Flare Recovery Successful Case Study

Abstract A stream of 2 up to 4 Million Standard Cubic Feet Per Day (MMSCFD) sweet gas used to be burnt and flared on site as a waste of energy causing more than 27,000 pounds per hour (lb/hr.) of CO2 emissions and wasting a power of 5.5 Mega Watt (MW), on the other hand site compressors and generators required a source of power, accordingly a new flared gas recovery skid with a capacity of 4 MMSCFD is installed on site for providing power to Compressors and Gas Generators, cutting the CO2 emissions, put an end to the bleeding running cost of flaring. Skid is designed to recover a flared sweet gas stream of approximately 73 % Molar fraction of Methane (C1) and 12 % Molar fraction of Ethane (C2), approximately 0.5 % of Pentane (C5) and 0.13 of Hexane plus (C6+). The maximum allowable acceptable water content for conditioned gas is 70 pound per Million Standard Cubic Feet Per Day (lb/MMSCFD). A maximum consumed power of 130 Kilo Watt (KW) as a total duty. The maximum allowable acceptable of CO2 downstream from the unit is 3.8 % Molar fraction. Gas Lower heating value should not be lower than 1,000 British Thermal Unit per Cubic Feet (BTU/FT3) The main process components of the skid are summarized as: gas filtration, gas metering (totalizer), gas heaters, gas reduction., outlet scrubbers, controlling and instrumentations and piping and accessories. Recovering a flared gas up to 4 MMSCFD, cutting total running cost of approximately 1.1 Million United States American Dollars (MMUSD)/year, saving the required power of approximately 10.6 MW for the site facilities and also reduce the environmental harm impacts of flared gas cutting the CO2 emissions of 27,141.34 lb/hr. As 60% of electric power is produced of natural gas, capturing flared gas could cover 5% of Egypt's energy needs and add 300 MMUSD to national economy the introduced solution of flared gas recovery skid is able to recover a flared gas up to 4 MMSCFD against an estimated cost of 1.1 MMUSD as a fixed cost and existing asset on site to put an end to the bleeding running cost of 1.1 MMUSD / year for power generation in addition to the cost of gas flaring. Moreover producing and saving total electrical power of approximately 10.6 MW for the existing sire facilities in addition to reduce the environmental harm impacts of flared gas through cutting the CO2 emissions of more than 27,000 lb/hr. matching with the Climate Change Conference that took place in Sharm El-Sheikh, Egypt (COP 27) and also Climate Change Conference (COP 28) that took place in United Arab Emirates.