Gas Processing

Single-Source Gas Processing Solution Provider

Through the use of specialized membranes, advanced adsorbents, proven process designs and hydrocarbon management and gas treating equipment, UOP provides modular gas processing and NGL recovery solutions.

Inquire Now

Jump To: Downloads

Single-source, modular construction enables off-shore applications

Offshore Modular Equipment

UOP’s single-source capability and expertise in modular plant construction is often ideally suited for off-shore gas processing applications. Whether fixed-platform, FPSO or FLNG applications, UOP provides a complete portfolio of gas treating processes integrated into a modular unit. Dependent on treating requirements, technologies may include:

  • UOP AmineGuard™ FS Process
  • UOP MOLSIV™ Adsorbent Unit
  • Mercury Removal Unit
  • UOP Separex™ Membrane System
  • Twister Supersonic Separation Unit

With a broad portfolio of technologies, UOP can provide robust equipment solutions to meet our customer’s specific processing requirements. Single-source modular equipment supply provides increased process integration and optimal equipment layout, yielding a lightweight design with a minimum footprint, reducing capital and installation costs, and reducing time to first gas. UOP systems are designed for ease of maintenance and enhanced reliability, providing high on-stream factors and minimal operator attention. The elimination of handoffs between multiple technology suppliers and engineering firms allows faster project implementation.

UOP provides a full portfolio of operator training, commissioning/start-up services and continuing technical support services for the life cycle of the facility. As the sole technology provider, UOP offers overall performance assurance on all process specifications.

Contact us for more information.

The industry’s most comprehensive portfolio

UOP’s single-source capability and expertise in modular plant construction is often ideally suited for onshore unconventional and remote or smaller scale conventional gas processing applications. The broad range of UOP solutions enable natural gas producers to remove contaminants from natural gas and recover high-value natural gas liquids used for petrochemicals and fuels. Dependent on application requirements, technologies may include:

  • UOP AmineGuard™ FS Process
  • UOP MOLSIV™ Adsorbent Unit
  • Mercury Removal Unit
  • UOP Separex™ Membrane System
  • Twister Supersonic Separation Unit
  • UOP Russell Packaged Plant Solutions

With a broad portfolio of technologies, UOP can provide robust equipment solutions to meet our customer’s needs. Single-source modular equipment supply provides increased process integration and optimal equipment layout, yielding a lightweight design with a reduced footprint, reducing capital and installation costs, and reducing time to first gas. UOP systems are designed for ease of maintenance and enhanced reliability, providing high on-stream factors and minimal operator attention. The elimination of handoffs between multiple technology suppliers and engineering firms allows faster project implementation.

UOP provides a full portfolio of operator training, commissioning/start-up services and continuing technical support services for the life cycle of the facility. As the sole technology provider, UOP offers overall performance assurance on all process specifications.

Contact us for more information.

Jump To: Downloads

Reliable and efficient contaminant removal

Mercury Removal

The leader in molecular sieve technology

UOP MOLSIV adsorbents are used in both gas and liquid service. With first offerings invented over 60 years ago, UOP scientists continue creating new and better sieves for a wide variety of gas processing applications. To this day, UOP remains the leading supplier of dehydration and treating adsorbents upstream of liquefaction.

Despite removal of acid gas to low-level upstream of NGL and LNG liquefaction, some CO2 and H2S can end up in the fractionated ethane, propane and butane streams. As a result, the natural gas processing industry uses UOP’s MOLSIV adsorbents for natural gas dehydration, mercury removal, CO2 removal, natural gas/LPG desulfurization and ammonia synthesis gas purification. With over 2,500 operating units worldwide, UOP is the commercial expert in molecular sieves for gas and liquid processing.

Reliable Mercury Removal

To cost-effectively address the critical issue of mercury removal from natural gas and associated gas liquids, UOP offers state-of-the-art adsorbent technology for a variety of applications in a skid-mounted, modular unit.  These turn-key units offer significant cost, schedule, and quality of construction advantages for the gas processing operator.

UOP offers two adsorbent technologies:

  • Regenerable, silver-loaded HgSIV adsorbents are typically installed within the dehydration section of the gas plant to protect downstream cryogenic equipment.  Mercury is desorbed using a temperature swing cycle with a hot regenerate gas.
  • Non-regenerable, Guard Bed (GB) metal oxide adsorbent technology provides complete mercury capture in wet environments while achieving high sulfur utilization ratios.  This high adsorbent efficiency allows for maximum adsorbent loadings and small plot requirements.

To ensure the removal of mercury from sales gas and protect plant cryogenic equipment, some operators are combining upstream HgSIV technology with the use of a small GB adsorbent bed on the lower volume regenerate gas stream to maximize overall efficiency and minimize cost.

UOP single-source turn-key equipment offers a number of significant advantages:

  • Enhanced adsorbent selection to meet processing requirements while minimizing cost
  • Experience in equipment selection, vessel design, and associated control schemes to assure long-term, trouble-free operation at minimum cost
  • High-quality, turn-key equipment supply, minimizing on-site construction issues
  • Efficient design that minimize weight and physical footprint, ideal for floating applications
  • Attractive cost and delivery timing relative to stick-built construction

UOP Separex Membrane Systems provide acid gas removal with reduced footprint and weight

UOP Separex Membrane solutions are used for acid gas and water removal from natural gas streams. Our systems are modular units containing spiral wound membrane elements and offer faster delivery and lower installation and operating costs. They are often ideal for remote locations where transportation logistics are challenging. Separex membrane solutions can be utilized for a wide range of natural gas treating applications and the advantages of Separex Membrane Systems over conventional solvent-based processes include:

  • Lower capital and energy costs
  • Reduced space requirements, faster delivery time and lower installation costs
  • Lower operating costs and lower manpower requirements
  • Increased flexibility for variations in feed gas flowrate and composition
  • Elimination of dehydration equipment
  • Shorter, easier start-up and shutdown
  • Higher waste gas pressure for reduced re-injection compression

The Separex compact membrane system simplifies process stream connections and significantly increases membrane packing density. The membrane system offers a 50% footprint reduction in most applications, making it even more attractive for offshore projects.

UOP has delivered over 130 membrane systems for commercial operation achieving high reliability with downtime of less than 0.5% per year.

Amine Modular Designs

UOP Russell has extensive expertise in providing efficient modular designs for amine treatment of gas. By putting the gas in contact with amines, contaminants such as carbon dioxide, hydrogen sulfide and others can be removed from the gas to help prepare it for market. We can also help you recover sulfur by converting H2S into sulfur or sulfuric acid downstream of the amine unit. Our skid-mounted, modular equipment is designed to provide increased recovery and revenue for the best production and bottom-line results, at the best value.

Improve Water & Hydrocarbon Dew Point with UOP-Twister

The UOP-Twister System is a unique natural gas dew pointing technology that improves the water and hydrocarbon dew point of wellhead gas to pipeline specifications in a single process unit. This system is supplied by UOP as a packaged system, including the proprietary Twister Supersonic Gas Separator (Twister Tube) and Twister Hydrate Separator.

The Twister Tube is a static mechanical device with multiple flow zones accelerating, rotating and expanding the feed gas to supersonic velocities. The condensable materials (water and hydrocarbons) drop out from the swirling gas due to expansion auto-refrigeration (Joule-Thompson effect) and are removed by the axial inline cyclone separator. The same Twister Tube converts kinetic energy back to pressure, thereby recompressing the dew pointed gas without rotating equipment. The Twister Hydrate Separator allows operation below the hydrate formation temperature without plugging the system.

Glycol Dehydration

UOP Russell helps prepare natural gas for cryogenic processing by dehydrating the gas to be free of water. Our skid-mounted, modular equipment is designed to provide increased protection for the best NGL production and bottom-line results, at the best value. For transportation of natural gas, UOP Russell offers packaged glycol systems to remove water, thus preventing potential water condensation and hydrate formation in the pipeline.

Contact us for more information.

Jump To: Downloads

The most diverse hydrocarbon management technology portfolio in the world

With the acquisition of UOP Russell and the marketing alliances of Twister B.V. and Ortloff Engineers, Ltd., UOP offers customers the most complete portfolio of hydrocarbon management solutions in the industry. The broad range of UOP solutions enable shale and conventional natural gas producers to remove contaminants from natural gas and recover high-value natural gas liquids used for petrochemicals and fuels. Many of these solutions are now available as packaged equipment.

Depending on feed gas composition, pressure, flow rate and hydrocarbon recovery goals, UOP’s equipment offerings include UOP Russell cryogenic, mechanical refrigeration, JT plants and adsorption systems and UOP-Twister® Supersonic Separators.

UOP Russell Modular Equipment Monetizes Gas

With modular equipment, monetizing your gas resources anywhere in the world becomes simple. The UOP Russell product family of skid-mounted hydrocarbon management equipment offers:

  • Savings on total project cost
  • Reduced time from investment decision to startup
  • Reduced on-site installation time
  • Simpler unit operations
  • Packaged plant solutions that can be nearly 100% fabricated before gas composition or site identified

UOP Russell provides cryogenic, mechanical refrigeration, JT plants and adsorption systems designed to increase NGL recovery by removing heavy hydrocarbons and controlling the dew point. Condensate stabilization and ethylene glycol regeneration systems can be included if required for any of the dewpointing options. In addition, UOP Russell offers a range of fractionators, from which specific products such as propane, butane, iso-butane and gasoline can be delivered.
Our modular cryogenic plants are sized for 40, 60, 120 and 200 MMscfd and process gas with compositions ranging from 2 GPM (Gallons per MSCFD) to 9 GPM. These plants are designed to recover over 90% of available ethane, if required. They can also operate in ethane rejection mode with propane recoveries in the 90% range. By the end of 2012, UOP Russell delivered over 90 plants to customers.

Watch the UOP Russell animation to learn how UOP Russell modular plants can be up and running six months faster than competitive offerings.

Mild Recovery with UOP-Twister technology

UOP-Twister Supersonic Gas Separation System is a robust solution for commercial gas processing applications. The UOP-Twister technology uses pressure drop to cool a stream to a condition where water and heavier hydrocarbons condense and are easily separated. The supersonic gas flow design results in a more efficient separation and can provide typically 20% higher liquids recovery for the same pressure drop compared to conventional Joule-Thomson gas cooling systems.

Contact us for more information.