Almost all oil and gas production facilities route gases separated during processing to flare systems for safe disposal. While flaring is necessary for operational safety, it also results in the loss of potentially valuable gases. To recover more of these flared gases, operators install flare gas recovery (FGR) systems. This article discusses the key components and functioning of such FGR setups.
Separator and Compressor Systems
The starting point for any FGR system is the gas-liquid separator installed after primary production separators. These large vessels allow additional separation of hydrocarbon gases from residual liquid fractions. The gases are then routed to compressors that boost the pressure to pipeline specifications. Centrifugal, reciprocating, and screw compressors are commonly used depending on throughput requirements. Multiple compressor trains may be installed in stages to achieve higher pressures.
Operating Modes and Controls
Flare Gas Recovery System units can operate in different modes depending on facility needs. During normal production, recovered gases join the sales line directly. In upset conditions, a recycle loop returns gases from the FGR system inlet to upstream of the separators. Automatic controls switch between modes based on inlet pressure. Blowdown silencers and scrubbers mitigate noise from compressor vents during transitions.
Gas Processing and Dew Point Control
Depending on pipeline specifications, recovered gases may need processing to remove impurities. Commonly used systems include molecular sieve or glycol dehydrators to lower water content. Cooling and refrigeration can further reduce hydrocarbon dew points if needed. Control valves modulate throughput to these units based on continuous analyzer readings.
Fuel Gas System Integration
Most FGR compressors run on a portion of recovered fuel gas. Fuel handling involves metering, pressure regulation and safety accessories like relief valves. Dual fuel configurations allow diesel or electric startup if fuel supply fails. Electronic controllers manage automated transfers between fuel sources. Some operations reuse volatile gases as blending components for fuel improvement.
Piping, Valves and Instrumentation
Reliable piping, valves and controls are essential for smooth FGR plant functioning. Carbon steel is typically used with cathodic protection in sour gas environments. Control valves modulate flows while check valves prevent backflows. Instruments continuously monitor pressures, flows, temperatures and hydrocarbon analyses. Leak detection equipment identifies fugitive emissions for maintenance.
System Optimization and Debottlenecking
Operators conduct regular reviews to optimize existing FGR capacities. Expanding compressors, adding processing trains or debottlenecking constraints can boost throughputs. Advanced automation using programmable logic controllers aids efficiency. Pipeline upgrades may be needed if significant volumes are to be reinjected. Ongoing reliability work prevents shutdowns that result in flaring and production losses.
Case Study: Maximizing Gas Capture in Permian Basin
A leading Permian producer recently installed new FGR facilities across multiple sites to reduce unnecessary flaring. Separator upgrades and two-stage centrifugal compression boosted recoveries by 25%. Processing and piping modifications allowed co-mingling of lower pressure gases prior to reinjection. Automation and Supervisory Control And Data Acquisition (SCADA) systems integrated all plant sections. As a result, flaring volumes reduced by 750 MMSCF per year, translating to annual revenue gains of $4 million from previously wasted gases. The project paid back in under 18 months through reduced emissions penalties and increased sales.
With sophisticated FGR systems, operators can eliminate routine flaring and capture substantial volumes of gases that would otherwise go wasted. Regular optimizations help maximize recoveries. Advanced controls and SCADA integration ensure smooth integrated operations. Such initiatives aid environmental compliance while improving field economics through increased production and gas sales. When conceived and executed comprehensively, flare gas recovery delivers significant returns across emissions, operational and financial metrics.
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This market report also allows you to identify the future opportunity and growth rate of the leading segment based on regions and countries.The research report also covers the comprehensive profiles of the key players in the market and an in-depth view of the competitive landscape worldwide.
The major players in the flare gas recovery systems market include Zeeco, Gardner Denver Nash, John Zink Hamworthy Combustion, AEREON, Pioneer Energy Inc.
This section includes a holistic view of the competitive landscape that includes various strategic developments such as key mergers & acquisitions, future capacities, partnerships, financial overviews, collaborations, new product developments, new product launches, and other developments.Get more information on "Global Flare Gas Recovery Systems Market Research Report" by requesting FREE Sample Copy athttps://www.valuemarketresearch.com/contact/flare-gas-recovery-systems-market/download-sampleMarket DynamicsThe greenhouse gas emission has been on increase in recent years due to expanding global population and improving living standards, especially in developing countries.
The flare emissions also impact on health due to exposure to these pollutants.
EPA has enforced stringent emission regulation for industrial emission.
The emissions standard is focused on limiting toxic air pollutants from chemical preparations facilities.
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