|18.00 Welcome Reception
|08.00||Welcome & Keynote Address
Tayba Al Hashemi, ADNOC, UAE
|SESSION A - Chair: Ahmed Saleh, ADNOC Gas Processing|
|08.15||Sulphur Recovery Unit Maximum Throughput Study
Muna Al Maazmi, ADNOC SOUR GAS
The Shah Gas Plant facilities were successfully commissioned in August 2015. Actual feed gas composition has higher H2S concentration in acid gas feed (i.e 64.8% vs 63% design). ADNOC SOUR GASengaged process licensor M/s Fluor to evaluate the maximum as-built capacity of SRU single train considering existing feed composition and pressure profile measured in one of the SRU for life cycle performance. Based on simulation study, it was observed that the Maximum sustainable throughput per SRU train can be higher than 133,000 Nm3/h of fresh acid gas feed and even higher with TGTU recycle to produce almost 3,000 MTD of liquid sulphur against the original design without any modification in plant and compromise on equipment sparing philosophy and any process safety & asset integrity limits. Subsequent to this study report a temporary MOS was raised to conduct the test run to validate the licensor study report and the test run results also shown the similar results with optimizing the fuel gas co-firing in SRU reaction furnaces. This additional capacity in SRU has helped the overall gas plant operations at 110% of the original design as well as provided additional availability of the gas plant at 86% capacity against the original design of 75% in case of one SRU shutdown. This has increased the overall gas plant profitability.
|08.45||Enrich Your SRU! How To Increase Sulphur Processing Capacity of an Existing Plant
Alessandro Buonomini, Gaja Croci and Daniela Boni, KT – Kinetics Technology S.p.A., Italy
The paper describes a case study performed by KT – Kinetics Technology on an increase of capacity in an existing SRU unit designed by KT for a longstanding Customer in Europe. The unit consists of two parallel Claus trains followed by a common TGT section using KT RAR™ technology. The expectation was to increase the sulphur production of about 50% of the design capacity without compromising the regular production of the re¬nery, thus all the modifi¬cations on fi¬eld were to be carried within the plant turnaround period (one month). After an accurate feasibility study, in which all the options have been investigated, the use of enriched air (oxygen concentration below 28% by vol.) in the thermal reactor burner was selected. To further confi¬rm the results of the study a week-long test with oxygen enrichment was carried on site reproducing the 50% capacity increase requested. The full study has shown that the system was suitable to withstand the requested operation and moreover, it has highlighted the bottlenecks of the system in the new operating conditions.
|09.15||Getting the Most Out Of Your SRU Performance Tests
Inshan S Mohammed, Sulfur Recovery Engineering Inc., Canada
Beyond explaining the rigors of completing the test work, this paper will describe what benefits a performance evaluation can deliver to the operator. The advantages apply to all stakeholders of the SRU including Operations, Maintenance, Management and Environmental personnel.- From reducing emissions to extending the life of SRU catalyst, a simple performance evaluation can provide a lot of insight to operators which can in turn save money.
|09.45||SESSION A - Speakers Panel|
|SESSION B - Chair - Manuel Jacques, TechnipFMC, France|
|10.45||Hydrogen Production Using H2S Methane Reforming Process As A Sulfur Recovery
Sawsan Mohammed Ali, American University of Sharjah, UAE
This paper summarizes the research work on producing hydrogen from hydrogen sulfide in SRU’s using an innovative chemical process of H2S methane reforming in a similar fashion to the well-known water shift reaction between water and methane. The preliminary conducted research is based on a highly sour rich H2S stream from an amine regeneration unit in a gas sweetening plant. While in conventional Claus sulfur recovery units, valuable hydrogen is wasted, methane reforming will allow the recovery of sulfur products and hydrogen simultaneously. This method of H2S methane reformation can be subject to R & D with the potential to become a revolutionary idea of simultaneously recovering sulfur from H2S while generating hydrogen as a fuel. The main challenges are analyzed in depth as part of the research: thermodynamic reaction kinetics, catalyst chemistry, membrane permeability factors separation technologies for H2S-CO2 separation, separation of reaction byproducts, as well as high energy requirements. The high energy requirement of the process makes the exploration of renewable energy sources worthwhile such as the use of solar reactors. Overall, the methane reforming process was found to have a potential in recovering hydrogen from hydrogen sulfide and can possibly and ultimately replace the Claus process units which has always been used as the conventional sulfur recovery process. This innovative idea shall be subject to intensive studies to explore its technical and economic feasibility of being implemented on large industrial basis.
|11.15||Compact, Selective H2S Removal Technology
Shwetha Ramkumar, Sean Philbrook, Scott Northrop, Norman Yeh and Don Shatto ExxonMobil Upstream Research Company, USA
ExxonMobil has developed the Compact Mass transfer and Inline Separation Technology (cMIST™) gas treating system, a novel, compact and low weight processing technology platform, to achieve process intensification in processing facilities. This paper describes the application of the cMIST™gas treating system to selective H2S removal from natural gas. The reaction and removal of H2S using amines is instantaneous while that of CO2 has significantly slower kinetics. This difference is exploited to obtain selective removal of H2S over CO2in the cMIST™ system by limiting the contact time of the solvent and the gas. The technology is highly modular to allow for simple transportation into remote, challenged, or offshore environments and provide installation configuration flexibility. It is also beneficial for debottlenecking and capacity enhancement applications.
|11.45||Separation Of CO2 And H2S From Sour Natural Gas Using Advanced Distillation Technology
Paul Higginbotham, Air Products, UK
Experience in low temperature gas separations and interest in recovery and purification of helium and CO2from sour natural gases in North America led the company to develop a distillation-based sour gas processing scheme including a novel, efficient distillation technology to separate CO2 and H2S.In this paper we will describe how, in this arrangement, bulk separation of H2S and CO2 from sour natural gas by condensation and distillation followed by separation of CO2 and H2S by our advanced distillation process can efficiently and cost-effectively produce concentrated H2S for reinjection as a pumped liquid and pure CO2 for enhanced oil recovery at elevated pressure.
|12.15||Guideline For Development Of CO2 Capture, Transport and EOR Integrated System For The UAE
Prachi Singh, Frank Geuzebroek, ADNOC Gas Processing, UAE
A high-level roadmap for carbon capture and utilization (CCU) project is proposed in this work. This gives guidelines and directions for activities required to develop successful future CCU projects in UAE. It is a crucial first step to evaluate the potential CO2 emission sources suitable for CO2 capture technology i.e. single point sources in UAE. Power generation followed by cement industry are the largest CO2 emission sectors in terms of CO2 volumes followed by oil and gas industry. This work indicates that source to sink matching is essential at this stage to develop a suitable CCU infrastructure. Moreover, further investments in research and development are required to develop low-cost CO2 capture technologies suitable for low CO2 concentration emission sources such as natural gas _red power generation.
|12.15||Affordable Carbon Dioxide Capture In The Middle East
Pavan Chilukuri , SHELL, Netherlands
A unique opportunity to capture produced CO2 from sour gas processing facilities and use it for EOR and free the natural gas currently used for EOR for electricity generation. This change in use may reduce the need to develop new natural gas reserves. However, the captured CO2 must be affordable for it to be used for EOR. At present, capital costs are high, as low-pressure CO2 sources in natural gas plants require large amine solvent volumes and thus large equipment sizes. Solvent regeneration steam requirements can also be high, which means high operational costs. This paper highlights three Shell technologies that can help to reduce capital and operational costs, and potentially cut captured CO2 costs by 20–40%: • ADIP® ULTRA solvent technology for lowering solvent circulation rates; • Shell Turbo Trays for smaller absorbers and/or fewer capture trains; and the CANSOLV® CO2 Capture System for lower steam requirements and/or fewer capture trains.
|12.45||SESSION B - Speakers Panel|
The future of flange isolation technology in sour oil & gas
|SESSION C - Chair - Cees Brummelkamp, Shell Abu Dhabi, UAE|
|14.30||Sulphur Dust – An Under Rated Risk Component In Sour Operations
Muhammad Jamil, Rabah Beggah, ADNOC Gas Processing, UAE
Since the commissioning of Etihad Rail as transportation mode for solid Sulphur, a new phenomenon of increased Sulphur dust generation is being observed. The phenomenon corresponds to transportation and handling of granulated Sulphur to the shipping terminals from two of the ADNOC distantly located Sulphur Granulation plants. This paper describes the Fire and Explosion Risk Assessment studies undertaken to deal with this new challenge. It discusses the impact of Rail transportation and granule pellets quality controls in dust generation and highlights the gaps identified in dust mitigation measures like water spray, wet scrubber, equipment accessibility/ maintainability, PPE and housekeeping. In the light of Sulphur dust incidents experienced, the paper provide insights on the improvements that can facilitate the smooth operation and maintenance of Sulphur handling units.
|15.00||Development and Validation of a CFD-based Modeling Methodology for Atmospheric Hazardous Gas Dispersion in Sour Gas Fields
Valerie Eveloy, Peter Rodgers, Antoine Diana, Sreekanth Mohnakumar, Khalifa University of Science and Technology, UAE
The exploitation of sour reservoirs with high concentrations of hydrogen sulphide in the raw well fluids poses significant health, safety and environmental threats. Atmospheric gas dispersion modeling is a vital component of mandatory hazard assessment, which can provide critical input data to the design of hazardous gas sensor networks, development of emergency response plans to hazardous gas releases, and post-hazard investigations. This presentation will summarize the limitations of industry-standard gas dispersion models to predict hazardous gas dispersion. A more accurate CFD-based prediction modeling methodology that account for the effects of the actual site terrain and climatic conditions will be outlined. Comparisons of gas dispersion predictions with reference experimental and numerical data will be presented, highlighting the value of CFD-based analysis.
|16.00||Numerical Study Of Erosion Of The Internal Wall Of Sales Gas Piping System By Black Powder Particles
Ahmed Al Haidari, Saudi Aramco, KSA
Transport particles with flow such as black powder can wreak havoc the Sales Gas system and reduce the life cycle. This thesis work focuses on real environmental conditions for one of the Sales Gas plants in Saudi Aramco where black powder , a product of internal corrosion, was evident in the Sales Gas pipeline. The objective of the study is to examine the erosion rate (ER) in an existing Sales Gas Piping by simulating different black powder particles sizes and considering variable operation conditions. An elbow-shaped pipe spool is used to determine the area of maximum destruction. It will help the designer, engineer and operation personnel to predict the ER and will also define the erosion limit.
|16.30||SESSION C - Speakers Panel|
|17.00||Close of Day 1|
|SESSION D - Chair - Pierre Crevier, CPC, Bahrain|
|08.00||Optimized Amine Operation with Correct Parameters
Ir. Egbert van Hoorn, Sulfur Recovery Engineering Inc, The Netherlands
Optimized operation of amine units can significantly increase the actual throughput and reduce the operating costs. Optimized amine operation is based on several parameters which are not always well understood. Best operation is not always based on the industry guideline of a 5°C difference between the lean amine and the acid gas to avoid hydrocarbon condensation. Best operation should not be only based on the guideline of 0.4-0.5 H2S & CO2 mol/mol amine loading because equilibrium loading is more important. The optimal choice of the amine solvent depends largely on the application; besides the frequently advertised MDEA, DEA and DGA can be used the most efficient amine solvents. Al these factors and more will be demonstrated and illustrated with many examples of actual case successes and simulations
|08.30||Control The Technical Integrity Of Your Amine Unit
Bert Aaftink, ADNOC Gas Processing, UAE
Amine units are crucial for removal of H2S and CO2 from the gas streams. Any failure in these units can lead to unavailability of the plant and may have substantial economic consequences. Therefore it is essential that potential degradation threats are recognised, understood and properly managed. The paper will discuss typical materials of construction, typical corrosion loops, potential degradation mechanisms for different types of amine and recommended integrity operating windows (IOW). The paper will also briefly discuss the interfaces and responsibilities of the various disciplines with respect to management of degradation mechanisms. Additionally the paper will highlight some potential critical areas in a typical amine unit and describe the effectiveness of various inspection techniques in relation to the different degradation mechanisms.
|09.00||Investigation Of Lean Diglycol Amine(DGA) And N-Methyldimethanol Amine(MDEA) Degra- Dation Products Using Chromotographic and Mass Spectrometric Analysis Techniques
Mohammed Al-Katheeri, Hossam Al-Qusty, Fatimah Al-Marzooq and S. Al-Shahrani, Saudi Aramco, KSA
Amine degradation products can cause problems to the gas sweetening processes, such as: Capacity loss, corrosion and equipment fouling. Therefore, revenue loss and higher operational and maintenance costs are commonly anticipated. In the past, gas plant area lab conducts amine strength and elemental analyses to characterize lean amines, however, they, alone, do not provide a full picture on amine’s quality, therefore, they can be misleading to process engineers, due to the lack of representative standards, analytical limitations and complexity. In this work, degradation products of lean DGA and MDEA from several gas plant amine units were fingerprinted by multiple chromatographic techniques and mass spectrometry (MS). To the best of our knowledge, the reported findings can be very useful for can help in providing process engineers with a better understanding of the analytical capabilities to assess and monitor the performance of gas sweetening units and help in optimization of gas sweetening processes.
|09.30||Modeling and Optimization of Membrane Contactors in Natural Gas Sweetening
Ven Chian Quek, PETRONAS, Malaysia ,Javier Rodriguez, Process Systems Enterprise Ltd and Nilay Shah and Benoît Chachuat, Imperial College London, UK
Membrane contactor (MBC) for CO2 absorption has been widely recognized for its large intensification potential compared to conventional absorption towers. MBC technology uses micro porous hollow fibre membranes (HFM) to enable effective gas and liquid mass transfer without the two phases mixing into each other. In this work, gPROMS Process Builder with custom modeling is used to develop a mathematical model that accounts for the effect of membrane pore-size distribution and operating conditions on membrane wetting for improved understanding of a novel MBC operating at a high pressure 50-70 bar.. The optimization problem involves minimizing the MBC’s annualized cost, which consists of membrane and solvent regeneration costs, subject to a given CO2 specification alongside operational constraints and size limitation of the MBC module.
|SESSION D - Chair - Frank Geuzebroek, ADNOC Gas Processing, UAE|
|10.30||Sorbent-Based Desulfurization Process For Removing Hydrogen Sulfide And Organic Sulfur Compounds
Gokhan O. Alptekin, SulfaTrap LLC , USA
The paper will provide the details of a new sorbent-based desulfurization process and the results of large scale pilot experiments showing the capabilities of processing natural gas liquids (C3/C4 streams) as well as scavengers systems used in the treatment of off-gases from Acid Gas Removal Units (AGRUs). A high fidelity economic assessment will provide the processing costs for the following case studies; 1- Removal of Mercaptans from Off-gases of Conventional Scrubbers and 2- Desulfurization of Off-spec C3/C4 Streams
|11.00||Scot Ultra: Staying Ahead Of The Curve With Tail Gas Treating
Pavan Chilukuri, SHELL, Netherlands
To meet today’s challenging cost and (future) emissions targets, a step change in SCOT performance is required. The development of the Shell SCOT ULTRA process enables improved profitability/ operability/ capacity. This is realized through: Application of the new C-834 SCOT catalyst (developed by Criterion Catalyst and Technologies), which allows operation at lower temperatures and in combination with joint developed Shell-Huntsman’s JEFFTREAT ULTRA solvent. The benefits of converting existing SCOT/TGTU’s (Tail gas Treating Units) to the SCOT ULTRA configuration will be illustrated through a number of case studies, showing improved profitability, due to reduced solvent circulation rate and reduced energy consumption. In addition, the new JEFFTREAT ULTRA solvent is able to maintain high H2S absorption at higher temperatures with improved CO2 slip, relative to MDEA, thereby making this solution very applicable for warmer climates, where typically solvent chilling would be required to meet solvent performance.
|11.30||HySWEET: A STEP FURTHER IN OPERATION CONSIDERING ENVIRONMENT AND ENERGY EFFICIENCY
Renaud Cadours, Stefano Langé, Jing Zhao and Claire Weiss, TOTAL S.A, France, Ayman Ghazaly, Dheeraj Nagwani , ADNOC Gas Processing, UAE
Conventional technologies such as amine solvents which are usually considered for H2S and CO2 have a limited absorption capacity for mercaptans. Additional treatment steps must be implemented to achieve the sulfur specifications, adding process complexity and further increasing costs. This paper presents several applications cases where the benefit of upgrading alkanolamine aqueous solvent to the hybrid solvent is demonstrated. The new solvent capability to remove mercaptans largely exceeded the one of the conventional amine solvent it replaced. In 2018, a significant milestone will be achieved after the first HySWEET process implementation in ADNOC Gas Processing’s Habshan units. The main study results will be discussed in this paper.
|12.00||SESSION D - Speakers Panel|
|SESSION E - Chair - Mohammad Haji, Saudi Aramco, KSA|
|13.30||SRU Reaction Furnace Internals to Boost Reliability and Performance
Uday N. Parekh, Blasch Precision Ceramics, USA
Keen attention must be paid to the basic “3 Ts” of combustion — time, temperature and turbulence — in the SRU Reaction Furnace (RF) to facilitate key reactions and the destruction of contaminants, including Ammonia and Benzene, Toluene, Xylene (BTX). Internal structures such as choke rings and checker walls are often used to enhance the mixing and temperature in the RF. Checker walls can have a high failure rate, resulting in large economic losses. With a choke ring, a large portion of the flow jets through the center of the ring, not meeting the minimum residence time requirements for key reactions. Blasch’s HexWallsTM and VectorWallsTM are specifically designed to address these issues. These walls have been successfully deployed at well over 100 SRUs, including sizes over 1,000 tons per day such as for the 8 trains at the Shah plant. Large SRUs with checker wall stability challenges and requiring adequate temperatures for Ammonia/BTX destruction particularly benefit from these advanced SRU RF internals, which is very relevant for this region. The paper will provide the basic theory, including CFD modelling, underpinning the performance of these checker walls, as well as plant data (case studies) confirming the benefits from commercial installations.
|14.00||Energy Savings by Optimising Plant Operating Parameters
Mahmoud Al Mahmoud, ADNOC Gas Processing, UAE
Energy saving initiatives are arrived at to achieve ADNOC’s 2020 target of reducing Energy Consumption by 10 % using 2014 data as a base. Identified opportunities are being implemented in ADNOC-GP plant in Bu Hasa and experiences with fuel gas reduction in lean gas compressor by optimizing lean gas discharge header pressure , fuel gas reduction in Train 1 & 2 by reducing mole sieve regeneration temperature and sequential ON/OFF control for fan fan air coolers will be described in detail and the subsequent benefits explained
|14.30||Energy Recovery Universal Loop For Evaluation of Hydraulic Turbocharger Application in Acid Removal Process
Jeremy Martin and Max Shirazi, Energy Recovery Inc, USA
The IsoBoost™ system uses a proprietary liquid phase turbocharger, essential piping, valves, instruments and control system to recover up to 80% of the rich solvent hydraulic energy. The energy, which is typically wasted through the let-down valve, is transferred directly to the lean solvent thus reducing operating costs. Integration, process control and energy saving analysis for the IsoBoost™ system will be discussed. The performance test results for a 6,000 gpm turbocharger unit will be presented and discussed. The 6,000 gpm unit is designed and manufactured for one of the largest gas processing facilities in the world, located in one of the GCC countries. Multiple 6,000 gpm units are expected to be installed in 2018. In normal operating conditions each system is capable of saving 12,000 MWh annually .
|15.00||The New Way to Increase Plant Safety, Reliability and Availability by “Experiential Learning”
Michele Colozzi, Simona Cortese , Kinetics Technology S.p.A., Tiziana Paolicelli, Maurizio Galardo, Schneider Electrics and Gaetano De Santis, EniProgetti Italy
|15.20||SESSION E - Speakers Panel|
|Keynote Closing Address
Derek Ritchie, Shell Global Solutions International B.V
Award for Best Paper
Recognition of SOGAT event support
Attendee Prize Draw