Lecture 3
Natural Gas Processing
Natural gas produced from either an oil or gas reservoir is a complex mixture with
different compounds of hydrocarbons (primarily methane and varying amounts
of ethane, propane, butane, and even higher molecular weight hydrocarbons), an
amount of water vapor, small amounts of nonhydrocarbon gases (hydrogen
sulfide, carbon dioxide, and mercaptans such as methanethiol and ethanethiol),
and even neutral gases such as nitrogen and helium. The gas composition depends
on the geological area, as well as the underground deposit type, depth, and
location. The gas that is finally transported in pipelines.
The purpose of gas processing is to produce a gas stream that meets sales
requirements and specifications including heating value and the recovery of
maximum amount of NGLs (Natural Gas Liquids).
3.1 Natural Gas and Liquid Separation
Natural gas and liquid separation are usually performed in the field immediately
after the gas is produced. A field separator is intended to remove solids and free
liquid from the gas, the entrained liquid mist from the gas, and the entrained gas
from the liquid. In addition, the separated gas and liquid from the vessel must be
discharged without re-entrainment. Several technologies are available to achieve
those goals: gravity separators, centrifugal separators or cyclone separators, filter
vane separators, mist eliminator pads, and liquid/gas coalescers.
3.1.1 Gravity Separation Mechanism
A gravity separator, also called a “knockout drum” or, more formally,
gravitational-forces-controlled separator, is typically used as a first stage
scrubber. In such a liquid-vapor separation vessel, there are typically three stages
of separation:
The first stage is gas passing through the inlet diverter. This causes the largest
liquid droplets to collide on the diverter and then drop out by gravity. Now inlet
diverters have evolved and new cyclonic and distribution baffle inlet devices are
used.
The next stage is when the gas flows through the vapor disengagement section
of the separator where smaller droplets are separated from gas by gravity.
The third and final stage is mist elimination where the smallest droplets
amalgamate and form larger droplets and separated by gravity.
• Gravity Separation of Two Phases (Gas and Liquid)
In separating two phases (gas and liquid) vertically, gravity and flow direction
are expected to play a significant role. The droplets of any liquid in a gas flow are
acted on by three forces (shown in Figure 3–1):
Gravity (directed downward), buoyancy (opposite of the gravity force), and drag
(opposite of the direction of droplet velocity). As a result, the liquid droplet will
move in the direction of the net force. See figure 3-2
Figure 3-1 Forces on liquid droplet
The net gravity force (gravity minus buoyancy) is:
………..3-1
where FG is the gravity force, MP is droplet mass in lb, ρl is liquid density in lb/ft3,
𝜌g is gas density in lb/ft3, g is gravity acceleration (32.17 ft/s2), and gc is
dimension proportionality constant equal to 32.2 lbf/lbm-ft/s2.
The drag force FD is:
……..3-2
where CD is the drag coefficient, dP is droplet diameter in ft, and Vv is vertical
velocity in ft/s. When FG equals FD, the liquid droplets will settle at a constant
terminal velocity, vT. Substituting the mass of the droplet and assuming a
spherical shape.
where:
……..3-3
Here K is the terminal velocity constant in ft/s for vertical gravity settling. dP is
the liquid droplet diameter in ft (microns × 3.28 × 10–6). CD is the drag coefficient,
dimensionless. For a separator without mist eliminator and with the droplet
diameter known, the drag coefficient can be calculated by using the following
correlation:
CD = exp (8.4111 – 2.243X + 0.273X2 – 1.865 × 10–2X3 + 5.201 × 10–4X4)
Where:
…….3-4
Here densities are in lb/ft3 and viscosity is in cp.
For very small droplets, it is not practical to separate them from the main flow
stream by gravity alone.
Figure 3-2 Vertical two-phase separator
• Three-Phase Separator Design
Three-phase separators can be either vertical or horizontal, but almost invariably
are horizontal. vertical orientation (Figure 3–3) is used when large amounts of
gas need to be separated from a relatively small amount of light and heavy
liquids (<10–20 wt%). To further facilitate the liquid separation, a baffle is
commonly used.
Figure 3-3 Vertical three-phase separator.
3.2 Natural Gas Dehydration—Water Removal
Water with natural gas can generate a great number of problems. One serious
problem is that it could form solid hydrates at certain pressures and
temperatures, which can plug facilities and pipelines. Also, when pressure and
temperature drop, water vapor condenses and can cause slug flow and possible
erosion and corrosion in the system, especially when acid gases are present.
Finally, water vapor increases the total volume and decreases the heating value
of gas, which subsequently, cannot meet gas stream specifications. Therefore,
water has to be removed from natural gas before it is transported.
Most free water is removed after the gas-liquid separation is at or near the
wellhead. However, there are still small amounts of water vapor associated with
the main stream of natural gas that requires further treatment to remove
(dehydration).
The water content in a natural gas stream will be determined. First, as it impacts
the selection of the type of dehydration method and the design procedure of the
dehydration system; then hydrates will be discussed; and finally, the
dehydration process is presented.
3.2.1 Water Content Determination
Natural gas, however, is usually a complex mixture and sometimes contains
acid/sour gas that changes the behavior of the natural gas, and causes the
deviation of water content calculation.
The calculation procedure using the Wichert and Wichert approach is outlined
below.
1. At given pressure and temperature, determine the water vapor content of
sweet gas from standard curve. Get the water content at 14.7 psi and 60°F from
the general chart, assuming 0.6 gravity gas contacting with pure water, W in
lb/MMcf.
1.2 Get the gravity correction factor, CG, from the inset chart, “Correction for
Gravity”, where:
……3-5
1.3 Get the salinity correction factor, CS, from the inset chart, “Correction for
Salinity,” where:
…3-6
1.4 The water content for the sweet natural gas is:
Wsweet = W × CG × CS. …………..3-7
2. Determine the mole% of H2S equivalent concentration of the sour gas by
mole% of H2S equivalent = mole% of H2S + 0.7 × (mole% of CO2). ….3-7
3. Determine the ratio of water in sour gas to water in sweet gas by using
standard curve in figure 3-4:
3.1 Locate the point that represents the “mole% of H 2S equivalent” calculated
from Eq. (3-7) and the given temperature in the lower part of Figure 3-4.
3.2 From this point, move to the upper chart to the given pressure, and move to
the left to get the ratio.
4. Determine the saturated water content of the sour gas (Wsour) at the given
pressure and temperature by multiplying the value from Step 1 (water vapor
content of sweet gas) and the ratio from Step 3 (correction).
Figure 3-4 Water content correction for sour natural gas
Example 3–1 Determination of equilibrium water vapor content in a sour gas
Assume a natural gas mixture with 66% hydrocarbon gas, 21 mole% H2S, and
13 mole% CO2 contacting with an aquifer that contains 3% of NaCl. γg = 0.86.
The conditions are p = 2,000 psi and T = 100°F.
Solution
Follow the procedure outlined above.
1. Determine water vapor content of sweet gas from Figure 3–4.
1.1 From general chart: W = 62 lb/MMcf.
1.2 From the inset chart “Correction for Gravity”: CG = 0.90.
1.3 From the inset chart “Correction for Salinity”: CS = 0.93.
1.4 The water content for the sweet natural gas is
Wsweet = 62 × 0.9 × 0.93 = 51.9 lb/MMcf/d.
2. Determine the mole% of H2S equivalent concentration of the sour gas from
Eq. (3-7), mole% of H2S equivalent = 21 mole% of H2S + 0.7 × (13 mole% of
CO2) = 30%.
3. Determine the ratio of water in sour gas to water in sweet gas by using Figure
3-4. With 30 mole% H2S equivalent, p = 2,000 psi and T = 100°F, ratio = 1.53.
4. Determine the saturated water content of the sour gas (Wsour) at the given
pressure and temperature by multiplying the value from Step 1 (water vapor
content of sweet gas) and the ratio from Step 3 (correction):
Wsour = 51.9 × 1.53 = 79.4 lb/MMcf/d.
