Crude Oil Vapor Pressure Stabilization by Methane Gas Stripping

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Solution Overview

Problem

Existing crude oil stabilization methods, such as direct-fired heater treaters and electric heating, face issues with emissions, safety risks, and high costs, making them impractical for large-scale oil and gas facilities.

Innovation Solution

A method utilizing gas stripping with methane to remove light hydrocarbons from crude oil, combined with optional electrical heating, which enhances light ends removal and reduces emissions and safety concerns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If direct-fired heater treaters are used to heat crude oil, then light ends removal is effective, but emissions of carbon dioxide and uncombusted hydrocarbons increase

Engineering Contradiction:
Improvelight ends removal efficiencyVSAvoidemissions
Core Design Contradiction:
ProductivityVSObject-generated harmful factors

Solution Approach 1:

The harmful combustion process is extracted and removed from the system. Instead of burning fuel gas to heat the crude, the patent uses a heater treater that heats the crude without combustion, separating the heating function from the harmful emission-generating combustion process.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the harmful combustion process into a beneficial non-combustion heating process. By using a heater treater that does not rely on fuel gas combustion, the system eliminates CO2 and uncombusted hydrocarbon emissions while maintaining effective light ends removal capability.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

2Temperature

If direct-fired heater treaters are used, then heating capability is provided, but safety risks from fire hazards increase

Engineering Contradiction:
Improveheating capabilityVSAvoidsafety
Core Design Contradiction:
TemperatureVSReliability

Solution Approach 1:

The fire hazard is extracted and removed by eliminating the combustion process. The heater treater provides necessary heating capability without burning fuel gas, thus removing the fire risk associated with direct-fired systems while maintaining temperature control for effective stabilization.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The system creates a safer, inert-like environment by avoiding combustion entirely. Without open flames or hot combustion gases, the process environment becomes inherently safer and less prone to fire hazards, while still achieving the required heating temperatures through alternative heating mechanisms.

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

3Reliability

If electric heaters are used to heat crude oil, then safety risks are reduced, but equipment cost and power infrastructure requirements increase

Engineering Contradiction:
ImprovesafetyVSAvoidequipment cost
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces a heater treater as an intermediary device that provides safe heating without requiring expensive electric infrastructure. This intermediate solution avoids both the safety issues of direct-fired systems and the high cost of electric heating, using a mechanically simple heating approach that is economically viable for remote field applications.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The system uses a simple, cost-effective heater treater design that avoids expensive electric heating equipment and infrastructure. By using a mechanically simple heating system rather than complex electric infrastructure, the patent provides an economically attractive solution that is suitable for remote field applications with limited infrastructure.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

4Use of energy by moving object

If fuel gas is combusted for heating, then heating energy is provided, but product consumption increases

Engineering Contradiction:
Improveheating energyVSAvoidproduct consumption
Core Design Contradiction:
Use of energy by moving objectVSLoss of substance

Solution Approach 1:

The fuel gas consumption is extracted and eliminated by removing the combustion process entirely. The heater treater provides necessary heating energy without burning fuel gas, thus preventing consumption of valuable hydrocarbon products that would otherwise be used as fuel.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the harmful fuel gas consumption into a beneficial non-consuming heating process. By using mechanical or thermal heating methods that do not require fuel gas combustion, the system preserves valuable hydrocarbon products while still achieving the required heating temperatures for effective light ends removal.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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

The method effectively stabilizes crude oil vapor pressure, minimizing emissions and safety risks while reducing the need for fuel gas combustion, thus lowering operational costs and enhancing process efficiency.

Implementation Method 1

A stripping gas stream comprising methane is introduced into the separator

Methodology Applied
Scientific EffectVapor-liquid equilibrium:

Implementation Method 2

Methods of vapor pressure stabilization of crude oil utilizing gas stripping

Methodology Applied
Scientific EffectGas stripping: Sparging

Implementation Method 3

At least a portion of the first, second, third, and fourth light hydrocarbon streams are treated in a vapor treatment process

Methodology Applied
Scientific EffectPhase change: Phase Change

Data Source

PatentUS12473502B2Methods of vapor pressure stabilization of crude oil
Publication Date: 2025.11.18 EXXONMOBIL TECHNOLOGY & ENGINEERING CO
  • US12473502B2 patent drawing
  • US12473502B2 patent drawing
  • US12473502B2 patent drawing

AI summary

Methods of crude oil stabilization may include separating crude oil in a bulk separator into a first light hydrocarbon stream, a first water stream, and a first bottoms stream; separating the first bottoms stream in an intermediate pressure separator into a second light hydrocarbon stream, a second water stream, and a second bottoms stream; separating the second bottoms stream in a separator into a third light hydrocarbon stream, a third water stream, and a third bottoms stream; introducing a stripping gas stream comprising methane into the separator; storing the third bottoms stream in a vessel comprising an outlet for a fourth light hydrocarbon stream; treating at least a portion of the first, second, third, and fourth light hydrocarbon streams in a vapor treatment process to form a final light hydrocarbon stream; and recycling at least a portion of the final light hydrocarbon stream to the separator.