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Transcript of 4-MTR - Fuel Gas Conditioning - Gas/Electric Partnership - Fuel Gas Conditioning.pdf · Why Fuel...
MEMBRANE FUEL GAS CONDITIONINGEngine Emissions Compliance and Site Rated Power Maximization by
Conditioning Fuel Gas
By
2014 Gas/Electric Partnership Conference XXIICypress, TX
Kaaeid Lokhandwala Sachin Joshi
Hesham Hussain
Membrane Technology & Research Inc.39630 Eureka DriveNewark, CA 94560www.mtrinc.com
Why Fuel Gas Conditioning?
• Oil-Rich Shale Production is increasing substantially and gas produced with the oil is very rich in C2+ components
• The produced raw gas is at low pressure and requires boosting into the pipeline infrastructure
• Compression Engine Fuel Choices are limited in the absence of clean residue gas lines in many production areas.
Poor Quality Raw Gas Issues
• Significantly increased unscheduled downtime - Detonation and Damage to engine parts
• Increased maintenance costs • Deration of Power to Compressors and Gensets.• Emissions Compliance
• Membrane Fuel Gas Conditioning is a Simple Process TechnologyWhich Operates Without Attention and Consumables.
Membranes and Regular Filters – A Comparison
Gas Composition Changed By Membranes
AerosolsFree-Liquid Droplets
Regular Filter Removes free liquids only
Methane 73.168
Ethane 13.534
Propane 9.065
Butanes 0.829
Pentanes 0.518
C6+ 0.614
Methane 84.760
Ethane 8.182
Propane 4.347
Butanes 0.264
Pentanes 0.142
C6+ 0.164
Heavy Hydrocarbons Removed(Gas Phase)
Methane 73.569
Ethane 13.558
Propane 9.020
Butanes 0.813
Pentanes 0.493
C6+ 0.480
Feed Gas
Fuel Gas
High Pressure
Low Pressure
Counter Intuitive InnovationBig Heavy Hydrocarbons Pass through
Small Methane is Held back
Small molecules pass through Big molecules pass through
Advantages of Membrane Systems
• Simple passive system• High on-stream factor (typically >99%)• Minimal or no operator attention• Small footprint, low weight• Ambient temperature operation in many applications• Large turndown ratio• Low maintenance• Lower capital and operating costs• Minimum on-site piping required• Complete standardized skid mounted units
Membrane Structure and Packaging
Generic Fuel Gas Conditioning Flow sheet
Compressed Gas To PipelinePipeline Compressor
And After-cooler
Slip Streamof Raw Fuel
Gas FromWellhead
Gas Engine
Condensate
Propane 4.60
i-Butane 1.97
n-Butane 1.53
Pentanes 1.74
Hexane 1.05
C6+ 0.91HP
LP
Heavies Return To Suction
Propane 1.48
i-Butane 0.52
n-Butane 0.30
Pentanes 0.28
Hexane 0.126
C6+ 0.078
• Raw Feed Gas Very Rich in Heavy Hydrocarbons, especially C2, C3 components.
• Engine Capacity De-rate• Emissions Non-Compliance• Detonation - Engine Knocking, Accelerated Parts Wear
Alternatives Considered
Compressor Station Issues and AlternativesFuel Gas Conditioning - Agave Energy Co, NM
JT Process Refrigeration Membranes
Separated Heavies (NGL) Phase Liquid Liquid Gas
Liquids Storage at Station Yes Yes No
Reduce Ethane (C2) No No Yes
Moving Parts No Yes No
Low Temps – Hydrate Issues Yes Yes No
Raw Feed Gas – BTU Variability Handled? No Likely No Yes
Raw Feed Gas– Pressure Variability Handled? No Likely Yes
Issues
Type & No. of engines - 3xCAT 3516B + 1xCAT 3520B
Total site rated engine HP - 5865 hp
Total engines fuel demand - 0.75 MMscfd
Total gas compressed - 14 MMscfd
Compressor suction - 25 psig
Compressor discharge - 890 psig
Fuel generating capacity - 1.5 MMscfd
Fuel spec quality (HHV) - 1050 BTU/SCF
No. of membrane Vessels - ONE (1)
Engine Driven Compression - Fuel Gas ConditioningAgave Energy Co, NM
Performance Data – Compressor Station (Sep 7, 2013)Reduced Heavy Hydrocarbon Content
Stream Raw Feed Gas
Conditioned Fuel Gas
Methane Number 53 74
HHV (Btu/scf) 1139 1028
Component (mol%)Nitrogen (N2) 1.69 2.98
Carbon Dioxide (CO2) 4.76 1.76
Methane (C1) 76.78 87.77
Ethane (C2) 9.77 5.38
Propane (C3) 4.68 1.54
Butanes (C4) 1.43 0.38
Pentanes (C5) 0.56 0.12
Hexanes plus (C6+) 0.34 0.06
Site Performance DataFuel Gas Conditioning - Agave Energy Co, NM
* Code of Federal Regulations (CFR) Title 40, Part 60, Subpart JJJJ, New Stationary Pollution Source (NSPS).
Reduced Emissions (Test – Sep 7, 2013)
Emission Parameter Rich Fuel(NO Membranes)
Lean Fuel(Post Membrane Processing)
Parameter Pre-Catalyst Post-Catalyst Pre-Catalyst Post-CatalystBSFC (btu/hp hr) 7973.1 7858.3
NOx ppm 83.85 92.72 84.08 89.54lb/hr 1.30 1.43 1.30 1.35
Permit Limit (lb/hr) 3.04CO ppm 591.18 28.76 553.19 25.94
lb/hr 5.57 0.27 5.20 0.24Permit Limit (lb/hr) 0.49
VOC ppm 115.56 49.00 57.98 21.97lb/hr 1.71 0.73 0.86 0.33
Permit Limit (lb/hr) 0.67Reduction in Pre-Catalyst Levels
(Rich v/s Lean Fuel) - 49.8%
Compressor Station - Engine Emissions DataFuel Gas Conditioning - Agave Energy Co, NM
One (1) Caterpillar G3516ULB Reciprocating Internal Combustion Engine (RICE)
4.5 MMscfd – Total Gas Processed
Acknowledgement: Ivan Villa, Jennifer Knowlton, Agave Energy Co, NM, USA
Increased Compression Capacity per Site (Test – Sep 7, 2013)
Compressor Station – Capacity IncreaseFuel Gas Conditioning - Agave Energy Co, NM
Parameter Raw Fuel GasNO Membranes
Conditioned Fuel GasWith Membranes
No of engines tested 1 x CAT 3516 1 x CAT 3516
Total gas compressed per engine (MMscfd) 4.5 4.5
Capacity per engine (hp) 951 951
% Load utilized by the engine 72% 62%
% Increase in compressor capacity - 10%
Additional gas potentially compressed (1 engine) - 0.45 MMscfd
(4.5 MMscfd x 10%)
Additional gas potentially compressed (CS – 4 engines) - 1.8 MMscfd
Additional Revenues (CS – 4 engines) - $ 2,299,500 per year*
* NG pricing based on $3.5/mscf
Data Acknowledgement: Ivan Villa, Jennifer Knowlton, Agave Energy Co, NM, USA
Feed Gas
Heavy Hydrocarbons Recycled as Gas Phase
To Suction Drum
Salt DrawCompressor
Station
Increased Condensate Recovery
33 bbl/d C3+ Additional Condensates Recovered
ConditionedFuel
RawFuelGasConditionedFuel Gas
TotalCondensatesSenttoNGL
Plant
$$$AdditionalRevenuesperyear
C3+ BurnedinFuel(bbls/d)
37.1 3.8 33.3 $519,760
1. Fuel Consumption – 0.75 MMscfd2. NGL pricing - $ 50-80 bbl/d
To NGL Recovery Plant
Raw Natural Gas
Compressor Station – Increased Condensate RecoveryFuel Gas Conditioning - Agave Energy Co, NM
Gas Plant
Processed gasTo Sales Line
Additional NGL Recovered in
Gas Plant
Compressor Station – Overall Monetary BenefitFuel Gas Conditioning - Agave Energy Co, NM
Annual Monetary Benefits• Increased Site Capacity $ 2,299,500• Increased C3+ Recovery $ 519,760
Total $ 2,819,260
Benefit due to Reduced Downtime (50% reduction in shutdowns, 2 shutdowns/month avoided, each outage 8 hrs)
• Increased Annual ProductionRevenues $ 392,000
Data Acknowledgement: Ivan Villa, Jennifer Knowlton, Agave Energy Co, NM, USA
Membrane Impact • Reduced Heavy Hydrocarbons & BTU Content – Engine
Performance significant improved
• Increased the Total Compressor HP Capacity at Site – Allows moving of higher gas volumes
• Added Revenues – Condensate Recovery - $$$
• VOC (NMHC) Emissions Reductions – Meet Strict emissions requirments
• Improved Emissions Catalysts Life. Maintain CO/NOx within emissions requirements
• Reduced Unscheduled Downtime and Engine Maintenance costs
Compressor Station – Summary of BenefitsFuel Gas Conditioning - Agave Energy Co, NM
Generic Field-Wide Perspective
Field Compression 1
2
3
4
5
6
4 MM
8 MM
8 MM
9 MM
20 MM
60 MM
11 MM
Total Field Compression HP: 12000 hpTotal Flow Improvement = 6 MMSCFDTotal NGL Saved to Gas Plant = US $ 1.25 Million/yrTotal Additional Gas Moved = US $ 7.35 Million/yr
(Gas Valued at $ 3.5/MSCF)
Total Central Compression HP: 7800 hpTotal Flow Improvement = 6 MMSCFDTotal NGL Saved to Gas Plant = US $ 0.78 Million/yrTotal Additional Gas Moved = US $ 0.42 Million/yr
(Gas Moved at $ 0.2/MSCF)
MidstreamCompression
MidstreamGas Plant
Gas To Sales
Total Additional Value Distributed to Producers ~ US $ 8 Million/yr.
Total Additional Value to Midstream Operators ~ US $ 1.8 Million/yr.
Additional Value Realized by Conditioning Fuel Gasin Oil Rich Shale Production
NGL to Sales
Successfully Proven in Most Producing Shale Areas - > 75 installations
Conclusions
• Solubility Selective Membranes Have Been Successfully Proven in Well head Natural Gas Conditioning Applications
• More than 200 combined Installations of these membranes Worldwide in Oil/Gas Industries.
• Standardized Fuel Gas Conditioning Units Designed for Unattended Operation Reduce Deployment Time and Cost
• Lowering of BTU value of Fuel Gas - Emissions Reductions
• Significant Monetary benefit from recovery of C2 and C3+ components otherwise lost to fuel.