Micro-Scale GTL Units for Stranded Gas Monetization
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Solution Overview
Problem
Conventional Gas-to-Liquids (GTL) processes are economically unviable for small and remote natural gas fields due to high capital and operating costs, and the need for large-scale facilities, making it difficult to monetize small stranded gas resources effectively.
Innovation Solution
The development of micro-scale GTL units capable of processing natural gas from 200 to 1,000 MSCFD, which are modular, transportable, and adjustable to match production rates, allowing for the production of liquid hydrocarbon products such as methanol and dimethyl ether, and can be easily relocated to other gas sources as production declines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional large-scale GTL plants are used, then acceptable returns on investment can be achieved, but the minimum economically viable size requires 10,000-20,000 bbl/d hydrocarbon liquid product or greater, which is too large for small stranded gas fields
Solution Approach 1:
The patent divides the conventional large-scale GTL plant into multiple modular micro-scale units, each capable of independent operation. Each micro-unit processes small quantities of natural gas (200-1,000 MSCFD) and can be deployed in parallel to match the feedstock availability from small stranded gas fields, thereby achieving economic viability without requiring a single large plant
Solution Approach 2:
The patent implements adjustable production capacity where the number of active micro-scale units can be dynamically changed based on gas production rates. This allows the system to adapt from processing small quantities when gas availability is low to handling larger volumes when production increases, maintaining economic efficiency across varying operating conditions
2Ease of manufacture
If micro-scale GTL units are deployed to match small gas field production, then capital and operating costs are reduced, but equipment underutilization occurs when gas production rates change
Solution Approach 1:
The system employs a dynamic configuration where the number of active micro-scale units is adjusted based on real-time or projected gas production rates. When gas availability increases, additional units are activated; when production declines, units are deactivated or relocated, preventing underutilization and maintaining economic efficiency
Solution Approach 2:
The patent changes the operational parameters of the micro-scale units by adjusting feed gas flow rates, reaction conditions, and production targets to match the actual gas supply. This allows each unit to operate at optimal efficiency levels regardless of the overall scale of gas availability from the stranded field
3Reliability
If conventional GTL plants operate for 20-30 years to achieve acceptable returns, then investment is justified, but small stranded gas fields with short production lives (1-10 years) cannot support such long-term operations
Solution Approach 1:
The patent segments the long-term investment horizon into multiple short-term micro-scale unit operations. Each micro-unit can be quickly deployed and relocated to match the short production life of small gas fields (1-10 years), allowing investors to achieve returns through multiple sequential deployments rather than requiring a single long-term commitment
Solution Approach 2:
The system dynamically adapts the operational duration and location of micro-scale units to match the declining production curve of the gas field. As gas production decreases over time, the system can relocate units to new fields or adjust operating parameters to maximize value extraction during the remaining productive life, thereby achieving investment returns aligned with the actual resource duration
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 reduces capital and operating costs, enables the economic monetization of small stranded gas fields, and minimizes equipment underutilization by adjusting production capacity to match changing gas production rates, thereby maximizing cash flow and extending the life of gas resources.
Implementation Method 1
The development of micro-scale GTL units capable of processing natural gas from 200 to 1,000 MSCFD, which are modular, transportable, and adjustable to match production rates, allowing for the production of liquid hydrocarbon products such as methanol and dimethyl ether
Data Source
AI summary
A method of tracking production from an NG source that includes the steps of providing one or more micro-scale GTL units, feeding NG from the source to the micro-scale GTL units, operating the micro-scale GTL units and adjusting the number of micro-scale GTL units employed to track or match the production from the source is provided. In some aspects of the invention, the micro-scale GTL unit includes both syngas manufacture and liquid product synthesis. The liquid product synthesis step may produce methanol, mixed higher carbon number alcohols, dimethyl ether, Fischer-Tropsch liquids, and/or any combination of these products.