Production of LPG From Natural Gas

CHAPTER 2

PROJECT DESCRIPTION

The important steps in the LPG production from Natural gas are:
 Natural gas coming from the source at high pressure is first dried in molecular
sieve dryers.
 The gas is chilled to around -40oC C using external propane refrigeration package.
 At each of the two stages of chilling there are separators to collect the condensed
liquids from the gas.
This liquid need to be fractionated to take the light ends (C1 and C2) out to
meet the LPG specifications. LPG and C5s (NGL) are also separated by the fractionation
system. Generally, this is done in a series of two fractionating columns. By an appropriate
combination of external refrigeration and turbo-expander process, very low temperatures
can be obtained. The choice of the process depends on various factors like:
 Pressure of the gas
 Temperature to which the gas need to be chilled and components to be recovered
 Pressure requirement of the outgoing gas by the customer.

2.1 USES & PRESENT STATUS OF THE PRODUCT:

2.1.1 Rural heating
Predominantly in Europe and rural parts of the United States, LPG can provide an
alternative to electricity and heating oil (kerosene). LPG is most often used where there is
no access to piped natural gas.

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 Production of LPG From Natural Gas

2.1.2 Motor fuel

When LPG is used to fuel internal combustion engines, it is often referred to as auto
gas or auto propane. Two recent studies have examined LPG-fuel-oil fuel mixes and found
that smoke emissions and fuel consumption are reduced but hydrocarbon emissions are
increased.

2.1.3 Refrigeration

LPG is instrumental in providing refrigeration, usually by means of a gas absorption

refrigerator. Blended of pure, dry propane and iso-butane the blend has negligible ozone
depletion potential and very low global warming potential and other chlorofluorocarbon in
conventional stationary refrigeration and air conditioning systems.

2.1.4 Cooking

According to the 2001 Census of India, 17.5% of Indian households or 33.6 million
Indian households used LPG as cooking fuel in 2001, which is supplied to their homes by
Indian Oil which is known as Indane. 76.64% of such households were from urban India
making up 48% of urban Indian households as compared to a usage of 5.7% only
in rural Indian households.

2.1.5 Industrial uses

a) Food Processing: Mainly used in bakeries, since LPG does not pose a risk of
contamination, it is used in the making of chips and biscuits.

b) It is also used in the metallurgical industry where the heat treatments are preferably
conducted in a controlled atmosphere. It is flexible in use and also offers comparably lower
maintenance costs.

c) LPG is also used in the sanitary ware industries. Apart from this, it is also used in
pottery and ceramic tiles industries. It is easily controllable and offers a cleaner
combustion.

2.1.6 FURTHER COMMERCIAL USES

2.1.6.1 Metal Cutting: Provides stable high temperature required for the purpose.
2.1.6.2 Kiln and Furnaces: Used In incinerators, ceramic and brick kilns.

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 Production of LPG From Natural Gas

2.1.6.3 Process Industries: Extensively used in Glass, automobile and textile industries
for glass blowing, paint drying/ surface coating. Also used by Electronics industry
involved in TV picture tube manufacturing etc.
2.1.6.4 Poultry: Used in Poultry rearing with accurate temperature controls.
2.1.6.5Aerosol: Used as a propellant in aerosol cartridges.

2.1.7 Agriculture uses

LPG offers farmers an extremely adaptable source of power; in fact no other fuel
solution offers the same levels of portability, accessibility and convenience of use. Because
it is a clean fuel, liquid petroleum gas ensures that farmers can meet the demands of
modern agricultural environment. Specific examples of LPG’s contribution on the farm
include: Poultry Rearing and Grain and fruit drying

2.1.8 Transport sector

On the trading level, we distinguish three LPG products in Algeria: the commercial
propane, the commercial butane and the LPG. Commercial propane and commercial
butane are marketed either in bulk, or in conditioned form.

2.2 Present status of the product

Domestic growth is 8‐9% but overall pie has reduced over the years. Commercial &
Industrial Consumption is increasing. World Consumption in Industrial Sector is almost
11% & in Transport is 9%.

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 Production of LPG From Natural Gas

Figure2.1 Increasing demand of LPG

Fig. 2.2 comparison of fuels emission

2.2.1 Global LPG demand

For 2010-14, Purvin & Gertz expects that additions to LPG supply will outpace the
growth in base demand, thus requiring more surplus LPG to be absorbed by the

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 Production of LPG From Natural Gas

petrochemical industry. Total LPG supply will likely grow by nearly 3.4%/year through
2014, but LPG base demand is likely to grow at only a 3.0%/year in the same period. Total
demand should reach about 260 million tonnes by 2014.

2.2.1.1 US, Canada

Overall LPG production in the US and Canada region declined by about 2.5%
2009-10 to about 55 million tonnes. Even with the 2010 dip in production, the region
consisting of the US and Canada remained the largest LPG producing region in the world,
with about 23% of global supply. LPG production in the US and Canada should increase to
about 57.7 million tonnes in 2014, driven by shale-related production in the US and an
increase in refinery production in the region as the economy improves.

2.2.1.2 Middle East

The Middle East is the world’s largest LPG exporting region and the second largest
LPG producer after the US-Canada. The Middle East produced about 51.9 million tonnes
of LPG in 2010, which was nearly 22% of global production. In the Middle East, about
75% of LPG production comes from associated gas and refineries. LPG production in the
Middle East increased by about 12.6% in 2010.Saudi Arabia is by far the largest producer
in the region, with about 21.0 million tonnes of LPG production in 2010.LPG production
in the Middle East should reach about 67.7 million tonnes by 2014, making the Middle
East the largest production region in the world.

2.2.1.3 Africa
Africa stands out as the world’s second largest net exporting region after the Middle
East. LPG production stood at about 16.9 million tonnes in 2010. Demand in Africa
increased by about 1.0 million tonnes over the same period to about 11.2 million tonnes,
resulting in declining net exports. Egypt is a major LPG producer (2.1 million tonnes in
2010) but is also a major LPG importer, at about 2.3 million tonnes in 2010. Tunisia is a
small producer that is also net short of LPG.
2.2.1.4 Northeast Asia
Northeast Asia is a remarkably diverse market for LPG. China produced about
69% of the LPG in the region in 2010, and nearly all of the region’s production growth was

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 Production of LPG From Natural Gas

in China. Base demand in northeast Asia increased by 1.9% 2009-10 driven mainly by an
increase in residential-commercial demand and a rebound in industrial demand after the
recession. China’s base demand surpassed Japan’s in 2006 and accounts for about 44% of
the 2010 regional total of 47.3 million tonnes.

2.2.1.5 Indian subcontinent

On the Indian subcontinent, LPG production rose by about 0.3 million tonnes to
10.6 million tonnes in 2009-10. India’s market dominates the region, with around 94% of
production and 92% of demand. More than 70% of LPG production is from refineries. Due
to increasing refinery output, Purvin & Gertz expects regional LPG production to increase
to about 11.9 million tonnes by 2014. About 96% of the region’s total LPG consumption is
residential-commercial demand. With a large, rapidly developing population and the lowest
regional per-capita residential-commercial consumption of LPG in the world, the Indian
subcontinent has great potential to expand LPG demand. Purvin & Gertz expects demand
to grow to 16.9 million tonnes by 2014 from 14.2 million tonnes in 2010.

2.3 BRIEF DESCRIPTION OF THE AVAILABLE PROCESSES FOR

THE PRODUCTION OF THE DESIRED PRODUCT:

2.3.1 AVAILABLE PROCESSES

There are two main sources of LPG. These are:
2.3.1.1 Extraction of LPG from natural gas, and
2.3.1.2 Refining of crude oil.

Extraction of LPG from natural gas

2.3.1.3 Re-contacting-Compression,
2.3.1.4 Refrigeration,
2.3.1.5 Absorption, and
2.3.1.6 Adsorption.

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 Production of LPG From Natural Gas

2.3.2 Brief Description

2.3.2.1 Extraction of LPG from crude oil

Distillation is the first step in the processing of crude oil and it takes place in a tall steel
tower called a fractionation column. The inside of the column is divided at intervals by
horizontal trays. The column is kept very hot at the bottom (the column is insulated) but as
different hydrocarbons boil at different temperatures, the temperature gradually reduces
towards the top, so that each tray is a little cooler than the one below. The crude needs to
be heated up before entering the fractionation column and this is done at first in a series of
heat exchangers where heat is taken from other process streams which require cooling
before being sent to rundown.

As the raw crude oil arriving contains quite a bit of water and salt, it is normally
sent for salt removing first, in a piece of equipment called a desalter. Vapors are directly
sent to the fractionation column. At about 200 - 280 0C the crude enters the furnace where
it is heated up further to about 330 -370 0C. The furnace outlet stream is sent directly to the
fractionation column. When each fraction reaches the tray where the temperature is just
below its own boiling point, it condenses and changes back into liquid phase. At the outlet
of the overhead condensers, at temperature about 40 0C, a mixture of gas, and liquid
naphtha exists, which is falling into an overhead accumulator. Gases are routed to a
compressor for further recovery of LPG (C3/C4), while the liquids (gasoline) are pumped
to a hydro treated unit for sulfur removal. Unfortunately, a lot of the heat provided by the
furnace to vaporize hydrocarbons is lost against ambient air in the overhead fin-fan
coolers. A clever way of preventing this heat lost of condensing hydrocarbons is done via
the circulating refluxes of the column. In a circulating reflux, a hot side draw-off from the
column is pumped through a series of heat exchangers, where the stream is cooled down.
The cool stream is sent back into the column at a higher elevation, where it is been brought
in contact with hotter rising vapors. The main objective of a circulating reflux therefore is
to recover heat from condensing vapors. An additional advantage of having circulating
refluxes is that it will reduce the vapor load when going upwards in the column. This
provided the opportunity to have a smaller column diameter for top sections of the tower.

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 Production of LPG From Natural Gas

The lightest side draw-off from the fractionating column is a fraction called kerosene,
boiling in the range 160 - 280 0C. The second and third (optional) side draw-offs from the
main fractionating column are gasoil fractions, boiling in the range 200 - 400 0C, which are
ultimately used for blending the final diesel product. At the bottom of the fractionation
column a heavy, brown/black colored fraction called residue is drawn off.

Fig 2.3 crude oil distillation

2.3.2.2 Re-Contacting-Compression

The overhead vapor product from the fractionators (a) is compressed to 1.2 –
1.5MPa (c) and combined with the liquid top product, as shown in Figure 2.4. The
combined stream is cooled to 40oC by air or water and directed to the separator (e).
Because of the higher pressure, more LPG is obtained in the liquid phase of the separator
than in the liquid phase in the overhead accumulator vessel (b) of the fractionators.
Components heavier than butane are also recovered from the fractionators vapor top
product by re-contacting. The liquid phase from the separator passes through a de-
ethanizer (f), from which the vapor product is recycled to the separator to improve LPG
recovery. The vapor phase from the separator, which still contains some LPG, is used as

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 Production of LPG From Natural Gas

fuel gas. The liquid product from the De-ethanizer is LPG, which may be further separated
into propane and butane products in a de-propanizer

2.2.2.3 Refrigeration

The objective of this process is to recover LPG (liquefied petroleum gases) with a
fixed mass fraction of methane & ethane, from a gas mixture. The main LPG components
are hydrocarbons (mainly in the C3-C4 range), propane and butane.
LPG Recovery unit consists of following sections
 Feed gas compression & Pre cooling
 Feed gas drying & Regeneration
 Chill down & Expansion
 Fractionation
 Lean gas compression
 Propane Refrigerant system.

2.2.2.4 LEAN OIL ABSORPTION

The lean oil absorption process employs a hydrocarbon oil to recover light
components from either a natural gas or a refinery fuel gas stream.

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 Production of LPG From Natural Gas

Fig.2.5 oil absorption plant

a) Fractionators b) Overhead accumulator vessel c) Compressor d) Deethanizer e) Aborber
column

An example of refinery lean oil absorption scheme is shown in Figure 2.5. The
fractionators overhead vapour stream is compressed and combined with the liquid top
product. The combined stream is then de-ethanized, and the vapour top product of the de-
ethanizer is brought into contact counter currently with the absorption oil in the absorber
column. The oil absorbs propane and butane components from the gas, replacing them with
fewer molecules of the absorber oil. The oil is taken from the main fractionation column
(a), pre saturated with vapour from the absorber column, chilled to 10 – 15 C, and fed to
the absorber column as lean oil. Pre saturation and chilling of the lean oil improve LPG
recovery in the absorber. The remaining vapour phase is directed to the fuel gas line. So-
called rich oil from the bottom of the column, which contains absorbed LPG, is recycled to
the main fractionation column to complete the oil circuit. There the LPG is stripped from
the rich oil and passed overhead to the deethanizer. The liquid product from the de-
ethanizer is routed to a fractionation column where the propane and butanes are separated.

2.2.2.5 ADSORPTION

In adsorption, gas molecules are reversibly bonded to the surface of a solid

material, the adsorbent. Examples of adsorbents include silica gel, activated carbon, and
alumina. Adsorption plants are generally used to obtain natural gasoline from natural gas to
satisfy sales gas specifications for heavy hydrocarbon content.

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 Production of LPG From Natural Gas

Fig.2.6 Schematic of Adsorption plant

a)-c) Adsorber d) Compressor e) Furnace f) cooler g) Separator h) Filter

The LPG recovery is significantly lower than that achieved by refrigeration or lean
oil absorption processes. A typical adsorption flow scheme is presented in Figure 2.6.
Three vessels are shown, each containing the solid adsorbent. The process is cyclical with,
at any one time, one vessel on adsorption, one on regeneration cooling, and one on
regeneration heating. The inlet gas passes through a bed (a) where heavy hydrocarbons are
adsorbed. A slipstream of the inlet gas is compressed and used to cool another bed (b),
which has previously been heated to remove adsorbed hydrocarbons.
Once this bed is cooled, it is placed on standby ready to be put into adsorption
service. Gas leaving this bed (b) is heated to ca. 300 •C in a furnace (e) and directed to
another bed (c) to remove adsorbed hydrocarbons. Heavy hydrocarbons present in the
regeneration gas leaving this bed (c) are recovered after cooling in a separator (g), from
which the remaining gas is returned upstream of the initial bed (a). Liquid removed from
the regeneration gas, consisting of natural gasoline and some LPG components may be
processed further by fractionation to yield separate LPG and natural gasoline products.
Whichever method is used to obtain LPG from natural gas or refinery fuel gas, LPG maybe
produced as a mixed product or as separate propane called C3 product, and butane called
C4 product. The relative quantities of saturated and unsaturated species depend on the
types of processes in the refinery that are responsible for LPG production.
2.4 TECHNO-ECONOMIC APPRAISAL OF ALTERNATIVE
PROCESSES/SCHEMES:

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 Production of LPG From Natural Gas
PROCESS COMPARISION
PROCESS ADVANTAGES DISADVANTAGES
Crude oil distillation  Best possible
separation.
Re-contacting –  Recovery is about
compression 75 %
Refrigeration  Heat losses are too
low.
 Simple in process.
 Low pressure drop.
 LPG recovery > 99%
 High purity.
 Less environmental
problems.
 Handling is easy
Lean oil absorption  Recovery 85-90%.
 Less environmental
problems.
Table 2.1 Comparison of various process schemes
2.5 STATUS OF TECHNOLOGIES/SCHEMES AVAILABLE:
15
 Highly sensitive
operation.
 Less purity of LPG
is obtained.
 Highly prone to
hazard.
 Cost ineffective.
 High energy cost.
 Somewhat complex
process.
 High pressure drops.
 There can be
freezing problems in
cold section.
 High production
cost.
 Maintenance cost is
high.
 Production of LPG From Natural Gas

Cryogenic plants
The Burgos project involved building six cryogenic plants. The plants recover
natural gasoline, propane and butane from natural gas extracted from the basin. After the
first two plants began operations in 2004, Pemex started to construct two more cryogenic
modular plants, each with a capacity of 200 million cubic feet, to expand the capacity.
These opened in 2006.
Fourth largest consumer of LPG in the world after USA, China & Japan
_ Third largest consumer in domestic sector in the world after China & USA
_ Major market of LPG is Domestic Sector
_ Home Delivery of 3 Million LP Gas cylinders per day (i.e900 Million/ year)
_ Steady Growth @ 8% p.a. in LPG Consumption in India

Liquefaction, LNG, and cryogenics are both a complex topic and an area
intrinsically linked to the broader gases in refinery subject. Cryogenics is the technology of
“cold”, including liquefaction, refrigeration, storage, handling and applications of
cryogenic liquids .Until about 50 years ago, around 1959, cryogenics was largely
concerned with air component gases in liquid form. These trials heralded the gigantic
changes in the energy markets which have taken place since then. Very soon, the technical
problems of storing and handling large quantities of LNG at around 112 to 120 K (-161 to
-153°C) started to appear, and the cryogenics industry rapidly became involved with these
problems as well as with developing the highly efficient, mixed refrigerant liquefaction
cycle.

2.6 SELECTION OF TECHNOLOGY/SCHEME:

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 Production of LPG From Natural Gas

2.6.1 BASIS OF SELECTION

Among above LPG manufacturing processes, refrigeration process is selected

because of it has following advantages compared to other processes.
 Easier erection using commonly available construction equipment and techniques
owing to low elevation layout and HP vessels.
 Easier maintenance owing to low elevation layout.
 Less energy consumption owing to optimized synthesis conditions and proprietarily
designed reactor and stripper.
 A high amount of LPG gets extracted from natural gas.
 This technology yields high quality of LPG.

2.7 DETAILS OF THE SELECTED PROCESS (Turbo Expander

technology through Cryogenic fractionation)

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Production of LPG From Natural Gas

Fig.2.7 LPG Process Flow Diagram

NOMENCLATURE

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 Production of LPG From Natural Gas

A FEED GAS KNOCK OUT DRUM

B DRYER INLET KNOCK OUT DRUM

C FEED GAS DRYER

D CHILLER SECTION

E LOW PRESSURE SEPARATOR

F HIGH PRESSURE SEPARATOR

G LIGHT END FRACTIONATION COLUMN

H LIGHT END FRACTIONATION COLUMN REFLUX DRUM

I LPG DISTILLATION COLUMN

J LPG REFLUX DRUM

K MULTI HEAT EXCHANGER

A COMPRESSOR

B HEAT EXCHANGER

C FEED GAS FILTER

D REGENERATION GAS HEATER

E PROPANE REFRIGERANT.

F TURBO-EXPANDER.

G REBOILER

H PUMP

Stream Temperatures and Pressures

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 Production of LPG From Natural Gas

Stream no. Temperature (oC) Pressure(kg/cm2g)

1 40.0 46.6
2 40.0 45.0
3 39.2 45.2
4 55.0 55.0
5 40.0 54.7
6 25.0 54.4
7 25.0 54.5
8 25.0 54.2
9 52.0 53.7
10 52.0 53.1
11 -39.0 52.0
12 -43.5 52.3
13 -34.0 52.3
14 10.4 28.5
15 -37.0 26.2
16 -40.24 32.0
17 -33.91 28.2
18 -20.3 25.8
19 7.0 24.8
20 35.0 22.9
21 97.5 28.7
22 -15.51 28.20
23 -40.0 27.70
24 -38.7 27.7
25 21.0 25.1
26 160.0 23.5
27 65.0 23.0
28 32.5 22.8
29 32.5 22.7
30 32.5 23.7
31 40.0 30.0
32 45.0 41.6
33 35.0 41.0
34 130.0 15.5
35 40.0 10.5
36 68.4 15.0
37 55.3 14.5
38 55.3 18.4
39 40.0 13.0
40 -40.0 0.13
41 -10.0 0.12

Table 2.2 Stream Summary

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 Production of LPG From Natural Gas

2.7.1 Feed Gas Compression & Pre-cooling

Feed gas is available from common sweet gas header. Feed gas is taken under
pressure control with a battery limit pressure of 46.6 kg/cm 2g. Feed gas knock out drum
separates out any liquid (water amines etc.) from the feed gas. The feed gas is then
compressed by Expander- Compressor to a Pressure of 55 kg/cm 2g. During the process of
compression the temperature of the gas rises to 55 oC. The compressed gas is then cooled
down to 40 0C in the Expander compressor after cooler by using cooling water.

2.7.2 Feed Gas Drying & Regeneration

Feed gas from the dryer inlet knock out drum goes through feed gas dryers where
the moisture content is reduced below 1ppm. Molecular sieves are used as desiccant in
dryers. Feed gas drying section consists of two molecular sieve beds. One dryer is used for
drying while the other during that period is under regeneration. During drying the flow of
gas is from top to bottom (downward) and the same is from bottom to top upward during
Regeneration operation. Feed gas filters are provided in the downstream of feed gas dryers
to remove any fine moil sieves particles escaping from feed gas dryer along with the dry
compressed gas.
Regeneration heating as well as cooling of the dryer is done with dry lean gas
(LEF Column overhead vapours) passing through it. LEF column overhead vapours
(regeneration gas) stream is heated in regeneration gas heater during heating cycle of the
dryer bed. LP fuel gas is used for firing in heater. Once the bed is dried, regeneration heater
is bypassed and the bed is cooled to ambient temperature with cold lean gas from LEF
column overhead, after which it is ready for drying the incoming process feed gas. The hot
regeneration gas after passing through the dryers is air cooled in Regeneration air cooler to
65 0C and thereafter finally in the regeneration gas water cooler to 40 0C. Subsequently
associated with free moisture is condensed and knocked out in Regeneration gas moisture
separator.

2.7.3 Chill down & Expansion

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 Production of LPG From Natural Gas

Dried gas is passed through the feed gas filters to remove any fines molecular sieve
dust particles. Filtered gas is routed to feed gas chiller and is cooled to -39 0C and the
Propane Refrigerant at -40 0C. The feed gas from chillers at -39 0C & 52.3 kg/cm2g is sent
to HP separator and the liquid condensed is separated.

2.7.4 Multi Heat Exchanger

Following are four streams which get passed through it named as:
a) Liquid from HP separator at -43.5 0C
b) Liquid from LP separator at -40.24 0C
c) LEF column overhead vapour at -38.7 0C.
d) Vapours from LP separator at -33.910C.

Liquid of HP separator is sent back to LEF column for fractionation via Multi heat
exchanger. Here the vapours get cooled -39 0C with pressure reduction to 52.3 kg/cm2g..
Vapours from LP separator are lean gas and are sent to LEF Condensers to partially
condense the LEF overhead vapours.

2.7.5 HP Separator

Separator is a vessel used in the field to remove well stream liquids from gas
components. The Separator may be either 2 phase or 3 phase. It causes a decrease in the
flow velocity, by permitting separation of gas & liquid by gravity & it always operates at a
temperature above the hydrate point of flowing gas. Here in this process separator
separates the incoming gas stream into two corresponding streams i.e. Top gas stream and
Bottom liquid stream.
The stream coming out of the chiller at temperature of -39oCand pressure of 52.3 kg/cm2 g
enters in the High Pressure Separator and then the separator do his job as follows:
 Primary Separation Section- reducing the momentum of entering fluid by using
any inlet device.

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 Production of LPG From Natural Gas

 Secondary seperation section- due to reduction in gas velocity & density

difference, liquid droplets settle down due to gravity.

 Liquid Accumulator Section- main function is to collect liquid & retaining it for
a sufficient time to reach the equilibrium with gas before gas being discharged.

 Mist Extraction Section- It is capable of removing the very fine liquid droplets,
which do not settle down due to gravity.
Therefore the top stream (Gas) goes at temperature of -34 oCand a pressure of 52.3
kg/cm2 g and moves towards the turbo-expander section whereas the bottom stream
(liquid) at a temperature of -43.5oC and a pressure of 52.3 kg/cm2 g and moves towards the
Multi heat exchanger.

2.7.6 LP Separator

Now the Outgoing top stream of HP separator moves through the turbo-expander
and then enters in the LP separator .The inlet stream at -37 oC temperature and 26.2
kg/cm2.g moves into the LP separator and the same mechanism follows as in the HP
separator .The outlet top (gas) stream at -33.91 oC temperature and 28.2 kg/cm2.g goes to
the Multi heat exchanger whereas the Bottom stream (liquid) at -40.24oCtemperature and
32 kg/cm2g goes into the LEF column through Multi heat exchanger.

2.7.7 Fractionation Section

The fractionation section consists of two columns
2.7.6.1 LEF column (light end fractionation Column)
2.7.6.2 LPG column

2.7.7.1 LEF Column

Liquid from HP& LP separator under level control cascaded with flow after
exchange of cold in feed gas chiller is mixed & then fed to LEF column. The column has a
total of 40 valve trays. The column operates at a pressure of 28.2 kg/cm 2g at the top. Lean
gas is generated as LEF column overhead vapours with main constituents of methane,
ethane & little amount of Propane.

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 Production of LPG From Natural Gas

Cold from uncondensed LEF column overhead vapours is recovered in feed gas
chiller and the lean gas is then used for regeneration of feed gas dryers and rest of it is sell.
Liquid from LEF column bottoms is withdrawn at approximately 97 0C and feed to LPG
column.

2.7.7.2 LPG column

Bottom liquid from LEF column is taken to LPG column. This column has overall
52 tray (valve type) and is designed to separate LPG (Propane & Butane) from heavier
Components. The column is operated at a pressure of 15kg/cm 2g at the top. The pressure is
maintained by varying the surface area of LPG column condenser. LPG Product is
withdrawn as overhead liquid Product from reflux drum under level control & is sent back
to column through LPG column reflux pumps under flow control. NGL from column
bottom is cooled to 45 0C by water Cooler and then sent to storage under level control of
column bottoms.

2.7.8 Lean gas compression

Following streams form LPG unit are routed to LEAN gas compression section
through regeneration gas moisture separator which also serves as suction knock out drum
for lean gas compressor
 LP separator overhead vapour is routed regeneration gas moisture separator after
passing through the LEF column condenser, multi heat exchanger.
 LEF column overhead vapours namely regeneration gas & regeneration gas bypass
are routed to regeneration gas moisture separator after passing through the Multi
Heat Exchanger.

Lean gas from regeneration gas moisture separator is compressed further by lean gas
compressor from a pressure of 22.5 kg/cm2g to 41.6 kg/cm2g. Lean gas compressor is
electric motor driven variable speed type compressor. Since the lean gas consumer header
(terminal area) pressure varies from 31kg/cm2g to 39.5 kg/cm2g, pressure control is
provided in lean gas compressor discharge line (after cooler) to ensure steady performance

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 Production of LPG From Natural Gas

of the lean gas compressor. This compressed gas is then cooled down to 41 0C in the lean
gas after cooler by using cooling water.

2.7.9 Propane Refrigerant System

A dedicated refrigerant system is Present to supply Propane refrigerant to meet the

balance cold duty requirement of feed gas chiller. High purity Propane (99.1 mol %
propane) at approximately 0.13 kg/cm2g and -40 0C is used as refrigerant supply to feed
gas chiller.

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 Production of LPG From Natural Gas

2.8 RAW MATERIAL:

2.8.1 Detailed Specification

The raw material being used in this process is “NATURAL GAS. The natural gas
has a Growing market in the present time. Feed stocks in advanced petrochemical
processes are based on natural gas mainly.

Raw Material Composition (Natural Gas Composition):

The composition of natural gas varies widely from one field to the other. The main
constituents of natural gas are the lightest hydrocarbons i.e. Methane, ethane, propane,
Butane and traces of heavier components like pentane. However, methane is generally the
largest component. Hydrogen sulfide (H2S) and carbon dioxide (CO 2) are often present in
the gas both are corrosive to the pipeline and equipment in presence of water.

Composition Mole %
Methane 78.14
Ethane 8.63
Propane 6.13
i – Butane 1.23
n – Butane 1.69
i – Pentane 0.4
n – Pentane 0.39
Hexane 0.43
CO2 2.52
N2 0.20
H2S 0.04-0.7
Table2.3 Natural Gas Compositions

2.8.2 REQUIREMENT OF RAW MATERIAL

2.8.2.1 Basic Assumptions:

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 Production of LPG From Natural Gas

 On yearly base, we consider that plant run 330 - 350 days in a year rest days are for the
shut down and maintenance and cleaning of equipments as corrosion and choking
problem is very much in LPG plant.
 We are taking 100% separation in High pressure and Low pressure separator.

2.8.2.2 Calculation:

We know the Plant capacity i.e. 2.816 Lac MTPA.

Or = 33820.82 kg/hr = 33825 kg/hr
As we know that in the raw material i.e. Natural Gas about 18% is hydrocarbons (C2-C6).
Therefore = 1,87,000 kg/hr

2.8.3 List of Licenses & Permissions required for LPG plant:

1. MPCB - WATER/AIR

Consent to Establish2. EIA3. PIL4. Consent to operate

2. Central Excise Registration

3. Factory Inspector's Certificate

7. BCC Certificate from MIDC or concern authority

8. State Excise permission for storage of Natural Gas.

9. State excise permission for manufacture of LPG from Natural Gas.

10. IEM - Registration certificate from Ministry of Industry / Letter of Intent

11. Labour office / Commissioner Permission for employing contracted persons / agencies

13. Site layout plans approved from State excise / central excise / MIDC if existing

14. Explosive license for storage of explosive product.

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 Production of LPG From Natural Gas

18. Storage tank calibrate from state excise authorities / its measurement

2.8.4 NATUARL GAS PROCESSING

Natural gas processing begins at the wellhead. The composition of the raw natural
gas extracted from producing wells depends on the type, depth, and location of the
underground deposit and the geology of the area. Oil and natural gas are often found
together in the same reservoir. Although they exist in a gaseous state at underground
pressures, these molecules will become liquid (condense) at normal atmospheric pressure.
Collectively, they are called condensates or natural gas liquids (NGLs).

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Production of LPG From Natural Gas

Fig 2.7 Stages in Gas Processing

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 Production of LPG From Natural Gas

A) Gas-Oil Separators
In many instance pressure relief at the wellhead will cause a natural separation of
gas from oil (using a conventional closed tank, where gravity separates the gas
hydrocarbons from the heavier oil). In some cases, however, a multi-stage gas-oil
separation process is needed to separate the gas stream from the crude oil. These gas-oil
separators are commonly closed cylindrical shells, horizontally mounted with inlets at one
end, an outlet at the top for removal of gas, and an outlet at the bottom for removal of oil.
Separation is accomplished by alternately heating and cooling (by compression) the flow
stream through multiple steps. Some water and condensate, if present, will also be
extracted as the process proceeds.

B) Condensate Separator

Condensates are most often removed from the gas stream at the wellhead using
mechanical separators. In most instances, the gas flow into the separator comes directly
from the wellhead, since the gas-oil separation process is not needed. The gas stream enters
the processing plant at high pressure through an inlet slug catcher where free water is
removed from the gas, after which it is directed to a condensate separator. Extracted
condensate is routed to on-site storage tanks.

C) Dehydration

Pipeline specifications and/or sales gas contracts often have to meet the maximum
water content of 7lbm H2O per MMSCF of gas. Dehydration process is done to eliminate
water, which may cause the formation of hydrates. Hydrates form when a gas or liquid
containing free water experiences specific temperature/pressure conditions. Dehydration is
the removal of this water from the produced natural gas and is accomplished by several
methods.
D(2.3) Treatment methods

Removal of contaminates includes the elimination of hydrogen sulphide, carbon

dioxide, water vapor, helium, and oxygen. The most commonly used technique is to first

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 Production of LPG From Natural Gas

direct the flow though a tower containing an amine solution. Amines absorb sulphur
compounds from natural gas and can be reused repeatedly. After desulphurization, the gas
flow is directed to the next section, which contains a series of filter tubes. As the velocity
of the stream reduces in the unit, primary separation of remaining contaminants occurs due
to gravity. Separation of smaller particles occurs as gas flows through the tubes, where
they combine into larger particles, which flow to the lower section of the unit. Further, as
the gas stream continues through the series of tubes, a centrifugal force is generated which
further removes any remaining water and small solid particulate matter.

E) Nitrogen Extraction

Once the hydrogen sulphide and carbon dioxide are processed to acceptable levels,
the stream is routed to a Nitrogen Rejection Unit (NRU), where it is further dehydrated
using molecular sieve beds. In the NRU, the gas stream is routed through a series of passes
through a column and a brazed aluminium plate fin heat exchanger. Using
thermodynamics, the nitrogen is cryogenically separated and vented. Another type of NRU
unit separates methane and heavier hydrocarbons from nitrogen using an absorbent*
solvent. The absorbed methane and heavier hydrocarbons are flashed off from the solvent
by reducing the pressure on the processing stream in multiple gas decompression steps.
The liquid from the flash regeneration step is returned to the top of the methane absorber
as lean solvent. Helium, if any, can be extracted from the gas stream through membrane
diffusion in a Pressure Swing Adsorption (PSA) unit.

F) Methane Separation

The process of de-methanizing the gas stream can occur as a separate operation in
the gas plant or as part of the NRU operation. Cryogenic processing and absorption
methods are some of the ways to separate methane from NGLs. The cryogenic method is
better at extraction of the lighter liquids, such as ethane, than is the alternative absorption
method. Essentially, cryogenic processing consists of lowering the temperature of the gas
stream .While there are several ways to perform this function the turbo expander process is
most effective, using external refrigerants to chill the gas stream. The absorption method,

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 Production of LPG From Natural Gas

on the other hand, uses a “lean” absorbing oil to separate the methane from the NGLs.
While the gas stream is passed through an absorption tower, the absorption oil soaks up a
large amount of the NGLs. The “enriched” absorption oil, now containing NGLs, exits the
tower at the bottom. The enriched oil is fed into distillers where the blend is heated to
above the boiling point of the NGLs, while the oil remains fluid.

G) Fractionation

Fractionation, the process of separating the various NGLs present in the remaining
gas stream, uses the varying boiling points of the individual hydrocarbons in the stream, by
now virtually all NGLs, to achieve the task. The process occurs in stages as the gas stream
rises through several towers where heating units raise the temperature of the stream,
causing the various liquids to separate and exit into specific holding tanks.

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