Modular Natural Gas Processing for Stranded Associated Gas Capture
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Solution Overview
Problem
Conventional methods for processing associated gas from oil wells are inflexible and costly, often leading to gas being flared due to varying compositions and pressures, which limits revenue potential and requires expensive, site-specific facilities.
Innovation Solution
A modularized natural gas processing system comprising a compressor, cooling unit, ethylene glycol regeneration unit, low-temperature gas-liquid separator, deethanizer, and condensers, allowing for flexible handling of different gas compositions and pressures to produce high-value natural gas liquids and compressed natural gas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If site-specific facilities are constructed to capture associated gas, then gas capture capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by designing a modular processing facility that can handle multiple gas types and compositions through standardized equipment units. The facility uses universal components like compressors, dehydrators, and fractionators that can process different gas streams (associated gas, flare gas, stranded gas) without requiring complete site-specific customization, thereby reducing overall facility complexity while maintaining capture capability.
Solution Approach 2:
The processing facility is segmented into modular functional units (compression, cooling, dehydration, fractionation) that can be independently configured and scaled. This segmentation allows the facility to be adapted to different gas compositions by simply adjusting or reconfiguring specific modules rather than redesigning the entire facility, reducing complexity while maintaining reliability.
2Device complexity
If conventional processing methods are used for associated gas, then processing simplicity is maintained, but adaptability to varying gas compositions deteriorates
Solution Approach 1:
The patent implements dynamics by incorporating adjustable processing parameters and reconfigurable equipment settings that allow the facility to adapt to varying gas compositions. The modular design enables dynamic adjustment of operating conditions (temperature, pressure, flow rates) and equipment configuration based on the specific characteristics of the incoming gas stream, maintaining both simplicity and adaptability.
Solution Approach 2:
The facility utilizes parameter changes by allowing modification of processing conditions (temperature, pressure, residence time) and equipment specifications to match different gas compositions. This enables the same basic facility design to handle varying gas types by simply changing operational parameters rather than requiring complete redesign.
3Ease of manufacture
If gas is flared instead of captured, then operational cost is reduced, but loss of substance increases
Solution Approach 1:
The patent converts the previously harmful practice of flaring (which wasted valuable gas resources) into a benefit by capturing and processing the gas through modular facilities. The system transforms what would be discarded flare gas into valuable products (natural gas liquids, compressed natural gas), simultaneously reducing operational costs associated with gas purchase and eliminating resource waste.
Solution Approach 2:
The facility enables self-service by allowing operators to capture and process their own associated and flare gases using modular units, reducing dependence on external gas supply contracts and eliminating the need to purchase replacement gas to compensate for flaring losses.
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
Enables the capture and processing of raw stranded associated gas, converting it into high-value natural gas liquids and compressed natural gas products, enhancing revenue potential by accommodating varying inlet conditions and compositions.
Implementation Method 1
a compressor for compressing the natural gas into a compressed gas
Implementation Method 2
a cooling unit for cooling the compressed gas
Implementation Method 3
a low-temperature gas-liquid phase separator for: separating the cooled compressed gas into a separator gas, a hydrocarbon liquid and a liquid water/ethylene glycol
Implementation Method 4
a deethanizer comprising a top section and a bottom section; the top section configured to separate the heated hydrocarbon liquid into a top section gas and a top section liquid
Implementation Method 5
the top section gas sent to the at least one condenser for cooling and condensing into a condenser liquid
Implementation Method 6
an ethylene glycol regeneration unit for injecting ethylene glycol into the cooling unit
Data Source
AI summary
Methods and systems for processing natural gas to meet gas pipeline specifications and/or recovering natural gas liquids (NGL). The natural gas is cooled and distilled such that propane and heavier components are produced as a bottoms NGL product, and inerts, methane, ethane, and other lighter portions are produced as a fuel gas grade/quality residue gas product stream. The gas can optionally be treated to remove hydrogen-sulfide and/or carbon dioxide. The NGL product can be split into a marketable propane and butane liquefied petroleum gas (LPG) liquid product and a natural gas condensate product.