Overview of UOP Gas Processing Technologies and Applications

Robert J. Rose
UOP LLC

UOP Southeast Asia Gas Processing Tour October November 2009 Malaysia, Thailand, Indonesia & Vietnam
2009 UOP LLC. All rights reserved.
UOP 5241A-01

UOP A Part of Honeywell

y Founded in 1886 y 118,000 employees in nearly 100 countries y A Fortune 75 company y ~$35 billion in sales in 2007 y Global leader in advanced technology products, services and solutions
Transportation & Power Systems Specialty Materials Aerospace
15% 36% 15%

UOP

34%

Automation & Control

Technology Company, Financially Strong and Global

UOP 5241A-02

UOP Company Profile

Profile
Business Units: Process Technology & Equipment (PT&E) Catalysts, Adsorbents & Specialties (CA&S) Employees: 2800+ Location: HQ: Des Plaines, Illinois (suburban Chicago) Offering: Process Technology & Services to Refining, Petrochemicals, and Gas Processing industries Supplier of catalysts to the process industry Supplier of molecular sieve adsorbents to process and Mfg. Industries

2008 Sales: Breakdown

Licensing 12% Services 12% Products 51%

Equipment 25%

Significant Brand Equity

UOP Facilities

Revenue Distribution
2008 Sales: Geographic
Europe, 20% China, 10% Americas, 28% Middle East, 12%

19 Offices 16 Countries 11 Manufacturing Facilities 5 Engineering Centers

UOP Offices UOP Manufacturing sites
India, 7% Asia, 23%

UOP Footprint

Global Market Coverage

UOP 5241A-03

What We Do
Technology Licensing & Equipment
y More than 70 different processes in the petroleum refining, gas & petrochemical industries y Engineered products
Packaged process units

Leading Supplier of Catalysts

y Catalysts to support our licensed technologies y 300+ catalysts supplied around the world y Catalyst manufacturing in USA, UK, China & Japan y Catalysts to support other refining & petrochemical technologies

Continuous renewal and innovation UOP technology in every refinery in the world Leading Supplier of R&D Technical Services Molecular Sieve Adsorbents
y Manufacturer of more than 140 MM lbs in USA, Italy, Japan & China y Portfolio of 150+ products y Diverse applications:
Drying & purification - natural gas, cracked gas, refrigerants, insulated windows, mercury removal, pollution abatement & deodorization Separations - normal/iso-paraffins, aromatics, O2 and N2 from air

& systems Proprietary equipment Control systems & instrumentation

y Optimization services y Technical support y Technical personnel training & development y Knowledge sharing systems y Sample Analyses

Complex market, numerous applications

The backbone of UOPs industry reputation UOP 5241A-04

Gas Processing Applications

y y y y y y Natural gas to pipeline Associated gas cleanup LPG (Liquefied Petroleum Gas) NGL (Natural Gas Liquids) LNG (Liquefied Natural Gas) GTL (Gas to Liquids)

UOP 5241A-05

UOPs Company History from Gas Processing Perspective

1914 1949 1954 1988 1994 1996 1998 2000 2004 2008

y UOP founded in Chicago as Universal Oil Products Company y Union Carbide develops and patents first commercially significant synthetic molecular sieve zeolites, MOLSIVTM adsorbents y Commercialization of Benfield process (now over 700 units) y Joint venture between Allied-Signals UOP and Union Carbides CAPS y UOP acquires SeparexTM technology y UOP develops MemGuardTM technology y UOP acquired licensing rights for the Union Carbide (Dow) Solvent Processes (SelexolTM / AmineGuardTM processes) y UOP develops CAP Membrane y First UOP Integrated Gas Complex and start-up of Gas-Phase RSH Removal integrated complex y UOP achieves 22 Bscfd of gas processing capacity in Middle East
UOP 5241A-06

Natural Gas Treating Market Segments & UOP Product Lines

MolSivTM ADS X X X X X X Mercury RU X X X X X Selexol Tech X X Separex Tech X X X X X Ortloff NGL X X Ortloff Sulfur X X Merox Tech X X

Amine Gas Plant (on-shore) LNG (on-shore) Platform FPSO FLNG X X

Market Segment Definitions y Gas Plant = Onshore processing plant to produce pipeline gas y LNG = Onshore processing plant to produce LNG y Platform = Offshore gas production platform. Gas is typically sent by pipeline to onshore plant for further processing. y FPSO = Floating production, storage and offloading a ship to process oil for transfer to tankers. Associated gas is flared, reinjected for EOR, sent by pipeline to shore, or (future) sent to an FLNG vessel. y FLNG = Ship to process gas and produce LNG for transfer to LNG transport vessels.
Note: For all segments, treating requirements depend on gas composition.
UOP 5241A-07

Typical Contaminants
The technologies can be combined to treat the many varied gas compositions worldwide

H2S, mol-% CO2, mol-% RSH, ppmv COS, ppmv Hg, g/Nm3

Middle East Africa 0.1- 2.9 0 - 0.2 2-7 2 - 7.5 0 400+ 0 1 - 40 0 0 - 50 1 - 130

Pacific Rim 0 - 0.02 9 - 38 0 0 1000 - 1500

Different locations require different processing schemes

UOP 5241A-08

Typical Product Specifications

Treated Gas Specs For: Pipeline H2S, ppmv Total Sulfur, ppmv CO2 Hg, g/Nm3 H2O, ppmv <4 < 20 - 50 <2% 8% < 0.01 <7 lb/ MMSCFD LNG <24 < 10 - 50 < 50 ppmv < 0.01 < 0.1 ppm GTL <24 < 10 - 50 < 50 1000 ppmv < 0.01 < 1 ppm

Liquid Specs LPG <1 - 10 < 50 < 500 NA <5

UOP 5241A-09

UOPs Unique Capability: The Entire Plant

High FluxTM Tubing
Natural Gas

Acid Gas

Sulfur

Tail

Alumina Catalyst
Acid Gas Removal Dehydration Hg Removal Chiller

Tail Gas Treating Sulfur

Wellhead
Dehydration

Ortloff

Dry Sweet Gas Raw

Molecular Sieves

High Flux Tubing MS Treater

Ethane

MeroxTM

MS Treater MS Treater
Depropanizer Debutanizer Deethanizer

Propane Mixed Butanes Isobutane Olefins Aromatics Natural Gasoline

Raw NGL

ButamerTM
Process

OleflexTM
Process

CyclarTM High Flux Heat Exchanger Integration & Trays

Process

Single source for multiple technologies to meet all gas processing requirements

UOP 5241A-10

UOPs Acid Gas Removal Technologies

Partial Pressure Acid Gas in Feed, psia

1000 Benfield Process Selexol Process PSA Unit SeparexTM Membrane Tech

1000

Technology # Units
Membranes Benfield Amine Guard Molecular Sieves Merox Selexol PSA 250 650 550 2,000 1,700 50 800

100

100

10

Amine Guard FS Process MolSiv Ads Scavengers

10

1.0

1.0

0.1 0.001

0.01

0.1

1.0

10

100

0.1

Partial Pressure Acid Gas in Product, psia

Established technologies
UOP 5241A-11

What Are UOP SeparexTM Membranes?

UOP 5241A-12

Separex Membranes
y Not a filtration process y Solution-Diffusion based separation process
Components dissolve into membrane surface and diffuse through it More soluble components permeate quicker Smaller components permeate quicker
Hydrocarbons, N2 High Pressure Low Pressure
Fast Slow

CO2, H2S, H 2O

Membranes are characterized by permeability (flux) and selectivity

UOP 5241A-13

UOP Wet Solvent Systems (Licensed)

y Gas/liquid contact Counter-current in absorber packed column y Solvent: liquid with A high affinity for acid gas A low affinity for the valuable components y UOP Amine Guard:
Chemical solvent Amine Guard II uses inhibitors to increase the alkanolamine strength 14 Unique formulated solvents tailored to specific end uses (UCARSOL - trademark of The Dow Chemical Company )

y UOP Benfield:
Chemical solvent Activated hot potassium carbonate

y UOP Selexol:
Physical solvent Based on dimethyl ethers of polyethylene glycol
UOP 5241A-14

Amine Guard FS Process

Treated Gas
XXXX XXXX Amine Absorber Lean Solution Pump Acid Gas Cooler
XXXXX

Make-Up Water
Amine Stripper XXXX Filtration System

Acid Gas
Acid Gas Knock-out Drum

Reflux Pump Lean Solution Cooler Lean/ Rich Exchanger

Feed Gas

Flash Gas to Fuel Header Make-Up Water

xxxx

Rich Flash Drum

Lean Booster Pump

Amine Reboiler
UOP 5241A-15

Acid Gas Removal Wet Solvent Technology

Application & Benefits
Amine Guard FS Process
y Remove CO2 & H2S to low levels y Selective H2S removal with CO2 slip y Natural gas to pipeline specs y Natural gas to LNG specs y Downstream of a membrane for CO2/H2S polishing y Treat synthesis gas for H2, NH3 or other applications y Bulk CO2 y Selective H2S removal y Total sulfur removal (COS, CS2, RSH) y Synthetic gas purification (steam reforming / coal gasification) y Landfill gas treating y CO2 removal from NG y CO2 removal from Synthesis gas y CO2 removal from gases containing oxygen

Limitations
Mercaptan removal

Selexol Process

y Rich HC steams y Low acid gas partial pressures

Benfield Process

CO2 or H2S removal to low levels requires a Hi Pure polishing unit

UOP 5241A-16

UOP Molecular Sieves

y Zeolite adsorbents Robust and long lasting Highly reliable with high on-stream efficiency y Dehydration water saturated feed gas is dried to less than 0.1 ppmv of H2O y Desulfurization removal of mercaptans and other sulfur compounds to meet product specification of 10 ppm y Mercury Removal - product specification of less than 0.01 microgram/Nm3 y CO2 Removal viable if feed gas CO2 < 2 % to meet product specification of 50 ppm
Purified Product Feed

Dehydration Sulfur Compounds Mercury

Multiple adsorbent layers may be used to remove different components to very low specs

UOP 5241A-17

Mercury Removal- UOP HgSivTM Adsorbent

y UOP holds a unique market position with two separate and clearly different mercury removal options covering all the bases y We offer regenerable solutions (HgSIV adsorbent) AND nonregenerable (GB562) guard bed mercury removal y We can work with customers according to their own requirements y We can ensure no additional vessels and Capex with HgSIV adsorbent , use HgSIV and GB-562 together, or GB-562 up-front to protect entire flow-scheme y 40 references globally y UOP on-site testing capabilities

UOP 5241A-18

Caustic Merox Process

y Extraction removes mercaptans from liquid hydrocarbons to specifications of 5 20 ppm, depending upon configuration y Uses 15 wt% caustic aqueous solution y Rich caustic is regenerated via oxidation and removal of resulting disulfides y 1700 units installed worldwide
Flow Diagram for LPG
Treated Product Disulfide Separator Spent Air Disulfide Oil

Oxidizer Air Regenerated Caustic Mercaptide - rich Caustic LP Steam

Feed

UOP 5241A-19

Ortloff: NGL/LPG Recovery Sulphur Recovery (SRU Claus)

y Ortloff Engineers, Ltd. (1960 - 2004) y Over 17 Patented NGL/LPG Recovery Technologies y Experience
94 NGL/LPG Recovery Units (57 New, 37 Retrofits) 76 Sulfur Recovery Plants

NGL/LPG Recovery
y Ortloff Technology Can Provide
Increased recovery with no increase in horsepower Increased capacity with no increase in horsepower Lower capital cost

Example: Gas Subcooled Process (GSP)

Subcooler Residue Gas to Compression Expander Inlet Gas Separator Demethanizer

y Improved Plant Reliability

Better CO2 tolerance Eliminates critical phase envelope problems

y Improved Plant Operating Flexibility

Ethane recovery / rejection mode of operation
NGL Product

Ortloff also provides Claus (SRU) technology

UOP 5241A-20

UOP Integrated Complex Flowscheme

RasGas 3, 4, 5 Design Basis
Acid Gas to Claus SRU Limit on Hydrocarbon Feed
750 MMSCFD CO2, H2S High RSH content, Hg
Acid Gas Removal Unit (UOP Amine Guard FS Unit) Dehydration, RSH, & Hg Removal (UOP Molecular Sieve System)

Product Gas Specifications

ppm level of CO2, Total Sulfur & H2S, Very low levels of H2O & Hg

Acid Gas
to Claus Limit on RSH
Greater Efficiency Process Guarantee Partner-like Relationship

Sweet Gas
to Fuel ppm level of RSH

RSH Removal (UOP Selexol Unit)

Single Source

Integrated Flow Scheme

UOP 5241A-21

Integrated Gas Complexes RasGas Trains - Ras Laffan, Qatar

Source: Presentation at LNG 15, The Value of Replication, RasGas Experience in the Execution of LNG trains 3, 4 and 5

UOP 5241A-22

NG & NGL Processing Flowscheme

Integrated UOP World Scale Experience (Oct09)
Project Location
Indonesia Adgas Adgas RasGas RasGas Dolphin Gasco Gasco QatarGas RasGas RasGas QatarGas Gasco (SGD) RasGas (Barzan)

Capacity MMSCFD 4 x 625 2 x 225 550 3 x 750 750 4 x 800 2 x 625 2 x 400 2 x 1400 2 x 1500 1600 2 x 1400 2x900 3x980 26.69 Bcfd

Technologies Application LNG+NGL B, M LNG+NGL B, M LNG+NGL B, M LNG I A, M, S, O SG I A, M, S, O SG+NGL A, M SG+NGL A, O SG+NGL A, O LNG+NGL I M, S, O LNG+NGL I A, M, S, O SG+NGL I A, M, S, O LNG+NGL I M, S, O SG+NGL I M, S, O A,M,S,O SG+NGL I

S/U Date
80s 85 95 04/05/06 05 07/08 09/10 09/10 09/10 09/10 09/10 09/10 12/15 12/15
UOP 4914-20

A UOP Amine Guard FS Unit, M UOP Molecular Sieve System,

B UOP Benfield Unit, O Ortloff, S UOP Selexol Unit, I Integrated

Integrated LNG Pretreatment (FLNG)

UOP GB-562 Absorbent Mercury Removal Unit UOP Separex Membrane System UOP Amine Guard FS Process Unit UOP MOLSIV Dehydration Unit

XXXX

Feed Gas Treated Gas to LNG

Mercury

Permeate Gas CO2 + H2S

Sour Gas CO2 + H2S

Water

y Single Source Technology Supplier : Value to End User / Address needs of FEED Contractor/PMC y Integrated unit operations provides efficient overall design package and project schedule y Guaranteed Performance

Integration of proven technologies provides a viable solution for FLNG

UOP 5241A-24

Summary
y Complete portfolio of Gas Treating processes
Separation (NGL) Removal: CO2, H2S, H2O, RSH, Hg, S-compounds Conversion: RSH (Merox Technology); H2S (SRU Claus)

y Proven technologies y Key technology provider for recent world-scale LNG and NGL Plants y Integration of multiple technologies allows for:

Integration and optimization of individual unit technologies into a systems package Single-source engineering integration with elimination of interfaces Full wrap process guarantees for the package Partner-like Greater facility efficiency and better environmental Greater Relationship Efficiency performance Process Can significantly impact project schedule and costs Guarantee Establishes partner-like relationship Single between client and technology provider Source from initial facility design through continuing technical support

Integrated Flow Scheme UOP 5241A-25