Offshore Separation Heat Network Using Compression Heat Integration
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Solution Overview
Problem
Conventional offshore fluid processing systems occupy significant space and weight, require high energy usage, and have large demands for heating and cooling utilities, limiting fluid handling capacity and increasing capital and operating costs.
Innovation Solution
A single stage separation module integrated with a heat network that uses produced fluids as heating and cooling media, eliminating the need for multiple compressors and separate heating/cooling systems, and optimizing glycol regenerator operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple compressors are used to compress flash gas from each separator stage, then gas compression is achieved, but the system occupies significant space and adds substantial weight
Solution Approach 1:
The patent combines multiple compression functions into a single integrated compressor unit that handles flash gas from multiple separator stages simultaneously. This merging of compression functions reduces the number of separate compressors needed, thereby decreasing platform weight and space occupation while maintaining the required gas compression capability.
Solution Approach 2:
The integrated compressor system is designed to perform multiple compression functions for different gas streams from various separator stages through a single unit. This multi-functional approach allows one compressor to replace what would traditionally require multiple separate compressors, reducing overall system weight and footprint.
2Productivity
If dedicated cooling medium is used to remove heat from each compressor, then gas compression cooling is achieved, but the system requires high energy usage and large cooling utility demands
Solution Approach 1:
The patent converts the waste heat generated by compression into a useful resource by using it for heating processes within the platform. Instead of discarding this heat or requiring additional cooling utilities, the system captures and utilizes the compression heat for heating applications, thereby reducing overall energy consumption and cooling utility demands while maintaining effective compression cooling.
3Temperature
If multiple waste heat recovery units are installed to support heating requirements, then heating capability is improved, but the system occupies significant space and adds substantial weight
Solution Approach 1:
The patent integrates waste heat recovery functionality into the existing compression system rather than installing separate dedicated heating units. The compression process itself becomes the heat source, and the heat exchange is accomplished through integrated heat exchangers within the compression system, eliminating the need for multiple separate waste heat recovery units and reducing platform space requirements.
Solution Approach 2:
The compression system is designed to serve dual purposes: gas compression and heat provision for heating requirements. This multi-functional integration allows the same equipment to provide both mechanical compression and thermal energy, eliminating the need for separate heating infrastructure and reducing overall platform space occupation.
4Productivity
If staged de-pressurizing through multiple separators is used, then fluid separation is achieved, but the system requires high energy usage for intermediate heating between stages
Solution Approach 1:
The patent utilizes the heat generated during compression and the thermal energy from produced fluids to provide intermediate heating between separation stages. Instead of requiring external heating utilities for each stage, the system recovers and redistributes thermal energy within the process stream, reducing overall heating energy consumption while maintaining effective staged de-pressurizing and separation.
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
Reduces space and weight, minimizes utility consumption, and lowers operational costs by integrating heating and cooling processes, resulting in a more efficient and compact offshore fluid processing system.
Implementation Method 1
A heat network is coupled between the inlet line and the single stage separation module. The heat network is configured to heat the fluid using gas from the gas stream.
Implementation Method 2
a single stage separation module configured to separate the fluid into a gas stream, an oil stream, and a water stream
Data Source
AI summary
A system for processing oil and gas at an offshore facility includes a single stage separation module. A gas stream from the single stage separation module is pressurized in a primary compressor, and then is used to heat the incoming oil and gas upstream of the single stage separation module. Flash gas from treatment of an oil stream from the single stage separation module is pressurized in a flash gas compressor and then is used to heat glycol utilized in a gas dehydration unit. The pressurized flash gas is then commingled with the gas stream from the single stage separation module upstream of the primary compressor.