Produced Gas Separation With CO2 Liquefaction and Reinjection
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Solution Overview
Problem
Current methods for processing produced gases from wells fail to efficiently and ecologically dispose of unusable gases like carbon dioxide and hydrogen sulfide, often venting them into the atmosphere, which is undesirable due to environmental concerns and economic factors.
Innovation Solution
A process that dehydrates and cools the produced gas to separate hydrocarbon gases from waste gases like carbon dioxide and hydrogen sulfide, converting these waste gases into a liquid form for injection into a separate well, where they can be disposed of in an ecologically acceptable manner, enhancing hydrocarbon recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If waste gases like carbon dioxide are vented into the atmosphere, then disposal is simple and low-cost, but environmental harm increases and ecological sustainability deteriorates
Solution Approach 1:
The patent converts the harmful waste gas (carbon dioxide) into a beneficial substance by injecting it into the underground formation to stimulate hydrocarbon production. The CO2 that would otherwise be vented and cause environmental harm is instead used as a tool to enhance oil and gas recovery, transforming a pollutant into a productive resource
Solution Approach 2:
The patent changes the physical state parameter of carbon dioxide from gaseous to liquid form through cooling and compression processes. This phase change enables the CO2 to be injected into the underground formation as a liquid, where it can effectively stimulate hydrocarbon production while avoiding atmospheric venting
2Manufacturing precision
If produced gas is cooled to separate hydrocarbon gases from waste gases, then separation efficiency improves, but energy consumption increases
Solution Approach 1:
The patent combines the cooling process with the separation process into a single integrated operation. By cooling the produced gas, the system simultaneously achieves both temperature reduction and phase separation of hydrocarbon gases from waste gases, eliminating the need for separate cooling and separation steps
Solution Approach 2:
The patent utilizes phase transition of gases to liquids through cooling. When the produced gas is cooled, hydrocarbon gases condense into liquid form while waste gases remain gaseous, enabling easy separation. This phase change mechanism achieves high separation efficiency without requiring additional energy-intensive separation equipment
3Productivity
If waste gases are injected into the ground to stimulate production, then hydrocarbon recovery increases, but disposal infrastructure complexity increases
Solution Approach 1:
The patent makes the waste gas injection system multi-functional by using it for both disposal and production stimulation. The same injection infrastructure that disposes of waste gases also serves to enhance hydrocarbon recovery, eliminating the need for separate disposal wells and reducing overall system complexity
Solution Approach 2:
The patent enables the waste gas injection system to serve itself by using the injected waste gases as the stimulating agent for hydrocarbon production. The CO2 injected into the formation performs dual functions: it displaces hydrocarbons for recovery while simultaneously being disposed of, making the system self-sufficient
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 prevents atmospheric venting of harmful gases, economically benefits by reusing methanol for carbon dioxide recovery, and stimulates hydrocarbon production by injecting waste gases back into the ground, promoting ecological sustainability.
Implementation Method 1
cooling the produced gas to a temperature at which carbon dioxide and other waste gases are in liquid form
Implementation Method 2
pressurizing the liquid carbon dioxide and other waste gases for injection into an injection well
Data Source
AI summary
Produced natural gas containing carbon dioxide is dehydrated and chilled to liquefy the carbon dioxide and then fractionated to produce a waste stream of liquid carbon dioxide and hydrogen sulfide. Natural gas liquids may be first separated and removed before fractionation. After fractionation, the waste stream is pressurized and transmitted to a remote injection well for injection either for disposal of the waste stream and preferably to urge hydrocarbons toward the producing well. A hydrocarbon stream proceeds from fractionation to a methanol absorber system which removes carbon dioxide gas. The hydrocarbon stream is thereafter separated into at least hydrocarbon gas, nitrogen and helium. Some of the nitrogen is reintroduced into a fractionation tower to enhance the recovery of hydrocarbons. A methanol recovery system is provided to recover and reuse the methanol. The hydrocarbons are sold as natural gas and the helium is recovered and sold. Excess nitrogen is vented.