Oilfield natural gas processing and product utilization
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Solution Overview
Problem
The existing methods for processing hydrocarbons are inefficient and wasteful, leading to significant environmental impact and economic losses due to the need for transporting hydrocarbons over long distances and the practice of flaring associated produced gas, which is both wasteful and environmentally harmful.
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 transportation to centralized plants and enabling the use of hydrocarbons as fuel for electricity generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hydrocarbons are transported to centralized processing plants, then processing can be performed, but transportation costs and environmental impact increase significantly
Solution Approach 1:
The centralized processing system is segmented into modular processing units that can be distributed to remote locations. Each module contains essential processing equipment (compressors, separators, dehydrators) that can function independently or in combination with other modules, eliminating the need for long-distance hydrocarbon transportation while maintaining processing capabilities.
Solution Approach 2:
Modular processing units serve as intermediaries between remote hydrocarbon sources and centralized infrastructure. These units perform preliminary processing functions (separation, dehydration, compression) locally, transforming raw hydrocarbons into processed products that can be efficiently transported or utilized on-site, thereby reducing transportation energy losses and environmental impact.
2Reliability
If associated produced gas is flared, then safety is maintained, but valuable resources are wasted and environmental harm increases
Solution Approach 1:
The system converts the previously harmful practice of gas flaring into a beneficial process by capturing associated produced gas and utilizing it as fuel for on-site power generation. The gas that would have been burned for safety reasons is now processed and used to operate compressors and other equipment, transforming a waste stream into a valuable energy resource while maintaining safety through controlled processing.
Solution Approach 2:
The modular processing system enables facilities to be self-sufficient by using captured associated produced gas to power on-site equipment. The processed gas fuels compressors and generators, allowing the facility to serve its own energy needs without external fuel supplies or gas flaring, thereby eliminating resource waste while maintaining operational safety.
3Productivity
If high-capacity centralized plants are constructed, then initial high production volumes can be accommodated, but underutilization occurs as production rates decline
Solution Approach 1:
The system transitions from static, fixed-capacity centralized plants to dynamic, scalable modular units. Modules can be independently activated or deactivated based on actual production rates, allowing the processing capacity to dynamically adapt to declining well productivity. This eliminates underutilization by ensuring processing capacity always matches production volume.
Solution Approach 2:
The processing capability is divided into discrete modular units that can be deployed in numbers matching the number of active producing wells. Each module handles a specific production rate, and as wells decline or are completed, modules are deactivated or relocated, preventing the underutilization that occurs with fixed-capacity centralized facilities.
4Loss of energy
If modularized remote processing is implemented, then transportation needs are eliminated, but device complexity increases
Solution Approach 1:
Each modular processing unit is designed as a universal, multi-functional package that can handle various hydrocarbon streams (natural gas, associated gas, condensate) and perform multiple processing functions (separation, dehydration, compression, heating). This standardization reduces overall system complexity despite the distributed architecture, as each module is a self-contained, interchangeable unit with standardized interfaces and 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
This system reduces waste and environmental impact, enhances the economic value of hydrocarbons, and provides flexible utilization of hydrocarbon components, allowing for their use as electric power generation fuel or blended into crude oil, thereby minimizing the need for flaring and optimizing resource use.
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 compress or 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.