Crude Stabilizer Column Low-Pressure Flash Separation
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Solution Overview
Problem
Conventional crude stabilization systems are inefficient, requiring high energy and temperatures that lead to equipment corrosion and unnecessary product shrinkage, necessitating the development of a system that operates at low pressures and temperatures to minimize energy consumption and prevent hydrolysis of chlorides.
Innovation Solution
A crude stabilization system comprising a stabilizer column with multiple sections and an overhead system where effluent is directly fed into a compressor, operating at low pressures and temperatures, eliminating the need for a desalting system and using crude feed for cooling instead of air or water coolers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stabilization units operate at high temperatures (350°F bottom temperature) to stabilize crude, then stabilization effectiveness is improved, but equipment corrosion increases due to hydrolysis of feed chlorides forming acids
Solution Approach 1:
The patent changes the operating temperature parameter from conventional high temperatures (350°F bottom temperature) to low temperatures (below 200°F throughout the column). This parameter change prevents hydrolysis of feed chlorides while still achieving effective stabilization through the unique flash separation mechanism, thereby eliminating equipment corrosion caused by acid formation.
Solution Approach 2:
The patent converts the harmful effect of light hydrocarbons (which cause high vapor pressure and require removal) into a beneficial mechanism. By allowing light hydrocarbons to flash-evaporate naturally at low temperatures and using them to strip heavier volatiles from the crude, the system achieves stabilization without the harmful high temperatures that cause corrosion.
2Reliability
If conventional stabilizer columns operate at high pressures (150 psig) to maintain crude products, then stabilization is achieved, but energy consumption increases and desalting systems are required
Solution Approach 1:
The patent changes the pressure parameter from conventional high pressure (150 psig) to low pressure (atmospheric or near-atmospheric). This pressure change enables the flash separation mechanism to work effectively, allowing light hydrocarbons to evaporate naturally without compression energy, while still achieving the required stabilization effectiveness.
Solution Approach 2:
The patent replaces the mechanical compression system (requiring 150 psig pressure maintenance and associated energy input) with a thermal-flash separation mechanism. The natural evaporation and stripping processes occur at atmospheric pressure, eliminating the need for high-pressure mechanical systems and their associated energy consumption.
3Reliability
If conventional heater treaters are used to stabilize crude, then crude stabilization is achieved, but fractionation efficiency is poor and light material losses increase
Solution Approach 1:
The patent converts the problematic light hydrocarbons (which cause fractionation issues in conventional treaters) into a beneficial stripping agent. The light hydrocarbons that flash-evaporate naturally are used to strip heavier volatiles from the crude through mass transfer, achieving effective fractionation while minimizing light material losses since these hydrocarbons are recovered and sold as valuable products.
Solution Approach 2:
The patent establishes a continuous flash separation process where light hydrocarbons continuously evaporate, strip heavier volatiles, and are continuously recovered. This continuous action maintains efficient fractionation throughout operation, preventing the poor fractionation and light material losses associated with batch processing in conventional heater treaters.
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 effectively stabilizes crude oil by reducing volatile components, minimizing shrinkage, and preventing equipment corrosion, allowing for safe transportation and processing at lower costs with reduced equipment requirements and operational expenses.
Implementation Method 1
The stabilizer column is operated at low pressures and temperatures... Effluent from the stabilizer column may be fed directly into a suction inlet of a compressor system
Implementation Method 2
Conventional stabilizer columns are more efficient than field heater treaters and operate at and/or maintain crude products therein at pressures of about 150 psig, top temperatures of about 250 degrees Fahrenheit, and bottom temperatures of about 350 degrees Fahrenheit
Implementation Method 3
Effluent from the stabilizer column may be fed directly into a suction inlet of a compressor system of the overhead system
Implementation Method 4
The fourth section may include a reboiler... The reboiler system is operatively connected to the stabilizer column and may include a heater
Data Source
AI summary
Embodiments described herein provide a method and apparatus for stabilizing a product, such as a petroleum or other hydrocarbon based product, for example crude oil. Stabilization removes volatile components from the crude such that the crude product may be safely handled, stored, and/or transported. In one embodiment, the crude stabilization system includes at least a stabilizer column and an overhead system. Effluent from the stabilizer column may be fed directly into a suction inlet of a compressor system of the overhead system. The stabilizer column is preferably operated at low pressures and temperatures, thus making a desalting system unnecessary. Furthermore, overhead trim cooling, recycle cooling, and interstage cooling may be provided by the crude feed rather than air coolers or cooling water. As such, stabilized crude product may be safely transported via any means of transportation, such as a railcar.