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Gas Dehydration
Part of the
Petroleum Processing Technology Series
OPITO
THE OIL & GAS ACADEMY
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Gas Dehydration
Contents
Page
Training Targets
Introduction
Adsorption
Solid Desiccant Dehydration Plant
Liquid Desiccants
Glycol Dehydration Plant
25
Visual Cues
40
46
Training Targets
The aim of this unit is to help you understand :
Quantify the amount of water in saturated natural gas under given conditions.
List the problems associated with water in gas.
q
q
q
q
q
q
q
q
q
Gas Dehydration
Introduction
Natural gas can be referred to as Associated Gas or Non-associated Gas. The former is produced together
with liquids from an oil reservoir and is liberated from the liquids at the surface. The latter is produced
independently of an oil accumulation, from what is commonly called a gas reservoir.
Irrespective of whether the gas is associated or non-associated, it invariably contains water in the form of a vapour
or a liquid.
Surface equipment is used to remove the water from the gas. This process is called dehydration, which is the
subject of the present unit.
The unit comprises 4 Sections :
Section 1, Water in Natural Gas, looks at the amount of water which can be held in gas and discusses the
problems that the water creates. In this section we will also look at options preventing hydrate
formation.
Section 1 will be followed by 3 further sections which deal with process systems used to remove water from gas.
Section 2, Auto Refrigeration, describes how water is removed by reducing the gas temperature.
In Section 3, Solid Desiccant Dehydration, you will look at theory of adsorption, and how it is
applied to water removal.
Finally, in Section 4, Liquid Desiccant Dehydration, we will look at how liquid desiccants work and see
how glycol is used in a typical dehydration plant.
You should be aware that the water removal processes described in Sections 2,3 & 4, are applicable to both
associated and non-associated gas treatment facilities. The actual process chosen for a particular application
depends on a number of factors. These include, location of plant, gas characteristics and so on.
Gas Dehydration
Methane
Ethane
Propane
Butane
Pentanes
The list is longer, but the amounts of other
hydrocarbons present are usually small.
The gases are listed above, starting the lightest
at the top. They get heavier, or denser, as you move
down the list.
Density gas is usually expressed as the weight in
pounds per cubic foot at standard conditions of
temperature and pressure.
Answer:
You can see from the point where the horizontal line
intersects the vertical axis, that 24 lbs of water are
required to saturate one cubic feet of gas at
70 deg F and 1 000 psi. Or, in abbreviated form 24
Ibs of water per mmscf.
Test Yourself 1
Assume that gas from the reservoir indicated above (3 000 psi, 120 deg F) is produced up a well
to the surface. At the surface the pressure has dropped to 1 500 psi and the temperature to
100 deg F. Now answer the following:
a)
b)
What water content in lbs/mmscf is required to achieve saturation of the gas at the surface?
Will the change in conditions from reservoir to surface result in the gas being unsaturated at
that point, or free water be present?
If free water is present, how many pounds will there be for every mmscf of gas?
pipeline efficiency
gas quality
hydrate formation
lets look at each of these problems in turn.
10
11
Corrosion
Corrosion is the next problem on our list. In natural
gas systems, corrosion carbon steel occurs when
free water forms in the presence of carbon dioxide
(C02) or hydrogen sulphide (H2S). You will
remember that these two substances are impurities
which may be found in natural gas.
Carbon dioxide and water together to form
carbonic acid which then reacts with an exposed
steel surface. The reaction causes chemical
substances to form which are called corrosion
products.
(The most common corrosion product in everyday
life is, of course, rust, which forms on iron or steel
exposed to the air).
These corrosion products are removed by the
force of the flowing gas stream, exposing fresh
metal for further attack. This action results in metal
loss and, therefore, corrosion pitting. The rate of
metal loss, called the corrosion rate, depends on
many factors, but principally on the amount of
carbon dioxide and free water present. Corrosion
rate also increases dramatically with increase in
temperature.
Pipeline Efficiency
Natural gas is usually transported by pipelines, and
water in gas pipelines causes our next problem.
The presence of free water in a gas pipeline can
give rise to the complication of two-phase flow. By
two-phase flow we mean that gas and liquid (say,
water) are flowing in the line together. (Gas is one
phase, and liquid is the other).
12
13
Gas Quality
Hydrates
14
Test Yourself 2
The hydrate temperature must be below, the
same as, but never above the dewpoint
temperature. Why is this?
Figure 5 : Shows a possible effect of a hydrate blockage
15
16
17
Test Yourself 3
Using Figure 7, read off the temperature below which hydrates will form in natural gas at
1 500 psi, in the presence of free water.
18
Test Yourself 4
a.
We have looked at some problems caused water in natural gas. Which of these will
affect our attempts at processing the gas.
b.
By reference Figure 7, indicate whether you think that gases at the following conditions
are in the hydrate formation regions (Yes) or not (No).
i)
Yes
No
ii)
iii)
Iv)
v)
19
Hydrate Prevention
From what we have covered thus far, you will
remember that hydrate formation was mentioned as
probably being the most troublesome problem
associated with water in natural gas.
So, how can we prevent these hydrates from
forming?
Activity
Jot down three things that you could do to a gas stream, in order to discourage hydrate formation.
20
1.
Heating.
2.
Removal of water.
3.
4.
Chemical inhibition.
21
22
Test Yourself 5
a.
It was mentioned in the text that. in gas processing, the maximum use is made of heat
conservation within the process. Why do you think that this is done?
b.
Indicate whether you would use methanol or glycol for the following inhibition requirements:
i) For initially starting a new oil well which has a high gas content?
iii) For long term storage offshore for use in gas well servicing jobs?
Methanol
Glycol
ii) For continuous injection into an offshore pipeline feeding an onshore gas plant?
23
Summary of Section 1
In this first section the origins of water in natural gas have been explained and you know that it can
take the form of vapour or liquid.
You should now be able to find out how much water is required to saturate a given gas, if you
know its temperature and pressure (by reference to the graphs). It is important to remember that
when the temperature of natural gas is lowered, water vapour condenses to produce free water.
We have discussed the problems created by the presence of water in gas, which are :
liquid accumulations in the wellbore
corrosion
lower pipeline efficiency
poor gas quality
hydrate formation.
Finally, we looked at preventing the formation of hydrates in gas, in particular by chemical inhibition
with methanol or glycol. We will be applying our knowledge of hydrate prevention, both by heat
and chemical inhibition, later on in this unit.
You now have the necessary background knowledge for working through the following sections
and understanding the processes described.
24
Gas Dehydration
25
Test Yourself 6
A gas is at 2400 psi and 80 deg F. From
Figure 9, work out what temperature rise
would be needed in this gas so that, after
expansion to 1 500 psi the final temperature
will be 75 deg F.
26
27
Test Yourself 7
Complete the following chart
Expanded to
Starting
Starting
Final
pressure
temperature
pressure
(psi)
(deg F)
(psi)
4000
102
2000
3800
154
1000
2800
90
1800
2000
86
1200
1800
123
600
Final
temperature
(deg F)
Hydrates
expected
Yes/No
28
Inhibition
or
2.
Melting
29
30
31
Test Yourself 8
The following statements refer to a series of steps in a low temperature separation process
with hydrate inhibition (LTS).
The steps are out of order. Without looking at the flow diagram (Figure 11), rearrange the steps
in their correct sequence.
1.
injection of glycol
2.
3.
4.
5.
6.
32
33
34
Now we will consider the other process which uses Low Temperature Separation.
This Figure shows a simple flow diagram of a typical process of this type. It is called a Low Temperature Extraction Process (LTX)
35
Cold gas, which has now had its water and liquid
hydrocarbons removed, is taken from the separator
and used as the cooling medium in the heat
exchanger. (A by-pass line round the exchanger
incorporating a 3-way valve maintains the correct
temperature in the process). The gas, now at the
correct specification, can be sold.
The low temperature separator is again a 3 phase
vessel, but of a different design. I have included a
simple drawing of one (Figure 15) so that you can
compare the two.
36
37
Test Yourself 9
The following statements apply to the LTS process or the LTX process or both. Indicate, by
ticking the box, which one is applicable.
1
LTS
LTX
BOTH
38
Summary of Section 2
This section opened with a description of the Joules/Thompson Effect, where gas expansion
results In a temperature drop. You have seen how this characteristic of gas is used to good effect
in low temperature separation, by condensing liquids from the gas phase.
Two main processes were described:
a.
b.
LTX, where hydrates are melted by passing the incoming, warm, gas stream through coils in
the bottom of the separator.
The LTX was seen to be more efficient as it utilised heat exchange within the process, thus
eliminating the need for expensive glycol inhibition or regeneration.
You now understand the principles of the first method of gas dehydration, using low temperature
separation which can be described as an Auto Refrigeration process.
We will now move on to look at a system which uses the principles of adsorption for gas
dehydration - the Solid Desiccant Dehydration process.
39
Gas Dehydration
Adsorption
Adsorption is a process in which a solid selectively
removes a particular component from a fluid (liquid
or gas) mixture and holds this component on its
surface.
This solid is known as an adsorbent material.
In our case the mixture consists of gas and water
vapour, and it is the water which is removed.
The adsorbent material, which removes the water, is
called a solid desiccant.
An everyday example of the adsorption process is
the use of sachets of silica gel, packed along with
sensitive photographic or electrical equipment. The
silica gel is a solid desiccant which prevents
moisture from damaging this equipment.
40
41
42
43
Test Yourself 10
a.
Referring to curve 2 in Figure 17, describe what is happening from the start to the end of
the regeneration cycle.
b.
Why do you think that the regeneration gas is fed in at the bottom of the tower?
c.
Why is the regeneration gas cooled after leaving the tower, before entering the separator?
44
Summary of Section 3
You have been introduced to the removal of water vapour from gas using the mechanism of
adsorption.
You saw that adsorption is a process in Which a solid desiccant selectively removes one
component from a fluid mixture. The solid desiccant has the capacity to attract and hold the
component on its surface.
We examined the workings of a dry bed dehydration unit, and concluded that such a unit relies
mainly on effective regeneration of the desiccant. Such plants can dry gas very thoroughly.
We are now going to look at a second process which utilises a desiccant, one in which a liquid,
rather than a solid, is used to dehydrate the gas - the Liquid Desiccant Dehydration process.
45
Gas Dehydration
Absorption
Liquid Desiccants
46
Figure 18 shows a simple flow diagram for a typical unit. Look at the figure and trace the flow paths with
the aid of the following brief description.
47
Gas Flow
48
49
Glycol Flow
Lets now look at what happens to the glycol.
The TEG, cooled in the coils (at the top of the
tower), passes down through the tower from tray to
tray, dehydrating the gas. This diluted (or rich)
glycol solution collects at the bottom of the absorber
section of the contactor tower.
Before the glycol can be used to dehydrate more
gas, it must be regenerated.
Before we go on to look at the regeneration process
itself, we should consider three other pieces of
equipment. These are:
flash tank
filter
heat exchanger
50
51
You will see that the cool, rich glycol passes first of
all through a coil in the top of the stripper column.
This is called a reflux coil. I will explain its function
shortly.
After pre-heating in the heat exchanger, the glycol is
then fed to the stripper column near the top. It
descends through packing in the stripper and mixes
with a rising stream of water rich, hot vapours.
These vapours are created by heating the glycol in
the reboiler to a high temperature. This temperature
should be above that of boiling water but below the
boiling point of the glycol itself.
Within the stripper column, two things are
happening:
the cooler, rich glycol liquid causes the hot
glycol vapour in the rising vapour stream to
condense out as a liquid and fall back.
Test Yourself 11
Following the flow path of glycol, place the
jumbled list of equipment given below into a
logical process order, starting with the
Reboiler;
Reboiler
Contactor tower
Heat exchanger
Filter
Surge tank
Flash tank
Pump
52
Plant operations
A glycol dehydration plant will only work efficiently if
certain process variables are maintained at constant
values.
The more important process variables are :
glycol concentration
glycol circulation rate
glycol solution condition
Test Yourself 12
Think about the process plant. What piece of
equipment is used to try to keep the
temperature of the TEG entering the
contactor as close as possible to that of the
gas leaving it?
Glycol Concentration
Glycol concentration refers to the amount of pure
glycol in solution and is measured as a percentage
by weight:
For instance, the rich glycol leaving the contactor
tower is a water rich solution whose glycol content is
less than 95% by weight.
However, after the glycol has been through the
regeneration section of the plant it is
reconcentrated. Now its concentration can vary
from 95% to 99% by weight, although we try to
achieve as near to 100% as possible.
Check your answer in Check Yourself 12 on
page 64
53
54
55
Test Yourself 13
Gas at the wellhead is at 3000 psi and 120 deg F. After separation, its pressure is reduced
across a choke to 1 000 psi, after which it is routed to enter the cold separator. The gas enters
an absorption tower for dehydration. The required water content should not be more than
4lbs per mmscf. The gas leaves the contactor at 90 deg F.
i)
ii)
What volume of free water is knocked out by the expansion (per mmscf)?
iii)
iv)
What reboiler temperature is necessary (at sea level) to achieve the TEG concentration?
56
57
Summary of Section 4
In Section 4, I explained the difference between Adsorption and Absorption. However, we
concentrated on the Absorption process.
You saw that Triethylene Glycol (TEG) is most commonly used as a liquid desiccant to absorb
water from gas.
You followed the operation of a glycol dehydration plant, and you will have noted that this consists
of two main units:
the contactor, in which gas dehydration is accomplished
the glycol regeneration system, in which water is removed from the wet glycol so that it
can be used again
Finally in this section, you looked at some of the process variables which must be maintained at a
constant value for efficient dehydration.
Now that you have completed the whole unit, you should have a basic understanding of the theory
and practice of gas dehydration.
Go back to the training targets on Page 2 of the unit, and check that you are able to meet those
targets.
58
Check Yourself 1
Check Yourself 2
Check Yourself 3
70 deg F.
59
Check Yourself 4
Check Yourself 5
Check Yourself 6
a.
a.
25 deg F.
gas quality
pipeline efficiency
hydrate formation
b.
i)
ii)
iii)
i) Yes
ii) No
iii) Yes*
iv) No
v) Yes
60
Check Yourself 7
Expanded to
Starting
Starting
Final
pressure
temperature
pressure
(psi)
(deg F)
(psi)
Final
temperature
(deg F)
Hydrates
expected
Yes/No
4000
102
2000
(63)
(Yes)
3800
154
1000
(74)
(No)
2800
90
1800
(60)
(Yes)
2000
86
1200
(52)
(Yes)
1800
123
600
(65)
(No)
61
Check Yourself 8
Check Yourself 9
LTS
LTX
a
a
a
a
BOTH
a
a
a
a
a
a
a
a
62
Check Yourself 10
a.
At first, hot gas warms up the tower and the contents. At 240 deg F water will begin to boil and
vaporise. The bed continues to heat up, but more slowly, as water is being driven out of the bed.
After the water, any heavier hydrocarbons will be driven off at a high temperature, and the bed
will become fully regenerated. The bed is cooled for a couple of hours by unheated gas flowing
through it.
b.
The regeneration gas is flowed bottom to top due to the lower layers of the desiccant being less
wet. Flowing from top to bottom would result in time being wasted in saturating the drier lower
layers with the wet regeneration gas flow.
c.
The regeneration gas is cooled before the separator in order to condense the water removed
from the regenerated tower, which can then be taken out at the scrubber.
63
Check Yourself 11
Check Yourself 12
Reboiler
Surge tank
Pump
Heat exchanger
Contractor tower
Flash tank
Filter
The cooling coil at the top of the contactor tower (reflux coil)
reduces the temperature of the glycol to near that of the gas.
64
Check Yourself 13
i)
Yes, as the expansion process takes the gas into the hydrate formation range (Figure 9).
ii)
From Figure 2, water content at 3 000 psi and 120 deg F = 48 lbs per mmscf.
From Figure 2, water content at 1 000 psi and 53 deg F = 14 Ibs per mmscf.
iii)
Figure 2, shows that for 4lbs water content a dewpoint of 19 deg F is required at 1 000 psi.
From Figure 21, a TEG concentration of 97.5% is necessary to achieve sales specification.
iv)
From Figure 22, the reboiler temperature will need to be set at about 360 deg F.
65