Designing a Natural Gas Plant – Fourth Year

CHAPTER ONE
“FUNDAMENTALS OF NATURAL GAS"

1.1 Background
Natural gas is a pivotal resource in the global energy landscape, widely recognized as the
cleanest-burning fossil fuel. It plays an indispensable role in meeting soaring energy
demands for power generation, industrial consumption, and residential heating. However,
the raw gas extracted from underground reservoirs is rarely pure methane (CH4) therefore
not immediately suitable for commercial transport or use. This raw stream, often called
wellhead fluid, is a complex mixture containing valuable hydrocarbons and significant
contaminants.

The need for a natural gas processing plant arises from the critical necessity to convert
this raw, impure stream into high-quality, marketable products. Processing ensures two
main objectives are met:

1. Safety and Integrity: Removal of corrosive and hydrate-forming components

(H2S, CO2, H2O) to prevent damage to pipelines and equipment.

2. Commercial Value: Conditioning the gas to meet strict pipeline specifications

(e.g., heating value, dew point) and extracting valuable heavier hydrocarbons (C2,
C3, C4, C5+, collectively known as Natural Gas Liquids or NGLs).

This entire process, from wellhead to pipeline, is a complex chemical engineering

challenge that forms the technical basis for this graduation project, this project focuses
on the conceptual and detailed engineering design of a Natural Gas Processing (NGP)
plant. The primary goal is to design a robust and economically viable facility capable of
treating a specific volume of raw feed gas per day, this project is not just a theoretical
exercise; it is a full-scale feasibility study for a critical piece of energy infrastructure,
detailing every step required to transform raw reservoir fluid into commercially ready
energy products.

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1.2 History
The history of natural gas spans from ancient civilizations, who revered its mysterious
earth-born flames, to its first industrial application in China over two millennia ago.
However, its emergence as a cornerstone of modern energy began with pipeline
technology in the 20th century, which enabled its large-scale transport. The oil crises of
the 1970s further cemented its status as a vital, cleaner-burning fossil fuel, critical to the
global energy mix.

In Iraq, this global narrative finds a powerful modern chapter. For decades, the country's
vast associated gas resources were largely flared, representing a significant economic and
environmental loss. A pivotal shift began in 2013 with the establishment of the Basrah
Gas Company (BGC), a joint venture between South Gas Company, Shell, and
Mitsubishi. BGC initiated Iraq's first large-scale project to capture and process associated
gas from major southern oil fields, transforming a wasted resource into a driver for power
generation and economic growth.

It is within this critical context of value creation and sustainable resource management
that this project is situated. The journey from raw, often flared, wellhead gas to a safe
and commercially viable product is a complex chemical engineering challenge. This
project focuses on the core of that transformation: the conceptual design and simulation
of the essential processing units required to purify natural gas and prepare it for the
market.

Primary Energy Consumption by Fuel

180000
160000
140000
120000
100000
TWh

80000
60000
40000
20000
0
1965 1975 1985 1995 2005 2015 2024

Coal Oil Natural Gas Nuclear Hydro Renewable

Figure 1.1 The global energy sources and their forecasted shares

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1.3 Natural Gas: Origin, Reservoirs, and Classification

1.3.1 Origin and Formation

Natural gas originates from the thermal and biological degradation of ancient organic
matter over millions of years. This occurs through two primary mechanisms:

 Thermogenic Gas: Formed deep underground were high heat and pressure crack
organic material into hydrocarbons. This is the primary source of commercial
natural gas.

 Biogenic Gas: Generated at shallower depths by microorganisms decomposing

organic matter in oxygen-poor environments.

1.3.2 Reservoirs and Gas Types

Natural gas accumulates in underground geological traps, typically porous rock

formations like sandstone or limestone, sealed by an impermeable cap rock. A key
classification of natural gas is based on its presence in the reservoir relative to crude oil:

 Associated Gas: This is gas dissolved in crude oil or forming a gas cap above the
oil within the reservoir. It is a direct by-product of oil production.

Figure 1.2 associated gas in an oil reservoir with a gas cap

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 Non-Associated Gas: This gas is found in reservoirs that contain little or no crude
oil, making it a standalone resource.

Figure 1.3 non-associated gas in a separate, gas-only reservoir

1.3.3 Composition and Commercial Classification

Raw natural gas is primarily methane but contains significant other components, leading
to its commercial classification:

 By Liquid Content:

o Dry Gas: Primarily methane, suitable for direct pipeline transport after
treating.

o Wet / Rich Gas: Contains significant heavier hydrocarbons (Natural Gas

Liquids or NGLs) like ethane and propane, which must be recovered.

 By Sulfur Content:

o Sweet Gas: Contains negligible Hydrogen Sulfide (H₂S).

o Sour Gas: Contains significant amounts of toxic and corrosive H₂S,

requiring extensive processing.

The specific type of gas (e.g., the sour associated gas found in Basra) directly determines
the complexity of the required processing plant to ensure safety, meet pipeline
specifications, and maximize economic value.

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1.4 Chemical and Physical properties

From a chemical perspective, natural gas can be broadly divided into hydrocarbon gases
and non-hydrocarbon gases

1.4.1 Hydrocarbons in Natural Gas

The hydrocarbon fraction of natural gas belongs mainly to:

paraffin (alkane) series, paraffin composed of hydrogen and carbon atoms arranged in
saturated chains. Methane (CH₄) is the dominant component, Methane is chemically
stable, colorless, and flammable, with a density lower than air, often comprising more
than 70% of the mixture, and is followed by

 Ethane (C₂H₆)
 Propane (C₃H₈)
 Butanes (C₄H₁₀)
 Heavier hydrocarbons are generally present only in trace amounts.

Methane Ethane Propane

Olefin hydrocarbons have the general formula of CnH2n and are classed as unsaturated
hydrocarbons. They usually occur only in traces.

 Ethene (C2H4)
 Propene (C3H6)
 Butene (C4H8)

Ethene Propene Butene

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Cyclic hydrocarbons also occur in traces most of the time. There are two kinds:
naphthenic, and aromatic, Naphthenic hydrocarbons are saturated cyclic hydrocarbons
with the general formula of CnH2n.

Cyclopropane Cyclobutane Cyclopentane

Aromatic hydrocarbons are unsaturated cyclic hydrocarbons classified by the number of

six-carbon rings in the molecule.

Benzene Toluene (Methyl benzene) Ethyl benzene

1.4.2 Non-Hydrocarbon Contaminants

In addition to hydrocarbons, raw natural gas contains various non-hydrocarbon gases

classified as contaminants due to their negative impacts on safety, equipment, and product
quality.

The primary non-hydrocarbon components are:

1. Acid Gases:

 Hydrogen Sulfide (H₂S): A highly toxic and corrosive compound. Gas

containing H₂S is classified as "sour" and requires removal (sweetening)
for safety and to meet pipeline specifications.

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 Carbon Dioxide (CO₂): An acidic gas that is also corrosive in the presence
of water and reduces the heating value of the gas. It must be removed to
meet sales gas quality standards.

2. Inert Gases:

 Nitrogen (N₂): A chemically stable gas that dilutes the natural gas,
lowering its heating value and requiring separation to meet pipeline
specifications.

 Helium (He): An inert trace component that can be recovered as a

valuable by-product in some gas fields.

The presence of these contaminants, particularly H₂S and CO₂, is the primary technical
driver for the gas sweetening unit in the processing plant designed in this project.

Component Wellhead Gas, Mole% Pipeline Gas, Mole%

Methane (CH4) 70–98 95–98

Ethane (C4H6) 1–10 2–5

Propane (C3H8) Trace–5 0.5–1.5

Butanes (C4H10) Trace–2 0.2–0.5

Pentanes (C5H12) Trac e–1 Trace

Hexanes (C6H14) Trace–0.5 Trace

Heptane & heavier (C7H16+) Trace Trace

Carbon Dioxide (CO2) Trace–3 0.5–2.0

Nitrogen (N2) Trace–15 0.5–1.5

Hydrogen Sulfide (H2S) Trace–2 <0.000004

Mercury (Hg) *200 to 300 μg/m3 *200 to 300 μg/m3

Water (H2O) Trace–5 <0.0001

Table 1.1 Typical composition of natural gas from the wellhead to the pipeline

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Natural gas is a colorless, odorless gas that is lighter than air and is mostly made of
methane (CH₄). Before it is sent through pipelines, it is treated to remove acid gases (like
CO₂ and H₂S), water, and heavy hydrocarbons so it meets pressure, energy, and quality
standards, and characteristic smell is added (usually an odorant like mercaptan) before
distribution to detect leaks safely.

A key property of natural gas is its heating value, which shows how much energy is
released when the gas burns. The heating value depends on the mix of methane, ethane,
propane, and heavier hydrocarbons, the more hydrocarbons it contains with higher carbon
numbers, the higher its heating value and the more energy it can release when burned due
to the fact that it has more carbon and hydrogen atoms. Each molecule contains more
chemical bonds that can release energy during combustion. The heating value is measured
in British thermal units (Btu), with larger amounts expressed as MBtu (1,000 Btu) or
MMBtu (1,000,000 Btu).

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1.5 Advantages and Disadvantages of Natural Gas

Natural gas occupies a pivotal yet complex role in the global energy matrix. Its
characteristics present significant benefits alongside considerable challenges, defining its
function as a transitional fuel.

1.5.1 Key Advantages

1. Cleaner Combustion: Compared to other fossil fuels like coal and oil, natural gas
combustion emits approximately 50% less carbon dioxide (CO₂) and significantly
lower levels of pollutants such as sulfur dioxide (SO₂), nitrogen oxides (NOₓ), and
particulate matter.

CO2 emission by Fuel

100
90
80
70
60
Kg/MBtu

50
40
30
20
10
0
Coal (asphalt) Diesel Gasoline w/o Propane Natural Gas
ethanol

Figure 1.3 CO2 emission by industry in the world and Iraq

2. High Efficiency and Versatility: It is highly efficient for electricity generation,

especially in modern combined-cycle power plants. Its applications are diverse,
spanning power generation, industrial heating, residential use, and as a feedstock
for the petrochemical industry.

3. Grid Stability: The rapid dispatchability of natural gas-fired power plants makes
them an ideal complement to intermittent renewable energy sources like wind and
solar, providing crucial stability to the electrical grid.

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1.5.2 Disadvantages

1. Methane Emissions: Methane (CH₄), the primary component of natural gas, is a

potent greenhouse gas with a global warming potential over 25 times that of CO₂
over a century. Leaks during extraction, processing, and transportation can
significantly undermine its climate advantages.

2. Non-Renewable and Finite: As a fossil fuel, it is a finite resource. Its extraction,

particularly via methods like hydraulic fracturing, can pose environmental risks
including groundwater contamination and habitat disruption.

3. Perpetuates Fossil Dependency: While often termed a "bridge fuel," heavy

reliance on natural gas infrastructure can create a "lock-in" effect, potentially
delaying the necessary transition to zero-carbon renewable energy sources

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1.6 Utilization of Natural Gas

The commercial value of natural gas is defined by its primary roles as a clean fuel and
an essential industrial feedstock. These core applications dictate the required
specifications for pipeline-quality gas.

The principal uses are:

TYPICAL CONSUMPTION (%)

Power Generation Industrial Residential & Commercial Transportation & Other

10%

20% 40%

30%

Figure 1.4 Global Natural Gas Consumption by Sector

1. Electricity Generation: Natural gas is a leading fuel for power generation,

especially in high-efficiency combined-cycle plants. Its rapid dispatchability
makes it crucial for balancing intermittent renewable energy sources like solar and
wind.

2. Industrial Feedstock and Fuel: It is a fundamental raw material (feedstock) for

producing fertilizers, hydrogen, methanol, and plastics. It also provides high-
grade process heat for manufacturing. These applications require the strict
removal of contaminants to protect catalysts and ensure product quality.

3. Residential and Commercial Heating: It is a primary energy source for space and
water heating in homes and businesses, necessitating reliable supply and specific
safety measures like odorization.

These end-uses justify the processing requirements to remove impurities, control heating
value, and ensure a safe, consistent product, which is the central goal of this project.

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REFRENCES

 Mokhatab, S., Poe, W. A., & Speight, J. G. (2012). Gas fundamentals. In Handbook
of Natural Gas Transmission and Processing (2nd ed.). Elsevier.
 Shell Iraq. (n.d.). Basrah Gas Company. from [Link]
and-sites/[Link]
 Our World in Data. (n.d.). Energy production and consumption.
[Link]
 U.S. Energy Information Administration (EIA). (2023, August 23). Carbon Dioxide
Emissions Coefficients.
[Link]
 International Energy Agency (IEA). (2023). Natural Gas Information: Overview.
IEA. [Link]

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