Simulation and Optimization of A Natural Gas Dehydration Plant With Triethylene Glycol
Simulation and Optimization of A Natural Gas Dehydration Plant With Triethylene Glycol
author's profile
University of Uyo
ABSTRACT
Dehydration of Natural Gas has been a subject of interest for decades due to the effect of wet gas on the
system. Specifically, the gas’ heating value and its flow assurance are challenged coupled with not meeting
markets’ specification. Besides these flow assurance and related issues, the hydrate in the gas quickly
deactivate catalyst and burn less. This study attempts to economically dehydrate the gas using Triethylene
Glycol (TEG) which has to be optimally regenerated and used for further dehydration process. The simulation
and optimization of the dehydration process through absorption with TEG was carried out using Aspen
HYSYS software and Design-Expert software respectively. The simulation was carried out using Glycol and
Peng-Robinson as the thermodynamic fluid package. Effects of parameters such as TEG circulation rate,
equilibrium stages of absorption column, operating conditions on the process efficiency were investigated. It
was found that, lowering the pressure in the absorption column reduces the amount of hydrocarbons trapped
in the wet TEG stream leaving the bottom of the absorber. The optimization of the Recycled TEG was carried
out using the numerical optimization of the Design-Expert software, the experimental design was based on
the Central Composite Design of the Response Surface Methodology of Design-Expert version 10, this
optimization yield a relative increase in TEG recycled stream from 99.59 mole% to 99.89 mole% at an
optimum operating parameters of 25oC, 6320 kpa and 1883 kgmole/h of the wet gas stream.
Language: English
London
LJP Copyright ID: 392974
Print ISSN: 2631-8474
Journals Press
Online ISSN: 2631-8482
LJP
(where water vapour is removed) and separation phases: an aqueous phase (produced water), a
of the heavy hydrocarbon components (Kong et liquid hydrocarbon phase (crude oil) and a gas
al., 2018; Shoaib et al., 2018). The water content phase with some suspended solids in the
in natural gas is a big problem in the oil and gas mixture. Normally, the three phases must be
industry as it can accelerates corrosion in the gas separated and then further processed in the
pipe lines and as well reduces the heating value of topside facilities, before being discharged or
the natural gas. exported to onshore (Figure 1.1).
Figure 1.1: Overview of upstream processes in the oil and gas industry
The separation of the three phases is carried out pressure of the middle separator is in between.
in 3-phase separators. These vessels slow down This arrangement serves to stabilize the crude oil
the reservoir fluid by reducing its momentum. by removing volatile components. The produced
Then, the phases are separated by means of water is treated in water treatment facilities. The
gravitational force. There are normally three objective is to remove the dispersed hydrocarbons
separators on offshore facilities, the first being from the water to meet environmental regulations
high pressure, the last being low pressure and the for the produced water discharge quality. The
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
62
2 Volume 22 | Issue 1 | Compilation 1.0 © 2022 London Journals Press
water purification facilities mostly consist of (TEG) as the absorbent. This involved simulation
hydrocyclones and skimmers. of Natural gas dehydration process using Aspen
HYSYS. Industry data available in this direction
The produced gas must be recompressed and was generously exploited to investigate the effect
exported to onshore facilities. The high-pressure of operating parameters on the efficiency of the
(9 - 14 MPa) pipelines (Bothamley, 2004) used for process. Design Expert was used to optimize the
exporting, lay on the seabed where the fluid can solvent regeneration of gas dehydration plant
cool down to as low as -1°C (Skjoldal, 2007). At (Luyben, 2011). Thus, optimizing the regeneration
this low temperature and high pressure, if there is of TEG is economical as fewer quantity of the
water in the gas phase it may form solid solvent (TEG) and eventually maximize the
crystalline hydrates with the light hydrocarbons. profitability of natural gas dehydration (Chebbi et
The hydrates can cause severe damage to the al., 2019).
pipelines. The gas phase in the reservoir fluid is
saturated with water because it was previously in
II. MATERIALS AND METHODS
contact with the brine and other aggressive
substances. Therefore, one of the purposes of the In this study, dehydration process of a typical
gas treatment is the removal of water from the gas natural gas from one of the Niger Delta oil field is
(dehydration). presented. The plant as simulated using one of the
popular commercial software in the oil and gas
Dehydration is the main operation employed in industry (Aspen HYSYS) explores the real
the industry to remove the contaminated moisture industrial experience of the researcher while in
from the natural gas (Mokhatab et al, 2019). This the field.
is necessary for hydrocarbon dew point control
which is to maintain the water content 2.1 Simulation of Natural Gas Dehydration Plant
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
Property Value
Inlet Pressure 7201Kpa
Inlet Temperature 250C
Flow Rate 1883Kgmole/hr
hydrocarbon systems applications and studies operated with 9 stages for higher purity (Pezman
(Elliot and Lira, 1999). It is specifically used for and Roya, 2011; Affandy et al., 2020). The mixed
gas phase components that handle the complex TEG (fresh and recycled TEG) inlet and Dry gas
thermodynamics that occur during compression, outlet are located at the top of the column while
and is useful in both upstream and downstream the TEG outlet (Rich TEG) and Natural gas with
industries. hydrate (Hydrated gas) inlet are located at the
bottom of the column Figure 2.1.
The simulation on HYSYS commences with
passing wet gas to the flash tank (Separator) at
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
64
2 Volume 22 | Issue 1 | Compilation 1.0 © 2022 London Journals Press
The TEG flow is dependent on the water (hydrate) Consequently the filtration does not have serious
content in the hydrated gas. Rich TEG leaves the impact on the process. Once filtered, the
bottom by level control and is depressurized by a depressurized TEG stream is subjected to heat
valve. The rich stream flows through a cartridge exchange with the hot regenerator bottom product
filter to remove solid particles coming from (lean TEG) coming out of the TEG regenerator at
corrosion or TEG degradation (Affandy et al., the Rich/Lean TEG Exchanger before it then
2017). However, solid particles and degradation becomes feed for the regenerator. The
are not taken into account in this model. Hence, it Regenerator is used to strip water from the lean
is not represented in the simulated plant. TEG (Figure 2.2).
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
The Process achieved high water removal and is reflected in zero water composition in the
natural gas outlet stream (Sale Gas) shown in Figure 2.4.
London Journal of Engineering Research
Figure 2.4: Composition of the Dehydrated (Sale Gas) control screen on HYSYS
Waste gases consisting of water and the and recycled back to the contactor as it mixes with
hydrocarbons dissolved in the TEG leave the fresh lean TEG in a mixer (TEG Mixer) and fed to
regenerator at the top. The lean TEG then enters a the contactor. Figure 2.5 shows Process Flow
Surge drum in which gaseous hydrocarbons that Diagram (PFD) of the HYSYS simulation of the
were absorbed along with the water in the Natural gas Dehydration process.
separator is vaporized as flash out. The Lean TEG
is then cooled, pumped (Glycol Circulation Pump)
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
66
2 Volume 22 | Issue 1 | Compilation 1.0 © 2022 London Journals Press
London Journal of Engineering Research
Figure 2.5: Process Flow Diagram of Natural Gas Dehydration Plant in Aspen HYSYS
2.2 Optimization of the Natural Gas Dehydration Aspen HYSYS to simulate the dehydration plant,
Plant the values of Recycled TEG using the new process
variables were used as response variable to
Optimization of the natural gas dehydration plant
analyze the maximum Recycled TEG yield using
was carried out using Design Expert version. 10 to
Design Expert numerical optimization method.
maximize the yield of recycled TEG that will be
used for further dehydration process. The
Response Surface methodology (RSM) using the III. RESULTS AND DISCUSSION
Central Composite Design (CCD) of design expert 3.1 Effects of Process Parameters on Natural Gas
was adopted for the optimization process, the Dehydration Plant
process variables of the wet natural gas stream
In the quest to maximize the absorption efficiency
were used to evaluate the optimum operating
of TEG in the contactor, the impacts of the key
condition at which maximum recycled TEG yield
parameters were evaluated using the simulation
could be achieved. By using design expert version
model presented in this study. These parameters
10, low and high values of the process variables
were:
(temperature, pressure and flow rate) were
specified and the response set to be Recycled i. The number of contactor theoretical trays
TEG. A total of 15 runs were generated from the ii. TEG circulation rate
specified low and high values of the process iii. Temperature of the reboiler in the
variables to generated different ranges of the regenerator
process variables at which one should give the It was found that lowering the pressure in the
maximum yield of the regenerated TEG. This absorption column reduces the amount of
generated process variables were then taken to hydrocarbons trapped in the wet TEG stream
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
Figure 3.1: Composition of the Rich TEG stream after simulation in HYSYS
London Journal of Engineering Research
However, other parameters may have also a Response Surface Methodology based on Central
limited impact. It was also observed that Composite Design Model (section 3.2.1), Anova
increasing the number of trays in the regenerator for Response Surface Reduced Quadratic Model
has no effect on the outlet stream composition. It (section 3.2.2).
was observed that increasing the flowrate of the
TEG above the minimum requirement is not 3.2.1 Analysis using Response Surface
necessary as maximum separation has already Methodology (RSM)
been achieved. TEG is known to decompose at a After performing the dehydration plant
temperature of 206oC which is far lower than its simulation, it was found that recycled TEG yield
boiling point of 284°C and this limits the depends on different parameters of the natural
temperature of the TEG regenerator reboiler gas dehydration process. So, by controlling these
(Kamin et al., 2017; Neagu and Cursaru, 2017). parameters, optimum recycled TEG yield was
3.2 Optimization of TEG Regeneration of the obtained. Response Surface Methodology (RSM)
Natural Gas Dehydration Plant based on Central Composite Design (CCD) was
used to monitor the yield of Recycled TEG with
The optimization of TEG regeneration of the response to the process variables. The variables
natural gas dehydration plant was carried out and their corresponding coded values for the
using Design Expert ver. 10 so as to recover process are analyzed (Table 3.1) and the Response
maximum TEG for further dehydration process. parameter (Table 3.2) as follows:
This section discusses the Analysis using
Table 3.1: Process variables and their corresponding coded values
Factor Name Units Type Subtype Minimum Maximum Coded Values Mean Std. Dev.
A Temperature oC Numeric Continuous 20.0522 53.8378 -1.000=25 1.000=48.89 36.945 9.02957
B Pressure kPa Numeric Continuous 6137.54 7383.46 -1.000=6320 1.000=7201 6760.5 332.987
C Flow rate kgmole/h Numeric Continuous 92.1477 12320.9 -1.000=1883 1.000=10530 6206.5 3268.26
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
68
2 Volume 22 | Issue 1 | Compilation 1.0 © 2022 London Journals Press
Table 3.2: Response parameter
Response Name Units Obs Analysis Minimum Maximum Mean Std. Dev. Ratio Trans Model
Recycled
R1 mole 15 Polynomial 0.9984 0.9989 0.998593 0.000109978 1.0005 None RQuadratic
TEG
The experimental design using the central response point, Table 3.3 shows the experimental
composite design consisted of a total of 15 base design of TEG regeneration optimization.
runs, comprising of 3 factorial points, and 1
3.2.2 Anova for Response Surface Reduced significant. In this case B, C, AB, AC, BC, B2, C2
Quadratic Model are significant model terms. Values greater than
0.1000 indicate the model terms are not
Analysis of variance table (Table 3.4), the model
significant. The summary of fit of the Factor and
F-value of 134.47 implies the model is significant.
Coefficient Estimates are presented in Table 3.5.
There is only a 0.01% chance that an F-value this The best fit model proposed by the software was
large could occur due to noise. Values of "Prob > the quadratic model.
F" less than 0.0500 indicate model terms are
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
70
2 Volume 22 | Issue 1 | Compilation 1.0 © 2022 London Journals Press
Figure 3.3: Graphical representation of the effect of pressure on Recycled TEG
Figure 3.4: Contour Plot showing the effect of temperature and pressure on the Recycled TEG
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
Figure 3.6: A cube showing the effect of wet gas parameters on the response
From the result of the optimization, it was seen on the system, gas’ value and market
that temperature, pressure and flow rate has specification. Specifically, dehydration is carried
significant effect on the process, the optimum out to prevent formation of hydrates which are
operating temperature, pressure and flow rates known to corrode pipelines and block valves.
were found to be 25oC, 6320 kpa and 1883 Besides these flow assurance issues, the hydrate in
kgmole/h respectively, this process variable the gas quickly deactivate catalyst and burn less.
values gives an optimum yield of Recycled TEG of Several studies emerged with an attempt to
99.89 mol%. economically dehydrate the gas. In this study,
TEG, proven to be the best and less aggressive on
IV. SUMMARY, CONCLUSION AND the environment has been exploited. This study
RECOMMENDATION evaluated the dehydration of Natural gas through
absorption with Triethylene glycol and HYSYS
4.1 Summary
simulation of the process was carried out using
Dehydration of Natural Gas has been a subject of
interest for decades due to the effect of the wet gas
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
17. Neagu, M. and Cursaru, D. (2017). Technical Gas Science and Engineering, 49: 324–330.
and economic evaluations of the triethylene 27. Siti, N. and Abdul G. (2012). Simulation of
glycol regeneration processes in natural gas Typical Natural Gas Dehydration Unit using
dehydration plants. Journal of Natural Gas Glycol Solutions. Engineering Reports 8 (2):
Science and Engineering. 37:327-340. 27-31
18. Netusil, M. and Ditl, P. (2011). Comparison of 28. Stewart, M. and Arnold, K. (2011). Gas
three methods for natural gas dehydration. Sweetening and Processing Field Manual.
Journal of Natural Gas Chemistry .20(5): Houston: Gulf Professional Publishing, pp.
471-476. 51–52.
19. Obonukut, M. E., Alabi, S. B. and Bassey, P. G.
(2016). Steam Reforming of Natural Gas: Value
Addition to Natural Gas Utilization in Nigeria.
Journal of Chemistry and Chemical
Engineering 10 (1): 2841.
20. Partho, S. and Ruhul, A. (2011) Aspen-HYSYS
Simulation of Natural Gas Processing Plant.
Journal of Chemical Engineering IEB 26:
62-65.
21. Patel, M. S., Wong, S. F. and Storm, D. A.,
(2005). Retrofitting Methanol Plants for
Higher Alcohols. 78th American Institute of
Chemical Engineer’s, National Meeting, New
Orleans, LA.
22. Pezman K. and Roya H. (2011). Sensitivity
Analysis of a Natural Gas Triethylene Glycol
Simulation and Optimization of a Natural Gas Dehydration Plant with Triethylene Glycol
74
2 Volume 22 | Issue 1 | Compilation 1.0 © 2022 London Journals Press