Prodcut Introduction
The Natural Gas Separation Plant utilizes cryogenic distillation technology to separate natural gas into methane, ethane, propane, butane, and other natural gas liquids (NGLs).
Key Technical Specifications
|
Item |
Specification |
|
Plant Type |
Natural Gas Separation / Fractionation Plant |
|
Process Technology |
Cryogenic distillation (multi-stage fractionation) |
|
Feed Gas Capacity |
50,000 – 1,000,000 Nm³/d |
|
Operating Pressure |
3.0 – 8.0 MPaG |
|
Feed Gas Temperature |
Ambient to pre-cooled condition (project dependent) |
|
Operating Mode |
Continuous operation (24/7 industrial duty) |
|
Design Life |
≥20 years |
|
Separation System |
Deethanizer / Depropanizer / Debutanizer columns |
|
Main Products |
Methane (CH₄), Ethane (C₂H₆), Propane (C₃H₈), Butane (C₄H₁₀) |
|
Methane Purity |
≥95% |
|
Ethane Purity |
≥90% |
|
Propane Purity |
≥95% |
|
Hydrocarbon Recovery |
Ethane ≥90%, Propane ≥95% |
|
Operating Temperature Range |
Approx. -40°C to -100°C (cryogenic section) |
|
Refrigeration System |
Integrated refrigeration/heat integration system |
|
Heat Recovery |
Yes (internal cold energy recovery system) |
|
Control System |
PLC / DCS automated control system |
|
Safety System |
Pressure relief, emergency shutdown (ESD), gas detection system |
|
Corrosion Protection |
Acid gas removal pre-treatment required (CO₂ / H₂S removal) |
|
Material Standard |
Low-temperature steel (e.g., 304L or equivalent for cryogenic service) |
|
Welding Standard |
WPS / PQR qualified welding procedures |
|
Inspection Standard |
NDT (UT, RT), hydrostatic pressure testing |
|
Quality System |
ISO 9001 compliant manufacturing & inspection |
|
Installation Type |
Skid-mounted / modular / field assembly (project dependent) |
|
Maintenance Interval |
Scheduled shutdown every 2–3 years |
|
Availability |
≥95% operational availability (excluding planned maintenance) |
Working Principle
1. Raw Natural Gas Feed
→ 2. Feed Gas Compression (3.0–8.0 MPaG)
→ 3. Feed Gas Pretreatment (H₂O, CO₂, H₂S & Hg Removal)
→ 4. Cryogenic Cooling & Partial Condensation (-40°C to -100°C)
→ 5. Gas-Liquid Phase Separation
→ 6. Deethanizer Fractionation (Ethane Recovery)
→ 7. Depropanizer Fractionation (Propane Recovery)
→ 8. Debutanizer Fractionation (Butane Recovery)
→ 9. Product Purification & Conditioning
→ 10. Final Product Streams
Output Streams:
Methane (CH₄) | Ethane (C₂H₆) | Propane (C₃H₈) | Butane (C₄H₁₀)
Key Features
- Cryogenic heat exchanger train configured for hydrocarbon condensation and separation.
- Fractionation columns equipped with trays or structured packing internals.
- Closed-loop refrigeration package supporting cryogenic process conditions.
- Gas-liquid separation vessels installed between cooling and fractionation stages.
- Independent hydrocarbon recovery sections for methane, ethane, propane, and butane streams.
- Instrumentation package incorporating pressure, temperature, flow, and level measurement devices.
- Pressure-rated vessels and process piping assemblies for gas handling operations.
- Dedicated product collection and transfer system for separated hydrocarbon streams.
- Isolation valve arrangement for equipment maintenance and process control.
Applications
- Natural gas processing plants
- Associated gas recovery projects
- LNG upstream facilities
- Petrochemical feedstock production
- NGL recovery plants
- Gas gathering and treatment stations
Engineering and Design Standards
- API (American Petroleum Institute standards)
- ASME pressure vessel codes
- ISO quality management systems
- GB national standards (where applicable)
Quality Control and Testing
- Material certification for low-temperature service (e.g., 304L stainless steel)
- Low-temperature impact testing down to -196°C
- Non-destructive testing (UT, RT) for weld integrity
- Pressure vessel inspection and certification
- Factory acceptance testing (FAT)
- Site acceptance testing (SAT) and commissioning validation
FAQ
Q: Can the plant be customized for different natural gas compositions?
A: Yes. The process configuration is customized based on feed gas composition, operating conditions, and target product specifications.
Q: What products can be recovered from the plant?
A: Depending on feed gas composition, the plant can recover methane, ethane, propane, butane, and other natural gas liquids (NGLs) as separate product streams.
Q: What processing capacity is available?
A: Standard plant capacities range from 50,000 Nm³/d to 1,000,000 Nm³/d. Plant configuration can be adapted to specific project requirements.
Q: Is EPC turnkey delivery available?
A: Yes. EPC services can include process engineering, equipment manufacturing, procurement, installation, commissioning, and operator training.
Q: What maintenance is required during operation?
A: Routine maintenance typically includes inspection of compressors, heat exchangers, fractionation columns, instrumentation, and control systems during scheduled maintenance shutdowns.
Q: What product purity levels can be achieved?
A: Product purity depends on feed gas composition and process configuration. Typical product specifications include methane purity ≥95%, ethane purity ≥90%, and propane purity ≥95%.
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