GOSP Gas Sweetening With H2S-CO2 Conversion to Methane
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Solution Overview
Problem
Conventional gas-oil separation plants (GOSP) face inefficiencies such as low product yield, high operating costs, large spatial footprint, and inefficient use of heat sources, with byproducts like hydrogen sulfide and carbon dioxide not being effectively utilized.
Innovation Solution
Integrate a system within the GOSP that captures hydrogen sulfide and carbon dioxide to produce valuable products like methane and steam, utilizing a Sabatier reactor to react hydrogen and carbon dioxide, and employs membrane systems to separate and utilize these gases efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separate units are used to meet BS&W specifications, then basic sediment and water removal is achieved, but device complexity and capital costs increase
Solution Approach 1:
The patent combines multiple separate processing units (gas separation, dehydration, sweetening, stabilization) into an integrated GOSP facility. The separation vessel simultaneously handles gas-oil-water separation, and the integrated system processes multiple fluid streams through coordinated but unified equipment, reducing the number of separate units while maintaining BS&W specification compliance
Solution Approach 2:
The separation vessel and associated equipment are designed to perform multiple functions: separating gas, oil, and water phases; removing H2S from gas streams; dehydrating oil; and stabilizing products. This multi-functionality reduces device complexity by eliminating the need for separate dedicated units for each function
2Ease of manufacture
If conventional heating requirements are implemented, then fluid processing is achieved, but operating costs increase
Solution Approach 1:
The patent converts waste heat from the gas compression process into a useful resource for heating and processing fluid streams. The compressor discharge stream, which would otherwise be wasted, is utilized to provide necessary heating for dehydration and other thermal processes, significantly reducing external heating requirements and operating costs
3Object-generated harmful factors
If H2S and CO2 are discharged as waste, then emission reduction is avoided, but environmental harm increases
Solution Approach 1:
The patent converts harmful emissions (H2S and CO2) into valuable products. H2S is processed through an electrolyzer to produce hydrogen, which reacts with CO2 in a Sabatier reactor to produce methane. This eliminates harmful emissions while generating sellable natural gas, simultaneously addressing environmental concerns and energy loss
Solution Approach 2:
Instead of discarding H2S and CO2 as waste emissions, the system recovers and utilizes these gases. H2S is recovered and converted to hydrogen, CO2 is captured from compressor exhaust, and both are recovered as feedstocks for methane production, eliminating emissions while recovering valuable resources
4Ease of operation
If compressor discharge heat is vented, then simple operation is maintained, but energy efficiency decreases
Solution Approach 1:
The system uses its own compressor discharge heat to serve heating requirements for fluid processing. The integrated design allows the compression process to self-provide thermal energy for dehydration and other heating needs, eliminating waste and improving overall energy efficiency while maintaining operational simplicity through automatic heat integration
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 plant efficiency by reducing carbon footprint, improving line integrity, and generating profit through the sale of methane and steam, while optimizing the use of heat and reducing operational costs.
Implementation Method 1
An H2S membrane system is fluidly coupled to the separation vessel to receive the gas sour stream therefrom, and is operable to separate the H2S from the sour gas stream
Implementation Method 2
An electrolyzer is fluidly coupled to the membrane system to receive the H2S therefrom and is operable to separate hydrogen (H2) from the H2S
Implementation Method 3
a CO2 membrane system operably coupled to the combustion gas turbine to receive the exhaust therefrom and to separate the CO2 from the exhaust
Implementation Method 4
The Sabatier reactor is operable to react the H2 and the CO2 with one another to produce methane (CH4) and water (H2O)
Implementation Method 5
a combustion gas turbine is operable to generate power by burning a fuel and producing an exhaust containing carbon dioxide (CO2)
Data Source
AI summary
A gas-oil separation plant (GOSP) system includes a crude inlet line extending to a separation vessel where a sour gas stream may be separated from an inlet fluid stream. The GOSP system provides an H2S membrane system where the sour gas stream may be directed for separation of H2S and an electrolyzer where H2 may be separated from the H2S. The GOSP system also includes a combustion gas turbine where an exhaust containing CO2 is produced and a CO2 membrane system where the CO2 may be separated from the exhaust. The H2 and CO2 may be combined and reacted in a Sabatier reactor to produce CH4 and H2O. The CH4 may be used to fuel the combustion gas turbine and the H2O may be directed to a steam head for use in other processes. Additionally, a sweetened gas stream having the H2S removed may be exported by the GOSP system.