Gas Processing: A Global Perspective

Transcription

2 Pipeline Gas Transportation Increasing Natural Gas Value Chain Complexity Conventional Gas, Shale Gas, CBM, Offshore (FPSO) Extraction Processing Gas Processing Plant Power Plant Gas Processing & LNG (Liquefaction) Plant SNG Generation LNG Loading Transportation (Pipeline + LNG) Big Industrial Plant (e.g. Cement or Fertilizers Plants) LNG Shipping Storage Underground Storage OR Bio Gas Producer Power Plant OR LNG Terminal: downloading Storage, re-gasification Distribution City Gate Station Commercial & Industrial User Residential User CNG /LNG Station Commercial User Industrial User Capability to Manage all Major Gas Processing Needs 2

3 Distributed Global Gas Reserves Remaining recoverable natural gas resources tm cubic meters (tcm), 2011 NORTH AMERICA (ex. Mexico) W. EUROPE CIS Unconventional Conventional World total = 790 MIDDLE EAST CHINA Acid Gas = High AFRICA INDIA = Med LATIN AMERICA = Low OAP NGL Content = High = Med = Low No circle within a region indicates minimal known Acid Gas or NGL Content Sources: IEA, BP, PFC Energy, EIA Gas Composition Varies, Continue to Develop Techno Economic Solutions 3

4 Gas Treating Requirements Pipeline Gas Gas Composition CH 4, C 2 +, H 2 O, H 2 S, CO 2, N 2, Hg Pipeline Spec: CO 2 < 2-8% ppm H 2 S < 4 ppm Hg < 0.01 µg/nm 3 H 2 O < 100 ppm Acid gas CO 2 H 2 S H 2 O N 2 Hg C 2 + LNG LNG Spec: CO 2 < 50 ppm H 2 S < 2-4 ppm Hg < 0.01 µg/nm 3 H 2 O < 0.1 ppmv Treating Technologies are Selected Based on Feed Composition and Product Specs 4

5 Lessons from U.S Shale Gas Variability Barnett Shale Gas Composition Marcellus Shale Gas Composition New Albany Shale Gas Composition Antrim Shale Gas Composition Well C C C CO N C2: C3: CO2: N2: C2: CO2: C3: C1: N2: Component Variations Impact Interchangeability with Other Gas Supplies 5

6 Typical FLNG Feed Properties LNG Specifications Typical Feed Properties in key areas South America South East Asia Australia H 2 S, ppmv < Total Sulfur, ppmv < CO 2, % < 50 ppmv Hg, μg/nm 3 < H 2 O, ppmv < 0.1 Saturated Saturated Saturated Tight Requirements Often Necessitate Sophisticated Pretreatment Solutions 6

7 Gas Plant Development: Decision Criteria Upstream Factors Methane Ethane Propane Butanes C 5 + condensate Oil Acid Gases: CO 2, H 2 S, Mercaptan, COS Other: Mercury, Arsenic, Nitrogen, Water HC Distribution Production Profile Contaminants Pressure, Flow Ambient Conditions Offshore/ Onshore Fiscal Regime Environmental Constraints Midstream Factors Compression Plant Configuration & Design Decisions: Gas Processing Functional Blocks Acid Gas Removal Sour Gas Removal Hydrocarbon Management Dehydration Other Contaminant Removal Utilities & Disposal Downstream Factors By-Products Products Opp. Efficiency Consumption Disposal Sales gas / LNG NGL s Spec products C 5 + condensate Availability Flexibility Energy Chemicals Labor Air Water Subsurface 7

8 Partial pressure of acid gas in feed, psi Acid Gas Removal Regions of Use for Technologies Benfield TM Process Selexol TM Process Polybed TM PSA Amine Guard TM FS Process Separex TM Membrane Systems 1.0 UOP MOLSIV Adsorbents UOP GB Adsorbents Partial pressure of acid gas in product, psia Requires a Diverse Portfolio of Treating Technologies 8

9 High Pressure Low Pressure Membrane Systems Membranes are: Membranes are thin, semi-permeable barriers that selectively separate certain components Characterized by permeability or capacity (flux) and selectivity Membrane Process Hydrocarbons, N 2 Fast Slow Residual CO 2, H 2 S, H 2 O Feed Spacer Membrane Permeate Spacer Membrane Feed Spacer Residual Membrane Advancement Dives Higher Capacity and Higher Selectivity 9

10 System Capacity, MMscfd Membrane vs Amine: Shale Gas Comparative Study % 15% 20% 25% 30% + Savings 5% 15% Feed Gas CO 2 Case Example Total Installed Savings = $12MM OPEX Savings = 1.5 MM / yr NPV advantage ~$28 MM Factors NPV Separex over NPV Amine NPV = Total install lost + 10x OPEX Remote Location Site Erection Logistics Clean water availability Solvent Transportation & Disposal Environmental Impact Acid Gas Destruction Hydrocarbon Values Significant Value for Membrane Over Amines; Project Dependent 10

11 Hydrocarbon Management Solutions C 2 + Gas Processing % Typical Recovery** Licensed Turbo-Expander Technology 99+% 99+% 99+% 99+% 98+% Open Art Turbo-Expander Designs Supersonic Separator 99+% 99+% 99+% 99+% 95+% 90+% 95+% 90+% 50+% Higher Pressure Drop Joule Thompson Expansion 99+% 85+% 70+% 35+% Mechanical Refrigeration Adsorption 99+% 95+% 90+% 30+% 99+% 98+% 20+% Heavies C 5 + Butanes Propane Ethane Lower Pressure Drop **Actual recovery dependent on feed gas composition, pressures, flow rates Primary Hydrocarbon Recovery Goal A Broad Portfolio to Fit your HC Recovery or Removal Requirement 11

12 Gas Treating Summary 1) Select the proper technology within each separate gas processing block 2) Account for interactions across the different processing blocks 3) Adjust sequence of processing blocks for overall system optimization Integrated Solutions Offer Operating & Investment Flexibility 12

13 Integrated Gas Pretreating Complex RasGas LNG Expansion Phase 1 / RGX Picture by courtesy of RASGAS 13 13

15 Key Technology Innovations Hydraulic fracturing Horizontal Drilling Seismic Imaging Fast gas NGL Recovery 14

16 What We Mean with Modular Design Modular Solution The overall process of design, component and/or process leverage, enabled by a common pre-engineered design architecture where the modules are standard except where customization is required Key definitions within Modular Solution Pre-engineered: Thoughtful initial design allowing for ultimate reuse Modularization: Discrete modules which can be aggregated into a single solution where only interfaces are prescribed, including inputs and outputs but not the block complete block design Standardization: General term used to cover the extent of module reuse Industrialization: Adoption of industry standards with no / minimal additional company specifications / requirements Modular pre-fabrication: Shop fabrication of modules SOURCE: Team analysis 16

17 Modular Solutions Increase Overall Lifetime Value CONCEPTUAL Potential effect Modular Design Historic Cost effects Time effects Program effect Lifecycle cost 2 Limited engineering 3 Lower purchase costs 6 Reduced lead time due to: Pre-order long lead items Less engineering time Repeat construction 1 Technical optimization Fewer overruns, less onsite construction 4 5 Loss from sub-optimal technical solution 7 Lower cost of ownership Spare parts Operational efficiency Staff flexibility Learning curve effect from programmatic approach % Savings per project 15-25% Reduction in time to build 5-10% Effect from learning curve SOURCE: Based on UOP estimation and various oil and gas industry examples 17

18 Cryogenic Plant Skids Skids are Factory Built and Ready for Installation Saving up to 20-30% per Project 18

19 Field Design Support Package 19

20 Standard Cryo Plant Inlet Gas MOLSIV TM Cryo Plant Residue Gas Y-grade 2 to 4 GPM C2+ Unsaturated Feed Low CO 2 in Feed 20

21 Standard Cryo + Mechanical Refrigeration (MR) Refrig Loop Inlet Gas MOLSIV TM Cryo Plant Residue Gas (saturated feed) Y-grade 6 GPM C2+ Unsaturated Feed Low CO 2 in Feed 21

22 Standard Cryo + MR + Rich Gas Conditioner Inlet Gas Refrig Loop RGC MOLSIV TM Cryo Plant Residue Gas (saturated feed) Stabilizer Y-grade 10 GPM C2+ Unsaturated Feed Low CO 2 in Feed 22

23 Scope Definition Starts with. Full Gas Plant Solution Utilities, site engineering, field fabrication and construction works Facilities design, engineering and fabrication. Ancillary equipment balance of fabrication Ancillary equipment design and engineering and some fabrication Technology Provider Core Modular Process Plants Core Modular Process Plants 23

24 @ 3GPM NGL s Rapid NGL Recovery Improves Return on Investment Typical example of revenue associated with NGL recovery 200 MMSCFD of 3 GPM gas (~1,100 BTU/SCF) Pre-engineered modular design can provide 20% schedule advantage vs. custom field erected Example Shale Gas Methane Ethane Barrel Comp 67% Price Basis 123 Fuel Value Fuel Value Value over fuel $M/month $0.0 $0.0 Amount Generated Monthly $ 5.8MM 200 million cubic feet per day (MMcf/d) Propane n-butane 15% 4% 73% of crude 83% of crude $2.7 $0.8 i-butane 5% 81% of crude $1.0 Natural Gasoline 9% 74% of crude $ Typical wellhead price $9/mmbtu (51% of crude) 2. Assuming crude price of $105/bbl Modular Plants Faster Delivery, Enhanced Value 24

25 China LPG Opportunity Production Consumption Net Imports China LPG Supply & Demand (MTA) Comments LPG Production (+3.7% CAGR) & consumption (+4.3% CAGR) growth Growing net import deficit Deficit increases on average 0.5 MTA per year Deficit growing at 7% CAGR Grows from 4 MTA in 2015 to 12 MTA in 2030 Displacement of imports enabled by increased economic LPG recovery via gas processing plants Increased Gas Processing Capacity for Enhanced LPG Supply 25

26 In Closing. A Complex Natural Gas Value Chain Varying Natural Gas Reserve Compositions and Geographies Diverse Gas Treating needs that Require Fit for Purpose Technology and Delivery Models 26

27 UOP Company Profile Serving the Gas Processing, Refining & Petrochemical Industries Profile Significant Technology Position Sales: Breakdown Business Units: Gas Processing and Hydrogen (GP&H) Process Technology & Equipment (PT&E) Catalysts, Adsorbents & Specialties (CA&S) Renewable Energy and Chemicals (RE&C) Offering: Technology, catalyst & services to the refining, petrochemical and gas processing industries Supplier of molecular sieve adsorbents to process and manufacturing industries Equipment Products Services Licensing Equipment 45% Products 35% Licensing 7% Services 13% UOP Facilities Global Footprint Sales: Geographic Worldwide Headquarters Des Plaines, Illinois (suburban Chicago) 3,500+ Employees 20 Offices 17 Countries 12 Manufacturing Facilities 5 Engineering Centers UOP Offices UOP Manufacturing Sites Global Customers Asia Pacific 19% North America 32% China 12% India 5% Middle East 9% South America 9% E&A 9% CIS 5% 27

28 Q u e s t i o n a n d A n s w e r 28