Replacing Regen Gas with Sales Gas in Dehydrators
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Solution Overview
Problem
In hydrocarbon processing plants, the inefficient use of regen gas in liquid recovery units leads to energy waste and increased operational costs, particularly during low plant feed rates when sales gas compressors are subjected to partial recycle.
Innovation Solution
Implementing an optimization logic using a computer system to control the flow of regen gas and sales gas in liquid recovery units, where the sales gas is used to replace regen gas in the dehydration unit when the sales gas flow rate meets or exceeds the regen gas flow rate, thereby optimizing energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If sales gas is used to replace regen gas in the gas dehydrator, then energy conservation is improved and operational costs are reduced, but the moisture level of sales gas must be controlled to ensure effective desiccant regeneration
Solution Approach 1:
The system changes the parameter of gas composition by substituting sales gas for regen gas in the gas dehydrator, while using a moisture level sensor and control logic to adjust and maintain the moisture content within acceptable ranges to ensure effective desiccant regeneration
Solution Approach 2:
A moisture level sensor continuously monitors the moisture content in the gas stream, providing feedback to the control system that adjusts the flow rates of sales gas and regen gas to maintain optimal conditions for desiccant regeneration while maximizing energy conservation
2Productivity
If the sales gas flow rate is used to replace regen gas flow rate, then productivity is improved by eliminating reprocessing, but the flow rate balance must be precisely controlled
Solution Approach 1:
The sales gas compressor and control system perform multiple functions: they not only compress and deliver sales gas to customers but also dynamically adjust sales gas flow to replace regen gas in the gas dehydrator, eliminating the need for separate reprocessing operations
Solution Approach 2:
The system uses dynamic control logic that continuously compares sales gas flow rate with regen gas flow rate requirements, automatically adjusting flow control valves to maintain optimal flow balance and maximize productivity while adapting to changing operational conditions
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 fully recycles the regen gas compressor, resulting in additional energy conservation and cost savings, while eliminating the need for reprocessing sales gas products.
Implementation Method 1
A moisture-carrying sweet gas stream is flowed through a gas dehydrator carrying desiccants. The desiccants adsorb moisture in the sweet gas stream.
Implementation Method 2
A moisture-free regen gas is flowed at a first volumetric flow rate through the gas dehydrator to regenerate the desiccants by adsorbing the moisture from the desiccants.
Data Source
AI summary
A moisture-carrying sweet gas stream is flowed through a gas dehydrator carrying dessicants. The dessicants absorb moisture in the sweet gas stream. A moisture-free regen gas is flowed at a first volumetric flow rate through the gas dehydrator to regenerate the dessicants by absorbing the moisture from the dessicants. Sales gas is received at a second volumetric flow rate from a sales gas compressor. It is determined that the second volumetric flow rate of the sales gas is at least equal to the first volumetric flow rate of the regen gas. In response and to optimize regeneration gas (regen gas) usage in liquid recovery units, the regen gas flowed through the gas dehydrator is replaced with the sales gas.