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PDF Offshore Processing of Co2 Rich Natural Gas With Supersonic Separator Multiphase Sound Speed Co2 Freeze Out and Hysys Implementation Jose Luiz de Medeiros Ebook Full Chapter
PDF Offshore Processing of Co2 Rich Natural Gas With Supersonic Separator Multiphase Sound Speed Co2 Freeze Out and Hysys Implementation Jose Luiz de Medeiros Ebook Full Chapter
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José Luiz de Medeiros
Lara de Oliveira Arinelli
Alexandre Mendonça Teixeira
Ofélia de Queiroz Fernandes Araújo
Offshore Processing
of CO2-Rich Natural
Gas with Supersonic
Separator
Multiphase Sound Speed, CO2 Freeze-
Out and HYSYS Implementation
Offshore Processing of CO2-Rich Natural Gas
with Supersonic Separator
José Luiz de Medeiros
Lara de Oliveira Arinelli
Alexandre Mendonça Teixeira
Ofélia de Queiroz Fernandes Araújo
Offshore Processing
of CO2-Rich Natural Gas
with Supersonic Separator
Multiphase Sound Speed, CO2 Freeze-Out
and HYSYS Implementation
123
José Luiz de Medeiros Alexandre Mendonça Teixeira
Escola de Química Escola de Química
Federal University of Rio de Janeiro (UFRJ) Federal University of Rio de Janeiro (UFRJ)
Rio de Janeiro, Brazil Rio de Janeiro, Brazil
This Springer imprint is published by the registered company Springer Nature Switzerland AG
The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland
Preface
The supersonic separator (SS) is a recent new kind of separation unit operation,
whose working principles offer several difficulties for precise modeling and sim-
ulation, which have retarded the development of a reliable and systematic engi-
neering approach for efficient design of such operations. In this book, the authors
disclose a new and powerful approach based on rigorous process simulations
conducted by professional simulators like HYSYS to predict the performance of
supersonic separators, which can accomplish certain steps of CO2-rich natural gas
(NG) offshore processing, such as water removal for water dew-point adjustment
(WDPA), C3+ hydrocarbon removal for hydrocarbon dew-point adjustment
(HCDPA), and CO2 removal. Traditionally, these operations are conducted in the
offshore scenario of CO2-rich NG processing via well-known conventional tech-
nologies, respectively, glycol absorption (TEG absorption), Joule–Thomson
expansion (JTE) or propane refrigeration (C3-RFG), and membrane permeation
(MP) or chemical absorption (CA).
In this context, the book addresses the utilization of SS for offshore processing of
CO2-rich NG, as an alternative to JTE/C3-RFG, TEG absorption, and MP or CA
for the same finalities. To do this, the book is divided into four conceptually distinct
but complementary parts.
Part I, comprehending Chaps. 1, 2 and 3, discusses the general aspects of CO2-rich
NG offshore processing by conventional technologies and, introductorily, by the
unconventional supersonic separator (SS). Several technical and economic com-
parisons of performance involving conventional technologies and the SS are pre-
sented. Evidently, the conventional technologies have strong points; otherwise, they
would not be the conventional ones. But it is understandable that such debate natu-
rally entails to discuss the unavoidable contextualization of the comparative advan-
tages of SS in terms of costs and power consumption vis-à-vis the conventional
alternatives.
Part II, comprehending Chaps. 4 and 7, approaches aspects related to the ther-
modynamic infrastructure necessary to the engineering of CO2-rich NG processing
with/without the supersonic separator (SS). This discussion encompasses thermo-
dynamic frameworks to predict PVT properties, thermal properties, and mixed
v
vi Preface
(ii) SS-UOE for NG processing and the second law of thermodynamics; (iii) SS-UOE
validation with the literature; (iv) SS-UOE with several levels of adiabatic efficien-
cies; (v) PEC-UOE for the sound speed of multiphase NG systems, including critical
neighborhoods; (vi) PEC-UOE for sound speed of multiphase oil–gas–water sys-
tems; (vii) Landau Model analysis on asymptotic behavior of the sound speed in
critical neighborhoods; and (viii) REC-UOE for multi-reactive sound speed for
multiphase oxidation chemical reactors and pyrolysis chemical reactors.
Finally, Part IV, comprehending Chaps. 8 and 9, aims at process flowsheets
applications within HYSYS environment using the previously developed unit
operation extensions SS-UOE, PEC-UOE, and MP-UOE. Three major NG process
applications are considered: (i) technical assessment of CO2-rich NG processing
with conventional technologies TEG absorption, JT expansion, and MP CO2
removal, compared with alternative processing using SS for WDPA and HCDPA,
but with conventional MP CO2 removal; (ii) idem as before compared with alter-
native processing using TEG absorption WDPA, JT expansion HCDPA, but with
SS for CO2 removal; and (iii) technical assessment of raw NG processing con-
sidering saturation of thermodynamic hydrate inhibitor (THI) in the raw NG, via
conventional technologies TEG absorption and JT expansion compared with
alternative processing using the new proposed concept SS-THI-Recovery, which
prescribes SS with water injection for simultaneous WDPA, HCDPA, and THI
recovery from the raw NG producing lean NG, good grade LPG, and recovered
THI, which otherwise would be lost. In the last SS-THI-Recovery application, three
most common THIs are individually considered: methanol, ethanol, and MEG.
The main public of this book corresponds to the broad category of researchers.
Evidently, interested design and operation engineers, graduate students, professors,
and scientifically initiating undergraduate students with interests in this matter can
be included. This selection of public is not, obviously, our choice, as any author
would adore an audience as large as possible. Instead, it is determined by the
concept of the book, the way it is written and its contents. In this regard, the book is
eminently a scientific one focusing on frontier subjects related to CO2-rich NG
processing in offshore platforms. That is, the book is committed with the presen-
tation of a new kind of process separation for very specialized systems, where the
content comprises results of our researches in the last 5 years on this subject.
ix
x Contents
xv
xvi Abbreviations
xix
xx Nomenclature
^
G ECS Gibbs free energy per mass unit (J/kg)
H Molar enthalpy of multiphase fluid (J/mol)
^
H ECS enthalpy per mass unit (J/kg)
S Molar enthalpy of compressed pure solid CO2 (J/mol)
H CO2 (T; P)
S;SAT Molar enthalpy of saturated pure solid CO2 (J/mol)
H CO2 (T)
J Jacobian matrix of multiphase equilibrium equations
k Ratio of heat capacities
K Molar kinetic energy of multiphase fluid (J/mol)
Kij Binary interaction parameter of EOS
L MP permeate molar flow rate (mol/s)
L, LC, LD SS lengths: total, converging and diverging sections (m)
LLAVAL SS lengths: Laval nozzle (m)
LDiffuser, LDiff SS lengths: ending diffuser (m)
LShock = LLAVAL SS lengths: axial position just before shock and liquid
removal (m)
Ma = v/c Mach number
MaShock Mach number just before condensate withdrawal
and normal shock
MaBS Mach number just before shock and after condensate removal
MaAS Mach number just after normal shock
MM Molar mass of multiphase fluid (kg/mol)
N Total number of moles (mol)
N Vector (nc 1) of species mole numbers (mol)
nc Number of components
P Pressure (Pa, bar)
Pc, PTP Critical and triple-point pressures (bar, Pa)
Pout out
L , PV MP permeate and retentate pressures (bar)
in
PV MP gas feed pressure (bar)
PSAT (T) Saturation pressure (bar)
DPLN k MP log mean difference of partial pressures of species k (bar)
q Mass flow rate of multiphase multi-reactive stream (kg/s)
R Ideal gas constant (8.314 J/mol.K, Pa.m3/mol.K,
kPa.L/mol.K)
S Molar entropy of multiphase fluid (J/K.mol)
^
S ECS entropy per mass unit (J/K.kg)
T Absolute temperature (K)
TL, TV Temperatures of permeate and retentate (K)
Tc, TTP Critical and triple-point temperatures (K)
U Molar internal energy of multiphase fluid (J/mol)
[; \ Union and intersect operators
v Axial velocity of non-segregated multiphase flow (m/s)
vV, vL+W Axial velocities of segregated vapor and L + W two-phase
liquid (m/s)
Nomenclature xxi
Greek Symbols
Subscripts
Superscripts
0
Ideal gas property
E Excess property
in, out Inlet, outlet
LAVAL Laval nozzle
Nomenclature xxiii
R Residual property
SAT Saturated
Shock Just before condensate withdrawal and normal shock
THROAT Relative to throat position in SS nozzle
* Sonic (choked) condition on steady-state 1D isentropic
plug-flow
* Ideal gas property of pure species at T and 1 atm
0 Ideal gas property for Span–Wagner EOS
VLE Vapor–liquid equilibrium
V, L, S Vapor, liquid, solid
Chapter 1
Offshore Processing of CO2-Rich
Natural Gas and the Role of Supersonic
Separators—Introduction
Abstract This chapter gives an overview on basic subjects that justify the exis-
tence of this book, the most important being the contextualization of offshore
processing of CO2-rich natural gas (NG), besides CO2 separation and destination.
A discussion and bibliographic review on alternatives for CO2 removal from CO2-
rich NG are included. Some basins worldwide have potential to produce oil with
associated gas, yet under high gas–oil ratios and high %CO2 ( 40 mol%) which
entails the onus of low-grade gas processing enchained to huge CO2 dispatch goals.
Here, the oil and gas industry meets great challenges, since the oil production, the
main revenue factor, is bounded to huge CO2-rich NG production with 10–80 mol%
CO2. Therefore, processing solutions are needed to turn high-capacity CO2-rich NG
processing rigs into feasible and safe operations, sometimes hundreds of kilometers
offshore. The supersonic separator (SS) is a promising technology that fits into this
context due to its capability of simultaneous adjustment of dew-points in a single
compact and low-footprint operation. Regarding CO2 removal, the most indicated
technology is membrane permeation, which besides being suitable for CO2 abate-
ment services, and is also compact and modular. On the other hand, the literature
already signalizes potential SS application for CO2 capture from CO2-rich NG.
Environmental concerns on global warming and its effects on the planet implicate in
research and investment on alternative energy sources as a replacement of fossil
fuels on the world energy matrix. On the other hand, natural gas (NG) is a
worldwide growing fossil energy source due to its lower carbon emission rates in
comparison to traditional fuels like coal and oil (BP 2016). The conditioning
process of raw NG to fuel gas comprises a well-known set of operations that depend
on its composition and conditions, and which are generally applied on the following
order: (i) removal of H2S; (ii) water dew-point adjustment (WDPA) via
Common conventional technologies for CO2 removal from CO2-rich natural gas
comprise: (i) chemical absorption; (ii) physical absorption; (iii) membrane perme-
ation; (iv) gas–liquid membrane contactors; and (v) cryogenic distillation.
Chemical absorption (CA) process consists of an absorption column with
chemical solvent which is usually aqueous alkanolamines, such as MEA and
MDEA, and a second column for solvent regeneration at low pressure, with CO2 as
top product. The main issue of processing CO2-rich NG with this technology is the
high solvent recirculation rate and high heat duty for solvent regeneration.
Moreover, CO2 is extracted at low pressure, requiring large compression trains for
EOR purpose (Araújo et al. 2017).
Physical absorption (PA) also comprises steps of absorption at high pressure and
regeneration at low pressure; thus, similarly CO2 is captured as a low-pressure
stream. Physical solvents have a large capacity of CO2 absorption at high CO2
partial pressure; however, CO2/CH4 selectivity is rather low, implying high
hydrocarbon losses along with the CO2 product stream. There are issues of
high solvent recirculation rates for CO2-rich NG as well. The main PA solvents for
CO2 removal are methanol, propylene carbonate, and dimethyl ethers of poly-
ethylene glycol, respectively, of Rectisol, Fluor, and Selexol processes (Bagirov
et al. 2015).
Membrane permeation (MP) process is based on different permeance of com-
ponents through skin-dense membranes. Polymeric membranes such as cellulose
acetate membranes are the most used industrially for CO2/CH4 separation in two
main configurations: hollow fiber membrane or spiral wound membrane. This
technology is flexible concerning feed CO2 content; however, high %CO2 implies
high permeation area and high hydrocarbon losses, which can be reduced by
multistage configurations with a recycle compressor that increases power demand
and capital instead. The comparative advantages of MP are the relatively lower
footprint and its modularity implying easy scale-up. On the other hand, permeate is
a low-pressure CO2-rich gas that requires a large compression unit for EOR
(Arinelli et al. 2017). MP process is currently being used for CO2 capture in
offshore rigs receiving gas from Brazil Pre-salt fields with %CO2 up to 20 mol%
4 1 Offshore Processing Of CO2-Rich Natural Gas …
composition from 5 mol% to 65 mol% CO2 and from 0 mol% to 15 mol% H2S.
Results show that the cryogenic process is more profitable for NG with CO2 content
above 10 mol%, with great power savings and dispatching CO2 to EOR with lower
power demand comparatively with the chemical absorption counterpart.
A relatively new operation for NG processing is the supersonic separator (SS). This
technology consists of expanding the gas to supersonic velocities through a con-
verging–diverging nozzle (Laval nozzle), resulting in a great temperature fall and
thus promoting condensation of heavier species in NG, like water and C3+. The
liquid drops are separated from the main flow by centrifugal swirling induced by
fixed vanes in SS inlet section (Arinelli et al. 2017). Figure 1.1 exhibits a general
SS scheme with swirling vanes, Laval nozzle, condensate collector, and ending
diffuser. The Mach number (Ma) describes the compressible flow along the device.
Flow is subsonic through the converging section (Ma < 1), sonic at nozzle throat
(Ma = 1), and supersonic through the diverging section (Ma > 1) until the normal
shock front. The supersonic flow is a metastable condition under higher discharge
pressures relative to the pressure profile in the diverging section. Consequently, the
flow is gradually becoming more unstable downstream the throat, as the pressure
gradient to SS outlet increases, eventually provoking the shock phenomenon. When
this sudden irreversible transition occurs, the supersonic flow collapses into sub-
sonic, sharply increasing pressure and temperature, producing entropy and reducing
flow velocity under conservation of mass, energy, and momentum. Therefore, the
condensed phases formed in the cold supersonic section of SS must be removed by
Condensate
Swirling Laval Nozzle
Collector Diffuser
Vanes
Throat
condensate collectors upstream the normal shock front; otherwise, they will
revaporize through the shock transition, destroying separation. After shock, the flow
in the diffuser is subsonic, so lean gas is further decelerated, gaining pressure and
temperature until SS exit.
The supersonic technology has been already extensively investigated in NG
processing for water dew-point adjustment (WDPA), hydrocarbon dew-point
adjustment (HCDPA), and natural gas liquid (NGL) extraction (Schinkelshoek and
Epsom 2008; Machado et al. 2012; Cao and Yang 2015; Secchi et al. 2016; Castier
2016; de Medeiros et al. 2017; Arinelli et al. 2017). The main SS advantages against
conventional alternatives are lower footprint, better separation efficiency for the same
head loss or just slightly better separation with lower head loss and power demand.
On the other hand, SS application for CO2 removal from CO2-rich NG is a new
field of application. In this case, the raw gas should be previously treated in terms of
WDPA dehydration and HCDPA, not only to prevent gas hydrate or ice solids, but
most importantly to avoid water and C3+ condensation processes that hinder the deep
fall of temperature necessary for CO2 condensation. Moreover, in cases with high and
ultra-high CO2 contents, CO2 freeze-out must be avoided to prevent risk of equip-
ment obstruction and plugging. Hence, the flow path inside SS should be controlled,
guaranteeing that the CO2 freeze-out border is not crossed (Arinelli et al. 2017).
In December 2014, Petronas announced an agreement with Twister BV and
other companies to develop a SS unit for processing of CO2 ultra-rich NG from K5
offshore gas field (%CO2 70%) in Sarawak, Indonesia (TheStar 2014). Samawe
et al. (2014) investigated SS application for CO2 removal from NG with 70 mol%
of CO2. The authors built a SS prototype to obtain experimental pilot test data and
validate a CFD model. Despite succeeding in proving the concept of SS for CO2
capture, the achieved CO2 removal was very low: only 2.1%. Imaev et al. (2014)
proposed a new low-temperature process combined with SS for CO2 extraction
from CO2 ultra-rich NG. The first step comprises a high-pressure low-temperature
distillation column for CO2 bulk removal, while the column top vapor with 10 mol%
to 20 mol% CO2 goes through a SS unit, decreasing CO2 content to the desired
level ( 2 mol%) and refluxing CO2-rich condensate to the column.
Arinelli et al. (2017) investigated SS for treating a CO2-rich (44 mol%) NG
simultaneously in terms of WDPA and HCDPA and, alternatively, for CO2
removal. SS alternatives were compared with conventional technologies: WDPA
via TEG absorption, HCDPA via JT expansion, and CO2 removal via MP. Process
alternatives were assessed in terms of technical performance and power demand via
HYSYS simulation using Unit Operation Extensions for SS simulation (Arinelli
et al. 2017) and for determination of the multiphase sound speed (de Medeiros et al.
2017). Results show that SS is the best alternative for WDPA and HCDPA, as both
are executed simultaneously in a single operation, hence with lower footprint
regarding the conventional process, producing lean gas with better quality, lower
power demand and higher rate of NGL extraction. Regarding CO2 removal, the MP
process presented the best results in terms of technical performance, while the
performance of SS operation was limited by the premise of freeze-out avoidance,
resulting in lower CO2 capture. On the other hand, SS for CO2 removal has a great
1.3 Supersonic Separator Application for CO2-Rich Natural Gas Processing 7
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the structural, condition of the optic nerve. That such an influence
may be exerted is shown by cases of transverse myelitis low down in
the cord, which, according to Erb and Seguin, were complicated by
double optic-nerve atrophy. The second theory is that the involved
part of the cord and the optic nerve present a similar vulnerability to
the same morbid influences. This is illustrated in some cases of
chronic alcoholic and nicotine poisoning, in ergotism, and in the
spinal affections due to hereditary influences and developmental
defects.
49 In one out of three female eases I found the active disturbance of gait as severe as
in males, but Leyden's observation is supported by all who have seen a sufficiently
large number of female cases.
51 Archiv für Psychiatrie, x. p. 545. There is another observation which bears in this
direction: James of Boston observed that absolute deaf-mutes in a large percentage
of cases are insusceptible to vertigo or to the allied phenomenon of sea-sickness.
Certainly, the auditory nerve is a space-sense nerve; its physiological elimination is,
however, accompanied by an immunity against a symptom which may be an evidence
of disturbed space-sense transmission. In like manner, the destruction of the central
perceptive and voluntary centres in the paretic dement inhibits the legitimate results of
posterior spinal sclerosis.
One of the most important questions which have grown out of the
pathological studies of tabes is the relationship between the lesions
and the not infrequently observed restoration of functions which had
been more or less seriously impaired in an earlier period of the
disease. Even those symptoms which ordinarily comprise the
continuous and essential clinical background of tabes may exhibit
remarkable changes in this direction. I have two well-established
observations—one of tabes of eight years' standing, the other of
more recent date—in which that symptom which, once established,
is the most constant, the reflex iridoplegia, disappeared, to reappear
in two months in one case where it had been associated with
myosis, and to reappear in eight months in the other, repeating this
oscillation the following year. I have now under observation a tabic
patient in the sixth year of his illness who two years ago had a return
of both knee-phenomena to a nearly normal extent, to lose them in
two months, and to regain the reflex on the left side four months ago,
retaining it up to the present. These three cases were of syphilitic
subjects. In a fourth advanced non-syphilitic tabic patient, whose
ataxia had reached a maximal degree, I found a return of both knee-
phenomena for three days after its absence had been established by
medical examiners for over a year, and had probably been a feature
for a much longer period. Hammond the younger and Eulenburg
have reported similar cases. Nothing is more surprising to those
unfamiliar with the progress of this disease than to find gross ataxia
or the electrical pains and anæsthesia to disappear or nearly so; and
the alleged success of more than one remedial measure is based on
the fallacious attributing to the remedy what was really due to the
natural remittence of the disease-process or of its manifestations.
The financial success of quacks and the temporary but rapidly
evanescent popularity of static electricity, Wilsonia belts, and like
contrivances are owing to the hopefulness inspired in the credulous
patient by the mere coincidence of spontaneous improvement and
the administration of a new remedy, supplemented, it may be, by the
influence of mind on body in his sanguine condition. It is to be
assumed that the influences which are at work in provoking the
trophic and visceral episodes of tabes are of an impalpable
character, and that all theorizing regarding the reason of their
preponderance in one and their absence in another case are as
premature as would be any speculation regarding their rapid
development and subsidence in the history of one and the same
case. But we have better grounds for explaining the remissions of
the ataxia and anæsthesia.
61 Derived from over five hundred cases which had presented themselves at the clinic
of the College of Physicians and Surgeons.
Chancre alone 23
Chancre followed by secondary symptoms 16
Total of those with history of chancre 39
No history of chancre in 15
Total 54
64 “Auge und Rückenmark,” Graefe's Archiv für Ophthalmologie, Bd. xxvii. iii.
68 Leyden states that coitus in the upright position has been accused of producing
tabes, without mentioning his authority. I have no observation on this subject touching
tabes, but am prepared to credit its bad effect from the account of a masturbator, who
during the orgasm produced while standing felt a distinct shock, like that from a
battery, shooting from the lumbar region into his lower limbs, and causing him to fall
as if knocked down. He consulted me in great alarm—was scarcely able to walk from
motor weakness, and had no knee-phenomenon; in a few weeks it returned, and no
further morbid sign appeared. Masturbators of the worst type occasionally manifest
ataxia, and in three cases I have been able to establish the return of the knee-jerk,
together with other improvements in the spinal exhaustion of these subjects. The loss
and diminution of the patellar jerk, and the frequently associated urinary incontinence,
as well as certain of the peripheral pains found in masturbators, certainly prove that
undue repetition of the sexual act (be it natural or artificial) is competent to affect the
cord in a way that cannot but be injurious in case of a predisposition to tabes, if not
without the latter.