Compressed Off-Gas Recycle for GOSP Heating
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Solution Overview
Problem
Current Gas Oil Separation Plant (GOSP) technologies face inefficiencies in heating processes, leading to high energy consumption and waste of heat, particularly due to long pipeline lengths causing crude oil to arrive at GOSP's with low temperatures, which reduces separation efficiency and requires extensive equipment.
Innovation Solution
The implementation of compressed gas recycle for indirect heating in GOSP systems, utilizing discharge gas from off-gas compressors to heat reboilers and directly injecting compressed off-gas into crude oil lines before separation vessels, thereby reducing the need for external heating sources and equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If external heating sources are used to heat crude oil in GOSP, then separation efficiency is improved, but energy consumption increases and equipment costs increase
Solution Approach 1:
The system uses its own waste heat from compressed discharge gases to heat the crude oil, making the heating process self-sufficient and eliminating the need for external heating sources. The compressed gas that would otherwise be wasted is utilized to provide the necessary thermal energy for separation.
Solution Approach 2:
The waste heat from compressed discharge gases, which would normally be discarded as useless thermal energy, is converted into a useful heating source. This transforms a harmful waste product into a beneficial resource that reduces external energy requirements and equipment needs.
2Productivity
If external heating sources are used to heat crude oil in GOSP, then separation efficiency is improved, but equipment complexity and costs increase
Solution Approach 1:
The heating function is merged with the existing compression and separation systems. The compressed discharge gases from the separators are directly utilized to heat the crude oil, combining multiple functions (compression, separation, and heating) into an integrated system that reduces the number of separate equipment pieces.
Solution Approach 2:
The compressed gas system serves multiple purposes: it performs the separation function and simultaneously provides the heating function. This multi-functionality eliminates the need for dedicated external heating equipment, reducing overall system complexity.
3Device complexity
If waste heat from discharge gases is not utilized, then system simplicity is maintained, but energy waste increases and heating loads increase
Solution Approach 1:
Instead of discarding the waste heat from compressed discharge gases, the system recovers and utilizes it to heat the crude oil. This recovery process captures the thermal energy that would otherwise be lost, converting it into a useful heating source for the separation process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances separation efficiency, reduces heating loads, and effectively meets crude oil export specifications with lower costs by utilizing waste heat, allowing for the treatment of crude oils with higher water cuts and tight emulsions that conventional systems cannot handle.
Implementation Method 1
heat exchangers are used to indirectly heat crude with compressed off-gas before the crude is introduced to separation vessels
Implementation Method 2
a first reboiler fluidly coupled to the high pressure off-gas compressor and operable to transfer heat from the compressed high pressure gas to crude oil removed from and recycled to the crude stabilizer column
Implementation Method 3
an atmospheric pressure off-gas compressor fluidly coupled to the LPDT operable to compress off-gas from the LPDT for production of compressed atmospheric gas for direct injection into the crude oil
Implementation Method 4
the pressure is often reduced in several stages to allow the controlled separation of volatile components, such as entrained vapors
Data Source
AI summary
Systems and methods for crude oil separations including degassing, dewatering, desalting, and stabilization. One method includes separating crude oil into a crude oil off-gas and a partially degassed crude oil output; compressing the crude oil off-gas; applying the compressed crude oil off-gas for indirect heating through reboilers of the partially degassed crude oil output; and directly mixing with the crude oil a compressed atmospheric pressure gas. In some embodiments, multiple reboilers are used. In some embodiments, heat exchangers are used. Aftercoolers are used after the compressor to cool the gas; knockout drums are used after the coolers to separate liquids.