Natural gas processing plants, or fractionators, are used to purify the raw natural gas extracted from underground gas fields and brought up to the surface by gas wells. The processed natural gas, used as fuel by residential, commercial and industrial consumers, is almost pure methane and is very much different from the raw natural gas.
Raw natural gas typically consists primarily of methane (CH 4 ), the shortest and lightest hydrocarbon molecule. It also contains varying amounts of:
- Heavier gaseous hydrocarbons: ethane (C 2 H 6 ), propane (C 3 H 8 ), normal butane (n-C 4 H 10 ), isobutane (i-C 4 H 10 ), pentanes and even higher molecular weight hydrocarbons. When processed and purified into finished by-products, all of these are collectively referred to NGL (Natural Gas Liquids).
- Acid gases: carbon dioxide (CO 2 ), hydrogen sulfide (H 2 S) and mercaptans such as methanethiol (CH 3 SH) and ethanethiol (C 2 H 5 SH).
- Other gases: nitrogen (N 2 ) and helium (He).
- Water: water vapor and liquid water.
- Liquid hydrocarbons: perhaps some natural gas condensate (also referred to as casinghead gasoline or natural gasoline) and/or crude oil.
- Mercury: very small amounts of mercury primarily in elementary form, but chlorides and other species are possibly present. blank">Mercury Removal from Natural Gas and Liquids UOP website page
The raw natural gas must be purified to meet the quality standards specified by the major _pipeline transmission and distribution companies. Those quality standards vary from pipeline to pipeline and are usually a function of a pipeline system’s design and the markets that it serves. In general, the standards specify that the natural gas:
- Be within a specific range of heating value (caloric value). For example, in the United States, it should be about 1,035 ± 5% Btu per cubic foot of gas at 1 atmosphere and 60 °F (41 MJ ± 5% per cubic metre of gas at 1 atmosphere and 0 °C).
- Be delivered at or above a specified hydrocarbon dew point temperature (below which some of the hydrocarbons in the gas might condense at pipeline pressure forming liquid slugs which could damage the pipeline).
- Be free of particulate solids and liquid water to prevent erosion, corrosion or other damage to the pipeline.
- Be dehydrated of water vapor sufficiently to prevent the formation of methane hydrates within the gas processing plant or subsequently within the sales gas transmission pipeline. Glycol Dehydration (includes a flow diagram}
- Contain no more than trace amounts of components such as hydrogen sulfide, carbon dioxide, mercaptans, nitrogen, and water vapor.
- Maintain mercury at less than detectable limits (approximately 0.001 ppb by volume) primarily to avoid damaging equipment in the gas processing plant or the pipeline transmission system from mercury amalgamation and embrittlement of aluminum and other metals.