Dew Point Control Technologies
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Powered by AIThe J-T valve refrigeration operates on the principle of constant enthalpy, leading to cooling when the gas expands through the valve. This method is often limited by the initial pressure and temperature of the feed gas. In contrast, Turbo-Expander refrigeration involves isentropic expansion, which achieves lower temperatures and more significant condensation of natural gas liquids (NGL) compared to J-T. It allows for higher pressure recovery after the expansion phase. The Turbo-Expander system also recuperates some of the energy from expansion to recompress the gas .
In the Turbo-Expander refrigeration process, the natural gas stream is isentropically expanded, resulting in a pressure drop from around 70barg to 55barg and a subsequent temperature fall from approximately 47°C to 0°C. This significant temperature and pressure drop facilitates the cooling and condensation of natural gas liquids (NGL), shifting the phase envelope to allow for dew point suppression. This method achieves a lower temperature for a given pressure drop, thus more effectively suppressing the dew point compared to the J-T valve method .
In the supersonic separation process, the cyclone separator plays a critical role by utilizing centrifugal forces to separate the condensed hydrocarbons from the main gas stream. After the feed gas is accelerated to supersonic speeds through a nozzle, resulting in pressure and temperature drops that cause condensation, the cyclone separator creates a swirling motion, effectively segregating the liquid hydrocarbons from the gaseous components. This mechanism enhances the separation efficiency and allows for clear demarcation of the phases, facilitating further processing .
Mechanical refrigeration in dew point control is limited by the pressures of the feed gas, as it cannot efficiently handle gas pressures above the critical pressure of the feed gas, particularly in the region of 80-100 bar. Additionally, it must operate below the cricondobar pressure, which restricts it from achieving the required gas specification if the operating pressure exceeds the critical pressure range. The mechanical refrigeration is less effective in the retrograde region at higher pressures .
Supersonic Separation offers several advantages over conventional dew point control methods, such as the J-T valve, including its capability for both NGL recovery and hydrocarbon dew pointing without the need for rotating parts or chemical injection for hydrate suppression. It is a simple, reliable technology that operates unmanned, boasting low capital and operational costs and eliminating emissions, thus making it an environmentally friendly solution that is easy to manufacture and deploy. Additionally, Supersonic Separation achieves higher efficiency with improved dew point suppression and reduced pressure loss over the years .
In Twister-2 technology, guide vanes are employed to enhance system efficiency by significantly increasing the swirl vorticity from 300,000g to 500,000g. This increase in vorticity results in a lower dew point, improving the overall performance of the supersonic separation process. The guide vanes facilitate a more efficient separation of condensates from the gas stream during the cyclone action, which happens after the initial supersonic acceleration and condensation of heavier hydrocarbons .
The pre-cooling phase in mechanical refrigeration initially reduces the gas stream's temperature as it passes through a gas-gas heat exchanger before entering the chiller. This step ensures the efficient extraction of latent heat of vaporization in the chiller, where the refrigerant absorbs the heat causing heavier hydrocarbons to condense. This pre-cooling is crucial in achieving the desired dew point suppression and thus ensuring that the dew point requirements for safe and efficient gas transportation are met .
Supersonic technology significantly minimizes environmental impact compared to traditional hydrocarbon dew pointing methods. It operates without emissions, relying solely on physical processes that eliminate the need for chemical injections required by other methods like the J-T valve. Its simplicity and reliability reduce operational risks associated with mechanical failures or chemical handling. The lack of rotating parts and the ability to function unmanned further decrease the environmental footprint of operations by reducing energy requirements and potential hazards, making it a more sustainable option .
The key technological trends in condensation methods for natural gas dew point control include the enhancement of condensation technologies, which are more developed compared to absorption and adsorption processes. These involve the reduction of gas stream temperature, causing heavier hydrocarbons to condense and shift the dew point line within the gas stream phase envelope to a lower temperature at a given pressure. The level of dew point suppression needed determines the quantity of heavier hydrocarbons extracted. The technologies discussed include Mechanical Refrigeration, Valve Expansion Refrigeration, Turbo-Expander Refrigeration, and Supersonic Separation .
Since its invention in 1998, Twister technology has seen several improvements, notably in its operational efficiency and performance metrics. Supersonic efficiency has increased from 85% to 98%, dew point suppression from 15°C to 35°C, and pressure loss has decreased from 30% to 20%. These enhancements have benefitted its application by making it more efficient and cost-effective, improving hydrocarbon recovery rates, and making the technology more attractive for various industry applications such as in Shell's onshore gas processing facilities .
