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❖ Objectives: The objectives of our tour to the Kailashtilla Gas Field are as follows:
• To observe the exploration and production processes of natural gas extraction.
• To gain insights into the technologies and equipment used in the industry.
• To understand the environmental considerations and sustainability measures adopted by
the gas field.
• To explore the economic and regional significance of the gas field.

❖ Introduction: Kailashtila MSTE Plant, a magnificent establishment of Sylhet Gas Fields Ltd. is
situated on 14.92 acres of land on the bank of river Surma at Golapganj Upazila, about 22 km
northeast of Sylhet City. A technological masterpiece in the field of gas treatment facilities and the
first of its kind in Bangladesh. It has total 8 gas wells and produce about 130 million cubic
centimeter which is about 5% of the total demand of our country. Now 3 well is in operation and
5 well is suspended.
The Molecular Sieve Turbo Expander (MSTE) type gas processing plant featuring cryogenic
mechanism was built so that the temperature of gas stream could be reduced to as low as -870C.
As a result, in addition to 7-8 barrels of heavy condensate, one million cubic feet of raw natural
gas was to liberate as much as 8-10 barrels of NGL, which would have not been possible if a
conventional type gas processing plant were introduced.
This plant is capable of processing 90 million cubic feet of natural gas. The processed natural Gas
is supplied to National Gas Grid Line and Jalalabad Gas. On the other hand, between the two by-
products of natural gas of this palnt, heavy condensate is supplied to Private Refineries or
Rashidpur Condensate Fractionation Plant and NGL to a NGL Fractionation Plant of Rupantarita
Prakritik Gas Company Ltd. (RPGCL), located at a distance of about 2 km from MSTE plant.

❖ Basic information of NGL: NGL is natural gas liquid. It is used as fuel for
cooking, household work and industrial purposes. If we want to ensure the
proper use of NGL then we need to know the physical properties of NGL,
chemical properties and composition of NGL. These are described below.

✓ Physical properties of NGL: The main products of our visited gas field
is natural gas liquids or NGL. Some important physical properties of
NGL are given below,
• State: NGLs can exist as gases at ambient temperatures and
pressures but can be liquefied under pressure or by lowering the
temperature.
• Boiling Points: Each component has a different boiling point, with ethane having the
lowest (around -88.6°C) and pentanes having higher boiling points (around 36°C).
• Density: NGLs are denser than natural gas but less dense than water, with densities varying
based on the specific composition.
• Viscosity: Generally, NGLs have low viscosities, allowing for easier flow in pipelines.
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✓ Chemical Properties of NGL: The important chemical properties of NGL are given below,
• Combustion: NGLs are combustible and release energy when burned, making them
valuable as fuel sources.
• Reactivity: They are relatively stable but can react with strong oxidizers and may form
hazardous compounds under certain conditions.
• Hydrogen Content: NGLs have a high hydrogen content, making them valuable for
hydrogen production.

✓ Composition of NGL: The composition of Natural Gas Liquids (NGLs) can vary based on the
source and processing methods, but a typical breakdown of the main components is as follows
• Ethane (C2H6): 20% - 30%
• Propane (C3H8): 30% - 50%
• Butanes (C4H10): 10% - 20%
• Pentanes and heavier hydrocarbons (C5+): 5% - 15%

These percentages can fluctuate based on factors such as the specific gas field, extraction
techniques, and market demand. In some cases, the proportions may differ significantly,
especially in rich gas plays where certain components are more abundant.

✓ Uses of NGL: Natural Gas Liquids (NGLs) have a variety of important uses across different
industries. Here are some of the primary applications:
• Fuel: It is used for heating, cooking, and as a fuel for vehicles (propane-powered cars).
• Petrochemical production: NGLs serve as feedstocks for producing plastics, synthetic
rubber, and other petrochemicals.
• Gas processing: NGLs are separated from natural gas to enhance the quality of the gas
and make it more marketable.
• Energy generation: Some NGLs can be used in power generation, providing a cleaner-
burning alternative to coal.
• Solvents: NGLs can act as solvents in various industrial processes, including oil extraction
and paint formulations.
• Residential use: NGLs like propane are commonly used for residential heating, hot water,
and cooking.

✓ So we can say that NGL is very important for our day to day life and our industrial applications.
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❖ Equipment and infrastructure: The industry we have visited recently is Kailashtilla Gas Field.
The main products of this gas field is natural gas liquids or NGL. There are a few instruments and
infrastructure in this gas field. Their figure and description are given below shortly.

➢ Wellhead: It is the instrument which is the gateway of the gas ore. After
drilling about 3000 to 3500 meter, Pakistan Shell Well company invented
and detected natural gas in Kailashtilla. There are total five valves in the
wellhead. The valve which is set in the below is called master valve. This
valve can stop the incoming gas flow and shut down the whole process.
The other four valves are used to control the flow rate of the gas. This
gate take the gas out from the gas well and send the gas to the further
refining process.
Fig: Wellhead of gas field

➢ Pipeline: This is the most important instruments in the industry

for mining and transporting the gas. Some pipes are used to
transport the gas from the gas well to the gas refining process.
Some are used to transport pure gas from industry to consumers.
All the pipe line of the industry are insulated so that the outer
temperature can not effect the inner temperature. The pipe lines
are also painted by strong paint so that the lines can be safe from
corrosion. If the lines becomes corroded then it can be a great
danger.
Fig: Pipelines

➢ Dehydrator: A dehydrator is an equipment that pulls the moisture out from the gas to prevent
the contamination and formation of steam. The industry we
have visited recently, we have spotted two dehydrator which are
indicated by Dehydrator tower-A and Dehydrator tower-B. Both
are used to remove the water content from the raw gas. If we do
not remove water from the gas then the water will form steam
at high temperature and this moisture will increase the rate of
corrosion. This moisture also reduces the quality of the gas,
forms smoke and reduces the calorific value of a gas fuel. For
this reason we use the dehydrator to remove the water content
from the gas. Fig: Dehydrator
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➢ Heat exchanger: A heat exchanger is a system used to transfer

heat between a source and a working fluid. Heat exchangers are
used in both cooling and heating processes. The industry we
have visited recently, there are total four heat exchangers in the
process. But there are two heat exchangers which are in
operation and the other two was suspended. Heat exchangers are
used to heat up the cold gas and cool down the hot gas which is
a vice versa process. There are only gas-gas heat exchanger
which is shell and tube type.
Fig: Heat exchanger

➢ Separator: Separator refers to the device which is used to

separate any unwanted particles from a mixture of fluids by using
force to get desire products. If the separator uses centrifugal force
then it is called centrifugal separator. If the separator uses
gravitational forces then it is called gravitational separator. The
industry we have visited recently, there are two separator
indicated by SP-1 and SP-2. Both use gravitational force and
remove unwanted particles like water, solids and make the gas
Fig: Separator
pure.

➢ Storage tank: The storage tank is used to store condensate

which we get from the raw gas after refining. In the industry
there are two storage tank indicated by T-07 and T-08. The
capacity of the tanks are 797500 liter and 816353 liter
condensate. After refining the raw gas we get condensate and
store them in those large tank. After that we send the
condensate to other industry by pipelines for further
processing.
Fig: Storage tank

➢ Compressor and Condenser: The instrument which can create high pressure and compress
the gas to reduce the volume is called compressor. It is used to compress the gas and keep a
huge amount of gas into a small space. There are total 5 compressor in the industry which are
in operation now. The instrument which is used to liquify the gas using low temperature is
called condenser. After condensation we get the condensate. After condensation the condensate
and the water separated from the raw gas and we get dry NGL.

➢ Surge drum and water pond: In the gas refining process we get the moisture in the form of
water and oil. When we get the oil from the process it is removed by a pipe and stored in the
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surge drum and remove water as drain water to close drain. In the industry there is also a water
pond and centrifugal pump. It is for the safety of the industry. If any fire accident occurs then
we can shut down the whole process and use water to control the fire accident.

➢ Heater and Cooler: When we need to heat up the gas then we use heater. For heating the gas
we use re-boiler and give some heat to the raw gas. When we need to cool down the gas then
we use cooler. The industry we have visited, there are a few large size fans which are used to
cool down the gas lines.

➢ De-Ethaniser: Ethane gas is not our desire product and it reduces the quality of the gas. For
this reason we need to remove ethane gas from our raw gas. In the industry we use de-ethaniser
to remove the ethane gas from the raw gas.

❖ Production process diagram: We take out the raw gas from the gas well, refine that raw gas.
After refining we get pure gas and condensate. From that condensate we get some black residue
like petroleum, bitumen etc. The production process from the raw gas to our desired product is
given below.

Figure: Flow diagram of gas production process

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❖ Process description: The process units of Kailashtilla Gas Field and their description is given
below,

• Inlet heater: It is a double pipe type heat exchanger. Gas from the wells is fed to three
separate inlet heaters to raise the temperature above 26°C. It is done to prevent hydrate
formation when inlet gas pressure is reduced to 88 bar from 150 bar. Gas is passed through
the tubes and hot oil (Therminol-6, 6) on the shell side.

• Inlet separator: Gases from three inlet heaters are fed to three corresponding inlet
separators. In these separators, components are separated by specific gravity and a pressure
of 88 bar is maintained. Feed is separated into Gas, water and Condensate. Water level in the
separator is maintained at a certain level and excess is drained, gas is fed to inlet filter and
condensate is charged into Stabilizer at 7 bar and 20°C.

• Inlet Filter Separator: Feed gas from the three-phase separator is further filtered here to
protect the molecular sieve in the dehydrator tower. There are two units, one is always on
duty and another is spare. This unit consists of filter area with replaceable filter element and
a vent type mist extractor.

• Molecular Sieve Type dehydrator: There are different types of gas dehydrator based on
desiccants such as silica-gel type, TEG (Glycol) type, Molecular sieve type etc. In this plant
Molecular sieves are used in dehydration of gas stream. Two dehydrators are used; one is on
duty and another in regeneration for time cycle of 8 hours. Molecular sieve has porous
cavities to entrap moistures. Feed gas at 88 bar pressure and 29°C are fed to one online
dehydrator from the top in a down flow pattern for 8 hours. When desiccants are exhausted
the unit is turned into regeneration cycle and the other one is made online.

• Regeneration of Molecular sieves: Regeneration is done by passing hot gas through the
bed; this gas is fed from the bypass of the residue gas. The steps in regeneration are:

➢ Depressurization: First the flow of gas to the tower to be regenerated cut off by closing
the valve and depressurized slowly from 88 bar to 32 bar over a time period of 30
minutes to avoid high gas velocity that can damage the bed. The residue gas from
expander-compressor or J-T valve is passed through a heat exchanger and gas
temperature is raised to 276°C. The hot gas is then passed through the bed for 4 hours,
bed temperature become 180°C and water in the molecular sieves are vaporized and
flow with hot gas. To make the bed ready for dehydration residue gas is passed through
a bypass line instead of the heat exchanger and then passed through the bed for 3 hours.
Bed temperature is decreased to 42°C.

➢ Pressurization: The tower is pressured back to 88 bar from 32 bar a period of 30 min.
Then the inlet gas is bypassed to this tower for dehydration and the other one starts
regeneration.
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• Regeneration gas heater: It is a shell & tube type heat exchanger. Hot oil at 276°C passes
through the tube side and gas is passed through the shell side and gas is heated for using in
regeneration of bed.

• Regeneration gas cooler: This is an air-cooled heat exchanger. It is used to condense the
water and hydrocarbon vapor produced during the regeneration heat cycle. The outlet
temperature is 16 to 49°C.

• Regeneration Gas scrubber: In this unit gas is passed to separate gas and any liquid
contents. Gas leaves this vessel at the top and passes through a mesh screen so that any
residue is collected.

• Dust Filter: Dusts maybe present in the gas and also can be the cracked particles of
molecular sieves. Dusts are removed by passing the gas stream through a dust filter. Water
molecules present after dehydration are also entrapped here. Outlet stream of this unit is then
passed to the Gas to gas heat exchanger (97%) and De-ethanizer feed heater (3%).

• Gas to Gas heat exchanger: It is a shell and tube type heat exchanger which is used to cool
the gas. The cooling gas is the gas stream from the top of the De-ethanizer column which is
at a temperature of -47°C as a result of going through the cryogenic process. The hot stream
is at 29°C that is to be cooled down.

• Cold separator: In gas-gas heat exchanger the inlet gas is cooled down to -18°C, as a result
liquid is formed by condensation. Cold separator extracts this condensed liquid. Inlet gas
then flows through the 3 expanders or their bypass J-T (Joule Thomson) valves. Then flows
to the expander separator. Liquid formed in this unit also flows to the expander separator.

• Turbo expander: A turbo expander, also referred to as an expansion turbine, is a centrifugal

or axial flow turbine through which a high-pressure gas is expanded to produce work that is
often used to drive a compressor. Turbo expanders are very widely used as sources of
refrigeration in industrial processes such as the extraction of ethane and natural gas liquids
(NGLs) from natural gas. Inlet gas from the cold separator flows through the 3 expanders at
88bar. The expansion of the gas releases energy and provides work. As a result, gas stream
is cooled down and as the temperatures of the gases drop below to the dew point, they
condense out as liquid and higher hydrocarbon such as propane, butane is recovered as NGL.

• J-T (Joule-Thomson) valve: It is an alternative to the turbo expander, also when turbo
expander is overloaded JT valve is used to expand the excess gas stream. The use of turbo
expanders does not eliminate the need for the Joule Thompson valve. This is typically
referred to as the expander bypass valve but operates under the Joule Thompson effect. The
valve is used to enable a more efficient startup and shutdown of the turbo expander. It is also
used to continue the process when the expander goes offline or if flow increases beyond the
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full speed capacity of the turbo expander. Inlet gas flows through the 3 expanders or their
bypass J-T (Joule Thomson) valves. Then it flows to the expander separator.

• Expander / Cold separator: It is designed to separate the NGL liquid from the gas stream
which is coming from turbo expander/JT valve. This separator has to inlet, one from cold
separator bottom and another from expander outlet. The gas from this unit is passed through
a mist extractor to recover residual NGL. Separated NGL from this unit is then fed to the De-
ethanaizer.

• De-ethanizer feed heater: This heat exchanger is used for pre heating the De-ethanizer feed.
Process gas from dust filter is used as heating media. The feed is heated so that ethane
recovery becomes easier.

• De-ethanizer: It is a fractionation column. The purpose of de-ethanizer is to remove ethane

and trace amount of methane from NGL that contains propane, butane etc. It consists of
number of trays with bubble caps. Lighter components are stripped from NGL and these
gases leave the tower at the top. De-ethanized NGL is then stored in NGL storage tanks.

• De ethanizer Reboiler: It is a kettle type reboiler that supplies sufficient heat to the bottom
liquid to produce enough vapors to strip the lighter components from NGL feed. Hot oil
flows through tube bundle. The reboiler shell has spillover internal weir that keep the tube
bundle submerged in liquid.

• Residue Gas Compressor: There are five gas compressors which are identical and separate
self-contained packaged unit. Each unit has lube oil and cooling systems. These compressors
work in parallel. Gas from expander compressor common discharge header in cryogenic
section is fed to these compressors after compression gas pressure is increased to 55 bar and
fed to the pipeline.

• Gas Cooler: Temperature of the gas raise as the pressure increased. So, gas needs to be
cooled. Compressed gas cooled at 300°C by a gas cool and fed to the pipeline. Final Gas
pressure and temperature in the pipeline is 55 bar at 300°C.

• Liquid Hydrocarbon (Condensate) Processing: After refining the raw gas we get some
residue called condensate. The process of condensate processing is given below.

• Liquid Stabilizer: The stabilizer with 16 trays to handle hydrocarbon Liquid that drops out
in the three inlet separators. Liquid from the inlet separator is flashed to 12.1 bar and is feed
into the top of the stabilizer. The stabilizer operates at 200°C on the top tray and 1800°C on
the bottom tray. The stabilizer reboiler outlet temperature is controlled at 2120°C at 7 bar.
The liquid is cooled to 350°C and then pumped to NGL surge drum. The vapor product is
fed to fuel gas system at a rate of 500 m3/hr. 97% of the ethane & 62% propane plus heavier
components exit the bottom as a stabilized NGL product. In this process all of the N2 & CO2
from the feed stream is removed. The total liquid stream from tray number 8 is routed through
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the separator where the water settles out of the hydrocarbon. The hydrocarbon is then
returned to the stabilizer on to tray no 9. The tower feed is saturated with water. Therefore, a
water separator is required to remove the undesired water. The separator is fed from a draw-
off tray below tray-8 & returns hydrocarbon condensate must flow through the mesh pad
mater molecules are coalesced to from larger droplets of water. In the separator section water
is separated from the hydrocarbon condensate & accumulated in the separated boot. Water
accumulated in the separated boot must be drained manually at regular intervals to prevent
flooding the stabilizer, which may reduce the efficiency of the stabilizer. Heat is added to the
bottom of the tower by the stabilizer reboiler. The reboiler is a kettle type with hot oil
circulated through the tube bundle. The hot oil flow is temperature controlled to maintain a
constant tower bottom temperature. The reboiler shell is equipped with a spill-over weir
which ensures that the tube bundle is completely submerged in liquids at all times. The weir
forms a reservoir on the down streamside where NGL product is collected. The excess NGL
product is level controlled from the reservoir section through the stabilizer product cooler.

• Stabilizer Product Cooler: The 1750°C NGL product from the stabilizer is cooled to 300°C
by to identical forced draft air cooled exchanger. One air cooler is spare & appropriate
isolating valves are provided. Each air cooler has three fans driven by 1.6 KW electric
motors. After cooling, NGL product is pumped to the surge drum.

❖ Safety of workers: The Kailashtilla gas field in Bangladesh is operated by Sylhet Gas Fields
Limited (SGFL). SGFL has implemented a number of safety protocols to ensure the safety of
workers and the public at the gas field. These protocols include:

• Regular inspections: The gas field is inspected regularly by SGFL engineers to identify and
address any potential safety hazards.

• Emergency procedures: SGFL has a comprehensive set of emergency procedures in place

in case of a gas leak or other incident. These procedures are regularly reviewed and updated
to ensure that they are effective.

• Training: SGFL employees receive regular training on safety procedures. This training
covers topics such as gas handling, emergency response, and first aid.

• Personal Protective Equipment: SGFL employees are required to wear personal protective
equipment (PPE) when working at the gas field. This PPE includes hard hats, safety glasses,
and steel-toed boots.

In addition to these safety protocols, SGFL also works closely with the government of Bangladesh
to ensure the safety of the Kailashtilla gas field. The government has a number of regulations in
place that govern the operation of gas fields in Bangladesh. SGFL complies with all of these
regulations to ensure the safety of the gas field and the public. These safety protocols have helped
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to ensure the safe operation of the Kailashtilla gas field for many years. The gas field has a good
safety record, and there have been no major accidents in recent history.

❖ Environmental consideration: During our visit to the Kailashtilla Gas Field, we had the
opportunity to learn about the gas field's commitment to environmental considerations and the
measures taken to minimize its ecological impact. The following are some of the key
environmental aspects we explored:

➢ Air pollution:The extraction and processing of natural gas can release pollutants into the air,
such as nitrogen oxides, sulfur dioxide, and volatile organic compounds. These pollutants
can contribute to respiratory problems, smog, and acid rain.

➢ Water pollution: The extraction and processing of natural gas can also contaminate water
supplies. This can be caused by leaks from pipelines, spills from storage tanks, and the
disposal of wastewater.

➢ Land disturbance: The construction of gas wells and pipelines can disrupt the landscape
and damage habitats. This can impact wildlife, plants, and people who live in the area.

➢ Noise pollution: The operation of gas wells and pipelines can generate noise pollution,
which can be disruptive to people who live nearby.

➢ Soil contamination: The extraction and processing of natural gas can contaminate soil,
which can make it unsafe for agriculture or other uses.

➢ Potential for accidents: The drilling and production of natural gas can be hazardous. There
is a risk of accidents, such as blowouts, spills, and fires. These accidents can have a
significant environmental impact.

➢ Impact on biodiversity: The construction of gas wells and pipelines can fragment habitats
and disrupt the movement of animals. This can have a negative impact on biodiversity.

➢ Climate change: The extraction and combustion of natural gas releases greenhouse gases
into the atmosphere, which contribute to climate change.

➢ Governance: It is important to have strong governance in place to ensure that the

environmental and social impacts of the Kailashtilla Gas Field are minimized.

These are just some of the environmental considerations that need to be considered running the
Kailashtilla Gas Field. It is important to carefully evaluate all of the potential impacts and develop
mitigation measures to minimize harm.
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❖ Role of chemical engineer: The role of a chemical engineer in the gas extraction industry
encompasses and responsibilities and tasks. Here are some key aspects of a chemical engineer’s
job in the gas industry.

➢ Process Design and Optimization: Chemical engineers are involved in designing the
processes and equipment used in gas processing. They develop process flow diagrams and
design equipment layouts to ensure efficient and safe operations.

➢ Safety and Environmental Compliance: Chemical engineers play a vital role in ensuring
safety and environmental compliance in gas extraction operations. They identify and assess
potential hazards, develop safety protocols, and implement risk management strategies to
protect workers and the environment.

➢ Equipment Selection and Maintenance: Chemical engineers are responsible for selecting
appropriate equipment and materials for gas extraction and processing operations. They
evaluate equipment performance, conduct cost-benefit analyses, and make recommendations
for equipment upgrades or replacements.

➢ Quality Assurance and Product Development: Chemical engineers are responsible for
ensuring product quality throughout the gas extraction and processing stages. They develop
and implement quality control procedures, conduct product testing and analysis, and oversee
product certification processes.

➢ Research and Development: Chemical engineers actively engage in research and

development activities to drive innovation and improve gas extraction processes. They
conduct experiments, analyze data, and evaluate new technologies to enhance process
efficiency, reduce environmental impact, and optimize resource utilization.

The role of a chemical engineer in the gas extraction industry is dynamic and multidimensional.
They contribute their expertise in process design, safety, equipment selection, quality assurance,
research and development, and project management to ensure efficient, safe and sustainable
operations within the industry.

❖ Economic Significance: Kailashtilla Gas field holds significant economic importance on both
regional and national levels. Here are some key details about the economic significance of the
industry:

➢ Job Creation and Employment: Kailashtilla gas field generates a good number of direct
and indirect employment opportunities. Direct employment includes positions such as
engineers, technicians, geologists, operators, and support staff involved in exploration.

➢ Revenue Generation and Economic Growth: Kailashtilla gas field contributes

significantly to government revenues through taxes, royalties, and lease payments. These
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financial contributions play a crucial role in supporting public services, education,

healthcare, and social welfare programs.

➢ Energy Security and Trade Balance: Natural gas extracted from Kailashtilla gas field
provides a reliable and domestically available source of energy. It strengthens the country's
energy independence.

➢ Technological Advancements and Innovation: Kailashtilla Gas Field drives technological

advancements and fosters innovation. Research and development initiatives within the
industry lead to the development of new technologies, improved extraction techniques, and
more efficient processes.

Overall, Kailashtilla Gas Field holds significant economic significance by creating employment
opportunities, generating government revenue, contributing to energy security, stimulating
regional development, fostering technological advancements and improving the trade balance. It
plays a vital role in driving economic growth and supporting sustainable development in the
regions where it operates.

❖ Future Prospect of the industry: The future prospects of the Kailashtilla Gas Field are influenced
by several factors, including technological advancements, market dynamics, energy policies, and
the global energy transition. Some considerations for its future prospects include: Advances in
drilling techniques, production optimization, and processing technologies can enhance the
extraction efficiency. Ongoing exploration activities and geophysical studies may provide a better
understanding of the field's geology and the potential for additional gas reserves, which could
extend the field's productive lifespan. The future prospects of the Kailashtilla Gas Field depend on
the energy demand in Bangladesh. Factors such as population growth, industrial development, and
energy policies will shape the demand for natural gas. The global shift towards renewable energy
sources and sustainability may influence the future utilization of natural gas. The 15 field's
prospects will be impacted by how it aligns with the country's energy transition plans and the
development of a diversified energy mix.

❖ Conclusion: The visit to the Kailashtilla Gas Field is a valuable experience for all participants. It
provided a unique opportunity to witness the operations, technologies, and processes involved in
gas extraction, purification, and control. Through the visit, we observed full processes of gas
extraction, starting from the uplifted raw gas to its purification and distribution. The processing
facilities and the control room allowed us to appreciate the complexity and scale of operations
within the industry. Interactions with industry professionals further deepened our knowledge as
we gained insights from their expertise and experiences. Furthermore, the visit helped us make
connections between theoretical knowledge acquired in the classroom and its practical applications
in the gas extraction industry. We extend our gratitude to the management and staff of the
Kailashtilla Gas Field for their warm hospitality, extensive support, and for providing us with an
invaluable educational opportunity.