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Ortloff NGL/LPG

Recovery, CO2
Separation and Sulfur
Recovery Technologies
CORE BUSINESS

NGL, LPG, AND SULFUR


LNG RECOVERY
TECHNOLOGY TECHNOLOGY
HISTORY OF ORTLOFF
• The Ortloff Corporation (1960 - 1985)
– Subsidiary of Elcor Corporation
– Formed to service Elcor sister companies
– Turnkey EPC Contractor in the gas processing industry
ƒ Developed 5 U.S. Patents - Gas Processing Technology
» MTP - Two Stage Expander Process
» LSP - Liquid Subcooled Process
» VEP - Vapor Enrichment Process
» OHR - Overhead Recycle Process
» GSP - Gas Subcooled Process

– Withdrew from EPC contracting in 1985 and formed Ortloff


Engineers, Ltd.
HISTORY OF ORTLOFF
• Ortloff Engineers, Ltd. (1985 - Present)
– Established Reputation as Technology Supplier/Developer
– (21) Additional Patents
– Established Cooperative Marketing Agreement with UOP in
2002
– Sold to Management Group in 2005
ORTLOFF TODAY

Since 1985, Ortloff NGL/LPG Technology has been licensed to process


over 50.0 BSCFD of natural gas in more than 120 plants ranging in
size from 25 MSCFD to 1.4 BSCFD located in over 20 countries.
COOPERATIVE MARKETING AGREEMENT

• UOP MARKETS & LICENSES ORTLOFF


TECHNOLOGY
– NGL / LPG / LNG / SULFUR
– Most countries outside of U.S.

• UOP / ORTLOFF SYNERGY


– Development of process technology
• CLIENT BENEFITS
− Single source for all major gas processing technology
− Simplifies technology contract agreements
NGL / LPG RECOVERY
TECHNOLOGY
MARKET SEGMENTS

• NGL / LPG RECOVERY TECHNOLOGY


Ortloff currently has eleven (11) active Patents in the recovery of
liquids from natural gas streams and six (6) pending.

• LNG TECHNOLGY
Ortloff currently has ten (10) active Patents and six (6) pending
related to the recovery of natural gas liquids either:
Integrated with LNG Production
or
at LNG Receiving Terminals
NGL / LPG RECOVERY TECHNOLOGY

Ortloff NGL / LPG recovery technology offers one or


more of the following advantages:
– Ethane and propane recovery levels up to 99%
– Increased recovery with no increase in horsepower
– Increased capacity with no increase in horsepower
– Lower capital cost
– High CO2 tolerance
– Improved operational stability
– Improved operating flexibility (dual mode ethane / propane recovery)
– Maintain ultra-high C3 recovery throughout all C2 operating modes
– Easily retrofit into existing NGL/LPG Recovery Plants
ETHANE RECOVERY

MRX – MULTIPLE RECTIFICATION AND REFLUX


SRX – SUPPLEMENTAL RECTIFICATION WITH REFLUX
SRC – SUPPLEMENTAL RECTIFICATION WITH COMPRESSION
RSV – RECYCLE SPLIT VAPOR
RSVE – RECYCLE SPLIT VAPOR WITH ENRICHMENT
GSP – GAS SUBCOOLED PROCESS

NOTE: ACTUAL PERFORMANCE MAY VARY DEPENDING ON ACTUAL FEED COMPOSITON AND CONDITIONS
PROPANE RECOVERY
100
MRX
SCORE
99 RSV
SRC
% PROPANE RECOVERY

98
RSVE

97
GSP

96
MRX – MULTIPLE RECTIFICATION AND REFLUX
SCORE – SINGLE COLUMN OVERHEAD RECYCLE
SRC – SUPPLEMENTAL RECTIFICATION WITH COMPRESSION
95 RSV – RECYCLE SPLIT VAPOR
RSVE – RECYCLE SPLIT VAPOR WITH ENRICHMENT
GSP – GAS SUBCOOLED PROCESS

94
42 46 50 54 58 62 66 70 74 78 82 86 90 94 98

RELATIVE COMPRESSION POWER


(HP/MMSCFD)
NOTE: ACTUAL PERFORMANCE MAY VARY DEPENDING ON ACTUAL FEED COMPOSITON AND CONDITIONS
CO2 TOLERANCE
100.0
99.0
98.0 MRX
97.0
96.0
95.0
RSV SRX
94.0
% Ethane Recovery

93.0 GSP SRC


92.0
91.0
90.0 RSVE
89.0
88.0
87.0
86.0
85.0
MRX – MULTIPLE RECTIFICATION AND REFLUX
84.0 SRX – SUPPLEMENTAL RECTIFICATION WITH REFLUX
83.0 SRC – SUPPLEMENTAL RECTIFICATION WITH COMPRESSION
RSV – RECYCLE SPLIT VAPOR
82.0
RSVE – RECYCLE SPLIT VAPOR WITH ENRICHMENT
81.0 GSP – GAS SUBCOOLED PROCESS
80.0
0.5 0.8 1.0 1.3 1.5 1.8 2.0
CO2 in Feed Gas
(mol%)

NOTE: ACTUAL PERFORMANCE MAY VARY DEPENDING ON ACTUAL FEED COMPOSITON AND CONDITIONS
TECHNOLOGY OPTIONS

RR
SC SRP

SF
OR SD
E R

RS V
IO

C
R
???? RSVE
R

SSP R SF
C S F SR
C D
TECHNOLOGY SELECTION

• Choose a process design which….


– Meets all product specifications and recovery levels
– Avoids CO2 freeze
– Avoids unstable phase region
– Requires the least heat and compression costs
– Provides the required operating flexibility and upgrade
potential
– Minimizes inlet/product treating costs
Iterations during early phase of project are critical!
LNG
NGL / LPG RECOVERY
TECHNOLOGY
LNG TECHNOLOGY
• INTEGRATED LNG TECHNOLOGY (SERIES)

FUEL

FEED GAS GAS TREATING ORTLOFF NATURAL GAS LNG


AND LIQUIDS LIQUEFACTION
DEHYDRATION RECOVERY

NGL or LPG
LNG TECHNOLOGY
• INTEGRATED LNG TECHNOLOGY (SERIES)

ORTLOFF NGL or LPG


LIQUIDS
RECOVERY

FUEL

FEED GAS GAS TREATING LNG


NATURAL GAS
AND
LIQUEFACTION
DEHYDRATION
LNG TECHNOLOGY
• INTEGRATED LNG TECHNOLOGY (ANGLE)
Offers a 10% to 20% improvement in overall efficiency
of the liquefaction process
LOW-LEVEL LOW-LEVEL
REFRIGERANT REFRIGERANT
COMPRESSION PRE-COOLING

HIGH-LEVEL
REFRIGERANT
COMPRESSION
FUEL

FEED GAS GAS TREATING ORTLOFF NATURAL GAS LNG


AND LIQUIDS LIQUEFACTION
DEHYDRATION RECOVERY

NGL or LPG
LNG TECHNOLOGY
• LNG Fractionation Process
BOG
(LFP) Technology
Recondenser

Ship Vapor
Return
Vaporizer
BOG
Gas to
Ship Compressor
Pipeline
Off-loading
High Pres.
LNG LNG Pump
Storage
Rich Lean
LNG LNG
In-Tank
LNG Pump
LFP
NGL / LPG NGL / LPG
Recovery Product
Unit
LNG FRACTIONATION TECHNOLOGY

Ortloff’s LNG fractionation technology for the recovery


of NGL / LPG at LNG receiving terminals offers the
following advantages:

– Flexibility to handle wide range of LNG composition


– Improved plant efficiency by utilizing inherent refrigeration available
in LNG
– No increase in heat load on vaporization
– Minimizes plant capital and operating costs over traditional straddle
plant design
– Recovery of liquids easily adjusted to meet natural gas pipeline
heating value specifications
– Requires no compression
– Easily retrofitted into an existing facility
CO2 / METHANE
SEPARATION IN
PRODUCED GAS WITH
HIGH CO2 CONTENT
Integrated DRCF / SELEXOL™ Process

• Two stage process for separation of CO2 and


Methane

– Stage 1: DRCF for bulk removal and purification of


CO2

– Stage 2: UOP SELEXOL™ for final separation and


purification of natural gas

DRCF - Dual Refrigerant CO2 Fractionation


Integrated DRCF / SELEXOL™ Process

SandRidge Century Plant


38 MMSCFD Flash
90% CO2 Comp.

400
Sales
65%MMSCFD
CO2 Dehy DRCF
585 DeC1 21% UOP

PSIG Comp. CO2 SELEXOL™ Gas


112065%
psigCO2
1120 psig 1200 PSIG
140 MMSCFD

CO2 Product
260 MMSCFD
2,000 PSIG
DRCF / SELEXOL™ Process Applicability

Factors indicating that the DRCF / SELEXOL™ process


should be evaluated

•CO2 content > 40%

•Capacity > 100 - 150 mmscfd

•CO2 delivery at high pressure

•Environmentally Sensitive Location


DCRF / SELEXOL™ Advantages

• When Compared to UOP SELEXOL™ Only Processing

– Increased efficiency yields 7% - 10% increase in


methane sales

– Lower CAPEX

– Lower OPEX
CO2 Removed

CO2 Removed (MMSCFD)

Process Single Dual Refg


Selexol™ Refg CO2 CO2 Frac
Frac
UOP Selexol™ 260 -- --
Single Refg CO2 Frac + UOP
69 191 --
Selexol™
Dual Refg CO2 Frac + UOP
38 -- 222
Selexol™
Based upon 400 mmscfd of 65% CO2 inlet gas
Power Comparison

Power Required (MW)

Process
Compression Pumping Total

UOP Selexol™ 71.3 10.6 81.9


Single Refg CO2 Frac +
44.1 9.3 53.4
UOP Selexol™
Dual Refg CO2 Frac +
37.6 7.9 45.5
UOP Selexol™

Note: UOP Selexol™ pumping HP is for solvent circulation


Fractionation pumping HP is for CO2 delivery
Summary of Potential Savings

• CAPEX - $30 – 40 MM

• OPEX - $39 MM / year


SULFUR RECOVERY
TECHNOLOGY
Early SRU Experience

• Designed / built 7 SRUs for sister company in 1960s


− Little design information available
− SRUs suffered typical reliability problems
− Sulfur plant reliability affects profitability

• Began analyzing reliability problems in 1969


− Developed design concepts to improve reliability
− Further improvements have been on-going
− Concepts used in all Ortloff plants since 1970
Sulfur Recovery Experience

• The Ortloff Corporation (1960 – 1985)


− Designed / constructed 53 SRUs

• Ortloff Engineers, Ltd. (1986 – Present)


− Designed 30 SRUs constructed by others
Small Modular Claus Plant
Large Modular Claus Plant
Large SRU / TGCU
Ortloff SRU Enhancements

• Cold reactor bed startup


• Sulfur vapor line block valves
• Waste heat boiler design
• Sulfur condenser outlet separator design
Cold Reactor Bed Startup

Advantages:
• Over 50 SRUs have been designed to use cold
reactor bed startup.
• Eliminates damage from sulfur fires
• Eliminates carbon fouling / plugging
• Allows use of oxidation-sensitive catalysts
• Simplifies hot standby operation
• Catalyst activity remains higher longer
Sulfur Vapor Line Block Valves

• Conventional high-performance trunnion valve


– Eccentrically-mounted shaft
– S.S./fiber laminated seal in disk
– Specially machined seat
• Modified for sulfur vapor service
– Integral steam jacket formed in body
– Bolted between jacketed spool pieces
– Actuators, switches, etc. added
– Tested/adjusted to bubble-tight shut-off
– Shipped as an assembly to jobsite
Sulfur Vapor Line Block Valves
Waste Heat Boiler Design

• Single most common cause of SRU downtime


• Designed using general practice of the time
• 6 month to 3 year service life
• Tube leaks develop at inlet end of tubes
Waste Heat Boiler Design

Calculated WHB Tube Temperature Profile


Results of Improved WHB Design

• New boiler designs in service beginning in 1971


– First boiler inspection in 1976
– Tubes, tubesheet, welds in excellent condition
• All subsequent WHBs have used this design
• No hot end tubesheet attachment failures in any of
these boilers.
Sulfur Condenser Outlet Separator Design

Shortcomings of Typical Outlet Separator Designs

• Mist eliminators alone inadequate


– Will not remove small droplets
– Significant carry-over of liquid sulfur
– Coalescer often required downstream of SRU
• Downstream reactors affected
– Catalyst beds deactivated
– Periodic “rejuvenation” required
– Requires extended sulfur “stripping” before S/D
Sulfur Condenser Outlet Separator Design

DISENGAGING LENGTH GAS OUTLET

TUBESHEET

SULFUR
OUTLET

Improved Sulfur Condenser Outlet Separator Design


LICENSING/CONSULTING
SUPPORT SERVICES
CONSULTING SERVICES

• PROCESS DESIGN PACKAGES FOR LICENSED


TECHNOLOGY
• TECHNOLOGY SELECTION STUDIES
• GENERAL OPERATING MANUALS
• OPERATOR TRAINING
• PLANT STARTUP
• PLANT PERFORMANCE TESTING
• PLANT TROUBLESHOOTING &
DEBOTTLENECKING
TECHNICAL PAPERS
415 W. Wall, Suite 2000
Midland, Texas USA 79701
Phone : (432) 685-0277
Fax : (432) 685-0258
E-mail : OEL@ortloff.com
or
NGL@ortloff.com
Visit our web site at www.ortloff.com