NATURAL GAS FIELD FIELD

DEVELOPMENT

Author: M. NistlerSenior Process Engineer

NATURAL GAS

Natural Gas ApplicationsNatural Gas Applications

NATURAL GAS

NATURAL GAS FORMS

GAS ASSOCIATED TO GIANT OIL FIELDS FREE GAS FROM GAS WELLS

Natural Gas ContaminantsNatural Gas Contaminants

Water (H2O)

Acid Gases (CO2, H2S)

COS, CS2, mercaptans

Heavy hydrocarbons (C5-C10)

Inert Gases (N2, Ar, He)

Mercury à Pollution, toxicityBTEX à LNG Plants

Raw Natural

Typical Oil & Gas Field ProcessingTypical Oil & Gas Field Processing

Sulphur

NG to Gas Phase

Sulphur Recovery

Acid Gas

Tail Gasto treatment

SINI CAPABILITIES

SINI CAPABILITIES( FEWER REFERENCES)

Natural Gas Inlet

Oil

NG to Sale

LPG to Sale

Three Phases Separation Oil TreatmentCrude

Oil Inlet

Con

densate

Sour Gas

Gas Treatment

Phase Separation

Gas

WaterWater Treatment

Typical Sour Gas ProcessingTypical Sour Gas Processing

Raw Gas fromSeparators

Gas Dehydration

NGLRecovery

COS & RSH Removal

LPG to Sales

GasCompression

NG to Sales

Natural GasSweetening

Acid Gas (H2S,CO2)

SRU & Tail Gas Treatm.

Stabilization Condensate Incineration

Sulphur Flue Gases

q Phase Separation & Gas Filtrationq Acid Gases Removal and Combined Removal of Sulphur Comp.

Ø Amines & Activated Amines, Physical Solvents & Mixed Solvents Ø Mol SievesØ CO2 Removal Membranes

q Gas Dehydration and Hydrate PreventionØ Glycol Process (MEG, DEG, TEG, Others)Ø Mol Sieve, Silica Gel

q Natural Gas Liquids Recovery & HC Dew Point Control

Siirtec Siirtec Nigi’sNigi’s Capabilities in Gas Capabilities in Gas ProcessingProcessing

q Natural Gas Liquids Recovery & HC Dew Point ControlØ Joule-Thompson LTS & Gas Expansion (Turbo-Expander)Ø Direct Cooling (Chiller)Ø Silica Gel

q NGL Fractionation and Condensate Stabilizationq NGL & Condensate Treatment (COS and Mercaptans Removal & Dehydration)

Ø Caustic Wash (MEROX), COS Hydrolysis and Amine WashØ Mol Sieve

q Non regenerative adsorptionØ Mercury, H2S and other low level impurities

q Claus, Tail Gas Treatment and Acid Gas Incineration Units

KashaganKashagan Oil Field DevelopmentOil Field Development

KashaganKashagan Oil Field DevelopmentOil Field Development

Siirtec Nigi involvement in the Kashagan Oil FieldN. Process Unit Installation Siirtec Nigi activity Main features / Activity Clarification

1 Sulphur Recovery OnshoreFeed-En /

Procurement

- 2 identical trains in parallel producing 1900 tons / day of elementary sulphur.

- Siirtec Nigi made the endorsement of the FEED provided by WorleyParsons.

- Siirtec Nigi purchased the main items of the unit such as Reaction furnace,

burners and Waste Heat Boiler, catalytic reactors, sulphur condensers.

2 Tail Gas Treatment OnshoreFeed-En /

Procurement

- Siirtec Nigi made the endorsement of the FEED provided by WorleyParsons.

- Siirtec Nigi purchased main items of the unit such as Reducing Gas Generator

Furnace, Hydrogenation Reactor, Reactor Effluent Cooler and relevant steam drum

- Siirtec Nigi performed Engineering and Procurement of thermal Oxidiser

downstream Solvent Contactor

3 Molecular Sieve Gas Dehydration Onshore EPCThis is a typical dehydration unit supplied by Siirtec Nigi – Molecular sieves

supplied by Grace

4 LPG Mercaptan Removal Unit Onshore EP- Basic Design by UOP (Merox Process)

- Consistency check, Detail Engineering and Procurement by Siirtec Nigi

5LPG Molecular Sieve Gas

Dehydration Onshore EPCThis is a typical dehydration unit supplied by Siirtec Nigi – Molecular sieves

supplied by Grace

6 TEG Dehydration Offshore EP 3 trains, only loose items purchased by Siirtec Nigi

7 TEG Regeneration Offshore EPC3 TEG regeneration skid + 1 Fuel Gas skid

Construction was performed in Taranto Tecnomec workshop, then the skids were

transported on a ship to Norway (Aker Kvaerner yard, Agip KCO Contractor) and

finally from Norway to Kazakhstan on barges via sea and river. 8 Fuel Gas Skid Offshore EPC

9Condensate Mercaptan

Removal UnitOnshore EP

- Basic Design by UOP (Merox Process)

- Consistency check, Detail Engineering and Procurement by Siirtec Nigi

Kashagan: a large Offshore “Super-Sour” Gas-Condensate Field in Caspian Sea (sub-arctic conditions during winter), developed by a Consortium (Years 2004-2007).

Main Data:● Shallow water (5 - 6 m depth), developed by means of

barges grouped in “Complex D Island”● Capacity: 450,000 BOPD (oil) & ≈ 42 MMSm3/d (associated

gas), 3 Process trains with a capacity of 14 MMSm3/d each● Extremely sour associated gas (H2S ≈ 22%) at very high

pressure ≈ 100 bar, water saturated at 50 °C

KashaganKashagan Field DevelopmentField DevelopmentTEG Dehydration UnitsTEG Dehydration Units

pressure ≈ 100 bar, water saturated at 50 °C ● Associated gas re-injected with need of a very low treated

gas dew point ≈ - 40 °C, dew point depression = 90 °C: upper limit for conventional TEG

● Regeneration by sweet stripping gas selected due to high H2S (not applicability of Drizo & Drigas), required lean TEG purity ≈ 99,95% (27 m3/h each Train)

Arrangement of TEG Dehydration UnitsArrangement of TEG Dehydration Units

Arrangement of Kashagan TEG DehydrationUnit is quite complex !!

Gas Dehydration

TEG Regeneration

Off-Gas Recovery

Overall Dimensions: 20 x 20,1 x 5,5 m

Required lean TEG purity = 99.95%

H2S and CO2 are co-absorbed by TEG à Process Design Challenge

KashaganKashagan TEG DehydrationTEG Dehydration

VERTICAL FLASH DRUM STRIPPING COLUMN

TEG REBOILER HOT SURGE DRUM

Middle East Field DevelopmentMiddle East Field DevelopmentSimplified Block Flow DiagramSimplified Block Flow Diagram

Reaction Furnace

Waste Heat Boiler

Waste Heat Boiler

1st Sulphur Condenser

Catalytic Reactor

2nd Sulphur Condenser

Catalytic Reactor

3rd Sulphur Condenser

HP STEAMto export

Feed Gas

BFW

BFWAir

Reaction Furnace

1st Sulphur Condenser

Tail Gas

Reducing Gas Generator

HydrogenationReactor

ReactorEffluent Cooler

To QuenchTower

SIIRTEC NIGI SUPPLY

BY OTHERS

LEGEND:

Feed Gas: 23% H2S, 10% CO2

4 SRU units in parallel, each one producing 2500 tons/day of sulphur :

SuplphurDegassing

Design of extraDesign of extra--large scale large scale Sulphur removal unitsSulphur removal units

Ø 4 trains with 2500 tons / day sulphur capacity

huge daily production

Ø Siirtec Nigi designed and supplied critical items

Ø Some examples of the huge SRU equipment dimensions:v reaction furnace: 6.1 m I.D. metal, 5.2 m I.D. refractory, 12.7 m lengthv reaction furnace: 6.1 m I.D. metal, 5.2 m I.D. refractory, 12.7 m lengthv waste heat boiler: 5.2 m shell diameter, tubes: N. 4200 / 2” O.D. / 8 m lengthv “1st sulphur condenser”: 240 tons weight, 4.7 m diameter, 19 m long, 5165 / 1½” O.D. / 10 m tubes v “2nd sulphur condenser” : 375 tons weight, 5.9 m diameter, 20 m long, tubes: N. 8701 / 1½” O.D. / 10 m

length v “3rd sulphur condenser”: 290 tons weight, 5.8 m diameter, 22 m long, tubes: N. 8140 / 1½” O.D. / 7 m

length

Ø Challenges in the mechanical design:v Finite Element analysis to check mechanical design of steel parts (shell, supports, vessel internals)

v Design of support saddles and stiffening rings à early engineering required

v Selection ad design of the acid gas burner for the reaction furnace

Finite Element AnalysisFinite Element Analysisfor reaction furnacefor reaction furnace

22nd nd CondenserCondenserTubes InsertionTubes Insertion

● Will transport 55 BCM/y of natural gas from Russia to Europe across Baltic Sea● By means of two 48”pipelines, for a length of 1220 km without intermediate compression. ● Requiring very high gas delivery pressure of about 200 bar● Nord Stream pipeline pressure drop 120 bar and gas temperature drops well below 0 °C● Low gas temperatures promote hydrate formation and hydrocarbons condensation● Gas quality for Nord Stream is therefore very stringent: HC dew point -20°C (at 22 bar) & Water dew point -30°C● These figures are considerably lower than what required for conventional transportation on European grid

The Nord Stream ProjectThe Nord Stream Project

GREIFSWALDGREIFSWALD

VYBORGVYBORG

Courtesy of www.nord-stream.com

Process Selection for Process Selection for PortovayaPortovaya GTPGTP

REGENERATION GAS HEATER

CHILLER UNIT

M

REGENERATION GAS HEATER

BOOSTER CHILLER

COMPRESSOR

Base Option: Mol Sieve for Dehydration + Turbo-Expander for HC dew point control + Compressor to recover lost

pressure

Optimized: Silica Gel Adsorption Process for combined removal of hydrocarbons and water optimize the GTP

arrangement

BOOSTER COMPRESSOR

Feed gas Pressure (bar)

Silica Gel GTP

Gas Expansion GTP

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

60 65 70 75 80 85 90

ENER

GY

CO

ST (E

UR

/ M

MSm

3)

0

25

50

75

100

125

150

175

200

225

250

Equi

vale

nt N

atur

al G

as C

onsu

mpt

ions

(MM

Sm3/

y)

Comparison of Investment Costs and Operating Costs indicates that Optimized solution based on Silica Gel Adsorption is the best solution

PortovayaPortovaya GTPGTPSimplified Flow DiagramSimplified Flow Diagram

Portovaya GTP – Nord Stream Project Gazprom, 170 MMSm3/d - from 3D Model

The largest Silica Gel GTP in the world

Combined removal of Water and hydrocarbons

Raw Gas

Treated Gas

Adsorption Regeneration

Portovaya Silica Gel Adsorption Plant Design features:

Ø Transportation constraints (max. transportable diameter 5 m, max. length 10 m)

Portovaya GTP requires installation of4 independent trains due to huge gasflow and constraints on maximumAdsorbers size

Silica Gel Adsorption Process Silica Gel Adsorption Process (ADAPT) for (ADAPT) for PortovayaPortovaya GTPGTP

Ø Transportation constraints (max. transportable diameter 5 m, max. length 10 m)

Ø Maximum gas flow to a single Adsorber train is limited by the size of silica gel bed (max. gas velocity across bed and load of HC and water to achieve treated gas purity)

Ø Each adsorption train consists in the following main equipment:

q 5 Adsorbers (3 adsorption, 1 regeneration, 1 spare)

q 1 Regeneration Fired Heater and 1 Regeneration Air Cooler

q 1 Feed Gas Coalescing Filter

q 1 Regeneration Gas Separator

Ø Common equipment outside adsorption trains:

q 4 Raw Gas Filters

q 4 Dry Gas Filters

In early 2009 Siirtec Nigi was awarded by GAZPROM a contract for the supply of Design, Equipment and Materials for Portovaya GTP.

About GTP:

● 4 Trains & Filtration + Auxiliaries

● Total 20 Adsorbers (OD: 5m, L:10m) & 12 Filters (OD: 2-2,5m, L:8-10m), 4 Fired Heater & 4 Air Coolers

● Total 2120 tons of Silica Gel

● Main line size: 36” Train in/out, 20” Adsorber in/out & regeneration

SiirtecSiirtec--Nigi’sNigi’s Project for Project for PortovayaPortovaya GTPGTP

● ≈ 400 automatic valves & 2000 manual ball valves (from 2” to 36”) of which: 90 cyclic (Orbit 16”/ 20”); ≈ 200 ball valves: 20”/ 36”

About Project:

● GTP Supply in 2 different stages

● Delivery 20 months & 32 months

● Application of International Standard + Russian GOST, design reviewed & approved by Gazprom

● Start-Up of the 1st stage successfully completed in 2011, respecting a very tight schedule

● 2nd stage foreseen in 2104.

Questions ?Questions ?

Thank you for Thank you for your kind attentionyour kind attention

Marco Marco NistlerNistlerPhone: +39Phone: +39--0239223102392231Mail: m.nistler@sini.itMail: m.nistler@sini.it

your kind attentionyour kind attention