Integrated GOSP System with Compressed Gas Recycle Heating
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Solution Overview
Problem
Current gas oil separation plants (GOSP) face inefficiencies and high costs due to the lack of effective, real-time monitoring of salt content in crude oil, leading to frequent off-spec crude production and increased maintenance needs, especially with existing online analyzers being expensive and labor-intensive.
Innovation Solution
The implementation of integrated GOSP systems with innovative process control strategies and compressed gas recycle for indirect heating, enabling continuous, real-time measurement and control of salt content in crude oil streams, which reduces the number of processing units and minimizes chemical usage, allowing for efficient dehydration, desalting, and stabilization in a single stage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple stages and units are used for dehydration, desalting, sweetening, and stabilization, then the crude oil can meet specifications, but the device complexity and processing cost increase
Solution Approach 1:
The patent combines multiple processing functions (dehydration, desalting, sweetening, and stabilization) into a single integrated separator unit. This merging of functions reduces the number of separate processing units while maintaining the ability to meet crude oil specifications through coordinated control of pressure, temperature, and gas recycling within the unified system.
Solution Approach 2:
The separator unit is designed to perform multiple functions simultaneously - separating water, removing salt, stripping H2S, and stabilizing the crude oil. This multi-functional design eliminates the need for dedicated units for each function, reducing overall device complexity while maintaining comprehensive processing capability.
2Measurement precision
If online salt-in-crude analyzers are used for real-time monitoring, then crude quality can be controlled, but the cost and maintenance requirements increase
Solution Approach 1:
The patent replaces complex electronic/optical salt-in-crude analyzers with a simpler inferential measurement system. Salt content is estimated through a mass balance calculation using readily available process data (inlet crude flow and composition, wash water flow and salinity, and outlet crude flow), eliminating the need for expensive analytical instruments and their associated maintenance requirements.
Solution Approach 2:
The system uses its own process data and built-in mass balance relationships to self-determine salt content without external analytical equipment. The control system continuously calculates salt content based on measured process variables, making the system self-sufficient for quality monitoring.
3Loss of energy
If compressed gas recycle for indirect heating is implemented, then energy efficiency improves, but the process control complexity increases
Solution Approach 1:
The system implements feedback control where the temperature and flow rate of the recycled compressed gas are continuously monitored and adjusted to maintain optimal heating conditions. The gas is compressed, heated through indirect heat exchange, and then recycled back to the separator, with control loops ensuring stable operation and energy efficiency.
Solution Approach 2:
The system recovers thermal energy from the compressed gas that would otherwise be wasted. The compressed gas is used as a heating medium in indirect heat exchangers to heat the crude oil and wash water, then the cooled gas is recycled back through the compressor, creating a closed-loop energy recovery system that minimizes energy loss.
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
This approach enables the production of crude oil meeting stringent specifications with reduced costs and increased efficiency, including a salt concentration of 10 lbs/1000 barrels, BS&W content of 0.3%, H2S content below 60 ppm, and RVP of 7 psia, while eliminating the need for multiple stages and units, thus improving product yield and reducing energy consumption.
Implementation Method 1
compressed gas recycle for indirect heating
Implementation Method 2
indirect heating
Implementation Method 3
controlled separation of volatile components
Implementation Method 4
pressure is often reduced in several stages
Implementation Method 5
high voltage electrostatic electrodes for water removal
Implementation Method 6
electrostatic electrodes for water removal
Implementation Method 7
wash water injection for salt removal
Implementation Method 8
desalting
Implementation Method 9
the conductivity is measured, which is proportional to the salt content
Data Source
AI summary
Systems and methods for crude oil separations including degassing, dewatering, desalting, and stabilization, one method including separating crude oil into a crude oil off-gas and a partially degassed crude oil output; compressing the crude oil off-gas; applying the compressed crude oil off-gas for indirect heating of the partially degassed crude oil output; further heating the partially degassed crude oil output indirectly with compressed low pressure gas; directly mixing with the partially degassed crude oil output a compressed atmospheric pressure gas; separating from the partially degassed crude oil output a low pressure gas for use in the step of further heating; and separating from the partially degassed crude oil output an atmospheric pressure gas for use in the step of directly mixing.