Well-Stream Multiphase Separator Pressure Control for Methane Recovery
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Solution Overview
Problem
Existing well stream flowback processes result in significant carbon emissions due to flaring of separated gases, and there is a need for more efficient separation methods that reduce the carbon footprint and recover valuable hydrocarbons for reuse.
Innovation Solution
A multiphase separator system that maintains a controlled pressure range of 15.7 psia to 500 psia, using back pressure devices and angled plates to separate light hydrocarbons from heavier fluids and solids, enabling recovery of over 95% of methane without compression and allowing the recovered gases to be used for on-site power or sales.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional separation techniques are used to separate well stream components, then gas-liquid-solid separation is achieved, but carbon emissions increase due to flaring of separated gases
Solution Approach 1:
The patent converts the harmful practice of flaring separated gases into a beneficial process by capturing the light hydrocarbon gas phase and routing it through a back pressure device to maintain separator pressure, thereby recovering valuable hydrocarbons that would otherwise be lost and converted into carbon dioxide through combustion
2Loss of substance
If pressure is maintained in the multiphase separator using a back pressure device, then hydrocarbon recovery is improved, but device complexity increases
Solution Approach 1:
The back pressure device operates automatically to maintain the pressure differential across the separator, using the flow characteristics of the well stream itself to regulate pressure without requiring external control systems or additional energy input, thereby achieving self-regulating hydrocarbon recovery
3Loss of substance
If compression is used to recover light hydrocarbons, then recovery efficiency increases, but energy consumption and device complexity increase
Solution Approach 1:
The patent achieves methane recovery without compression by changing the pressure parameter management approach - using a back pressure device to maintain elevated pressure in the separator (15.7 to 500 psia range) rather than using compression downstream, thereby recovering over 95% of methane through pressure control alone
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
The system effectively reduces carbon emissions by recovering and utilizing light hydrocarbons for on-site power generation or sales, achieving greater than 95% methane recovery and minimizing the need for compression, while maintaining efficient separation of gases from liquids and solids.
Implementation Method 1
separating the second stream in a multiphase separator into a first portion including light hydrocarbons that are in the gas phase and a second portion including liquid hydrocarbons, water, and sand
Implementation Method 2
maintaining, by the back pressure device, a pressure in the multiphase separator in a range of from 15.7 psia to about 500 psia
Data Source
AI summary
Hydrocarbon gas capture from a well stream can involve recovering light hydrocarbon gases from liquids and solids via a multiphase separator that is upstream of a sand removal system. Pressure is controlled in the multiphase separator to facilitate hydrocarbon gas capture. The light hydrocarbon gases can be recovered for sale or can be used on-site.