System and method for oil and condensate processing

• US 10,465,492 B2
• Filed: 05/25/2018
• Issued: 11/05/2019
• Est. Priority Date: 05/20/2014
• Status: Active Grant

• Current Assignee: KATA Systems LLC
• Original Assignee: KATA Systems LLC
• Inventors: Ricotta, Joseph A.
• Primary Examiner(s): Robinson, Renee
• Application Number:
  US15/989,581
• Publication Number:
  US 20180274347A1
• Time in Patent Office: 529 Days
• CPC Class Codes: B01D 17/02 Separation of non-miscible liquids
• CPC Class Codes: B01D 17/0202 by ab- or adsorption
• CPC Class Codes: B01D 17/0214 with removal of one of the phases
• CPC Class Codes: B01D 2257/702 Hydrocarbons
• CPC Class Codes: B01D 3/143 by two or more of a fractionation, separation or rectification step
• CPC Class Codes: B01D 3/42 Regulation; Control
• CPC Class Codes: C10G 33/06 with mechanical means, e.g. by filtration
• CPC Class Codes: C10L 2290/543 Distillation, fractionation or rectification for separating fractions, components or impurities during preparation or upgrading of a fuel
• CPC Class Codes: C10L 3/06 Natural gas; Synthetic natural gas obtained by processes not covered by C10G, C10K3/02 or C10K3/04 liquefying by pressure and cold treatment F25J
• CPC Class Codes: C10L 3/101 Removal of contaminants
• CPC Class Codes: E21B 43/20 Displacing by water
• CPC Class Codes: E21B 43/34 Arrangements for separating materials produced by the well

Abstract

A system and method for the on-site separating and treating of a hydrocarbon liquid stream at an oil and gas production site is disclosed. The system comprises an oil and condensate distillation unit and a vapor recovery unit. In one embodiment, the oil and condensate distillation unit operates at low pressure or vacuum conditions to reduce the vapor pressure above the column of oil within a distillation column, thereby increasing the production of oil and condensate and capturing entrained natural gas otherwise lost or burned off. In another embodiment, oil from the distillation column can be measured by a flow meter and then transferred to one or more of an oil tank, a mobile tank, and an oil pipeline. Optionally, produced water at the production site can be run through the oil and condensate distillation unit to reduce the volume of produced water. The system further functions to improve the quality and volume of recovered natural gas and to decrease air pollution, in addition to increasing oil and condensate production at the well site.

Claims

1. A system for processing a produced fluid from a wellbore at an on-site production facility, the produced fluid including oil, natural gas and water, comprising:

a separator to separate the oil, natural gas and water at a first pressure;

a distillation unit configured to receive the oil downstream from the separator and reduce the pressure, the distillation unit configured to separate natural gas from the oil, wherein the distillation unit operates in a vacuum at between approximately 0 psig and 14 psig, and wherein the pressure in the distillation unit is controlled by a valve positioned downstream from the distillation unit;

a first conduit to transfer oil from the distillation unit;

a lease automatic custody transfer (LACT) unit interconnected to the first conduit to measure a volume of oil transferred through the first conduit and transfer title of the oil from a first entity to a second entity; and

further comprising a reflux drum to receive vapor from the distillation unit, wherein liquid that condenses in the reflux drum flows through a second conduit to the distillation unit.

2. The system of claim 1, wherein the first pressure in the separator is controlled by a valve positioned between the separator and the distillation unit.

3. The system of claim 1, further comprising a third conduit to transfer natural gas separated from the oil from the distillation unit to a generator which converts the natural gas into electricity.

4. The system of claim 1, wherein the LACT unit includes a pump and a flow meter.

5. The system of claim 1, further comprising a vapor recovery unit positioned downstream from the distillation unit to receive natural gas separated from the oil.

6. The system of claim 5, further comprising a third conduit to transfer the separated natural gas from the distillation unit to the vapor recovery unit.

7. The system of claim 1, wherein the oil is transferred downstream from the LACT unit to a mobile tank.

8. The system of claim 1, wherein the oil is transferred downstream from the LACT unit to an oil pipeline.

9. The system of claim 1, wherein the oil is routed, downstream of the LACT unit, from the first conduit to an oil storage tank.

10. The system of claim 1, further comprising a heat exchanger to provide heat energy to the oil upstream from the distillation unit, wherein the heat exchanger recovers waste heat from sources at the on-site production facility.

11. The system of claim 1, further comprising a third conduit to inject one or more of natural gas, fuel gas, and compressed vapor into the distillation unit.

12. A system for processing a produced fluid from a wellbore at an on-site production facility, the produced fluid including oil, natural gas and water, comprising:

a separator to separate the oil, natural gas and water at a first pressure;

a distillation unit configured to receive the oil downstream from the separator and reduce the pressure, the distillation unit configured to separate natural gas from the oil, wherein the distillation unit operates in a vacuum at between approximately 0 psig and −

14 psig, and wherein the pressure in the distillation unit is controlled by a valve positioned downstream from the distillation unit;

a first conduit to transfer oil from the distillation unit;

a lease automatic custody transfer (LACT) unit interconnected to the first conduit to measure a volume of oil transferred through the first conduit and transfer title of the oil from a first entity to a second entity; and

a second conduit to inject one or more of natural gas, fuel gas, and compressed vapor into the distillation unit.

13. The system of claim 12, wherein the first pressure in the separator is controlled by a valve positioned between the separator and the distillation unit.

14. The system of claim 12, wherein the LACT unit includes a pump and a flow meter.

15. The system of claim 12, wherein the oil is transferred downstream from the LACT unit by the first conduit to one or more of a mobile tank, an oil storage tank, and an oil pipeline.

16. The system of claim 12, further comprising a reflux drum to receive vapor from the distillation unit, wherein liquid that condenses in the reflux drum flows through a third conduit to the distillation unit.

17. The system of claim 12, further comprising a heat exchanger to provide heat energy to the oil upstream from the distillation unit.

18. A system for processing a produced fluid from a wellbore at an on-site production facility, the produced fluid including oil, natural gas and water, comprising:

a separator to separate the oil, natural gas and water at a first pressure;

a heat exchanger to heat the oil from the separator, wherein the heat exchanger recovers waste heat from sources at the on-site production system;

a distillation unit configured to receive the oil downstream from the separator and the heat exchanger and reduce the pressure, the distillation unit configured to separate natural gas from the oil, wherein the distillation unit operates in a vacuum at between approximately 0 psig and −

14 psig, and wherein the pressure in the distillation unit is controlled by a valve positioned downstream from the distillation unit;

a first conduit to transfer oil from the distillation unit; and

a lease automatic custody transfer (LACT) unit interconnected to the first conduit to measure a volume of oil transferred through the first conduit and transfer title of the oil from a first entity to a second entity.

19. The system of claim 18, further comprising a reflux drum to receive vapor from the distillation unit, wherein liquid that condenses in the reflux drum flows through a second conduit to the distillation unit.

20. The system of claim 18, further comprising a second conduit to inject one or more of natural gas, fuel gas, and compressed vapor into the distillation unit.