Non-condensable Gas Stripping for Hydrocarbon Upgrading
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Solution Overview
Problem
Hydrocarbon processing facilities face challenges in reducing capital and operating costs while improving environmental performance, as the use of steam for various functions such as stripping, heat transfer, and power generation is costly and environmentally impactful.
Innovation Solution
Implementing non-condensable gases as an alternative to steam for stripping, heat transfer, and power generation in hydrocarbon processing facilities, integrating them into the process to eliminate the need for steam and reduce greenhouse gas emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam is used for stripping, heat transfer, and power generation in hydrocarbon processing facilities, then facility performance and process reliability are maintained, but capital costs and operating costs increase significantly
Solution Approach 1:
The patent changes the physical-chemical parameters of the processing system by replacing steam (condensable gas) with non-condensable gases such as nitrogen, carbon dioxide, or recycled process gases. This fundamental parameter change eliminates the need for steam generation infrastructure, water treatment systems, and condensate handling equipment, thereby reducing capital costs while maintaining the stripping, heating, and power generation functions through alternative mechanisms
Solution Approach 2:
The patent extracts and removes the steam generation and water treatment subsystems from the hydrocarbon processing facility. By eliminating the steam cycle entirely and using non-condensable gases directly for process functions, the system removes the associated capital investment in boilers, turbines, condensers, and water treatment plants, while preserving the core hydrocarbon processing functionality
2Productivity
If steam is used for stripping and heat transfer, then hydrocarbon separation efficiency is improved, but operating costs and environmental footprint increase
Solution Approach 1:
The patent implements self-service by using non-condensable gases that are either already present in the process stream or can be generated as byproducts. For example, nitrogen is used for stripping without requiring external steam generation, and the stripped hydrocarbons are directly combusted to provide heat for the process, creating a self-sufficient system that eliminates continuous operating costs associated with steam production and water treatment
Solution Approach 2:
The patent converts what would normally be waste streams into useful resources. The hydrocarbons stripped from the crude oil, which would otherwise be wasted or require additional processing, are combusted to provide the heat needed for the stripping and heating operations. This converts a potential waste product into a valuable energy source, eliminating the need for external steam generation and reducing operating costs
3Use of energy by moving object
If steam is used for power generation and heat transfer, then energy needs are met, but greenhouse gas emissions increase
Solution Approach 1:
The patent changes the energy conversion pathway by eliminating the steam cycle and using direct combustion of stripped hydrocarbons to generate heat and power. Non-condensable gases drive the process, and the energy is extracted directly through combustion and heat exchange rather than through steam turbine cycles, reducing the carbon footprint associated with water heating and steam generation
4Adaptability or versatility
If steam infrastructure is installed for multiple process functions, then process versatility is achieved, but capital investment requirements increase
Solution Approach 1:
The patent achieves universality by using non-condensable gases to perform multiple functions that traditionally required steam. The same nitrogen or carbon dioxide stream provides stripping, heating, and power generation functions throughout the facility, eliminating the need for separate steam generation, distribution, and condensate handling infrastructure for each process unit
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 approach reduces capital and operating costs while maintaining facility performance and significantly lowering greenhouse gas emissions by utilizing non-condensable gases for hydrocarbon separation, heat generation, and power production, eliminating the need for steam-based systems.
Implementation Method 1
contacting the hydrocarbon liquid with stripper gas, thereby transferring at least a portion of volatile hydrocarbons in the hydrocarbon liquid to the stripper gas
Implementation Method 2
separating the stripper gas and the volatized hydrocarbons removed from the hydrocarbon liquid by condensing the volatized hydrocarbons
Implementation Method 3
combusting the fuel as gas in a fired heater to produce heat which is conveyed to the hydrocarbon liquid
Implementation Method 4
injecting the fuel as gas into a turbine to generate power
Implementation Method 5
recovering the waste heat directly with the process fluid
Data Source
AI summary
Non-condensable gas is used as an alternate to steam at hydrocarbon processing facilities removing any steam requirements thereby reducing greenhouse gas emissions, and improving profitability through capital and operating cost reductions. The non-condensable gas serves at least two functions sequentially in heavy hydrocarbon processing; firstly, providing the non-condensable gas as a stripping medium to evolve lighter hydrocarbons from the heavy hydrocarbon feedstock followed by secondly directing the same non-condensable gas and any evolved non-condensable gas at operating conditions for use as at least one of heat through combustion or power through electricity generation.