Overview of UOP Gas Processing Technologies and

Applications

Overview of UOP Gas Processing Technologies and

Applications

Robert J. RoseUOP LLC

Robert J. RoseUOP LLC

© 2009 UOP LLC. All rights reserved. UOP 5241A-01

UOP Southeast Asia Gas Processing TourOctober – November 2009Malaysia, Thailand, Indonesia & Vietnam

34%

15%36%

15%

Founded in 1886118,000 employees in nearly 100 countriesA Fortune 75 company~$35 billion in sales in 2007Global leader in advanced technology products, services and solutions UOP

Technology Company, Financially Strong and Global

UOP – A Part of Honeywell

Aerospace

Automation & Control

SpecialtyMaterials

Transportation& Power Systems

UOP 5241A-02

UOP Company ProfileProfileBusiness 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 industriesSupplier of catalysts to the process industrySupplier of molecular sieve adsorbents to process and Mfg. Industries

Significant Brand Equity

Global Market Coverage

UOP Facilities

UOP Footprint

Licensing12%

Products51%

Services12%

Equipment25%

Revenue Distribution

2008 Sales: Geographic

19 Offices16 Countries11 Manufacturing Facilities5 Engineering Centers

UOP OfficesUOP Manufacturing sites

2008 Sales: Breakdown

Middle East, 12%

Americas, 28%

Asia, 23%

India, 7%

China, 10%

Europe, 20%

UOP 5241A-03

What We Do

Continuous renewal and innovation

The backbone of UOP’s industry reputation

UOP technology in every refinery in the world

Complex market, numerous applications

Technology Licensing & EquipmentMore than 70 different processes in the petroleum refining, gas & petrochemical industriesEngineered products

– Packaged process units & systems

– Proprietary equipment– Control systems &

instrumentation

Leading Supplier of Catalysts

Manufacturer of more than 140 MM lbs in USA, Italy, Japan & China Portfolio of 150+ productsDiverse applications:Drying & purification - natural gas, cracked gas, refrigerants, insulated windows, mercury removal, pollution abatement & deodorizationSeparations - normal/iso-paraffins, aromatics, O2 and N2 from air

Leading Supplier of Molecular Sieve Adsorbents

Optimization servicesTechnical support Technical personnel -training & developmentKnowledge sharing systemsSample Analyses

Catalysts to support our licensed technologies300+ catalysts supplied around the world Catalyst manufacturing in USA, UK, China & JapanCatalysts to support other refining & petrochemical technologies

R&D Technical Services

UOP 5241A-04

Gas Processing Applications

Natural gas to pipelineAssociated gas cleanupLPG (Liquefied Petroleum Gas)NGL (Natural Gas Liquids)LNG (Liquefied Natural Gas)GTL (Gas to Liquids)

UOP 5241A-05

UOP’s Company History from Gas Processing Perspective

1914

1949

1988

1994

2000

2004

1954

UOP founded in Chicago as Universal Oil Products CompanyUnion Carbide develops and patents first commercially significant synthetic molecular sieve zeolites, MOLSIVTM

adsorbents Commercialization of Benfield process (now over 700 units)Joint venture between Allied-Signal’s UOP and Union Carbide’s CAPSUOP acquires SeparexTM technologyUOP develops MemGuardTM technologyUOP acquired licensing rights for the Union Carbide (Dow) Solvent Processes (SelexolTM / AmineGuardTM processes) UOP develops CAP MembraneFirst UOP Integrated Gas Complex and start-up of Gas-Phase RSH Removal integrated complexUOP achieves 22 Bscfd of gas processing capacity in Middle East 2008

1996

1998

UOP 5241A-06

Natural Gas Treating Market Segments& UOP Product Lines

X

X

Merox Tech

XXXXFLNG

XXXFPSO

XXXPlatform

XXXXXXXLNG (on-shore)

XXXXXXXGas Plant (on-shore)

Ortloff Sulfur

Ortloff NGL

Separex Tech

Selexol Tech

Mercury RU

MolSivTM

ADSAmine

Market Segment DefinitionsGas Plant = Onshore processing plant to produce pipeline gas LNG = Onshore processing plant to produce LNGPlatform = Offshore gas production platform. Gas is typically sent by pipeline to onshore plant for further processing.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.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

H2S, mol-%CO2, mol-%RSH, ppmvCOS, ppmv Hg, μg/Nm3

→ Different locations require different processing schemes

Africa0 - 0.22 - 7.5

00

1 - 130

Pacific Rim0 - 0.029 - 38

00

1000 - 1500

Middle East0.1- 2.9

2 - 70 – 400+

1 - 400 - 50

Typical Contaminants

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

UOP 5241A-08

<7 lb/MMSCFD

< 0.01

<2% – 8%

< 20 - 50

<4

Pipeline

< 1 ppm < 0.1 ppmH2O, ppmv

< 0.01 < 0.01 Hg, µg/Nm3

< 50 – 1000ppmv< 50 ppmvCO2

< 10 - 50Total Sulfur, ppmv < 10 - 50

< 2 – 4< 2 – 4H2S, ppmv

GTLLNG

Treated Gas Specs For:LiquidSpecs

< 5

NA < 500

<1 - 10

LPG

Typical Product Specifications

< 50

UOP 5241A-09

NaturalGasoline

Aromatics

MixedButanes

Isobutane

Olefins

Propane

Ethane

Raw

Sulfur

TailSulfur

Raw NGL

ChillerDehydrationHg Removal

Acid GasRemoval

Deet

hani

zer

Depr

opan

izer

Debu

tani

zer

High Flux Heat Exchanger

Integration & Trays

High Flux Tubing

CyclarTMProcess

OleflexTM

Process

Ortloff

MeroxTM

High FluxTM Tubing

ButamerTM

Process

Alumina Catalyst

MolecularSieves

UOP’s Unique Capability: The Entire Plant

Tail GasTreating

Acid Gas

DrySweet Gas

MS Treater

MS Treater

MS Treater

Single source for multiple technologies to meet all gas processing requirements UOP 5241A-10

WellheadDehydration

NaturalGas

TechnologyMembranesBenfieldAmine GuardMolecular SievesMeroxSelexolPSA

# Units250650550

2,000

1,70050800

1000

100

10

1.0

0.1

Scavengers

MolSiv ™ Ads

PSAUnit

Selexol™Process

Amine Guard™ FSProcess

SeparexTM

MembraneTech

Benfield™Process

Par

tial P

ress

ure

Aci

d G

as in

Fee

d, p

sia

Partial Pressure Acid Gas in Product, psia0.001 0.01 0.1 1.0 10 100

1000

100

10

1.0

0.1

UOP’s Acid Gas Removal Technologies

Established technologiesUOP 5241A-11

What Are UOP SeparexTM Membranes?

UOP 5241A-12

Not a filtration processSolution-Diffusion based separation process

– Components dissolve into membrane surface and diffuse through it

– More soluble components permeate quicker– Smaller components permeate quicker

FastSlow

Hig

h Pr

essu

re

Low

Pre

ssur

eCO2, H2S,

H2O

Hydrocarbons, N2

Separex Membranes

Membranes are characterized by permeability (flux) and selectivity UOP 5241A-13

UOP Wet Solvent Systems (Licensed)

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 )UOP Benfield™: – Chemical solvent – Activated hot potassium carbonate

UOP Selexol™: – Physical solvent – Based on dimethyl ethers of polyethylene glycol

Gas/liquid contact –Counter-current in absorber packed column

Solvent: liquid with –A high affinity for acid gas –A low affinity for the valuable components

UOP 5241A-14

TreatedGas

RichFlash Drum

xxxx

FeedGas

Flash Gasto Fuel Header

LeanSolutionCooler

FiltrationSystem

Lean Solution

Pump Reflux Pump

XXXXX

AcidGas

Acid GasKnock-out

DrumAmineAbsorber

XXXX

XXXX

XXXXAmine Stripper

Make-UpWater

Acid GasCooler

Make-UpWater

Lean/Rich

Exchanger

Lean BoosterPump

AmineReboiler

Amine Guard FS Process

UOP 5241A-15

CO2 or H2S removal to low levels requiresa Hi Pure polishing unit

CO2 removal from NGCO2 removal from Synthesis gasCO2 removal from gases containing oxygen

Benfield Process

Rich HC steamsLow acid gas partial pressures

Bulk CO2

Selective H2S removalTotal sulfur removal (COS, CS2, RSH)Synthetic gas purification (steam reforming / coal gasification)Landfill gas treating

Selexol Process

Mercaptan removalRemove CO2 & H2S to low levelsSelective H2S removal with CO2 slipNatural gas to pipeline specsNatural gas to LNG specsDownstream of a membrane for CO2/H2S polishingTreat synthesis gas for H2, NH3 or other applications

Amine Guard FS Process

LimitationsApplication & Benefits

Acid Gas Removal Wet Solvent Technology

UOP 5241A-16

Zeolite adsorbents– Robust and long lasting– Highly reliable with high on-stream efficiency

Dehydration – water saturated feed gas is dried to less than 0.1 ppmv of H2ODesulfurization – removal of mercaptans and other sulfur compounds to meet product specification of 10 ppmMercury Removal - product specification of less than 0.01 microgram/Nm3

CO2 Removal – viable if feed gas CO2 < 2 % to meet product specification of 50 ppm

Feed

Purified Product

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

Dehydration

Sulfur Compounds

Mercury

UOP Molecular Sieves

UOP 5241A-17

Mercury Removal- UOP HgSivTM Adsorbent

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

UOP 5241A-18

Caustic Merox ProcessExtraction removes mercaptans from liquid hydrocarbons to specifications of 5 – 20 ppm, depending upon configurationUses 15 wt% caustic aqueous solutionRich caustic is regenerated via oxidation and removal of resulting disulfides1700 units installed worldwide

DisulfideSeparator

Treated Product

Spent AirOxidizer

DisulfideOil

LP Steam

Regenerated Caustic

Mercaptide- richCaustic

Feed

Air

Flow Diagram for LPG

UOP 5241A-19

Ortloff: NGL/LPG RecoverySulphur Recovery (SRU – Claus)

Demethanizer

NGL Product

Expander

Subcooler

Residue Gasto Compression

Inlet Gas Separator

Example: Gas Subcooled Process (GSP)

Ortloff also provides Claus (SRU) technology

Ortloff Engineers, Ltd. (1960 - 2004)Over 17 Patented NGL/LPG Recovery TechnologiesExperience

– 94 NGL/LPG Recovery Units (57 New, 37 Retrofits)– 76 Sulfur Recovery Plants

NGL/LPG RecoveryOrtloff Technology Can Provide

– Increased recovery with no increase in horsepower

– Increased capacity with no increase in horsepower

– Lower capital costImproved Plant Reliability

– Better CO2 tolerance– Eliminates critical phase envelope

problemsImproved Plant Operating Flexibility

– Ethane recovery / rejection mode of operation

UOP 5241A-20

Acid Gas to Claus SRU Limit on Hydrocarbon

Product Gas Specifications

ppm level of CO2,Total Sulfur

& H2S,Very low levels

of H2O & Hg

Dehydration, RSH, & Hg Removal

(UOP MolecularSieve System)

Sweet Gasto Fuel

ppm level of RSH

Acid Gasto Claus

Limit on RSH

Acid Gas Removal Unit(UOP Amine

Guard™ FS Unit)

RSH Removal (UOP Selexol™

Unit)

Feed750 MMSCFD

CO2, H2SHigh RSH content,

Hg

UOP Integrated Complex FlowschemeRasGas 3, 4, 5 Design Basis

Integrated Flow SchemeIntegrated Flow Scheme

SingleSource

ProcessGuarantee

GreaterEfficiency

Partner-likeRelationship

UOP 5241A-21

Integrated Gas ComplexesRasGas 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

IndonesiaAdgasAdgasRasGasRasGasDolphinGascoGascoQatarGasRasGasRasGasQatarGasGasco (SGD)RasGas (Barzan)

4 x 6252 x 225

5503 x 750

7504 x 8002 x 6252 x 400

2 x 14002 x 1500

16002 x 1400

2x9003x980

26.69 Bcfd

B, MB, MB, MA, M, S, OA, M, S, OA, MA, OA, OM, S, OA, M, S, OA, M, S, OM, S, OM, S, OA,M,S,O

80’s8595

04/05/0605

07/0809/1009/1009/1009/1009/1009/1012/1512/15

ProjectLocation

CapacityMMSCFD Technologies S/U DateApplication

LNG+NGLLNG+NGLLNG+NGL

LNGSG

SG+NGLSG+NGLSG+NGL

LNG+NGLLNG+NGLSG+NGL

LNG+NGLSG+NGLSG+NGL

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

NG & NGL Processing FlowschemeIntegrated – UOP World Scale Experience (Oct’09)

II

IIIIII

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

UOP 4914-20

Single Source Technology Supplier : Value to End User / Address needs of FEED Contractor/PMCIntegrated unit operations provides efficient overall design package and project scheduleGuaranteed Performance

Integrated LNG Pretreatment (FLNG)

UOP 5241A-24

TreatedGas

to LNG

Sour GasCO2 + H2S

UOP GB-562Absorbent

Mercury Removal UnitUOP Separex

Membrane SystemUOP Amine Guard FS

Process UnitUOP MOLSIV

Dehydration Unit

FeedGas

Mercury Permeate GasCO2 + H2S

Water

XXXX

Integration of proven technologies provides a viable solution for FLNG

Integrated Flow Scheme

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

Proven technologiesKey technology provider for recent world-scale LNG and NGL PlantsIntegration 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− Greater facility efficiency and better environmental

performance− Can significantly impact project schedule and costs − Establishes partner-like relationship

between client and technology provider from initial facility design through continuing technical support

Summary

SingleSource

ProcessGuarantee

GreaterEfficiency

Partner-likeRelationship

UOP 5241A-25