Natural Gas Dehydration Lessons Learned from the Natural Gas STAR Program ConocoPhillips The Colorado Oil and Gas Association, and The Independent Petroleum Association of Mountain States Producers Technology Transfer Workshop Durango, Colorado September 13, 2007 epa.gov/gasstar
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Natural Gas Dehydration
Lessons Learned from the Natural Gas STAR Program
ConocoPhillipsThe Colorado Oil and Gas Association, andThe Independent Petroleum Association of
Mountain States
Producers Technology Transfer Workshop Durango, Colorado
September 13, 2007
epa.gov/gasstar
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Natural Gas Dehydration: AgendaMethane LossesMethane RecoveryIs Recovery Profitable?Industry ExperienceDiscussion
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Methane Losses from DehydratorsDehydrators and pumps account for:
17 Billion cubic feet (Bcf) of methane emissions in the production, gathering, and boosting sectors
EPA. Inventory of U.S. Greenhouse Gas Emissions and Sinks 1990 – 2005. April, 2007. Available on the web at: http://yosemite.epa.gov/oar/globalwarming.nsf/content/ResourceCenterPublicationsGHGEmissions.htmlNatural Gas STAR reductions data shown as published in the inventory.
*Bcf = billion cubic feetOffshore Operations
34 Bcf
Well Venting and Flaring
9 Bcf
Compressor Fugitives, Venting, and Engine
Exhaust14 Bcf
Pneumatic Devices 57 Bcf*
Meters and Pipeline Leaks
9 Bcf
Other Sources 10 Bcf
Storage Tank Venting
6 Bcf
Dehydrators and Pumps
17 Bcf
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What is the Problem?Produced gas is saturated with water, which must be removed for gas transmissionGlycol dehydrators are the most common equipment to remove water from gas
36,000 dehydration units in natural gas production, gathering, and boosting Most use triethylene glycol (TEG)
Glycol dehydrators create emissionsMethane, Volatile Organic Compounds (VOCs), Hazardous Air Pollutants (HAPs) from reboiler ventMethane from pneumatic controllers
Source: www.prideofthehill.com
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Glycol Energy Exchange Pump
Dry Sales Gas
Basic Glycol Dehydrator System Process Diagram
Glycol Contactor
Inlet Wet Gas
Lean TEGPump
Driver
Water/Methane/VOCs/HAPsTo Atmosphere
Rich TEG
Fuel GasGlycol Reboiler/
Regenerator
MotiveGas Bypass
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Methane RecoveryOptimize glycol circulation ratesFlash tank separator (FTS) installationElectric pump installationZero emission dehydrator Replace glycol unit with desiccant dehydratorOther opportunities
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Optimizing Glycol Circulation RateGas pressure and flow at wellhead dehydrators generally declines over time
Glycol circulation rates are often set at a maximum circulation rate
Glycol overcirculation results in more methane emissions without significant reduction in gas moisture content
Partners found circulation rates two to three times higher than necessaryMethane emissions are directly proportional to circulation
Lessons Learned study: optimize circulation rates
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Installing Flash Tank Separator (FTS)Methane that flashes from rich glycol in an energy-exchange pump can be captured using an FTSMany units are not using an FTS
0
20
40
60
80
100
Perc
ent
<1 1-5 >5MMcf/day processed
With FTS
Without FTS
Source: APIMMcf = Million cubic feet
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Methane RecoveryRecovers about 90% of methane emissionsReduces VOCs by 10 to 90% Must have an outlet for low pressure gas
FuelCompressor suctionVapor recoveryunit Flash
Tank
Gas Recovery
Reduced Emissions
Low Capital Cost/Quick Payback
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Flash Tank CostsLessons Learned study provides guidelines for scoping costs, savings and economics
Capital and installation costs:Capital costs range from $3,500 to $7,000 per flash tankInstallation costs range from $1,684 to $3,031 per flash tank
Negligible Operational & Maintenance (O&M) costs
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Electric Pump Eliminates Motive Gas
Glycol Contactor
Dry Sales Gas
Inlet Wet Gas
Lean TEGPump
Gas Driver
Water/Methane/VOCs/HAPsTo Atmosphere
Rich TEG
Fuel GasGlycol Reboiler/
Regenerator
Electric MotorDrivenPump
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Overall BenefitsFinancial return on investment through gas savings
Increased operational efficiency
Reduced O&M costs (fuel gas, glycol make-up)
Reduced compliance costs (HAPs, BTEX)
Similar footprint as gas assist pump
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Is Recovery Profitable?Three Options for Minimizing Glycol Dehydrator Emissions
< 1 month to several years
360 to 36,000 Mcf/year
$165 to $6,500
$1,400 to $13,000
Install Electric Pump
4 to 11 months
710 to 10,643 Mcf/yearNegligible$6,500 to
$18,800Install Flash Tank
Immediate394 to 39,420 Mcf/yearNegligibleNegligible
Optimize Circulation Rate
Payback Period1
Emissions Savings
Annual O&M Costs
Capital CostsOption
1 – Gas price of $7/Mcf
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Zero Emission DehydratorCombines many emission saving technologies into one unit
Vapors in the still gas coming off of the glycol reboiler are condensed in a heat exchangerNon-condensable skimmer gas is routed back to the reboiler for fuel useElectric driven glycol circulation pumps used instead of energy-exchange pumps
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Overall Benefits: Zero Emissions Dehydrator
Reboiler vent condenser removes heavier hydrocarbons and water from non-condensables(mainly methane)The condensed liquid can be further separated into water and valuable gas liquid hydrocarbons Non-condensables (mostly methane) can be recovered as fuel or productBy collecting the reboiler vent gas, methane (and VOC/HAP) emissions are greatly reduced
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Replace Glycol Unit with Desiccant Dehydrator
Desiccant DehydratorWet gasses pass through drying bed of desiccant tabletsTablets absorb moisture from gas and dissolve
Moisture removal depends on:Type of desiccant (salt)Gas temperature and pressure
More expensive<60oF @ 250 psigLithium chloride
Least expensive<47oF @ 440 psigCalcium chloride
Cost Typical T and P
for Pipeline SpecHygroscopic
Salts
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Desiccant Performance Curves at Maximum Pipeline Moisture Spec (7 pounds water / MMcf)
Max Spec Line for CaCl2
Max Spec Line for LiCl2
Desiccant Performance
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Filler Hatch
Drain Valve
Support Grid
Minimum Desiccant Level
Maximum Desiccant Level
Brine
Desiccant Tablets
Drying Bed
Inlet Wet Gas
Dry Sales Gas
Desiccant Dehydrator Schematic
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Estimate Capital CostsDetermine amount of desiccant needed to remove waterDetermine diameter of vesselCosts for single vessel desiccant dehydrator
Capital cost varies between $3,500 and $22,000Gas flow rates from 1 to 20 MMcf/day
Capital cost for 20-inch vessel with 1 MMcf/day gas flow is $8,100Installation cost assumed to be 75% of capital cost
Normally installed in pairsOne drying, one refilled for standby
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How Much Desiccant Is Needed?Example: Where:D = ? D = Amount of desiccant needed (pounds/day)F = 1 MMcf/day F = Gas flow rate (MMcf/day)I = 21 pounds/MMcf I = Inlet water content (pounds/MMcf) O = 7 pounds/MMcf O = Outlet water content (pounds/MMcf)B = 1/3 B = Desiccant/water ratio vendor rule
Example: Where:ID = ? ID = Internal diameter of the vessel (inch)D = 4.7 pounds/day D = Amount of desiccant needed (pounds/day)T = 7 days T = Assumed refilling frequency (days)B = 55 pounds/cf B = Desiccant density (pounds/cf)H = 5 inch H = Height between minimum and
maximum bed level (inch)
Calculate:
ID = 12 * 4*D*T*12 = 16.2 inchH*B*π
Standard ID available = 20 inch
Calculate Vessel Diameter
Source: Van Aircf = cubic feet
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Operating CostsOperating costs
Desiccant: $2,556/year for 1 MMcf/day example$1.50/pound desiccant cost
Brine Disposal: Negligible$1.40/bbl brine or $20/year
Labor: $2,080/year for 1 MMcf/day example$40/hour
Total: about $4,656/year
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SavingsGas savings
Gas vented from glycol dehydratorGas vented from pneumatic controllersGas burned for fuel in glycol reboilerGas burned for fuel in gas heater
Less gas vented from desiccant dehydratorMethane emission savings calculation
Gas fuel for gas heater1 MMcf/day dehydratorHeat gas from 47ºF to 90ºFSpecific heat of natural gas: 0.441 Btu/lb-ºFDensity of natural gas: 0.0502 lb/cfEfficiency: 70%
Fuel requirement:483 Mcf/year
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Example: Where:GLD = ? GLD = Desiccant dehydrator gas loss (Mcf/year)ID = 20 inch (1.7 feet) ID = Internal Diameter (feet)H = 76.75 inch (6.4 feet) H = Vessel height by vendor specification (feet) %G = 45% %G = Percentage of gas volume in the vessel P1 = 15 Psia P1 = Atmospheric pressure (Psia) P2 = 450 Psig P2 = Gas pressure (Psig)T = 7 days T = Time between refilling (days)
Type of Costs and Savings Year 0 Year 1 Year 2 Year 3 Year 4 Year 5
Capital costs -$28,169Avoided O&M costs $6,446 $6,446 $6,446 $6,446 $6,446O&M costs -Desiccant -$4,656 -$4,656 -$4,656 -$4,656 -$4,656Value of gas saved1 $7,441 $7,441 $7,441 $7,441 $7,441Glycol dehy. salvage value 2 $12,382Total -$15,787 $9,232 $9,232 $9,232 $9,232 $9,232
1 – Gas price = $7/Mcf, Based on 563 Mcf/year of gas venting savings and 500 Mcf/year of fuel gas savings2 – Salvage value estimated as 50% of glycol dehydrator capital cost
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Partner ExperienceOne partner routes glycol gas from FTS to fuel gas system, saving 24 Mcf/day (8,760 Mcf/year) at each dehydrator unitTexaco (now Chevron) has installed FTS
Recovered 98% of methane from the glycolReduced emissions from 1,232 - 1,706 Mcf/year to <47 Mcf/year
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Other Partner Reported OpportunitiesFlare regenerator off-gas (no economics)With a vent condenser,
Route skimmer gas to fireboxRoute skimmer gas to tank with VRU
Instrument air for controllers and glycol pumpMechanical control valvesPipe gas pneumatic vents to tank with VRU (not reported yet)
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Lessons LearnedOptimizing glycol circulation rates increase gas savings, reduce emissions
Negligible cost and effortFTS reduces methane emissions by about 90 percent
Require a low pressure gas outletElectric pumps reduce O&M costs, reduce emissions, increase efficiency
Require electrical power sourceZero emission dehydrator can virtually eliminate emissions
Requires electrical power source Desiccant dehydrator reduce O&M costs and reduce emissions compared to glycolMiscellaneous other PROs can have big savings
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DiscussionIndustry experience applying these technologies and practices
Limitations on application of these technologies and practices