Oilfield natural gas processing and product utilization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for processing hydrocarbons are inefficient, leading to significant waste and environmental impact due to the need for centralized gas processing plants, which are costly and often result in flaring of associated produced gas, especially in remote locations with declining oil wells, where capacity utilization is low and pipeline limitations are common.
Innovation Solution
A modularized remote hydrocarbon processing system that includes a gas compressor skid, a gas processing skid for thermal separation, a power generation skid, and a blending skid, allowing for on-site separation and utilization of hydrocarbons, eliminating the need for transporting NGLs to fractionation plants and utilizing residual gas for electric power generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If centralized gas processing plants are used, then hydrocarbon separation can be achieved, but high capital and operating expenses are incurred
Solution Approach 1:
The centralized gas processing plant is divided into modular skid-mounted units that can be deployed at remote well sites. Each module performs specific functions (compression, dehydration, NGL separation, power generation) independently, allowing the system to achieve full separation capability while maintaining modularity and reducing overall system complexity.
Solution Approach 2:
A modular processing unit acts as an intermediary between remote well sites and centralized fractionation plants. This intermediate facility performs preliminary separation and processing functions, reducing the burden on both well sites and centralized plants while enabling efficient hydrocarbon recovery at remote locations.
2Productivity
If high-capacity processing plants are constructed, then initial high production volumes can be accommodated, but underutilization occurs as production declines
Solution Approach 1:
The system uses dynamic, modular skid-mounted units that can be added or removed based on production rates. As oil well production declines, processing capacity can be adjusted by removing or deactivating modules, ensuring optimal utilization and avoiding the energy waste associated with underutilized fixed-capacity plants.
Solution Approach 2:
Processing capacity is segmented into discrete modular units rather than a single fixed-capacity plant. This allows the system to scale processing capacity dynamically with production rates, maintaining high utilization efficiency across the declining production lifecycle of remote oil wells.
3Manufacturing precision
If NGLs are transported to fractionation plants, then pure hydrocarbon products can be obtained, but transportation costs and environmental risks increase
Solution Approach 1:
The fractionation function is extracted from centralized plants and integrated into remote modular processing units. This allows NGLs to be separated and purified at the source, eliminating the need for long-distance transportation of volatile hydrocarbon liquids and significantly reducing environmental risks associated with pipeline or truck transport.
Solution Approach 2:
The modular processing unit serves as an intermediary that performs fractionation at remote well sites, eliminating the need to transport NGLs to centralized fractionation plants. This intermediate processing step maintains product purity while avoiding transportation-related environmental hazards.
4Adaptability or versatility
If associated produced gas is flared, then gas processing capacity constraints are avoided, but significant resource waste and environmental damage occur
Solution Approach 1:
The system converts what would be wasted associated produced gas (typically flared due to capacity constraints) into valuable resources. The gas is captured and processed to recover NGLs, and the remaining residue gas is used as fuel for power generation, transforming a harmful waste stream into economic value and reducing environmental damage.
Solution Approach 2:
The modular processing units enable remote well sites to self-sufficiently process and utilize their own associated produced gas. The system recovers NGLs from the gas stream and uses the remaining residue gas to power the processing equipment itself, eliminating the need to flare gas while achieving energy self-sufficiency at remote locations.
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 system reduces waste and environmental impact by enabling efficient on-site processing and utilization of hydrocarbons, improving economic value and reducing transportation risks, while allowing for flexible use of lighter hydrocarbons as fuel or blended into crude oil, thus avoiding flaring and enhancing crude oil product quality.
Implementation Method 1
A gas processing skid is gas flow connected to the gas compressor skid and configured for thermal separation of compressed natural gas received from the gas compressor skid into a first processed gas stream and a first processed liquid stream
Implementation Method 2
A power generation skid is gas flow connected to the gas processing skid and configured to generate electricity from the first processed gas stream received from the gas processing skid
Data Source
AI summary
A remote hydrocarbon processing system comprising a gas compressor skid, gas processing skid, electric power generation skid, liquid storage tank, blending skid, and crude oil source, are fluid flow interconnected and located proximate to a producing well. Produced gases are delivered from the well to the gas compressor skid. Compressed natural gas is delivered to the gas processing skid where it is thermally separated to generate a processed gas stream and a processed liquid stream. The processed gas stream is delivered to the electric power generation skid and burned to generate electricity that may be delivered to an electric power transmission line. The processed liquid stream is delivered to the liquid storage tank. Crude oil from the crude oil source and processed liquid stream from the liquid storage tank are delivered to the Blending skid and blended into a lower viscosity, higher API gravity transportable crude oil.