NGL recovery from fuel gas at Safaniya + Tanajib by JT Expansion Valve Otis Armstrong 02 Nov.

2009 (analysis by Twister BV & P&CSD)

Agenda Background & Technical SA interest in JT expansion for Economics to apply to

Fuel Gas of TPD & SONPD

Why? Apply to Saf & Tan Fuel Gas no deep recovery of condensate in gas
55F dew point vs -32F dew Point by JT

Design approach -Use PFD Composition + sensitivity from Labs results Tanajib vs. Safaniyah same fuel composition with new FG line, diff P&T

Economic analysis Results SONPD higher IRR due to bigger gas use & no line dp

HOW? JT Valve = Min stages to Max Vena Cava +meet noise dB

Single stage device Multi stage device

Expansion at ~S=C Recovery at ~P=C Intersection ~= max JT

Twister technology Reduces valve friction heating to increase cooling & NGL recovery. H-S valve analysis does not account for friction heating in gas flow OP Armstrong 2009

Condensate Recovery module = Goal for our application- LSTK

Design approach for Tanajib & Safaniyah JT LTX Application Objective : Recover valuable C3+ hydrocarbon NGLs from boilers & furnaces fuel gas at Tanajib &Safaniya by LTX gas expansion using Twister Technology Sweet fuel gas for Tanajib originates from Safaniya- identical composition, but flow rate, inlet P & T are not identical- system drawing Sufficient pressure drop available for expansion (~90%) in both Twister LTX applications Gas is dehydrated to 7 lb/MMSCF Cool gas in gas-gas heat exchanger(s) to increase condensate recovery Configuration with only 1 JTX valve or Twister selected at both location Apply maximum heat integration; use MEG when Low T Separator temperature is below Hydrate Forming Temperature Hydrocarbon Condensate goes into condensate line by independent pump

PFD Safaniya EXISTING FUEL SYSTEM w/o JT bypass

36-P-230 (FG frm P/L Ks)

Hot oil furnace

Condensate 10P253

Point A
Flare, Purge & Misc. users

P/L Comps

Point C

Glycol Heater & Purge Boilers

Point B
8-P-222 (FG frm Refrig)

PCV 104 A/B

6-FG-3/4

PCV 107 A/B 12-FG-5

Sweet gas from Refr

12FG-4 to SEC

PFD Safaniya F/G w/ JT By-Pass System INSTALLED

36-P-230 (FG frm P/L Ks)

Heavy Fuel Gas

Point A

Hot oil furnace

Condensate 10P253

JT Unit

Flare, Purge & Misc. users

P/L Comps

Glycol Heater & Purge

Point C
Condensate out Light Fuel Gas
Boilers

8-P-222 (FG frm Refrig)

PCV 104 A/B 6-FG-3/4

PCV 107 A/B 12-FG-5

Sweet gas from Refr

12FG-4 to SEC

Point B

PFD Safaniya

Twister LTX

PFD

Internal

Configuration

JT

PFD Tanajib EXISTING Fuel Gas System w/o LTX bypass

Hot oil furnace G80-F010/011
Flare, Purge & Misc. users (G80)

Glycol Heater & Purge (G54) Boilers G80-F007/008

Condensate

Point C

PCV 1512 A/B

PCV 1516 A/B

Point B
G82-D-091

12-FG-610-3A1L

NC

Point A
ZV 1507
Sour gas from Offshore gas pipeline

G82-D-090
8-FG-600-9A2L

Sweet gas from Safaniya (new)

PFD Tanajib F/G with LTX Twister By-Pass INSTALLED

LTX Unit
Point C
Light Fuel Gas
Hot oil furnace G80-F010/011 Flare, Purge & Misc. users (G80) Glycol Heater & Purge (G54) Boilers G80-F007/008

Condensate

Condensate out

Point B
PCV 1516 A/B

Heavy Fuel Gas

PCV 1512 A/B

12-FG-610-3A1L NC

G82-D-091

Point A

ZV 1507 Sour gas from Offshore gas pipeline

G82-D-090
8-FG-600-9A2L

Sweet gas from Safaniya (new)

Existing

New

PFD Tanajib Twister LTX Internal PFD

JT

Liquid recoveries by Twister using PFD Compositions

C3+ recovery summer Safaniya 875 bpd Tanajib: 535 bpd

winter 1032 bpd 475 bpd

Total

1410 bpd

1507 bpd

Economic analysis - parameters

LPG 25 US$/bbl C5+ 35 US$/bbl Fuel gas 3.3 US$/MMBTU Electricity 3 ct/kWhr MEG 5,000 US$/metric tonne Inflation 5% per year NPV discount rate 15% per year Maintenance 250,000 per 3 years Operating days 350 days per year Lifetime 20 years Apply gas shrinkage for constant BTU to gas system

Economic analysis results

(nearly identical CAPX but SONPD higher gas demand)

Safaniya: MMBTU/d constant Total installed cost US$ 10,000,000 NPV net profits US$ 24,260,000 IRR 49.1%
Tanajib: Total installed cost US$ 9,000,000 NPV net profits US$ 9,500,000 IRR 31.3%

Economic Analysis - sensitivities

1. Some Gas analysis have indicated that the gas is much dryer than 7 lb/MMSCF. This means possible operation w/o chemicals thus reducing OPEX. 2. Black powder in Gas line also indicates intermittent off-spec operation 3. Chemical free operation is possible by maintaining the LTS temperature above the hydrate formation temperature 4. Chemical free operation is also possible by using a hydrate separator (Twister BV proprietary technology) which uses hot oil/hot water to melt hydrates inside the vessel 4. Conservative gas shrinkage case taken as base case

Conclusions & Recommendations

___________________ Conclusion______________________ OP Armstrongs claim is substantiated by P&CSD review to extract substantial amounts of NGL s from fuel gas at both Safaniya and Tanajib by LTX Twister with Gas to Gas LTX cooling Economic analysis indicates both locations provide a positive income & high IRR Maximum profits can be obtained by maximising heat integration and using MEG only when required

__________________Action Recommended__________________ Install 1st Unit at SONPD due to higher IRR, but also for Tanajib Submittal was made to P&CSD and Concurred for Application Make Request to Facility Planning for Formal DBSP, pending Management approval. FPD to review economic alternatives.

Salient Points of P&CSD Evaluation, emails dated 10/3&7 of 09

The LTS liquids from the Twister and J-T systems are compared as follows: SUMMER CONDITIONS Raw Fuel Gas, MMSCFD Inlet Pressure, psia Inlet Temperature, F Fuel Gas Pressure, psig LTS Liquids Flow, Std BPD Proposed Twister System 27.98 997 140 85 1292 Conventional J-T Expansion 27.98 997 140 85 1295
Regarding the need to recover higher-value hydrocarbon s from fuel gas, yes that should be considered on its own economics. Perhaps that should have been done long time ago, and that remains true wherever rich gases are consumed as fuel.

addition of Twister technology does not offer any significant advantage ... Therefore, for the Safaniyah application, addition of proprietary Twister system to recover heavier condensate from rich fuel gases cannot be recommended.

Overview of Safaniyah area Flow Lines

Overview of Twister LTX Swirl Valve

Twisters field experience with Swirl Valve as JT Choke for LTX shows : HC dew-point reduced by 7C at design capacity. Flow rate increases 20% from capacity with conventional JT choke Cold separator temperature increases by 5C, Pressure drop over conventional JT valve is reduced by 20% A safe Noise level of 70dB(A) at design capacity. It Provides linear control characteristic like other traditional cage valves
Swirl Valve Working Principle : Compared to a traditional valve, the SWIRL Valve enlarges the mean diameter of droplets and bubbles by at least a factor of 5. Only droplets with a diameter smaller than 0.2 micron will not be separated by the SWIRL Valve. A SWIRL Valve works using Tangential slots in the cage valve trim to force the liquid flow into a strong rotational motion, causing small droplets to concentrate and agglomerate along the perimeter of the pipe wall. Free pressure energy is dissipated through dampening of vortex along the extended pipe length downstream of the valve. Advantage of creating a swirling flow in the valve is twofold: 1. Regular velocity pattern provides less interfacial shear meaning less droplet break-up resulting in larger drops, then concentrating the droplets in circumference of the flow area to increased number density giving improved coalescence from larger drops. The flow is normally throttled over a perforated cylinder (cage). These perforations, either slots or holes have a radial orientation perpendicular to the cylinder surface. Dissipation of energy by centrifugal forces produces useful work as opposed to conventional valve energy dissipation via eddy currents which produce no useful work.

Overview of Twister LTX Swirl Valve

Overview of Twister Twister Supersonic Separator works by taking Process in a feed of saturated ('dirty') gas, and then
using available pressure drop to expand preswirled gas via a Laval nozzle (contracting and then widening pipe throat) which accelerates the gas to supersonic velocities . The cooling effect of this expansion forces the water and hydrocarbons to condense forming tiny droplets which are then efficiently separated from the gas using the high centrifugal forces(500,000g) caused by the rotating vortex (conservation of angular momentum angular velocities increase in direct proportion to the reducing diameter of the tube inner body - like a figure skater spinning). The Static inlet guide vanes twist the gas, and it moves through the Twister tube at over Mach 1, while swirling around in a vortex fashion. Droplets are thrown to the outside of the tube, where they are removed from the processed gas using a simple pipe-in-pipe separator and some of the process gas (slip gas) as a carrier The gas that flows straight through the tube is conditioned, with impurities removed

Detailed Engineering should review merits of a conventional Twister Tube as opposed to the JT Twister valve. The Twister personnel claim deeper recovery is possible in a twister tube due to the supersonic effect imposed on a gas by a true Twister tube. The issue is does the additional cost justify use of the twister tube as opposed to Twister JTX valve?