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CHAPTER 5

GAS TREATMENT

Prof. Dr. Ariffin Samsuri

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Gas Treatment
Theory of Gas Treatment
Gas Treatment Method
Chemical Absorption
TOPIC Physical Absorption
Hybrid
Direct Conversion
Dry Bed Processes
Selection Criteria

Expected Outcomes
Students should be able to
Identify the impurities in gas stream and its consequences to
the equipment and gas utilities
Explain the various type of gas treatment methods such as
chemical absorption, physical absorption, hybrid, direct
conversion and dry bed processes
Select the suitable process based on certain selected
criteria

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Definitions
Dry gas: produced in absence of a liquid stream (<5 bbls/MMSCF liquid)
Wet gas: is a gas produced with some liquid (10 20 bbls/MMSCF liquid).
Associated gas: gas produced simultaneously with a black oil
Non-associated gas: gas produced from gas reservoir
Sales gas: consists largely of C1 and some C2
Liquified natural gas (LNG): natural gas liquefied by cooling to 258 oF (-161 oC) under atmospheric pressure
Condensate: mainly C5 to C12
Natural or casing head gasoline: lighter fraction of condensate, roughly C5 to C8
Heavy condensate: consists of kero and diesel roughly C9 to C12
Natural gas often contains products termed natural gas liquids (NGL), which can be recovered economically in a processing plant and
sold separately. They are:
Liquefied petroleum gas (LPG) consists of propane/propylene (C3) and butane/butylene (C4) in various mixtures, and can be
liquefied under light pressure at normal temperature. In Malaysia, the mixture is mainly propane and butane whereas for all fuel
in the United States, the mixture is mainly propane. LPG is used in all major end-user sectors as a heating fuel, engine fuel,
cooking fuel, and chemical feedstock
Natural gasoline or casing head gasoline - liquid at normal temperature and pressure, and consists of a mixture of butane and
heavier hydrocarbons such as pentanes and hexanes
Sour gas contains H2S, sulfur or any sulfur compounds
Sweet gas contains no or very little sulfur or sulfur compounds
Acid gas contains mainly H2S and CO2 + H2O acid
Natural gas for vehicle (NGV) may be classified as follows, according to the fuel storage method:
CNG vehicles stored as a gas at high pressure (3,000 psig) in a gas cylinder
LPG vehicles stored as a liquid (at 162 oC) in a low temperature container
Adsorbed natural gas (ANG) stored at a pressure of 142 psig adsorbed into adsorbent material inside a gas cylinder
Compressed natural gas (CNG) is natural gas compressed to about 1,500 psia. and same properties as natural gas except that the
volume is reduced

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Natural Gases Characteristics
Leman Bank Groningen Libya* Brent* Lacq (France)
Compt (high C1) (high N2) (high C2, C3, C4) (North Sea) (high H2S, CO2)
C1 94.7 81.2 66.8 85.9 69.1

C2 3.0 2.9 19.4 8.1 2.8


C3 0.5 0.4 9.1 2.7 0.8
C4 0.2 0.1 3.5 0.9 1.5
C5+ 0.2 0.1 1.2 0.3 0.6
H2S - - - - 15.4
CO2 0.1 0.9 - 1.0 9.7
N2 1.3 14.4 - 0.5 -
He/Argon <0.1 <0.1 - - -
S.G. 0.59 0.64 0.81 0.62 0.75
Cal. value3
Btu/ft3 1037 843 1332 1053 910
MJ/m 38.6 31.4 49.6 39.2 33.9

* Associated gas

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Condensate vs Crude Oil

Light crude oils are often hard to distinguish from condensate, therefore production by
OPEC beyond quota limits can be done by declaring light crude to be a gas condensate
Therefore, in 1988 OPEC have agreed the following definition:
Condensates Crudes
API gravity above 50o below 45o
C7+ (mol % wt) below 3.5% above 8.0% min.
Gas/liquid ratio above 5,000 scf/bbl below 5,000 scf/bbl

Import of condensate into Japan*


Quota restriction on crude oil production in OPEC (natural gas production is
not restricted, therefore the productions of natural gas liquids is not
subject to quota)

* Japan imports all petroleum products and imposes an import duty on all of them. This duty is
however waived in the case of chemical feedstocks such as naptha or gas oil, imported by the
petrochemical industry. Condensate being alike to naptha, can therefore be imported duty free
provided its 90% boiling point does not exceed 200 oC. As a result heavy condensates are
frequently subject to import duty.

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LPG - Properties and Uses

Composition: C3 and C4 (atmospheric


boiling point: -46 to +1 oC)
Storage pressure: 5 - 30 bar approx.
(either butane only or all LPG)
Storage in cylinders, tanks, refrigerated
vessel, underground
Uses: domestic, industrial, commercial,
generally where piped is not available

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Need for Gas Treatment
Natural gas consists various components which are present in different concentration (water, HC and
impurities)

Removal of contaminant from natural gas

Gas compositions to customers should be the same (eliminate all components other than methane)
purified version
it is essential to remove undesirable impurities such as H2O, HC, CO2 and H2S and to isolate for
separation

Impurities and heavy HCs can be commercially attractive but they are just contaminants. Water vapor is
always unwanted

Low concentration of C2 is acceptable but C2 is normally separated because of its potential use as a
chemical feedstock for ethylene manufacture

C3 and C4 - for LPG

C5+ - gas condensate, need to separate because of their interference with normal operation of gas
compression, transmission, metering, utilization, etc

Liquids - NGLs - are more valuable than gases

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Reasons for Natural Gas Treatment

To meet sales specifications and


customers requirement
To recover other materials such as He,
CO2, condensate, natural gasoline, etc.
(higher price if marketed separately)
To extract materials such as sulfur from
H2S - extra income
To facilitate transmission - careful
moisture removal

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Gas Purification

Removal of acidic gases (sour gas


processing)
Removal of water vapour
(dehydration)
Removal of heavier HCs

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Removal of Acidic Gases from NG

Content :
CO2 and H2S are main acidic gases; others only in
trace quantity
Method:
Combination of chemical reaction and physical
absorption; heat regeneration
For high CO2, low H2S, carbonate processes and
molecular sieves are used occasionally

Chemical:
Monoethanolamine (MEA) [most effective)
Diethanolamine (DEA) [most effective]
Propanolamines, eg in Sulphinol process

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Why H2S must be removed?

H2S
highly toxic and
poisonous.
A brief exposure of 1,000 ppm (0.1 volume %) H2S is fatal
H2S in the presence of water can cause corrosion to valves, pipelines,
pressure vessels, etc.
Most pipeline specification limit H2S content to 0.25 g/100 cuft (4
ppm)

Sulfur compounds, {reactive sulfur residue (RSR), carbonyl sulfide


(COS) and carbon disulfide (CS2)}
have objectionable odors and
tend to concentrate in gas plant liquid product (most sulfur
compounds must be removed before liquid products are usable)

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Why CO2 must be removed?

Corrosive in the presence of water


As an inert gas :
has no heating value, in sufficient quantities,
CO2 might reduce the heating value (Btu/cf)
below acceptable limits
CO2 removal may be required in gas going
to cryogenic plants to prevent solidification
of the CO2

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Removal of Water Vapor from NG
Reasons:
1. Risk of solid hydrates formation
2. Natural gas containing liquid water is corrosive
3. Water vapor in natural gas may condense in pipelines slugging flow
4. Water vapor increases volume & decreases heating value reduced line
capacity
Sources: Water from formations, purification, etc.
Content estimation : experimental data such as McKetta & Wehe chart
Typical values: Reservoir gas (5000 psig/250deg.F = 500 lbm/mmscf
Trap gas (500 psig/125deg.F = 400 lbm/mmscf
Pipeline gas = 6- 8 lbm/mmscf
Treatment:
Water stabilization vs removal
Glycol treatment (DEG, TEG)
Other methods are molecular sieves, alumina, silica gel, etc.

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Heavier HCs Removal from NG

Gas refrigeration/cooling
Joule-Thomson refrigeration (Joule-
Thomson Effect)
Expander for energy recovery
Absorption in refrigerated solvent
Expansion/compression energy exchange
(condensation in right order)
Adsorption on molecular sieves

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Gas Sweetening Process

Gas sweetening process SWEET RESIDUE


splits a sour gas stream into GAS
C1 Cn To dehydration
two process stream: N2 & HC recovery
- Sweet residue gas H2O
- Acid gas
ACID GAS
H2S
CO2
COS Flared or sent to
CS2 Claus sulfur
recovery unit
RSR
H2O
SOUR NATURAL GAS
C1 CN
N2
H2S
CO2
COS (carbonyl sulfide)
CS2 (carbon Disulfide)
RSR (mercaptans)

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Gas Sweetening Process

A number of gas sweetening processes are commercially


available, and more are being developed each year
Gas sweetening processes can be group into 5 general
categories according to the type:
Chemical absorption
Physical absorption
Hybrid
Direct conversion
Dry bed

Note: A process is classified as selective if it removes H2S but


leaves CO2 in the sweet residue gas.

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Gas Sweetening Process

Chemical absorption
Includes use of amine and potassium carbonate
Utilize an aqueous solvent that reacts chemically with acid components
Acid gas components are held in solution until chemical reaction is reversed in
regenerator by T and P
Physical absorption
Use a solvent to physically absorb acid gas components
Use solution ambient T to separate acid gas components in the regenerator.
Hybrid
Mixture of chemical and physical solvents
Direct conversion
Elemental sulfur produced directly from H2S. No Claus unit is required.
Dry bed
Utilized no solvent.
Gas is passed over a dry bed, which removes H2S from sour gas.
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Gas sweetening process classification

Direct
Chemical Physical Hybrid Dry bed
conversion
MEA Selexol Shell Stretford Iron sponge
Sulfinol
DEA Purisol Claus Molecular
sieve
DGA Rectisol Sulfa-check Zinc oxide
Shell ADIP Flour solvent LOCAT Sulfa treat
(DIPA)* (propylene
carbonate)
Benfield
Catacarb
Hindered
Amine
*Diisopropanol amine
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Chemical absorption
Uses weak aqueous base solution to chemically react with and absorb the acid
gases in the contactor to form a new complex compound, which is held in the
solvent
Contactor is operated at low T, high P
Some of the absorbed HCs are released in a flash drum and normally used as fuel
In regenerator, complex compound decomposes at higher T and lower P, which
force the reaction to reverse & to liberate the acid gas components
Reactions involved are reversible by changing P and T, or both
Aqueous base solution can be regenerated & thus circulated in a continuous cycle

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Alkanolamine Sweetening

Chemical use: MEA, DEA & TEA (triethanolamine)


Not selective total acid gas removal (H2S & CO2)
Typical reaction between acid gas & MEA:
Absorbing:
MEA +H2S MEA hydrosulfide + heat
MEA + H2O + CO2 MEA carbonate + heat
Regenerating :
MEA hydrosulfide + heat MEA + H2S
MEA carbonate + heat MEA + H2O + CO2
MEA :
stronger base
more reactive
Lower molecular weight required less circulation to
maintain amine/acid gas ratio
Greater stability
Can be reclaimed from contaminated solution by
semicontinuous distillation
than DEA or TEA MEA is preferred

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Chemical absorption - Comparison of Chemical Solutions

Process MEA DEA DGA DIPA MDEA


Amine Type Primary Secondary Primary Secondary Tertiary
Reactivity High Moderate Moderate Moderate Moderate
Stability Fair Good Fair Good Good
HC Absorptivity Low Moderate High Moderate High
Vaporization Losses High Moderate High Moderate Low
H2S Selective No No No No Yes
Organic S Removal Low Low Moderate Low Low
Corrositivity High Moderate Moderate Low Low
Cost Low Low Moderate Low Moderate
Degradability
H2S None None None None None
CO2 Some Low Some Some Low
COS Yes Minor Some Severe Minor

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Physical Absorption - Introduction

Physical solvent processes use


organic solvents and accomplish acid
gas removal mainly by physical
absorption.
Most applicable to P gas streams
containing appreciable quantities of
sour components.
Physical solvent processes e.g.
Selexol, Purisol and Fluor Solvent.

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Selexol Process
Use physical solvent
made of a dimethyl ether
of polyethylene glycol to
remove acid gas from
streams of synthetic or
natural gas.

Chemically inert and is


not subject to
degradation.

Most applications for


high CO2 contents but
very little H2S.

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Selexol Process

Advantages Disadvantages
Selective for H2S, due to High hydrocarbon coabsorption.
higher absorption capacities
for H2S than CO2. Not applicable at low treating
pressures.(<400 psi)
Since there are no chemical
reactions, no reclaimer is Cost are relatively high and requires
required. payment of a license fee.
Little corrosion

Utilizes high acid gas


loadings & has a low utility
requirements (high partial
pressure condition)

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Selexol Process Facilities

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Purisol Process

Use N-methyl-2 pyrolidone solution.

Processing scheme is similar with Selexol.

More promise in refining and syngas applications where sour gas is especially
lean.

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Purisol Process

Advantages
Disadvantages
Selective for H2S, due to
higher absorption capacities
High hydrocarbon coabsorption.
for H2S than CO2.

Since there are no chemical Not applicable at low treating


reactions, no reclaimer is pressures.(<400 psi)
required.
Cost are relatively high and requires
Little corrosion payment of a license fee.
There must be a use for sour stripping
Utilizes high acid gas loadings gas from regenerator such as boiler
& has a low utility
requirements (high partial fuel.
pressure condition)
Exhibit better mercaptan (RSR)
removal than Selexol.

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Rectisol Process

Uses methanol as a solvent in 2-stages


refrigerated absorber.
Refrigerated to -5oF to -75oF prior to entering the
absorber.
Used primarily in sweetening synthesis gas.

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Fluor Solvent Process

Employs propylene glycol to remove CO2 and H2S


from sour gas streams.
Basically the same advantages and disadvantages
as selexol.

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Physical Absorption Process Selection

Depends on process objectives and


characteristics of the solvents, such as selectivity
for H2S, CO2, HCN, etc.
Ease of controlling water content of circulating
solvent.
Concurrent hydrocarbon loss
Solvent cost & supply
Chemical inertness, royalty cost, thermal stability
and proven plant performance for various
processing techniques.

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Comparison of Commercial Physical Solvents

Aspects need to be consider:


Heavy hydrocarbon effect
Recycle compressor effect
Selective H2S removal
Process configuration

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Physical Absorption Effect of Heavy Hydrocarbon

In natural gas treating, loss of heavy


hydrocarbons is a concern. Selexol are miscible
with water, and water may be used to reject
these hydrocarbons.
Water can actually be added to this stream to
reduce hydrocarbon solubility further.

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Physical Absorption Effects of Recycle Compressor

Major energy user in physical solvent processes is


compression for recycle of flash gas to limit
methane losses.
The higher the solubility of methane, the higher
the recycle compressor horsepower for the same
amount of methane product in treated gas.

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Physical Absorption Selective H2S Removal

Data indicate that Selexol and Purisol are superior


if selective H2S removal from gas containing
carbon dioxide is required.
Actual experience confirms this prediction.

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Physical Absorption Process Configuration

Good thermal stability, chemical inertness, and thermal conductivity are also
necessary to permit flexibility in process schemes.
For example, selective H2S removal can be benefited by use of heat.

Reboiling solvent in regenerator may be necessary to meet treated gas purity


requirements for CO2, H2S.
Demands on physical solvent processes are:
increasing,
losses of valuable components must be minimized,
removal of acid gas and trace components to lower levels must be achieved.

Process designer's ingenuity and innovations might easily outdistance small


inherent advantages of one solvent over another.

Selexol has a clear experience advantage over all other solvents in all applications
involving H2S and C02 removal in hydrocarbon systems.

Fluor Solvent and Selexol both enjoy a clear experience advantage over the other
processes in applications for CO2 removal only.

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Solubility of Gases in Physical Solvents
Gas Solubility (cc gas at 1 atm, 75F/cc solvent)
(Ferrin & Manning, 1984)

Gas Selexol Purisol Fluor Solvent


H2S 25.5 43.3 13.3
CO2 3.6 3.8 3.3
COS 9.8 10.6 6
C3 4.6 3.5 2.1

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Solubility of Gases in Physical Solvents

Gas Solubilities Relative to CO2 (Bucklin & Schendel, 1984)


Ga s Se le x ol Purisol Fluor Solve nt
H2 0.013 0.006 0.008
CO 0.028 0.021 0.021
C1 0.067 0.072 0.038
C2 0.42 0.38 0.17
CO2 1.0 1.0 1.0
C3 1.02 1.07 0.51
nC4 2.33 3.48 1.75
COS 2.33 2.72 1.88
H2S 8.93 10.2 3.28
nC6 11.0 42.7 13.5
CH3SH 22.7 34.0 27.2
C6H6 253.0 / 200.0
H2O 733.0 4000.0 300.0
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Hybrid Process
Chemical absorption (to achieve H2S specifications) + Physical absorption (low
energy & easy of regeneration)
Only truly commercial process = Sulfinol
Consists of a mixture of sulfolane, isopropanol amine and water

FLASH
RESIDUE GAS CONDENSER
GAS ACID
CW GAS

CW
LEAN /RICH
LEAN
EXCHANGER
SOLVENT
REFLUX
LEAN
SOLVENT
COOLER
FLASH
TANK

STEAM

FREE
GAS

LEAN SOLVENT
SURGE

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Glycol/Amine Process

Combination of dehydration & sweetening


Use solution composed : 10 30% weight MEA + 45 85% weight
glycol + 5 25% water
To remove water vapor. H2S & CO2
Benefit : lower equipment cost than MEA unit followed by glycol
dehydrator
Disadvantages:
increased MEA vaporization losses due to high regeneration T
Reclaiming must be by vacuum distillation
Corrosion problems
Application limitation - must be for gas stream that do not require
low dew points

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Hybrid Process - Sulfinol
Uses of solvent mixture behave as chemical & physical solvent process
Solvent composed :
1. Sulfolane physical solvent
2. diisopropanolamine (DIPA) chemical solvent
3. water

Formation of heavy, tar-like sludge block exchangers & liners


Absorb HCs due to sulfolane (physical solvent)
Advantages:
Low solvent circulation rate
Small equipment & lower plant cost
Low heat capacity of solvent
Low utility costs
Low degradation rate
Low corrosion rate
Low foaming tendency
High effectiveness for carbonyl sulfide (ROS), carbon disulfide (CS2) & mercaptans (RSR) removal
Low solvent vaporization losses
Low heat-exchanger fouling tendensy
Noneexpansion of solvent when freezes
Excellent H2S & CO2 removal
Good for low P (100 300psia)
Can remove COS, CS2 & RSR with no degradation
Selective H2S removal
Disadvantages:
Absorption of heavy hc, aromatic
Formation of heavy, tar-like sludge block exchangers & liners

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Direct Conversion

Uses chemical reactions to oxidize H2S &


produce elemental sulfur
Based on reaction of H2S and O2 or H2S and
SO2, to yield H2O & S
Licensed processes
Involved specialized catalysts and/or solvents
Can be used directly on the produced gas
stream

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Dry Bed Adsorption

Utilize solid materials rather than aqueous


solvents to remove acid gas constituents
Retention may be:
chemical reaction,
capillary condensation,
intermolecular forces,
or combinations
Gas stream must flow through solid particles
fixed bed that remove acid gases & hold them
in the bed

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Iron Sponge

Dry oxidation batch process -for sulphur compounds removal from coal gas.
H2S is converted to sulphur, using oxygen in carriers which react with it at ordinary
temperatures.
Reaction between iron sponge & H2S:
6H2S + 2Fe2O3 = 2Fe2S3 + 6H2O
Reaction proceeds best at temperature 37.8C (kept below 120deg.F) and alkaline
environment.
Can be with supplemental water spray
Pellets, or hydrated iron oxide (sensitive) on shavings are distributed in large containers
called dry boxes or on trays in towers.
Bed can be regenerated by air addition (continuously or batch)
Regeneration reaction: 2Fe2S3 + 3O2 = 6S + 2Fe2O3
Process is a two-stage one.
First stage removing H2S,
Second stage reoxidizes (regeneration) Fe2S3 to the oxide.
Since sulfur remains in the bed, regeneration steps is limited

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Iron Sponge

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Iron Sponge

Advantages
Low initial cost Disadvantages
Low power consumption Proprietary media
No furnace erosion and Level of effort for
boiling, more patching life removal of media
varies
Low consumption of cast
iron High unit operating
costs
Better yield
Increase in production
Low burning gas, harmless
to worker's health
More profit
Positive effect on bottom line
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Molecular Sieve
Inlet gas simply passed through tower containing absorbent.
When molecular sieve approaches saturation, inlet stream
switched to second tower.
While absorbent in first generated by following heated, dry
gas counter-flow to the direction of stream that was being
dried.
Moist generation gas is cooled and much of water is
condensed, separated and removed from the system.
Generation gas is then either
Mixed with wet inlet gas to the adsorbing tower, or
Returned to lower pressure distribution line.
Tower must be cooled by a cool flow of dry gas before being
placed back in service.

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Molecular Sieve

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Molecular Sieve

Pros Cons
Economically favored for Regeneration of gas
small quantities of H2S requires treatment if it
Very selective (reject can not be blended
100% of CO2) into fuel.
Sweeten & dehydrate Carbonyl sulfide
gas simultaneously if H20 (COS) can be formed
present in the molecular sieve
bed from the reaction
of CO2 and H2S

FACULTY OF PETROLEUM & RENEWABLE ENERGY ENGINEERING (FPREE)


50
Innovative. Entrepreneurial . Global
Characteristics of Gas Treating Processes

Process Capable of Treating Capable of Treating Chemical Reclaiming Average Losses


Rich Gas Streams At Low Pressure Degradation Possible LB/MMscf Acid Gas
MEA Yes Yes Yes Yes 5
DEA Yes Yes Yes No 5.5
DGA Sometimes Yes Yes Yes 3.5
Shell ADIP Yes Yes Yes Yes 5
Benfield Yes No No Not required 3
Catacarb Yes No No Not required 3
Physical Solvents Yes No No Not required 4
Shell Sulfinol Sometimes Yes Yes Yes 1.5/5
Stretford Sometimes Yes Yes No /
Mol Sieve Sometimes Yes Requires Regeneration / /
Iron Sponge Yes Yes Cannot be regenerated / /
FACULTY OF PETROLEUM & RENEWABLE ENERGY ENGINEERING (FPREE)

Innovative. Entrepreneurial . Global 51


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FACULTY OF PETROLEUM & RENEWABLE ENERGY ENGINEERING (FPREE)


52
Innovative. Entrepreneurial . Global

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