Shandong Kosman Environmental Technology Co., Ltd. is one of the leading manufacturers and suppliers of light hydrocarbon recovery equipment in China. Please feel free to buy premium equipment for sale here and get pricelist from our factory. All customized products are with high quality and low price.
I. Product Overview
Light hydrocarbon recovery equipment is a specialized, integrated system designed for the purification, separation, and resource utilization of hydrocarbon-bearing gases, such as associated petroleum gas, condensate gas from natural gas fields, refinery tail gas, and chemical waste gas. Associated petroleum gas is a mixture primarily composed of methane, alongside low-molecular-weight alkanes (such as ethane, propane, and butane) and small amounts of non-hydrocarbon gases (such as nitrogen, carbon dioxide, and hydrogen sulfide). Historically, large quantities of associated gas have been directly vented or flared, resulting in both the waste of valuable light hydrocarbon resources and severe environmental pollution.
This product utilizes multi-stage condensation separation as its core process. Through steps such as feed gas compression, dehydration, refrigeration, and fractionation, it liquefies and recovers light hydrocarbon components of C3 and heavier (e.g., liquefied petroleum gas, light oil), while utilizing the resulting dry gas (primarily methane) for power generation or as fuel. The product complies with relevant national environmental protection and workplace safety standards and is widely used in various settings, including oilfield wellheads, gas gathering stations, refining and chemical enterprises, scattered gas wells, and offshore platforms.
II. Technical Principles and Process Flow
2.1 Core Technical Principles
The core technical approach for light hydrocarbon recovery is primarily based on condensation separation. The fundamental principle relies on the varying vapor pressures of hydrocarbons at different temperatures; by progressively lowering the temperature, different components within the associated gas condense into liquid form sequentially, enabling the fractional recovery of light hydrocarbons.
Depending on the refrigeration temperature, condensation separation methods are categorized as follows:
Shallow refrigeration process (-25°C to 15°C): Recovers heavy hydrocarbon components of C5 and heavier.
Medium refrigeration process (-60°C to -30°C): Recovers C4 and partial C3 components.
Deep refrigeration process (-100°C to -90°C): Recovers C3 and lighter hydrocarbon components.
Current mainstream technologies include turbo-expander refrigeration and Mixed Refrigerant Cycle (MRC) processes; these have become industry standards due to their low energy consumption and high efficiency. Additionally, adsorption methods (utilizing porous materials for the selective adsorption of hydrocarbons) and oil absorption methods (separating components based on solubility differences) are also utilized to some extent.
2.2 Typical Process Flow
Taking the multi-stage condensation recovery process as an example, it primarily comprises the following steps:
|
Process Step |
Functional Description |
|
Gas-Water Separation |
Feed gas passes through a separation system-utilizing low-speed centrifugal separation and metal filter mesh-to remove impurities such as water, heavy oil, and sediment. |
|
Compression & Purification |
Gas is pressurized using an oil-free compressor and cooled via an evaporative condenser for further condensation and purification. |
|
Deep Drying |
Deep dehydration is achieved using 4A molecular sieves, with regeneration performed via automatic switching and gas-fired heating. |
|
Multi-stage Condensation & Separation |
Gas enters the refrigeration system, where different components are recovered through staged condensation based on temperature gradients. |
|
Product Storage & Transport |
Light hydrocarbons (C3+) flow through a reflux tank to the storage area; dry gas is utilized for power generation or other applications. |
Multi-stage condensation temperature gradient (using four-stage condensation as an example):
|
Condensation Stage |
Temperature |
Recovered Components |
|
First-stage precooling |
+3°C |
Preliminary oil removal; recovery of partial heavy hydrocarbons |
|
Second-stage cooling |
-18°C |
Recovery of C6+ components |
|
Third-stage cooling |
-25°C |
Recovery of C5 components |
|
Fourth-stage cooling |
-45°C |
Recovery of C4 and C3 components |
2.3 MRC Refrigeration Process (Advanced Technology Route)
The associated gas light hydrocarbon recovery unit, based on the MRC (Mixed Refrigerant Cycle) process, utilizes molecular sieve adsorption principles to lower gas temperatures and effectively separate light hydrocarbon components. Its primary system components include: an inlet separation skid, compressor, molecular sieve skid, cold box, cryogenic separator, heavy absorption tower, de-ethanizer, liquefied gas tower, and a central control system. This technology effectively lowers the temperature of the associated gas and enhances the recovery rate of light hydrocarbons.
III. System Composition
Light hydrocarbon recovery equipment typically comprises the following functional modules:
|
System Module |
Key Equipment/Components |
Functional Description |
|
Feed Gas Purification System |
Gas-liquid separator, three-phase separator, filter, coalescer |
Removes impurities such as water, oil, and sediment |
|
Compression System |
Oil-free compressor, evaporative condenser |
Compresses low-pressure associated gas to process requirements |
|
Drying System |
Molecular sieve drying tower, regeneration heater |
Deeply removes moisture from the gas |
|
Refrigeration & Condensing System |
Multi-stage cooler (evaporator), pre-cooling heat exchanger, refrigeration compressor |
Cools the gas in stages to condense and recover light hydrocarbons |
|
Fractionation System |
Heavy absorption tower, de-ethanizer, LPG tower, cryogenic separator |
Precisely separates different components |
|
Product Storage & Loading System |
Reflux tank, product storage tank, metered loading system |
Stores and loads recovered products |
|
Control System |
PLC/DCS central control system, explosion-proof instrumentation |
Fully automated control and online monitoring |
IV. Main Technical Parameters
4.1 General Technical Parameters
|
Parameter Item |
Technical Specifications |
Notes |
|
Processing Capacity |
30–20,000 Nm³/h (customizable) |
Covers applications ranging from small, scattered wells to large oilfields |
|
Daily Processing Volume |
2,000–120,000 Nm³/d |
Available in various product specifications |
|
Recovered Products |
LPG, light hydrocarbons, mixed hydrocarbons |
C3+ components |
|
Condensation Temperature |
+3°C → -18°C → -25°C → -45°C (deep cryogenic cooling optional) |
Four-stage cascade condensation |
|
Purification Rate |
≥98% |
VOC removal rate |
|
Compressor Power |
22–850 kW |
Depends on processing capacity |
|
Explosion-proof Rating |
Ex d IIB T4 (optional) |
Suitable for flammable and explosive environments |
|
Control System |
PLC/DCS fully automatic control |
Supports remote monitoring and data transmission |
|
Product Configuration |
Skid-mounted / Fixed |
Skid-mounted units facilitate transport and rapid deployment |
Taking a light hydrocarbon recovery unit (500 m³/h) as an example
|
Parameter Item |
Technical Specifications |
|
Model |
ZW-2.0/(1.5-2.5)-25 |
|
Process Medium |
Hydrocarbons, Natural Gas |
|
Rated Flow Rate |
500 Nm³/h |
|
Compression Stages |
2 stages |
|
Inlet Pressure |
0.1–0.2 MPa |
|
Discharge Pressure |
2.5 MPa |
|
Motor Power |
22 kW |
|
Cooling Method |
Air cooling or water cooling |
|
Overall Dimensions |
4200 × 2200 × 2200 mm |
V. Application Scenarios
|
Application Area |
Typical Scenario |
Recommended Product Form |
|
Associated Gas |
Recovery of associated gas at wellheads and gathering stations |
Skid-mounted / Mobile |
|
Scattered Gas / Remote Wells |
Low-yield, dispersed gas sources lacking pipeline access |
Small-scale skid-mounted |
|
Natural Gas Processing Plants |
Hydrocarbon and water removal |
Stationary |
|
Refineries / Chemical Plants |
Light hydrocarbon recovery from refinery tail gas or chemical waste gas |
Stationary / Skid-mounted |
|
Offshore Platforms |
Space constraints and strict safety requirements |
Compact skid-mounted unit |
|
Well Testing / Pilot Production |
Short-term operations with fluctuating gas flow |
Mobile integrated unit |
IX. Ordering Information
|
Item |
Details |
|
Product Name |
Light Hydrocarbon Recovery Unit |
|
Process Options |
Multi-stage condensation separation / MRC refrigeration / Combined condensation & adsorption |
|
Processing Capacity |
30–20,000 Nm³/h (customizable) |
|
Daily Throughput |
2,000–120,000 Nm³/d (standardized product series) |
|
Product Form |
Skid-mounted / Mobile integrated / Stationary |
|
Explosion-proof Rating |
Ex d IIB T4 (optional) |
|
Design Service Life |
≥10 years |
|
Warranty Period |
12–24 months |
|
Production Lead Time |
60–120 days (depending on capacity and configuration) |
|
Optional Configurations |
Online monitoring system, DCS communication interface, waste heat recovery system, generator set |
|
After-sales Service |
Technical support, on-site response within 48 hours |
Specific prices and delivery times are subject to actual quotation.
X. Contact Information
Please contact us for further product details, technical solutions, or a quotation.
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