Specialized Dehydration Processes

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Specialized Dehydration Processes
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Process
File Reference: CHE20605
For additional information on this subject, contact

R.A. Al-Husseini on 874-2792
Process
Specialized Dehydration Process
CONTENTS
PAGES
OPERATION OF AND EQUIPMENT THAT IS USED FOR

SPECIALIZED DEHYDRATION PROCESSES......................................................... 1
CALCIUM CHLORIDE (CACL2) .............................................................................. 1
Equipment.................................................................................................... 3
Operation .................................................................................................... 4
PRESSURE SWING ADSORPTION (PSA) ................................................................. 5
LOW-TEMPERATURE DEHYDRATION SYSTEMS ..................................................... 6
Low-Temperature Separation With Hydrate Formation ............................. 7
Low-Temperature Separation Without Hydrate Formation (LTS) ............ 11
Refrigeration-Aided Low-Temperature Separation................................... 11
AIR DRYERS ....................................................................................................... 13
Process Flow ............................................................................................. 13
Uses of Dry Air.......................................................................................... 14
Equipment.................................................................................................. 15
Pressure Swing Adsorption ....................................................................... 16
Instrument Air Dryers................................................................................ 17
Instrument Air Filters ................................................................................ 18
ADVANTAGES, DISADVANTAGES, AND APPLICATIONS OF
SPECIAL DEHYDRATION PROCESSES................................................................ 19
CALCIUM CHLORIDE ........................................................................................... 19
Advantages............................................................................................... 19
LOW-TEMPERATURE ........................................................................................... 19
Low-Temperature Separation with Hydrate Formation............................ 19
Disadvantages/Limitations ........................................................................ 20
Disadvantages/Limitations ........................................................................ 20
Process

Applications............................................................................................... 21
Applications............................................................................................... 21
Low-Temperature Separation Without Hydrate Formation ...................... 21
Refrigeration-Aided Low-Temperature Separation................................... 21
PRESSURE SWING ADSORPTION (PSA) ............................................................... 21
ADVANTAGES, DISADVANTAGES, AND APPLICATIONS OF
GLYCOL AND REGENERATIVE SOLID DESICCANT SYSTEMS ..................... 22
GLYCOL (TEG) DEHYDRATION PROCESSES ....................................................... 22
Advantages ................................................................................................ 22
Disadvantages ........................................................................................... 23
Applications............................................................................................... 23
REGENERATIVE SOLID DESICCANT PROCESSES .................................................. 23
Advantages ................................................................................................ 23
Disadvantages ........................................................................................... 24
Applications............................................................................................... 24
COMPARISON OF DEHYDRATION PROCESSES ...................................................... 25
Dew Point .................................................................................................. 25
Capacity .................................................................................................... 25
Cost............................................................................................................ 26
Maintenance .............................................................................................. 26
Materials ................................................................................................... 26
CALCIUM CHLORIDE DEHYDRATORS .................................................................. 27
LOW-TEMPERATURE SEPARATION UNITS ........................................................... 27
GAS PLANT AIR SYSTEMS ................................................................................... 27
GLOSSARY ............................................................................................................... 28
Process
OPERATION OF AND EQUIPMENT THAT IS USED FOR SPECIALIZED

DEHYDRATION PROCESSES
This section covers the operation of and equipment that is used for the following specialized
dehydration processes:
Calcium chloride (CaCl2)

Low-Temperature Dehydration Systems
Pressure swing adsorption (PSA)
Calcium Chloride (CaCl2)

Nonregenerable solid desiccant dehydrators are used to dehydrate natural gas that is produced
by small, remote fields and for offshore retrofits with severe space and weight limitations.
They are also used to dehydrate instrument air. Although many other brines have been
experimented with, most nonregenerable dehydrators use calcium chloride for their solid
desiccants. CaCl2 exists in anhydrous form and in four levels of hydration.
Figure 1 shows how the water content (lb H2O/MMSCF) of natural gas in equilibrium with
solid CaCl24H2O varies with gas pressure and temperature. Similar graphs are available for
the other hydrates: CaCl2H2O, CaCl22H2O, and CaCl26H2O.
Process
1,000
Note:
800
600
400
300
Curves for 120F, 130F, and 140F

are fictitious in that CaCl24H2O does
not exist at temperatures above 113.5F.
However, these extrapolated values at
elevated temperatures are useful for
predicting dehydrator performance.
Humidity, lb H
200
100
80
60
40
30
140
20
120
10
8
110
6
4
3
2
1
10
Source:
130
113.5
90
100
70
80
T=60F
20
40
60
100
200
400 600 1,000
Pressure, psia
2,000
5,000
Dow Chemical in Manning, Francis S. and others, Oilfield Processing of Petroleum, Volume One: Natural Gas;
PennWell Books, Tulsa: 1991; p. 192, Figure 9-24.
FIGURE 1: WATER CONTENT OF NATURAL GAS IN EQUILIBRIUM WITH CaCl24H2O
Process
Equipment
Except for its liquid level controls, calcium chloride dehydrators have no moving parts.
Figure 2 shows the three sections of a calcium chloride dehydrator: separation section, tray
section, and the solid CaCl2 bed section.
Heater
Source:
Gas Dehydration and Hydrate Inhibition; Version 1;

Operations Division; June 1992; p. 100, Figure 41.
Exxon Production Research Company, Production
FIGURE 2: CALCIUM CHLORIDE DEHYDRATOR
Process
Separation Section - As in other types of dehydration systems, the inlet separator removes
free water and other contaminants from the inlet gas. After separation, the inlet gas enters the
tray section above it.
Tray Section - Three to five trays contact concentrated CaCl2 with the process gas. The brine
flows downward and the process gas flows upward. As the brine flows downward, the wet
gas increasingly dilutes it and as the gas flows upward, it is progressively dehydrated. The
trays are specially designed so that the gas velocity is used to recirculate the brine on each
tray. Because very small amounts of brine are formed from large gas volumes, liquid
recirculation is required to obtain good liquid-vapor contact or high tray efficiency.
CaCl2 Bed Section - The top section contains pellets (3/8 in. to 3/4 in.) of CaCl2. The wet
gas rising up from the tray section contacts the pellets. The anhydrous CaCl2 absorbs water in
the process gas and turns into a brine. The brine flows down into the tray section. As the
process gas flows up through the bed it contacts increasingly drier CaCl2.
As the CaCl2 at the bottom of the bed changes to liquid, the rest of the bed settles and takes its
place. Beds with at least 2 ft of CaCl2 pellets provide satisfactory gas dehydration.
In addition to the three sections, Figure 2 shows a heater at the base of the dehydrator. The
heater operates only when the ambient temperature falls below the freezing point of the brine.
Operation
The inlet gas enters the bottom of the dehydrator, rises through the tray section and the bed
section, then returns down the sides of the dehydrator and exits through the outlet. Both the
brine and the solid CaCl2 absorb water from the process gas. Normally, the pressure drop
across the entire unit (trays and bed section) is less than 8 psi.
Process
At typical inlet gas temperatures (80F to 100F), the brine that drips from the CaCl2 bed
section contains about 1 lb of water per lb of CaCl2. In the tray section, this brine absorbs
enough water from the wet gas to dilute it to about 20 wt% to 25 wt% CaCl2. With five trays,
a CaCl2 dehydrator removes about 3.5 lb of water for each pound of CaCl2 consumed.
Maximum dew point depressions of 60F to 70F are achievable. For example, a well
producing 1 MMSCFD of gas at 1000 psig and 80F contains about 34 lb H2O/MMSCF.
Reducing this amount of water to a pipeline specification of 7 lb H2O/MMSCF, requires the
removal of approximately 27 lb H2O/MMSCF. If efficiently used, 7.7 lb of CaCl2 would be
consumed in removing this water. At this rate, a 350-lb drum would last 45 days. Minimum
unit capacity is two drums, or 700 lb. These units are manufactured in capacities up to 10 to
15 MMSCFD and in working pressures up to 3000 psig for wellhead use.
Packed nonregenerable CaCl2 dehydrators are also used in instrument gas-dehydration
services. Dryers are available from a number of suppliers.
Pressure Swing Adsorption (PSA)
Instead of using high temperatures to regenerate solid desiccants, dehydrators that use the
pressure swing adsorption cycle use changes in pressure to regenerate solid desiccants. As
pressure decreases, the adsorption capacity of solid desiccants decreases. Therefore, pressure
swing adsorption dehydrators cycle adsorber towers between high and low pressures. The
only changes in temperature are caused by the heat of adsorption and desorption. The
desiccant adsorbs water at high pressure. The desiccant regenerates at low pressure.
Pressure swing adsorption is commonly used to regenerate molecular sieves in dehydrators
designed to recover high-purity hydrogen from demethanizer off-gases. Saudi Aramco uses
PSA units to dry instrument air (covered later).
Process

When wellhead pressures are high, low-temperature processes efficiently perform the
following tasks:
The dehydration of natural gas streams to pipeline specifications.
The recovery of additional hydrocarbon liquids (condensate) from gas streams.
The separation of hydrocarbon liquids and water from natural gas streams.
If the wellhead pressure exceeds that of the pipeline, then the gas can be passed through a
choke or throttled in a constant-enthalpy Joule-Thomson expansion to provide cooling.
Figure 3 can be used to estimate the magnitude of this Joule-Thomson cooling.
FIGURE 3:
TEMPERATURE DROP ACCOMPANYING A GIVEN

PRESSURE DROP
Process
This section covers the following classes of low-temperature processes:
Systems that intentionally form and melt hydrates

Systems that require the use of hydrate inhibition
Systems that require additional cooling (refrigeration)
Low-Temperature Separation With Hydrate Formation

Cooling wet gases condense the water vapor held by the gas stream. Once condensed, the
water can be removed easily by a separator. Lowering the temperature of natural gas streams,
however, can cause hydrates to form. Low-temperature dehydration systems, therefore, must
either avoid the formation of hydrates or use the formation of hydrates to advantage.
These systems take advantage of the three following properties of hydrates:
Hydrates are less dense than water.

Hydrates are more dense than condensate.
The formation of hydrates extracts water from a gas stream.
Equipment - Low-temperature separation units that use hydrate formation use the following
major components:
Indirect heater (if the inlet gas requires heating)

Low temperature (LTX) separator
High pressure knockout (HPKO)
Inlet gas/sales gas heat exchanger
Choke
Flash separator or stabilizer
Piping and controls
Process
Operation - Figure 4 shows a typical LTX separation unit. The following section describes
the process flow of this system.
Source:
NATCO in Manning, Francis S. and others, Oilfield Processing of Petroleum, Volume One: Natural Gas;
FIGURE 4: LOW TEMPERATURE SEPARATION UNIT (LTX)
If the inlet gas requires heating for use as a heating fluid in the LTX separator, it is heated by
the indirect heater. The inlet gas stream then flows through the hydrate melting coils in the
bottom of the LTX separator. In addition to heating the hydrate melting coils, the gas stream
provides enough heat to prevent the buildup of hydrates and the plugging of the choke located
nearby.
Process
From the hydrate melting coils, the gas stream flows to the HPKO drum. This drum separates
the free liquids from the process gas stream. The temperature drop from the wellbore at the
system temperature condenses some of the water and the heavier hydrocarbons from the
process gas stream. These liquids may be handled in one of the three following ways:
The HPKO removes all liquids (water and condensate) from the process gas. The
HPKO dumps all of the separated liquids into the lower liquid section of the LTX
(as shown in Figure 4).
The HPKO removes all liquids (water and condensate) from the process gas. The
HPKO dumps the water to disposal and feeds the condensate to the lower liquid
section of the LTX separator. This requires that the temperature of the HPKO be
warm enough (about 100F) to inhibit the formation of hydrates in the liquid dump
valves.
The HPKO removes only water from the process stream. The process gas and the
condensate both pass through the choke.
From the HPKO, the process gas flows through the tube side of the inlet gas/sales gas heat
exchanger. This exchange cools the process gas to the coldest temperature that will not cause
the formation of hydrates on the upstream side of the choke. This low temperature ensures
the lowest separation temperature in the LTX separator and the maximum recovery of
hydrocarbon liquids. To maintain the lowest safe temperature in the heat exchanger, a threeway valve controls the flow of the sales gas through the heat exchanger.
The inlet gas/sales gas heat exchanger also warms the sales gas before it enters the sales
pipeline. Warming the sales gas prevents the cooling of the gas in the sales pipeline to a point
below its hydrate formation temperature.
From the inlet gas/sales gas heat exchanger, the process gas flows through the choke. The
choke expands the gas from the wellbore pressure to the salesline pressure. The choke can
be used to regulate either the flow rate of the process gas or the pressure in the low
temperature separator. The expansion of the process gas in the choke condenses most of the
water and some of the hydrocarbon gas. This expansion also causes hydrates to form in the
choke, but sonic flow breaks them up and carries them into the LTX separator. This flow of
broken up hydrates sounds like pellets entering the LTX vessel.
The liquid, vapor, and solid stream that leaves the choke tangentially enters a cylindrical
spinner box. A tangential entry absorbs inlet momentum, directs the process stream onto the
hydrate melting coils, and helps to separate the vapor from the liquid.
Process
The hydrate melting coils in the bottom of the LTX separator heat the condensate to 65F to
75F and heat the water to a temperature 15F to 20F hotter than the condensate. Therefore,
the condensate remains the top liquid layer while the hydrates sink through the condensate.
The hydrates float on the layer of liquid water, but beneath the condensate, at the bottom of
the LTX separator. As the liquids flow through the LTX separator toward the liquid outlets,
the hydrates decompose (melt).
Figure 5 shows the temperatures and layers of liquids in a horizontal LTX separator.
Source:
Mapes in Manning, Francis S. and others, Oilfield Processing of Petroleum, Volume One:
PennWell Books, Tulsa: 1991; p. 190, Figure 9-20a.
Natural Gas;
FIGURE 5: HORIZONTAL LTX SEPARATOR
If the choke pressure drop is barely adequate, then the HPKO is generally placed ahead of the
inlet gas/sales gas heat exchanger. On the other hand, the placement of the HPKO
downstream from the inlet gas/sales gas heat exchanger allows the removal of additional
liquids, feeds the liquid-free gas to the choke, and generates the lowest expansion
temperatures in the choke.
10
Process
Low-Temperature Separation Without Hydrate Formation (LTS)

Low-temperature separation units without hydrate formation are similar to LTX separation
units. However, in LTS systems the inlet gas/sales gas heat exchanger cannot cool the inlet
gas below its hydrate-formation temperature. Therefore, the available pressure drop from the
inlet gas pressure to the sales gas pressure controls the resulting temperature in the lowtemperature separator (LTS).
When this Joule-Thomson cooling cannot achieve the required gas dehydration, then the inlet
gas requires additional cooling before it enters the choke. Because this additional cooling
lowers the temperature of the gas stream below its hydrate-formation temperature, a system
that requires additional cooling also requires the use of hydrate inhibition (covered in
ChE 206.02).
Refrigeration-Aided Low-Temperature Separation
External refrigeration is required when the combined cooling of the gas-to-gas exchanger and
any Joule-Thomson expansion is insufficient to achieve the desired water and hydrocarbon
dew points. Figure 6 shows an LTS separation unit that uses mechanical refrigeration to
supply the required additional cooling.
11
Process
Source:
NATCO in Manning, Francis S. and others, Oilfield Processing of Petroleum, Volume One: Natural Gas;
FIGURE 6: SIMPLIFIED FLOW IN A REFRIGERATION-AIDED LOW-TEMPERATURE

SEPARATION UNIT
In Figure 6, the system injects glycol into the inlet gas stream ahead of the inlet gas/sales gas
heat exchanger. The chiller then supplies the required additional cooling to condense the
water and heavier hydrocarbons in the process stream. In this example, the process gas enters
the chiller at about 50F and leaves it at about -20F. This temperature and the other
temperatures shown in Figure 6 are typical, but operating temperatures vary with different
applications.
After the chiller, the cold separator separates the process fluid into dry gas, hydrocarbon
liquids, and water (mixed with glycol). The system then pipes the dry gas to the sales line, the
glycol-water solution to the glycol reboiler, and the condensate to the stabilizer. The glycol
reboiler reconcentrates the glycol. The stabilizer separates the condensate into overhead gas
and natural gas liquids.
12
Process
Air Dryers
Saudi Aramco gas plants use air for many purposes and produce the three following classes of
air:
Instrument air
Plant air
Process air
Process Flow
Figure 7 shows the flow of air through a Saudi Aramco gas plant air system. The air enters
the compressors and coolers from the atmosphere. From the compressors, the air enters the
compressed air receivers. After the receivers, the system diverts instrument air from the
process and plant air for further processing. The system then cools, prefilters, dries, and
afterfilters the instrument air.
Air
Process and plant air
Air compressor
and coolers
Air compressor
and receivers
Auxiliary
after- cooler
Instrument
air prefilters
Instrument
air dryers
Instrument
air afterfilters
Instrument
air
FIGURE 7: PROCESS FLOW OF SAUDI ARAMCO GAS PLANT AIR SYSTEM
13
Process
Uses of Dry Air

Plant Air and Process Air - Gas plants use plant air to run air-operated equipment and for
many jobs in different areas of the gas plant. Dry air is preferred for all uses. Wet plant air
can cause corrosion in piping and damage equipment and tools. Also, a small amount of
instrument air is used to keep the flame scanners of fired heaters and boilers clean. Process
air is also used to regenerate Merox catalysts.
Instrument Air - Gas plants use instrument air to operate many of their instruments. To keep
operating, gas plants require that instrument air be available at all times.
Each type of air must be clean, but instrument air must be very clean and very dry. Dirty air
can cause equipment damage. Moisture in instrument air damages instruments and can cause
erratic instrument readings.
14
Process
Equipment
Figure 8 shows the flow of air through the filters and the dryers. The prefilters remove
particles too small to be removed by the intake filters. The afterfilters remove any desiccant
picked up by the air in the dryer.
Vent to
atmosphere
Drain
FIGURE 8:
SAUDI ARAMCO GAS PLANT AIR SYSTEM PROCESS FLOW THROUGH AIR
DRYER
As with solid desiccant dehydrators that dry natural gas, the drying of air requires at least two
drying vessels. While one vessel dries the instrument air, dry instrument air regenerates the
other vessel. These Saudi Aramco systems use activated alumina and silica gel for their solid
desiccants.
15
Process
Pressure Swing Adsorption

Saudi Aramco also uses air dryers that use pressure swing adsorption to regenerate their solid
desiccants. Saudi Aramco uses these heatless dryers to dry instrument air in new facilities.
Figure 9 shows a pressure swing adsorption (heatless) regenerative air dryer.
Source: Van Air Systems, Inc.; Regenerative Compressed Air dryers; Lake City, PA; p. 6.
FIGURE 9:
PRESSURE SWING ADSORPTION (HEATLESS) REGENERATIVE AIR DRYER
16
Process
The operation of this dryer is similar to that of other solid desiccant dehydrators. While one
tower dries the air, the other tower is regenerating. Valves at the top and bottom of the
dehydrator direct inlet and product air through the towers. Wet, inlet air flows up thorough
one tower while a portion of the dry, product air flows down through the other.
In Figure 9, the pressure of the inlet air ranges from 60 psig to 150 psig and the dry air used
for regeneration is at atmospheric pressure. At the higher pressure, the desiccant adsorbs
water from the inlet air. At the lower pressure, the dry air strips water from the desiccant and
regenerates it. As with other solid desiccant systems, either timers or moisture analyzers can
be used to control cycle times. The dehydrator in Figure 9 uses activated alumina for its
desiccant.
The following specifications on instrument air dehydration are covered in Saudi Aramco
Engineering Standard SAES-J-901.
Instrument Air Dryers
Dryers shall be supplied to deliver dry air to the air system at a maximum dew point of -4F at
system pressure (75 to 125 psig). The maximum air inlet temperature, inlet flow rate, and
inlet pressure range shall be clearly stated to vendors for correct sizing of desiccant chambers.
Dryers shall be heatless regeneration, desiccant type. Refrigeration type dryers shall not be
used.
Dryers shall be automatic cycle type using two desiccant chambers. An inline continuous
moisture indicator shall be provided in the dryer discharge. One chamber regenerates while
the other chamber adsorbs moisture from the air. Regeneration shall consume less than 20%
of the total air capacity. This consumption shall be included in the system air requirements.
The desiccant shall be a type that does not disintegrate upon contact with water. Activated
alumina is preferred.
Pneumatic cycle timers and switching valves are to be used only in areas where electronic
power is not available.
17
Process
Instrument Air Filters

Instrument air shall be filtered before entering the air dryer. The filters shall be of the
coalescing type, capable of removing entrained droplets of oil or water, and dust or other
foreign matter down to a particle size of a one micrometer absolute. Filters are to be fitted
with automatic drains.
All desiccant type dryers shall be provided with an afterfilter capable of removing 100% of all
particles one micrometer absolute or larger to prevent desiccant dust entering the downstream
system.
The pressure drop caused by the drying and filtering equipment when it is clean shall not
exceed 5 psi at maximum flow rates.
18
Process
ADVANTAGES, DISADVANTAGES,
DEHYDRATION PROCESSES
AND
APPLICATIONS
OF
SPECIAL
This section covers the advantages, disadvantages, and applications of the following
specialized dehydration processes:
Calcium chloride (CaCl2)

Pressure swing adsorption (PSA)
Calcium Chloride
Advantages
Calcium chloride dehydrators have the following advantages:
Can operate unattended until they require fresh desiccant

Contain few moving parts
Do not require fuel or heat to operate
Have low capital costs
Present no fire hazard
Very compact
Low-Temperature
Low-Temperature Separation with Hydrate Formation
Advantages
Because of minimal energy consumption, these units have low operating costs.
These units experience minimal corrosion, especially when they do not use hydrate
inhibitors.
With adequate wellhead pressure, these units can achieve pipeline specification for
water and hydrocarbon dew points.
19
Process
Calcium Chloride
Disadvantages/Limitations
Calcium chloride dehydrators have the following disadvantages or limitations:
CaCl2 solutions are highly corrosive in the presence of air.
Even with five trays, 1 lb of CaCl2 removes only 3.5 lb of H2O.
The CaCl2-H2O equilibrium limits the dew point depression they can achieve.
They are subject to bridging, which normally causes channeling.
Bridging is the joining or fusing (freezing) of adjacent CaCl2 pellets in the desiccant bed.
Intermittent or cyclic operation of a calcium chloride dehydrator is the most common cause of
bridging. The following situations can cause bridging:
A slight temperature drop freezes the brine that drips off the CaCl2 pellets. This
fuses the pellets.
The dehydrator is removed from service, left idle, and returned to service. While
the dehydrator is idle, a slight temperature drop causes the CaCl2 pellets to fuse
together.
Wet gas or free water contacts the bed, forms more brine, and intensifies an
existing bridging condition.
Low Temperature
Disadvantages/Limitations
Low temperature systems have the following disadvantages or limitations:
The addition of a hydrate inhibition system increases both its capital and operating
costs.
The addition of mechanical refrigeration increases both its capital and operating
costs.
They require adequate wellhead pressure, otherwise they are unable to function
properly.
20
Process
Calcium Chloride
Applications
Generally, calcium chloride dehydrators are used to dry small volumes of natural gas that are
gathered from wells located in remote areas. CaCl2 dehydrators are particularly useful for
wells located in areas in which the terrain, climate, or other conditions make servicing
expensive. CaCl2 dehydrators are also useful for offshore retrofits with severe space and
weight limitations.
Low Temperature
Applications
Low-temperature separation systems are generally selected for wells producing sweet gas
with wellhead pressures considerably higher than pipeline pressure.
Low-Temperature Separation Without Hydrate Formation
These systems cannot cool the process gas below its hydrate-formation temperature.
Therefore, these systems require a greater pressure drop from the well to the separator or the
aid of mechanical refrigeration. The addition of a hydrate inhibition system increases both its
capital and operating costs.
Refrigeration-Aided Low-Temperature Separation
Mechanical refrigeration can make up for an inadequate pressure drop from the well to the
separator. However, the addition of mechanical refrigeration increases both its capital and
operating costs.
Pressure Swing Adsorption (PSA)
Because PSA systems do not require heat, they are more easily installed than systems that use
heat to regenerate solid desiccants. However, the venting and low-pressure purging of the
regeneration gas produces greater losses.
Pressure swing adsorption is used to regenerate molecular sieves in dehydrators that are
designed to recover high-purity hydrogen from demethanizer offgases. These systems
generally produce very high purities of hydrogen, but they recover only about 70% of the
hydrogen in the gas stream. However, the remaining gas can be used for fuel gas.
21
Process
ADVANTAGES, DISADVANTAGES, AND APPLICATIONS OF GLYCOL AND

REGENERATIVE SOLID DESICCANT SYSTEMS
This section covers the advantages, disadvantages, and applications of the following
dehydration processes:
Glycol
Regenerative solid desiccant
Glycol (TEG) Dehydration Processes

Advantages
Glycol dehydration systems using TEG have the following advantages:
Can dehydrate natural gas to 0.5 lb H2O/MMSCF (0.25 lb H2O/MMSCF in

special applications).
Dehydrates natural gas continuously.

process).
Easily automated for unattended operation in remote locations.
Operate effectively in the presence of materials that would foul solid desiccant
dehydrators.
Lower installed costs than solid desiccant dehydrators for smaller plants (Solid
desiccant plants cost about 50% more for 10-MMSCFD applications and about
33% more for 50-MMSCFD applications.)
Lower pressure drop: 5 psi to 10 psi for glycol dehydrators versus 10 psi to 50 psi
for solid desiccant dehydrators.
Lower utility costs: glycol units require less regeneration heat per pound of water
removed than solid desiccant dehydrators.
Simple to operate and maintain.
(Solid desiccant dehydration is a batch
22
Process
Disadvantages
Glycol dehydration systems using TEG have the following disadvantages and limitations:
Dehydrating gases to dew points below -25F requires the use of a stripping gas
and column.
Glycol is susceptible to contamination.
When contaminated or decomposed, glycol is corrosive.
Glycol is susceptible to foaming.
Applications
TEG dehydrators are by far the most common system for dehydrating natural gas. TEG
dehydrators are used unless the conditions listed under the other dehydration systems are
present.
Regenerative Solid Desiccant Processes
Advantages
Regenerative solid desiccant dehydrators have the following advantages:
Achieve dew points as low as -150F [1 ppm(vol)].
Small changes in gas pressure, temperature, or flow rate affect them less than other
dehydrators.
They are less susceptible to corrosion and do not foam.
23
Process
Disadvantages
Solid desiccant dehydrators have the following disadvantages or limitations:
High regeneration heat requirements and high utility costs.
High space and weight requirements.
Higher capital costs.
Higher pressure drops.
Solid desiccants are susceptible to crushing and other mechanical breakage.
Solid desiccants are susceptible to desiccant poisoning by heavy hydrocarbons,

H2S, CO2, and other contaminants.
Applications
Solid desiccant dehydrators are generally used for the following applications:
The dehydration of natural gas to dew points low enough for cryogenic processing
(below -30F).
The dehydration of natural gas to pipeline specifications (4 to 7 lb H2O/MMSCF

or water dew points of 10F to 30F) when TEG is not effective. For example,
desiccant dehydrators are used to dehydrate sour gas and aboard floating
production platforms, where wave action disturbs glycol flow on the contactor
trays.
To recover hydrocarbon liquids from lean (0.5 GPM C3+ or less) natural gas (often
with refrigeration).
To simultaneously remove water and hydrocarbons to meet both water and

hydrocarbon dew points.
24
Process
Comparison of Dehydration Processes

This section compares the dehydration processes on the basis of the following factors:
Dew Point
Capacity
Cost
Maintenance
Materials
Dew Point
All of the dehydration processes discussed in this module can meet natural gas pipeline
specifications (7 lb H2O/MMSCF). With the use of a stripping gas, TEG systems can
dehydrate natural gas streams to 0.5 lb H2O/MMSCF. Solid dessicants that use molecular
sieves can dehydrate natural gas streams to 1 ppm(vol) of water.
Capacity
Solid desiccant dehydrators most efficiently dehydrate the largest capacities of natural gas.
Calcium chloride dehydrators efficiently dehydrate natural gas gathered from small wells in
remote areas.
25
Process
Cost
Figure 10 summarizes and compares the relative operating costs of dehydration processes.
DEHYDRATION
PROCESS
CAPITAL COSTS
OPERATING COSTS
Calcium Chloride
Low
High
Glycol
Moderate
Moderate
Low Temperature
Moderate
Solid Regenerative
Desiccant
High
Low
(Moderate to High if
Refrigeration is Used)
High
FIGURE 10: COMPARISON OF CAPITAL AND OPERATING COSTS OF DEHYDRATION

PROCESSES
Maintenance
None of the dehydration processes discussed in this module require a lot of maintenance.
Calcium chloride dehydrators periodically need to be reloaded with solid desiccant. Because
of the high cost of replacing the contaminated desiccant, solid desiccant dehydrators require
more monitoring than the other dehydration processes. Also, for efficient operation, the
drying cycles of solid desiccant dehydrators that do not use moisture analyzers for control
require periodic adjustment.
Materials
Only nonregenerative dehydrators need a constant supply of materials. Glycol dehydrators
require periodic additions of glycol to replenish losses. Solid desiccants need large
investments in desiccant when they are started, but do not require replenishment until the
desiccant bed can no longer economically dehydrate natural gas. Except for calcium chloride
dehydrators and solid desiccant dehydrators that use pressure swing adsorption, all of the
dehydration processes require continuous supplies of fuel or heat. Solid desiccant
dehydration systems need additional piping and instrumentation to control the
adsorption/regeneration sequence.
26
Process
Calcium Chloride Dehydrators

Calcium chloride dehydrators have separation, tray, and solid CaCl2 bed sections. The
separation section uses an inlet separator to remove free water and other contaminants. The
tray section uses three to five trays to contact the process gas and the CaCl2 brine (20 wt % to
25 wt % CaCl2). The design of the trays maximizes contact between the brine and the
process gas. The bed contains solid CaCl2 pellets that adsorb water from the process gas.
The water and solid bed form brine that flows down into the tray section.
Calcium chloride dehydrators are simple and can operate unattended. They dry natural gas to
pipeline specifications and have low capital costs. For these reasons, calcium chloride
dehydrators are used to dehydrate small volumes of natural gas produced by wells located in
remote areas. They are also useful for offshore retrofits with severe space limitations.
Low-Temperature Separation Units
Low-temperature separation units dehydrate natural gas streams by expanding the natural gas
from well head pressure to pipeline pressure. The Joule-Thomson expansion of the gas cools
the gas and condenses the water in it. It may also cause the formation of hydrates. A
separator removes the hydrate or the free water from the process stream.
Low-temperature separation units have low operating costs. With adequate wellhead
pressure, they can dry gases to pipeline specifications. However, the addition of hydrate
inhibition or mechanical refrigeration systems increases the capital and operating costs of
these systems. Therefore, low-temperature separation units work best for high-pressure wells
that produce sweet gas.
Gas Plant Air Systems
Plants typically produce two classes of air: instrument and plant/process air. Instrument air
must be very clean and very dry. Plant air is used to run air operated equipment, process air is
used in chemical processes, and instrument air is used to operate instruments.
Air enters the compressors and coolers from the atmosphere. From the compressors, the air
enters the air receivers. After the receivers, part of the air goes to the instrument air for
further filtering and drying. The remainder of the air is available for use as plant or process.
Saudi Aramco gas plants use two-tower solid desiccant dehydration systems to dry air. The
system uses both activated alumina and silica gel. In new facilities, Saudi Aramco use
pressure-swing adsorption dehydrators to dry instrument air.
27
Process
GLOSSARY
HPKO
High pressure knockout.
inlet gas
Feed gas to a processing plant.
instrument air
Dry, compressed air used to operate pneumatic instruments

and instrumentation.
LTS
Low temperature separation unit that does not use hydrate

formation.
LTX
Low temperature separation unit that uses hydrate formation.
LTX separator
Low temperature separator used in low-temperature separation

units.
Merox
A caustic treating process developed and licensed by UOP for

mercaptan extraction and sweetening of light and middle
boiling range distillates.
plant and processor

air
Compressed air used in plants to run air-operated equipment

and other uses.
process gas
See inlet gas.
28

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