UOP SeparexTM Membrane Technology

UOP SeparexTM Membrane Technology

Mander Singh UOP LLC

Mander Singh UOP LLC

© 2009 UOP LLC. All rights reserved. UOP 5241E-01

UOP Southeast Asia Gas Processing TourOctober – November 2009Malaysia, Thailand, Indonesia & Vietnam

Agenda

Membrane Technology OverviewPretreatment OptionsFlow Scheme OptionsCommercial Experience

UOP 5241E-02

Regions of Use for Acid Gas Technologies

1000

100

10

1.0

0.1

Part

ial p

ress

ure

of a

cid

gas

in fe

ed, p

sia

Partial pressure of acid gas in product, psia0.001 0.01 0.1 1.0 10 100

SeparexTM

Membrane

UOP 5241E-03

What Is a Membrane?

A semi-permeable film of various:Materials: Cellulose Acetate (CA), Polyimide (PI), Polyamide, Polysulfone, SiliconeTypes: Asymmetric, Thin Film CompositeConstruction: Spiral-Wound, Hollow Fiber

UOP 5241E-04

Asymmetric Membranes

Single polymerThin selective layerPorous support layer

Non-porous LayerNonNon--porous Layerporous Layer

Porous LayerPorous Layer

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Composite Membrane Structure

Composite MembranesTwo or more polymersThin layer of highly optimized polymerMounted on an asymmetrical structureHighly tailored properties at low cost

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Membrane Elements - Spiral Wound

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Spiral Wound Membrane Element and Tube

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Hollow Fiber Membranes

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Hollow Fiber Membranes

PermeateOutlet

PermeateOutlet

Feed Gas Inlet

Residue GasOutlet

UOP 5241E-10

Not A Filtration ProcessSolution-Diffusion Based Separation Process–Components dissolve into membrane surface and diffuse

through it–More soluble components permeate quicker–Smaller components permeate quicker

FastSlow

Hig

h Pr

essu

re

Low

Pre

ssur

e

CO2, H2S,H2O

Hydrocarbons, N2

Separex Membranes

Membranes are characterized by permeability (flux) and selectivity UOP 5241E-11

Driving Force

Membrane

Membrane

PCO2PCO2

High Pressure(Feed)

Low Pressure(Permeate)

A pressure differential across the membrane

PCO2PCO2

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What Are Separex Membranes?

UOP 5241E-13

Separex Membranes Regions of Use

Flow Rates: Economical only for > 5 MMSCFD

Feed Pressure: Up to ~ 2,000 psiA (138 barA)

Permeate Pressure: Typically below ~50 psiA (3.5 barA)

∆p (Feed→Permeate): 1,500 psi max (100 barA)

Feed Temperature: 60 to 150°F (16 to 65°C)

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Agenda

Membrane Technology OverviewPretreatment OptionsFlow Scheme OptionsCommercial Experience

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Pretreatment Design Considerations

Feed Composition– CO2 Content or Percentage of CO2 Removal – Heavy Hydrocarbons

Feed Contaminants– Compressor Oils– Well Additives– Pipeline Corrosion Inhibitors

All Membranes Require Some Form of Pretreatment

UOP 5241E-16

Standard Pretreatment

Filter Coalescer

Non-Regenerative

AdsorbentBed

Feed

Particle Filter Heater Membrane

Removes feed contaminants such as lube oil and corrosion inhibitorNot meant for removal of heavy HC tail in very rich feed gas

UOP 5241E-17

Particle Filter Heater Membrane

MemGuard™RegenerableAdsorbent

System

Enhanced UOP MemGuard™ Pretreatment

UOP 5241E-18

Filter CoalescerFeed

MemGuard Flow Scheme

Adsorbing Bed(s)

ParticleFilter

Filter Coalescer

Feed

Liquids

Clean GasRegen Gas

Blower

RegeneratingBed

Regen GasSeparator

Regen Heater

Regen GasCooler

UOP 5241E-19

MemGuard System Performance

0

100

200

300

400

500

600

700

C6 C7 C8 C9+

Pretreatment Feed GasPretreatment Discharge Gas

Hyd

roca

rbon

Con

tent

, ppm

UOP 5241E-20

Benefits of MemGuard System

Selectively removes heavy HC tail and hence can provide efficient dew point suppression MemGuard™ product gas is bone dry which allows use of carbon steel metallurgyIf permeate gas is to be sequestrated, additional dehydration is typically not required

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Agenda

Membrane Technology OverviewPretreatment OptionsFlow Scheme OptionsCommercial Experience

UOP 5241E-22

Flow Scheme Options

1 Stage1 Stage

2 Stage2 Stage

Pre-Membrane

Pre-Membrane

HybridHybrid

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Processing Schemes

Allows greater CO2 removalHigh hydrocarbon recoverRequires recycle compressor

Feed

Residue

Permeate

Feed

Residue

Permeate

Feed

Residue(Low H2S/CO2)

Permeate(High H2S/CO2)

No moving partsSimple, reliable operationLow hydrocarbon recovery

Feed with high CO2Intermediate hydrocarbon recoveryReduced compression

UOP 5241E-24

Hybrid

Debottleneck existing plantsReduce size of Amine UnitAllows high CO2 removal, low ppm of CO2 & H2S in sales gasMinimizes capital and operating costs

Feed

To Boiler

Single StageMembrane

Amine System

xxxx

FiltrationSystem

Reflux XXXX

TreatedGas

To Acid Gas

Cooler

To/FromAmine

Reboiler

XXXX

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Effect of CO2 Removal

0

2

3

4

1

0 20 40 60 80 10060

80

90

70

100

% CO2 Removed

Rel

ativ

e A

rea

Req

uire

men

t

% H

ydro

carb

on R

ecov

ery

(1 S

tage

)

One StageSystem

MultistageSystem

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Effect of Number of Stages

75%

80%

85%

90%

95%

100%

0% 20% 40% 60% 80% 100%

Percentage CO2 Removal

Hyd

roca

rbon

Ret

entio

n

One Stage

Two Stage

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Effect of Feed Pressure on Performance

0.0

0.4

0.8

1.2

1.6

2.0

400 600 800 1000 1200 1400 1600

Feed Pressure, psia

Rel

ativ

e A

rea

or L

osse

s

HydrocarbonLosses

MembraneArea

UOP 5241E-28

0.6

1.4

1.8

2.2

2.6

3.0

0 40 80 120 160

Permeate Pressure, psia

Rel

ativ

e A

rea

or L

osse

s

HydrocarbonLosses

MembraneArea

Effect of Permeate Pressure on Performance

1.0

UOP 5241E-29

Effect of Feed Temperature on Performance

0.5

0.7

0.9

1.1

1.3

1.6

70 90 110 130 170

Operating Pressure, °F

Rel

ativ

e A

rea

or L

osse

s

HydrocarbonLosses

MembraneArea

150

UOP 5241E-30

Effect of CO2 Removal on Performance

0

4

8

12

182.0

0% 20% 40% 60% 100%

Percentage CO2 Removal

Rel

ativ

e A

rea

or L

osse

s

HydrocarbonLosses

MembraneArea

80%

1614

10

6

2

UOP 5241E-31

Agenda

Membrane Technology OverviewPretreatment OptionsFlow Scheme OptionsCommercial Experience

UOP 5241E-32

Small Large Larger Largest

Capacity Over Time

0.1

1

10

100

1000

1980 1985 1990 1995 2000 2005

Year

Feed

Flo

w (M

MSC

FD)

Avg Size

UOP 5241E-33

Large Separex Membrane Projects

2% 2%3%5%20%3%3%3%20%8%21%

7% 6.5%12%70%50%6.7%6.8%9%

40%44%40%

200 550+450

240 12032

107218234254680620

NigeriaPakistanPakistanMexico

Thailand *EgyptEgyptEgypt

IndonesiaMalaysia *Thailand *

CO2Outlet

CO2InletMMSCFDLocation

5%25%176S.America *10%17%163Thailand3%9%117Egypt

10%35%520Thailand *

In Construction

* Offshore

Ease of Operation – Remote PlantsUOP 5241E-34

Commercial Experience

Installation Type No. of UnitsNatural Gas 52Enhanced Oil Recovery (EOR) 5Hybrids 5Offshore 3+2Landfill Gas 7Digester Gas 1H2 Purification 56

Total 130

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Pakistan II Overall Layout

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Pakistan II Expansion Skids

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Pakistan II MemGuard System

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Egypt I Plant Layout

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Egypt I Plant Membrane Skid

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Egypt I Plant –2nd-Stage Membrane Skid

Carbon Guard Bed

2nd Stage Membrane

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Recent Project Offshore

< 540 maxMercury, µg/Sm3

Hydrocarbon Recovery: 95%< 5SaturatedWater, lb/MMSCFD

<8.044.5 CO2, mol% 350630 Flow, MMSCFD

ProductFeed

UOP 5241E-42

Malaysia Platform

UOP 5241E-43

Optimized Layout & Packing Density

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Installed Malaysian MemGuard System

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Offshore Thailand Membrane Skids

UOP 5241E-46

Thailand Platform

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Separex Technology SummaryModular supply advantages

–High degree of shop fabrication–Minimized installation time & cost

Phased in expansion for future capacity or CO2increase Weight and space efficiencyEasy to start-up, operate, turndown and shutdownHigh reliability and on-stream time

–Low maintenance requirementsLowest processing cost as low as $ 0.09/MSCFAdvanced pretreatment and materialsMembranes operate in gas phase (no flammable liquids, refrigerants or chemicals)Meets API-521 RP for system inventory blowdown during ESD

UOP 5241E-49

Separex Technology Summary

Synergies with other UOP technologies with one system wide performance warrantyUnparallel capabilities– UOP manufactures its own membranes– Membrane and Pretreatment development program

Extensive commercial experienceLong-term proven commitment– Ongoing operational support– Supply of continually improved membranes

UOP 5241E-50

UOP’s Project Services Expertise

Project Schedule

Project Definition &OptimizationBasic DesignStudies

HazopDetailed EngineeringSystem Integration

UOP

Commissioning and Startup ServicesOngoing Technical Services/Monitoring

ProjectDevelopment OperationsDesign & Construction

UOP Ongoing R&D and Process Improvements

UOP 5241E-51

Conceptual Engineering TechnicalSupport