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ABSTRACT
Thirty Corporate Oil & Gas Working Owners in the Calgary Gas
Fields became shareholders of
Petrogas Processing Ltd. for the
purpose of establishing gas plant
processing facilities to process their
combined gas reserves of in excess
of 1500 hillion cu. ft. Jefferson
Lake Petrochemicals has been appointed the Operator of the Petrogas Plant Facilities.
This $13,000,000 Plant facility consists of some 135 miles of field pipe
line systems; a gas purification section design for 150 million cu.
ft./day capacity utilizing the Hot
Potassium and Conventional Amine
treating processes; a modified
Claus process to produce 875 long
tons/day of elemental sulphur; a
conventional refrigeration unit for
125 million cu. ft./day of pipe line
gas delivery to meet water and
hydrocarbon dewpoint specification;
and, a 2'200 bbl.!day liquid condensate stabilization unit.
The combined plant inlet gas
streams have approximately 24%
acid gas, or 16% hydrogen sulphide
and 8% C'arbon dioxide. The use of
the Hot Potassium gas purification
section is proving very satisfactory
for extracting a large part of the
acid gas having this ratio of acid
gas volumes. The plant design has
resulted in lower C'apital costs, less
gas fuel consumption and comparatively little chemical losses as compared to other gas processing plant
designs in Canada.
(*) H. W. Manley, President, Petro-
Glycol pipe line delivery and gathering systems to and from each
wellhead for gas dehydration in the
fields is used whereby central plant
regeneration of the glycol can be
obtained. This type of functional
design will reduce corrosion in the
gas gathering systems and prevents
excessive gas hydrates occurring at
the 1200 psia gas gathering pressures. With the Crossfield gas field
now having proved 81.4 square
miles and the Elkton gas field having proved 47.7 square miles of productive area, the field gas dehydration design capital cost has proved
to be comparatively low for the five
Elkton gas wells and eight Crossfield wells now connected to the
Plant. As additional gas producing
wells are completed in these large
fields, the unit cost/wellhead dehydration will continue to be reduced.
fields which were used for the design basis of the Calgary Petrogas
Processing Plant.
Attention is called to the above
analyses which shows 44.15 mol.
percent of hydrogen sulphide and
carbon dioxide commonly called
"acid gas" in the Crossfield field
gas. Likewise, it will be noted the
small mol. percent of carbonyl suI
phide and carbon disulphide in the
Crossfield gas. The experience factor of other Alberta gas processing
plants having like mol. percentages
of carbonyl sulphide and carbon
disulphide had proven a degradation of amine gas treating solutions
and losses of the M.E.A. chemicals
in excess of 20 lbs./million cubic
feet of gas treated. This fact was
given very careful consideration in
TABLE No.1
DESIGN ANALYSIS OF FIELD GAS
Elkton
Mol. %
Crossfield
Mol. %
Reservoir
Component
Nitrogen
_ 3.72
Carbon Dioxide
_ 10.14
FIydrogen Sulphide
_ 34.01
Carbonyl Sulphide
_ 0.06
0.03
Carbon Disulphide ------------------------Methane
_ 51.07
Ethane
_ 0.40
Propane
_ 0.15
Iso Butane
_ 0.15
N-Butane
_ 0.09
Iso Pentane
_ 0.04
N-Petane
_ 0.02
FIexane
)
FIeptane plus)
_ 0.12
0.50
5.50
1.00
79.96
6.91
2.34
0.49
0.72
0.35
0.33
1.90
100.00
100.00
TABLE NO.2
Participation in Gas Reserves
Elkton %
Crossfield %
Company
Alminex Limited
Bailey Selburn Oil & Gas Ltd.
Banff Oil Ltd.
Britalta Petroleums Ltd.
The British American Oil Company Limited
Canada-Cities Service Petroleum Corporation
Can'ada Oil Lands Ltd.
Canadian Fina Oil Limited
Canadian Pacific Oil & Gas Limited
Canadian Petrofina Ltd.
Canadian Superior Oil Ltd.
Devon-Palmer Oils Ltd.
FIome Oil Company Limited
Imperial Oil Limited
Jefferson Lake Petrochemicals of Canada Ltd.
Lehman Brothers
Lincoln-McKay Development Company Ltd.
Medallion Petroleums Limited
Mobil Oil of Canada, Ltd.
Pacific Petroleums Ltd.
Phillips Oil Company Limited
Royalite Oil Company. Limited
Scurry-Rainbow Oil Limited
Selbay Exploration Ltd.
Texaco Exploration Company
Union Oil Company of Canada Limited
Shell Oil Company of Canada Limited
Texas Gulf Sulphur Company -------
.4866672
2.4113450
6.0933272
2.3371472
.526182'6
.1001398
4.6742926
9.2372664
.0671234
.4969980
1.8086115
2.2574928
6.3696443
.0495046
23.8840464
2.3371473
.0523788
.783'5193
23.8840464
1.0568404
.3484524
2.1750377
.0339900
5.4495296
.1294301
.1232'512
.6443799
2.1318020
99.9495941
(*)
24
Ownership of
Petro gas %(*)
2.6738376
.1749
1.6422
3.4976
1.3867
.1863
2.1063
2.7735
3.6321
.0238
.1760
1.7482
2.6669
2.3999
.3337
32.3180
1.3867
.0185
.5630
32.3180
.8989
.1234
1.3913
.0120
5.3300
.1268
.0436
.2281
2.4936
99.3548799
100.0000
.0039955
1.2124826
2.0611020
.8600345
3.1842277
1.7200690
.5563796
1.7035228
2.8718113
.2227223
.4862313
36.6917069
.8600345
.4392105
36.6917069
.8068678
.9553608
5.2290346
.1245417
TABLE NO.3
ESTIMATED ULTIMATE PRODUCT RECOVERY
Horizon
Recoverable
Field Gas
Pipe Line
Gas
Oondensate
at 7.5 RVP
Sulphur
861 BCF
89'5 BCF
442 BCF
797 BCF
1,722,000 Bbl.
18,258,000 Bbl.
10,048,000 LT
304,000 LT
1756 BFC
1239 BCF
19,980,000 Bbl.
10,352,000 LT
Crossfield
Elkton
Total
The objectives having salient consideration in the Petrogas Processing Calgary Plant design and operation are set out as follows:
1. That the Plant facility must be
MAP NO.1
CALGARY GAS FIELDS
W,5M.
R. 29
W4M.
R.28
CROSSFIELD
CROSSFIELD
ELKTON
CROSSFIELD
7-9
IMPERIAL ET AL CALGARY
ELKTON
CROSS FI ELD
MOBIL KATHRYN 3- 2
ELKTON
CROSSFIELD
~
_
~:
ELKTON
6-8
CROSSFIELD
ELKTON
I
GATHERING
L1 ' k
SYSTEM
'" ~:.-''
I
~-+:~IF=~:Lt--+-;"..";:,,,.~-~~ ~I:
ELKTON
CROSSFIELD
~.,.........~
~
~_,
~I/'
,r ~t
I \
1,
~- ~
T.24}
I~
- - - - - - - - - "CROSSFIELD
=""-'-=-----
~........"I
IC_RO_S-JSL.F1_E._Zo_r
_ _t,...1..."'I...-l.
_J~
I:......
CROSSFIELD
I DEVON
~------'--'----""-'-----
.TYPICAL SECTION
CROSSFIELD DITCH
f_
2" L. GLYCOL
, - - - - - - - SOUR GAS
2" F. WATER
I I
2" R.GLYCOL
~ 2"FUEL GAS
2S
inlet liquid-gas separators essentially has a three stage separator system to absorb such excessive liquid
flow rates at the inlet of the plant.
These are as follows:
(a) 1200 feet of 16" liquid drip
traps are installed on each of the
Elkton and Crossfield gas gathering
lines adjacent to the plant inlet
separators. These each have a
liquid capacity of 300 bbls. of liquid
as so-called "slug catchers." The
liquids from the liquid traps are
then uniformly brought into the
plant processing equipment through
flow rate controllers.
(b) Any excess of liquids not
separated in the inlet slug catchers
is discharged into a large flash
drum operating at a 360 psig. having a liquid capacity of 3'25 bbls.
(c)
In the event that both the
slug catcher and the 360 psig. large
liquid flash drum cannot handle the
excessive liquid flow rates, then
such excessive liquid flows are
flashed to a50 psig. liquid receiver
having a capacity of 1300 bbls.
Experience to date indicates that
the above stage liquid separators'
design has given a very satisfactory
uniform control of such liquid slugs
at the inlet of the plant. Even with
the required scraper "pigs" to
clear the gas gathering systems of
excessive liquid accumulations it
has been proven that our design is
capable of absorbing such excessive
liquid slugs without upsetting the
gas treating or liquid hydrocarbon
recovery sections of the plant.
Gas Treater Unit
INLET UNIT
TO FLARE"
IT . L 1'.
GAS TO
TREAT ING
INLET
,--_\\l_.i'~."O_i~__
ED
T~.~~_~_----J..-~_ _ .L...-.-.---W---'--_______
TO CCNDE NSA-=- E
S',mGE DRU~
He
---------->:T70:cCO~N~DE~N-;-SA~rE
LP SURGE Tf,N...;
Diagram No. 1
Journal of Canadian Petroleum
PC
t=
~~
,,_
c"
ACID GAS
HP. CARBONATE
CONTACTOR
TO
SU LPHUR
PLAN T
BOOSTER
UNIT
Diagram No. :2
treater design.
Ca) The hot carbonate solution
operates at absorption of the acid
gas at 250F.
This materially reduces the required fuel for
regeneration of the circulating acid
gas treating solution as compared
to the conventional amine gas
purification process.
(b) The use of hydraulic power
recovery turbir.es on the high pressure hot carbonate solution from
the absorbers to the hot carbonate
regeneration still saves approximately 1,000 HP, that would require fuel for power generation, in
the required pumps for putting the
regenerated solution back to the
high pressure absorbers.
(c) Experience to date indicates
that we obtain a 94 percent removal
of the acid gas in the hot carbonate
gas treater section.
(d) The moL percent of carbonyl sulphide and carbon disulphide appears to be hydrolized into
H2S and C02, thereby practically
eliminating any "amine" degradation from these components, as experienced in other Alberta sour gas
treating plants.
(e) To date there have been
very little chemical losses or degradation of both the hot carbonate
or amine solutions under normal
design operating conditions. These
facts are contrary to the forecasts
of published "bench scale" tests or
theoretical calculations on the use
of the hot carbonate process by
reputable chemical suppliers of
"amine" some three years ago.
SALES GAS
TO FLARE
""FR:-:O"'M-"P"'A"'RA="-L':=-LE:7L'"'U"'N"'1T --r--t-:-::-:-o---'SA--'L-"E-SG~7
SUCTION
SCRUBBER
CONDENSER
Diagram No.3
GLYCOL PUMP
TO
fLARE
ELK~
CROSSFIELD
TO CARBONATE
CONTACTOR
REB OILER
ELKTON
INLET
RECYCLE
COMPRESSOR
TO BURN
PIT
BOTTOMS
COOLER
Diagram No. 4 shows the schematic design of the liquid hydrocarbon recovery and stabilization unit.
This unit is designed to recover
85,600 gallons per day of debutan
ized condensate having a four
pound RVP.
The RVP can be
varied according to demand up to
ten pound RVP in which case the
production capacity will be 92,000
gallons per day. The stabilized condensate from the unit is completely
free of hydrogen sulphide. Essen-
28
Diagram N0.4
Field
TO
PARALLEL
UNIT
ACID GAS
KNOCKOUT DRUM
ESO
FROM
PARALLEL
UNIT
AIR BLOWER
r:
i "
[SO
!
i
AUXILIARY
BURNER
LJ~
INCINERATOR
STACK
SULPHUR TO STORAGE
Diagram No.5
2.
3.
4.
5.
6.
2.
3.
4.
5.