February 2011, Vo lu me 2, No.

1
International Journal of Chemical and Environ mental Engineering

Flowsheet Development and Simulation of Off-

Shore Carbon Dioxide Removal System at Natural
Gas Reserves
Tigabwa Yosef Ah med, Murni M Ah mad a
Chemical Engineering Department, Universiti Teknologi PETRONAS,
Bandar Sri Iskandar, 31750 Tronoh, Malaysia.
a
Corresponding author: murnim@petronas.com.my

Abstrac t
Carbon dioxide content in natural gas can cause corrosion and environmental issues. M ost natural gas reserves in M alaysia contain 50
to 74 mol% of CO 2 . However, the capability of most existing acid gas treatment systems is limited to treat natural gas with CO2
content of 30 to 40 mol%. The purpose of this paper is to present preliminary study on the potential of an off-shore application of an
adsorption system using aminated resin to capture CO2 at the natural gas reserves. This system is intended to reduce the CO2 content
down to the capability of existing acid gas treatment. The flowsheet simulation based approach implemented in PETRONAS’ iCON
and HYSYS process simulators is used to study the effect of temperature, pressure, adsorbent concentration and flow rate on the CO 2
removal performance using the proposed system. For the assumed CO2 content of 70 mol% in the natural gas from reserves, the
developed iCON and HYSYS models predict reduction to 11.8 mol% and 14 mol% of CO 2 in the treated gas stream, respectively. The
preliminary economic study indicates positive economic potential. Thus, the results showed that the aminated resin can be used for
effective and efficient CO 2 removal process using the proposed off-shore system from the natural gas stream.

Keywords: CO 2, Adsorption, Simulation, M DEA, Resin, Aminated Resin

1. Introduction Much has been done on the development of novel

When CO2 exists in natural gas prior to combustion, it
introduces several disadvantages: the heating value of the
natural gas is lowered, the gas volume to be handled and
transported is increased and the greenhouse gasses are
released.
Many technologies have been used to remove CO 2
fro m natural gas such as, membrane, absorption and
adsorption. Some specially designed membranes such as
aromat ic polyimide separation membranes are proved
effective to remove CO2 in concentration between 5 and
40 mo l% [1]. However, in the majority of membrane
separation techniques, membrane saturation might lead to
gas losses. Furthermore, the technology requires a
regulated and extensive pretreatment of the feed gas to
maintain the life time of the membrane wh ich contributes
to the increase in operating cost of the membrane capture
system. Membranes are also sensitive to thermal and
pressure variation in feed gas conditions [2]. On the other
hand, in absorption process aqueous amines are the most
common and widely used for CO2 removal fro m natural
gas. However, recently there is a need to utilize solid
sorbents for CO2 removal due to the issues observed in
aqueous amine utilization i.e. its lifetime, susceptibility to
degradation through oxidation and corrosion problems
[3].
adsorbents for CO2 . Adsorption of CO2 on phenolic resin-
based carbon spheres [4], act ivated carbons [5], amine
surface-bonded silica gel [6], amine-
functionalized mesoporous silica [7] and amine-enriched
fly ash carbon sorbents [8] are some of the adsorption
processes used for CO2 removal. The use of amine
surface-bonded solid materials has proved the valuable
contribution of the porous supports in the solid structures
for providing the amine with structural integrity and a
surface for gas/solid contact [7]. However, instead of
surface area or pore volume, amine content of
the materials is the governing factor to achieve high
CO2 removal capacity. To date, designing sorbents with
high CO2 removal capacity and favorable kinetics is an
ongoing process.
The use of process simu lators to evaluate the
performance of various CO2 removal processes is
justifiable as testing at industrial scale is very expensive.
In process simulat ions choosing an appropriate fluid
package is one of the crucial steps. The process
simu lators such as HYSYS [9], Aspen HYSYS [10],
Aspen Plus [11] and TSWEET  [12] have been used for
simu lation of CO2 absorption with various amine
solutions. Most of the simu lation systems for fluid
 processes offer some basic support for simu lation of Table 1. Natural gas feed conditions [15]
solid processes as well.
Natural Gas
This work focuses on designing and simulating a Components Mole fraction Mass fraction
system for CO2 adsorption with aminated resin which is N2 0.0016 0.001
proposed to be installed at natural gas reserves. Two
CO2 0.70* 0.813
commercial process simulators i.e. HYSYS and iCON are H2 S 0.0172 0.015
used. iCON, a simu lator based on Sim42, is jointly C1 0.2105 0.089
developed by PETRONAS, the Malaysia’s national oil C2 0.0393 0.031
corporation in collaboration with Virtual Materials Group C3 0.0093 0.011
(VM G) Inc. iC4 0.0026 0.004
nC4 0.0029 0.004
iC5 0.0014 0.003
2. Process Development nC5 0.0012 0.002
nC6 0.0018 0.004
The natural gas received from the reserves contains
nC7 0.0072 0.019
some hydrocarbon condensates and water. Hence, the gas H2 O 0.005 0.002
is usually passed through field separators to remove those Temperature (ºF) 86
components. The two known separators used for this Pressure (psia) 1000.0
purpose are slug catcher and stabilizer [13]. The natural * Concentration of CO2 in natural gas reserves in Malaysia [16]
gas is resent to gas treating plants at refineries for fu rther
processing. In this work, an off-shore CO2 removal unit at
1.1.1 3. Process Description
natural gas reserves is proposed to be introduced before
the gas is sent to gas treating plants. This unit is In this work, the CO2 removal process in the off-shore
developed due to the alarming of high concentration of unit is developed based on counter current flow operation
CO2 in natural gas reserves. Fig.1 illustrates the general to achieve optimu m contact time between the natural gas
flow d iagram for natural gas treatment system with the and aminated resin. The aminated resin–water mixture
inclusion of the newly designed off-shore CO2 removal enters the top of the adsorber and flows to the bottom
unit. while the natural gas heavy in CO2 enters from the bottom
of the adsorber column. The treated natural gas leaves
Table 1 fro m the top of the column while the exhausted aminated
< 30 mol% CO2
Natural Gas resin-water mixture leaves the column fro m the bottom.
Off-shore Unit Gas Treatment Plant
Reserves The exhausted resin–water mixtu re then is flowed into a
flash tank to remove the hydrocarbon components carried
over. The flashed overhead product containing the
Fig.1. Outline of the overall process for natural gas processing hydrocarbons can be used as a fuel. To make the resin
system
ready for reuse a regeneration section using a distillation
column, wh ich acts as CO2 stripping colu mn, is used to
The conditions of the natural gas stream co ming fro m remove the adsorbed CO2 fro m the resin. Some water
the reserves are listed in Table 1. To design the process, vapor also removed together with the CO2 and water can
the commonly known heuristic-based design approach by be separated from the mixture via condensation. Fig.2
[14] has been adopted. This method helped to make shows the flow diagram of the off-shore unit for CO2
various design-based decisions in a hierarchical manner removal.
by decomposing the design into a serious of sub- Cooler Q

problems. Acid gas

Pump Q

Sweet gas Cond.Q

Reflux Makeup
Aminated resin-water water
mixture Regeneration Regenerator
Adsorber
feed
Reboiler.Q
Sour Natural gas Flash vapor

Bottom products Regeneration

Flash tank bottoms

Fig.2. Flow diagram of the off-shore unit for CO 2 removal [12]

Due to the slow reaction rate of MDEA with CO2 , it is

necessary to use tray column to give more time for the
reaction to occur. Moreover, since the solid resin presents
in the towers the tray column is preferred for easier
cleaning. Heat stable salts [17] and other solid process

21
 contaminants which might be accumu lated over some Hence, the generalized equation governing the
run times are assumed to be removed fro m the cycle by reaction mechanism of CO2 with the aminated resin can
filtration process as appropriate. be summarized as follo ws:

4. Chemical Reaction Analysis CO2  H 2O  R  MDEA  R  MDEAH   HCO3
Aminated resin is an amine functionalized resin in
(3)
which the active sites on the resin are amines capable of
capturing CO2 . The amine group selected is where R represents the resin (Fig.3).
methyldethanolamine (M DEA) known for its bulk CO 2
removal capacity. The tertiary amine, MDEA, has two As H2 S is among the contaminant gases in natural gas,
ethanol groups attached to the nitrogen atom along with a it also undergoes reaction with the MDEA on the resin
methyl group [18]. Fig.3 illustrates the simp le structures instantaneously with infinite reaction rate. In this wo rk, its
of the aminated resin. concentration is assumed to be constant. The overall
Active sites reaction of H2 S with the MDEA is summarized as
HOCH2 CH2
.. N CH3
follows:
HOCH2CH2

Resin
H 2 S  R  MDEA  R  MDEAH   HS  (4)
HOCH2 CH2
.. N
The resulting anions from the overall reaction
CH3
HOCH2CH2
equations 3 and 4 i.e. HCO3  and HS  , would give off
Fig.3. Simple structure of the Aminated Resin
CO2 and H2 S when heated, respectively [22].
Since the resin is functionalized 1.1.2
with
methyldethanolamine, the resin itself is considered as a 5. Process Simulation
simp le inert solid. Hence, the reaction mechanis m of CO2 In the simulat ion using iCON, the MDEA flu id
with the MDEA on the resin’s active sites is assumed to package that supports a simp le inert solid is used.
be similar to CO2 with liquid MDEA. The reaction Meanwhile, in HYSYS a generalized package for amines
mechanis m of CO2 with liquid MDEA is readily availab le called amine fluid package is used instead as the
in various literatures [19] and [20]. simu lator does not have a fluid package designed
Three overall react ions, given in equations 1-3 are explicit ly meant for MDEA.
assumed to occur during the adsorption process. MDEA is The concentration of MDEA assumed is 38 wt% as
a tertiary amine and does not have hydrogen atom the tertiary amine, MDEA , is found to be efficient and
attached to the nitrogen, thus the reaction with CO 2 can effective for CO2 removal between the concentration
only occur after the CO2 dissolves in the water to form a range of 20–50 wt% [23]. Another assumption made is
bicarbonate ion [21]. that the tray efficiency of the adsorption column is

CO2  H 2O  HCO3  H  assumed as 15% and 80% for CO2 and H2 S [24]
(1) respectively. This is because H2 S can instantly react with
MDEA, and CO2 reacts more slowly. The number of trays
The bicarbonate ion format ion is slow and only occurs for the adsorption column is assumed to be 20.
in the liquid phase [20]. The bicarbonate ion then The simulations of the system imp lemented in ICON
involves in an acid-base reaction with the amine to yield and HYSYS process simulators are given in Figs.4 and 5,
an overall CO2 adsorption reaction. respectively.

CO2  H 2O  MDEA  MDEAH   HCO3 (2)

P-1 E-2
M-1
MDEA_TO_PUMP
MDEA_TO_COOL MAKEUP_WATER
MDEA_TO_RECY

MDEA_TO_CONT MDEA_TO_CONTACTOR SWEET_GAS

M-2

ADSORBER FLASH_VAP
REGEN_BTTMS

ACID_GAS
MDEA_TO_FLASH_TK
Vlv-1 DISTILLATION_COLUMN
GAS_TO_CONTACTOR RICH_TO_REGEN
FLASH_TANK
RICH_MDEA

SOUR_GAS
SEPARATOR

BOTTOMS_LIQUIDS

Fig.4. Simulation model for the off-shore CO 2 removal system using iCON process simulator.

22
Fig.5. Simulation model the off-shore CO 2 removal system using HYSYS process simulator.

Table 2. Material balance for the off-shore CO2 removal system using Icon process simulator

Table 3. Material balance for the off-shore CO2 removal system using HYSYS process simulator

23
 Based on simu lations, the concentration of CO2 in
the treated natural gas stream labeled as “sweet gas” in 0.35

CO2 mass fraction in Sweet Gas

the process flow diagrams (Fig.4 and Fig.5) is predicted
to be 11.8 mo l% and 14 mol% fro m iCON and HYSYS 0.3
580.00, 0.29
models respectively i.e. less than 30 mol%.
40.00, 0.27
550.00, 0.26
370.00, 0.25

6. Results and Discussion 0.25

130.00, 0.24

The simulation models are next used to study effect of

some parameters on the CO2 removal performance. The 0.2
0 100 200 300 400 500 600

most important parameters for the design of CO2 removal MDEA-resin Tem perature [F]

system are the adsorbent circulation rate and its

concentration, temperature of the adsorbent and pressure Fig.7. Effect of the MDEA-resin temperature on CO2 amount at 38
of the sour gas [12] and [24]. The effect of each wt% MDEA using HYSYS process simulator
parameter is studied while holding all other process
(P = 6860.283 kPa)
variables constant. Moreover, the identification of best
operating parameters were done in a two
6.2 Effect of Temperature

dimensional search
performance with
simu ltaneously.
6.1 Effect of Resin Flow Rate
Fig.6 compares the CO2 removal performance for the
system at different adsorbent concentration of 38 wt%
MDEA and 48 wt% MDEA when increasing the MDEA
flow rate. A similar trend to Fig.6 was also reported [12]:
when the circulation rate is increased for any given
column, the CO2 adsorption increases in a column of
fixed diameter. Another observation is that high
concentration of MDEA favors the CO2 removal in the
developed unit. The higher the quantity of reactive amine
present, the higher the quantity of CO2 removed.
CO2 mass fraction in Sweet Gas
i.e. not identify ing the best Fig.7 shows the acid gas concentration in the sweet gas
respect to all parameters in relation to the MDEA-resin temperature at 38 wt%
MDEA. Based on Fig.7, belo w 130 ºF, the increase in
temperature enhances CO2 removal in the system. This is
because high temperature improves the reaction kinetics
to a greater extent and less viscosity i.e. higher
diffusivity. However, beyond 130 ºF, the decrease in
solubility of the CO2 becomes the overriding factor
leading to less CO2 removal. A similar trend is also
reported in the work by [24] and [26]. Based on the trend
plotted in Fig.7 it can be concluded that the system
removes the highest amount of CO2 at 130 ºF.
6.3 Effect of Sour Gas Pressure
Fig.8 illustrates that both simulat ion models generate
similar trends of sour gas pressure effect on CO2 removal.
Up to 1500 kPa, the increase in pressure shows
insignificant effect on the CO2 adsorption capacity of the
aminated resin. That is because the CO2 reaction is driven
by kinetics and it is less affected by lowered pressure.
However, Fig.8 indicates that high pressure, more than

0.26
4500 kPa, enhances CO2 removal. This can be exp lained
38 wt% MDEA
48 wt% MDEA
as with the increase of pressure carbon dio xide seems to
0.24
485.00, 0.24
interact stronger with the adsorbent [1].
485.00, 0.22
605.00, 0.22
0.22
765.00, 0.21 0.26
CO2 Mass Fraction in Sweet Gas

605.00, 0.21
765.00, 0.21
Using ICON
0.2 1150.00, 0.24 1900.00, 0.25
Using HYSYS
400 500 600 700 800
0.24
MDEA-resin flow rate [m 3/hr]

Fig.6. Effe ct of MDEA-resin flow rate on CO 2 amount using 38

0.22
wt% and 48 wt% MDEA using HYSYS process simulator (T=35°C 4500.00, 0.21

and P=6860.28 kPa) 7300.00, 0.21

1100.00, 0.20
0.2
0 1000 2000 3000 4000 5000 6000 7000 8000

Sour Gas Pressure [kPa]

Fig.8. Effect of the sour natural gas pressure on CO2 amount at 38 wt%
MDEA using HYSYS and ICON process simulators (T = 30ºC)

24
 Deviation analysis for results for the effect of pressure results
was performed using equations 5, 6 and 7 [27]. Table 4
shows the detail of the calculat ion. MDEA-  Simulator 
2 Resin converged Simulation did not
N  x 
iCON  x HYSYS circulation converge for various
RSS     
 rate
i 1
tries
xiCON 
(5) 7. Preliminary Cost Analysis
RSS A preliminary cost analysis is performed to evaluate
MRSS  economic potential level 1 of the system, given in
N
(6) equation 8.
Economic Potential 1 = Profit fro m Product – Cost of
Mean error  MRSS
Reactant
(7) (8)
The calculation is performed based on the basis given
Table 4. Deviation between the results in Table 6. The price of the aminated resin is assumed to
D P CO2 (wt %) Deviation be 40 % and 16 % h igher than the price of the solvent
ata MDEA and a resin [28] and [29], respectively (Table 6).
(kP in treated gas
P a) A total of 330 operational days in a year is considered to
oint HYS IC RS M Mean obtain the estimate for the economic potential level 1.
YS ON S RSS error
1 100 0.24 0.2 Table 6. Price of Raw materials and products
05 Material Price Amount Total price
0.1 0.0 0.187 consumed/ ($ per year)
2 130 0.24 0.2 05 35 produced
0 06 (m3 /hr)
3 190 0.25 0.2 Aminated $0.70 per
0 11 resin lb* 273
26,872,673
Water

The deviation is calculated as 18.7% (Table 4). Possible $0.337 per

m 3 **
factors contributing to the deviation include; one, the
different flu id packages used for simulat ion models and Natural gas $154.47 per 206 252,020,89
two, the difference in the sour gas pressure used in the m 3 *** 4
simu lations. Each simulat ion models developed for this
*
work has advantages and limitat ions as discussed in T he price for the aminated resin is considered to be 40 % and 16
% higher than the price of the reactants i.e. solvent MDEA [28] and
Table 5. Polyethylene [29] respectively, to produce the aminated resin
**
Industrial water tariff for Terengganu as of 2008 is taken for the
calculation [30]
***
http://www.indexmundi.com/commodities/?commodity=natural-
gas

Table 5. Observation on simulators performance during parametric The economic potential is calculated to RM
study 697,959,485 per year. The positive value indicates the
economic v iability of the off-shore CO2 removal system.
Simulator
Parameter HYSYS ICON 8. Conclusion
Fluid  Amine  MDEA
package fluid package fluid package In this paper the use of MDEA functionalized resin
Pressure  Simulator  based CO2 removal system for off-shore application was
converged for each Simulator converged investigated according to the two simulation models
∆P attempted and for each ∆P
produced consistent attempted
created using iCON and HYSYS process simu lators. The
results features and capabilit ies of the simulat ion softwares are
 However, also reported. From the simulat ion conducted, it was
the simulator did not observed that the increase in temperature of the MDEA -
converge for
P > 2000 kPa
resin of 38 wt% up to 130 °F enhances the CO2 removal
Temperat  Simulator  and the 130 °F is spotted being the best operating
ure converged for each Simulator did not condition. Moreover, introducing the sour gas at a
∆T attempted and converge for various pressure higher than 4.5 MPa is identified to bring better
produced consistent ∆T attempted performance to the system. Needless to say, the increase
25
 in flo w rate of the MDEA-resin imp roved the CO2
removal performance of the unit as the quantity of
reactive amine present for CO2 removal is high. Hence,
we concluded that the use of MDEA functionalized resin
is effective and economical for CO2 removal for off-shore
application where the resin allows the amine to withs tand
high pressure. The work can further be improved by
considering heat integration to make the system more
energy efficient.
ACKNOWLEDGMENT
The authors are thankful to Universit i Teknologi
PETRONAS for providing research facilit ies to
accomplish the task.
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