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Collaborating Authors
Results
Development of an Online Soft Analyzer for the Continuous Analysis of BTEX Emissions from the Furnace of Sulfur Recovery Units
Dara, Satyadileep (ADNOC Gas Processing, Abu Dhabi, UAE) | Ibrahim, Salisu (Khalifa University of Science and Technology, Abu Dhabi, UAE) | Raj, Abhijeet (Khalifa University of Science and Technology, Abu Dhabi, UAE) | Khan, Ibrahim (ADNOC Gas Processing, Abu Dhabi, UAE) | Al Jenaibi, Eisa (ADNOC Gas Processing, Abu Dhabi, UAE)
Abstract The oxidation of Benzene, Toluene, Ethylbenzene, and Xylenes (BTEX) in the furnace of SRUs at high temperature is an effective solution to prevent Claus catalyst deactivation in the downstream catalytic converters. However, the existing SRUs do not have the means to monitor BTEX emissions from Claus furnace due to lack of commercial online analyzers in the market. This often leads to excessive temperatures up to 1150 °C in the furnace to ensure BTEX destruction. Such high temperatures increase fuel gas consumption and CO emission and reduce sulfur recovery efficiency. To obtain continuous BTEX indication at the furnace exit, an online BTEX soft sensor model is developed to predict BTEX concentration at furnace exit. Subsequently, this soft sensor will be implemented in one of the SRUs of ADNOC Gas Processing. The BTEX soft sensor has been developed by constructing a compact kinetic model for aromatics destruction in the furnace based on the understanding of BTEX oxidation mechanisms derived using a detailed and well validated kinetic model developed previously. The kinetic model, including its rate parameters were incorporated into Hysys/Sulsim software, where both the reaction furnace and catalytic converters were simulated. The BTEX soft sensor has been validated with plant data from different ADNOC Gas Processing SRU trains under a wide range of feed conditions (particularly, with varying relative concentrations of H2S, CO2, and hydrocarbons in acid gas feed) in order to ensure its robustness and versatile predictive accuracy. The model predicts BTEX emissions from the reaction furnace under a wide range of operating conditions in the furnace with deviation not exceeding +/- 5 ppm. It also predicts the reaction furnace temperature (with a deviation of +/- 5%) and species composition from the furnace exit within a reasonable error margin. Presently, the model is in the process of being deployed in one of the SRUs of ADNO Gas Processing as an online soft sensor, where it can read the feed conditions, predict the BTEX exit concentration and write this value to the DCS. Thus, plant operators can monitor BTEX exit concentration on continuous basis and use it as a reliable basis to lower fuel gas co-firing rate in the furnace to achieve optimum furnace temperature that provide efficient BTEX destruction and low CO emission. The online soft analyzer, when deployed in SRU, will continuously predict BTEX emission from SRU furnace with high accuracy, which cannot be done experimentally in the plant or reliably using most of the existing commercial software. This approach can be used to seek favorable means of optimizing BTEX destruction to enhance sulfur recovery, while decreasing fuel gas consumption and carbon footprint in sulfur recovery units to reduce operating cost.
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- Energy > Oil & Gas > Downstream (1.00)
- Government > Regional Government > Asia Government > Middle East Government > UAE Government (0.45)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Health, Safety, Environment & Sustainability > Sustainability/Social Responsibility > Sustainable development (1.00)
- Health, Safety, Environment & Sustainability > Health > Noise, chemicals, and other workplace hazards (1.00)
- (3 more...)
Abstract ADNOC Gas Processing Ruwais NGL Fractionation plant receives and fractionates the NGL produced in upstream gas processing plants. After operation of newly designed upstream NGL plants, composition of NGL feedstock has become richer in Ethane and Propane. Consequently, nameplate capacity were reduced by~25%. In view of future increased NGL production, nameplate capacity of fractionation trains needs to be re-instated. Alternatively, a new fractionation train needs to be installed to accommodate additional NGL. To explore the opportunity for maximum utilization for existing trains, in line with the ADNOC strategy of enhancing profitability and asset utilization, a technical study was conducted to increase the processing capacity back to original nameplate capacity with lighter NGL composition. This was to identify the potential bottlenecks in the facility and suggest debottlenecking options with a reasonable investment. The Technical study covers the following activities: Simulation: Rigorous process simulation including the licensor units of DEO/Propane amine units Adequacy checks and identification of bottlenecks: Line sizing adequacy check and detailed hydraulic evaluation of the major piping Equipment adequacy check Relief & blowdown and flare system adequacy check Proprietary equipment/design evaluation of licensed units Adequacy check for In-line instruments like control valves, flow elements/transmitters, thermowells Rotating equipment adequacy checks performed with the concurrence from OEMs. Licensor Endorsement: Obtained the endorsement of AGRU licensor (Shell) for the increased flow rate with revised contaminant levels with recommendations of removing identified bottlenecks. Bottlenecks mitigation: Various options for bottleneck mitigation was studied and most optimum solution was selected to remove the identified bottleneck. The study has concluded that current capacity limitation was mainly due to bottlenecks in Ethane loop. Therefore, by mitigating the identified bottlenecks (i.e. replacing lines with bigger size, providing high performance trays, high performance internals, replacing few equipment's with new one etc.), the original nameplate capacity can be re-instated. The study concludes that increased NGL forecasted flow with lighter composition could be processed in existing Ruwais fractionation trains by doing minor modifications (as compared to new train). A capacity increase of ~25% was achieved with minimum investment and requirement of new fractionation train could avoided. If extensive adequacy studies are carried out to identify the bottlenecks, the capacity enhancement in existing facilities can be achieved with minimum investment and major cost for new plants/trains can be avoided.
- Production and Well Operations (1.00)
- Facilities Design, Construction and Operation > Processing Systems and Design > Gas processing (1.00)
Abstract Saudi Aramco operates several electrostatic coalescers for bulk emulsion separation and crude desalting. One of the major challenges in operating electrostatic coalescers is the potential buildup of tight emulsions and a rag layer at the interface layer, which causes short-circuiting of the electrostatic grids which increases the risk excessive carryover of water with the crude. Conventional liquid level instrumentation cannot measure the thickness of emulsion layers since the level taps are at the clean oil and water layers. Consequently, the buildup of emulsions is normally not detected by operators. A capacitance-based emulsion detection system was installed at one of the electrostatic coalescers of a Saudi Aramco facility. The system is comprised of multiple probes installed at various elevations in the vessel. Each probe measures the capacitance of the liquid in which it is immersed in. The data is then transmitted to the DCS, where an algorithm computes the oil/water content. Saudi Aramco developed an enhanced predictive alarm logic and advisory tool using the measured capacitance data so that operations may take preemptive measures to prevent upsets from occurring. The alarm system was tested over an extended period of time and it has shown that it can accurately detect the buildup of emulsions prior to an upset in the electrostatic coalescer. What is unique about the system is that it utilizes a combination of absolute capacitance measurements and capacitance variations in the algorithm. Emulsion buildups are detected by the alarm system hours before a potential upset, providing operators ample time to take preemptive measures such as increasing the demulsifier injection rate, desludging the vessel or lowering the interface level. The system significantly reduced the number of electrostatic coalescer upsets at the facility and crude quality was enhanced. Upon inspection of the probes during shutdowns, no buildup of deposits, which impacts capacitance readings, were found on the probes since a flushing system was installed. The alarm system has been utilized for four years with no major issues. Utilizing the capacitance probes to develop an algorithm for an alarm system is a novel technique to detect emulsion layer buildup hours prior to a potential electrostatic grid upset. Large-scale deployment is more economical as it is more cost-effective than radioactive profilers and is logistically easier to manage.
- Government > Regional Government > Asia Government > Middle East Government > Saudi Arabia Government (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- Energy > Oil & Gas > Downstream (1.00)
- Reservoir Description and Dynamics (1.00)
- Production and Well Operations (1.00)
- Facilities Design, Construction and Operation > Processing Systems and Design > Separation and treating (1.00)
Abstract The present work describes one of the key areas of research activity of the modern oil and gas scientific world: decarbonization and increasing the efficiency of the natural and associated gas usage which is a method for producing carbon black. The technology is characterized by relative simplicity of the technological process and a wide market for the resulting product. This method is also included in the list of BAT (BREFs, 2020). The article presents a techno-economic assessment of the proposed method of using gas, there is also a comparison with other existing methods.
- Asia > Russia (0.30)
- Europe > Russia > Central Federal District (0.16)
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- Energy > Oil & Gas > Downstream (0.95)
- North America > United States > Louisiana > China Field (0.89)
- North America > Canada (0.89)
- Europe > Slovakia (0.89)
- (6 more...)
- Reservoir Description and Dynamics > Reserves Evaluation > Economic evaluations (0.62)
- Facilities Design, Construction and Operation > Natural Gas Conversion and Storage > Liquified natural gas (LNG) (0.50)
- Facilities Design, Construction and Operation > Processing Systems and Design (0.49)
- Health, Safety, Environment & Sustainability > Environment (0.49)
Abstract The Modulated AC/DC Crude Desalting technology was successfully commissioned at several Saudi Aramco facilities. Enhancements to desalting performance and optimization of plant operating expenditures were realized. Benefits of the Modulated AC/DC Desalting technology, installation and operational best practices and a comparison to conventional AC technology is shared in the paper. The conventional AC desalting technology was replaced with the Modulated AC/DC Crude Desalting technology at some Saudi Aramco facilities. After the successful commissioning, the performance of the new units was tested in one of these facilities to identify operating limits, such as maximum water cut and minimum demulsifier injection at the production header, in which the stable operation is sustainable. A comparison of the performance of the technology compared to that of previous conventional AC desalting technology was conducted through analysis of grid/plate voltage stability, demulsifier injection rate, wash water rates and crude quality parameters. Some enhancements to the process were also introduced which resulted in realizing additional benefits. The technology resulted in several benefits, including: (1) A reduction in the required demulsifier injection rate during the testing period compared to the same time period from the previous year, leading to significant cost savings; (2) Ability to maintain normal operations beyond the design water cuts of the facility; (3) No major grid outages since installation; (4) Additional data that can be used to diagnose separation performance as each transformer provides a number of feedback signals to DCS that are good indicators of the separation process. Based on the observations and analysis, the Modulated AC/DC Crude Desalting Technology has several advantages over the conventional AC Crude Desalting Technology in regards to crude desalting performance and process stability. The Modulated AC/DC Crude Desalting technology at Saudi Aramco was the first installation in Saudi Arabia for Arab Light crude oil. The paper captures Saudi Aramco’s experience and best practices that other companies can find beneficial in their efforts to maintain crude quality and reduce operating expenditures.
- Government > Regional Government > Asia Government > Middle East Government > Saudi Arabia Government (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- Energy > Oil & Gas > Downstream (1.00)
Modelling and Simulation of Acid Gas Absorption from Natural Gas by Amine Solution Using Aspen HYSYS
IKPEZE, Victoria Kamnetochi (Afe Babalola University, Ado-Ekiti, Ekiti State, Nigeria) | OWOLABI, John Olusoji (Afe Babalola University, Ado-Ekiti, Ekiti State, Nigeria) | OLATEJU, Idowu Iyabo (Afe Babalola University, Ado-Ekiti, Ekiti State, Nigeria) | GIWA, Abdulwahab (Afe Babalola University, Ado-Ekiti, Ekiti State, Nigeria)
Abstract This work has been carried out to model and simulate a typical acid gas absorption process using Aspen HYSYS process simulator. The chemical components involved in the process development were water, methane, ethane, propane, higher alkanes, carbon dioxide, hydrogen sulphide, nitrogen and amines: monoethanolamine (MEA), diethanolamine (DEA), triethanolamine (TEA) and methyldiethanolamine (MDEA). The fluid package selected for the simulation before entering the simulation environment was Acid Gas – Chemical Solvents. In the simulation environment, the model was developed by picking an absorber from the Model Palette, placing it and assigning the input and the output streams involved before inputting the parameters required for model convergence. The carbon dioxide-rich feed gas was made to enter the absorber at the bottom inlet stream while the lean amine stream entered at the top inlet and showered down on the uprising gas thereby trapping the carbon dioxide molecules within the gas. The top product from the absorber was the treated gas while the amine solution and the trapped carbon dioxide left the absorber as the bottom product. Different simulations were run to investigate the performance of the amines under the same operating conditions. It was discovered that, of all the four amine solvents considered in this work for the removal of carbon dioxide by chemical absorption, MEA had the highest efficiency but would require more dehydration because it had the highest water content. DEA was also found to scrub the carbon dioxide down to acceptable levels. However, TEA and MDEA barely scrubbed any carbon dioxide under these conditions, as their carbon dioxide compositions were found to be unacceptable. The analyses of the results obtained from the simulations indicated that Aspen HYSYS can be used to study the process of acid gas absorption successfully.
- Africa > Nigeria (0.70)
- Asia (0.47)
- North America > United States (0.46)
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- Energy > Oil & Gas > Downstream (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Health, Safety, Environment & Sustainability > Health > Noise, chemicals, and other workplace hazards (1.00)
- Facilities Design, Construction and Operation > Processing Systems and Design (1.00)
- Facilities Design, Construction and Operation > Natural Gas Conversion and Storage > Liquified natural gas (LNG) (1.00)
- Information Technology > Knowledge Management (0.60)
- Information Technology > Communications > Collaboration (0.60)
Abstract The first Grid system for cathodic protection of aboveground storage tank (AST) bottoms was energized in 1989. This paper examines how the system is performing 30 years later. Design, system commissioning and long-term performance data are reviewed. Tank pad materials and current densities for protection at both ambient and high temperatures are discussed. The performance of individual system components is examined including ribbon anodes, conductor bars, electrical connections, power feeds, reference electrodes and power supplies. The economics of alternative tank bottom cathodic protection system configurations for new tanks are discussed. System limitations are identified. Conclusions are presented as to the effectiveness and optimal configurations for tank bottom protection that will assist with designing proper protection systems for new-build installations. Introduction High density polyethylene (HDPE) liners have been installed for secondary containment under new aboveground storage tanks since the 1980s. The HDPE liner creates an electrically insulating barrier which requires that cathodic protection (CP) anodes be installed between the liner and the tank bottom to achieve effective CP for the soil side of the AST bottom. Sacrificial anodes were sometimes used, but they had limited life and current capacity. There was a need for a long life (50 years), low-profile, CP system that could be installed in the tank pad material between the liner and tank bottom. This need lead to the development of the Grid™ by Corrpro, which was covered by U.S. Patents No. 5,065,893 and 5,340,455 - Cathodic Protection System for Above-Ground Storage Tank Bottoms. Now, over 30 years later, the first systems continue to perform and are providing CP as designed. Trademark: Gridis a registered trademark of Corrpro Companies Inc. First Systems A large, 345-foot diameter AST was to be built at a refinery in Texas City, Texas to store surface water from heavy rains that needed to be treated before being discharged into the Houston Ship Channel. The tank was to have an HDPE liner under the tank pad, requiring that a low-profile anode system be designed for installation between the HDPE liner and the tank bottom. A number of anode configurations were examined and ultimately the Grid system was developed, which consists of mixed metal oxide (MMO) coated titanium anode ribbons and titanium conductor bars resistance welded at each point of intersection as illustrated below in Figure 1. The conductor bar lowers the circuit resistance and limits the voltage drop along the anode ribbon to assure an even distribution of cathodic protection current. Redundant power feeds are shop assembled and field welded; and several reference electrodes are installed for system commissioning and performance monitoring.
- North America > United States > Texas > Harris County > Houston (0.34)
- North America > United States > Texas > Galveston County > Texas City (0.24)
Laboratory Investigation of Susceptibility of Carbon Steel to Amin SCC in Monoethylene Glycol
Toqi, S. (Petroleum Development Oman) | Munir, N. (Petroleum Development Oman) | Gonuguntla, M. (Petroleum Development Oman) | Zada, F. M. (Petroleum Development Oman) | Behlani, N. (Petroleum Development Oman) | Sundararajan, G. (Shell Technology Centre) | Rao, S. (Shell Technology Centre)
Abstract High pH (11-11.5) measured in Glycol units due to Monodiethanol amine (MDEA) carryover from sweetening units was a concern as it is generally considered that caustic cracking is possible at these conditions in equipment not subject to post weld heat treatment (PWHT). However, risk of amine stress corrosion cracking (SCC) in glycol rich system is not well studied or documented to define the limits. Monitoring of pH may not be the right integrity operating window (IOW) parameter as it may not reflect the actual risk of Amine SCC. Laboratory testing was performed to determine the susceptibility of welded carbon steel specimens (ASTM A106 Gr.B and ASTM A 516 Gr.70) to amine SCC under field conditions of glycol contactor at 190 °C, in monoethylene glycol (MEG) mixture at pH 11. A blank test at pH 8 was conducted for comparison. The testing indicated that there is no perceptible detrimental impact of the presence of amine in glycol on non-post weld heat treated carbon steel. Introduction Carryover of amine from acid gas removal units (AGRU) results in an increase in pH of glycol in many dehydration units that are downstream of AGRU. The pH of the liquid samples from glycol dehydration units were reported to be in the range of 11-11.5 exceeding the integrity operating window of 10.5 which was in place to avoid caustic SCC. Piping and equipment in the glycol dehydration process units are not subject to PWHT as Amine SCC was not identified as a probable degradation threat. It was not evident if the increase in pH due to amine carryover presented a risk of Amine SCC in carbon steel equipment of glycol process, particularly at higher temperatures like in the reboiler section which operates at about 190 °C. McIntyre et.al reported that caustic cracking was not observed in testing at pH 14 in the glycol solution but there is no similar reported data on amine SCC in glycol medium [1]. In order to further analyse the potential risks associated with the increase in pH from amine carryover and the susceptibility of carbon steel to amine SCC, laboratory testing of the materials of construction of the piping and equipment was considered essential.
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
- Energy > Oil & Gas > Downstream (1.00)
In 2019, the US experienced the lowest natural gas prices since 2016. This was despite natural gas consumption increasing in the residential and commercial sector by 2% (between October and December) according to the US Energy Information Administration (EIA). In July and August, the electric generation sector also experienced an increase in natural gas consumption because of above-average humidity levels in the Midwest and Northeast. Natural gas inventories at the end of March recorded the lowest levels since 2014 during withdrawal season, whereas the injection season recorded the second-highest levels from sustained growth in natural gas production. This trend of low gas prices was because of natural gas production growth, as prices continued to decline through the rest of 2019.
- Government > Regional Government > North America Government > United States Government (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- Energy > Oil & Gas > Downstream (1.00)
- Reservoir Description and Dynamics > Storage Reservoir Engineering > Natural gas storage (1.00)
- Facilities Design, Construction and Operation > Processing Systems and Design > Gas processing (0.85)
- Facilities Design, Construction and Operation > Natural Gas Conversion and Storage > Liquified natural gas (LNG) (0.84)