Condensate reduction process tunes

Question

Condensate reduction process tunes

(OP)

15 Jul 22 14:20

Good day all,
We have a Condensate Gas Stabilizer that contains 20 single pass trays to stabilize condensate from an Onshore Field. Our production rate is declining exponentially. I was wondering what process move can we perform to still using this stabilizer under very low flows .

georgeverghese (Chemical) · Answer 1 · 2022-07-15 23:23:00

Variable lift valves and bubble caps have an operating turndown of about 3: 1 to 4:1. Structured packing may allow a 10:1 turndown if I remember correctly.
For valved trays, suggest capping off some of the valves and changing out the trays to reverse flow trays to allow a longer liquid path across the tray.

On the other hand, there is nothing you can to increase reflux rates at column top if the feed gas condensate to gas ratio (CGR) has dropped off also

horacio Torres (Chemical) · Answer 2 · 2022-07-19 02:03:42

Could you give us some number, design rate vs new gas rate

Horacio

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Vivaldi M. Smith (Chemical) · Answer 3 · 2022-07-19 07:35:09

Horacio: Design condensate flow rate is 50000 BPD new gas rate is 15000 BPD

georgeverghese (Chemical) · Answer 4 · 2022-07-19 23:25:55

You mean current condensate rate is 15000 bpd ?
And this condensate probably now has much less light ends than your design case condensate composition, so vapor traffic through the column is lower.

Vivaldi M. Smith (Chemical) · Answer 5 · 2022-07-20 08:25:23

Yes, the current condensate rate is approximately 15000 bpd.

georgeverghese (Chemical) · Answer 6 · 2022-07-20 23:27:24

Run the process simulation program for this stabilizer with the new feed condensate composition and examine the vapor and liquid traffic loads at each tray. That should tell you where the vapor traffic is too low for the current setup.
Am assuming you have no means to introduce a light ends reflux stream from some other unit to counter the loss in light ends reflux now.

horacio Torres (Chemical) · Answer 7 · 2022-07-21 16:53:12

Horacio: Design condensate flow rate is 50000 BPD new gas rate is 15000 BPD

Mr Smith

It is a very low rate compared with the design.

I will assumed that your facilities in the middle time will be out of service due to the lack of gas/light or crude... It means you are not able to invest a lot of money... According of it, you can close open area in your sieve tray until you reach and stable operation (avoid weeping) at low rate. If is were my decision i set 16000 BPD as new design rate.. Keep in main the future flow rates.. It apply too for bubbles trays.

It is not usual recommendation, We have be done it, on field with low gas production rate or decreasing lights flows.

Horacio

https://www.linkedin.com/company/lagotuy/

georgeverghese (Chemical) · Answer 8 · 2022-07-21 23:30:00

@smith, You havent said much since your first post, and not much by way of detail, a process scheme or what options you've investigated so far.

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Condensate reduction process tunes