LECTURE 9 - NATURAL GAS

PROCESSING
1
INTRODUCTION
 Natural gas produced from either an oil or gas
reservoir is a complex mixture with different
compounds of hydrocarbons and non hydrocarbons
 Compounds of hydrocarbons includes: methane and
varying amounts of ethane, propane, butane, and even
higher molecular weight hydrocarbons)
 Non hydrocarbons may include: small amounts of
hydrogen sulfide, carbon dioxide, and mercaptans such
as methanethiol and ethanethiol, water vapor, and
even neutral gases such as nitrogen and helium, etc.
 The gas composition depends on the geological area,
as well as the underground deposit type, depth, and
2
location.
INTRODUCTION
 The gas that is finally transported in pipeline, as such
it must meet the quality standards specified by
pipeline companies.
 Those quality standards vary from pipeline to
pipeline and are usually a function of a pipeline
system’s design, its down- stream interconnecting
pipelines, and its customer base.
 In general, these standards specify how a
commercially acceptable natural gas should be.

3
SOME OF THE GAS SPECIFICATIONS INCLUDES :
 It must be within a specific Btu content range
 It should be delivered at a specified hydrocarbon
dew point temperature level. This would prevent
liquids to condense and form liquid slugs which
could be very damaging to the pipeline.
 The gas should not contain more than trace
amounts of compounds or elements such as
hydrogen sulfide, carbon dioxide, mercaptans,
nitrogen, water vapor, and oxygen.
 The water vapor must be removed (i.e., dehydrate
the gas) sufficiently to prevent corrosion and the
formation of gas hydrates in the processing plant or
the pipelines. 4

 All particulates must be removed.

INTRODUCTION

 The above suggest that the natural gas produced

from wells must be processed and treated, i.e.,
cleaned, before it can be delivered to the pipelines.

 Natural gas that is not within certain specific ranges of

gravities, pressures, Btu content range, or water
content levels will cause operational problems,
pipeline deterioration such as corrosion and fouling, or
even pipeline rupture

5
INTRODUCTION
 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).

 The processing of wellhead natural gas into pipeline-

quality natural gas (e.g., 99.9% methane) can be
quite complex and usually involves several processes.

6
 A generalized flow diagram is shown below
INTRODUCTION

7
8
INTRODUCTION
 In addition to those four processes (to remove oil, water
(dehydration), compounds, or elements such as sulfur,
helium, carbon dioxide, and natural gas liquids),
 It is often necessary to install scrubbers and heaters at or
near the wellhead.
 The scrubbers serve primarily to remove sand and other
large particle impurities.
 The heaters ensure that the temperature of the natural
gas does not drop too low to form a hydrate with the
water vapor content of the gas stream.
 Natural gas hydrates are crystalline solids that
block the passage of natural gas through valves
and pipes. 9
NATURAL GAS AND LIQUID SEPARATION

 Natural gas and liquid separation is 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. 10
NATURAL GAS AND LIQUID SEPARATION

 Common types of separators in gas

processing include vertical, horizontal
(with single or double tube), and
spherical separators.

11
NATURAL GAS AND LIQUID SEPARATION
 The cyclone separator uses only centrifugal force
to effect the separation between gas and liquid.
 This type of separator is used primarily as a
scrubber, i.e., for the separation of small volumes
of liquid from relatively large volumes of gas.
 Because a cyclone separator requires a relatively
small diameter, it can be constructed very
economically

12
NATURAL GAS AND LIQUID SEPARATION
 The selection of the separator type and its size is
dictated by
 the gas and liquid flow rates,
 the type of natural gas as denoted by its
specific gravity,
 the specifications of the produced oil and
water,
 the separator operating conditions (pressure
and temperature),
 the presence of solids,
 the floor space availability such as on an
offshore plat- form, cost, etc.
 Since vertical and horizontal gravity separators
are widely used 13
TYPES OF LIQUID/GAS SEPARATORS

Technology Droplet Size Removed

Gravity Separator Down to 300 µm

Centrifugal Separator Down to 8–10 µm

Mist Eliminator Pad Down to 10 µm

Vane Separator Down to 10 µm

High Efficiency L/G Down to 0.1 µm

Coalescer 14
 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:
1. 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
2. Then the gas flows through the vapor disengagement
section of the separator where smaller droplets are
separated from gas by gravity.
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3. Mist elimination where the smallest droplets amalgamate
and form larger droplets and separated by gravity.
GRAVITY SEPARATION MECHANISM
 Gravity Separation of Two Phases (Gas and
Liquid)
 In separating two phases (gas and liquid) vertically,
gravity and flow direction play a significant role.
 The droplets of any liquid in a gas flow are acted on by
three forces :
(i) gravity (directed downward),
(ii) buoyancy (opposite of the gravity force),
(iii) drag (opposite of the direction of droplet
velocity).
 As a result, the liquid droplet will move in the
direction of the net force. 16
GRAVITY SEPARATION MECHANISM

FB

FD

Liquid Droplet Vp

ap

FG
17
GRAVITY SEPARATION MECHANISM
 Therefore, the primary design feature of gravity
separation is to size the separator so that the drag
and buoyancy forces become less than the gravity
force.
 This forces the liquid droplets to separate from
the flowing gas.
 The net gravity force is given by

M p (rl  rg ) g
FG 
rl g c 18
GRAVITY SEPARATION MECHANISM
𝜋𝑑𝑝 3
Buoyancy force FB is given by 𝐹𝐵 = 𝜌𝑙 − 𝜌𝑔
6
 Where FG is the gravity force, MP is droplet mass
in lb,  l is liquid density, in lb/ft3, 𝜌𝑔 is gas
density in lb/ft3, g is gravity acceleration (32.17
ft/s2), and gc is dimensional proportionality
constant equal to 32.2 lbf/lbm-ft/s2.

 The drag force FD is

(𝜋/8)𝐶𝐷 𝑑𝑝2 𝑣 2 𝜌𝑔
𝐹𝐷 =
𝑔𝑐
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GRAVITY SEPARATION MECHANISM
 where CD is the drag coefficient, dP is droplet
diameter in ft, and vV is vertical velocity in ft/s.
When FB equals FD, the liquid droplets will
settle at a constant terminal velocity, vT.
Substituting the mass of the droplet and assuming a
spherical shape 3
4  dp 
M p      l
3  2 

4𝑔𝑑𝑝 (𝜌𝑙 − 𝜌𝑔 )
𝑉𝑇 =
3𝐶𝐷 𝜌𝑔 20
GRAVITY SEPARATION MECHANISM
 As long as the vapor velocity, vV, is less than vT,
the liquid droplets will settle out. The above
equation can be rewritten as follows

( l   g )
VT  K
g
4 gd p
 where K
3C D
 (a well-known Souders-Brown (1934) form)
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 GRAVITY SEPARATION MECHANISM
 K = the terminal velocity constant in ft/s for
vertical gravity settling. dP = the liquid droplet
diameter in ft (microns × 3.2808 × 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

2 4
C D  exp(8.4111  2.243 X  0.273 X  1.865 *10 X  5.201*10 X
2 3 4

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GRAVITY SEPARATION MECHANISM
 Where

 0.95 *108 d 3p  g (  l   g ) 
X  ln  
 g 2


 Here densities are in lb/ft3 and viscosity is in cp

23
GRAVITY SEPARATION MECHANISM
 For very small droplets, it is not practical to
separate them from the main flow stream by gravity
alone
 A coalescing device such as a mist eliminator is
required.
 The complication is that the droplet diameter
changes as the droplets coalesce, and therefore, the K
factor for coalescing devices is usually an empirical
value, determined from experiments, published data,
or vendors (for their particular coalescing devices).
 A commonly used source of empirical K factors for
mist eliminators is the GPSA (Gas Processors24
Suppliers Association engineering Data Book).
GRAVITY SEPARATION MECHANISM
 Horizontal separators have an additional
complication because the liquid droplets to be
separated are subjected to a horizontal drag force,
which is perpendicular to gravity, and therefore,
different from the case of vertical separators.
 The time that it takes for the droplet to travel
from the inlet to the outlet of the horizontal
separator must be greater than the time it
takes for the droplet to travel the vertical
distance to the liquid surface.
 This design requirement implies that the vertical K
values listed in literature have to be modified 25
GRAVITY SEPARATION MECHANISM

Gravity Separation of Three Phases (Gas,

Light and Heavy Liquids)
 For three-phase separation, while the gas and
liquid separation is the same as the one
described above, the settling of the heavy liquid
droplet in the light liquid is assumed to obey
Stoke’s law of buoyancy:

1488𝑔𝑐 𝑑𝑝2 (𝜌𝐻𝑙 − 𝜌𝐿𝑙 )

𝑉𝑇 =
18𝜇
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GRAVITY SEPARATION MECHANISM

 Where 1,488 converts viscosity of the continuous

phase from lb/ft-s to cp,  Hl and  Ll ) are heavy
and light liquid densities in lb/ft3, respectively. A
simplified version of the above equation (and also
converting the terminal settling velocity units
from ft/s to in./min) is
𝑘𝑠 (𝜌𝐻𝑙 − 𝜌𝐿𝑙 )
𝑉𝑇 =
𝜇
where
k s  2.0615 *10 5 d p2

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GRAVITY SEPARATION MECHANISM
 Values of ks, are given for some systems in
Table1.

28
GRAVITY SEPARATION MECHANISM
 As should be expected, the above equation
suggests that the terminal settling velocity is
inversely proportional to the viscosity of the
continuous phase.
 Therefore the bigger the viscosity of the
continuous phase is, as would be the case in
heavy crude, the more difficult would be to settle
droplets out of the continuous phase. In
separator design, vT is usually limited to 10
in./min

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THREE-PHASE SEPARATOR DESIGN
 Three-phase separators can be either vertical or
horizontal, but almost invariably are
horizontal.
 Vertical orientation 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.

30
THREE-PHASE SEPARATOR DESIGN
 Baffles are fitted downstream of the inlet
device in the separator. ... Intended to
distribute the liquid flow evenly over the cross-
section, prior to entry into the liquid/liquid
separation region, this baffle plays an important
role in maximizing the liquid/liquid separation.

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THREE-PHASE SEPARATOR DESIGN
 Definitions:
 Holdup time —the time it takes to reduce the
liquid level from normal to empty while
maintaining a normal outlet flow without feed
makeup. This allows for control and safe
operation
 Surge time—the time it takes for the liquid level
to rise from normal to maximum, while
maintaining a normal feed without any outlet
flow (i.e., accumulating liquid as result of
upstream or downstream variations or an upset,
32
such as a slug).
THREE-PHASE SEPARATOR DESIGN
 In the absence of specific requirements, surge
time may be taken as one half of the holdup
time.
 Holdup time can be obtained from experiences or
published data.
 It is usually between 2 to 10 minutes multiplied
by a factor of 1.0 to 1.5 depending on the
personnel (experienced or inexperienced) and
instrumentation (good or poor).

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THREE-PHASE SEPARATOR DESIGN

34
Basic Steps on the design of Vertical
and Horizontal separator

35
STEP BY STEP DESIGN
 Step 1: Calculate the vertical terminal vapor
velocity.
 For a conservative design, set

𝑉𝑉 = 0.75 𝑈𝑇

 Step 2: Calculate the vapor volumetric flow rate

Wg Wg = Gas Mass flowrate

Qg 
3600  g 36
 SEPARATOR K FACTORS
 Vendor: Otto H. York Company Inc.
 With Mist Eliminator:
 1 ≤ p ≤ 15 K = 0.1821 + 0.0029p + 0.0461 ln(p)
 15 ≤ p ≤ 40 K = 0.35
 40 ≤ p ≤ 5,500 K = 0.430 – 0.023 ln(p)

 where p is in psia.

 Gas Processors Suppliers Association

 0 ≤ p ≤ 1,500 K = 0.35 – 0.0001(p – 100)
 For most vapors under vacuum, K = 0.20
 For glycol and amine solutions, multiply K by 0.6–0.8
 For vertical vessels without demisters, divide K by 2
 For compressor suction scrubbers, mole sieve scrubbers and 37
expander inlet separators, mutiply K by 0.7–0.8 where p is in psig.
STEP BY STEP DESIGN
 Step 3: Calculate the vessel internal diameter, Di
0.5
 4Q g 
Di   
 VV 
 With a mist eliminator, add 3–6 in. to Di to
accommodate a support ring, and round it up to the
next half or whole foot increment to obtain D. Without
a mist eliminator, D = Di
 Step 4: . Calculate the settling velocity (vHl) of the
heavy liquid out of the light liquid. Here µ equals the
light liquid viscosity, µLl.
38
STEP BY STEP DESIGN
 Step 5: Calculate the rising velocity (vLl) of the light liquid
out of the heavy liquid . Here µ equals the heavy liquid
viscosity, µHl.

 Step 6: Calculate the light /heavy liquid volumetric flow

rates, QLl and QHl
WLl WHl
 QLl  and QHl 
60  Ll  Hl
 Step 7: Calculate the settling times for the heavy liquid
droplets to settle through a distance HL (minimum of 1 ft)
and the light liquid droplets to rise through a distance HH
(minimum of 1 ft) 39
STEP BY STEP DESIGN
12𝐻𝑙 12𝐻𝐻
𝑡𝑠,𝐻𝑙 = 𝑡𝑠,𝐿𝑙 =
𝑈𝐻𝑙 𝑈𝐿𝑙
12 converts 1 feet into inches.

 Step 8: If there is a baffle plate, calculate the baffle

plate area, which is the settling area for the light
liquid AL = A - AD
 where A is the vertical vessel cross-sectional area

 A = 𝜋D2 / 4

 AD is the downcomer cross-sectional area. In the

design, the larger value calculated from the following
two ways is used
 7.48 gal  60 min  QLl  QHl  40
 AD     
 1hr  
3
 ft G
STEP BY STEP DESIGN
 Where G is baffle liquid load in gph/ft2 (gallon per
hour per square foot) and can be obtained from
Figure below.

41
STEP BY STEP DESIGN
 The “high liquid level above interface” can be
obtained from Figures in literature refers to HL +
HR , where the minimum value for HR is 9 in.
 Assume WD = 4 in., calculate x = WD /D. Then use
the following equation to calculate y = AD /A
 where

a  cx  ex  gx  ix
2 3 4
y
1.0  bx  dx  fx  hx
2 3 4

 a = –4.755930×10–3 , b = 3.924091, c = 0.174875, d =

–6.358805, e = 5.668973, f = 4.018448, g = –
4.916411, h = –1.801705, i = –0.145348. 42
STEP BY STEP DESIGN
 Step 9: Calculate the residence time of each phase based on the
volumes occupied by the light and heavy liquid phases

H L AL H H ALh
tr ,Ll  tr ,Hl 
QLl QHl
o Step 10: Calculate the height of the light liquid above the outlet
(holdup height) based on the required holdup time:

 Compare this value with the assumed one in Step 8 and check
whether the assumed value is reasonable.
 Calculate the surge height, Hs, (minimum of 6 in.) based on
surge time if surge is not specified:

43
STEP BY STEP DESIGN

t s (QLl  QHl )
HS 
A
 Step 11: Calculate the vessel total height

HT = HH + HL + HR + HA + HBN + HD

 With the following design guidelines:

 The minimum value of HA is assumed to be 6 in.
 HBN = 0.5dN + greater of (2 ft or Hs + 0.5 ft).
 Here dN is the inlet or outlet vapor/liquid nozzle 44
diameter in ft and can be calculated by
STEP BY STEP DESIGN
0.5
 4Q 
d N   m  0.5 
 60 
 where Qm and ᵨm are the inlet mixture volumetric flow
rate (ft3/s) and density (lb/ft3).
 HD = 0.5D or minimum of 3 ft + 0.5dN (without mist
eliminator), or 2 ft + 0.5dN (with mist eliminator).
 If a mist eliminator pad is used, additional height is
added
 Step 12: Make sure that the ratio of HT /D is within a
reasonable range (1.5–6.0).
 The two-phase vertical separator design is very
similar to that of the three-phase vertical separator,
except it does not need to separate light liquid from 45
heavy liquid as there is only one liquid phase.
THREE-PHASE HORIZONTAL SEPARATOR
DESIGN PROCEDURE
 Step 1: Calculate the vapor volumetric flow rate, Qg
using
Wg
Qg 
 3600  g
 Step 2: Calculate the light and heavy liquid
volumetric flow rates, QLl and QHl

WLl WHl
QLl  QHl 
60  Ll  Hl
 Step 3: Calculate the vertical terminal velocity, vT,
(select a K value) and set vV = 0.75vT.
 46
THREE-PHASE HORIZONTAL SEPARATOR
DESIGN PROCEDURE
 Step 4: Select holdup and surge times from
experiences or published data, and calculate the
holdup and surge volumes, VH and VS , (unless
surge is otherwise specified, such as a slug
volume),
 Step 5: Obtain an L/D from Table below and
initially calculate the diameter according to
Vessel operating pressure, L/D
psig
0 < p ≤ 250 1.5–3.0

250 < p < 500 3.0–4.0 47

p > 500 4.0–6.0

Class assignment.
Size a three-phase vertical separator with baffle plate and wire
mesh mist eliminator.
 A field produces 121 MMscf/d of natural gas (Specific gravity
of gas = 0.7 with no sour gas). The wellhead pressure and
temperature are 105°F and 460 psi, respectively. At those
conditions, the fluid density and formation volume factor
can be calculated as: density = 1.72 lb/ ft 3 and Bg = 0.0319 ft
3 /scf. The separator operating pressure and temperature are
165 psi and 100°F, respectively. At separator conditions,
assume the mixture contains 1% (weight) of water and 4%
(weight) hydrocarbon liquid. The densities and viscosities of
hydrocarbon gas, liquid (light liquid or Ll), and water (heavy
liquid or Hl) are also calculated by using the correlations and
are given here: density (gas) = 0.72 lb/ ft 3 , density Ll = 54.0
lb/ft 3 , and density Hl = 62.1 lb/ ft 3 , Viscosity (gas) = 0.0113
cp, Viscosity Ll = 0.630 cp, and Viscosity Hl = 0.764 cp. The 48
hydrocarbon liquid holdup time is 25 minutes and the surge
time is assumed to be 5 minutes.