Process control systems and methods for simultaneous crude oil dehydration, desalting, sweetening, and stabilization with indirect recycle heating

Patent metadata

Field	Value
Publication number	US-11732201-B2
Application number	US-202117330077-A
Country	US
Kind code	B2
Filing date	May 25, 2021
Priority date	May 25, 2021
Publication date	Aug 22, 2023
Grant date	Aug 22, 2023

Abstract

Systems and methods for crude oil separations including degassing, dewatering, desalting, and stabilization, one method including separating crude oil into a crude oil off-gas and a partially degassed crude oil output; compressing the crude oil off-gas; applying the compressed crude oil off-gas for indirect heating of the partially degassed crude oil output; further heating the partially degassed crude oil output indirectly with compressed low pressure gas; directly mixing with the partially degassed crude oil output a compressed atmospheric pressure gas; separating from the partially degassed crude oil output a low pressure gas for use in the step of further heating; and separating from the partially degassed crude oil output an atmospheric pressure gas for use in the step of directly mixing.

First claim

What is claimed is:

1. An integrated gas oil separation plant system, the system comprising:
a crude oil inlet feed stream;
an inline cyclonic separator, wherein the inline cyclonic separator is fluidly coupled to the crude oil inlet feed stream and is operable to separate gas from crude oil in the crude oil inlet feed stream;
a first indirect heat exchanger fluidly coupled to the inline cyclonic separator to heat the crude oil in the crude oil inlet feed stream;
a second indirect heat exchanger fluidly coupled to the first indirect heat exchanger to heat the crude oil in the crude oil inlet feed stream;
a direct mixer device fluidly coupled to the second indirect heat exchanger to mix compressed atmospheric pressure gas directly with the crude oil in the crude oil inlet feed stream;
a low pressure production trap (LPPT), where the LPPT is fluidly coupled to the direct mixer device;
a low pressure degassing tank (LPDT), where the LPDT is fluidly coupled to the LPPT;
an atmospheric pressure off-gas compressor fluidly coupled to the LPDT to compress off-gas from the LPDT for production of the compressed atmospheric pressure gas for the direct mixer device;
a low pressure off-gas compressor fluidly coupled to the LPPT to compress off-gas from the LPPT for production of compressed low pressure gas for use in heating in the second indirect heat exchanger;
a high pressure off-gas compressor fluidly coupled to the inline cyclonic separator to compress off-gas from the inline cyclonic separator for production of compressed high pressure gas for use in heating in the first indirect heat exchanger; and
a low pressure knockout drum (KOD) fluidly coupled to the second indirect heat exchanger and fluidly coupled to the high pressure off-gas compressor to accept cooled gases from the second indirect heat exchanger, to remove gas condensates and water from the cooled gases from the second indirect heat exchanger, and to supply gas to the high pressure off-gas compressor.

2. The system according to claim 1 , further comprising a high pressure KOD fluidly coupled to the first indirect heat exchanger to accept cooled gases from the first indirect heat exchanger, to remove gas condensates and water from the cooled gases from the first indirect heat exchanger, and to supply gas to a natural gas treatment facility.

3. The system according to claim 1 , wherein the atmospheric pressure off-gas compressor is further fluidly coupled to a crude oil stabilizer with reboilers to accept atmospheric off-gas from the crude oil stabilizer.

4. The system according to claim 1 , wherein the atmospheric pressure off-gas compressor is further fluidly coupled to a treated crude oil export product tank to accept atmospheric off-gas from the treated crude oil export product tank.

5. The system according to claim 1 , wherein the atmospheric pressure off-gas compressor is further fluidly coupled to a crude oil stabilizer without reboilers and with stripping gas injection to accept atmospheric off-gas from the crude oil stabilizer without reboilers and with stripping gas injection.

6. The system according to claim 5 , where the stripping gas injection stream is operable to supply steam in addition to or alternative to an additional stripping gas of reduced H 2 S concentration relative to crude oil in the crude oil stabilizer, where the stripping gas stream is operable to lower concentration of H 2 S in crude oil in the crude oil stabilizer.

7. The system according to claim 1 , where the system is operable to refine crude oil in the crude oil inlet feed stream to produce a refined crude oil product for storage and shipment meeting the following specifications: (1) a salt concentration of not more than about 10 pound (lbs.) of salt/1000 barrels (PTB); (2) basic sediment and water (BSW) of not more than about 0.3 volume percent (V %); (3) H 2 S concentration of less than about 60 ppm; and (4) a maximum RVP of about 7 pounds per square inch absolute (psia) and a maximum true vapor pressure (TVP) of about 13.5 psia at 130 degrees Fahrenheit (° F.).

8. The system according to claim 1 , further comprising a multi-variable prediction controller operable to control variables selected from the group consisting of: demulsifier injection rate; wash water injection rate; wash water recycle rate; LPPT temperature; LPPT pressure; LPPT oil-in-water emulsion level; LPDT temperature; LPDT pressure; and LPDT oil-in-water emulsion level; and
where the system is operable to refine crude oil in the crude oil inlet feed stream to produce a refined crude oil product for storage and shipment meeting the following specifications: (1) a salt concentration of not more than about 10 pound (lbs.) of salt/1000 barrels (PTB); (2) basic sediment and water (BSW) of not more than about 0.3 volume percent (V %); (3) H 2 S concentration of less than about 60 ppm; and (4) a maximum RVP of about 7 pounds per square inch absolute (psia) and a maximum true vapor pressure (TVP) of about 13.5 psia at 130 degrees Fahrenheit (° F.).

9. The system according to claim 1 , where the operating pressure within the LPPT is greater than operating pressure in the LPDT.

10. The system according to claim 1 , further comprising a crude oil charge pump, a trim heater, and a desalter following the LPDT and in fluid communication with the LPDT.

11. The system according to claim 1 , wherein the operating pressure of the inline cyclonic separator is between about 50 psig and about 150 psig greater than the operating pressure of the LPPT.

12. The system according to claim 1 , wherein the LPPT and LPDT comprise an inlet cyclonic separator, insulated electrostatic electrodes, and a weir, wherein oil-in-water emulsions are disposed proximate the weirs during operation.

13. The system according to claim 1 , wherein the compressors do not require after coolers.

14. An integrated gas oil separation plant system, the system comprising:
a crude oil inlet feed stream;
an inline cyclonic separator, wherein the inline cyclonic separator is fluidly coupled to the crude oil inlet feed stream and is operable to separate gas from crude oil in the crude oil inlet feed stream;
a first indirect heat exchanger fluidly coupled to the inline cyclonic separator to heat the crude oil in the crude oil inlet feed stream;
a second indirect heat exchanger fluidly coupled to the first indirect heat exchanger to heat the crude oil in the crude oil inlet feed stream;
a direct mixer device fluidly coupled to the second indirect heat exchanger to mix compressed atmospheric pressure gas directly with the crude oil in the crude oil inlet feed stream;
a low pressure production trap (LPPT), where the LPPT is fluidly coupled to the direct mixer device;
a low pressure degassing tank (LPDT), where the LPDT is fluidly coupled to the LPPT;
an atmospheric pressure off-gas compressor fluidly coupled to the LPDT to compress off-gas from the LPDT for production of the compressed atmospheric pressure gas for the direct mixer device;
a low pressure off-gas compressor fluidly coupled to the LPPT to compress off-gas from the LPPT for production of compressed low pressure gas for use in heating in the second indirect heat exchanger;
a high pressure off-gas compressor fluidly coupled to the inline cyclonic separator to compress off-gas from the inline cyclonic separator for production of compressed high pressure gas for use in heating in the first indirect heat exchanger; and
a high pressure KOD fluidly coupled to the first indirect heat exchanger to accept cooled gases from the first indirect heat exchanger, to remove gas condensates and water from the cooled gases from the

Assignees

• Saudi Arabian Oil Co

Inventors

• Soliman Mohamed

Classifications

• C10G53/02 Primary

  plural serial stages only · CPC title

• B01D17/045

  with coalescers · CPC title

• B01D19/001

  by bubbling steam through the liquid (B01D19/0042, B01D19/0047 and B01D19/0052 take precedence) · CPC title

• B01D19/0057

  the centrifugal movement being caused by a vortex, e.g. using a cyclone, or by a tangential inlet · CPC title

• B01D19/0063

  Regulation, control including valves and floats (for construction and details of valves F16K) · CPC title