Basic Engineering Design of NGL-2300 and CFU-200 (C2+ Separation) Units
The Basic Engineering Design of NGL-2300 and CFU-200 Units is a critical undertaking for maximizing the recovery of valuable C2+ hydrocarbons from natural gas streams in Iran’s oil and gas sector. This two-part project includes the design and integration of the NGL-2300 plant in Ahwaz and the CFU-200 C2+ Separation Plant in Bandar Mahshahr, ensuring optimal utilization of Iran’s hydrocarbon resources.
A) NGL-2300 Plant (Ahwaz)
The NGL-2300 plant is specifically designed to optimize the extraction and recovery of C2+ components, including ethane, propane, butane, and heavier hydrocarbons, from multiple gas feed sources. The main feed gases for the plant are:
- Separated gas from the 1st stage of the Maroon-Khami plant: 156 MMSCFD (million standard cubic feet per day)
- Gas condensate stabilization units of the Maroon-Khami plant: 18 MMSCFD
- Produced gas from the Maroon-5 production unit: 82 MMSCFD
The recovered C2+ condensates from NGL-2300 are transported via dedicated pipelines to the CFU-200 separation unit in Mahshahr, while the produced sweet gas is injected back into the Maroon oil field to enhance reservoir performance. This approach maximizes hydrocarbon recovery while supporting the sustainability of field operations.
Main Units in NGL-2300 Plant:
- Low-pressure gas compression unit: Compresses incoming feed gas to the required pressure for downstream processing.
- Gas sweetening unit: Removes hydrogen sulfide (H₂S) and carbon dioxide (CO₂) to ensure gas purity and environmental compliance.
- Gas dehydration unit: Eliminates water vapor from the gas stream to prevent hydrate formation and corrosion.
- Acid gas compression unit: Handles acid gas for safe injection or disposal.
- C2+ recovery unit: Extracts valuable C2+ hydrocarbons using advanced separation technology.
- C2+ purification unit: Further refines the C2+ stream to meet product specifications.
- Utilities: Comprehensive systems supporting all plant operations, including power, water, and instrument air.
- Pipelines: Dedicated lines for transferring C2+ condensates, sweet gas, and acid gas to relevant destinations.
B) CFU-200 C2+ Separation Plant (Bandar Mahshahr)
The CFU-200 plant at Bandar Mahshahr is engineered to collect and process C2+ condensates not only from NGL-2300, but also from the NGL 1700, 1900, and 2000 plants. Its main function is to fractionate the incoming C2+ stream into marketable products—ethane, propane, butane, and C5+ components—while ensuring efficient storage and transfer operations for downstream petrochemical and energy applications.
Main Units in CFU-200 Plant:
- De-ethanizer: Separates ethane from the C2+ stream for use in petrochemical synthesis and energy generation.
- De-propanizer: Recovers high-purity propane, suitable for LPG and chemical markets.
- De-butanizer: Extracts butane for blending and commercial distribution.
- Storage tanks for propane, butane, and C5+: Dedicated storage systems for product inventory and export readiness.
- Transfer pumps: Ensure reliable, efficient movement of liquid products to storage or export terminals.
- Utilities: Support all process and safety systems, including power supply, water, fire protection, and control systems.
The synergy between NGL-2300 and CFU-200 maximizes value recovery from Iran’s natural gas assets, supporting the country’s position as a leading energy producer and exporter in the region.
