New Membrane Applications in Gas ProcessingNew Membrane Applications in Gas Processing

By By

Kaaeid A. Lokhandwala and Marc JacobsKaaeid A. Lokhandwala and Marc Jacobs

Membrane Technology and Research, IncMembrane Technology and Research, Inc. .

1360 Willow Road, Menlo Park, CA 94025 1360 Willow Road, Menlo Park, CA 94025

Membrane Separation MechanismMembrane Separation Mechanism

MTR’s Rubbery Membranes Reject Methane MTR’s Rubbery Membranes Reject Methane and preferentially permeate the heavy hydrocarbonsand preferentially permeate the heavy hydrocarbons

PP11 D D1 1 . S. S11

PP22 D D2 2 . S. S22

=

Permeability = Diffusivity * Solubility Permeability = Diffusivity * Solubility (P) (D) (S)(P) (D) (S)

Membrane SelectivityMembrane Selectivity

Glassy v/s Rubbery MembranesGlassy v/s Rubbery Membranes

Glassy MembranesGlassy MembranesFast GasFast Gas Slow GasSlow Gas

HexaneHexane

PropanePropaneHH22OO

EthaneEthane

COCO22

MethaneMethane

HydrogenHydrogenNitrogenNitrogen

HydrogenHydrogen

COCO22HH22OO

NitrogenNitrogen

MethaneMethane

EthaneEthane

PropanePropaneHexaneHexane

Rubbery Membranes Rubbery Membranes

Fast Gas Fast Gas Slow GasSlow Gas

Membrane System InstallationsMembrane System Installations

Gas/Gas Separation SystemsGas/Gas Separation Systems

Glassy Glassy MembranesMembranes

Rubbery Rubbery MembranesMembranes

HH22/N/N22, CH, CH44 ~ 200 Units ~ 200 Units

OO22/N/N22 ~ 5,000 Units ~ 5,000 Units

COCO22/CH/CH44 ~ 200 Units~ 200 Units

Vapor/Gas Separation SystemsVapor/Gas Separation Systems

VOC/Air VOC/Air

Hydrocarbon/NHydrocarbon/N22. CH. CH44 ~ 100 Units ~ 100 Units

Polymeric Selective Polymeric Selective LayerLayer

Microporous Microporous SupportSupport

Support Support FabricFabric

Separating LayerSeparating Layer

Layers for Mechanical Layers for Mechanical SupportSupport

MTR’s Composite Membrane

Module housingModule housing

SpacerSpacer

MembraneMembrane

SpacerSpacer

Feed flowFeed flow

Permeate flowPermeate flow

after passing throughafter passing throughmembranemembrane

Feed flowFeed flow

Feed flowFeed flow

Permeate flowPermeate flow

Residue flowResidue flow

Residue flowResidue flow

MTR Spiral Wound Cartridge

NGL Separation Skid

Flow CapacityFlow CapacityMax: 8 MMSCFD Max: 8 MMSCFD Operated: 2.5-3.0 MMSCFD Operated: 2.5-3.0 MMSCFD Pressure ratingPressure rating Max: 1250 psig Max: 1250 psig Operated: 475 psigOperated: 475 psig TemperatureTemperatureMax: 135Max: 135ooF F Operated: 100-125Operated: 100-125ooF F

Field Data - Feed/Permeate Flow ratesField Data - Feed/Permeate Flow rates

0

200

400

600

800

1000

1200

1400

4/20 5/10 5/30 6/19 7/9 7/29

Time (Date)

Flo

w R

ate

(s

cfm

)

0 20 40 60 80 89

Operating Time (Days)

Location: Chevron’s Lost Location: Chevron’s Lost Hills Hills Station, CA Station, CA Feed pressure: 450 psig Feed pressure: 450 psig Avg. Feed Flow rate:Avg. Feed Flow rate:

2.8 MMSCFD 2.8 MMSCFD Avg. Permeate Flow rate: Avg. Permeate Flow rate:

0.6 MMSCFD 0.6 MMSCFD

Field data - Percent Removal RatesField data - Percent Removal Rates

10

20

30

40

50

60

70

80

90

100

1997-11-16 1998-1-5 1998-2-24 1998-4-15 1998-6-4 1998-7-24

Date

Per

cen

t R

emo

val

(%

)

C3

C4

C5

C6

C8

Component Average %Removal

Propanes 55.7Butanes 61.0

Pentanes 68.1Hexanes 74.0Octanes 91.4

Field Data - Hydrocarbon Dewpoints

0

20

40

60

80

100

120

140

160

8/8/97 9/27/97 11/16/97 1/5/98 2/24/98 4/15/98 6/4/98 7/24/98

Date

Hyd

rocarb

on

Dew

po

int

in

Dewpoint of Conditioned Gas oF

Feed Gas Temperature oF

Dewpoint of Feed Gas oF

Field Data - Hydrocarbon DewpointsField Data - Hydrocarbon Dewpoints

0

20

40

60

80

100

120

140

160

1997-8-8 1997-9-27 1997-11-16

1998-1-5 1998-2-24 1998-4-15 1998-6-4 1998-7-24

Date

Hyd

roca

rbo

n D

ewp

oin

t in

Dewpoint of Conditioned Gas oF

Feed Gas Temperature oF

Dewpoint of Feed Gas oF

NGL Separation and Recovery ApplicationsNGL Separation and Recovery Applications

• Well-head Gas Dewpoint Control Well-head Gas Dewpoint Control

• Associated Gas Liquids Recovery Associated Gas Liquids Recovery

• Engine and Turbine Fuel Gas Conditioning Engine and Turbine Fuel Gas Conditioning

• Propane Refrigeration Plant Debottleneck Propane Refrigeration Plant Debottleneck

• Re-injection Gas Liquids Recovery Re-injection Gas Liquids Recovery

• Flare Gas Liquids Recovery/Conditioning Flare Gas Liquids Recovery/Conditioning

• Vapor Recovery from Storage Tank LossesVapor Recovery from Storage Tank Losses

Value of NGL (@ $ 14/bbl): $ 1.2 Million/yr Value of NGL (@ $ 14/bbl): $ 1.2 Million/yr Both Hydrocarbon and Water Dewpoint Reduced in one processBoth Hydrocarbon and Water Dewpoint Reduced in one process

Price of VaporSep System: $ 750,000-850,000Price of VaporSep System: $ 750,000-850,000

Membrane Membrane SystemSystem

Raw Raw Natural GasNatural Gas

To High Pressure To High Pressure PipelinePipeline

Stabilizer Stabilizer 250 psia250 psia

Booster Booster CompressorCompressor

250 psia 250 psia 6 MMSCFD6 MMSCFD

Hydrocarbon Hydrocarbon Dewpoint: 15Dewpoint: 15ooF F

1000 psia1000 psia

10562 gpd10562 gpdNGLNGL

1000 psia 1000 psia 9595ooFF

CC33+ enriched gas+ enriched gas

Wellhead Dewpoint ControlWellhead Dewpoint Control

Economic Comparison – Dewpoint ControlEconomic Comparison – Dewpoint Control

ProcessProcess Installed Cost Installed Cost Processing Cost Processing Cost (MM$)(MM$) ($/inlet Mscf) ($/inlet Mscf)

Propane Refrigeration 1.6 0.165 Propane Refrigeration 1.6 0.165 MembraneMembrane 1.1 1.1 0.098 0.098

Propane Refrigeration Cost: Purvin and Gertz, June 1999, Private Study Propane Refrigeration Cost: Purvin and Gertz, June 1999, Private Study

Basis: 10 MMSCFD Plant/Lean Gas (3.9 GPM, 1185 Btu/SCF)Basis: 10 MMSCFD Plant/Lean Gas (3.9 GPM, 1185 Btu/SCF)

Increased Oil Production: Increased Oil Production: 870 Barrels/day 870 Barrels/day Value of Additional Oil Recovered (@ $ 10/bbl): Value of Additional Oil Recovered (@ $ 10/bbl): $ 3.0 Million/yr $ 3.0 Million/yr Additional Power required: Additional Power required: 470 hp 470 hp

Price of VaporSep System: $ 1 - 1.25 MillionPrice of VaporSep System: $ 1 - 1.25 Million

Well-head Well-head Crude Crude

1015 psia1015 psia

Compressed Compressed Natural Gas Natural Gas 47 MMSCFD47 MMSCFD

Crude to Crude to Storage Storage 315 psia315 psia

Membrane System

250 psia250 psia

15 psia15 psia

Associated Associated GasGas

Associated Associated GasGas

Platform Associated Gas TreatmentPlatform Associated Gas Treatment

Gas EngineGas Engine

Raw Fuel GasRaw Fuel Gas

Conditioned Conditioned Fuel GasFuel Gas

CompressorCompressor

Membrane SystemMembrane System

Compressed Compressed Natural GasNatural GasMembrane System Price : $150,000Membrane System Price : $150,000

Process Conditions Process Conditions MembraneMembrane FeedFeed Conditioned Fuel GasConditioned Fuel GasTemperature Temperature ooFF 9595 5151Pressure (psia) Pressure (psia) 955 955 945945Flow Rates (MMscfd)Flow Rates (MMscfd) 0.95 0.95 0.50.5Octane NumberOctane Number 113.7113.7 116116Hydrocarbon Dewpoint (Hydrocarbon Dewpoint (ooF)F) 9595 3737

Fuel Gas Conditioning - Gas Engine ExampleFuel Gas Conditioning - Gas Engine Example

Existing fuel gas compressorExisting fuel gas compressor

Membrane FuelMembrane FuelConditioning UnitConditioning UnitRaw FuelRaw Fuel

GasGas

Conditioned Conditioned Fuel Gas Fuel Gas To TurbineTo Turbine

Fuel Gas Flow Rate (MMSCFD) :Fuel Gas Flow Rate (MMSCFD) : 6.1 6.1 Feed Temperature (Feed Temperature (ooF) :F) : 120 120 Conditioned Fuel Dewpoint(Conditioned Fuel Dewpoint(ooF) :F) : 76 76 NGL Recovered (gpd) :NGL Recovered (gpd) : 15,000 15,000 Value of Recovered NGL (US $) :Value of Recovered NGL (US $) : 500,000 500,000 Membrane System Price (US $) :Membrane System Price (US $) : 400,000 – 600,000400,000 – 600,000

Fuel Gas Conditioning - Gas Turbine Case

Typical Fuel Conditioning Skid-mounted Unit

Location: Nigeria Location: Nigeria Flow Capacity: 2.5 MMSCFD Flow Capacity: 2.5 MMSCFD Pressure rating 550 psig Pressure rating 550 psig Operating pressure: 220 psig Operating pressure: 220 psig Feed hydrocarbon dewpoint: 82Feed hydrocarbon dewpoint: 82ooF F Conditioned Gas Dewpoint: 20Conditioned Gas Dewpoint: 20ooFF

Designed for Offshore Installation Designed for Offshore Installation Main System Components Main System Components Membrane Modules/Housings Membrane Modules/Housings Filter Separator/Coalescer Filter Separator/Coalescer Inlet and Discharge Valves Inlet and Discharge Valves System Dimensions: 6 ft (W) x 8 ft (L) x 8 ft (H)System Dimensions: 6 ft (W) x 8 ft (L) x 8 ft (H)

Advantages of Membrane SystemsAdvantages of Membrane Systems

• Simple passive system Simple passive system

• High on-stream factor (typically > 98%) High on-stream factor (typically > 98%)

• Minimal or no operator attention Minimal or no operator attention

• Small footprint, low weight (Platform Applications) Small footprint, low weight (Platform Applications)

• Ambient temperature operation in many applications Ambient temperature operation in many applications

• Large turndown ratio Large turndown ratio

• Low maintenance Low maintenance

• Lower capital and operating costsLower capital and operating costs

SummarySummary

Wide range of applications in the Oil, Gas and RWide range of applications in the Oil, Gas and R

efining Industries efining Industries

Gas:Gas: Fuel gas conditioning, NG dewpointing, Natural Fuel gas conditioning, NG dewpointing, Natural

Gas Dehydration. Gas Dehydration.

Oil:Oil: Associated gas processing, Vapor recovery from Associated gas processing, Vapor recovery from

storage tanks and transportation. storage tanks and transportation.

Refining:Refining: LPG/Fuel gas, Hydrotreater/Hydrocracker Purg LPG/Fuel gas, Hydrotreater/Hydrocracker Purg

e, Refinery gas plant, Hydrogen recovery. e, Refinery gas plant, Hydrogen recovery.