Design and optimization of membrane-based integration process for advanced utilization of associated gases in N2-EOR oilfields

doi:10.11949/0438-1157.20221611

Abstract

Abstract:

The enhanced oil recovery technology driven by nitrogen, usually abbreviated as N₂-EOR, has been widely launched in Chinese oilfields in recent years. As a result, more and more associated gases are discharged with excessive nitrogen concentration. In this instance, the methods to upgrade the unconventional and inferior resources into qualified natural gas for pipeline transmission, with the intent to enhance material utilization and increase economic benefit, are urgently demanded. After meticulously thinking about associated gases’ feature and added value, two crucial missions are accomplished in this research: the high permeable PDMS composite membrane modules are fabricated, the integrated separation process including the shallow condensation and the multi-membrane permeation units are customized. It is anticipated that this novel process can generate chemical feedstock with sufficient ethane and propane recovery, and meanwhile, generate qualified natural gas meeting Chinese National Standard, i.e., GB 17820—2018. Taking a gathering and transportation station in Northwest Oilfield as an implementation case, the coupled process design was carried out for 7000 m³/h associated gas. The simulation results show that the yield of light hydrocarbons is greater than 77.6%, the utilization rate of methane upgrading is greater than 54.4%, and the output of ethylene cracking raw materials is 23604 t/a. The pipeline natural gas output is 18.03×10⁶ m³/a, and the economic benefit is expected to reach 79.0×10⁶ CNY/a, which provides a promising processing approach for the efficient utilization of nitrogen-containing oilfield associated gas.

Key words: membrane separation, oilfield associated gas, natural gas, optimum design, process intensification

摘要：

近年来，随着氮气强化采油的不断推广，含氮油田伴生气产量不断增加，生产合格的管道天然气成为提高资源利用率、增加经济效益的重要命题。本研究从组成特征出发，成功研制并批量生产功能层减薄至700 nm的硅橡胶复合膜，大幅提高分离能力，未溶胀状态下甲烷渗透速率达到358 GPU ［1 GPU=1.24 mol/(m²·h·MPa)］，同时提出浅冷液化与多级膜渗透集成的耦合分离工艺，在充分回收乙烷和丙烷等化工原料的同时，生产热值满足国家标准GB 17820—2018的管道天然气，实现伴生气高效提质和综合利用。以西北油田某集输站为实施案例，针对7000 m³/h(标准工况)伴生气进行耦合工艺设计，模拟结果显示轻烃收率大于77.6%，甲烷提质利用率大于54.4%，乙烯裂解原料产量23604 t/a，管道天然气产量18.03×10⁶ m³/a(标准工况)，创造经济效益预计可达79.0×10⁶ CNY/a，为含氮油田伴生气的高效利用提供了极具前景的加工途径。

关键词: 膜分离, 油田伴生气, 天然气, 优化设计, 过程强化

CLC Number:

TQ 028.2

Yongyao SUN, Qiuying GAO, Wenguang ZENG, Jiaming WANG, Yifei CHEN, Yongzhe ZHOU, Gaohong HE, Xuehua RUAN. Design and optimization of membrane-based integration process for advanced utilization of associated gases in N₂-EOR oilfields[J]. CIESC Journal, 2023, 74(5): 2034-2045.

孙永尧, 高秋英, 曾文广, 王佳铭, 陈艺飞, 周永哲, 贺高红, 阮雪华. 面向含氮油田伴生气提质利用的膜耦合分离工艺设计优化[J]. 化工学报, 2023, 74(5): 2034-2045.

Figures/Tables 18

References 38

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Component	Generation cases in oilfield/ %(mol)			Critical properties
Component	Early stage	Middle stage	Later stage	T_c/K	V_c/ (cm³/mol)
N₂	11.43	23.87	33.26	126.2	90.0
CH₄	58.53	47.67	39.71	190.7	99.0
C₂H₆	11.30	10.35	9.48	305.5	98.6
C₃H₈	6.30	6.12	5.94	369.9	200.0
i-C₄H₁₀	2.02	1.99	1.97	408.1	263.0
n-C₄H₁₀	2.75	2.73	2.71	425.2	255.0
i-C₅H₁₂	1.71	1.71	1.71	460.4	308.0
n-C₅H₁₂	1.44	1.44	1.44	469.7	311.0
C₆H₁₄	0.50	0.50	0.50	507.9	368.0
C₇H₁₆	0.21	0.21	0.21	540.2	426.0
CO₂	2.56	2.21	1.92	304.2	93.9
H₂S	0.85	0.78	0.72	373.7	98.0
H₂O	0.41	0.42	0.42	647.3	57.1

Component	Generation cases in oilfield/ %(mol)			Critical properties
Component	Early stage	Middle stage	Later stage	T_c/K	V_c/ (cm³/mol)
N₂	11.43	23.87	33.26	126.2	90.0
CH₄	58.53	47.67	39.71	190.7	99.0
C₂H₆	11.30	10.35	9.48	305.5	98.6
C₃H₈	6.30	6.12	5.94	369.9	200.0
i-C₄H₁₀	2.02	1.99	1.97	408.1	263.0
n-C₄H₁₀	2.75	2.73	2.71	425.2	255.0
i-C₅H₁₂	1.71	1.71	1.71	460.4	308.0
n-C₅H₁₂	1.44	1.44	1.44	469.7	311.0
C₆H₁₄	0.50	0.50	0.50	507.9	368.0
C₇H₁₆	0.21	0.21	0.21	540.2	426.0
CO₂	2.56	2.21	1.92	304.2	93.9
H₂S	0.85	0.78	0.72	373.7	98.0
H₂O	0.41	0.42	0.42	647.3	57.1

Cases	P/MPa（表压）	T/ °C	Composition/%（mol）
Cases	P/MPa（表压）	T/ °C	N₂	CH₄	C₂H₆	C₃H₈
MG-1	1.50	30	13.6	68.6	11.6	6.2
MG-2	1.50	30	28.0	55.3	10.6	6.1
MG-3	1.50	30	37.9	45.3	10.8	6.0
MG-4	1.50	30	16.0	76.6	6.5	0.9
MG-5	1.50	30	32.0	60.7	6.4	0.9
MG-6	1.50	30	43.7	49.4	6.0	0.9
MG-7	1.50	30	43.0	56.8	0.2	0
MG-8	1.50	30	50.9	48.9	0.2	0
MG-9	1.50	30	58.2	41.7	0.1	0
MG-10	1.50	30	67.5	32.4	0.1	0

Cases	P/MPa（表压）	T/ °C	Composition/%（mol）
Cases	P/MPa（表压）	T/ °C	N₂	CH₄	C₂H₆	C₃H₈
MG-1	1.50	30	13.6	68.6	11.6	6.2
MG-2	1.50	30	28.0	55.3	10.6	6.1
MG-3	1.50	30	37.9	45.3	10.8	6.0
MG-4	1.50	30	16.0	76.6	6.5	0.9
MG-5	1.50	30	32.0	60.7	6.4	0.9
MG-6	1.50	30	43.7	49.4	6.0	0.9
MG-7	1.50	30	43.0	56.8	0.2	0
MG-8	1.50	30	50.9	48.9	0.2	0
MG-9	1.50	30	58.2	41.7	0.1	0
MG-10	1.50	30	67.5	32.4	0.1	0

Main components	Permeation rate/GPU				Selectivity
Main components	N₂	CH₄	C₂H₆	C₃H₈	CH₄/N₂	C₂H₆/N₂	C₃H₈/N₂
N₂+CH₄+C₂H₆+C₃H₈	151	518	1059	2208	3.4	7.0	14.6
N₂+CH₄+C₂H₆	132	422	966	2005	3.2	7.3	15.2
N₂+CH₄	119	358	911	1855	3.0	7.7	15.6

Design and optimization of membrane-based integration process for advanced utilization of associated gases in N₂-EOR oilfields

面向含氮油田伴生气提质利用的膜耦合分离工艺设计优化

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Parameter	CASE-1	CASE-2	CASE-3
investment/10⁶CNY	15.93	27.19	38.68
depreciation/(10⁶CNY/a)	1.12	2.27	3.40
operation cost/(10⁶CNY/a)	6.03	10.82	14.93
gross profit/(10⁶CNY/a)	47.67	61.90	79.00
NGL yield/(t/a)	16296	22092	23604
NGL recovery/%(mass)	53.4	74.5	77.6
NG yield/(10⁶m³/a, standard condition)	—	—	18.03
NG recovery/%	—	—	54.4
poor NG yield/(10⁶m³/a，standard condition)	49.87	46.10	27.79

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