝑎𝑐𝑖𝑑𝑔𝑎𝑠, mainly H2S is fed to sulfur recovery unit to
recover sulfur, 𝐹𝑠𝑢𝑙𝑓𝑢𝑟. So, mass balance around Sulfur unit (C) is given in
following equation,

𝐹𝑎𝑐𝑖𝑑𝑔𝑎𝑠𝑗,𝑚 = 𝐹𝑡𝑎𝑖𝑙𝑔𝑎𝑠𝑗,𝑚 + 𝐹𝑠𝑢𝑙𝑓𝑢𝑟𝑗,𝑚

The sweet gas stream 𝐹𝑠𝑤𝑒𝑒𝑡𝑔𝑎𝑠 is sent to the dehydration unit to remove water.
Water balance around Dehydration unit (D) is given in following equation,

𝐹𝑠𝑤𝑒𝑒𝑡𝑔𝑎𝑠 = 𝐹𝑤𝑎𝑡𝑒𝑟−𝐷 + 𝐹𝐷𝑒ℎ𝑔𝑎𝑠

The rich methane stream, 𝐹𝐶𝐻4 is recovered from NGL unit and the overall mass
balance around NGL Recovery unit (E) is given in following equation,

𝐹𝐷𝑒ℎ𝑔𝑎𝑠 = 𝐹𝐶𝐻4+𝐹𝑁𝐺𝐿

The recovered 𝐹𝑁𝐺𝐿 stream is sent to fractionation unit and the overall mass
balance around the Fractionation unit (F) is given in following equation,

𝐹𝑁𝐺𝐿= 𝐹𝐶2+𝐹𝐿𝑃𝐺+𝐹𝑝𝑙𝑎𝑛𝑡𝐶5+

The Processed Natural Gas Stream that is mostly methane (>85%) from
fractionation unit and it is now sent to compressor to convert it into Compressed
Natural Gas (CNG) and the overall mass balance around Compressor is given in
following equation,

𝐹CH4 = 𝐹𝐶NG

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