Gas Processing

The energy industry has relied on Propak for 30+ years to provide the necessary equipment and packages to process and treat raw natural gas to meet pipeline specifications, and to produce quality hydrocarbon liquid products. Since 1976, Propak has lead the industry is the design, engineering, and manufacturing of modularized type gas processing and gas treating plants.

Whether our clients require single processing/treating units, or a complete gas processing facility, Propak has the engineering know-how and experience to deliver modern state-of-the-art process design and modularization technologies. For example, Propak is a leader in the design, engineering, and manufacturing of LPG and NGL extraction plants, utilizing cryogenic turbo expander technology, and holds leading patented process technology, for effectively achieving unsurpassed 99.6+% propane (C3) recovery.

Propak also maintains leading edge process/treating and modularization technologies for natural gas dehydration, natural gas amine sweetening, NGL fractionation, and sulphur recovery units (SRU). Propaks extensive experience, process technology expertise, and fully backed process performance guarantees is an asset to our clients. Every design that we propose or recommend is offered based on our design innovation to:

• minimize capital cost
• reduce project schedule
• increase product recovery
• minimize operating costs
• maximize our clients return on investment

Listed below are the major gas processing & gas treating units that Propaks gas processing division has extensive experience in, and maintains a market for the supply of design, engineering, and fabrication:

• Gas and HC Liquid Treating

  • Propak can provide the design, engineering, and manufacturing of various natural gas treating technologies for contaminant removal such as H₂S, CO₂, mercaptan, mercury, and more.

    Amine Sweetening Units (H2S and CO2 Removal) Propak has extensive experience in the design, engineering, and manufacturing of modular type amine sweetening units. Propak has completed amine sweetening units ranging from a gas capacity of 1 MMSCFD to 400 MMSCFD and amine circulation rates from 1 USGPM to 5000 USGPM. Typically, they are operating from 150 psig to 1400 psig and are designed to achieve less than 4.0 ppm H2S, and/or <20 ppm to less than 2.0 mol% CO2 outlet gas. Propak has experience with various amine and solvent technologies such as: DEA MDEA DGA mixed amines proprietary amines (various) sulfinol selexol

    Non-Regenerative Sweetening Units

    Propak has the technical experience in rating, design, engineering, and manufacturing of non-regenerative treaters for removal of small quantities of H2S and mercapatans from natural gas or hydrocarbon liquids. Typically, non-regenerative treaters are used for less than 1 MMSCFD up to 50 MMSCFD, with H2S or mercaptan content from 4 to 100 ppm.

    Molecular Sieve CO₂ and Mercaptan Removal Units

    Molecular sieve units are typically used to remove CO₂ and mercaptans when they exist in small quantities in the gas and/or where very low content is to be achieved.

    Mercury Removal Units

    Propak has the technical experience in rating the design, engineering and manufacturing of mercury removal units typically required when mercury is present in the gas, up stream of LPG and NGL recovery units, and where brazed aluminum BAHX and turbo expanders are present.

    Propak has experience in building mercury removal units with molecular sieve technology as well as non-regenerative, sulphur impregnated, activated carbon bed technology.

    Natural Gas Liquid Treating

    

    Propak has completed the design, engineering, and fabrication of natural gas liquid treating up to 50,000 BBL/D capacity utilizing liquid-liquid amine contactors, stirred reactors, and molecular sieve technologies.

    In the area of natural gas liquid treating, Propak has experience with the following technologies:

    amine hydrocarbon liquid treating (for H₂S, mercaptan, and CO₂ removal)

    molecular sieve hydrocarbon liquid dehydration

• Gas Dehydration

  • Propak packages natural gas dehydration units to treat gas-to-natural-gas pipeline water content specification or to prevent freezing or hydrate formation in downstream processing units.

    TEG Dehydration Units

    

    Propak has been manufacturing TEG dehydration units more than 30 years. We manufacture several standard size units as well as fully custom designed units. We have manufactured TEG dehydration units for field gas gathering units, gas processing plants, and off-shore production units.

    Propak has completed units ranging from 1 MMSCFD to 400 MMSCFD and TEG circulation rates from 1 USGPM to 72 USGPM.

    Typically, units operating from 150 psig to 1400 psig are designed to achieve less than 4.0 lbs/MMSCF (65 mg/m3) outlet gas water content. Propak has designed units with lean TEG concentrations from 99.3 wt% up to 99.8 wt%.

    Propak also builds TEG dehydration units for sweet or sour gas applications.

    Propak has designed TEG glycol regenerators as:

    direct fired (firetube)

    hot oil heated

    electric emersion heated

    Molecular Sieve Dehydration Units

    Propak has been manufacturing molecular sieve dehydration units for over 20 years. Typically, these units are for larger gas processing plants (40 MMSCFD to 750 MMSCFD) to achieve outlet gas dewpoints less than -150°F or to achieve outlet gas water contents less than 0.02 ppmw. Propak has designed and built 2, 3, and 4 tower molecular sieve dehydration units utilizing dry gas or low pressure regeneration gas systems. We can provide the PLC or DCS based mole sieve automatic sequencing controllers and have the engineering capability to provide performance evaluation of the molecular sieve dehydration units.

    Silica Gel Desiccant Dehydration Unit

    Silica gel desiccant dehydration units are recommended for applications where sour gas, logistics, and/or lower outlet water content prevents the usage of a TEG dehydration unit.

• Gas Dew Point Control (C3+C5+)
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    Propak is one of the world's largest manufacturers of natural gas dew point control units with several hundred units in operation. This process utilizes mechanical refrigeration (typically propane refrigeration) to chill and partially condense raw natural gas to separate out the heavier hydrocarbon components, and to produce a pipeline quality natural gas. The condensed hydrocarbon liquids are then distilled in either a stabilizer distillation column to produce a pentane plus (C5+) natural gasoline condensate, or, distilled in a deethanizer distillation column to produce a propane plus (C3+) LPG liquid product.

    The dew point control units usually have an integrated gas dehydration process utilizing 80 wt% ethylene glycol injection into the cooling heat exchangers which captures the water, preventing hydrate formation in the process, and produces an outlet gas with less than 4.0 lbs/MMSCF.

    Propak manufactures several standard size units with capacity of 5 to 50 MMSCFD and refrigeration power of 100 hp to 900 hp. As well, Propak can provide full custom designed units or full gas plants with a typical capacity of 5 MMSCFD to 300 MMSCFD and refrigeration power of 50 hp to 2500 plus hp.

    Propak has manufactured dew point control units using the following process technologies:

    mechanical refrigeration plants

    Joule-Thompson (JT) units

    silica gel absorber units

• Gas Liquid Fractionation

  • Propak has extensive experience in designing, engineering, and manufacturing gas liquid fractionation units for applications as follows: inlet liquid stabilizers - C5+ liquid product condensate stabilizers - C5+ liquid product demethanizers - C2+ liquid bottoms product deethanizer - ethane & C3+ products depropanizers - propane (C3) LPG debutanizers - butane (C4) LPG depentanizers - pentane (C5) condensate butane splitter - i-C4 & n-C4 LPG products

• Liquefied Petroleum Gas (LPG)
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    Propak has completed more than 20 cryogenic turbo expander LPG and NGL recovery plant projects and has a proven track record of successful plant performances and start-ups.

    Propak can provide not only the LPG recovery unit for your project, but we can also cover all aspects of your project depending on what fits your needs and requirements. Propak has supplied:

    stand alone modular LPG recovery (extraction) units

    complete cryogenic turbo expander LPG recovery plants, including gas treating units, molecular sieve dehydration units, fractionation units, refrigeration systems, heat medium systems, utilities, etc.

    EPC turn-key gas processing plants

    Propak is a leader in the design, engineering, and manufacturing of LPG and NGL extraction plants utilizing cryogenic turbo expander technology for natural gas liquid recovery and separation. For LPG recovery (extraction), Propak can offer state-of-the-art, patented, process technology for cryogenic turbo expander LPG recovery plants, efficiently achieving 99.6+% propane (C3) recovery.

    Propak's proven technology for LPG extraction from natural gas has many distinct values which sets it apart from other LPG turbo expander type process technologies:

    relatively low capital cost

    lowest specific energy requirement

    flexible to changes in gas conditions and composition for stable operation

    east to start-up and operate

    Propak's extensive experience, process technology expertise, and backed process performance guarantee puts our clients at ease.

    Flare Gas Recovery

    

    Propak has the experience and capability to design, engineer, and package flare gas recovery units for on-shore and off-shore application. Propak has designed LPG recovery units specifically developed to recover LPG and condensate liquids from stranded flare gas.

    Propak has completed this type of project, as a single super-module, outfitted onto an existing off-shore FPSO (Floating Production System Offshore). This unit processed 13 MMSCFD of oil production associated gas to recover 2200 BBL/D of C3/C4 LPG & 1800 BBL/D of C5+ condensate. This allowed the operator to utilize the residual gas for power generation and significantly reduced the operators' net flare gas volume providing cleaner flare gas combustion.

    Propak designed all the auxiliary systems related to the flare gas recovery unit including:

    flare gas booster compressors

    molecular sieve dehydration unit

    LPG recovery unit, with deethanizer

    debutanizer

    refrigeration system

    LPG storage, c/w weight balancing system

    LPG off-loading system to off-load via floating hose system

• Natural Gas Liquefaction (NGL)
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    Propaks capabilities in the area of natural gas liquefaction is centered around the smaller LNG units processing less than 20 MMSCFD of natural gas or 250,000 US gal/day. Propak utilizes a dual expander nitrogen refrigeration loop. This type of refrigeration is a low cost and lower complexity to a mixed refrigeration or cascade refrigeration unit. This simplified design is ideal for the smaller size, remote LNG units or where less complex operations are desired.

• NGL Recovery (C2+)
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    Propak has over 20 cryogenic turbo expander LPG and NGL recovery plant projects completed to date and a proven track record of successful plant performance and start-ups.

    We can provide the NGL recovery unit for your project or we can cover all aspects of your project depending on what fits your needs and requirements. Propak has supplied:

    stand alone modular NGL recovery (extraction) units

    complete cryogenic turbo expander NGL recovery plants, also including gas treating units, molecular sieve dehydration units, fractionation units, refrigeration systems, heat medium systems, utilities, etc.

    EPC turn-key gas processing plants

    Propak is a leader in the design, engineering, and manufacturing of LPG and NGL extraction plants utilizing cryogenic turbo expander technology for natural gas liquid recovery and separation. For NGL recovery (extraction), Propak can offer proprietary modified GSP process technology for cryogenic turbo expander NGL recovery plants achieving 94+% ethane (C2) recovery (depending on the gas conditions and composition).

    Propak also has experience with other patented cryogenic turbo expander NGL recovery plants with ethane recovery ranging from 85% to 99+%.

• Sulphur Recovery Units (SRU)

  • Propak has over 15 sulphur recovery units (SRU) projects located around the world with a proven track record of successful plant performances and start-ups. Propak has built complete, modularized sulphur recovery units with a broad experience in the following aspects: sizes ranging from 5 LTD up to 310 TPD sulphur recovery from 92% to 99% 2 or 3 stage Claus designs, lean or rich design some units complete with tail gas treaters or super Claus 4th stage oxygen enriched Claus technology ammonia destruction technology reheater designs, direct fired, glycol heated, or hot oil heated tail gas incinerators sulphur storage as tanks or concrete pit