Hydrocarbon Dewpoint

Control and Liquid

Recovery and
Fractionation
Wayne Monnery, Ph.D., P.Eng.

02/19/16

H/C Dewpoint Control vs Liq

Recovery
Make specifications
No liquid condenses in the sales gas pipeline
while maximum keeping the heating value

Recover Liquids
Mixed: NGL (C2+), LPG (C3 - C4), Condensate
(C5+)
Pure: C2, C3, C4

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Hydrocarbon Liquid
Recovery
Typically in BBL/MMscf or % of Inlet
% Inlet = 100 (Comp In- Comp Out in Sales
Gas)/Comp In

Inlet also expressed in BBL/MMscf or

GPM
GPM = (USgal/Mole)(Mole Frac)(1000/379.5)
BBL/MMscf = GPM (1000/42)
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Hydrocarbon Liquid
Recovery
Function of Composition
For same P, T conditions, recovery
higher from richer stream
For same recovery, must go to lower
temp

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H/C Dewpoint Control vs Liq

Recovery
Sales Gas/Mixed Liquid Specifications:
Table 1 Sales Gas and Mixed Liquid Product Specifications
Product

Specification

Specification Value

Sales Gas

Hydrocarbon Dewpoint

15.0 F at 800 psig (or P/L pressure)

NGL/LPG

Ethane Content

C2/C3 2.0 vol %

Condensate

RVP/C4 content

12.0 psia/ 5 vol %

Table 2 Typical Ethane Product Specifications

02/19/16

Specification

Specification Value

Ethane Content

95 mole%

Methane/Propane Contents

2 mole%

CO2/H2S Contents

2 mole% / 50 - 100 ppm

H/C Dewpoint Control vs Liq

Recovery
Liquid Specifications:
Table 3 Typical Propane Product Specifications
Specification

Specification Value

Propane Content

90 liq. vol %

Propylene/Butane Contents

5 liq vol % / 2.0 2.5 liq vol %

Vapour Pressure @ 100 F

208 psig

95% Evaporation Temperature

- 37 F

Volatile Sulphur

123 185 ppmw (10 15 grains/100 scf)

Table 4 Typical Butane Product Specifications

02/19/16

Specification

Specification Value

Vapour Pressure @ 100 F

70 psig

95% Evaporation Temperature

34 F

Volatile Sulphur

140 ppmw

H/C Dewpoint Control vs Liq

Recovery

Decision to recover liquid

hydrocarbons vs make dewpoint only
based on equivalent values between
liquid and gas

02/19/16

H/C Dewpoint Control/Liq

Recovery
Basics - Refrigeration, 2 types: Auto
Refrigeration and Mechanical Cycle
Auto Refrigeration
Derived from thermodynamic first
principles
Isenthalpic H = 0 (JT Effect), Valve
Isentropic S 0, Turbo Expander
For same P, T is greater for isentropic
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H/C Dewpoint Control/Liq

Recovery

Basics - Refrigeration Mechanical Cycle

Based on condensing refrigerant at high
pressure (and temperature) so it can
reject heat to ambient air or cooling water
Uses isenthalpic JT effect to cool
refrigerant
Some refrigerant flashes across valve
Simple Cycle, Economizer Cycle

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H/C Dewpoint Control/Liq

Recovery
Basics - Simple
Refrigeration Cycle
Vapor to Compressor,
Satd Vapor
Liquid from
Condenser, Satd
Liquid
Example manual
calcs in notes
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H/C Dewpoint Control/Liq

Recovery
Basics - Economizer Refrigeration
Cycle
Increases efficiency of simple cycle
2 Stage Compression & Pressure Drop
Vapor that is formed across valve is
flashed and separated (it contributes
nothing in chiller and if removed, does
not have to be compressed from lowest
pressure)
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H/C Dewpoint Control/Liq

Recovery
Basics - Economizer Refrigeration
Cycle
Often saves 15-20% in compression HP
Adds capital cost, so must compare this
to HP savings for payout

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H/C Dewpoint Control/Liq

Recovery
Basics - Mechanical Refrigeration Cycle
Another method for compression savings
is use of subcooler
Reduces liquid from condenser to below
satn temperature (less flashing across
valve)
Cold stream can be liquid H/C process
stream from LTS or De-C2 ovhd (examples
in Refrig Gas Plant section)
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H/C Dewpoint Control/Liq

Recovery

Basics - Mechanical Refrigeration

Cycle
Effect of Condensing Temperature

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H/C Dewpoint Control/Liq

Recovery
Basics - Mechanical Refrigeration Cycle
Effect of Refrigerant Composition

C3 good to -40 F/C (metallurgy?)

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H/C Dewpoint Control/Liq

Recovery
Ton Refrigeration = 12,000 BTU/hr
GPSA Example 14-1
GPSA Figures for Compression and
Condensation (Propane 14-18, 14-24, 1429)
Compressor GPSA Types p. 14-19
Controls GPSA p. 14-24
Chiller T controlled by compressor suction P
Compressor suction P control depends on compressor
type (as per Ench 607) + HGBP
Condensing control (low, high ambient)
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H/C Dewpoint Control/Liq

Recovery
Basics
-Heating/Cooling
Curves
Can be plotted for
any heat
exchange

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H/C Dewpoint Control/Liq

Recovery
Basics - Heating/Cooling Curves
Area between heating & cooling curve
indicates irreversibility (efficiency)
Should be as close as possible without
touching (requires more surface area but
lower compression)

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H/C Dewpoint Control/Liq

Recovery
Basics - Refrigeration
For refrigeration below -40, Cascaded
Cycle

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H/C Dewpoint Control/Liq

Recovery

Basics - Cascaded Refrigeration

C2 condensed against C3, C1 condensed

against C2
Heating/Cooling curve for 9-stage
system shown previously
Drawbacks
System Complex
Lots of HP required

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H/C Dewpoint Control/Liq

Recovery
Basics - Refrigeration
For refrigeration below -40, Mixed Refrigerant
Cycle
Mixture contains C1 - C5 and vaporizes over
range of temperatures
Cooling curve shown previously; more
efficient than cascaded cycle but can have
high condensing pressure & compression
power
Design Considerations: Vaporization Curve
Shape, Suction/Discharge Pressures
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H/C Dewpoint Control/Liq

Recovery
Processes:
Refrigerated Gas Plant
Silica Gel Plant
Lean Oil Absorption
Cryogenic Turbo Expander
Cryogenic Refrigeration

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H/C Dewpoint Control/Liq

Recovery

Choke (JT) Gas Plant

G a s T o R e c y c le
o r S a le s

A fte r c o o le r

R e c o m p re s s o r

EG
I n je c t i o n
S ta b iliz e r

Feed
G as

G as To
S a le s

J T /C h o k e
V a lv e

LTS

R ic h E G T o
R e g e n e ra tio n
N G L /C 5 +
P ro d u c t

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H/C Dewpoint Control/Liq

Recovery
Refrig Gas Plant

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H/C Dewpoint Control/Liq

Recovery

Refrig Gas
Plant Process
Alternatives

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H/C Dewpoint Control/Liq

Recovery
Choke/Refrig Gas Plants
LTS Temperature typically 10 to -30 F
Optimum Pressure depends on phase
behaviour (cricondentherms or quality
lines); typically 400 - 600 psig but also
depends on existing facilities

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H/C Dewpoint Control/Liq

Recovery
Choke/Refrig Gas Plants
Will require either TEG dehydration or EG
injection to avoid hydrates
Choice depends on processing goals
Details of these processes are given in
Dehydration Course
Increase liquid recovery w/condensate
recycle
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H/C Dewpoint Control/Liq

Recovery
Choke/Refrig Gas Plants
Process Material and Energy Balance
calcs done on computer
Refrigerant circuit calcs also done on
computer (manual as shown in notes)

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H/C Dewpoint Control/Liq

Recovery
Choke/Refrig Gas Plants
Equipment consists of separators, heat
exchangers and De-C2/Stabilizer tower
Separators sizing/rating details in
Appendix VIII (diamter, height or length)

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H/C Dewpoint Control/Liq

Recovery
Choke/Refrig Gas Plants
Heat Exchanger sizing from
software/vendor (surface area); Rating
from software or current performance UA,
heat exchange design can be complex
Tower sizing/rating based on flooding, P
(Diameter from hydraulics, Height from
trays, packing + sump + ovhd)
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H/C Dewpoint Control/Liq

Recovery
Choke/Refrig Gas Plants
Process Operating Problems in Appendix
II: Review Case Studies
Refrigerant Circuit Operating Problems in
Appendix III

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H/C Dewpoint Control/Liq

Recovery

Silica Gel Plants

R E G E N E R A T IO N G A S

G AS
FEED

REG EN GAS
CO O LER
M

IN L E T
SEPARATO R

R E G E N E R A T IO N
&
C O O L IN G

A B S O R B IN G

REG EN
G AS
HEATER

02/19/16

REG EN GAS
H C /W A T E R
KNO CKO UT

LEAN/
DRY G AS

32

H/C Dewpoint Control/Liq

Recovery
Silica Gel Plants
Silica absorbs hydrocarbons in short
cycle (30-60 min)
To be continuous, 1 bed on absorption, 1
bed on heating regen, 1 bed on cooling
regen
Absorption @ 80-100 F, Regen @ 450550 F
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H/C Dewpoint Control/Liq

Recovery
Silica Gel Plants
Not very popular anymore, compared to
choke/refrig gas plants
Process is applicable when small amount
of C7+ causes H/C dewpt problem
Recovery is limited to 70-90% C5+, low
C4 recovery

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H/C Dewpoint Control/Liq

Recovery
Silica Gel Plants
Material and energy balance calcs usually done
by Silica vendors with software but some
manual estimates can be made (see notes)
Major equipment is beds, regen heater, cooler,
separator
Bed diameter based on pressure drop,
Desiccant Volume (bed length) based on
absorption calcs but pressure drop needs to be
re-checked
Operation/Troubleshooting in Appendix IV
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H/C Dewpoint Control/Liq

Recovery
Lean Oil Plants

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H/C Dewpoint Control/Liq

Recovery
Lean Oil Plants
Gas is contacted with paraffinic lean oil
solvent which absorbs the C3+ compounds
Like other absorption/regen processes
(sweetening, dehy), the rich solvent is then
regenerated with pressure reduction and heat
ROD boils of any C1/C2 from rich oil
Release the C3+ compounds in the still as an
ovhd NGL product
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H/C Dewpoint Control/Liq

Recovery
Lean Oil Plants
Btms from still is lean oil which is
recirculated and cooled by using it as
heat medium for ROD reboiler, followed
by coolers
Pre-saturation of oil with light gas
removes heat of mixing from contactor

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H/C Dewpoint Control/Liq

Recovery

Lean Oil Plants:

Typically recoveries: 80 - 85% C3, 100%

C4+, 15-50% C2
Major design/rating/operating issue is
lean oil flow which depends on oil MW,
Table 6 Lean Oil Molecular Weight versus Temperature
temp

02/19/16

Temperature (F)

Lean Oil Molecular Weight (lb/lbmol)

80

180 200

140 160

-30

100 120

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H/C Dewpoint Control/Liq

Recovery
Lean Oil Plants
No large pressure drop required but lots of
equipment and energy intensive
Many have been replaced by turbo expander
plants for high C2 or C3 recovery
Material & Energy Balance calcs done on
computer
Major variables are lean oil circulation rate and
composition (low MW oil more efficient but
requires lower temp to minimize vapor losses)
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H/C Dewpoint Control/Liq

Recovery
Lean Oil Plants
Major equipment is towers, heat exchangers,
separators; design as previously discussed
Operation and Troubleshooting mainly
involves sufficient circulation rate and proper
lean oil composition (aromatics can cause
foaming); lean oil temperatures to contactor
also important
Many operating problems involve mechanical
equipment
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H/C Dewpoint Control/Liq

Recovery

Turbo Expander Plants

Refer to notes (p 30-31) for process

description

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H/C Dewpoint Control/Liq

Recovery
Turbo-Expander Plant
De-C1 pressure important (for given
temp, at higher pressures, more C1
condenses; at lower pressures higher
C2/C3 recovery with less C1 condensing
but higher re-compression)
Economic trade-off between recovery vs
re-compression
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H/C Dewpoint Control/Liq

Recovery

Turbo-Expander Plant

Conventional process recovery limited to about

80% C2
Modifications to recover more C2/C3 without
more re-compression and make the process
more CO2 tolerant (for example: GSP +12% C2
recovery, CO2 up to 1.25% lean, 4% rich)
Modifications involve re-fluxing the De-C1 so
HP Cold Sep a little warmer
More discussion of modifications in Appendix VI
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H/C Dewpoint Control/Liq

Recovery

Turbo-Expander Plant - Residue

Recycle
Refer to notes (p 32) for process
description

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H/C Dewpoint Control/Liq

Recovery

Turbo-Expander Plant - Gas

Subcooled

Refer to notes (p 32-34) for process

description

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H/C Dewpoint Control/Liq

Recovery
Turbo-Expander Plant - Calcs/Equip
Important Design Factors:
inlet and outlet pressures,
feed gas flow rate,
feed gas composition,
feed gas liquid content,
feed gas temperature and
required ethane or propane recovery

Refer to notes p 35
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H/C Dewpoint Control/Liq

Recovery
Turbo-Expander Plant - Calcs/Equip
Several pieces of specialized equipment:
plate-fin heat exchangers, turboexpander, De-C1
Lets review Appendix VI for discussion
of equipment
Metallurgy not carbon steel as it is too
brittle for temps below -50 F; use
stainless steel, aluminum
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H/C Dewpoint Control/Liq

Recovery
Turbo-Expander Plant - Calcs/Equip
Material and Energy Balance calcs done
on computer; some manual calcs can be
done (estimating expander efficiency,
inlet cooling requirement for reqd
external refrig) and some other calcs in
Appendix VI

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H/C Dewpoint Control/Liq

Recovery
Turbo-Expander Plant - Operation &
Troubleshooting
Operations can check liquid produced
per gas inlet flow (BBL/MMscf) and
expander outlet temperature
Rising expander outlet temperature may
indicate reduction in heat exchange
efficiency, reduction in expander
efficiency or change in feed composition
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H/C Dewpoint Control/Liq

Recovery

Turbo-Expander Plant - Operation &

Troubleshooting

Control can be sophisticated but primarily

upstream or downstream pressure on expander
and De-C1 btms temperature are controlled
Upstream pressure controlled via PC on HP cold
separator manipulating guide vanes into
expander; downstream would be controlled by
re-compression
De-C1 btms temp controlled by regulating heat
medium (manual valve)
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H/C Dewpoint Control/Liq

Recovery
Turbo-Expander Plant - Operation &
Troubleshooting
Most common operating problem is
freeze-up by ice, hydrate or solid CO2
(deriming reqd)
Upstream dehydration and CO2 removal
reqd
Other common problems are reduction in
liquid product or off-spec NGL
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H/C Dewpoint Control/Liq

Recovery

Turbo-Expander Plant - Operation &

Troubleshooting
Indicator of stable operation is HP cold
separator temperature
Should be relatively constant as long as
feed rate and composition are also
relatively constant

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H/C Dewpoint Control/Liq

Recovery
Turbo-Expander Plant - Operation &
Troubleshooting
Increase can be due to heat exchanger
freeze-up, expander problem, excessive flow
to De-C1 reboilers, vapor locked reboiler or
open parallel JT valve
Decreasing HP cold separator temperature
can be due to insufficient feed to De-C1
reboilers or snowballing
Refer to notes p 37-38
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H/C Dewpoint Control/Liq

Recovery
Cryogenic Mixed Refrig Plant

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H/C Dewpoint Control/Liq

Recovery
Cryogenic Mixed Refrig Plant
Refer to notes p 39-40 for process
description
Operation and troubleshooting similar to
turbo expander plant except for
expander itself
Refrigerant composition very important

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H/C Dewpoint Control/Liq

Recovery
Cryogenic Processes Pre-Treatment
Remove water and CO2 to prevent freeze-ups
Dehydration requires -150 F water dewpoint,
typically use mole sieve
CO2 removal typically solvent type process or
concurrent removal in mole sieve (see notes
for CO2 removal chart)
Mole Sieve dust filters very important as dust
can ruin plate-fin heat exchangers
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H/C Dewpoint Control/Liq

Recovery
Process Selection - Factors:
Feed Composition
Recovery Desired
Inlet Gas Pressure
Residue Gas Pressure
Turndown/Operational Reliability
Plot Space

Refer to notes p 42-43

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H/C Dewpoint Control/Liq

Recovery

Process
Selection - H/C
Dewpoint

G a s A n a ly s is

S a le s
G as

D e h y d ra tio n

D e w p o in t M e t?
Yes
N o

C 3+ < 3%

3% < C 3+ < 10%

C 5 + > > C 3 /C 4

C 3 /C 4 > 2 %
C 4 >> C5+

C o m p re s s io n ?

D ew P t vs
L iq R e c o v e r y

N o

Yes

Dew Pt

L iq A n a ly s is
C 2 <= C 3

C 3+ > 10%

L iq A n a ly s is
C 2 >> C3

E c o n o m iz e r

R e flu x e d
D e -C 2
w/ O H
r e c y c le

L iq R e c
C 3+

02/19/16

S ilic a
G el

Top Feed
C 5 + S ta b
w/ O H
r e c y c le

R e flu x e d
C 5 + S ta b
w/ O H
r e c y c le

Top Feed
D e -C 2
w/ O H
r e c y c le

R e flu x e d
D e -C 2
w/ O H
r e c y c le

D eB u ta n iz e r

C 5+

C 5+

C 5+

C 3+

C 3+

L P G /C 5 +

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H/C Dewpoint Control/Liq

Recovery

Preliminary Process Selection - H/C Liq

Recovery
Refer to notes p 43-45
C 3 R e c o v e r y R e q u ir e d

< 30%

3 0 -5 0 %

S im p le R e frig
G a s P la n t

02/19/16

5 0 -8 0 %

C 5 + R e c y c le
G a s P la n t

C 2 R e c o v e r y R e q u ir e d

> 80%

>95%

L e a n O il
A b s o r p tio n
P la n t

< 40%

S im p le T u rb o
E xpander
P la n t

4 0 -8 0 %

> 80%

C o m p le x T u r b o
E x p a n d e r P la n t

60

Liq Hydrocarbon
Recovery/Fractionation
Fractionation:
Types of towers:
absorber (no condenser, no reboiler)
reboiled absorber (reboiler, no condenser)
refluxed absorber (condenser, no reboiler)
distillation (condenser and reboiler)

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Liq Hydrocarbon
Recovery/Fractionation
Fractionation:
Types of internals: trays (sieve, valve,
bubble cap) and packing (random,
structured)
Difference between equilibrium stages
and actual stages or height of packing is
tray efficiency and HETP

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Liq Hydrocarbon
Recovery/Fractionation
Fractionation - Tray efficiency (Appendix
III)

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Liq Hydrocarbon
Recovery/Fractionation
Fractionation - HETP

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Liq Hydrocarbon
Recovery/Fractionation
Fractionation:
Tower Pressure determined by cooling
medium and relative ease of separation;
higher pressure lower relative volatility,
more reboiler energy, thicker vessel
Tower design is capital cost vs operating
cost (energy) trade-off; trays vs reflux
(GPSA Fig 19-6; Typical Fractionators GPSA
Fig 19-19)
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Liq Hydrocarbon
Recovery/Fractionation
Fractionation:
ProcessTower
No. Trays Eff.(%)
Lean Oil
Absorber 25-35
25-35
De-C2
35-45
25-60
Still 25-30
50-67
Cryogenic De-C1
18-26
45-60

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Liq Hydrocarbon
Recovery/Fractionation
Frac Train (order of fractionation):

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Liq Hydrocarbon
Recovery/Fractionation
Fractionation
Types of reboilers - GPSA
Tower feeds, drawoffs, sumps - GPSA

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