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Achieving product specifications forethane through to pentane plus fromNGL fractionation plants

Malcolm Harrison Divisional Director Oil & Gas Division, Foster Wheeler

Essam Bahnassi Head of Process Department, GASCO

Abdul Rahman Khouri Senior Process Engineer, GASCO

Peter Alderton Process Consultant, Foster Wheeler

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Maximum Value for your LPG andNGL Recovery

Gastech 2005

� Overview of NGL Recovery

� Management of Contaminants

� Maximising the Value of the Gasco Ruwais Plant

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Gastech 2005

Processing NGL into Saleable Products involves

followed by

FRACTIONATIONFRACTIONATION

TREATINGTREATING

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Typical Fractionation Process Scheme

Gastech 2005

Ethane

Depropaniser

Butane

Natural Gasoline (C5+)

Debutaniser

Propane

NGL liquidDe-ethaniser

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Possible Fractionation Products

Gastech 2005

� Demethanised Product

� De-ethanised Product

� Ethane

� Commercial Propane

� Propane/Butane Mixtures

� Butane(s)

� Butane/Gasoline Mixtures

� Natural Gasoline

� Vapour Pressure Specification Mixtures

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Potential Heat Integration Improvements

Gastech 2005

Ethane

Depropaniser

Butane

Natural Gasoline (C5+)

Debutaniser

Propane

NGL liquidDe-ethaniser

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Reasons for Contaminant Removal

Gastech 2005

• Hydrogen Sulphide• Carbon Dioxide• Carbonyl Sulphide• Carbon Disulphide• Mercaptans• Organic Sulphides• Nitrogen• Water

Contaminants

• Safety and Environmental• Corrosion Control• Product Specification • Freeze-Out Prevention • Catalyst Poisoning Prevention

Reasons for Removal

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Treating Processes

Gastech 2005

Caustic MercaptansCondensate

Caustic or Mol Sieve

Mol Sieve

Mercaptans

H2OButane

Amine

Caustic or Mol Sieve

Mol Sieve

COS/H2S

Mercaptans

H2O

Propane

Amine

Mol Sieve

H2S/CO2

H2OEthane

Treating ProcessImpurityProduct

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Site Locations

Gastech 2005

AsabHabshan

Ruwais

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OGD III/AGD II Project

Gastech 2005

OGDOGD

HabshanHabshan

AGDAGD

AsabAsab

RuwaisRuwais

Train 3Train 3

TakreerTakreer

RefineryRefinery

NGLNGL

CondensateCondensate

C2C2

C4C4

C3C3

C5+C5+

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Studies Undertaken

Gastech 2005

� Fractionation Sequences

� Refrigeration System

� Sulphur Recovery

� Reboiler Heating Medium

� Cooling System

� Molecular Sieve Regeneration

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Fractionation Sequences Studied

Gastech 2005

FeedFeed

C2C2 C3C3 C4C4

C3/C4/C5+C3/C4/C5+ C4/C5+C4/C5+C5+C5+

1) De1) De--ethaniser/Depropaniser/Debutaniserethaniser/Depropaniser/Debutaniser

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Fractionation Sequences Studied

Gastech 2005

FeedFeed

C2C2C3/C4C3/C4

C3C3

C3/C4/C5+C3/C4/C5+C5+C5+ C4C4

2) De2) De--ethaniserethaniser/Debutaniser/Propane/Debutaniser/Propane--Butane SplitterButane Splitter

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Fractionation Sequences Studied

Gastech 2005

FeedFeed

C2/C3C2/C3 C2C2

C4/C5+C4/C5+C5+C5+ C3C3

3) 3) DepropaniserDepropaniser/Debutaniser/Ethane/Debutaniser/Ethane--Propane SplitterPropane Splitter

C4C4

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Product Treating Processes Selected

Gastech 2005

� Ethane MDEA (SGSI Licensed)

Molecular Sieves

� Propane ADIP (SGSI Licensed)

Molecular Sieves

� Butane Molecular Sieves

� Pentane Plus Option for Hydrotreater

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Ruwais Fractionation Plant

Gastech 2005

Ethane to Petrochem Plant

Propane to Storage

NGL Feed

Butane to Storage

Pentane Plus to Storage

Liquid Sulphur Export

Fractionation

Amine

Treating

Mol

Sieves

Hydrotreater

Amine

Treating

SRUOff-Gas

Treating

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Value Engineering – Progress Of Ideas

Gastech 2005

� Raw Ideas Generated in Workshop 83

� Ideas Considered in Workshop Evaluation 68

� Ideas Developed in Syndicates 57

� Proposals taken from Workshop 23

� Hydrocarbon Related Proposals 5

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Value Engineering – Final Selection

Gastech 2005

EasyNo ChangeNeutralIncrease>$5MReplace steam with water/glycol in reboilers

EasyNo ChangeNeutral

<$500KIncreaseSponge loss recovery in mol sieves

EasyNo ChangeNeutralIncrease<$500KDirect Air Coolers

EasyNo ChangeNeutral>$5M>$5MReplace C2 mol sieve dryers with dew point control

EasyNo ChangeIncrease$500K to $1M>$5MCommon regen for C3/C2 treating

Implement-ation

RiskSchedule OPEXSaving

CAPEXSaving

Proposal

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Conclusions

Gastech 2005

� Know your market

� Assemble the right team

� Understand what you already have

� Know your life cycle costs

� Use real value engineering

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Thank you

Malcolm Harrison Divisional Director Oil & Gas Division, Foster Wheeler

Essam Bahnassi Head of Process Department, GASCO

Abdul Rahman Khouri Senior Process Engineer, GASCO

Peter Alderton Process Consultant, Foster Wheeler

oilandgas@fwc.com www.fwc.com