Variable Multi-Phase Fluid Conversion System for Remote Gas Processing
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Solution Overview
Problem
Current natural gas processing technologies at remote oil well sites are inefficient and unable to effectively manage variable compositions of associated gas, leading to unnecessary flaring and waste of valuable components, due to energy-intensive processes and limited adaptability to changing gas compositions, resulting in reduced production capacity and environmental emissions.
Innovation Solution
A modular, scalable system for managing variable multi-phase fluid conversion that uses automated feedback and control to direct gas constituents to different application units, adjusting flow and composition in real-time to meet demand, incorporating a gas conditioning subsystem, compressor, and Joule-Thomson separation to produce methane-rich and blended gases for efficient use in onsite or offsite applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If membrane separation is used to process natural gas, then gas can be separated into methane-rich stream, but the process is energy intensive and cannot remove ethane effectively
Solution Approach 1:
The system changes the operating parameters of the membrane separation process by operating at lower pressures (avoiding 1000+ PSI requirements) and uses multiple membrane stages with different selectivity characteristics to achieve effective ethane removal while reducing energy consumption. The patent specifies operating pressures in the range of 10-100 atm rather than the conventional 1000+ PSI, and employs staged separation to progressively remove different hydrocarbon components.
2Manufacturing precision
If Joule-Thomson or cryogenic separation is used to remove NGLs, then methane-rich gas can be produced, but the process is energy intensive and requires onsite electrical power
Solution Approach 1:
The system segments the gas separation process into multiple distinct stages: initial NGL removal via Joule-Thomson effect, followed by membrane separation stages, and final polishing stages. Each stage handles a specific portion of the separation task, allowing the system to achieve high methane purity without requiring continuous high-energy input. The segmented approach enables flexible operation where energy-intensive stages can be optimized or bypassed based on feed gas composition.
Solution Approach 2:
The system introduces intermediate storage and blending stages between the Joule-Thomson separation and final product delivery. These intermediaries allow the system to decouple the energy-intensive separation process from continuous high-purity product demand, enabling the system to operate at lower energy input levels while maintaining product quality through strategic blending of streams from different separation stages.
3Power
If natural gas generators are used at remote well sites, then power can be generated, but the generators require near pipeline quality natural gas which is often not available
Solution Approach 1:
The system implements dynamic control of the separation process to continuously adapt to variations in feed gas composition. Controllers adjust operating parameters (pressure, temperature, flow rates) in real-time based on online analysis of the feed stream composition. This dynamic operation allows the system to maintain generator-quality gas output even when feed gas quality varies significantly, enabling reliable power generation from associated gas with varying alkane content.
4Manufacturing precision
If the entire associated gas flow is processed through separation, then NGLs can be removed, but production volume is reduced and valuable components are wasted
Solution Approach 1:
The system applies partial separation action by removing only the excessive NGL components that would interfere with downstream applications, rather than removing all NGLs. The membrane separation stages are configured to remove ethane and heavier components to levels sufficient for generator fuel quality while preserving valuable propane and butane components. This selective partial removal maintains both product quality and production volume.
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 utilization of natural gas constituents, reduces flaring, and enhances production capacity by efficiently processing a wider range of gas compositions, providing customizable management and adaptable operation to changing fuel demands and gas source content, thereby minimizing environmental impact and maximizing energy output.
Implementation Method 1
a gas conditioning subsystem that receives a flow of input gas from a gas source input gas stream of varying composition comprising methane and non-methane hydrocarbons with the gas conditioning subsystem converting the input gas into conditioned gas
Implementation Method 2
a compressor subsystem adjusting pressure of the conditioned gas
Implementation Method 3
a separation subsystem comprising a Joule-Thomson (JT) apparatus in fluid communication with the first blending subsystem that receives a conditioned gas stream and separating at least a portion of the conditioned gas using a thermal management subsystem and Joule-Thompson effect to condense heavier hydrocarbons out of the conditioned gas stream
Implementation Method 4
separating at least a portion of the conditioned gas using a thermal management subsystem and Joule-Thompson effect to condense heavier hydrocarbons out of the conditioned gas stream
Implementation Method 5
separating at least a portion of the conditioned gas using a thermal management subsystem and Joule-Thompson effect to condense heavier hydrocarbons out of the conditioned gas stream, to produce (a) a condensed liquid comprising primarily non-methane hydrocarbons
Data Source
AI summary
A method and apparatus for managing variable, multi-phase fluid conversion to output fuel and energy for providing customizable management for processing a volume of natural gas including a volume of methane and a volume of other alkanes that may be cleaned of the other alkanes using a conversion system to create synthesis gas and other fuel products to be used in onsite or combined heat and power or cogeneration applications. In particular, the method, system and apparatus provide for automated feedback and control directing various gas constituents to different application units with allocations according to settings system parameters to quickly and efficiently meet demand for various products while making adjustments in real time.