aker solutions presentation - drying of natural gas
TRANSCRIPT
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part of Aker
2008 Aker Solutions
Drying of natural gas
Thomas Frde, October 21, 2010
Troll A
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Layout
1. Introduction/motivation
2. Industrial examples
3. Theory drying Dehydration
4. Summary
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BackgroundExplanations
Raw natural gas; gas produced
from the well
Sour natural gas; containshydrogen sulfide H2S or carbon
dioxide CO2
Sweet natural gas; contains little
sulfur and carbon dioxide Rich natural gas; contains larger
quantities of higher hydrocarbons
Wet natural gas; is saturated with
water vapor under natural
conditions
Petroleum technology volume 1-2 chapter 13 natural gas
Introduction
Krst Statoilhydro photo
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IntroductionGas specifications
Gas and liquid contracts usually contain the following basic considerations:
Gas
1. Minimum, maximum and nominal delivery pressure
2. Maximum water content (expressed as a dewpoint at a given pressure orconcentration)
3. Maximum condensable hydrocarbon content (expressed as ahydrocarbon dewpoint )
4. Allowable concentration of contaminants (H2S, carbon disulfide)
5. Minimum and maximum heating value
6. Cleanliness (allowable solids concentration)
Liquid
1. Quality of product (expressed as vapor pressure, relative or absolute
density)2. Specification (color, concentration of contaminants)
3. Maximum water content
Introduction
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Motivation
Treating
Water must be removed
Solid hydrates with hydrocarbons or hydrogen sulfide
Slugs in pipeline
Corrosive H2S and CO2
Petroleum technology volume 1-2 chapter 13 natural gas, Natural gas production processing transport A.Rojey et.al
Introduction
Hydrogen sulfide (H2S) must be
removed
Toxic and corrosive
Often done centralized treatment
plants Nitrogen
No heating value
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MotivationFlow configurations
Principal sketch natural gas, well to consumer
Well-stream from sub-sea/platform to shore (LNG; Snhvit, gas export; Troll and Ormen Lange)
Platform with full gas processing gas export (Sleipner)
Sleipner
snhvit
Troll, ormen lange
Troll
Introduction
Off shore platform
processing
Pipe line
Pipe line to europe
LNG
1: Off shore to land, pipe line demands2: Export pipe line, demands
3: LNG composition demands
Refinery and
petrochemicals
4: Condensate composition
demands
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Motivation
Typical north sea natural gas composit ion
Major components (mol percentage dry gas) in some north sea gas reservoirs
It can be seen from the table, that Troll produced very lean gas.
Other fields contains more CO2 and heavy components.
Introduction
1 Petroleum technology chapter 13 * hydrocarbons
A Well stream, B Pipeline stream
Saturated
Saturated
Saturated
Saturated
Saturated
H20
1-10
3
0.15
4.13
1.51
Propane
0-1
0.38
7.9
12.4
0.31
Other*
0-5
-
He
0-3
0.49
-
H2S
8.6833.421.6SleipnerB
0.4724.865.80.38South-east
asian field
8.7071.083.360.32KristinA
1-15
3.53
EthaneMethaneCO2N2
75-99
92.69
0-300-15Typical [1]
0.221.74TrollAA
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Industrial
examples
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Natural gas processing
Principal sketch natural gas processing route
Industrial
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Industrial examples
Troll, Kolsnes onshore plant
Industrial
Simplified flow sheet Troll onshore gas treatment plant Kolsnes
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Industrial examples
Principal sketch Troll, MEG*
System
Industrial
Background:
Troll is located in the north part of the North Sea, about 65 km west of Kolsnes
Ocean depth is above 300 meter
The field is divided into Troll east and Troll west
2/3 of the recoverable gas reserve is located in the east
* Monoethylene Glycol (MEG) also called ethylene glycol (EG)
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Troll
Dehydration system
Feed gas from
slug catchers
Inlet gasseparator
(Pressure, BARG)
(90)
(89.5)
(67)
(69.4)
Condensateand Glycol
(69)
(68.5)
(78.4)
Lean gas to pipelinecompressorsTurboexpander
Suction drum
Dewpointseparator
MEG
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Principal sketch KristinAll processing offshore
Kristin is a high pressure field (900 in the well, choke sea bottom to 350 bar)
Ocean depth is about 350 meters
Gas is transported to KrstEconomic choice of technology; takes advantage of high well pressure and existing single phase
pipe-line to Krst
Full processing offshore to meet existing pipe-line spec (105 cricondenbar) inlet pipeline pressure
211 bar and 50 degrees Celsius
Gas is delivered at Krst at 100 bar
Industrial
Q Q
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Kristin
Liquid separation system
Sketch of Kristins liquid separation system
Inlet
separator
2nd stage
separator
3rd stage
separator
1st stage
recompressor
2st stage
recompressor
3st stage
recompressor
To Dehydration system
(Pressure, BarA)
(87)
(26)
(2.15)
(1.7)
(7)
(25)
To condensate
storage
Inlet wet
gas
pressurereduc
tion
Pressureincreasing
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Kristin
Separation re-compressor package
From separator
To separator
Out of recompressorCompressor
separator
Sketch of Kristins separator recompression system
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Principal sketch KristinAll processing offshore
Kristin is a high pressure field (900 in the well, choke sea bottom to 350 bar)
Ocean depth is about 350 meters
Gas is transported to Krst
Economic choice of technology; takes advantage of high well pressure and existing single phase
pipe-line to Krst
Full processing offshore to meet existing pipe-line spec (105 cricondenbar) inlet pipeline pressure
211 bar and 50 degrees Celsius
Gas is delivered at Krst at 100 bar
Industrial
Q Q
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Kristin
De-hydration (TEG) system
Sketch of Kristins dehydration system
TEG: Triethylene glycol
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Snhvit
Principal sketch
Industrial
Slug
catcher
Inlet
separation
MEG
Recovery
Condensate
treatment
Feed from
pipeline CO2
Removal
CO2
De-
hydration
Mercury
Removal
Natural gas
liquefaction
To
pipeline LNG
storage
LPG
storage
Condensate
storageFractionation
First developed field in the Barents sea
Ocean depth of 300-350 meters
A gas field with condensate and an underlying thin oil zone
Choice of technology: Make LNG, no existing gas lines to Europe
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Snhvit dehydration system
Molecular sieve
Snhvits molecular sieve
Hot Oil
Regeneration
gas
Dry gas
(pressure, barA)
(64.9)
(63.0)
(64.0)
(63.7)
(63.2)
Wet gas
Regeneration gas
Example ofMolecular sieves
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Summary
Introduction, industrial examples and pipeline
These points have been discussed/explained:
General facts about natural gas
The dehydration system at: Troll (onshore), MEG injection and dehydration by cooling
(turboexpanders)
Kristin (offshore), dehydration by absorption (TEG system) Snhvit (onshore), dehydration by adsorption (molsieve)
Some of the issues related to transport of natural gas in pipelines
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Dehydration
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Natural gas processing
Principal sketch of a natural gas processing plant
Dehydration
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Dehydration
Natural gas is commerciallydehydrated in one of three ways
1. Absorption (Glycol dehydration)2. Adsorption (Mol sieve, silica gel, or activated
alumina)
3. Condensation (cooling) (Refrigerationwith glycol or methanol injection)
Four glycols are used for dehydrationand/or inhibition
1. Monoethylene Glycol (MEG) also
called ethylene glycol (EG)
2. Diethylene glycol (DEG)
3. Triethylene glycol (TEG)
4. Tetraetylhene glycol (T4EG)
Dehydration
Absorption and refrigeration with hydrate inhibition is the most common dehydration
process used to meet pipeline sales specifications
Adsorption processes are used to obtain very low water contents required in lowtemperature processes, for example LNG
TEG is most common in absorption systems
MEG is most common in glycol injection systems
Dehydration is the process of removing water from a gas and/or liquid
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AbsorptionDehydration
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Absorption
DehydrationNatural gas is dried by absorption,
often in a countercurrent scrubbing
unit
A liquid having a strong affinity forwater is used as an absorbent
A good absorbent should have:
1. Strong affinity for water
2. Low cost
3. Non corrosive
4. Low affinity for hydrocarbons andacid gases
5. Thermal stability
6. Easy regeneration
7. Low viscosity
8. Low vapor pressure at the contacttemperature
9. Low tendency to foam
Absorption
Dehydration
TEG
DEG
TEG
TEG
Vapor pressure25 C
Freezing point
C
Viscosity (25 C)
Molecularweight
T4EGDEGMEG
-13 - -7TEGT4EGMEG
17- 49T4EGDEGMEG
62 194T4EGDEGMEG
Increasing values
Basic glycol properties
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Basic glycol dehydration unit
Simplified flow diagram for a glycol dehydration unit. from the GPSA Engineering Data Book, 11th
ed.
Absorption
Dehydration
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The glycol dehydration unit
Wet gas (no liquid water) enter bottomof absorber and flowscountercurrent to the glycol. Leanglycol enters at the top
Absorber internal
Tray
Bubble cap
Valve
Sieve
Packing
Berl Saddle, Raschig Ring
ReactorOne, two pass trays
Bubble Cap
Bearl Saddle
Valve tray
Sieve trayBubble Cap tray
Absorption
Dehydration
Maximize
Contact area
and time
Gas/glycol
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Absorber design
Design parameters
Purity demand
Working temperatures
Working pressure
Choice of absorbent
Design procedure
Mass balance circulate enough glycol toabsorb the water in the gas
Gas rate tank diameter (flooding)
Equilibrium analysis number of equilibriumstages
Real analysis, have to take into account thereaction kinetic and contact time betweenglycol and gas. Gives number of actual trays
Dryer glycol higher concentrationdifferences higher reaction kinetichigher efficiency more expensive andheavier glycol regeneration system
Higher glycol circulation rate higherconcentration differences higher reactionkinetic higher efficiency higher pressure
drop
more expensive and heavier pumps
Principal sketch assuming:
Mass transfer are controlled by
resistance on the gas side
Straight operation and equilibrium
lines of mol fraction water in the gasphase
stagesactualofNo
stagesEQofNo
.
.
Absorption
Dehydration
Mol fraction water
in glycol
Molfractionwater
ingas
Bottom of
tower
Top of tower
Glycolflo
w
Gasflow
EQlineOP
line
Yb*
Yb
Yt*
Yt
Y mol frac. Watergas phase
Y* EQ mol frac.
Water gas phase
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Glycol regenerationAlternatives
A) Open stripping loop
B) Closed stripping loop
C) Cold finger
Increasedtemperature
A) Any inert gas is suitable. Theoretically best to insert
stripping gas between re boiler and surge tank
B) A closed stripping loop, isooctane can be used.
Vaporizes at re-boiler temperature and condenses and
can be separated from water in a three phase separator.
High stripping gas rates with little venting of
hydrocarbons. Glycol cons> 99.99% (w/w) has been
achieved.
C) A cold finger is inserted into a bucket in the
surge drum vapor space. A TEG mixture rich inwater condenses out. This mixture is taped off.
H2O partial pressure is lowered and lean glycol
concentration is increased. 99.5-99.9 % (w/w)
glycol has been achieved.
Absorption
Dehydration
Rich TEG
Re boilerHeat
Exchanger
A; Stripping gas
A; Wet strippinggas
Water
B; strippinggas
TEG unit
Cool
Heat
still
column
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Glycol regeneration
ComponentReboiler:
Temperature should not exceed 204 C (TEG) due to
degradation.
Some degradation of glycol in contact with heattransfer surface maximum heat flux rates.
Heat provided with direct fired fire tubes immersed in
the bath, hot oil, steam or electric resistance heating.
Stripping Colum:
Can be trayed or structural packed. Stripping gas
lowers the partial pressure of H2O in the gas phase,
and more water can be absorbed by the gas (Raoultslaw).
Surge drum:Retention time >20 min
Be able to hold all the re-boiler glycol, to allow repair
or inspection of the re-boiler heating coil.
Flash tank:
Used to remove light hydrocarbons,CO2, H2S. Operation pressure 15% of
the contactor operating pressure.
Filters:
Captures chemical impurities and solid
particles. Pressure drop is measured
and used as a replacing criteria.
Absorption
Dehydration
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Glycol absorptionPros and cons
Pros
Low initial cost
Low pressure drop across absorption towers
Recharging of towers present no problems
Materials that would cause fouling of somesolid adsorbents can be tolerated in thecontactor
Cons
Suspended matter, such as dirt, scale, and ironoxide may contaminate glycol solutions
Overheating of solutions may produce both lowand high boiling decomposition products
The resultant sludge may collect on heatingsurfaces, causing some loss in efficiency, or, insevere cases, complete flow stoppage
When both oxygen and hydrogen sulfide ispresent, corrosion may become a problembecause of the formation of acid material in the
glycol solution Liquids such as water, light hydrocarbons or
lubrication oils in inlet gas may requireinstallation of an efficient separator ahead ofthe absorber. Highly mineralized water enteringthe system with inlet gas may, over longperiods crystallize and fill the re-boiler with solid
salts Foaming of solution may occur with a resultant
carry-over of liquid. The addition of a smallquantity of antifoam compound usuallyremedies this problem
Absorption
Dehydration
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Dehydration by
cooling
D h d ti b
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Refrigeration system
A refrigeration system lowers thetemperature of a fluid or gas below thatpossible when using air or water atambient conditions.
Refrigeration systems are used for Removing of water Chilling natural gas for NGL
extraction
Chilling natural gas forhydrocarbon dew-point control
LPG product storage
Natural gas liquefaction (LNG)
Refrigeration processes: Mechanical refrigeration
Compression (uses energy in form of workto pump heat)
Absorption (use energy in form of heat topump heat, ammonia systems) Expansion refrigeration
Valve expansion (Joule Thompson)
Turbine expansion (Turbo expander)Natural gas liquid fractions as a function of
temperature at atmospheric pressure
Dehydration by
cooling NGL
recovery
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Refrigeration cyclePrincipal thermodynamic path
A-B,E cooled by heat exchange with the process gas.
B-C Natural gas is cooled by heat exchange with the refrigeration cycle. The gas temperature is lowered at
constant pressure.
E-F Natural gas is cooled by isentropic (constant entropy S) expansion through a turbine (turbo expander), EF
actual path.
B-D Natural gas is cooled by isenthalpic (constant enthalpy) expansion through a valve (Joule Thompson).
Dehydration by
cooling NGL
recovery
Thermodynamic pathLiquid recovery by refrigeration
D h d ti b
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Principal sketch of arefrigeration cycle
Refrigeration is achieved by vaporization at relatively low refrigerant pressure.
The refrigerant can be a propane or sometimes a halogen of the Freon type.
Dehydration by
cooling NGL
recovery
Natural
gas
Dehydration by
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Turbo expander cycle(Troll gas)
Dehydrated
gas
Condensate
and Glycol
Lean gas to pipeline
compressorsTurboexpander
Suction drum
Dewpointseparator
Turbo expander process for
NGL extraction
Phase envelope based Troll, dehydrated gas
1 Feed gas
1-2 Gas-gas heat exchanger
2-3 Suction drum
3-4 Turbine expander
4-5 Dewpoint separator
5-6 Gas-gas heat exchanger
6-7 Compression
A hydrate inhibitor (MEG) is
often injected upstream of the
heat exchanger, if the gas is un-hydrated
y y
cool ing NGL
recovery
-10
10
30
50
70
90
110
-170 -140 -110 -80 -50 -20 10 40
Temperature [C]
Pressu
re
[Bar]
Path turbo expander
Feed gas phase envelope
Path joule thompson
1 2
3
45
67
Joule Thompson cycleDehydration by
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Joule Thompson cycle(Trol l gas)
Inlet gas
Condensateand Glycol
(69)
Lean gas to pipeline
compressorsTurboexpander
Suction drum
Dewpoint
separator
Phase envelope based on Troll, dehydrated
gas
Joule Thompson process
for NGL extraction
1 Feed gas
1-2 Gas-gas heat exchanger
2-3 Suction drum
3-4 Valve expander
4-5 Dewpoint separator
5-6 Gas-gas heat exchanger
A hydrate inhibitor (MEG) is
often injected upstream of the
heat exchanger, if the gas is un-
hydrated.
y y
cool ing NGL
recovery
-10
10
30
50
70
90
110
-170 -140 -110 -80 -50 -20 10 40
Temperature [C]
Pre
ssure
[Bar]
Path turbo expander
Feed gas phase envelope
Path joule thompson
1 2
3
45
6
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Dehydration
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Dehydration by adsorption
Adsorption describes any process where gas molecules are held onthe surface of a solid by surface forces. Adsorbents may bedivided into two classes.
Species is adsorbed due to physisorption and capillarycondensation
Species is adsorbed due to chemisorption (not much used innatural gas processing)
A sorbent must have the following properties:
1. High adsorption capacity at equilibrium
2. Large surface area
3. Easily and economically regenerated
4. Fast adsorption kinetics
5. Low pressure drop
6. High cyclic stability (kinetic and capacity)7. No significant volume change (swelling shrinking)
Dehydration
by sorption
Dehydration by adsorptionDehydration
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Dehydration by adsorption
The commercial available sorbents can be divided into three broad categories:1. Gel
A granular amorphous solid (silica gel (SiO2), alumina gel Al2O3)
2. AluminaHydrated form of aluminum oxide Al2O3, activated by drying off part of the hydrated water
adsorbed on the surface
3. Molecular sievesAlkali metal crystalline aluminosilicates, very similar to natural clays
Example of sorbents:
Silica gel (Gel type)Outlet gas water content down to 10 ppm (v/v) and dew point -60 C can be achieved
Regenerated between 120 and 200 C
It adsorbs hydrocarbons, which are desorbed during regeneration
Silica gel is destroyed by free water which causes the granules to burst, and react with bases
Activated alumina Al2O3Outlet gas water content
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Principal sketchAdsorbent system
http://www.uop.com/objects/96%20MolecularSieves.pdf
Flow sheet of a basic two tower adsorption system with regeneration
Molecular sieves
Dehydration
By sorption
Re
generation
Operation
Process gas
Regeneration gas
Regeneration gasProcess gas
Dehydration
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AdsorptionConcentration profiles
Active
Zone
Mass transfer
Zone
Equilibrium
Zone
Dry gas
Wet gas
Variation of adsorption zones with time and height Schematic view of reactor bed with adsorption zones
Equilibrium zone: Sorbent is saturated with water.
Mass transfer zone: All the mass transfer takes place in this zone.
Active zone: The sorbent has its full capacity for water, contains only residual
water left from regeneration cycle.
y
by sorption
Ad iDehydration
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AdsorptionGeneral point and re-generation
Design parameters
Number of adsorption unitsregeneration time
Gas velocity and allowablepressure drop diameter
Good internal flow distribution avoidchanneling
Proper pre-treating of the gas Degradation due to loss of
effective surface area Degradation due to blockage of
small capillary or latticeopenings
Proper heat loss management(insulation internal/external)
optimize regeneration Proper heat recovery
Possible to replace adsorbent
Principal sketch of reactor temperature duringregeneration
T0-TA heating of the reactor
TA-TB evaporation and breaking of surface
forces
TB-TC removing of heavy contaminants
and residual water
TC Cooling, heat recovery phase
Dehydration
by sorption
S d h d ti
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Summary dehydration
Different dehydration technologies have been discussed Absorption
Glycol system Trayed towers
Structural packing
Concentration profiles Design guide lines
System components
Cooling System
Compressor cooling Turbo expander Joule Thompson
Adsorption Concentration profiles
Design guide lines
System component/operation
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CO2 capturetechnology
CO capture from energy related sources
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CO2 capture from energy related sources
CombustionFossil fuel
Flue gas
Air
Energy
CO2separation
CO2
N2 ,O2
Gasification/
reforming
Fossil fuelH2, CO2
Air/O2 Steam
Energy
CO2separation
CO2
H2 Combustion
Air
N2 ,O2 , H2O
Energy
CO2 capture from large scale power plants is yet
to be implemented
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Selcetion of CO2 capture technology
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Selcetion of CO2 capture technology
http://www.uop.com/gasprocessing/6010.html
Typical CO2 absorption loop
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Typical CO2 absorption loop
Amine
AbsorberFeed
Gas
KO Drum
Product
Gas
KO Drum
Feedgas
Product gas
Lean-Rich
Exchanger
WaterMake Up
Water Wash
Pumps
Rich Solvent
Flash Drum
Flash gas
Lean Sol.
Cooler
(CW)
Carbon
Filter(Lean Sol)
Amine
Regen-
erator
HP Lean
Pump
LP Lean
Pump Regen.
Reboiler
(LPS)
Acid Gas
Condenser
(CW)
Regen.
Reflux
Drum
Reflux
Pump
Acid gas
Summary of presentation
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Summary of presentation
These points have been discussed/explained:
General facts about natural gas
Industrial dehydration examples The different mechanism in gas/liquid separation
Different dehydration technologies Absorption
Cooling
Adorption
Sour gas removal