IFPEX-1: A PROCESS WELL SUITED TO SHALE GAS PROJECTS

1

IFPEX-1: A PROCESS WELL SUITED TO

SHALE GAS PROJECTS

GPA CONVENTION

San Antonio, TX

April 12 – 15, 2015

Cécile Génin

Jérémie Esquier

2 2015 GPA Convention - San Antonio, TX

Who We Are

PROSERNAT’s Offer PROSERNAT in the IFP Group

34%

100%

LICENSOR OF

GAS TREATMENT

TECHNOLOGIES

MODULAR UNIT

& EQUIPMENT

SUPPLIER


NG SWEETENING

MEG RECOVERY

NG DEHYDRATION

NGL RECOVERY

SEPARATION & DESALTERS

SULPHUR RECOVERY

REFINERY UNITS

CO2 CAPTURE

Drizo™, Ifpexol™,

Cleanol™, Progly™

Ifpexol™, Proserpack™

SmartSulf™,

AdvaSulf™

AdvaCap™

AdvAmine™, HySWEET®,

SweetSulf™, SPREX®,

COSWEET™ GAS

ACID GAS

WATER

OIL

SULPHUR

EXPORT GAS

ATM.

END USER

PROSERNAT’s Field of Expertise


PROSERNAT’s HC Dewpointing Technologies

HC Dewpoint Process

Configuration Cooling Source

> -10°C

HC Dewpointing

Hydrate inhibition

MEG Cold Process JT – C3 Chiller

-10°C and -30°C

HC Dewpointing

Hydrate inhibition

(MeOH): IFPEX-1

Upstream

Dehydration: (TEG) +

Cold Process

Upstream dehydration:

(TEG) + Proserpack™

JT – C3 Chiller – Turbo

Expander

JT – C3 Chiller – Turbo

Expander

C3 Chiller – Turbo

Expander

< -30°C

NGL

Upstream dehydration:

(Improved TEG),

Drizo™ or molecular

sieve + Cryogenic

Process

Mixed refrigerant –

Turbo Expander


First IFPEX-1 Unit in 1992

Marathon Markham, TX

Patented process originally

developed by

MeOH is used for simultaneous

H2O (dehydration) and HC (NGL

extraction) dew point control

Valid for H2O and HC dew points

between -20°C and -80°C

IFPEX-1 Technology Main Features

IFPEX-1 is a low CAPEX /

OPEX Solution for

Dehydration and C3+ NGL

Recovery


CUSTOMER LOCATION CAPACITY

(MMSCFD) COLD PROCESS

START-UP

DATE

ENCANA Canada 8 x 200 C3 Refrig. 2016

JAPEX Japan 50 C3 Refrig. 2009

O.G.D.C. Pakistan 6 C3 Refrig. 2002

NOVAGAS Canada 105 C3 Refrig. 2001

CUPET / SHERITT Cuba 28 C3 Refrig. 1999

OCCIDENTAL Bangladesh 200 C3 Refrig. 1999

CUPET / SHERITT Cuba 14 C3 Refrig. 1998

MAERSK OLIE OG Denmark (North Sea) 350 Turbo Exp. 1997

NGAPU ALLIANCE New Zealand 62 C3 Refrig. 1997

WEST COAST

ENERGY Canada 77 C3 Refrig. 1997

A.E.C. WEST Canada 50 C3 Refrig. 1996

JAPEX Japan 84 C3 Refrig. 1996

A.E.C. WEST Canada 140 C3 Refrig. 1995

DAGANG

PETROLEUM China 42 Turbo Exp. 1995

PETROCANADA Canada 70 C3 Refrig. 1995

PETROCANADA Canada 50 C3 Refrig. 1992

MARATHON United States 8 Jt Exp. 1992

IFPEX-1 Industrial References


IFPEX-1 Applied to a Shale Gas Project

Cut Bank

Ridge Development

Program

• Eight IFPEX-1 units licensed in 2014 to Encana

Corporation in NE British Columbia, Canada

• Total processing capacity of 1,600 MMSCFD of feed

gas


Pro

ject

Co

mp

letio

n

Un

it

On

-Str

ea

m

Fe

asib

ility

Sta

ge

Analysis and modeling in early stages,

feasibility & conceptual study

License supply, basic design, process

engineering, detailed engineering,

procurement, supply of complete processing

units / turn-key units

Assistance at commissioning and start-up

and after sales services (technical

assistance, analysis, training, supply of

spare parts, revamp studies)

PROSERNAT’s Scope of Supply


Case Study Hypothesis

“A newly shale gas field will be

developed in Europe over the

next years”

Shale Gas Characteristics

Flowrate 207 MMSCFD

Operating range 40% to 110%

Temperature 43 °C

Pressure 49.1 barg

Molecular Weight 19.0

Composition

C1 86.08 vol%

C2 9.20 vol%

C3 2.50 vol%

iC4 0.54 vol%

nC4 0.60 vol%

C5 0.33 vol%

C6+ 0.33 vol%

H2O 0.21 vol%

CO2 0.21 vol%


COLD

PROCESS

METHANOL

MAKE UP

WATER

<100 ppm mol of MeOH

SALES GAS

20 to 200

ppm mol of

MeOH

NGL

3,000 to

4,000 ppm

mol of MeOH

MeOH / WATER

IFPEX-1 Base Scheme

Stripper with high

specific surface

for adequate

mass transfer

H2O & HC dew

points between

-20°C and -80°C

Methanol circulation

avoids hydrates

formation

Vaporization of

MeOH from the

liquid water phase Low

Temperature

Separator SHALE GAS

FROM INLET

FACILITIES


• Client Required performances are as follows:

Hydrocarbon and water dew point = -35°C @ 45 barg

Methanol content in produced water = 0.5 wt%

Methanol content in C3+ NGL = 500 ppm vol max

To limit MeOH carryover in the NGL, IFPEX-1 with

C3+ water wash is selected.

• Simulations are realized using GASWEET 4 in house

model for methanol absorption by HC.

IFPEX-1 Unit Requirements


MeOH / H2O

STRIPPER

WATER

WASH

STRIPPER

COLD

PROCESS

METHANOL

MAKE UP

SHALE

GAS

WATER

SALES

GAS

NGL MeOH / WATER

DEETHA-

NIZER

WATER

WASH

COLUMN

NGL

300 to 500

ppm mol of

MeOH

EXCESS WATER

IFPEX-1

WATER

IFPEX-1 Scheme with Water Wash


MeOH Content Specification in Produced Water

• The hydrate temperature formation depends on the

operating pressure and methanol concentration in

the free water phase.

In our case 70 wt% MeOH concentration is

required.

• To reach 0.5 wt% in the produced water, each

stripper is equipped with 6m of height efficiency

SS316L structured packing.


Sales Gas from Low Temperature Separator

Sales Gas Characteristics

Flowrate 196 MMSCFD

Temperature -35 °C

Pressure 45.0 barg

Molecular Weight 17.9

Composition

C1 89.20 vol%

C2 8.40 vol%

C3 1.62 vol%

iC4 0.20 vol%

nC4 0.20 vol%

C5+ 0.18 vol%

H2O 5 ppm vol

CO2 0.20 vol%


MeOH Content in C3+ NGL

• Liquid/liquid extraction column equipped with 20

sieves trays

• The major parameters that impact this design are:

Overhead Temperature of De-ethaniser Column

Concentration of MeOH in the Inlet Wash Water

• Design with trays is more appropriate than packing


C3+ NGL

C3+ NGL Characteristics

Flowrate 12,764 kg/h

Temperature 42 °C

Pressure 16 barg

Molecular Weight 60

Composition Recovery versus feed

C1 0.02 mol% -

C2 0.77 mol% -

C3 39.11 mol% 32 %

iC4 13.62 mol% 62 %

nC4 16.72 mol%

C5 13.83 mol% 85 %

C6+ 15.82 mol% >99.5 %

H2O 0.11 mol% -

C3 recovery linked to LTS Temperature (-35°C in our case).

>80% C3 recovery can be reached with a lower T


Utility / Chemical Consumption

• Electricity:

• Methanol consumption: 38 kg/h

• Cold process :

Gas/gas heat exchanger

Propane chiller using 35,000 kg/h of C3 refrigerant

with an evaporating temperature of -38°C / -40°C

Equipment Electrical Consumption

MeOH Circulation Pumps 0.8 kW

Wash Water Pumps 2.0 kW

MeOH Make-Up Pumps 0.2 kW


Comparison with TEG Unit - General

• Glycol is more expensive than methanol: higher

losses of methanol can be tolerated

• Methanol separation is easy, requires shorter

residence time than glycol:

Glycol carry over in downstream fractionation

units can lead to loss of sales due to

contamination

• Heating medium required for glycol regeneration

• Hydrocarbon (BTX) are absorbed by glycol and

rejected to atmosphere during regeneration

• Glycol also picks up H2S that will be partially

released during regeneration


Comparison with TEG Unit – N° of Equipts

STRIPPING GAS

• More equipments with TEG Unit than with IFPEX-1

Typical TEG Unit

Flow Scheme


Comparison with TEG Unit – Equipts Dimension

Technology Design details

IFPEX-1

• IFPEX-1 stripper ID = 1.5 m / TL-TL = 10 m

• Wash Water stripper ID = 1.5 m / TL-TL = 10 m

• Wash Water column ID = 1.0 m / TL-TL = 14 m

• Methanol pumps 1 m3/h

• Wash Water pumps 1 m3/h

TEG Unit

• Contactor ID = 2 m / TL-TL = 11 m

• Flash drum ID = 1.6 m / TL-TL = 6 m

• Glycol reboiler ID = 1.8 m / TL-TL = 8 m (fuel gas type)

• Still Column ID = 0.65 m / TL-TL = 4 m

• Stripping column ID = 0.65 m / TL-TL = 3 m

• Surge drum ID = 1.4 m / TL-TL = 4 m

• Glycol/glycol heat exchanger

• Glycol circulation pumps 11 m3/h

• Lean glycol cooler


Comparison with TEG Unit – Utilitites & Chemicals

Technology Utilties & Chemicals

IFPEX-1 • Electricity 2.8 kW

• 300 Gallon/day of methanol

TEG Unit

• Stripping gas 0.5 MMSCFD

• Reboiler fuel gas 0.15 MMSCFD

• Electricity 25 kW

• 40 Gallon/day of glycol


IFPEX-1 Benefits on a Shale Gas Project

• IFPEX-1 is a low CAPEX / OPEX Solution for

Dehydration and C3+ NGL Recovery:

30 to 40% saving compared to conventional TEG unit

40 to 50% saving compared to molecular sieve

• No atmospheric emission

• No heating medium required

• Easy to operate (simple equipments, no foaming,

no sequence)

• Water recovered for re-use

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IFPEX-1: A PROCESS WELL SUITED TO

SHALE GAS PROJECTS

GPA CONVENTION

San Antonio, TX

April 12 – 15, 2015

Cécile Génin

Jérémie Esquier

Documents

IFPEX-1: A PROCESS WELL SUITED TO SHALE GAS PROJECTS