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are installed
after drilling is complete.
Oil and gas wells
typically produce a mixture of hydrocarbon gases, liquids and 2
water.
Oil and gas wells
the structure at the surface of a well that comprises of valves, spools and adapters
wellhead
to control the pressure from the well
to ensure safe operation and to manage the flow from the well
wellhead
can also provide a means of gas injection or attaching a
pump to increase production.
wellhead
Pressures in the well can exceed….
20,000 kPag
takes the gas- liquid mixture from the wellheads and divides it into three
components - water, condensate, and gas.
separator
takes flow from one well, and separates the phases into produced gas, produced
condensate, and produced water for well monitoring and production accounting
The test separator header
takes flow from all the wells and separates the phases into produced
gas, produced condensate, and produced water, which is metered for accounting purposes
before being recombined and sent to a gas processing facility.
the group separator
a mechanical piece of equipment that is used to increase
the pressure and reduce the volume of a gas stream
compressor
It is critical in natural
gas processing, transportation, and delivery of natural gas to our homes.
compressor
maintains suction
pressure and allows
the compressor to
operate even when
there is no supply of
gas coming into the
compressor
the recycle line
are
not compressible and can cause
catastrophic damage in the
compressor
liquids
require
a suction scrubber to remove any
liquids in the stream prior to
compressing the gas.
most types of compressors
can be a concern in compressors due to changing pressures from compressing and recycling gas, as well as the wide
temperature operating range due to heating from compression and then after-cooling.
hydrates
Common
products stored in tank farms are:
-diesel
-gasoline
-NGLs
-crude
-waste water
-etc
also called oil terminals
tank farms
form in solutions that contain water and gas, like emulsion. Under high pressures and low temperatures, the
water/gas structure will form a crystalline solid that can block flow in pipe
hydrates
The outlet of most
compressors is around
140-160C
the temperature can
increase significantly
every when..?
during compression
can flow to one of two headers,
the group separator header or
the test separator.
Emulsion from the well
tank farms Products supplied from upstream or midstream
facilities are transported via
-pipeline
-truck
-train
-boat
are storage facilities for
hydrocarbon liquids
tank farms
The storage capacity of
a tank farm manages_______ in supply upstream
fluctuations
The storage capacity of
a tank farm manages __(1)___ in supply upstream and ________ _______ to prevent costly delays in distribution
demand downstream
There are two main categories of tank roofs
: fixed and floating
are solidly connected to the top of the tank wall and are either
welded or bolted to remain stationary during the operation of the tank.
fixed roofs
They can be flat cylinders, cones, or domed shaped.
fixed roofs
roofs that
can be internal or external.
floating roofs
similarity of floating and fixed roofs
Both have a roof that floats
on the liquid level in the tank
that can move up or down
as the product level rises and
falls
has an additional fixed roof at the top of the tank
internal floating roof
only uses the floating roof
to separate tank contents from the environment
external floating roof tank
Tanks can have many other components like:
coatings, insulation, mixers, etc.
Transportation of hydrocarbons can be performed by
pipeline, trucking, or rail.
The product is brought into the terminal
by tank cars. The tank cars
contain ..?
hydrocarbon liquids and
flammable vapours
can be attached to the tankcars
to remove the
product. In many
cases, product can be
removed from multiple
tank cars at once.
Hoses with special
couplings
is used to
pump liquid product
from the bottom of the
tank car to the storage
tank at the facility.
pump
can be used to transport liquid hydrocarbons and pressurized gases
Rail cars
The design of the tank car, including the pressure rating and
material, dictates which type of product it can carry. Common commodities include
crude oil, ethanol, diesel, etc.
is also a good alternative when
there is no pipeline infrastructure in place.
Rail transportation
generally considered a safer alternative, with a
lower likelihood of a spill.
pipelines
One of the biggest concerns
for rail transportation is
derailment
enters the bottom
of the tower, contacting
amine as it rises up
sour gas
weak
points of tank cars
Topfittings, heat shields, and
valves
stripped of
H2S and CO2 exits the top of
the contactor
Sweetened gas
enters
the top of the
contactor tower and
flows downward
through the trays of
the tower
Lean amine
absorbs H2S
and CO2 from the
gas.
amine
exits the bottom
of the tower and flows to the
flash drum which operates at
a much lower pressure,
flashing off some of the
absorbed gases.
Rich amine
enters the
regeneration tower
Rich amine
flashes off from the
tower heat and drop in
pressure as it flows down
the tower.
H2S
and CO2
is sent to
a condenser to recover water
and amine which is sent
back to the tower.
Acid gas off the top of the
regeneration tower
can either be sent to a Claus reaction
process to produce elemental sulphur, or to an
acid gas injection compressor.
Acid gas
is sent to a
heater to flash off the
remaining H2S and CO2 in
the amine before it is sent
back to the contactor
The amine from the bottom
of the tower
is pumped from
the regenerator tower back
into the contactor tower.
Amine is cooled to between
40-60°C
___________produced from wells usually has a high water
content.
Natural gas
It is important to remove the water in
order for the gas to meet sales specification requirements..
if not met..
This can cause several issues for natural gas
operations including
freezing and hydrate formation, as
well as corrosion.
enters the glycol
contactor and mixes with
glycol.
Wet gas
exits the
bottom of the contactor
with water stripped from
the gas stream.
glycol
exits
the top of the tower
Dry Gas
drops the pressure of the
rich glycol and allows any initial water vapour
and trapped hydrocarbons to separate from the
liquid prior to the stripping tower.
The glycol flash drum
recovers heat from the
lean glycol which helps
to preheat the rich
glycol before it enters
the stripping tower.
A heat exchanger
enters the stripping
tower and water begins to flash
out of the glycol from the pressure
drop and increased temperature.
Rich glycol
exits the
top of the tower with
potential for some
contaminants like
benzene / toluene /
ethyl-benzene / xylene
(BTEX).
water vapour
Water vapour exits the
top of the tower with
potential for some
contaminants like
-benzene
-toluene
-ethyl-benzene
-xylene
(BTEX).
is heated to remove
remaining excess water content
to complete the regeneration.
Glycol
is an important midstream
process to reduce the vapour pressure of
hydrocarbon liquids to make them safer and
easier to transport.
Stabilization
enters the
inlet surge drum, off gas
begins to flash off, and water
separates into the water
boot.
Condensate from an
upstream process
sent downstream for
treatment and / or disposal
Water off the bottom of the surge
drum
is recovered from the hot
stabilized condensate to preheat the
unstabilized condensate before the
stabilization tower
heat
Gases flash out of
the condensate
stream due to the
heat input into the tower
which
causes lighter end
hydrocarbons to
vapourize.
Gases flash out
of the condensate stream
due to the
heat input into
the tower
maintains a constant
temperature at the bottom of the
tower to ensure any hydrocarbons
with a low boiling point are
vapourized
reboiler
are sent downstream to a compressor to recover the flashed gases back into the gas process.
The gas off the top
of the stabilizer
and surge drum
is an important process for
removing more valuable hydrocarbons such as ethane, propane,
butane
Natural gas liquids (NGLs) recovery
.This process typically operates at high pressure and low
temperatures to cause those hydrocarbons to condense.
Natural gas liquids (NGLs) recovery
enters the process and flows
through a series of heat exchangers to
drop the temperature.
gas
is injected into the stream to
prevent any water in the system from
freezing when the temperature goes
below 0°C.
glycol
is used to drop
the temperature of the gas further,
causing propane and butane and
other NGLs to condense in the gas
stream
Refrigerant propane
is recovered and
separated from the NGLs in the boot of
the low temperature separator
injected
is sent downstream to be regenerated.
glycol
are sent to a
stabilzation tower to remove some
lighter end products and reduce the
vapour pressure
Recovered NGLs
is sent downstream
typically to a compressor to increase
the pressure and is re-injected to the
stripped gas stream or for further
treating / processing.
Stripped gas
maintains
temperature at the
bottom of the tower to
boil off any remaining
light end products.
reboiler
are sent downstream to a
storage bullet which is a
pressurized vessel designed to
store the NGLs at a pressure high
enough to prevent vapourization.
NGLs
play an important role in the safety of hydrocarbon facilities
Flares
They provide a
controlled means of releasing product pressure, volume and energy which can be
very hazardous if contained in the wrong situation.
Flares
The three main components of
a flare system are
-flare header piping
-flare knockout drum
- flare stack
a network of piping throughout a facility that collects relief
flow paths and directs them to the flare knockout
flare header piping
is a vessel that captures liquids from a blowdown or relief event.
The flare knockout drum or
FKOD
is a release of gas and/or liquid product and pressure from the process
piping and equipment.
blowdown
is a tall cylindrical structure that releases
flammable, toxic or corrosive waste vapours high into the air where they are then
combusted into products that are less harmful to the environment.
Flare stack
emissions are tightly monitored and regulated.
Flare stack
keeps a positive
pressure slightly above
atmospheric in the relief
system
A continuous purge of
fuel gas
controlled with a
pressure regulator valve
Pressure
Blowdown from other systems
combine in a relief header and are
directed to the
flare knockout drum
is separated from hydrocarbon
liquids and water
gas
upstream of the
stack tracks the
emission rate
A flow meter
typically natural
gas, is controlled
with a pressure
regulating valve.
Pilot fuel gas
is continuously
burned at the flare stack tip in
order to maintain a constant
source of ignition at the stack.
Pilot fuel gas
are used to convert heavy oil products into lighter products such as diesel, gasoline, and naphtha.
Hydrocracking units
This is achieved
by cracking the longer heavier hydrocarbon molecule chains into shorter chains in a reactor, then saturating these shorter chains with hydrogen
Hydrocracking units
dampens any surges coming
from the inlet and allows for appropriate control of
the feed to the unit.
feed surge drum
is used to feed the
heavy oil into the unit at the
desired rate.
feed pump
is critical for the hydrocracking reaction for temperature
control and saturating the hydrocarbons.
Hydrogen
is critical in the
hydrocracking
unit. Product from the
bottom of the reactor is
cooled and this heat is
used to preheat the feed
oil going to the reactor.
Appropriate temperature
control
The feedstock to the
reactors consists of the
feed oil and hydrogen.
This mixture is preheated
in a charge heater to
bring it up to the
required temperature for
the reaction.
The feedstock to the
reactors consists of the
feed oil and hydrogen.
can come from other units such as a fluidized catalytic cracking unit,
a coker unit, or an atmospheric or vacuum distillation tower including kerosene, gas
oil, light cycle oil, and heavy cycle oil
The feed
can handle feeds with
more aromatic oils better than catalytic cracking processes.
Hydrocracking units
is commonly used in
the place of a fluidized catalytic
cracking unit for jet fuel and diesel
production due to the low aromatic
and sulphur and high hydrogen
content of the products.
Hydrocracking
The
process can yield high quality fuels
and environmentally more friendly fuels
compared to a fluidized catalytic
cracking unit
Hydrocracking
contain
catalysts which help
convert long heavy
chain molecules into
shorter chain saturated
hydrocarbons. Sulfur
and nitrogen impurities
are also removed.
the reactors
is used to separate the hydrogen
rich gas, the hydrocarbon
liquids, and water
A high pressure separator
is recycled back to the reactors
to control the temperature in
the reactors.
Cool hydrogen quench gas
separates the off gas from the
hydrocarbon liquid in order to get
the desired products.
The low pressure separator
can be further processed in an amine
unit to remove hydrogen sulfide
and carbon dioxide.
Off gas from the hydrocracker
are sent for
further processing in another unit
such as a fractionation tower
Hydrocarbon liquids
three types of catalyst bed
-Wire mesh
-Non reactive ceramic balls
-Catalyst pellets
three types of trays
-Quench hydrogen ring
-Liquid collection tray
-Distribution tray
is performed to remove impurities such as sulfur and
nitrogen.
Hydrotreating
impurities such as sulfur and
nitrogen. These impurities are converted to..
ammonia and hydrogen
sulfide.
Other impurities removed during this stage (hydrotreating) of the process
include
nickel, silicon, alkali metals, iron, arsenic, and vanadium
need to occur prior to
the feed interacting with the hydrocracking catalyst, since the impurities
can reduce the catalyst activity. Often the feed is pretreated to remove
impurities
Hydrodenitrogenation and hydrodesulfurization
Common hydrotreating catalysts include
cobalt molybdenum and silica- alumina.
Hydrocracking consists of two main reactions
-Catalytic cracking
-The hydrogenation reaction
uses
heat to break longer heavier molecules into shorter chains with the use
of a catalyst
Catalytic cracking
These shorter chains are then saturated by adding hydrogen
in a hydrogenation reaction.
Catalytic cracking
creates more
heat than is used in the cracking reaction, so the overall hydrocracking
reaction is exothermic. Due to the catalytic cracking occuring in the
presence of hydrogen, the hydrocracking reaction does not produce
coke like in a pure catalytic cracking reaction.
The hydrogenation reaction
decreases over time due to fouling and coking
Catalyst activity
is required to regenerate or replace the catalyst.
shutdown
are used to allow for injection of quench hydrogen
for temperature control and more uniform mixing.
Multiple catalyst beds
is a core component in a modern refinery and
processes about one third of the crude oil produced worldwide.
The Fluidized Catalytic Cracking or FCC unit
It is particularly common in
North America due to its high yield of gasoline over diesel/kerosene.
The Fluidized Catalytic Cracking or FCC unit
produces a combination of olefin rich
hydrocarbon vapours, gasoline, diesel and heavy fuel oil from a
feed of atmospheric / vacuum gas oil from the crude distillation
unit
The FCC unit
is high molecular weight, long chain
hydrocarbons, w ith boiling points above 340 ֯C.
The feed to the FCC
The process utilizes a ____ which lowers
the temperature that the long chain hydrocarbons will crack at.
powdered zeolite catalyst
play an important role in the control of
the FCC operation.
The regen and spent slide valves
They maintain a catalyst barrier between the
regenerator and reactor, preventing the mixing of the hydrocarbon
atmosphere in the reactor and the oxygen rich atmosphere in the
regenerator.
The regen and spent slide valves
They are large hydraulically operated valves designed for the
severe conditions of the FCC unit.
The regen and spent slide valves
operates at extremely
high temperatures between 1000-1400
°F (~540- 760 °C) so that the carbon on
the surface of the catalyst will autoignite. The only heat input into the
process during normal operation is
from this combustion heating the
surface of the catalyst
The regenerator
is then fed to the reactor
standpipe where it mixes with the feed
stream of heavy gas oils and lift gas.
catalyst
causes the long chain hydrocarbon
molecules to breakdown into shorter
molecules. This process is endothermic
so the reactor operates at a lower
temperature than the regenerator.
The heat and activity of the catalyst
separate the
catalyst from the hydrocarbon stream
and return it to the regenerator.
Cyclones in the reactor
must be
maintained in order to circulate the
catalyst from the system.
A positive differential pressure from the
regenerator to the reactor
enters the reactor
standpipe
through feed nozzles to
atomize the liquid and
mix with the lift steam.
The feed stream of
heavy oil
leaves
the regenator
and mixes with
the feed stream.
Regenerated
catalyst
quickly
causes the long chain
hydrocarbons to
crack.
The heat and activity
of the catalyst
cools the
process stream.
The endothermic
reaction
disengage
the catalyst from
the hydrocarbon
vapour stream.
Cyclones in the
reactor
exits the
top of the reactor.
A stream of cracked
hydrocarbon
vapours
collects above
the spent slide
valve and
flows to the
regenerator.
catalysts
enters the bottom
of the regenerator
and mixes with the
temperature
regenerator
spent catalyst. The
in the
is high
enough that it autoignites the catalyst.
air
exits the
reactor
fuel gas
the reactor product vapour enters the bottom of the fractionation tower
fractionation
the fractionation tower splits the
vapour into different products
-Overhead gases which contain
a large amount of olefins
-Gasoline / naphtha cuts that
requires further treating
-Diesel
-Heavy fuel oils
enter the
fractionation tower around 500°C
and begin cooling by mixing with
the slurry from the pump around.
the hot reactor vapours
begin to
condense in the higher trays.
Products are drawn out and sent
downstream or are recycled back
to the tower to provide cooling.
less dense products
flow through a condenser which causes water
and a gasoline product to drop out as liquids.
Overhead gases
is separated
from the hydrocarbon liquid which is either sent downstream or
recycled back to the tower as a reflux stream
water
