Patent Application
20170369791
The present disclosure generally relates to the processing of crude oil. More specifically, embodiments of the disclosure relate to crude quality enhancement using microwaves.
Elemental sulfur and sulfur compounds are naturally present in many petroleum crude oils. The amount of sulfur varies over a wide range; for example, crude oil from Texas contains about 0.1 weight percent sulfur, whereas crude oil from Saudi Arabia and Kuwait contains about 3 weight percent sulfur to 5 weight percent sulfur. Crude oil may also include a wide variety of sulfur-containing compounds. Such sulfur-containing compounds range from hydrogen sulfide, which is a gas at room temperature, to organosulfur compounds that vaporize at over 1000° F.
Sulfur compounds are undesirable because of their odors and because sulfur compounds such as hydrogen sulfide are corrosive. The corrosive nature of sulfur compounds contributes significantly to the costs of construction, operation and maintenance of a petroleum refinery. Additionally, sulfur compounds may cause problems in gasoline engines and can contribute to environmental pollution. Sulfur in crude oil can generate hydrogen sulfide and other sulfur containing gases during transportation and, consequently, increase the difficulty of such operations.
When crude petroleum is processed in an oil refinery, one of the steps is the separation of the crude into various products based on boiling points. The unit typically used for this separation is a distillation column operated at atmospheric pressure and is commonly referred to as the crude still. Such oil refinery processes may yield a variety of useful fuels and desirable petroleum products, such as lower-boiling gasoline, middle distillate fuels such as kerosene and diesel oil, to fuel oil for heating, and higher-boiling waxes and heavy oils such as lubricating oil and asphalt products. The separation of the hydrocarbons also separates the sulfur compounds so that the lower boiling hydrocarbons contain lower-boiling sulfur compounds and higher-boiling hydrocarbons contain higher-boiling sulfur compounds.
Many technologies have been developed relating to sweetening and desulfurizing gasolines and other petroleum stocks depending upon the particular type of sulfur compound to be removed. Some technologies for sweetening, desulfurizing, or both include: oxidation reactions, solvent extraction, adsorption, metal catalysis, and hydrodesulphurization. However, most of these technologies are based on conventional refining techniques and have a relatively high cost. Furthermore, these technologies fail to sufficiently address the problem of removing sulfur and resulting formed sulfur compounds such as H2S.
In some embodiments, a method of processing crude oil is provided. The method includes irradiating water at a first temperature with microwaves to produce heated water at a second temperature such that the second temperature is greater than the first temperature. The method further includes providing the heated water to a crude oil stream. The crude oil stream includes a gas phase, an oil phase, and a water phase. The method also includes providing the crude oil stream to a downstream crude oil processing unit.
In some embodiments, providing the heated water to the crude oil stream includes directing the heated water at a gas-oil interphase of the crude oil stream. In some embodiments, providing the heated water to the crude oil stream includes directing a first portion of the heated water at a gas-oil interphase of the crude oil stream and directing a second portion of the heated water at an oil-water interphase of the crude oil stream. In some embodiments, the method also includes disrupting an oil-water emulsion using the second portion of the heated water. In some embodiments, the method further includes obtaining the water at the first temperature from the crude oil stream. In some embodiments, the method also includes separating solids from the water before irradiating the water with microwaves to produce the heated water at the second temperature. In some embodiments, the water includes treated water from a water treatment unit of a crude oil processing plant. In some embodiments, the crude oil processing unit includes a high pressure production trap (HPPT), a low pressure production trap (LPPT), a stabilization unit, a desalter, or a dehydrator. In some embodiments, the method includes producing a gas stream and a separated crude oil stream from the crude oil processing unit. Additionally, in some embodiments, the method includes boiling an H2S component of the crude oil stream using the heated water and, in some embodiments, boiling light end components of the crude oil stream using the heated water. In some embodiments, the microwaves have a frequency of 915 MHz. In some embodiments, the second temperature is 194° F. to 250° F.
In some embodiments, a system is provided that includes a pipe configured to transport a crude oil stream to a crude oil processing unit and a microwave unit upstream from the crude oil processing unit and coupled to the pipe. The microwave unit is configured to receive water at a first temperature from the crude oil stream and irradiate the water to produce heated water at a second temperature, wherein the second temperature is greater than the first temperature. The outlet of the microwave unit is coupled to an inlet of the pipe such that the inlet is configured to direct the heated water at an oil-gas interphase of the crude oil stream. In some embodiments, the system further includes a solids separator coupled to the microwave unit, the solids separator configured to separate solids from the water before the microwave unit receives the water. In some embodiments, the crude oil processing unit includes a high pressure production trap (HPPT), a low pressure production trap (LPPT), or a stabilization unit. In some embodiments, the crude oil stream is a first crude oil stream having a first composition and the crude oil processing unit is configured to output a second crude oil stream having a second composition. In some embodiments, the system includes a crude oil analyzer configured to determine at least one parameter of the second crude oil stream and a controller. The controller is configured to receive the at least one parameter from the crude oil analyzer, compare the at least one parameter to a respective at least one threshold value and modify a power of the microwaves based on the comparison. In some embodiments, the at least one parameter includes H2S content, salt content, or Reid vapor pressure.
In some embodiments, a system is provided that includes a pipe configured to provide a crude oil stream to a crude oil processing unit and a microwave unit upstream of the crude oil processing unit and coupled to the pipe. The microwave unit is configured to irradiate water at a first temperature to produce heated water at a second temperature, wherein the second temperature is greater than the first temperature. An outlet of the microwave unit is coupled to a first inlet of the pipe such that the first inlet is configured to direct a first portion of the heated water at an oil-gas interphase of the crude oil stream. The outlet of the microwave unit is further coupled to a second inlet of the pipe such that the second inlet configured to direct a second portion of the heated water at an oil-water interphase of the crude oil stream. In some embodiments, the water includes treated water from a water treatment unit. In some embodiments, the crude oil processing unit includes a desalter or a dehydrator. In some embodiments, the crude oil stream is a first crude oil stream having a first composition and the crude oil processing unit is configured to output a second crude oil stream having a second composition such that the crude oil processing unit is configured to output a second crude oil stream having a second composition. In some embodiments, the system includes a crude oil analyzer configured to determine at least one parameter of the second crude oil stream and a controller configured to receive the at least one parameter from the crude oil analyzer, compare the at least one parameter to a respective at least one threshold value, and modify a power of the microwaves based on the comparison. In some embodiments, the at least one parameter includes H2S content, salt content, or Reid vapor pressure.
The present disclosure will now be described more fully with reference to the accompanying drawings, which illustrate embodiments of the disclosure. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
Embodiments of the disclosure include the use of microwave heating to promote the separation of components of crude oil, such as performed in a crude oil processing plant. In some embodiments, microwaves may be used to heat a crude oil stream to promote the separation of sulfur (for example, H2S) and light end components from the crude oil stream. In such embodiments, the microwaves may be used to provide interphase heating between the gas phase and the oil phase of the crude oil stream. In some embodiments, microwaves may be used to heat a crude oil stream to promote the separation of water, salt, or both from the crude oil stream. In such embodiments, the microwaves may be used to provide interphase heating between the oil phase and the water phase of the crude oil stream.
In some embodiments, microwave heating may be used to heat the interphase between the gas phase and the oil phase of the crude oil. In some embodiments, microwave heated water may be directed at the gas-oil interphase of a crude oil stream to promote the separation of sulfur components and light end components. In such embodiments, the gas-oil interphase heating may promote the separation of sulfur (for example, H2S) and light end components, as the composition of the crude oil at the gas-oil interphase includes such components having lower-boiling components than other components of the crude oil. In some embodiments, the gas-oil interphase heating may provide sufficient heating to boil the sulfur components (for example, H2S) and light end components while heavier components remain in the liquid phase. In some embodiments, the gas-oil interphase heating may provide heating to promote the separation of sulfur (for example, H2S) and light end components in a downstream processing unit (for example, a stabilization unit).
In some embodiments, microwave heating may be used to heat the interphase between the oil phase and the water phase of the crude oil. In some embodiments, microwave heated water may be directed at the oil-water interphase of a crude oil stream to promote the separation of water and salt. In such instances, the oil-water interphase heating may disrupt the emulsion present in the oil-water interphase. The disruption of the emulsion may promote the coalescence of larger water droplets that settle to the bottom of the crude oil stream via gravity. The gravity separation of the larger water droplets facilitates the separation of salt dissolved in the water phase of the crude oil. In some embodiments, the oil-water interphase heating may provide heating to promote the separation of water, salt, or both in a downstream processing unit (for example, a desalter).
Advantageously, crude oil processing using the microwave heating techniques described in the disclosure may result in improved economics and operability of a crude oil processing plant, such as by reducing energy costs, maintenance costs, and capital costs. For example, as described herein, crude oil processing using microwave heating in the manner described in the disclosure may reduce or eliminate the energy requirements of a separation unit (for example, a stabilization unit) of a crude oil processing plant. In another example, crude oil processing using microwave heating may eliminate the use of a stabilization unit if the separation achieved by the microwave heating meets or exceeds a crude oil specification.
The stabilizer tower 102 includes multiple trays 114 which, in combination with the heat from the heated stream 110, provide for separation of vapor and liquid from the feed stream 104. The heated stream 110 may be used to generate vaporized crude, depicted as vapor flow 116, from the feed stream 104. As shown in
The fuel cost to operate the stabilizer tower 102 using steam as the heat source 112 or a furnace as the heat source 112 may vary according to the capability of the crude oil processing facility. For example, assuming a fuel gas tariff of about $2.5/million British Thermal Units (MMBtu), the annual fuel gas cost to run the prior art crude oil stabilization operation 100 may be in the range of $2M/year to over $20M/year, depending on production rates. Increasing energy efficiency of a crude oil stripping operation may thus reduce fuel gas consumption and operating costs. The prior art crude oil stripping operation 100 may, in addition to having an energy intensive operation, have a high capital cost, a high risk of losing desired product due to unselective separation, and a high cost of maintenance.
Other crude oil processing operations, such as desalting, of a crude oil processing plant also have associated operational and capital costs. A crude oil desalting operation may use water (for example, freshwater or wash water) to first mix with the remnant water. The mixing dilutes the salt concentration in the remnant water and results in the formation of an oil-water emulsion. The oil-water emulsion may be disrupted by chemical treatment (for example, a demulsifier), and an electrical treatment (for example, an electrostatic field). For example, the electrostatic field generated in a dehydrator and desalter unit promotes coalescence of small water droplets resulting from the mixing between the remnant water and added water. The formation and subsequent coalescence of the water droplets assists in the settling and thus, separation, of water from the oil using gravity. This separation may be modeled according to Stoke's law, shown in Equation 1:
Where Vt is the droplet settling velocity of water, ΔSG is the difference in specific gravity relative to water, d is the droplet diameter in microns, and μ is the viscosity of the continuous phase (that is, the viscosity of the oil). Equation 1 illustrates that heating affects both the specific gravity and viscosity and, consequently, increases the droplet settling velocity Vt. However, although heating decreases the viscosity, oil viscosity is significantly greater than the water viscosity. Thus, heating the crude oil phase may increase the speed of separation of water from the crude oil and, consequently, may increase the separation of salt from the crude oil.
With the foregoing in mind,
The microwave unit 202 receives a crude oil feed stream 210. In some embodiments, the feed stream 210 may be dewatered crude oil. As will be appreciated raw crude oil may be a relatively homogenous 3-phase stream of water, oil and gas. In some embodiments, waste water may be separated from the raw crude oil, such as at an upstream facility, before the crude oil is provided to the crude oil stripping operation 200.
The crude oil feed stream 210 may be directly or indirectly heated by microwaves provided by the microwave source 204 of the microwave unit 202. In some embodiments, the microwave source 204 may provide microwaves having a frequency in the range of about 890 MHz to about 940 MHz or a frequency in the range of about 2400 MHz to about 2500 MHz. In some embodiments, the microwave source 204 may provide microwaves having a frequency of about 915 MHz or about 2450 MHz. In other embodiments, the microwave source 204 may provide microwaves at different frequencies. In some embodiments, the microwave source 204 may be manufactured by Industrial Microwave Systems, LLC, of New Orleans, La., USA. In some embodiments, as described further herein, the microwave source 204 may be used to heat water, and the heated water may be provided to the crude oil feed stream to heat the crude oil.
After heating by the microwave unit 202, the heated crude oil stream 212 may be provided to the pressure vessel 208 for processing. For example, the pressure vessel 208 may be a stabilization unit that operates in a similar manner to the stabilizer tower 102 described supra. Separated gas 214 and stabilized crude oil 216 may exit the pressure vessel 208 and be provided to downstream facilities for further processing.
The microwaves from the microwave source 204 may, by directly or indirectly heating the crude oil feed stream 210, selectively target sulfur-containing components and light end components in the crude oil feed stream 210. In some embodiments, the microwave unit 202 may be coupled to a pipe transporting the crude oil feed stream and may be positioned relatively close to the pressure vessel 208 so that the separated ELS and light end components may be more effectively removed from the vessel 208. In other embodiments, as described further in the disclosure, microwave heating of a crude oil stream may be used to promote dehydration, desalting, and other operations of crude oil processing.
Some embodiments may include the retrofit or modification of existing microwave systems to provide microwave heating of a crude oil stream. For example, in some embodiments a microwave water cut meter used to measure the water content in crude oil may be retrofitted or modified for use as the microwave unit 202 for microwave heating of the crude oil feed stream 210. In some embodiments, the microwave unit 202 may be a spool microwave unit that connects via flanges and does not require any vessel for mounting to existing pipe.
The control unit 206 may control the amount of microwaves emitted to achieve a desired crude oil specification via a feedback loop. For example, the amount of H2S and light end components in the stabilized crude oil 216 may be measured at a sample point 220, and a signal 222 indicative of the amount of H2S and light end components may be provided to the control unit 206 via an electrical circuit. The control unit 206 may provide a control signal 224 to the microwave source 204 to control the power of microwaves irradiating the crude oil feed stream 210. For example, the control unit 206 may provide a controls signal 224 to increase the power of the microwaves of the microwave source 204 or decrease the power of the microwaves of the microwave source 204.
As shown in
In the example embodiment depicted in
The separated water 316 output from the solids separator 312 may be provided to the microwave unit 301 for irradiation by microwaves to produce heated water 318. The heated water 318 may then be provided to the crude oil pipe 302. In some embodiments, the heated water 318 may be heated to a temperature in the range of about 194° F. to about 250° F. In other embodiments, the heated water 318 may be heated to a temperature in the range of about 194° F. to about 250° F. In some embodiments, the temperature of the heated water 318 may be based on the pressure capability of a downstream vessel receiving the crude oil in the crude oil pipe 302. It should be appreciated that such heating may be localized to the heated water 318 and may be sufficient to heat and, in some instances, boil some components (for example, H2S and light end components) of the crude oil. In some embodiments, the microwave unit 301 may have flow chambers having a microwave waveguide that forms a double-ended resonant chamber with multiple radiofrequency (RF) energy reflections.
In some embodiments, the heated water 318 may be provided via a non-metallic pipe that couples the outlet of the microwave unit 301 to an inlet 320 of the crude oil pipe 302. In some embodiments, the inlet 320 of the heated water may be targeted at the oil and gas interphase between the oil phase 306 and the gas phase 304 to direct the heated water 318 at the oil-gas interphase. For example, in such embodiments, the inlet 320 may be located at a level of about 50% to about 60% from the top of the pipe 302.
In some embodiments, the microwave unit 301 may provide microwaves having a frequency in the range of about 890 MHz to about 940 MHz or a frequency in the range of about 2400 MHz to about 2500 MHz. In some embodiments, the microwave unit 301 may provide microwaves having a frequency of about 915 MHz or about 2450 MHz. In other embodiments, the microwave unit 301 may provide microwaves at different frequencies. In some embodiments, the microwave unit 301 may be manufactured by Industrial Microwave Systems, LLC, of New Orleans, La., USA. In some embodiments, the microwave unit 301 may be a retrofit or modification of an existing microwave system. In some embodiments, the microwave unit 301 may be a spool microwave unit that connects via flanges and does not require any vessel for mounting to existing pipe. In some embodiments, the microwave unit 301 may be placed directly in crude oil pipe 302 (in such embodiments, for example, the microwave unit 301 may have an electromagnetic-transparent housing).
The configuration 300 illustrated in
In some embodiments, for example, the configuration 300 shown in
In contrast to the embodiment depicted in
As shown in
In some embodiments, the heated water 412 may be provided via a non-metallic pipe that couples the outlet of the microwave unit 401 to a first inlet 414 of the pipe 402. In some embodiments, the first inlet 414 may be targeted at the oil and gas interphase between the oil phase 406 and the gas phase 404, such that a first portion 416 of the heated water is directed at the oil and gas interphase of the crude oil. For example, in such embodiments, the first inlet 414 may be located at a level of about 50% to about 60% from the top of the pipe 402. As previously discussed, providing the microwave-heated water at the oil-gas interphase provides localized heating that at the interphase to boil or improve the boiling of those components having lesser boiling points (for example, H2S and light end component).
Additionally, the outlet of the microwave unit 401 may be coupled to a second inlet 418 of the pipe 402. In some embodiments, the second inlet 418 may be located at the oil and water interphase between the oil phase 406 and the water phase 408, such that a second portion 420 of the heated water 412 is directed at the oil and water interphase of the crude oil. The second portion 420 of the heated water 412 may be directed at the oil-water interphase to heat the water phase 408 and promote oil-water separation in subsequent processing units, such as a dehydrator or a desalter. As previously discussed, providing the microwave-heated water 412 at the oil-water interphase promotes the break-up of the emulsion present in the oil-water interphase and formation of larger water droplets that settle to the bottom via gravity, thus further promoting the separation of salt from the oil phase. In some embodiments, the use of the second portion 420 of the heated water 412 may depend on the pipe length, such as the pipe length between the inlet 418 and a subsequent processing unit.
In some embodiments, the microwave unit 401 may provide microwaves having a frequency in the range of about 890 MHz to about 940 MHz or a frequency in the range of about 2400 MHz to about 2500 MHz. In some embodiments, the microwave unit 401 may provide microwaves having a frequency of about 915 MHz or about 2450 MHz. In other embodiments, the microwave unit 401 may provide microwaves at different frequencies. In some embodiments, the microwave unit 401 may be manufactured by Industrial Microwave Systems, LLC, of New Orleans, La., USA. In some embodiments, the microwave unit 401 may be a retrofit or modification of an existing microwave system. In some embodiments, the microwave unit 401 may be a spool microwave unit that connects via flanges and does not require any vessel for mounting to existing pipe.
The configuration 400 illustrated in
In some embodiments, for example, the configuration shown in
As shown in
The crude oil pipe 504 may provide a crude oil stream to the mixer 506. The mixer 506 may be used, in some embodiments, to promote mixing of the crude oil steam. In some embodiments, the mixer 506 may be eliminated and the operation 500 may not include the mixer 506.
The microwave unit 508 and solids separator 512 may operate in a manner similar to the microwave source and solids separator described supra and illustrated in
The filtered water 520 output from the solids separator 512 may be provided to the microwave unit 508 for heating by microwaves. The microwave unit 508 (which, in some embodiments, includes the microwave source) may output heated water 522 which is then provided to the crude oil feed stream via an inlet 524 of the pipe 504. In some embodiments, the heated water 522 may be provided via a non-metallic pipe that couples the outlet of the microwave unit 508 to the inlet 524. In some embodiments, the inlet 524 of the crude oil pipe 504 may be located such that the heated water 522 is directed at the oil and gas interphase of the crude oil feed stream. For example, in such embodiments, the inlet 524 to the crude oil pipe 504 may be located at a level of about 50% to about 60% from the top of the pipe 504.
In some embodiments, the microwave unit 508 may provide microwaves having a frequency in the range of about 890 MHz to about 940 MHz or a frequency in the range of about 2400 MHz to about 2500 MHz. In some embodiments, the microwave unit 508 may provide microwaves at a frequency of about 915 MHz or about 2450 MHz. In other embodiments, the microwave unit 508 may provide microwaves at different frequencies. In some embodiments, the microwave unit 508 may be manufactured by Industrial Microwave Systems, LLC, of New Orleans, La., USA. In some embodiments, the microwave unit 508 may be coupled to the pipe 504 transporting the crude oil feed stream and positioned relatively close to the pressure vessel 510 so that the separated H2S and light end components may be more effectively removed from the vessel 508. As previously noted, some embodiments may include the retrofit or modification of existing microwave systems to provide heating for crude oil stripping.
After heating by the microwave unit 508, the heated crude oil stream may be provided to the pressure vessel 510 for separation. For example, separated gas 526 and separated crude oil 528 may exit the pressure vessel 510 and be provided to downstream facilities for further processing. Additionally, produced water 530 from the crude oil may exit the pressure vessel 510.
The control system 502 includes a controller 532 and an analyzer 534. The analyzer 534 may detect the properties of the separated crude oil 528 to determine parameters (for example, properties and composition) of the separated crude oil 528. For example, in some embodiments, the analyzer 534 may analyze the separated crude oil 528 to determine the amount of H2S present in the separated crude oil 528, the amount of light end components present in the crude oil 528, and the Reid vapor pressure (RVP) of the separated crude oil 528. The analyzer 534 may output a signal 536 indicative of the determined parameters of the separated crude oil 528 to the controller 532.
The controller 532 receives the signal 536 and may determine whether the crude oil parameters deviate from a crude oil specification for the separated crude oil 528. Based on the determination, the controller 532 may provide a control signal 538 to the microwave unit 508. The control signal 538 may modify the power of microwaves used to irradiate the treated water 522 and, consequently, the temperature of the heated water 522 provided to the crude oil feed stream via the inlet 524. In some embodiments, the controller 532 may compare the crude oil parameter to a stored value, such as a value obtained from the crude oil specification. In some embodiments, the comparison may determine whether the crude oil parameter deviates from the stored value by a threshold amount or threshold percentage. In some embodiments, the controller 532 may compare the crude oil parameter to a threshold value to determine whether crude oil parameter is less than or exceeds the threshold value. In some embodiments, the control system 502 may monitor and control the microwave unit 508 based on one parameter or multiple parameters. In other embodiments, the control system 502 may monitor and control the microwave unit 508 based on a parameter (for example, temperature of the heated water 522).
For example, in some embodiments, the amount of H2S in the separated crude oil 528 may be compared to a threshold value for stabilized crude oil that meets or exceeds a crude oil specification. If the controller 532 determines that the amount of H2S in the separated crude oil 528 exceeds the threshold value, the controller 532 may increase the power of the microwave unit 508 via the control signal 538. To promote removal of H2S, for example, the controller 532 may increase the power of the microwave unit 508 to raise the temperature of the heated water 522, thus providing more heating at the oil-gas interphase of the crude oil.
In some embodiments, the controller 532 may include a processor and memory to enable processing of crude oil parameters received from the analyzer. For example, the controller 532 may include one or more processors. In some embodiments, the controller 532 may include an application-specific integrated circuit (AISC). Additionally, in some embodiments the controller 532 may include a single-core processors and multicore processors. The controller 532 may further include a memory (which may include one or more tangible non-transitory computer readable storage mediums) such as volatile memory, such as random access memory (RAM), and non-volatile memory, such as ROM, flash memory, a hard drive, any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof. The memory may store executable computer code having computer program instructions for implementing one or more techniques described in the disclosure, For example, the executable computer code may include instructions for processing parameters of crude oil and controlling a microwave unit in accordance with embodiments of the present disclosure.
In some embodiments, the control system 502 may include or implement aspects of the performance monitoring described in U.S. Pat. No. 9,092,124 entitled “System and method for effective plant performance monitoring in gas oil separation plant (GOSP)” and issued Jul. 28, 2015, a copy of which is incorporated by reference.
The crude oil pipe 604 may provide a crude oil stream to the mixer 606. The mixer 606 may be used, in some embodiments, to promote mixing of the crude oil steam. In some embodiments, the mixer 606 may be eliminated and the operation 600 may not include the mixer 606.
The microwave unit 608 (which may include a microwave source) may operate in a manner similar to the microwave source and separator illustrated supra and described in
In some embodiments, the microwave unit 608 may provide microwaves having a frequency in the range of about 890 MHz to about 940 MHz or a frequency in the range of about 2400 MHz to about 2500 MHz. In some embodiments, the microwave unit 608 may provide microwaves at a frequency of about 915 MHz or about 2450 MHz. In other embodiments, the microwave unit 608 may provide microwaves at different frequencies. In some embodiments, the microwave unit 608 may be manufactured by Industrial Microwave Systems, LLC, of New Orleans, La., USA. In some embodiments, the microwave unit 608 may be positioned relatively close to the pressure vessel 610 so that the separated H2S and light end components may be more effectively removed from the vessel 610.
After heating by the microwave unit 608, the heated crude oil stream may be provided to the pressure vessel 610 for gas and liquid separation. Separated gas 618 and separated crude oil 620 may exit the pressure vessel 610 and be provided to downstream facilities for further processing. As also shown in
Some embodiments may include the retrofit or modification of existing microwave systems to provide heating for crude oil stripping. For example, in some embodiments a microwave water cut meter used to measure the water content in crude oil may be retrofitted or modified for use as the microwave unit 608 for heating for separation of H2S and light end components in the crude oil stripping operation 600.
The control system 602 may operate in a manner similar to the control system 502 depicted in
The controller 624 receives the signal 628 and may determine whether the crude oil parameters deviate from a crude oil specification for the separated crude oil 620. Based on the determination, the controller 624 may provide a control signal 630 to the microwave unit 608. The control signal 630 may modify the amount of microwaves used to heat the treated water 612 and, consequently, the temperature of the heated water 614 provided to the crude oil feed stream via the inlet 616. In some embodiments, the controller 624 may compare the crude oil parameter to a stored value, such as a value obtained from the crude oil specification. In some embodiments, the comparison may determine whether the crude oil parameter deviates from the stored value by a threshold amount or threshold percentage. In some embodiments, the controller 624 may compare the crude oil parameter to a threshold value to determine whether crude oil parameter is less than or exceeds the threshold value. In some embodiments, the control system 602 may monitor and control the microwave unit 608 based on one parameter or multiple parameters. In other embodiments, the control system 602 may monitor and control the microwave unit 608 based on a parameter (for example, temperature of the heated water 614).
For example, in some embodiments, the amount of H2S in the separated crude oil 620 may be compared to a threshold value for stabilized crude oil that meets or exceeds a crude oil specification. If the controller 624 determines that the amount of H2S in the separated crude oil 620 exceeds the threshold value, the controller 624 may modify the operation of the microwave unit 608 via the control signal 630. To promote removal of H2S, for example, the controller 624 may increase the power of the microwave unit 608 to raise the temperature of the heated water 614, thus providing more heating at the oil-gas interphase of the crude oil.
In another example, the amount of salt in the separated crude oil 620 may be compared to a threshold salt value for stabilized crude oil that meets or exceeds a crude oil specification. If the controller 624 determines that the amount of salt in the separated crude oil 620 exceeds the threshold value, the controller 624 may modify the operation of the microwave unit 608 via the control signal 630. To promote removal of salt, for example, the controller 624 may increase the power of the microwave unit 608 to raise the temperature of the heated water 614 and provide more heating at the oil-water interphase of the crude oil.
In some embodiments, the controller 624 may include a processor and memory to enable processing of crude oil parameters received from the analyzer. For example, the controller 624 may include one or more processors. In some embodiments, the controller 624 may include an application-specific integrated circuit (AISC). Additionally, in some embodiments the controller 624 may include a single-core processors and multicore processors. The controller 624 may further include a memory (which may include one or more tangible non-transitory computer readable storage mediums) such as volatile memory, such as random access memory (RAM), and non-volatile memory, such as ROM, flash memory, a hard drive, any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof. The memory may store executable computer code having computer program instructions for implementing one or more techniques described in the disclosure, For example, the executable computer code may include instructions for processing parameters of crude oil and controlling a microwave unit in accordance with embodiments of the present disclosure.
In some embodiments, the control system 602 may include or implement aspects of the performance monitoring described in U.S. Pat. No. 9,092,124 entitled “System and method for effective plant performance monitoring in gas oil separation plant (GOSP)” and issued Jul. 28, 2015, a copy of which is incorporated by reference.
In some embodiments, a microwave source may be placed upstream of one or more units of a gas oil separation plant (GOSP).
As shown in
Wash water 730 may also be provided to the desalter 708 for removal of salt from the crude oil to meet or exceed salt content specifications for the crude oil. Separated water 732 exits the desalter 708, and the crude oil 734 output from the desalter 708 is provided to the stabilization unit 710. The crude stabilization unit 710 may also include or be referred to as a stripper unit and may separate H2S and light end components 736 from the crude oil to meet H2S and vapor pressure specifications for the crude oil. The stabilization unit 710 outputs stabilized crude 738 having, for example, salt content, H2S, and light end components within a desired crude oil specification.
In some embodiments, a microwave unit 740 may be placed upstream of the HPPT 702 (for example, at an entrance to the HPPT 702) to improve separation of oil, gas, and water in the crude oil in the HPPT 702. As shown in
In some embodiments, a gas oil separation plant having the units depicted in
In some embodiments, one or more of the microwave units 740, 742, 744, 746, and 748 may each be controlled via control system similar to the control systems 502 and 602 discussed supra. For example, if the amount of salt in the stabilized crude oil 738 exceeds a threshold salt value, the microwave unit 746 may be controlled to increase the temperature of the crude oil provided to the desalter 708. Similarly, other microwave units may be controlled via a control system in response to monitored crude oil parameters in the crude oil 738.
The filtered water may be irradiated with microwaves in a microwave to produce heated water (block 806). For example, the filtered water from the solids separator may be at a first temperature and the filtered water may be heated to a second temperature by irradiation with microwaves. The heated water from the microwave unit may be directed at a gas-oil interphase of the crude oil stream (block 808). For example, the heated water may be directed from an outlet of the microwave unit to an inlet at a crude oil pipe that directs the heated water to the gas-oil interphase of the crude oil stream. The crude oil stream may then be provided to a crude oil processing unit (such as a high pressure production trap (HPPT), low pressure production trap (LPPT), or stabilization unit) for processing (block 810). As discussed supra, the heating of the gas-oil interphase via the heated water may promote separation of components (for example, H2S and light end components) of crude oil stream in the crude processing unit.
A second portion of the heated water from the microwave unit may be directed at an oil-water interphase of the crude oil stream (block 908). For example, the heated water may be directed from an outlet of the microwave unit to a second inlet at a crude oil pipe that directs the heated water to the oil-water interphase of the crude oil stream in the pipe. The crude oil stream may then be provided to a crude oil processing unit (such as a dehydrator or desalter) for processing (block 910). As previously discussed, the heating of the gas-oil interphase via the heated water may promote separation of components (for example, H2S and light end components) of crude oil stream. Additionally, the heating of the oil-water interphase via the heated water may promote separation of water and salt of the crude oil stream via, in some embodiments, gravity separation.
Ranges may be expressed in the disclosure as from about one particular value, to about another particular value, or both. When such a range is expressed, it is to be understood that another embodiment is from the one particular value, to the other particular value, or both, along with all combinations within said range.
Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the embodiments described in the disclosure. It is to be understood that the forms shown and described in the disclosure are to be taken as examples of embodiments. Elements and materials may be substituted for those illustrated and described in the disclosure, parts and processes may be reversed or omitted, and certain features may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description. Changes may be made in the elements described in the disclosure without departing from the spirit and scope of the disclosure as described in the following claims. Headings used described in the disclosure are for organizational purposes only and are not meant to be used to limit the scope of the description.
This application claims priority from U.S. Provisional Application No. 62/355,683 filed Jun. 28, 2016, and titled “CRUDE QUALITY ENHANCEMENT BY SIMULTANEOUS CRUDE STABILIZATION, SWEETENING, AND DESALTING VIA MICROWAVE ASSISTED HEATING.” For purposes of United States patent practice, this application incorporates the contents of the Provisional Application by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62355683 | Jun 2016 | US |
