Fundamentals of Vapor
Recovery
“Waste Gas” IS LOST PRODUCT
And LOST REVENUE
Presented by:
Larry S. Richards
VAPOR RECOVERY
VAPOR RECOVERY
SYSTEMS
SYSTEMS
What is Vapor
Recovery?…
A little history...
HISTORY
OIL STORAGE FROM THE
OIL STORAGE FROM THE
PAST
OPEN PIT OIL STORAGE
EARLY TANKS
EARLY TANKS
VAPOR RECOVERY
VAPOR RECOVERY
SYSTEMS
TANK OPERATIONS
TANK OPERATIONS
As the oil
As the oil
resides in
resides in
the tanks, it
the tanks, it
gives off
gives off
vapors,
vapors,
thereby
thereby
increasing
increasing
the pressure
the pressure
inside the
inside the
tank.
tank.
Sources of Methane Losses
Sources of Methane Losses
Approximately 26.6
Approximately 26.6
Bcf
Bcf
/yr of Methane
/yr of Methane
are lost from storage tanks
are lost from storage tanks
Flash losses
Flash losses
occur when crude is transferred from
occur when crude is transferred from
containment at a high pressure to containment
containment at a high pressure to containment
at a lower pressure
at a lower pressure
Working losses
Working losses
occur when crude levels change and when
occur when crude levels change and when
crude in the tank is agitated
crude in the tank is agitated
Standing losses
Standing losses
occur with daily and seasonal temperature and
occur with daily and seasonal temperature and
pressure changes
pressure changes
Source: Natural Gas STAR Partners
PURPOSE
• Vapor Recovery units are designed to comply with EPA
standards, provide additional profits to the oil producer
and eliminate the emission of stock tank vapors to the
atmosphere.
• Most vapors contain varying amounts of methane,
ethane, isopentane, propane, and butane and contribute
to the gravity of lease crude.
• Dissipation of these products to the atmosphere on a
conventional tank battery means a reduction in gravity of
the liquid in the tank, thereby decreasing its value.
VAPOR RECOVERY
VAPOR RECOVERY
SYSTEMS
ENVIRONMENTAL HAZARDS
ENVIRONMENTAL HAZARDS
This flare was
This flare was
causing a variety
causing a variety
of health and
of health and
environmental
environmental
concerns
concerns
–
–
a gas
a gas
stream now
stream now
generating over
generating over
$150,000 per
$150,000 per
month in
month in
additional
additional
revenue. Methane
revenue. Methane
gas has 23 times
gas has 23 times
the impact as a
the impact as a
greenhouse gas as
greenhouse gas as
CO2
CO2
–
–
although
although
almost 100% of
almost 100% of
industry focus is
industry focus is
currently on CO2.
currently on CO2.
WHY LET $ ESCAPE INTO
WHY LET $ ESCAPE INTO
THE AIR?
THE AIR?
Besides being an
Besides being an
environmental
environmental
hazard, escaping
hazard, escaping
vapors actually
vapors actually
cost the operator
cost the operator
money. What
money. What
money?
money?
Uncaptured
Uncaptured
profits!! An
profits!! An
average tank
average tank
battery can emit
battery can emit
from $15,000 to
from $15,000 to
$50,000 in
$50,000 in
natural gas per
natural gas per
month!
month!
$
$
$
$
$
$
$
$
$
$
VAPOR RECOVERY
VAPOR RECOVERY
SYSTEMS
Standard Vapor Recovery Unit
Standard Vapor Recovery Unit
Crude Oil Stock Tank(s) Control Pilot Vent Line Back Pressure Valve Suction Scrubber Suction Line Condensate Return Bypass Valve Electric Control Panel Electric Driven Rotary Compressor Gas Sales Meter Run Gas Liquid Transfer Pump Check Valve Sales
Automated bypass allows
precise pressure control and
extends driver / compressor
life dramatically.
VRU’s cannot operate
effectively without this
element in their design
Automated liquid transfer
systems are imperative
due to the amount of
condensate derived from
this wet gas stream.
VAPOR RECOVERY
VAPOR RECOVERY
Typical stock
Typical stock
tank vapor
tank vapor
recovery unit in
recovery unit in
operation. This
operation. This
unit is
unit is
configured to
configured to
capture 90
capture 90
mcfd of gas
mcfd of gas
and discharge
and discharge
into a 40 psig
into a 40 psig
sales line.
sales line.
VRU Evaluation
VRU Evaluation
Checklist
Is the unit on location a vapor
Is the unit on location a vapor
recovery unit ?
recovery unit ?
Does it have a pressure sensing device on the
Does it have a pressure sensing device on the
tanks or on the skid?
tanks or on the skid?
Does it have a bypass system to circulate gas
Does it have a bypass system to circulate gas
between the compressor and the inlet or suction
between the compressor and the inlet or suction
vessel?
vessel?
Is the correct type of compressor being utilized?
Is the correct type of compressor being utilized?
(Rotary vane compressors, rotary screw
(Rotary vane compressors, rotary screw
compressors or
compressors or
venturi
venturi
jet design recommended
jet design recommended
vs. reciprocating compressors)
Is the production system properly
Is the production system properly
configured to capture the vent gas?
configured to capture the vent gas?
Is the piping from the tanks to the compressor
Is the piping from the tanks to the compressor
sloped downward with no visible liquid traps
sloped downward with no visible liquid traps
(U in the piping)?
(U in the piping)?
Are the tanks
Are the tanks
manifolded
manifolded
together properly?
together properly?
Is a gas blanket being used?
Is a gas blanket being used?
Is the pressure sensing device sensing pressure
Is the pressure sensing device sensing pressure
off the top of the tanks?
Benefits of Vapor Recovery
Benefits of Vapor Recovery
Units
Units
Capture up to 95 percent of
Capture up to 95 percent of
hydrocarbon vapors that accumulate
hydrocarbon vapors that accumulate
in tanks
in tanks
Recovered vapors have much higher Btu
Recovered vapors have much higher Btu
content than pipeline quality natural gas
content than pipeline quality natural gas
Recovered vapors can be more valuable
Recovered vapors can be more valuable
than methane alone
than methane alone
Reduce regulatory & liability exposure
Criteria for VRU Locations
Criteria for VRU Locations
Steady source and sufficient quantity
Steady source and sufficient quantity
of losses
of losses
Available gathering system
Available gathering system
Outlet for recovered gas
Outlet for recovered gas
Access to pipeline or on
Access to pipeline or on
-
-
site fuel use
site fuel use
Tank batteries that are subject to
Tank batteries that are subject to
state/federal air regulations
VRU Decision Process
VRU Decision Process
Identify possible locations for VRUs
Quantify the volume of losses
Quantify the volume of losses
Determine the value of recoverable losses
Determine the cost of a VRU project
Quantify Volume of Losses
Quantify Volume of Losses
Estimate losses from chart based on oil
Estimate losses from chart based on oil
characteristics, pressure, and temperature
characteristics, pressure, and temperature
at each location
at each location
Estimate emissions using the
Estimate emissions using the
E&P Tank
E&P Tank
Model
Model
Measure losses using orifice well
Measure losses using orifice well
tester and recording manometer
Estimated Volume of Tank
Estimated Volume of Tank
Vapors
Vapors
Pressure of Vessel Dumping to Tank (Psig)
Pressure of Vessel Dumping to Tank (Psig)
Vapor Vented fr
om Tanks
Vapor Vented fr
om Tanks
--SCF/BBL --SCF/BBL
--GORGOR
110 110 100 100 90 90 80 80 70 70 60 60 50 50 40 40 30 30 10 10 20 20 10 10 2020 3030 4040 5050 6060 7070 8080 Under 30 Under 30°° API API 30 30°°AP I to 39 API to 39°°AP I API 40 40°°AP I and Ove r API a nd O ver 43 43Estimating Tank Emissions
Estimating Tank Emissions
Example 1:
Example 1:
Pressure of the Vessel dumping to the
Pressure of the Vessel dumping to the
tanks:
tanks:
40 PSIG
40 PSIG
API Gravity of the Oil:
API Gravity of the Oil:
40
40
Barrels of Oil through the battery per day:
Barrels of Oil through the battery per day:
1,000
Estimating Tank Emissions
Estimating Tank Emissions
Example 1:
Example 1:
60 SCF per bbl X 1000
60 SCF per bbl X 1000
bbls
bbls
per day =
per day =
60,000 SCFD or 60 mcfd of gas
60,000 SCFD or 60 mcfd of gas
60 mcfd of gas X $6 per mcf = $360 per day
60 mcfd of gas X $6 per mcf = $360 per day
or $10,800 per month
Estimating Tank Emissions
Estimating Tank Emissions
Example 2:
Example 2:
Pressure of the Vessel dumping to the
Pressure of the Vessel dumping to the
tanks:
tanks:
70 PSIG
70 PSIG
API Gravity of the Oil:
API Gravity of the Oil:
35
35
Barrels of Oil through the battery per day:
Barrels of Oil through the battery per day:
500
Estimating Tank Emissions
Estimating Tank Emissions
Example 2:
Example 2:
67 SCF per bbl X 500
67 SCF per bbl X 500
bbls
bbls
per day =
per day =
33,500 SCFD or 33.5 mcfd of gas
33,500 SCFD or 33.5 mcfd of gas
33.5 mcfd of gas X $6 per mcf = $201 per day
33.5 mcfd of gas X $6 per mcf = $201 per day
or $6,030 per month
Estimating Tank Emissions
Estimating Tank Emissions
Chart method is a quick and easy way to get
Chart method is a quick and easy way to get
a fast ballpark estimate
a fast ballpark estimate
Notice the impact of higher gravity oil, as well
Notice the impact of higher gravity oil, as well
as higher separator pressures
as higher separator pressures
This method is VERY CONSERVATIVE and
This method is VERY CONSERVATIVE and
generally underestimates actual emission
generally underestimates actual emission
levels
Quantify Volume of Losses
Quantify Volume of Losses
E&P Tank
E&P Tank
Model
Model
Computer software developed by API
Computer software developed by API
and GRI
and GRI
Estimates flash, working, and standing losses
Estimates flash, working, and standing losses
Calculates losses using specific operating
Calculates losses using specific operating
conditions for each tank
conditions for each tank
E&P TANK INPUT SCREEN
E&P TANK OUTPUT
E&P TANK OUTPUT
SCREEN
E&P TANK EXAMPLE
E&P TANK EXAMPLE
OUTPUT
-- Emission Composition
---Component Uncontrolled Uncontrolled Controlled Controlled [ton/yr] [lb/hr] [ton/yr] [lb/hr] H2S 12.137 2.771 0.607 0.139 O2 0.000 0.000 0.000 0.000 CO2 85.667 19.559 85.667 19.559 N2 2.284 0.521 2.284 0.521 C1 122.391 27.943 6.120 1.397 C2 159.072 36.318 7.954 1.816 C3 415.158 94.785 20.758 4.739 i-C4 96.442 22.019 4.822 1.101 n-C4 261.360 59.671 13.068 2.984 i-C5 82.901 18.927 4.145 0.946 n-C5 97.357 22.228 4.868 1.111 C6 28.130 6.422 1.407 0.321 C7 26.984 6.161 1.349 0.308 C8 10.294 2.350 0.515 0.118 C9 2.081 0.475 0.104 0.024 C10+ 0.544 0.124 0.027 0.006 Benzene 2.029 0.463 0.101 0.023 Toluene 0.250 0.057 0.013 0.003 E-Benzene 0.032 0.007 0.002 0.000 Xylenes 0.264 0.060 0.013 0.003 n-C6 19.202 4.384 0.960 0.219 224Trimethylp 0.000 0.000 0.000 0.000 Total 1424.579 325.246 71.229 16.262
-- Emission Summary
---Item Uncontrolled Uncontrolled Controlled Controlled
[ton/yr] [lb/hr] [ton/yr] [lb/hr]
Total HAPs 21.780 4.973 1.089 0.249
Total HC 1324.491 302.395 66.225 15.120
VOCs, C2+ 1202.100 274.452 60.105 13.723
VOCs, C3+ 1043.029 238.134 52.151 11.907
Uncontrolled Recovery Info.
Vapor
71.3400 [MSCFD]
HC Vapor 66.3900 [MSCFD]
GOR
35.67 [SCF/bbl]
-- Emission Composition
---Component Uncontrolled
Concontrolled
Controlled
Controlled
[ton/yr]
[lb/hr]
[ton/yr]
[lb/hr]
H2S
12.137
2.771
0.607
0.139
O2
0.000
0.000
0.000
0.000
CO2
85.667
19.559
85.667
19.559
N2
2.284
0.521
2.284
0.521
C1
122.391
27.943
6.120
1.397
C2
159.072
36.318
7.954
1.816
C3
415.158
94.785
20.758
4.739
i-C4
96.442
22.019
4.822
1.101
n-C4
261.360
59.671
13.068
2.984
i-C5
82.901
18.927
4.145
0.946
n-C5
97.357
22.228
4.868
1.111
C6
28.130
6.422
1.407
0.321
C7
26.984
6.161
1.349
0.308
C8
10.294
2.350
0.515
0.118
C9
2.081
0.475
0.104
0.024
C10+
0.544
0.124
0.027
0.006
Benzene
2.029
0.463
0.101
0.023
Toluene
0.250
0.057
0.013
0.003
E-Benzene
0.032
0.007
0.002
0.000
Xylenes
0.264
0.060
0.013
0.003
n-C6
19.202
4.384
0.960
0.219
224Trimethylp
0.000
0.000
0.000
0.000
Total
1424.579
325.246
71.229
16.262
-- Stream Data
---No. Component MW LP Oil Flash Oil Sale Oil Flash Gas W&S Gas Total Emissions mol % mol % mol % mol % mol % mol %
1 H2S 34.80 0.0508 0.0358 0.0065 0.6793 1.4580 1.0368 2 O2 32.00 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 3 CO2 44.01 0.2437 0.0950 0.0002 6.4933 4.6923 5.6664 4 N2 28.01 0.0102 0.0005 0.0000 0.4189 0.0235 0.2374 5 C1 16.04 0.9543 0.1553 0.0000 34.5319 7.6894 22.2079 6 C2 30.07 0.6701 0.3661 0.0087 13.4456 17.7009 15.3993 7 C3 44.10 2.1827 1.7950 1.0502 18.4760 37.9263 27.4061 8 i-C4 58.12 1.1269 1.0530 0.9606 4.2332 5.5332 4.8301 9 n-C4 58.12 4.6091 4.4328 4.2283 12.0182 14.3518 13.0896 10 i-C5 72.15 3.1066 3.1043 3.0959 3.2018 3.5131 3.3447 11 n-C5 72.15 5.0558 5.0864 5.1064 3.7713 4.1125 3.9280 12 C6 86.16 4.1726 4.2496 4.3162 0.9366 1.0199 0.9748 13 C7 100.20 10.3655 10.5937 10.7945 0.7742 0.8517 0.8098 14 C8 114.23 10.8426 11.0945 11.3173 0.2563 0.2861 0.2700 15 C9 128.28 5.5127 5.6428 5.7580 0.0450 0.0543 0.0492 16 C10+ 166.00 45.9695 47.0631 48.0331 0.0087 0.0106 0.0095 17 Benzene 78.11 0.5685 0.5803 0.5906 0.0723 0.0795 0.0756 18 Toluene 92.13 0.2132 0.2181 0.2224 0.0075 0.0084 0.0079 19 E-Benzene 106.17 0.0711 0.0728 0.0743 0.0008 0.0009 0.0009 20 Xylenes 106.17 0.6802 0.6962 0.7104 0.0068 0.0077 0.0072 21 n-C6 86.18 3.5939 3.6646 3.7261 0.6222 0.6798 0.6486 22 224Trimethylp 114.24 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 MW 123.89 125.93 127.59 37.91 45.66 41.47 Stream Mole Ratio 1.0000 0.9768 0.9570 0.0232 0.0197 0.0430 Heating Value [BTU/SCF] 2001.39 2458.73 2211.37
Gas Gravity [Gas/Air] 1.31 1.58 1.43
Bubble Pt. @ 100F [psia] 56.28 20.19 8.70 RVP @ 100F [psia] 18.38 11.68 7.71 Spec. Gravity @ 100F 0.800 0.803 0.806
TANK TEST
TANK TEST
A chart recorder is set
up on the tank battery
for a 24-hour pressure
test. The resultant
chart is brought into the
office for evaluation.
Information such as
ambient temperature,
test apparatus size and
orifice size is recorded
and used in the
calculation of volume of
tank vapors.
TANK TEST
TANK TEST
Ultrasonic meters and Mass flow meters
are also highly effective
The key is DURATION – a minimum of
24 hours of emissions must be charted
for accurate results
What is the Recovered Gas
What is the Recovered Gas
Worth?
Worth?
Value depends on BTU content of gas
Value depends on BTU content of gas
Value depends on how gas is used
Value depends on how gas is used
On
On
-
-
site fuel
site fuel
-
-
measured in terms of fuel that
measured in terms of fuel that
no longer must be purchased
no longer must be purchased
Natural gas pipeline
Natural gas pipeline
-
-
measured by the higher
measured by the higher
price for rich (higher Btu) gas (=2.5 X)
price for rich (higher Btu) gas (=2.5 X)
Gas processing plant
Gas processing plant
-
-
measured by sale of
measured by sale of
NGLs and methane, which can be separated
Value of Recovered Gas
Value of Recovered Gas
Gross revenue per year = (Q x P x 365 x
Gross revenue per year = (Q x P x 365 x
B) + NGL
B) + NGL
Q = Rate of vapor recovery (Mcfd)
Q = Rate of vapor recovery (Mcfd)
P = Price of natural gas
P = Price of natural gas
B = Btu adjustment (typically 2.5)
B = Btu adjustment (typically 2.5)
NGL = Value of natural gas liquids
Estimating Tank Emissions
Estimating Tank Emissions
Example 1:
Example 1:
60 SCF per bbl X 1000
60 SCF per bbl X 1000
bbls
bbls
per day =
per day =
60,000 SCFD or 60 mcfd of gas
60,000 SCFD or 60 mcfd of gas
60 mcfd of gas X $6 per mcf = $360 per day
60 mcfd of gas X $6 per mcf = $360 per day
or $10,800 per month
or $10,800 per month
60 mcfd X $6 X 2.5 + 2
60 mcfd X $6 X 2.5 + 2
bbls
bbls
/thousand ($100) =
/thousand ($100) =
$1,000 per day or $30,000 per month
Estimating Tank Emissions
Estimating Tank Emissions
Example 2:
Example 2:
67 SCF per bbl X 500
67 SCF per bbl X 500
bbls
bbls
per day =
per day =
33,500 SCFD or 33.5 mcfd of gas
33,500 SCFD or 33.5 mcfd of gas
33.5 mcfd of gas X $6 per mcf = $201 per day
33.5 mcfd of gas X $6 per mcf = $201 per day
or $6,030 per month
or $6,030 per month
33.5 mcfd X $6 X 2.5 + 1 bbl ($50) =
33.5 mcfd X $6 X 2.5 + 1 bbl ($50) =
$552.50 per day OR $16,575 per month
$552.50 per day OR $16,575 per month
Cost of a VRU (cont
Cost of a VRU (cont
’
’
d)
d)
Vapor Recovery Units Sizes and Costs
Capacity
(Mcfd)
Compressor
Horsepower
Median
Capital
Costs ($)
Installation
Costs ($)
O&M Costs
($/year)
25
5 – 10
15,125
7,560 – 15,125
5,250
50
10 – 15
19,500
9,750 – 19,500
6,000
100
15 – 25
23,500
11,750 – 23,500
7,200
200
30 – 50
31,500
15,750 – 31,500
8,400
500
60 – 80
44,000
22,000 – 44,000
12,000
Note: Cost information provided by Partners and VRU
manufacturers.
What Is the Payback?
What Is the Payback?
Financial Analysis for VRU Projects
Peak
Capacity
(Mcfd)
Installation &
Capital Costs
1($)
O&M
Costs
($/year)
Value of
Gas
2($/year)
Payback
3Return on
Investment
4(%)
25
26,470
5,250
25,869
1 yrs, 4 mos
73
50 34,125
6,000
51,738
9
mos 132
100 41,125 7,200
103,477
7
mos 234
200 55,125 8,400
206,955
3
mos 360
500 77,000
12,000
465,648
2
mos 589
1Unit cost plus estimated installation cost of 75% of unit cost. 2
$5.67 per Mcf x ½ capacity x 365. Assumed price includes value of Btu-enriched gas (1,285 Btu/scf). 3
Based on 10% discount rate for future savings. Excludes value of recovered gas liquids. 4
Calculated for 5 years.
To evaluate this practice for your situation, fill in the values below and click "Calculate Results".
NATURAL GAS & CRUDE OIL
TANK VALUES
Pressure of the vessel dumping to the tank (PSIG)
API gravity (degrees)
Amount of crude oil cycled through the tank (bbl/d)
Number of days per year the Vapor Recovery Unit will be operated (days/yr)
CALCULATE CAPITAL AND O&M COST
ESTIMATES
Click to calculate estimates for capital equipment costs and O&M costs.
23 psi
42 api gravity
2,000 bbl/day
351 days
Calculate
EPA Website – PRO Tools
CAPITAL
EQUIPMENT AND O&M COSTS
Enter your own values for the capital equipment listed below or accept the estimates.
Vapor Recovery Unit cost ($)
$30,068
Vapor Recovery Unit installation cost ($)
$22,551
Depreciable life of equipment (Years)
10
Vapor Recovery Unit O&M cost ($/year)$8,649
GENERAL ECONOMIC
VALUES
Natural gas cost ($/Mcf)
Natural gas cost escalator (%) O&M cost escalator (%)
Discount rate (%)
Marginal tax rate* (%) Investment tax credit (%)
Working interest for capital costs (%)
Working interest for O&M costs (%) Working interest for gas savings (%)
EPA Website – PRO Tools
Each variable can
be added based on
your companies
specific conditions
and contract terms
Gas emission reduction
5 Year gas savings
141,453
(mcf)
First Year gas savings
28,291
Without-tax effect
5 Year NPV
$504,434
Payback (Years)
0.36
DCFIRR
279%
Simple ROI
279%
With-tax effect
5 Year NPV (AT)
$350,477
Payback (AT) (Years)
0.47
DCFIRR (AT)
208%
Simple ROI (AT)
201%
Analysis results for:
INSTALLING VAPOR RECOVERY UNITS ON CRUDE OIL STORAGE
TANKS
To save this specific case for viewing in the Results Summary page, provide a name and click "Save"
Other Costs to Consider
Other Costs to Consider
Regulatory Liability Exposure
Regulatory Liability Exposure
Public Relations Exposure
Public Relations Exposure
Positive or Negative
Positive or Negative
Litigation Exposure
Litigation Exposure
BP and Shell lawsuits
BP and Shell lawsuits
Producing a clean energy source (natural gas)
Producing a clean energy source (natural gas)
and simultaneously improving air quality in the
and simultaneously improving air quality in the
community
community
–
–
with an economic payback of
with an economic payback of
usually less than 3 months
HY
HY
-
-
BON ENGINEERING
BON ENGINEERING
COMPANY, INC.
COMPANY, INC.
Setting a New Standard!!
Technical Solutions for
Capturing Vented Stock Tank
Gas
“Waste Gas” IS LOST PRODUCT
And LOST REVENUE
Presented by:
Larry S. Richards
CASE STUDIES
1000 MSCFD 500 psi 1131 BTU/cu. ft 70 MSCFD 80 psi 1401 BTU/cu. ft 90 MSCFD 25 psi 1588 BTU/cu. ft 100 MSCFD 0 psi 2534 BTU/cu. ft Vented Vented Vented $5.00 x 1.13 x 1000 MSCFD = $5650 $5.00 x 0 MSCFD = $0 $5.00 x 0 MSCFD = $0 $5.00 x 0 MSCFD = $0
TOTAL GAS SALES = $5650
THE SOLUTION
THE SOLUTION
A system was designed to allow the customer to
A system was designed to allow the customer to
capture the vented gas from all phases of his
capture the vented gas from all phases of his
separation process. A multi
separation process. A multi
-
-
stage unit was
stage unit was
designed and built that took the gas from the tank
designed and built that took the gas from the tank
vapors at atmospheric pressure, gathered the vent
vapors at atmospheric pressure, gathered the vent
gas from the other separators and delivered the
gas from the other separators and delivered the
stream to the sales line at 500 psig.
Crude Oil
Crude Oil
Analysis
Analysis
600 PSIG
600 PSIG
SEPARATION
SEPARATION
500 PSIG
500 PSIG
SEPARATION
SEPARATION
At 500 psig
At 500 psig
separation pressure
separation pressure
the gas has a BTU
the gas has a BTU
content of 1131
content of 1131
BTU/cu. ft.
80 PSIG
80 PSIG
SEPARATION
SEPARATION
At 80 psig separation
At 80 psig separation
pressure the gas has
pressure the gas has
reached a BTU value
reached a BTU value
of 1401 BTU/ cu. ft.
25 PSIG
25 PSIG
SEPARATION
SEPARATION
At 25 psig
At 25 psig
separation, the gas
separation, the gas
stream is at its
stream is at its
richest point yet,
richest point yet,
with a BTU value
with a BTU value
of 1588 BTU/cu. ft.
OIL TANK
OIL TANK
STORAGE
STORAGE
This gas stream
This gas stream
reaches its most
reaches its most
valuable point
valuable point
during storage in
during storage in
the oil tank. This
the oil tank. This
gas has a BTU value
gas has a BTU value
of 2514 BTU/ cu. Ft.
of 2514 BTU/ cu. Ft.
Obviously, this gas
Obviously, this gas
is worth capturing!
1000 MSCFD 500 psi 1131 BTU/cu. ft 70 MSCFD 80 psi 1401 BTU/cu. ft 90 MSCFD 25 psi 1588 BTU/cu. ft 100 MSCFD 0 psi 2534 BTU/cu. ft Recovered Recovered Recovered $5.00 x 1.13 x 1000 MSCFD = $5650 $5.00 x 1.40 x 70 MSCFD = $490 $5.00 x 1.59 x 90 MSCFD = $716 $5.00 x 2.53 x 100 MSCFD = $1267
TOTAL GAS SALES = $8123
Multi-Stage Gas Booster
VRU
MONTHLY GAS SALES INCREASE
= $74,190
Case Study 2
Case Study 2
Mid Size Independent in Hobbs, NM area March
Mid Size Independent in Hobbs, NM area March
‘
‘
04
04
Installation of 2
Installation of 2
VRU
VRU
’
’
s
s
on 2 stock tank batteries, each emitting
on 2 stock tank batteries, each emitting
approximately 90 MSCFD of 2500
approximately 90 MSCFD of 2500
btu
btu
tank vapors / 45 psig sales
tank vapors / 45 psig sales
line
line
Previous gas sales revenue: $0 (venting)
Previous gas sales revenue: $0 (venting)
Monthly gas revenue: $5 X 2.5 X 90 MSCFD X 30 days
Monthly gas revenue: $5 X 2.5 X 90 MSCFD X 30 days
x 2 tanks = $ 67,500
x 2 tanks = $ 67,500
Capital expense: $24,000 X 2 units = $48,000
Capital expense: $24,000 X 2 units = $48,000
Payback: 21 DAYS
Producing Well Heater 1000 MSCFD 800 psi 1000 BTU/cu.ft. Glycol Unit 60 MSCFD 100 psi 1200 BTU/cu.ft.
Flared
90 MSCFD 0 psi 2000 BTU/cu.ft.Flared
Gas Sales Gross Sales Per Day $5.00 x 1000 MSCFD = $5000 $5.00 x 0 MSCFD = $0 $5.00 x 0 MSCFD = $0TOTAL GAS SALES = $5000
Price Based upon $5.00/MMBTU
Case
Study 3
Heater Producing Well 1000 MSCFD 800 psi 1000 BTU/cu.ft. 60 MSCFD 100 psi 1200 BTU/cu.ft. 90 MSCFD 0 psi 2000 BTU/cu.ft.
Glycol Unit Gas
Sales Gross Sales Per Day $5.00 x 1000 MSCFD = $5000 $5.00 x 1.2 x 60 MSCFD = $360 $5.00 x 2.0 x 90 MSCFD = $900
TOTAL GAS SALES = $6260
Price Based upon $5.00/MMBTU
RECOVERED
RECOVERED
Gas Booster
VRU
MONTHLY GAS SALES
INCREASE = $37,800
Case
Study 3
Case Study 4
Case Study 4
–
–
Chevron
Chevron
Chevron installed eight VRUs at crude
Chevron installed eight VRUs at crude
oil stock tanks in 1996
oil stock tanks in 1996
Project Economics – Chevron
Methane Loss Reduction (Mcf/unit/yr) Approximate Savings per Unit1 Total Savings Total Capital and Installation Costs Payback 21,900 $43,800 $350,400 $240,000 <1 yr 1
Assumes a $2 per Mcf gas price; excludes value of recovered NGLs. Refer to the Lessons Learned for more information.
Case Study 5
Case Study 5
Large Independent in North Texas in June
Large Independent in North Texas in June
‘
‘
04
04
Installation of 1 VRU on a stock tank battery emitting approxima
Installation of 1 VRU on a stock tank battery emitting approxima
tely 190
tely 190
MSCFD of 2400
MSCFD of 2400
btu
btu
tank vapors / 50 psig sales line
tank vapors / 50 psig sales line
Previous gas sales revenue: $0 (venting)
Previous gas sales revenue: $0 (venting)
Monthly gas revenue: $5 X 2.4 X 190 MSCFD X 30 days
Monthly gas revenue: $5 X 2.4 X 190 MSCFD X 30 days
= $ 68,400
= $ 68,400
Capital expense: $32,000
Capital expense: $32,000
Payback: 14 DAYS
Payback: 14 DAYS
Other Emission Sources
Other Emission Sources
Gas can also be
Gas can also be
captured from
captured from
separators and
separators and
other field
other field
equipment.
equipment.
This unit is
This unit is
capturing natural
capturing natural
gas off several
gas off several
separators for
separators for
sale down a high
sale down a high
pressure line.
Other Emission Sources
Other Emission Sources
This unit captures
This unit captures
a 98% CO2 gas
a 98% CO2 gas
stream in a field
stream in a field
outside Snyder,
outside Snyder,
Texas. Flooded
Texas. Flooded
screw compressor
screw compressor
for volumes to 1.5
for volumes to 1.5
MMSCFD. The CO2
MMSCFD. The CO2
is captured and re
is captured and re
-
-injected into the
injected into the
formation,
formation,
dramatically
dramatically
reducing
reducing
operating costs.
operating costs.
COMPRESSOR
COMPRESSOR
SELECTION CRITERIA
SELECTION CRITERIA
HOW DO WE CHOOSE THE
HOW DO WE CHOOSE THE
APPROPRIATE COMPRESSOR?
TYPICAL COMPRESSOR TYPES
TYPICAL COMPRESSOR TYPES
USED IN LOW PRESSURE
USED IN LOW PRESSURE
Rotary Vane
Rotary Vane
Compressors
Compressors
Eccentrically mounted
Eccentrically mounted
rotor
rotor
Centrifugal force
Centrifugal force
causes vanes to slide in
causes vanes to slide in
or out
or out
Gas is forced into
Gas is forced into
decreasing space
decreasing space
thereby causing
thereby causing
compression
compression
Jacket water cooling
Jacket water cooling
system
system
RPM range 400 to 1600
ROTARY VANE OPERATING
ROTARY VANE OPERATING
PRINCIPLE
PRINCIPLE
Gas enters the suction flange
at low pressure. The rotor is
mounted eccentrically toward
the bottom of the
compressor. Centrifugal
force imparted as the rotor
turns forces the blades out
against the cylinder wall. The
gas is forced into a ever
decreasing space, thereby
compressing the gas which
then exits the discharge. The
rotor clearance at the bottom
(typically .005”) is sealed with
lubricating oil to create a
closed system within the
cylinder.
Rotary Vane Compressor
Rotary Vane Compressor
Typical Operating Parameters
Typical Operating Parameters
Differential pressure
Differential pressure
equal to or less than
equal to or less than
60 psig (for single
60 psig (for single
-
-stage models).
stage models).
Volume from
Volume from
approximately 15
approximately 15
MSCFD to 2
MSCFD to 2
MMSCFD (for single
MMSCFD (for single
-
-compressor units).
compressor units).
Relatively low suction
Relatively low suction
temperatures
temperatures
(< 120
Rotary Vanes
Rotary Vanes
Advantages
Advantages
•
•
Excellent for relatively high volumes and relatively
Excellent for relatively high volumes and relatively
low differential pressures
low differential pressures
•
•
Efficient at low pressures
Efficient at low pressures
•
•
Can handle wet gas relatively easy
Can handle wet gas relatively easy
•
•
Comparatively low initial cost and ongoing
Comparatively low initial cost and ongoing
maintenance
maintenance
Disadvantages
Disadvantages
•
•
Limited as to discharge pressure
Limited as to discharge pressure
•
•
Limited as to suction temperature capabilities
Limited as to suction temperature capabilities
•
TYPICAL COMPRESSOR TYPES
TYPICAL COMPRESSOR TYPES
USED IN LOW PRESSURE
USED IN LOW PRESSURE
Flooded Screw
Flooded Screw
Compressors
Compressors
Twin helical rotors
Twin helical rotors
Oil is both the cooling
Oil is both the cooling
medium and the
medium and the
compression medium
compression medium
Various configurations of
Various configurations of
gears, internal porting and
gears, internal porting and
loader/
loader/
unloader
unloader
valves
valves
available
available
Gas mixed with oil. Must be
Gas mixed with oil. Must be
separated after
separated after
compression
Rotary Screw Packages
General Principle
General Principle - Rotary
Screws - Continued
3-D
MODEL
FINISHED
PRODUCT
FINISHED
PRODUCT
3-D
MODEL
Oil Flooded Screw Compressor
Oil Flooded Screw Compressor
Typical Operating Parameters
Typical Operating Parameters
Differential pressure
Differential pressure
equal to or less than
equal to or less than
300 psig (for single
300 psig (for single
-
-stage models).
stage models).
Volume from
Volume from
approximately 20
approximately 20
MSCFD to 2.5 MMSCFD
MSCFD to 2.5 MMSCFD
(for single
(for single
-
-
compressor
compressor
units).
units).
Virtually any
Virtually any
temperature (< 180
temperature (< 180
°
°
F)
F)
Oil Flooded Screws
Oil Flooded Screws
Advantages
Advantages
Excellent in a large volume/medium differential pressure
Excellent in a large volume/medium differential pressure
range
range
Can handle wet gas better than rotary vanes
Can handle wet gas better than rotary vanes
Excellent temperature control for controlling condensate
Excellent temperature control for controlling condensate
fallout
fallout
Disadvantages
Disadvantages
More sophisticated system w oil/gas separator
More sophisticated system w oil/gas separator
Higher maintenance
Higher maintenance
Higher operational expense (oil, filters, etc.)
TYPICAL COMPRESSOR TYPES
TYPICAL COMPRESSOR TYPES
USED IN LOW PRESSURE
USED IN LOW PRESSURE
Liquid Ring
Liquid Ring
Compressors
Compressors
Vacuum pump
Vacuum pump
technology
technology
Uses lobes rather than
Uses lobes rather than
vanes
vanes
Gas is mixed with non
Gas is mixed with non
-
-lubricating oil. Must be
lubricating oil. Must be
separated after
separated after
compression.
compression.
Good for extremely low
Good for extremely low
differential pressures.
differential pressures.
Compression oil must be
Compression oil must be
segregated from
segregated from
lubrication oil
Liquid Ring Compressor Typical
Liquid Ring Compressor Typical
Operating Parameters
Operating Parameters
Differential pressure
Differential pressure
equal to or less than 25
equal to or less than 25
psig (for single
psig (for single
-
-
stage
stage
models).
models).
Volume from
Volume from
approximately 15 MSCFD
approximately 15 MSCFD
to 2.5 MMSCFD (for
to 2.5 MMSCFD (for
single
single
-
-
compressor units).
compressor units).
Virtually any suction
Virtually any suction
temperature (< 180
Liquid Rings
Liquid Rings
Advantages
Advantages
High volumetric efficiency
High volumetric efficiency
Few moving parts
Few moving parts
Disadvantages
Disadvantages
Extremely limited on discharge pressure
Extremely limited on discharge pressure
Used primarily in vacuum applications
Used primarily in vacuum applications
Higher operational expense (oil, filters, etc.)
TYPICAL COMPRESSOR TYPES
TYPICAL COMPRESSOR TYPES
USED IN LOW PRESSURE
USED IN LOW PRESSURE
Reciprocating
Reciprocating
Compressors
Compressors
Piston/cylinder
Piston/cylinder
arrangement
arrangement
May be air, water
May be air, water
or oil cooled
or oil cooled
Ages old
Ages old
technology
technology
May be slow
May be slow
speed or high
speed or high
speed
speed
Reciprocating Compressor
Reciprocating Compressor
Typical Operating Parameters
Typical Operating Parameters
Differential pressure
Differential pressure
in excess of 2000
in excess of 2000
-
-3000 psig (for multi
3000 psig (for multi
-
-stage models).
stage models).
Volumes in excess
Volumes in excess
of 20 MMSCFD
of 20 MMSCFD
(dependent upon
(dependent upon
suction pressure).
suction pressure).
Relatively high
Relatively high
suction
suction
temperatures (<
temperatures (<
200
200
°
°
F)
F)
Reciprocating Compressors
Reciprocating Compressors
Advantages
Advantages
High volume/high pressure
High volume/high pressure
Able to handle spikes in pressure
Able to handle spikes in pressure
Relatively low maintenance
Relatively low maintenance
Disadvantages
Disadvantages
Low suction pressure results in large first stage cylinder
Low suction pressure results in large first stage cylinder
size
size
Inefficient at low pressures
Inefficient at low pressures
Rings and valves fail in wet gas applications
Rings and valves fail in wet gas applications
Control is difficult at atmospheric pressures
TYPICAL COMPRESSOR TYPES
TYPICAL COMPRESSOR TYPES
USED IN LOW PRESSURE
USED IN LOW PRESSURE
Dry Screw
Dry Screw
Compressors
Compressors
Similar in design to
Similar in design to
flooded screw
flooded screw
Lubricating oil never
Lubricating oil never
comes in contact
comes in contact
with process gas
with process gas
Extremely high rpm /
Extremely high rpm /
very sophisticated
very sophisticated
seal systems
seal systems
Noise suppression
Noise suppression
systems req
systems req
’
’
d
d
Dry Screw Compressor Typical
Dry Screw Compressor Typical
Operating Parameters
Operating Parameters
Not recommended
Not recommended
for volumes less
for volumes less
than 2 MMSCFD.
than 2 MMSCFD.
Discharge pressure
Discharge pressure
up to 600 psi
up to 600 psi
Volumes in excess
Volumes in excess
of 25 MMSCFD
of 25 MMSCFD
TYPICAL COMPRESSOR TYPES
TYPICAL COMPRESSOR TYPES
USED IN LOW PRESSURE
USED IN LOW PRESSURE
Vapor Jet
Vapor Jet
Utilizes
Utilizes
pressurized water
pressurized water
to affect gas
to affect gas
gathering
gathering
No moving
No moving
internal parts
internal parts
Uses produced
Uses produced
water in a closed
water in a closed
system
system
Separation of gas
Separation of gas
and water
and water
required
required
VAPOR JET VAPOR
VAPOR JET VAPOR
RECOVERY TECHNOLOGY
RECOVERY TECHNOLOGY
PRODUCED WATER TANK VAPORS JET PUMP (EDUCTOR) WATER PUMP WATER/GAS MIX SEPARATOR PRODUCED WATER RETURN SALES LINEVapor Jet Typical Operating
Vapor Jet Typical Operating
Parameters
Parameters
Differential pressure equal
Differential pressure equal
to or less than 40 psig (for
to or less than 40 psig (for
single
single
-
-
stage models).
stage models).
Volume from approximately
Volume from approximately
5 MSCFD to 75 MSCFD (for
5 MSCFD to 75 MSCFD (for
single
single
-
-
compressor units).
compressor units).
Suction Temperature is not
Suction Temperature is not
an issue.
an issue.
Gas composition and
Gas composition and
saturation level is not an
saturation level is not an
issue.
issue.
Gas can be sent down the
Gas can be sent down the
pipeline, or re
pipeline, or re
-
-
injected into
injected into
the formation
JET PUMP VAPOR
JET PUMP VAPOR
RECOVERY RANGES
RECOVERY RANGES
Jet Pump Size ( in. ) 1 1/2 2 2 1/2
Operating Medium Pressure ( psig ) 200 200 200
Operating Medium Rate ( gpm ) 45 82 143
Gas Volume Recovered ( Mcfpd ) 25 45 77
Centrifugal Pump Eff. ( % ) 26 42 53
Motor Eff. ( % ) 0.9 0.9 0.9
KW-HR/day 401 453 625
Power Cost ( $/KW-HR ) 0.045 0.045 0.045