Crude Oil Stabilization Through Integrated Two-Stage Separation

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Solution Overview

Problem

Existing crude oil stabilization processes are inefficient, costly, and require a large footprint, especially for shale or tight oil, with multiple separation stages and equipment, making them unsuitable for remote locations.

Innovation Solution

A two-stage separation system comprising a High Pressure Separation (HPS) unit and a Heated Low Pressure (LP) Separator unit, operating at reduced pressures and temperatures, which integrates a vapor recovery unit and eliminates the need for additional stages, reducing equipment and space requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple separation stages are used to achieve desired stabilization and RVP, then the crude oil meets storage and transportation specifications, but the system footprint increases and complexity increases

Engineering Contradiction:

ImproveRVP specificationVSAvoidsystem footprint

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The patent combines multiple separation functions into a single integrated separator unit that performs both high-pressure separation and low-pressure separation stages simultaneously. This merging of functions reduces the overall system footprint while maintaining the required RVP specification through integrated vapor recovery and liquid separation capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separator unit is designed to perform multiple functions: high-pressure separation, low-pressure separation, vapor recovery, and liquid stabilization all within a single piece of equipment. This multi-functionality eliminates the need for separate dedicated units for each separation stage, thereby reducing the overall system area requirement.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If multiple separation stages and equipment are used to stabilize crude oil, then the desired RVP is achieved, but the device complexity increases

Engineering Contradiction:

ImproveRVP specificationVSAvoidnumber of separation stages

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple separation stages and vapor recovery functions into a single integrated separator unit, reducing device complexity from multiple separate pieces of equipment to one unified system that achieves the same RVP specification.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Within the single separator unit, the patent implements segmented separation zones that handle different pressure stages and vapor-liquid separation functions, allowing complex multi-stage separation to be achieved through internal segmentation rather than external multiple units.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If conventional stabilization systems are used at remote locations, then crude oil can be stabilized, but the difficulty of installation and relocation increases

Engineering Contradiction:

Improvestabilization qualityVSAvoidinstallation and relocation

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines multiple separation and stabilization functions into a single portable unit, making the system easier to install and relocate at remote locations while maintaining stabilization quality. The integrated design eliminates the need for assembling multiple separate units on-site.

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If traditional multistage separation process is used, then vapor pressure is reduced to meet RVP, but the cost of equipment and operation increases

Engineering Contradiction:

Improvevapor pressure controlVSAvoidequipment cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines multiple separation stages into a single integrated unit, reducing equipment costs while maintaining vapor pressure control to meet RVP specifications. The consolidated design eliminates redundant equipment and reduces overall system cost.

Inventive Principle:

Principle #5Merging (Combining)

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 system achieves efficient crude oil stabilization with reduced costs and smaller size, enabling easier installation and relocation, while meeting Reid Vapor Pressure specifications without additional separation stages.

Implementation Method 1

a High Pressure Separation (HPS) unit in fluid communication with a feedstock inlet... separate a gas product and/or a water product from the hydrocarbon feedstock

Methodology Applied

Scientific EffectPressure-driven phase separation: Phase Change

Implementation Method 2

a Heated Low Pressure (LP) Separator unit downstream from the oil outlet of the HPS unit... heating the un-stabilized oil portion of the hydrocarbon feedstock

Methodology Applied

Scientific EffectThermal heating: Heating

Implementation Method 3

separate lighter hydrocarbons, and thereby reducing vapor pressure

Methodology Applied

Scientific EffectVaporization: Evaporation

Data Source

PatentUS12391884B2Crude oil stabilization

Publication Date: 2025.08.19 TECHNIP ENERGIES FRANCE SAS

AI summary

A system for stabilizing a hydrocarbon feedstock includes a High Pressure Separation (HPS) unit in fluid communication with a feedstock inlet. The HPS unit includes an oil outlet. A Heated Low Pressure (LP) Separator unit is downstream from the oil outlet of the HPS unit. The Heated LP Separator unit includes an oil outlet.