ZAP Engineering EPC sour gas cryogenic processing facility — Texas

Onshore Oil & Gas Midstream

EPC Delivery of a Sour Gas Processing Facility

Full EPC delivery of a greenfield 300 MMSCFD sour gas treatment and cryogenic processing facility in Texas.

Project Overview

ZAP was engaged by a major integrated energy and midstream operator to deliver full EPC services for a greenfield 300 MMSCFD sour gas treatment and cryogenic processing facility in Texas. The plant receives sour gas and liquids from a gathering pipeline and produces four product streams — residue gas, natural gas liquids, condensate, and an acid gas byproduct — with design recoveries reaching 99 percent ethane and 100 percent propane in recovery mode.

Inlet Compression & Acid Gas Treating

Inlet gas is handled by parallel slug catchers and four engine-driven Ariel reciprocating compressors rated 5,500 brake horsepower each, feeding an amine treating unit that removes carbon dioxide and hydrogen sulfide to pipeline specification, followed by triethylene glycol and molecular sieve dehydration. The residue gas specification calls for no more than 0.3 grains of hydrogen sulfide per 100 standard cubic feet and combined inerts below 3.0 mol%.

Cryogenic Recovery & Nitrogen Rejection

Treated gas enters a standard 300 MMSCFD recycle split-vapor cryogenic unit with three 2,000-horsepower electric refrigeration compressors, followed by residue compression using five engine-driven Ariel units. A dedicated reciprocating compressor supports a nitrogen removal unit that reduces nitrogen content, allowing the plant to operate in both ethane recovery and ethane rejection modes to meet varying product specifications.

Liquids Handling & Electrical Systems

Liquids handling includes a 10,000 barrel-per-day condensate stabilizer, natural gas liquids pumps, stabilizer overhead compression, six API 650 storage tanks, and full flare and disposal systems. Electrical service is distributed from a new main electrical building at 13.8 kilovolts down through 4.16-kilovolt and 480-volt systems, controlled through a DeltaV-based redundant process control system and an independent safety control system with fire-and-gas detection.

Client

Major Integrated Energy & Midstream Operator

Market

Energy & Chemicals

Location

Texas

Services

  • EPC Project Delivery
  • Detailed Engineering & Design
  • Procurement
  • Construction

Engineering Disciplines

  • Process/Chemical
  • Mechanical
  • Civil
  • Structural
  • Electrical
  • Instrumentation & Controls

Shane Wilson

Vice President of Business Development


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