Mubarek Gas Processing Plant

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Mubarek Gas Processing Plant
Issues of the flared gas utilization with high
contamination of acid components
Presented by Mr. Elmurod Kurbanov
Chief Engineer
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Mubarek Gas Processing Plant
Mubarek Gas Processing Plant is an unitary
subsidiary of Uzneftegazdobycha Joint Stock
Company operating under the Uzbekneftega?
National Holding Company. The Mubarek GPP removes
acidic content (hydrogen sulfide and carbon
dioxide) and dehydrates natural gas producing
technical sulfur and stabilized gas condensate,
with parallel production of liquefied
propane-butane mixture.
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Mubarek Gas Processing Plant
Mubarek GPP is a Category 1 enterprise
contaminating the atmosphere with harmful
emissions. The design of technological blocks
envisages flaring of acidic gases. Products of
combustion as a result of flaring gas vented from
technological units (expander gases, flash gases
and de-ethanization gases) and of burning
resurgent gas from the Clauss process in sulfur
production plants afterburners are emitted into
the atmosphere.
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Mubarek Gas Processing Plant
Maximum admissible emission of contaminants (in
accordance with the draft regulation on MAEs from
MGPP sources)
Substances Emission, t/yr
Sulphur dioxide 71227.9
Hydrogen sulphide 0.118
Nitric oxide 277.2
Nitrogen dioxide 1112.6
Carbon monoxide 6060.8
Hydrocarbons 2067.9
Ammonia 71.6
Methane 123.1
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PROCESS DIAGRAM FOR LOW PRESSURE FLARE SYSTEM
OLD FLARE SYSTEM
NEW FLARE SYSTEM
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Mubarek Gas Processing Plant

• Flaring of products at MGPPs process units
• Source low temperature separation units
• Flow rate 0.008 thousand m3 per hour.
  Composition, vol.

?1 ?2 ?3 iC4 n?4 i?5 n?5 ?6 N2 ??2 ?2S
94.24 3.06 0.66 0.11 0.15 0.05 0.05 0.08 0.40 1.20 0.00
Source desulfurization expansers. Flow rate
3.1 thousand m3 per hour (flare makeup)

• Source desorption units of sweet gas
  desulfurization units
• Flow rate 75.5 thousand m3 per hour
• Composition, vol.

Composition, vol Sour gas unit Sweet gas unit
?2S up to 4.0 up to 0.03
??2 up to 14.1 up to 0.14
? 2? up to 1.0 up to 0.83
??4 80.9 99.0
?2S 2-4
??2 94-96
??4 0-4.0
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Mubarek Gas Processing Plant
Flaring of products at MGPPs process units

• Source - Condensate Stabilisation Unit
  (degassing).
• Flow 0.3 thousand m3 per hour
• Composition, vol.

?1 ?2 ?3 iC4 n?4
65.45 24.32 8.93 0.58 0.72

• Source Plant Nr 14 (fuel gas) flare makeup.
• Flow rate 16.5 thousand m3 per hour.
  Composition, vol.

?1 ?2 ?3 iC4 n?4 i?5 n?5 ?6???? ?5???? N2 ??2 ?2S
92.22 3.76 0.84 0.15 0.21 0.08 0.07 0.19 0.34 0.40 2.08 0.00
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Gross Emissions, thousand tons
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Specific Emissions, thousand tons/bln m3
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MGPPs environmental facilities
Mubarek Gas Processing Plant

• Sweet acidic gas concentration unit
• Capacity of the sweet acidic gas concentration
  unit 20.0 thousand m3 per hour.
• Clauss process is used to produce 10.0 thousand
  tons of sulphur from concentrated acidic gases
  per year.
• Plant for cleanup of tail gases from Clauss
  Process using Sulphren method
• A process for cleanup of residual tail gases from
  the U-351 Clauss plant producing sulphur has been
  introduced in order to reduce emissions.
• Utilization of tail gases from the Clauss process
  that used to be burned in afterburners is
  organised using Sulphren Plant with a capacity of
  17.0 thousand tons of sulphur per year
• Propane Refrigeration Cycle
• The plant includes a propane refrigeration plant
  generating cold for the low-temperature
  separation units of the PRC. As a result of PRC
  commissioning, ammonia emissions intrinsic to
  ammonia based refrigeration units have been
  substantially reduced

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MGPPs environmental measures
Mubarek Gas Processing Plant

• The flaring system has been rehabilitated,
  introducing two high pressure and two low
  pressure flares in order to optimize utilization
  of emissions
• Clauss and Sulphren process catalysts are used at
  sulphur production plants that constitute the
  source of the most harmful emissions these
  processes ensure maximum sulphur extraction and
  minimum sulphur dioxide content in combustion
  products
• A system forwarding expanse gases as a fuel to
  afterbuners at sulphur production plants was
  introduced in order to maximize utilization of
  process emissions

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Planned flaring reduction activities
Mubarek Gas Processing Plant

• 1. Reduction of greenhouse gas content in process
  emissions from MGPPs units can only be ensured
  by latest technologies.
• For example, it should be feasibly to look for
  and to introduce a technology allowing to extract
  CO2 from the gas flared, provided such technology
  proves economically viable
• 2. Installation of a unit for automatic
  monitoring of composition of gases coming from
  Clauss Process, with automatic adjustment of
  acidic gas to air ratio at the inlet

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Mubarek Gas Processing Plant
Planned flaring reduction activities

• 3. Construction of a unit for cleanup of tail
  gases from the Clauss process featuring
  adsorption at the catalysts cold layer.
• The process is similar to the Sulphren process.
  The only difference is that in Sulphren process,
  catalyst regeneration is done using heated tails
  gases from the Clauss process while the cold
  adsorption process takes heat required for
  sulphur desorbtion from the catalyst, using part
  of process gas coming from the Clauss processs
  generator-reactor

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Mubarek Gas Processing Plant
Issues preventing complete elimination of flaring
at Mubarek GPP
The technical facilities available at Mubarek GPP
do not allow to stop the practice of flaring due
to H2S content being up to 4.0 and CO2 content
being up to 94. Mubarek GPP looks forward to
receive active support from the GGFR to solve
this issue
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Thank you for your attention!
Mubarek Gas Processing Plant