Oil Stabilizer Tower Gas Recirculation for Emission Control

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Solution Overview

Problem

Conventional oil stabilization processes face challenges in maximizing oil volumetric output and minimizing fugitive emissions, as they often result in reduced oil production rates and increased gas production, with inefficiencies in separation and processing leading to suboptimal conditions for oil recovery and emission control.

Innovation Solution

A system and method that includes a separator, stabilizer tower, and heater treater, where the heater treater output gas is recirculated to the stabilizer tower, and a portion of the heater treater oil output is recycled, enhancing the separation process and increasing the volumetric flow rate of stabilized oil by promoting gas dissolution in the oil stream, while reducing emissions through optimized pressure and temperature management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional separation and processing methods are used, then oil and gas can be separated, but oil volumetric output is reduced and fugitive emissions increase

Engineering Contradiction:

Improveoil volumetric outputVSAvoidfugitive emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent recycles the gas stream from the heater treater back to the stabilizer tower, converting what would be fugitive emissions into a beneficial recirculated stream that enhances oil swelling and volumetric output. This transforms the harmful gas release into a useful process feature that increases oil recovery.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent implements continuous recirculation of the heater treater gas stream to the stabilizer tower, maintaining continuous useful action rather than intermittent or batch processing. This continuous recirculation ensures sustained enhancement of oil swelling and prevents emission interruptions.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If heater treater output gas is recirculated to stabilizer tower, then volumetric flow rate of stabilized oil increases, but system complexity increases

Engineering Contradiction:

Improvevolumetric flow rate of stabilized oilVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The stabilizer tower performs multiple functions: it not only stabilizes the oil stream but also receives and processes the recirculated gas stream from the heater treater. This multi-functionality reduces the need for additional dedicated equipment, thereby limiting the increase in system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the gas recirculation function with the existing stabilizer tower operation, combining what could be separate processes into a unified system. This integration approach increases productivity while avoiding the complexity of entirely separate recirculation infrastructure.

Inventive Principle:

Principle #5Merging (Combining)

3Volume of moving object

If gas is recirculated to promote dissolution in oil stream, then oil swell increases, but pressure management becomes more difficult

Engineering Contradiction:

Improveoil swellVSAvoidpressure management

Core Design Contradiction:

Volume of moving objectVSStress or pressure

Solution Approach 1:

The recirculation of gas from the heater treater to the stabilizer tower creates a feedback loop where the gas stream that would otherwise be emitted is instead reused to enhance oil swelling. This feedback mechanism naturally regulates pressure by redirecting gas flow back into the system where it can be dissolved into the oil stream under controlled conditions.

Inventive Principle:

Principle #23Feedback

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

The system increases the volumetric flow rate of stabilized oil by 1.8% and decreases fugitive emissions, maintaining the fuel heating value and commercial value of the oil, with improved separation and retention of higher hydrocarbons, and reduced Reid Vapor Pressure, indicating lower emission levels.

Implementation Method 1

enhancing the separation process and increasing the volumetric flow rate of stabilized oil by promoting gas dissolution in the oil stream

Methodology Applied

Scientific EffectGas dissolution: Absorption (physical)

Implementation Method 2

The separator 1230 reduces the pressure of the live crude stream 1320 and outputs an oil stream 1332, a gas stream 1334, and a water stream 1336

Methodology Applied

Scientific EffectPressure reduction: Depressurisation

Implementation Method 3

a heater treater 1240, which typically outputs an oil stream 1342, a gas stream 1344, and a water stream

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20230383199A1System and Method of Reducing Emissions And Increasing Swell In An Oil Conditioning Process

Publication Date: 2023.11.30 MAZE IP LLC

AI summary

A system for conditioning live crude oil to produce stabilized oil that can be stored in a conventional oil storage tank and hydrocarbon gas includes a stabilizer tower and a heater treater. The stabilizer tower receives oil from separators at the wellhead production facility and outputs oil to the heater treater. The heater treater outputs gas back into the stabilizer tower and, optionally, recycles a portion of oil output back into the heater treater, which enhances oil output.