60 MMSCFD RSV CRYO GAS PLANT

60 MMSCFD RSV Cryogenic Gas Processing Plant

Condition: New - Never Installed

Overview

The 60 MMSCFD RSV Cryo Deep Cut Gas Plant is a high-efficiency natural gas liquids (NGL) recovery facility engineered by UOP Russell utilizing Ortloff’s Recycle Split Vapor (RSV) process technology. The plant combines turbo-expander cryogenic recovery with an integrated propane refrigeration loop to maximize ethane and propane recovery across a wide range of operating conditions and gas compositions.

Originally built in 2019, the facility is modularized for transportability and field installation and is designed for:

• Ultra-high ethane recovery
• High propane recovery
• Hydrocarbon dew point control
• Flexible ethane rejection/recovery operation
• Midstream gas processing
• Rich gas monetization
• LPG Production
• LNG Pre-Treatment

The RSV process enhances conventional GSP-style cryogenic recovery by incorporating a residue gas reflux stream and additional rectification section to significantly improve recovery efficiency and operational flexibility.

Key Specifications

Process Description

The facility utilizes Ortloff’s RSV process, an advanced enhancement of the original Gas Subcooled Process (GSP), allowing:

• Ultra-high ethane recovery
• High propane recovery
• Ethane rejection flexibility
• Increased throughput capability
• Improved CO₂ tolerance
• Stable operation across varying flow rates

The process incorporates:

• Molecular sieve dehydration
• Cryogenic heat exchange
• Turbo-expander refrigeration
• Propane refrigeration chilling loop
• Demethanizer fractionation
• Residue gas reflux generation

The integrated propane refrigeration system provides supplemental chilling for richer gas streams and improved recovery performance.

Enhanced CO₂ Tolerance

The integrated Ortloff RSV process offers improved tolerance to elevated CO₂ concentrations in the inlet gas stream compared to conventional cryogenic recovery processes.

By utilizing a leaner reflux configuration and higher tower operating pressures, the RSV process helps reduce the risk of CO₂ freeze-out within the cryogenic section while still maintaining high ethane and propane recovery efficiencies.

• Increased operational flexibility
• Improved reliability on varying gas compositions
• Better handling of challenging feed gas streams
• Greater margin against cryogenic CO₂ freezing

Integrated Propane Refrigeration System

The plant includes a dedicated propane refrigeration package designed to provide supplemental pre-cooling and enhanced liquid recovery performance.

Refrigeration Compressors

• Multiple screw compressor packages
• Oil-flooded screw refrigeration compressors
• Dedicated air-cooled condenser systems
• Oil separation and management systems

Refrigeration Vessels & Exchangers

• Propane accumulator vessels
• Refrigeration chillers
• Economizer vessels
• Refrigeration heat exchangers
• Integrated control and safety systems

Benefits of Integrated Refrigeration

• Increased NGL recovery efficiency
• Improved propane recovery
• Better handling of rich gas streams
• Increased operational flexibility
• Enhanced recovery during varying ambient conditions

Major Equipment Included

Turbo Expander Package

• L.A. Turbine Expander / Compressor Package (EC-101)
• Model: LA Turbine L2000
• Approximate operating speed: 35,600–40,000 RPM depending on operating case

Cryogenic Heat Exchange System

• Gas / Gas Exchanger – Chart Industries
• Gas / Product Exchanger – Steeltek
• Demethanizer Reboilers
• Reflux Condenser
• Trim Reboiler

Fractionation Section

• Stainless Steel Demethanizer Tower
• Approximate Dimensions: 60"/42" x 98' OAL
• Sulzer Chemtech Internals

Dehydration System

• Dual Molecular Sieve Dehydrators
• Stainless Steel Construction
• Inlet Filter / Coalescer
• Dust Filtration System
• Regen Gas Scrubber

Product Handling

• Cold Separator
• Product Surge Tank
• Product Charge Pumps
• NGL Product Cooling System

Utility & Support Systems

• Regen Gas Heater
• HMO Heater
• Fuel Gas Scrubber
• Methanol Injection Pump
• Lube Oil Make-Up Pump