FLARE GAS RECOVERY & MODULAR GAS PROCESSING PLANTS

 

AIPCC has a proven track record of providing comprehensive gas utilization solutions for onshore and offshore projects. Such solutions often ensure the implementation of innovative technologies packaged with global project management and execution expertise.


A natural gas processing plant is required for most gas streams that are produced from a gas well or an associated oil well. Natural gas in its raw form can contain water, NGL (Natural Gas Liquids), CO2 and H2S.


The flared natural gas from well heads usually requires processing to remove these contaminates from the gas stream. Gas streams from refineries or other processes require gas processing as well to remove liquids and condition the gas stream for its optimum purpose.

  • We supply the whole value chain solution for flare gas recovery.

  • Products produced: LNG/LPG/CNG/Mixed Hydrocarbons.

  • Capacity from 6MMSCFD TO 24MMSCFD.

  • EPC + OM = Turnkey Solution + Operation and Maintenance.

  • Processing of Department of Petroleum Resources (DPR) certificates (LTE + ATC + LTO).

  • Mixed financing structure.

  • High performance to price ratio.

  • DCS + SILIII and global monitor

  • Local maintenance team within 48 hours coverage.

  • 8 - 10 months for project execution.

  • 25 years warranty for static equipment.

LNG

After compression, the feed gas is processed by dehydration and heavy hydrocarbon separation units. Please follow the link at the end for a full description and diagram. The process description is detailed as follows:

  • FGCU: Feed Gas Compress Unit


After measuring, the feed gas flows into the compress unit, and boosts the pressure to 2.4Mpag, pressurized gas flows into the dehydration unit.

  • HDU: Dehydration Unit

Remove H2O in the feed gas, output dry gas and control dew point lower than -80℃.

After gas sweetening unit (GSU), next process is dehydration unit (DHU). DHU is used to meet water content in the specification, and it can reduce water to 1ppm. The technology adopted is temperature swing adsorption (TSA).

  • LQU: Liquefaction Unit


Liquefaction technology is based on refrigeration cycles, which takes hot and pretreated feed gas, cools and condenses it to cryogenic temperature into liquid product. Refrigerant is a part of natural gas, R22 and ethylene fluid being continuously recirculated.

LPG

This unit is applicable to wellhead associated gas pretreatment, including dehydration, hydrocarbon recovery, compression, storage transportation and pressure regulation project, meets the requirement of skid mounted vehicular design, manufacture, and simple, flexible loading and installation at the well site.

According to the gas source and usages, we design to remove the heavy hydrocarbon in feed gas, produce LPG and stable light hydrocarbon, and make dry gas at the same time.

  • HSU -- Heavies Separation Unit


The Heavies Separation Unit (HSU) is installed in conjunction with HRU. Once NGL has been removed from the natural gas stream, it must be fractioned into base components, which can be sold as C3 LPG and C4+ hydrocarbons products.

Please follow the link below for a full description and diagram.

CNG

  • CNG Compress Unit


Rich methane gas meets with rich gas ethane reheated by cooling heat exchanger, this steam of gas flows through the CNG compressor to increase pressure to 25Mpag, CNG product can be obtained.


The compressor skid adopts motor drive, and an ASPRO piston dynamic balance less oil lubrication type compressor. The drive is completely explosion-proof motor, its security level is class 1. Motor is connected to the compressor by belt wheel, and by aligns laser alignment instrument. Natural gas is cooled by the interstage air coolers. Gas collected by the downtime interstage gas collecting device will directly enters to the compressor's input pore at the next start. What’s more, there’re interstage liquid-gas separators and last stage gas scrubbing device. At compressor downtime, these devices will bring the impurities within the system to the recovery tank by gas flow. All the automatic valve drive is driven by the natural gas in the recovery tank, an external air compressor is unnecessary. The whole compressor system is installed on a steel structure, the control panel is at the side.


The pressurized CNG is filled to gas tanker by gas filling column.

HEAVY HYDROCARBON REMOVAL UNIT

  • HRU – Heavies Removal Unit


The Heavies Removal Unit (HRU) is used to remove C3+ hydrocarbons from feed gas. The operation of a HRU is based on the deep refrigeration provided by vapor ethylene to produce reflux to NGL recovery columns.


The process includes direct heat exchange process, NGL/LNG integrating process, and freezing process. HRU can be operated with or without liquefaction unit.


  • HSU -- Heavies Separation Unit


The Heavies Separation Unit (HSU) is installed in conjunction with the HRU. Once NGL has been removed from the natural gas stream, it must be fractioned into base components, which can be sold as C3 LPG and C4+ hydrocarbons products.

 

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