Hydrocarbon Recovery Flow Diversion for Gas Plant Blowdown Surges
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Solution Overview
Problem
Conventional gas plant hydrocarbon recovery systems have limited capacity, leading to high CO2 emissions and reduced hydrocarbon recovery, especially during slugging, turnaround, and emergency scenarios, which also shorten the lifespan of burn pits and increase operational costs.
Innovation Solution
Incorporating a three-phase gravity separator and a three-way control valve into the gas plant hydrocarbon recovery system to manage hydrocarbon drainage, allowing diversion to either a recovery vessel or a gravity separator based on flow rates, enhancing recovery and reducing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional recovery vessels are used, then the system structure is simple, but the hydrocarbon recovery capacity is limited
Solution Approach 1:
The system divides hydrocarbon recovery into two segments: a first recovery vessel for normal operations and a second recovery vessel for high-flow scenarios, allowing each vessel to be optimized for its specific function while collectively increasing total recovery capacity
Solution Approach 2:
The system dynamically switches between recovery vessels based on real-time flow rate conditions, using the first vessel during normal operations and transitioning to the second vessel when flow exceeds the first vessel's capacity, thereby adapting recovery capacity to actual operational demands
2Object-generated harmful factors
If burn pits are used for excess hydrocarbons, then the system is simple to operate, but CO2 emissions increase
Solution Approach 1:
The system converts what would be harmful emissions (excess hydrocarbons destined for burn pits) into beneficial recovered resources by capturing and storing them in the second recovery vessel, transforming a waste disposal problem into a resource recovery opportunity
Solution Approach 2:
The system prepares a second recovery vessel in advance specifically for capturing excess hydrocarbons during high-flow scenarios, so that when overflow occurs, the hydrocarbons are immediately diverted to storage rather than being burned, preventing emissions before they occur
3Duration of action of stationary object
If high volumes of hydrocarbons are burned, then excess hydrocarbons are disposed of, but burn pit lifetime is reduced
Solution Approach 1:
Instead of discarding excess hydrocarbons through combustion in burn pits, the system recovers and stores them in the second recovery vessel, preserving both the hydrocarbon substance and extending burn pit life by reducing the frequency and volume of burn pit operations
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 achieves near-zero CO2 emissions and increases hydrocarbon recovery, extending the life of burn pits and reducing operational costs while maximizing hydrocarbon productivity.
Implementation Method 1
a three-phase gravity separator in fluid communication with the recovery flowline via a first flowline
Data Source
AI summary
A gas plant hydrocarbon recovery management system includes a hydrocarbon blowdown header flowline for receiving a hydrocarbon drainage composition, a recovery flowline extending from the header flowline to receive a portion of the composition, a three-phase gravity separator in fluid communication with the recovery flowline via a first flowline, and a hydrocarbon recovery vessel in fluid communication via a second flowline. A three-way control valve is arranged in the recovery flowline and actuatable between a first operational state, where the portion of the composition is entirely diverted through the first flowline and to the three-phase gravity separator, and a second operational state, where some of the portion of the composition is diverted also to the second flowline and to the hydrocarbon recovery vessel. The valve is actuated from the first to the second operational state when a flow rate through the first flowline reaches a predetermined maximum flow rate.