Gas-Condensate Separator and Ejector for Flare-Safe Recycling
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Solution Overview
Problem
Existing gas gathering manifold systems inefficiently manage condensate recovery and utilization, leading to unnecessary burning of valuable condensate and potential safety hazards due to oxygen ingress in flare systems.
Innovation Solution
Implementing a gas-condensate separator and an ejector system to separate condensate from gas, compress it, and reintroduce it into the production header, using a high-pressure motive stream to enhance pressure and recycle the condensate, while ensuring continuous flare operation with purge and pilot gas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If condensate is sent directly to flare-tip for burning, then flare operation is maintained, but valuable condensate is wasted and system efficiency is reduced
Solution Approach 1:
The patent recovers condensate from the production fluid stream using a gas-condensate separator, then recompresses and recycles it back to the production header. This replaces the conventional practice of discarding condensate to the flare-tip, thereby eliminating waste while maintaining flare operation continuity through the purge and pilot gas systems.
Solution Approach 2:
The system uses the high-pressure gas stream itself to drive the ejector that compresses and recycles the condensate. The high-pressure motive stream from the production header provides the energy needed to compress the recovered condensate, making the system self-sufficient without requiring external compression equipment.
2Productivity
If condensate is recovered and recycled, then system efficiency is improved, but additional equipment and complexity are required
Solution Approach 1:
The patent employs an ejector-based compression system that uses gas dynamics and fluid mechanics to compress condensate. The ejector utilizes a high-pressure motive stream to create a low-pressure zone that draws in and compresses the recovered condensate, eliminating the need for mechanical compressors and reducing equipment complexity.
Solution Approach 2:
The gas-condensate separator serves multiple functions: it separates gas from condensate, provides the high-pressure motive stream for the ejector, and enables both condensate recovery and flare operation. This multi-functionality reduces the need for separate dedicated equipment for each function.
3Stress or pressure
If high-pressure gas is used to compress condensate via ejector, then condensate pressure is enhanced for recycling, but energy consumption increases
Solution Approach 1:
The system uses the high-pressure gas stream from the production header itself as the motive force to drive the ejector. The energy required for compression is provided by the existing high-pressure gas flow, not by external energy input, making the process energy-efficient and self-sustaining.
Solution Approach 2:
The ejector utilizes gas dynamics to convert the kinetic energy of the high-pressure motive stream into compression force. The high-pressure gas creates a low-pressure zone that draws in condensate and compresses it through fluid dynamic principles, achieving pressure enhancement without mechanical compression energy input.
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
Enhances condensate recovery and utilization, reduces waste, and maintains safe flare operation by recycling condensate, thereby optimizing system efficiency and safety.
Implementation Method 1
an ejector comprising a motive inlet, a suction inlet, and an ejector outlet. The recovered condensate outlet is in fluid communication with the suction inlet of the ejector, and the ejector outlet is in fluid communication with the production header
Data Source
AI summary
The present disclosure is directed toward a system and a method for gas-condensate recovery. A gas-condensate separator is in fluid communication with a production header and an ejector comprising a motive inlet, a suction inlet, and an ejector outlet. The gas-condensate separator comprises an inlet, a gas outlet, and a recovered condensate outlet. The recovered condensate outlet is in fluid communication with the suction inlet of the ejector, and the ejector outlet is in fluid communication with the production header. The method comprises feeding a production fluid from a production header to a gas-condensate separator. The production fluid is separated in the gas-condensate separator. A gas and a recovered condensate are recovered and the recovered condensate is recycled into the production header.