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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
UOP 5241E-05
Composite Membrane Structure
Composite MembranesTwo or more polymersThin layer of highly optimized polymerMounted on an asymmetrical structureHighly tailored properties at low cost
UOP 5241E-06
Membrane Elements - Spiral Wound
UOP 5241E-07
Spiral Wound Membrane Element and Tube
UOP 5241E-08
Hollow Fiber Membranes
UOP 5241E-09
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
UOP 5241E-12
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)
UOP 5241E-14
Agenda
Membrane Technology OverviewPretreatment OptionsFlow Scheme OptionsCommercial Experience
UOP 5241E-15
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
UOP 5241E-21
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
UOP 5241E-23
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
UOP 5241E-25
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
UOP 5241E-26
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
UOP 5241E-27
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
UOP 5241E-35
Pakistan II Overall Layout
UOP 5241E-36
Pakistan II Expansion Skids
UOP 5241E-37
Pakistan II MemGuard System
UOP 5241E-38
Egypt I Plant Layout
UOP 5241E-39
Egypt I Plant Membrane Skid
UOP 5241E-40
Egypt I Plant –2nd-Stage Membrane Skid
Carbon Guard Bed
2nd Stage Membrane
UOP 5241E-41
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
UOP 5241E-44
Installed Malaysian MemGuard System
UOP 5241E-45
Offshore Thailand Membrane Skids
UOP 5241E-46
Thailand Platform
UOP 5241E-47
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
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