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 to centralized plants, resulting in underutilization of resources and increased costs, especially in remote locations where production decline rates are high and pipeline capacities are limited, often necessitating gas flaring.
Innovation Solution
A modular, remote hydrocarbon processing system comprising gas compressor, processing, power generation, and blending skids that dehydrate, compress, thermally separate, and utilize hydrocarbons on-site, allowing for the generation of electricity and blending of liquids with crude oil to create a higher-value product, thereby reducing waste and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If centralized gas processing plants are used to process natural gas from remote wells, then gas processing and purification can be achieved, but transportation costs increase and pipeline capacity limitations occur
Solution Approach 1:
The centralized processing system is segmented into modular processing units that can be distributed to remote well locations. Each module handles specific processing functions (dehydration, compression, NGL separation) independently, allowing gas to be processed at or near the source rather than transported long distances to a central facility.
Solution Approach 2:
The system transitions from a single centralized processing location to a distributed network of processing modules across multiple locations. This spatial redistribution eliminates the need for long-distance gas transportation while maintaining processing quality through standardized modular units.
2Adaptability or versatility
If high-capacity gas processing plants are constructed to accommodate initial high production volumes, then future gas processing capacity is ensured, but the plants become underutilized as production rates decline
Solution Approach 1:
The processing system transitions from a fixed, static capacity plant to a dynamic, scalable modular configuration. Modules can be added or removed based on actual production rates, allowing the system to adapt flexibly to changing well productivity without over- or under-capacity issues.
Solution Approach 2:
Instead of constructing complete high-capacity plants that exceed actual needs, the system implements partial processing capacity through modular units that can be expanded incrementally. This avoids excessive capacity while ensuring sufficient processing ability through scalable deployment.
3Manufacturing precision
If NGLs are transported to fractionation plants for separation into pure products, then product purity is achieved, but transportation costs and environmental risks increase
Solution Approach 1:
The fractionation process is segmented and integrated directly at the wellsite processing modules rather than requiring separate transportation to distant fractionation plants. This keeps the entire value chain (processing, separation, storage) localized, eliminating transportation-related environmental risks while maintaining product purity through dedicated separation equipment.
4Ease of operation
If associated produced gas is flared due to lack of pipeline capacity or processing options, then gas disposition is achieved, but valuable energy resources are wasted and environmental harm occurs
Solution Approach 1:
The processing modules provide self-service capabilities at remote well locations, handling dehydration, compression, and NGL separation without requiring external pipeline infrastructure or centralized processing facilities. This eliminates the need to flare gas due to infrastructure limitations while capturing and utilizing the energy resources locally.
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 eliminates the need for transporting NGLs to fractionation plants and residue gas to other users, enhances processing flexibility, reduces waste and environmental harm by utilizing hydrocarbons as fuel for power generation, and creates a higher-value modified crude oil product that can be sold within existing pipeline specifications.
Implementation Method 1
a gas compressor skid positioned proximate to a natural gas or associated gas producing well and configured to receive, dehydrate, and compress produced natural gas from the well
Implementation Method 2
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 3
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.