Modular gas processing plants are an increasingly desirable solution in remote, hard-to-reach, and hazardous locations. When constructed by experienced contractors and in specific applications, it can be a more cost-efficient alternative to traditional construction methods. The added benefits can include increased safety and quality and shorter project timelines while reducing the need for on-site construction crews.
What is a Modular Gas Processing Plant?
A modular gas processing plant contains all the necessary components to process, transfer, and store crude oil or natural gas. The main difference between a traditional gas processing plant and a modular gas processing plant is how the processing chain of a gas processing plant is developed.
With the modular approach, all components are produced in modular process units. These modular units contain all the components needed to process natural gas. They are produced in a fabrication facility, tested, and then shipped to the project site for installation and commissioning.
The main benefits of the modular approach are time and cost savings, as traditional construction in remote locations can be both time-consuming and expensive and introduce additional project management challenges.
What is a Typical NGL Plant Like?
NGL (Natural Gas Liquids) processing plants isolate natural gas, such as methane, from other contaminants, such as the acid gases H2S, CO2, and BTX. This is required by pipeline restrictions that mandate natural gasses are purified before they are transferred.
In general, natural gas processing is less complicated than crude oil processing. NGL plants typically have an on-site field processing facility and a centralized processing plant. This is because some processing will occur near the wellhead of the plant before being transported through a network of gathering pipelines to a centralized processing plant for final processing.
Heaters and scrubbers are usually installed at or near the wellhead of the NGL plant. When natural gas is processed at the centralized processing facility, NGL must be further processed (or fractionated) to produce base components. This process involved specialized equipment (fractionators) capable of distilling and separating different components of NGL from one another.
How Much Does a Gas Processing Plant Cost?
The cost of a gas processing plant varies depending on the type of construction, equipment, and components used for the plant, as well as the size of the project. Costs will also include the cost of necessary supportive infrastructure.
Site preparation, regulatory compliance, and environmental impact assessments also contribute to the overall project cost. The plant's geographic location can significantly influence costs due to labor availability, material transportation, and local taxes. Moreover, advanced technologies like automation and emissions control systems may increase upfront expenses but can enhance long-term operational efficiency and environmental compliance.
What is the Process of Developing a Modular Gas Processing Plant?
Developing a modular gas processing plant will vary based on project requirements, equipment and components used, and the contractor chosen to construct the modular units. When working with a qualified EPC contractor, development will be divided into several phases that include:
H+M Modular: Modular Gas Processing Plant Development
Modular gas processing plants provide several benefits in terms of safety and quality, greater control over project timelines and cost. It also reduces the need for on-site manpower during construction phases in remote and hazardous locations. However, working with an expert contractor with established experience in modular construction will ensure that the best project outcomes are achieved on time and within budget.
H+M’s modular group specializes in designing and fabricating truckable modules, providing exceptional capital project execution from concept to start-up for clients across the United States. From our engineering and fabrication headquarters in Houston, Texas, we can transport your project to wherever you are. For over three decades, we have provided end-to-end solutions for a wide range of project sizes within the energy, chemical, and terminals and logistics industries.
We are dedicated to providing trust, experience, and efficiency through all stages of engineering, procurement, and construction through our proven strategic EPC approach. Our comprehensive services, including front-end planning, detail engineering and design, procurement, fabrication, and construction allow us to take your modular process plant project from conception to completion, tailoring engineering and design solutions to meet your unique needs.
The H+M Industrial Team
For over three decades, we have provided best-in-class capital project management services to Energy and Chemical industries through our proven EPC approach. We are dedicated to providing trust, experience, and efficiency through all stages of engineering, procurement, and construction--on budget and on time.
Partnering with H+M Modular
H+M Modular, a division of H+M Industrial EPC, specializes in custom fabricated equipment, modules, and skids for energy and chemical industries. The approach emphasizes the potential for decreased risk through more controlled fabrication, leading to enhanced quality and safety, reduced labor costs and construction times, improved labor availability, and solutions to geographic challenges. We are dedicated to providing trust, experience, and efficiency through all stages of traditional and modular construction projects using our proven EPFC approach, If you're considering modular fabrication, we invite you to connect with us to learn about how modular solutions can improve project outcomes.
