Natural Gas Compression System with Two-Stage Scrubbing and Intercooling
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Solution Overview
Problem
Existing natural gas compression systems are inefficient and expensive, failing to effectively scrub and compress natural gas while maintaining efficient operation at lower pressures.
Innovation Solution
A compression system comprising first and second stage scrubbers, heat exchange units, compression units, liquid dump containers, an engine, and a control unit, with a compact design that operates within a range of 1-600 psi, utilizing a natural gas fueled reciprocating engine and featuring a vertical compressor orientation to reduce horsepower requirements and enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional scrubbers and compressors are used in freestanding systems, then the system can process natural gas, but the system is inefficient and expensive to operate
Solution Approach 1:
The patent combines multiple processing stages (scrubbing, compression, cooling) into an integrated system where components work in sequence. The two-stage scrubber removes liquids, the compressor increases pressure, and the heat exchange unit cools the gas, all within a unified processing flow that improves overall efficiency and reduces operational costs compared to separate conventional systems.
Solution Approach 2:
The processing system is divided into distinct stages: first stage scrubbing, second stage scrubbing, compression, and cooling. Each stage handles a specific function, allowing for optimized performance at each step while maintaining overall system efficiency. The segmentation enables better control and reduced energy loss compared to monolithic conventional systems.
2Stress or pressure
If gas is compressed to high pressure, then the gas can be transported through pipelines, but the horsepower requirements increase significantly
Solution Approach 1:
The compression process is divided into two stages with cooling in between. The first compressor raises pressure to an intermediate level, the heat exchange unit removes heat generated during compression, and the second compressor completes the pressure increase. This segmented approach with intercooling reduces the total horsepower required compared to single-stage compression to the same final pressure.
Solution Approach 2:
The system changes the temperature parameter between compression stages by incorporating a heat exchange unit that cools the gas after the first compression stage. This parameter change (cooling) reduces the gas temperature and density, making the second compression stage more efficient and reducing overall power requirements while achieving the desired high pressure for pipeline transport.
3Volume of moving object
If a compact design is used, then the system is easier to deliver and install, but space constraints require careful component arrangement
Solution Approach 1:
Multiple functional components (scrubbers, compressors, heat exchange units, liquid dump containers) are merged into a single integrated processing system. This consolidation reduces the overall footprint and simplifies installation compared to separate conventional systems, while the systematic arrangement of components manages the complexity through unified design and coordination.
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 efficiently scrubs, compresses, and cools natural gas, achieving higher mcf/hp ratios and reducing fuel consumption, with a compact design that allows for easier delivery and operation at lower pressures, moving the same daily volume as larger systems with less horsepower.
Implementation Method 1
Because liquid descends and gas rises, within the scrubber, liquid particles fall from the inlet stream and exit the bottom of the scrubber
Implementation Method 2
The first stage compressed gas enters the first heat exchange unit through a first heat exchange unit inlet. The first stage compressed gas is cooled within the first heat exchange unit such that cooled first stage compressed gas is formed
Implementation Method 3
Within the first stage compression unit, the first stage scrubber gas is compressed to form first stage compressed gas
Implementation Method 4
The second stage compressed gas enters the second heat exchange unit through a second heat exchange unit inlet. The second stage compressed gas is cooled within the second heat exchange unit such that cooled second stage compressed gas is formed
Implementation Method 5
Within the second stage compression unit, the second stage scrubber gas is compressed to form second stage compressed gas
Data Source
AI summary
The compression system comprises a main fluid inlet adapted to receive a production stream of natural gas; first and second stage scrubbers; first and second compression units; first and second heat exchange units; one or more liquid dump containers; and an engine. The engine operates within a range of 1600-2100 revolutions per minute and the compressed gas comprises a pressure within a range of 360-600 pounds per square inch. The system comprises a weight to thousand cubic feet of gas per day ratio of less than twenty.