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LL Flashtanks3
LL Flashtanks3
Technology Background
Many producers use triethylene glycol (TEG) in
dehydrators to remove water from the natural gas stream
and to meet pipeline quality standards. In a typical TEG
system, shown in Exhibit 1, lean (dry) TEG is pumped to
the gas contactor.
In the contactor, the TEG absorbs water, methane, VOCs,
and HAPs (including benzene, toluene, ethyl benzene and
xylenes (BTEX)), from the wet production gas. The
rich (wet) TEG leaves the contactor saturated with gas at
Volume of
Natural Gas
Savings (Mcf)
$5 per
Mcf
$7 per
Mcf
370 to 37,000
per year
$2,750
$118,000
$1,960
$196,000
$2,700
$275,000
Energy Exchange
pump and a 150 gal/hr
TEG circulation rate
3,573
$10,719
$17,865
Energy Exchange
pump and a 450 gal/hr
TEG circulation rate
10,717
$32,151
1,191
3,553
Implementation
Cost ($)
Payback (Months)
$3 per
Mcf
$5 per
Mcf
$7 per
Mcf
Negligible
Immediate
Immediate
Immediate
$25,011
$6,500 $7,600
79
46
34
$53,585
$75,019
$9,500 $18,800
37
25
13
$3,573
$5,955
$8,337
$6,500 $7,600
22 26
13 16
9 11
$10,659
$17,765
$24,871
$9,500 $18,800
11 22
6 13
59
50% to 200% TEG over-circulation rate. Optimal circulation rates ranged from 30 to 750 gal TEG/hr.
79 %
Processing
87 %
94 %
NESHAP Regulation
On June 29, 2001 EPA finalized the National Emission
Standards for Hazardous Air Pollutants (NESHAP) for
Oil and Natural Gas Production Facilities (40 CFR 63
Subpart HH) and for Oil and Gas Transmission and
Storage Facilities (40 CFR 63 Subpart HHH). These
standards set a throughput floor of 3MMscf/day for
production facilities and a higher 10MMscf/day for
transmission and storage facilities. Above these floors
operators need to install equipment to either reduce
HAPs from dehydrator vents by 95 percent using
closed-vent control systems or making process
modifications, or combust HAPs below 20 ppmv. These
standards are also triggered if total benzene emissions
exceed 1 ton/year.
exchange pumps also often leak rich (wet) TEG into the
lean (dry) TEG. Leakage of only 0.5 percent can double the
circulation rate necessary to maintain sales gas moisture
content, thus increasing potential emissions. For more
information on this practice, see EPAs Lessons Learned:
Replacing Gas-Assisted Glycol Pumps with Electric Pumps.
Decision Points
Operators can estimate the costs and the benefits of
optimizing the TEG circulation rate and installing a flash
tank separator by following these five steps:
G=3
L(min) = 46.66 * 3 = 140 gal TEG/hr
This is the minimum circulation rate. Adding 15 percent over L(min)
for the comfort zone yields an optimal circulation rate of 150 gal
TEG/hr. For example:
L(opt) = Optimal circulation rateL(opt) = 140 gal TEG/hr * 1.15 = 160 gal
TEG/hr
The total cost of a flash tank separator depends on: (A) capital
costs and (B) installation and operating costs.
(A) Capital Costs
Costs of flash tank separators can range between $3,375 and
$6,751, uninstalled, depending on flash tank design and size. If
the required size exceeds the largest standard flash tank
available, operators can either have a custom tank built, install
multiple flash tanks in parallel, or install a separate NGL
accumulation tank.
Diameter
(feet)
Height
(feet)
Capital
Costs ($)
O&M
Installation
Costs
Costs ($)
($)
8.2
1.08
$3,375
$1,684-3,031
N/A
13.5
1.33
$4,455
$1,684-3,031
N/A
22.3
1.66
$5,806
$1,684-3,031
N/A
33.6
$6,751
$1,684-3,031
N/A
O&M
Installation
Costs
Costs ($)
($)
Diameter
(feet)
Height
(feet)
Capital
Costs ($)
49
$4,050
$1,684-3,031
N/A
65
$4,320
$1,684-3,031
N/A
107
2.5
$4,590
$1,684-3,031
N/A
158
$6,481
$1,684-3,031
N/A
225
7.5
$6,751
$1,684-3,031
N/A
L Original L Optimal A E H P
1,000
Applying this formula shows that minor reductions in circulation rates can yield
substantial savings as shown in the following examples. Note that savings
should be reduced by 2/3 where lean glycol is pumped using an electric motor
instead of an energy-exchange pump.
Original
Optimal
Circulation Rate Circulation Rate
Annual
Methane Savings
(Mcf)
Annual
Savings
(@ $7/Mcf)
45
30
394
$2,758
90
30
1,577
$11,039
225
150
1,971
$13,797
450
150
7,884
$55,188
675
450
5,913
$41,391
1350
450
23,652
$165,564
1125
750
9,855
$68,985
2250
750
39,420
$275,940
Mcf
V = 3,942 Mcf/yr
Energy-exchange Pump
Mcf/yr
$/yr
Electric Pump
Mcf/yr
$/yr
30
710
$4,970
237
$1,659
150
3,548
$24,836
1,183
$8,281
300
7,096
$49,672
2,365
$16,555
450
10,643
$74,501
3,548
$24,836
Capital and
Total
Gas
Installation Savings2 Savings3
Costs ($)1
$/yr
$/yr
Payback
Period
(months)
IRR4
30
$6,967
$4,970
$5,005
17
66%
150
$7,507
$24,836
$25,013
333%
300
$9,667
$49,672
$50,012
517%
450
$18,7945
$74,501
$75,019
399%
Capital and
Gas
Installation Savings2
Costs ($)1
$/yr
Total
Savings3
$/yr
Payback
Period
(months)
IRR4
30
$6,9675
$1,669
$1,670
51
6%
150
$6,967
$8,281
$8,338
11
117%
300
$6,967
$16,555
$16,572
237%
450
$9,667
$24,836
$24,869
257%
Circulation rates are set to match the plant design capacity, rather
than actual throughput.
$5/Mcf
$7/Mcf
$8/Mcf
$10/Mcf
Value of Gas
Saved
$10,644
$17,740
$24,836
$28,384
$35,480
Payback Period
(months)
Internal Rate of
Return (IRR)
142%
238%
333%
380%
475%
NPV
$33,515
$60,414
$87,314
$100,76
3
$127,663
throughput rates.
adjustments inconvenient.
Lessons Learned
TEG circulation rates at glycol dehydrators are often two
to three times higher than the level needed to remove
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References
American Petroleum Institute. Specification for GlycolType Gas Dehydration Units (Spec 12GDU). July 1993.
Garrett, Richard G. Rotor-Tech, Inc. Personal contact.
Gas Research Institute Environmental Technology and
Information Center (ETIC). Personal contact.
GRI and U.S. EPA. Methane Emissions from Gas-Assisted
Glycol Pumps. January 1996.
Griffin, Rod. Sivalls, Incorporated. Personal contact.
Henderson, Carolyn. U.S.
Program. Personal contact.
EPA Natural
Gas
STAR
Radian
International
LLC.
Personal
United States
Environmental Protection Agency
Air and Radiation (6202J)
1200 Pennsylvania Ave., NW
Washington, DC 20460
October 2006
EPA provides the suggested methane emissions estimating methods contained in this document as a tool to develop basic methane emissions estimates only. As
regulatory reporting demands a higher-level of accuracy, the methane emission estimating methods and terminology contained in this document may not conform to
the Greenhouse Gas Reporting Rule, 40 CFR Part 98, Subpart W methods or those in other EPA regulations.
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