Method and an apparatus for obtaining energy by expanding a gas at a wellhead

• US 9,394,764 B2
• Filed: 03/29/2011
• Issued: 07/19/2016
• Est. Priority Date: 03/29/2010
• Status: Active Grant

• Current Assignee: Sime S.r.l.
• Original Assignee: Sime S.r.l.
• Inventors: Favilli, Stefano, Leitempergher, Giacinto, Scibola, Luciano
• Primary Examiner(s): Ta, Tho D
• Application Number:
  US13/638,598
• Publication Number:
  US 20130015669A1
• Time in Patent Office: 1,939 Days
• Field of Search: 290/1.R, 290/43
• US Class Current: 1/1
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: F01D 15/00 Adaptations of machines or engines for special use; Combinations of engines with devices driven thereby
• CPC Class Codes: F02C 1/00 Gas-turbine plants characterised by the use of hot gases or unheated pressurised gases, as the working fluid by the use of combustion products F02C3/00, F02C5/00
• CPC Class Codes: F02C 1/02 the working fluid being an unheated pressurised gas
• CPC Class Codes: F03B 13/10 Submerged units incorporating electric generators or motors
• CPC Class Codes: F03G 7/04 using pressure differences or thermal differences occurring in nature F03G7/06 takes precedence
• CPC Class Codes: F05B 2220/602 with energy recovery turbines
• CPC Class Codes: F05D 2220/62 with energy recovery turbines
• CPC Class Codes: F17D 1/075 by mere expansion from an initial pressure level, e.g. by arrangement of a flow-control valve
• CPC Class Codes: Y02B 10/50 Hydropower in dwellings
• CPC Class Codes: Y02E 10/20 Hydro energy

Abstract

A method and an apparatus (100) for reducing the pressure of a natural gas (2) at a wellhead of a natural gas field. The method provides prearranging an energy recovery expansion device (20), which comprises a stator and a rotor mechanically connected with a power generator (29), and a gas passageway between the rotor and the stator, and conveying the natural gas into the passageway of the energy recovery expansion device (24) to cause a rotation of the rotor and the expansion of the gas, the pressure being reduced from the extraction pressure (P₁) to the use pressure (P₂), which makes it possible to obtain an electric power (W) during the expansion, adapted to satisfy the energy requirements of the gas extraction unit, in particular of an offshore platform, without installing local electric generators. In order to allow a reliable operation of a recovery expansion device, such as a turbine, a means is provided for finely separating solid and liquid matter present in the gas, as well as a means (7) for conditioning the gas entering the expansion device, which may comprise a feeding means (12) of an additive into the gas (3), said additive adapted to decrease the formation temperature of the solid, and, in an advantageous way in case of higher amount of water, a means for heating the gas such that the temperature is maintained above the formation temperature of the solid.

Claims

1. An apparatus for reducing the pressure of a fluid comprising a natural gas, water, and solid residues, said fluid being available at an extraction pressure at a wellhead of a natural gas field and for recovering energy directly from said natural gas at said wellhead, said apparatus comprising:

a vertical elongated container having an inlet nozzle for said fluid for connection with said wellhead and an outlet nozzle for a treated natural gas, said outlet nozzle above said inlet nozzle in said vertical elongated container;

a cyclone centrifugal separation stage arranged in said vertical elongated container at said inlet nozzle, said cyclone centrifugal separation stage configured for separating said water and solid residues from said natural gas of said fluid,

an inertial separation stage arranged in said vertical elongated container at said outlet nozzle for separating liquid droplets and mist from the gas,

a gas-conditioning means arranged downstream of said outlet nozzle and configured to prevent a formation of ice in said natural gas during a subsequent expansion in a rotor,

an energy recovery expansion device arranged downstream of said gas-conditioning means for expanding said natural gas until a use pressure is reached, said energy recovery expansion device having said rotor rotatably arranged about an own axis and a stator, and a gas passageway defined between said rotor and said stator;

an electric power generator that is mechanically connected to said rotor of said energy recovery expansion device, so that said electric power generator can generate an electric power when a stream of said natural gas exiting from said wellhead is conveyed in said passageway of said energy recovery expansion device, thus causing a rotation of said rotor and causing the gas to expand; and

an electric power extraction means for extracting said electric power generated by said electric power generator.

2. An apparatus according to claim 1, wherein said additive feeding means comprises an additive flow rate adjustment means that is adapted to decrease the formation temperature of a solid and/or a heating electric power adjustment means for adjusting said heating electric power according to said extraction pressure and/or to said use pressure.

3. An apparatus according to claim 1, comprising a substantially isentropic expansion valve that is installed in parallel with respect to said energy recovery expansion device, and a diversion means for at least in part diverting said natural gas from said energy recovery expansion device to said expansion valve and vice-versa.

4. An apparatus according to claim 1, comprising an expansion valve that is installed in parallel with respect to said energy recovery expansion device, and a diversion means for at least in part diverting said natural gas from said energy recovery expansion device to said expansion valve and vice-versa.

5. An apparatus according to claim 1, wherein said cyclone centrifugal separation stage of the solids comprises multiple cyclones.

6. An apparatus according to claim 1, wherein said inertial separation stage comprises a plurality of multi-folded plates that are arranged adjacent to one another to form a pile.

7. An apparatus according to claim 1, wherein said conditioning means comprises an additive feeding means for feeding an additive into said stream of said natural gas, said additive adapted to decrease the formation temperature of a solid from water present in said natural gas, in particular in combination with a hydrocarbon compound of said natural gas, more in particular in combination with methane and/or ethane.

8. An apparatus according to claim 7, wherein said additive feeding means is adapted to feed an additive selected from the group comprised of:

an alcohol and a glycol.

9. An apparatus according to claim 7, wherein said additive feeding means is adapted to feed an additive selected from the group comprised of:

methanol and ethylene glycol.

10. An apparatus according to claim 1, wherein said conditioning means comprises a heating means of said stream of said natural gas adapted to increase the temperature of said stream of said natural gas up to a predetermined temperature value, such that during said expansion up to said use pressure, the temperature of said treated gas remains above the formation temperature of a solid that may be formed starting from water present in said natural gas, in particular in combination with a hydrocarbon compound of said natural gas, such that the temperature of said treated gas remains above the freezing temperature of water.

11. An apparatus according to claim 10, wherein said heating means is an electric heating means that is adapted to be supplied with a fraction of said electric power generated by said electric power generator, said fraction of electric power forming a heating electric power.

12. A method for reducing the pressure of a fluid comprising a natural gas, water, and solid residues, said fluid being available at an extraction pressure at a wellhead of a natural gas field and for recovering energy directly from said natural gas at said wellhead, comprising the steps of:

prearranging a vertical elongated container having an inlet nozzle for said fluid for connection with said wellhead and an outlet nozzle for a treated natural gas, said outlet nozzle above said inlet nozzle in said vertical elongated container;

prearranging a cyclone centrifugal separation stage arranged in said vertical elongated container at said inlet nozzle, said cyclone centrifugal separation stage configured for separating said water and solid residues from said natural gas of said fluid,

prearranging an inertial separation stage arranged in said vertical elongated container at said outlet nozzle for separating liquid droplets and mist from the gas,

prearranging a gas-conditioning means arranged downstream of said outlet nozzle and configured to prevent a formation of ice in said natural gas during a subsequent expansion in a rotor,

prearranging an energy recovery expansion device arranged downstream of said gas-conditioning means for expanding said natural gas exiting from said wellhead until a use pressure is reached, said energy recovery expansion device having said rotor rotatably arranged about an own axis and a stator, and a gas passageway defined between said rotor and said stator;

connecting an electric power generator to said rotor of said energy recovery expansion device, so that a rotation of said rotor causes an electric power generation by said generator;

conveying a stream of said fluid exiting from said wellhead in said inlet nozzle for separating said water and solid residues from said natural gas of said fluid in said cyclone centrifugal separation stage, and then conveying said natural gas in said vertical elongated container up to said inertial separation stage for separating liquid droplets and mist from the natural gas and up to said outlet nozzle;

conditioning said natural gas exiting from said outlet nozzle in said gas-conditioning means for preventing a formation of ice in said natural gas during said subsequent expansion,

conveying said natural gas in said passageway of said energy recovery expansion device in such a way to cause a rotation of said rotor and to cause said expansion, the pressure of said gas decreasing from said extraction pressure to said use pressure;

extracting said electric power that is generated by said generator as a consequence of said rotation of said rotor.

13. A method according to claim 12, wherein said step of conditioning comprises a step of feeding an additive that is adapted to decrease said solid formation temperature, in said natural gas stream upstream of said energy recovery expansion device.

14. A method according to claim 12, wherein said additive is an additive that is adapted to decrease the freezing temperature of said water.

15. A method according to claim 12, wherein said additive is selected from the group comprised of an alcohol and a glycol.

16. A method according to claim 12, wherein said additive is selected from the group comprised of methanol and ethylene glycol.

17. A method according to claim 12, wherein said natural gas field is accessible from an underwater floor of a water body, and a step is provided of arranging said energy recovery expansion device and said electric power generator in a underwater position of said water body, in particular upon said underwater floor.

18. A method according to claim 12, wherein said step of conditioning comprises a step of heating said stream of said natural gas to increase the temperature of said stream of said natural gas up to a predetermined temperature value, such that, during said expansion down to said use pressure, the temperature of said treated gas remains above the formation temperature of a solid that may be formed starting from water present in said natural gas, in particular in combination with a hydrocarbon compound of said natural gas, more in particular in combination with methane and/or ethane, in particular such that the temperature of said treated gas remains above the freezing temperature of water.

19. A method according to claim 18, wherein a step is provided of removing a fraction of said electric power, and a step of transferring said fraction of said power to a device that is adapted to carry out said step of heating.

20. A method according to claim 19, wherein said fraction of said electric power is less than 50% of the recovered power.