Organic rankine cycle based conversion of gas processing plant waste heat into power
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Solution Overview
Problem
Crude oil associated gas processing plants generate significant waste heat that is typically released into the environment, rather than being utilized for energy conversion or cooling, leading to inefficiencies and increased energy consumption.
Innovation Solution
Integration of a waste heat recovery system using an Organic Rankine cycle, Kalina cycle, or modified Goswami cycle that captures low-grade waste heat to generate power and provide cooling, by pumping a working fluid through a network of heat exchangers to heat and expand it, driving a turbine and generator, and utilizing the cooled fluid for in-plant or ambient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If waste heat is released into the environment, then the system is simple and operates continuously, but energy is lost and environmental harm increases
Solution Approach 1:
The patent converts the harmful waste heat release into a beneficial energy source by implementing an Organic Rankine Cycle system. The waste heat from gas processing plant equipment (compressors, separators, dehydrators) is captured and used to vaporize an organic working fluid, which then drives a turbine to generate electricity. This transforms the previously harmful thermal pollution into a useful energy resource, simultaneously reducing energy loss and environmental harm while managing system complexity through modular heat exchanger integration.
2Productivity
If waste heat is captured and converted to power, then energy efficiency improves and power is generated, but system complexity and initial investment increase
Solution Approach 1:
The Organic Rankine Cycle system serves multiple functions simultaneously: it generates electricity from waste heat, provides cooling through the condensation process, and can be integrated with existing gas processing equipment. The working fluid cycle performs both power generation and thermal management functions, reducing the need for separate systems and justifying the initial complexity investment through multifunctional operation.
Solution Approach 2:
The patent implements a nested system architecture where the Organic Rankine Cycle components (evaporator, turbine, condenser, pump) are integrated within and around existing gas processing plant equipment. The evaporator is positioned to capture heat from compressor discharge lines, and the condenser utilizes ambient air or water cooling resources already present at the site. This nesting approach minimizes the footprint and complexity of the additional system while maximizing power generation capability.
3Use of energy by stationary object
If a heating fluid stream is used to transfer waste heat, then heat transfer efficiency improves, but the system requires additional fluid circulation infrastructure
Solution Approach 1:
The patent introduces a heating fluid stream as an intermediary medium to transfer thermal energy from the waste heat sources (compressors, separators, dehydrators) to the Organic Rankine Cycle evaporator. This intermediate fluid circulation system enables efficient heat transfer by providing a controlled thermal coupling between the process equipment and the power generation system, while the closed-loop circulation minimizes infrastructure requirements compared to direct heat extraction methods.
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 enables the conversion of waste heat into carbon-free power and reduces energy consumption by providing in-plant sub-ambient cooling and ambient air conditioning, optimizing energy use based on environmental conditions and demand.
Implementation Method 1
a waste heat recovery heat exchanger configured to heat a heating fluid stream by exchange with a heat source
Implementation Method 2
an energy conversion heat exchanger configured to heat the working fluid by exchange with the heated heating fluid stream
Implementation Method 3
The turbine and generator are configured to generate power by expansion of the heated working fluid
Implementation Method 4
The turbine and generator are configured to generate power by expansion of the heated working fluid
Implementation Method 5
The cooling element is configured to cool the expanded working fluid by exchange with cooling fluid
Implementation Method 6
a pump configured to pump a working fluid to a pressure of between 1.1 Mpa and 1.2 MPa
Data Source
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AI summary
A system includes a waste heat recovery heat exchanger configured to heat a heating fluid stream by exchange with a heat source in a crude oil associated gas processing plant. The system includes an Organic Rankine cycle energy conversion system including a pump, an energy conversion heat exchanger configured to heat the working fluid by exchange with the heated heating fluid stream, a turbine and a generator configured to generate power by expansion of the heated working fluid, a cooling element configured to cool the expanded working fluid after power generation, and an accumulation tank. The heating fluid flows from the accumulation tank, through the waste heat recovery heat exchanger, through the Organic Rankine cycle energy conversion system, and back to the accumulation tank.