A sustainable design for gas fields development and processing

Alessia Mangiapane's picture
Alessia Mangiapane, Business Development Project Coordinator, KT Kinetics Technology
Paolo Mazzara's picture
Paolo Mazzara, Proposals and Sales Manager, KT Kinetics Technology
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In this article we are going to summarize some case studies in Oil and Gas field applications based on the approach No Flaring, both for some capital intensive and smaller size industrial projects. The purpose of each one is mostly to depict how much a Value Engineering approach can succeed in maximizing Client’s profits and how new technologies can provide solutions to minimize both Clients’ Variable Costs and Environmental Costs.

How a new Train for a giant Gas Processing complex recovered large CAPEX and OPEX results.

This case is regarding one of the world’s largest Gas Fields in the World (in Middle East), where we executed engineering review consultancy services some years ago and we gained:

  • A dramatic reduction of the total Electrical Power to the half, from 48 MW down to 24 MW
  • We Modified Open Sea Water system having a Sea Water raising to the Plant by 70 mts, with a Closed Loop concept, we reduced the outlet pressure of Propane refrigeration compressors and switched from air to closed loop water cycles)
  • A consequent CO2 equivalent reduction of 100,000 T/y
  • A dramatic overall reduction of CAPEX in the order of magnitude of -80 MM$ was proposed as achievement of the maximum effort of Value Engineering.

Associated Gas recovery for No Flaring and cost saving in Gas delivery.

It is concerning our patented application for Mini Methanol Plants, adopting the Catalytic Partial Oxydation in Short Contact Time (CPO-SCT), fully skidded and in a very compact layout, presented already for a 40,000 MTy mini-Methanol Plant to a Gas Company in Russia, suitable for remote locations where the payback of such installation can be shown to be very short, when compared to the cost of methanol purchasing and transportation to Site. We achieved also the overall CO2 reduction, once it is fed by Associated Gases which needs to be reduced as per the World Bank’s Global Gas Flaring reduction (GGFR).

NH3 thermal Treatment in Ammonia-Urea plants.

We present our patented application for Ammonia vents thermal treatment in place of the traditional Ammonia Flare system, to save CAPEX and control NH3, NOX emissions , for a modern approach. Our idea is to integrate KT’s incineration and DeNOx system in sister company Stamicarbon’s (innovation and license centre of Maire Tecnimont) urea melt plant in order to eliminate ammonia emission from urea melt plant. Our Invention is concerning the architecture for use of thermal treatment in urea melt plant pointing the attention to the market of all urea melt plant owners which suffer emission issues. Process characteristics of thermal treatment are: guaranteed NH3 and NOx emission from the urea melt plant (Expected NH3 emission: <1 ppm, NOx emission: <100 ppm).
Complementary MP steam generation with waste heat recovery. Only a fraction of the gas used for flaring is required, no nitrogen required.

Read more on how to find a technical solution for application of Innovative Technology.

Wednesday, October 28th - Technical Stream focusing on “Application of Innovative Technology” at the Gastech Conference in Singapore.

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Picture: "GRUPA LOTOS S.A. - Sulphur Recovery Complex (Gdansk, Poland)"