Lower Rich Glycol Temperature Causes Glycol Flash Tank Operational Problem

One of major problem in glycol dehydration plant is hydrocarbon carry over. Plant observation conclude, glycol flash tank is one of equipments which hydrocarbon carry over tends to occur. One factor which participate in hydrocarbon carry over on glycol flash tank is temperature.


Since lower temperature of rich glycol has higher viscosity, rich glycol solution tends to form emulsion.
Many ways can be taken to observe whether hydrocarbon carry over take place in glycol flash tank or not.

1. Take sample from glycol flash tank, observe while taking sample. If glycol solution comes out from the tank and forms foam or emulsion, we can say "WE HAVE PROBLEMS HERE". Since vapour hydrocarbon is trapped (carry over) in to glycol solution.
2. If glycol particulate or glycol charcoal filter is installed, observe it's pressure drop. Pressure differential will tell many. If pressure drop is fluctuating, it seems "WE HAVE PROBLEM HERE". Trapped vapour in pressure differential tube line can causes wrong reading of instrumentation. 
3. Another ways to make sure is open vent on top of glycol particulate/charcoal filter (if vent valve available). If large amount of vapour comes out while venting is opened, it seems the problems is confirmed. Hydrocarbon carry over in rich glycol solution will caused vapour trapped in glycol particulate or glycol charcoal filter. Since there is no on line vent on glycol filter, it will accumulate on top of filter. 

If hydrocarbon carry over take place, several methods can be applied to avoid

1. Operating at higher temperature, since hydrocarbon vapour will be flashed into top of glycol flash tank and reduce hydrocarbon carry over.
2. Operate at lower pressure also result same effect, increase flash effect and reduce hydrocarbon carry over
3. Check glycol flash tank design. Glycol flash tank may not be design for three phase separator.

Other problem may be found here

Glycol Dehydration -Stripping Column Overhead Temperature

A higher temperature in the top of the still column can increase glycol losses due to excessive vaporization. The boiling point of water is 212°F and the boiling point of TEG is 546°R The recommended temperature in the top of the still column is approximately 225°F. When the temperature exceeds 250°F the glycol vaporization losses may become substantial. The still top temperature can be lowered by increasing the amount of glycol flowing through the reflux coil.

If the temperature in the top of the still column gets too low, too much water can be condensed and increase the reboiler heat load. Too much cool glycoi circulation in the reflux coil can sometimes lower the still top temperature below 220°F. Thus, most reflux coils have a bypass to allow manual or automatic control of the stripping still temperature.

Stripping gas will have the effect of requiring reduced top still temperature to produce the same reflux rate.

Glycol Dehydration - Feed Gas Temperature

At constant pressure, the water content of the inlet gas increases as the inlet gas temperature increases. For example, at 1,000 psia and 80°F gas holds about 34 Ib/MMscf, while at 1,000 psia and 120°F it will hold about 104 Ib/MMscf. At the higher temperature, the glycol will have to remove over three times as much water to meet a pipeline specification of 7 lb/MMscf.

An increase in gas temperature may result in an increase in the required diameter of the contact tower. As was shown in separator sizing , an increase in temperature increases the actual gas velocity, which in turn increases the diameter of the vessel.

inlet gas temperatures above 120°F result in high triethylene glycol losses. At higher gas temperatures tetraethylene glycol can be used, but it is more common to cool the gas below 120°F before entering the contactor. The more the gas is cooled, while staying above the hydrate formation temperature, the smaller the glycol unit required.

The minimum inlet gas temperature is normally above the hydrate formation temperature and should always be above 50°F. Below 50°F glycol becomes too viscous. Below 60°F to 70°F glycol can form a stable emulsion with liquid hydrocarbons in the gas and cause foaming in the contactor.

There is an economic trade-off between the heat exchanger system used to cool the gas and the size of the glycol unit. A larger cooler provides for a smaller glycol unit, and vice versa. Typically, triethylene glycol. units are designed to operate with inlet gas temperatures between 80°F and 110°F.

Glycol Dehydration - Feed Gas Temperature

We invariably cool the compressor discharge prior to dehydration. Unfortunately, natural gas will be reheated—sometimes by 10°F — in a typical gas field dehydration contactor. This occurs because of two factors:
• The circulating glycol may be 70° hotter than the contactor gas inlet temperature.
• The heat of condensation or absorption of the water vapor contained in the wet natural gas must be dissipated into the dried natural gas.

If the glycol contactor is properly designed (see chapter 6) this temperature rise will not effect dehydration efficiency. However, transmission temperatures will increase.

Glycol Dehydration - Tower Flooding

The field supervisor’s first indication of a flooded contactor tower is usually a report of excessive glycol loss. A check of a lowpoint bleeder on the gas pipeline downstream of the tower will show glycol. After refilling the glycol reboiler, the level in the reboiler gauge glass noticeably decreases after a few hours. This is a further indication of flooding. Of course, a dehydration system loosing glycol this fast cannot dry natural gas on a continuous basis.

One simple explanation of such glycol losses is a leaking dry gas to dry glycol heat exchanger (Figure 6-2). Note that the glycol pressure in this heat exchanger will be slightly higher than the gas pressure. To check for leakage, shut off and block in the glycol pump, block in the dry glycol at the contactor tower, and open an intervening bleeder between the pump and the tower. If gas does not blow out of the bleeder, the exchanger is not leaking.

Glycol Dehydration - Glycol Gas Heat Exchanger Leak

The hot glycol from the reboiler is cooled by heat exchange with the wet glycol from the contactor. This heat transfer typically takes place in a double-pipe or plate-type exchanger. On one of the double-pipe heat exchangers, I noticed that the reboiled glycol was being cooled to a rather low temperature. I suspected that this could be an indication of a leaking feed-effluent exchanger. That is, cooler (120°F) wet glycol might be leaking into warmer (165°F) dry glycol. To verify my suspicions, I blocked in the dry glycol at the reboiler and at the suction to the pump. The appearance of a steady stream of liquid at an intervening bleeder confirmed that the feed-effluent exchanger was leaking, hi effect, wet glycol was bypassing the reboiler and flowing straight back to the contactor tower.

After fixing the leak, this reboiler and the units that had suffered from an inefficient pump and a faulty temperature controller were put back on-line. The treated natural gas was checked and found to meet pipeline moisture specifications.

Glycol Dehydration

The gas exiting the top of the contactor in Figure 6-1 can be assumed to be in equilibrium with the reboiled—i.e., dry—glycol. The higher the glycol reboiler temperature, the dryer the glycol. The dryer the glycol, the dryer the treated natural gas. For most of the year in El Gringo, critical control of the glycol reboiler temperature gas was not vital. Relatively cool ambient temperatures maintained the top temperature of the contactor towers below 110°F. But now, in mid-July, this temperature was peaking at 122°F every afternoon. I checked my gas purification data book1 and calculated that, for the 1,020 psig operating perssure of the contactors, it should be possible to meet the required moisture specification. My calculations were based on a reboiler temperature at 375°F. For triethylene glycol, which is the work horse of the gas drying industry, the maximum recommended reboiler temperature to prevent thermal degradation of the glycol is 400°F. The six El Graingo dehydrator reboilers were all set to hold 375°F. But by checking the actual reboiler temperatures with a calibrated thermometer, I determined that one of the reboilers was actually operating at 350°F as opposed to 375°F. This reduced temperature was sufficient to greatly increase the water concentration of the “dry” glycol, so that the moisture content of gas treated with this glycol stream was doubled.

A simple recalibration of the reboiler temperature controller rectified this problem. Incidentally, operating a triethylene glycol reboiler at 375°F-400°F does not necessarily result in a noticeable increase in glycol degradation. The trick is to keep the glycol filters in good repair. Dirty glycol fouls the reboiler heat-transfer tube. This in turn causes hot spots on the heat-transfer surface, which accelerates thermal decomposition.

GLYCOL REGENERATION PROCESS AND EQUIPMENT

THE GLYCOL REBOILER

The glycol regeneration process is very important to maintain the correct concentration of the lean glycol. Refer to Figures: 50 & 52 for the equipment used in the Glycol Regeneration Process.


The glycol reboiler is the main piece of equipment that plays this role in the regeneration process. The reboiler supplies heat to separate the glycol and water by a simple distillation process.


The system consists of a ' U ' shaped, combustion chamber with gas burners, set into the shell of the reboiler and includes an outlet stack for the waste combustion gases.


The shell also contains a ' Weir ' that maintains the level of glycol above the fire-tube in order to prevent overheating of the tube and subsequent damage and/or glycol decomposition by excess heat.



Figure: 32 - Fire-tube Reboiler


The temperature of the reboiler should be in the range of 375 to 390 °F. This temperature will usually give good distillation of the rich glycol and evaporate all water out of it.


The glycol should never be heated above 400 °F as it begins to decompose above that temperature.


Note: When making adjustments to reboiler temperature, never increase the temperature setting by more than five degrees at a time.


Too great an increase will cause the control system to open the fuel gas valve too wide, giving a large burner flame which in turn will cause flame impingement on the inside of the fire-tube. This will lead to ' Hot-spots ' and cause damage to the fire-tube and breakdown of the glycol into corrosive organic acids.


If coke , salts or tar deposits form on the fire tube, the heat transfer into the glycol is reduced, the control system will increase the fuel to maintain the glycol temperature and tube failure can result. Localised overheating, especially where salt deposits accumulate, will decompose the glycol.


Salt deposits can be detected by shutting off the burner on the glycol reboiler system at night and looking down the fire-box. A bright red glow will be visible at the hot spots on the fire tube walls where salt deposits have collected. An analysis of the glycol will determine the degree of the contamination.


It is highly recommended that, during a plant start-up, make sure the reboiler is up to the desired operating temperature before flowing gas through the contactor .


Some fires have been caused by leaks in the gas lines near the fire-box. The best precaution is to have valves and regulators in the gas line at a suitable distance from the firebox.


Another very effective measure is the addition of a flame arrestor around the fire-box. If the flame arrestor is properly designed, even severe gas leaks in the immediate vicinity of the fire-box will not ignite.

McKenzie Dehydration of Natural Gas

Dehydration of Natural Gas

Natural Gas usually contains significant quantities of water vapor. Changes in temperature and pressure condense this vapor altering the physical state from gas to liquid to solid. This water must be removed in order to protect the system from corrosion and hydrate formation.

In 1810, an English scientist by the name of John Dalton stated that the total pressure of a gaseous mixture is equal to the sum of the partial pressures of the components. This statement, now known as Dalton's Law of Partial Pressures, allows us to compute the maximum volume of water vapor that natural gas can hold for a given temperature and pressure.

The wet inlet gas temperature and supply pressures are the most important factors in the accurate design of a gas dehydration system. Without this basic information the sizing of an adequate dehydrator is impossible.

As an example, one MMSCF (million standard cubic feet) of natural gas saturated @ 80 degree F. and 600 PSIG (pound per square inch gauge) will hold 49 pounds of water. At the same pressure (600 PSIG) one MMSCF @ 120 degree F will hold 155 pounds of water.

Common allowable water content of transmission gas ranges from 4 to 7 pounds per MMSCF. Based upon the above examples, we would have two very different dehydration problems as a result of temperature alone.

There are many other important pieces of design information required to accurately size a dehydration system. These include pressures, flow rates and volumes.

All gasses have the capacity to hold water in a vapor state. This water vapor must be removed from the gas stream in order to prevent the formation of solid ice-like crystals called hydrates. Hydrates can block pipelines, valves and other process equipment. The dehydration of natural gas must begin at the source of the gas in order to protect the transmission system. 

The source of the gas moved through the transmission lines may be producing wells or developed storage pools. Pipeline drips installed near well heads and at strategic locations along gathering and trunk lines will eliminate most of the free water lifted from the wells in the gas stream. Multi stage separators can also be deployed to insure the reduction of free water that may be present.

Water vapor moved through the system must be reduced to acceptable industry levels. Typically, the allowable water content in gas transmission lines ranges from 4 lb. to 7 lb. per MMSCF. There are basically three methods employed to reduce this water content. These are: 

1.  Joule-Thomson Expansion
2.  Solid Desiccant Dehydration
3.  Liquid Desiccant Dehydration 

Joule-Thomson Expansion utilizes temperature drop to remove condensed water to yield dehydrated natural gas. The principal is the same as the removal of humidity from outside air as a result of air conditioning in your house. In some cases glycol may be injected into the gas stream ahead of the heat exchanger to achieve lower temperatures before expansion into a low temperature separator. 

Solid desiccant dehydration, also known as solid bed, employs the principal of adsorption to remove water vapor. Adsorbents used include silica gel (most commonly used), molecular sieve (common in NGV dryers), activated alumina and activated carbon. The wet gas enters into an inlet separator to insure removal of contaminants and free water. The gas stream is then directed into an adsorption tower where the water is adsorbed by the desiccant. When the adsorption tower approaches maximum loading, the gas stream is automatically switched to another tower allowing the first tower to be regenerated. 

Heating a portion of the mainstream gas flow and passing it through the desiccant bed regenerates the loaded adsorbent bed. The regeneration gas is typically heated in an indirect heater. This undersaturated regeneration gas is passed through the bed removing water and liquid hydrocarbons. 

The regeneration gas exits the top of the tower and is cooled most commonly with an air-cooled heat exchanger. Condensed water and hydrocarbons are separated and the gas is recycled back into the wet gas inlet for processing. The third method of dehydration is via liquid desiccant and is most common in the Northeast United States. This method removes water from the gas stream by counter current contact in a tray type contactor tower with tri-ethylene glycol (TEG). Natural gas enters the unit at the bottom of the adsorber tower and rises through the tower were it intimately contacted with the TEG solution flowing downward across bubble trays. Through this contact, the gas gives up its water vapor to the TEG. 

The water laden TEG is circulated in a closed system, where the water is boiled from the TEG. The regenerated TEG then is recirculated to the contacting tower.

Dehydration

Dehydration

Natural gas often comes out of the ground mixed with water vapor. This "wet gas" can be separated using two primary methods:

Glycol dehydration – Wet gas moves through an inlet pipe into a tank called a "contactor." A rounded cap over the inlet pipe forces the gas to flow down into a pool of glycol solution at the bottom of the tank. Glycol has a strong affinity for water, so the water molecules from the wet gas bond to the glycol molecules in the solution. The vapor-free natural gas is collected from the top of the contactor.

Because water boils at 212F and glycol doesn't boil until 400F, simple heating is all that is required to vaporize the captured water so the glycol solution can be reused.

Solid-desiccant dehydration - This method is typically more effective than glycol dehydration, but requires higher volumes of natural gas moving under high pressure. The wet gas is pumped downward through a tower filled with a solid desiccant (drying agent). The desiccant attracts and binds the water molecules so that only dry gas flows out the bottom of the tower.

When the desiccant has captured all the water it can, operators flush the tower with heated gas that re-vaporizes the water molecules, thereby "reactivating" the desiccant.

TEG Dehydrator

TEG Dehydrators

GENERAL PROCESS DESCRIPTION

The basic function of the triethylene glycol (TEG) dehydration unit is to remove water vapor from natural gas streams to an outlet water content meeting pipeline specifications, usually seven lb./MMSCF or less. QBJ has designed and built special TEG dehydration units which have met water specifications of less than 1 lb. / MMSCF.

Dehydration, or water vapor removal, is accomplished by depressing the water dew point (defined as the temperature at which vapor begins to condense into a liquid) from the inlet dew point temperature to the dew point temperature for the outlet water content required.

The most common dehydration method used for natural gas is the absorption of water vapor in the liquid desiccant, Triethylene Glycol. The wet gas is brought into intimate contact with lean dry glycol in the tray or structured packing section of an absorber tower where water vapor is absorbed in the glycol thus depressing the water dew point. The wet rich glycol is pressure reduced and then flows from the absorber to the regeneration system. The wet rich TEG is pre-heated (via heat exchange), entrained gas is separated, additionally heated (via heat exchange) and fractionated in the still column and reboiler by heating and boiling off the absorbed water vapor. The water dry lean glycol is cooled (via heat exchange) and pumped back to the absorber.

The QBJ regeneration systems can be equipped with proprietary baffling and stripping columns. These units produce lean TEG glycol concentrations from 99.1% up to 99.95% (wt.) concentration by the use of dry gas to strip more water out of the hot regenerated glycol. The proprietary QBJ “Enhancelator” produces TEG glycol concentrations of 99.5% (wt.) without the use of stripping gas.

With special design, material selection and fabrication requirements, the TEG dehydration process can be applied to CO2, H2S, oxygenated gases or any other application.

Dewpoint depression is dependent on TEG circulation rate (gallons per pound of water in the gas), lean TEG concentration, number of equilibrium stages (number of trays) in the absorber, contact temperature and pressure.

Dewpoint depression is especially sensitive to inlet gas temperature. TEG dehydration units yield a higher dew point depression with an increase in temperature and correspondingly a lower dew point depression with a decrease in inlet gas temperature. This performance change is primarily due to the change in gas-glycol contact efficiency in relation to temperature. Even though the dew point depression increases with an increase in inlet gas temperature, the outlet gas dew point will be higher. For the lowest obtainable outlet dew points it is desirable to have a low inlet gas temperature.

Normal operating temperatures range from 50 to 135 F. 50 F is considered to be the minimum operating temperature due to the high viscosity of glycol at lower temperatures. 135 F. is the upper practical temperature limit for TEG dehydrators because of the increased TEG vaporization losses at higher temperatures.

Pressure appears to have little effect on dewpoint depression in the dehydration process. Existing data indicates that the dewpoint depression is essentially constant over a range of 0 to at least 3000 PSIG. Pressure does however affect the water vapor capacity of the gas. At lower pressures the gas can absorb more water per unit volume.

Typically, increasing the number of trays, the glycol circulation rate or the lean TEG concentration will increase the dew point depression. Increasing glycol rates above 4 to 6 gallons per pound does not usually have an appreciable effect on dewpoint depression.  Increasing TEG concentration or the number of trays is usually more effective than increasing glycol circulation rate in maximizing dewpoint suppression.

GENERAL EQUIPMENT DESCRIPTION

The dehydration unit consists of an absorber and regenerator. The mass transfer section of the absorber may be trays, structured packing or random packing. A standard design, unique to QBJ, is a large TEG disengagement space above the top tray and below the mist extractor. This space allows additional time for glycol - gas separation and minimizes TEG losses. The standard QBJ regenerator is a high concentration type concentrating the glycol to over 99.1% by the use of stripping gas or by concentrating the glycol to 99.5% without the use of stripping gas in the Enhancelator.

The lean, dry TEG entering the absorber should be cooled to within 10 degrees of the gas temperature to maximize the efficiency of the mass transfer media and to minimize TEG vaporization losses. The absorber is normally equipped with an external glycol/gas heat exchanger; however, some units are supplied with a fin fan air-cooled exchanger.

The water rich glycol is withdrawn from the bottom section of the absorber via a level controller and level control valve on units utilizing electric or gas fired pumps. Units using an energy exchange glycol / gas powered pump, do not require a level control system since the pump transfers the energy available from the wet glycol, at the absorber pressure, to an equivalent volume of dry glycol at reboiler pressure. The additional energy to overcome friction, line and system pressure losses is supplied by gas at the absorber pressure.

The absorber may be provided with an integral scrubber to remove free liquid from the incoming gas. The scrubber may be two phase for separation of gas and liquids, or three phase to separate gas, hydrocarbon liquid and water. The gas stream to the absorber must be free of liquids prior to entering the mass transfer section of the absorber. A filter separator or coalescer upstream of the absorber will fulfill this requirement.

Cold weather protection can be provided for the dehydration unit by the addition of an enclosure, extra insulation, heat trace or a catalytic heater.

TEG heat exchange is optionally provided by a three-section glycol/glycol heat exchanger. The heat exchanger is of a fixed tube sheet BEM construction, with bolted bonnets. The first section preheats the water rich TEG for optimum gas separation in the low-pressure three-phase separator. The second and third sections raise the rich TEG from separation temperature to approximately 300 F (for maximum heat conservation) prior to the inlet of the still column. The lean TEG from the surge tank provides the heat and is cooled by exchange for pump suction.

The QBJ standard regenerator consists of the reboiler with a firetube, burner control assembly, flame arrestor, stack with down draft diverter, still column with reflux condenser and integral surge accumulator with stripping column. The reflux condenser, integral to the QBJ still column, aids in the condensation of glycol vapors and reduces glycol losses.  QBJ units are test fired in the shop to verify performance and reduce startup problems.

The stripping column uses a source of dry gas, usually taken from the dry gas leaving the absorber to strip additional water out of the regenerated glycol. The amount of stripping gas varies with the application and dew point depression requirements from 0.5 SCF/gal. of glycol circulated up to 6 SCF.

Fuel gas and instrument supply gas is usually supplied from the dry gas leaving the absorber but other sources may be used. A fuel gas scrubber with fuel gas safety valve is provided to prevent free liquids from entering the fuel gas system.

The regenerator temperature is controlled by the temperature controller and fuel gas control valve(s) along with a high temperature shutdown.

The glycol pump(s) are provided with valves and strainers. The electric driven positive displacement pump is provided with a suction stabilizer and pulsation bottle in the discharge line. A redundant valve system bypasses glycol back to pump suction for manual flow control of lean TEG. A bypass relief valve is provided on the discharge of all electric and gas powered pumps.

Standard units are provided with low pressure three phase separator (flash separator) to separate solution gas (and glycol powered pump energy gas) from the glycol and hydrocarbon condensate. The flash separator is installed on the rich glycol line between first pass of the glycol/glycol heat exchanger and the glycol sock filter. The flash gas is generally routed to the fuel gas system.

Additional Optional Features

1. Enhancelator for 99.5% (wt.) without the use of stripping gas.
2. Standby glycol pump
3. Charcoal filter
4. Flame failure shutdown
5. Low temperature shutdown - glycol reboiler
6. High temperature shutdown - stack
7. High and Low level shutdown - glycol reboiler, surge tank and flash separator
8. High and Low level shutdown – inlet separation / integral scrubber
9. Cold weather enclosure
10. PLC control and DCS interface
     

QBJ glycol dehydration units GUARANTEE outlet gas dewpoints and unit performance.

Dehydration Unit

GLYCOL DEHYDRATION UNIT The DPS Delta glycol dehydration Unit removes water vapour from a gas stream to allow further treatment and transportation without risk of hydrate formation or corrosion in the presence of H2S or CO2 by using ethylene glycol as a liquid desiccant. PROCESS DESCRIPTION Wet gas containing HC droplets enters the integral scrubber section of the contactor tower where free liquid is removed. Saturated gas flows up through the mass transfer section of the tower mixing with the downward flowing lean glycol. Dry gas will exit the tower via a demister pad and the rich glycol goes to a coil within the still column mounted on the reboiler. The condensing vapours provide reflux for the still column. The warmed rich glycol flows via the lean/ rich glycol exchanger to the Flash Drum to remove entrained gas and separate HC liquid from the rich glycol. The rich glycol then passes through a solids filter to remove particulates and a carbon filter to remove traces of aromatic compounds. After filtering the rich glycol is heated by the lean glycol from the Surge Vessel. Lean glycol flows from an integral gas stripping column via the Surge Drum to the Lean/ Rich Glycol Exchanger before flowing to the Lean Glycol Pump which sends the glycol under high pressure to the Glycol Contactor via the Lean Glycol Cooler. Please click on the image below to view a larger version.

Liquid/Gas Coalescer

Pall Solutions

A Pall SepraSol™ Liquid/Gas coalescer in the gas feed line will remove virtually all of the entrained liquids in the feed gas. This eliminates the problem of hydrocarbons and amines mixing with the glycol, minimizing any problems with foaming.

Pall disposable filters are recommended on the recirculating glycol stream to remove iron oxide particulates. Since the glycol is a circulating system, the solids concentration will gradually increase unless removed by a filter. The high solids result in equipment fouling and stabilize foaming. The circulating glycol should contain less than 1ppm by weight of suspended solids and should be filtered to an efficiency of 10 µm absolute. This circulating glycol system often requires that coarser filters be installed at first to clean the system of solids which have been accumulating over a period of time. Progressively finer filters are introduced to the system until a filter efficiency of 10 µm absolute is obtained.

Figure 1. Glycol Dehydration System

Table 1. Filter Recommendations

Filter Location	Recommended Pall Assembly	Purpose of Filtration	Benefits of Filtration
1	Pall SepraSol Liquid/Gas Coalescer: CC3LG7A CC3LGO2-H13 CS604LGH13	Removes water, hydrocarbon, carried over amines and other liquids and solids from gas feed	Reduces foaming problems Increases absorber efficiency Prevents exchanger and reboiler fouling
2	Pall Profile® II or Ultipleat® High Flow cartridge: 10 µm	Removes scale, solid particles	Reduces foaming problems Reduces glycol losses Increases energy efficiency Increases absorber efficiency Prevents exchanger and reboiler fouling
3	Pall SepraSol Liquid/Gas Coalescer: CC3LG7A CC3LGO2-H13 CS604LGH13	Removes water, carried over glycol, and liquid hydrocarbon	Protects downstream processes Reduces downstream equipment maintenance costs

If glycol losses are significant due to operating at higher than design capacity, Pall’s SepraSol Liquid/Gas coalescers can be installed downstream of the contactor overheads to recover glycol and protect downstream equipment like compressors, desiccant beds and heat transfer equipment.

Glycol Dehydration process

Introduction The use of Glycol to dehydrate gas streams is an established method that has proven its functionality and versatility time and again. There are 3 common types of Glycol used for Gas Dehydration: Mono-Ethylene Glycol (MEG) Di-Ethylene Glycol (DEG) Tri-Ethylene Glycol (TEG) The type of Glycol used and the package design depends on several factors, and the end-users specific requirements and objectives for the gas stream being processed. Each package is typically designed in close consultation with the client to ensure the best overall design is achieved. Design Basis The design of TEG and MEG Dehydration Systems is unique for every requirement, and the overall package design will vary to meet the specified moisture content of the gas at the process conditions. Each system is typically designed and built as a complete turn-key package with particular emphasis given to the following issues: Discharge gas moisture content High gas dehydration capacity Minimum glycol losses Minimum power consumption Optimum plant efficiency & design integrity Compliance with HSE requirements Environmentally conscientious design Process Description In a typical TEG package, water saturated gas enters near the bottom of the Contactor Tower and flows upwards through the internal trays/packing (1).  Lean Glycol enters the Contactor Tower near the top and cascades down through the Contactor internals (9), making contact with the up-flowing gas stream.  The counter-current flow path of the Glycol and the high contact surface area adsorbs water into the Glycol from the gas stream. Dehydrated gas flows out of the top of the Contactor, while the Rich Glycol flows out of the bottom of the Contactor and to the Glycol Regeneration Package. The TEG Regeneration process typically involves passing the Rich Glycol through the still column to gain some heat (2) before entering the Flash Drum (3).  The Glycol is then passed through Particle Filters to remove particulates and Activated Carbon Filters to remove any dissolved hydrocarbon and/or chemical compounds (4).  The Rich Glycol is heated in a cross exchanger to preheat the feed (5) to the Still Column where the Glycol present in the water vapour leaving the Reboiler is recovered (6). Depending on the application, it may be necessary to increase the Lean Glycol concentration by using stripping gas (7), or running the Reboiler/Still Column under a slight vacuum.  Lean TEG (typically >99wt%) is then cooled and pumped back to the top of the Contactor Tower (8) to repeat the process.

Glycol dehydration: handling and operational problems pH - salt - oxidation

5. GLYCOL pH CONTROL

The pH of a glycol solution is the measure of its acidity or alkalinity, and is measured on a scale of 0 - 14. A pH of less than 7 is an acid solution , 7 is neutral and, greater than 7 is an alkaline solution.

The corrosion rate of equipment increases rapidly with a decrease in the glycol pH. The formation of organic acids, resulting from the oxidation of glycol, thermal decomposition products or acid gases picked up from the gas stream, are the most troublesome corrosive compounds. Therefore, the glycol pH should be checked periodically and kept on the basic side by neutralising the acidic compounds with borax, Ethanol-amines or other suitable alkaline chemicals to maintain the pH at 7.5 to 8.0. A glycol solution that is too alkaline - i.e. pH greater than 9.00, tends to foam and emulsify .

6. SALT CONTAMINATION

Salt deposits accelerate equipment corrosion, reduce heat transfer in the glycol reboiler and change the specific gravity readings when a hydrometer is used to determine glycol concentration. These troublesome compounds cannot be removed by normal regeneration processes. Salts should be prevented by the use of effective filters or an efficient scrubber.

7. GLYCOL OXIDATION

Oxygen can enter the glycol system via the vapour space of an un-blanketed storage tank or through the glycol make-up pump packing glands ... etc. The glycol will oxidise readily in the presence of oxygen (air) and form corrosive organic acids

Precautions should be taken to prevent glycol oxidation. It is highly recommended, that process vessels that can draw in air as the liquid level is lowered, should contain a gas blanket to keep oxygen (air) out of the system. Oxidation inhibitors, such as Hydrazine can be used to prevent the formation of corrosive, organic acids.

8. SLUDGE FORMATION

Accumulation of solid particles and tarry hydrocarbons very often forms in the glycol solution. This sludge is suspended in the circulating glycol and, over a period of time, the accumulation becomes large enough to settle out.

This action results in the formation of a black, sticky and abrasive gum which can cause erosion of the equipment. It usually occurs when the glycol pH is low and becomes very hard and brittle when deposited on the absorber trays, still column parts and other areas in the circulating system. Good, effective filtration will prevent the build-up of sludge in the glycol system.

Glycol dehydration : Coldfinger processes

Instead of using gas to reduce the vapor pressure of water, the Coldfinger process condenses and extracts water from the vapor phase using a cold tube bundle (“Coldfinger”).

The lean glycol is routed from the regeneration still to a separate vessel which contains the Coldfinger process. The vessel is half filled with lean glycol, while the other half is occupied by vapor consisting of water and glycol. A cold bundle is inserted in the vapor space, condensing water from the vapor, which again is extracted from the vessel by the use of troughs. As all systems naturally seek equilibrium conditions, water will evaporate from the liquid glycol to restore equilibrium in the vapor phase, thereby concentrating the glycol. The glycol exiting the vessel therefore has a higher purity of glycol than the glycol entering, reaching as high as 99.9 wt% (Comart undated). In the most common applications, rich glycol from the absorber column is used as coolant for the Coldfinger bundle (GPSA (2004)).

As for the Drizo process, the Coldfinger process requires extra equipment added to the regeneration process. In addition to the Coldfinger vessel itself, equipment for processing the extracted water is also needed. The manufacturer (Comart (undated)) claims that 61 000 MMscfd is processed using the Coldfinger process for enhanced glycol regeneration. One of the largest gas processing facilities in Norway, Ormen Lange, exports alone approximately 2 500 MMscfd (StatoilHydro undated), indicating that use of the Coldfinger process also is limited.