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Evaluation of Different Flare Gas Recovery Alternatives with Exergy and Exergoeconomic Analyses

  • Research Article-Chemical Engineering
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Abstract

Natural gas flaring is considered one of the significant sources of greenhouse gas emissions in the upstream oil and gas industry. It plays an essential role in reducing the energy efficiency of oil and gas production. Depending on flare gas properties, it can be used for different destinations. Herein, we have evaluated the main flare gas recovery alternatives, including sweet gas production, Gas to Liquid (GTL), and power generation, by using exergy and exergoeconomic analysis tools. For this purpose, flare gas condition in two phases of the Pars Special Economic Energy Zone in south of Iran was chosen as a case study. The mass sensitivity analysis is conducted to examine the processes in different flare gas volumes. Mass flow fluctuation analysis is carried out to analyze the effect of mass flow fluctuation as an intrinsic characteristic of flare systems. Results indicate that the production of electrical power from flaring gas is an economical method regarding the exergoeconomic criteria. While the power generation process has disadvantages such as high exergy destruction and high capital cost, advantages such as higher revenue, local potentials for designing, equipment, and construction should be regarded. On the other hand, the sweetening plant has the highest exergetic efficiency rather than other substitutes. This method also has a lower exergoeconomic factor, especially in lower flaring volume. The mass flow sensitivity analysis in these processes shows the GTL production unit's appropriate performance in low flare gas volume. The results also offer the superior performance of sweetening plants in high flare gas volume. Combined Cycle Power Plant (CCPP) process shows an acceptable performance in a broad range of flare gas volumes. Additionally, mass flow fluctuation analysis has been conducted to determine the effect of mass flow fluctuation in these alternatives. The investigation suggested that the CCPP process has lower fluctuation in terms of cycle product (power generation).

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Abbreviations

\(\dot{C}\) :

Cost rate ($/h)

\(\dot{C}_{D}\) :

Cost rate of exergy destruction ($/h)

\(\mathop {{\mathrm{Ex}}}\limits^{ \cdot }\) :

Exergy rate (kW)

\(\dot{m}\) :

Mass flow rate (kg/s)

\(\dot{W}\) :

Work rate (kW)

\(\dot{Z}\) :

Investment, operation and maintenance cost rate ($/h)

c :

Cost per exergy unit ($/GJ)

\(c_{F}\) :

Unit cost of the fuel ($/GJ)

\(c_{P}\) :

Unit cost of the product ($/GJ)

e :

Specific exergy (kJ/kg)

f :

Exergoeconomic factor (%)

h :

Specific enthalpy (kJ/kg)

I :

Irreversibility or exergy destruction (kW)

P :

Pressure

r :

Relative cost difference (%)

s :

Specific entropy (kJ/kg-C)

T :

Temperature (°C)

x :

Mole fraction

Z :

Purchased equipment cost

ε :

Exergetic efficiency (%)

\(\varphi\) :

Maintenance factor

0:

Reference state

AC:

Air cooler

Air comp:

Air compressor

ATR:

Autothermal reactor

ASF:

Anderson–Schulz Flory

bcm:

Billion cubic meters

C:

Compressor

CC:

Combustion chamber

CCPP:

Combined cycle power plant

CCS:

Carbon capture and storage

ch:

Chemical

CHP:

Combined heat and power

CRF:

Capital recovery factor

D:

Destruction

DEA:

Diethanol amine

DME:

Dimethyl ether

E:

Heat exchanger

F:

Fuel

FGR:

Flare gas recovery

FT:

Fischer–Tropsch

GT:

Gas turbine

GTE:

Gas to ethylene

GTG:

Gas turbines generation

GTL:

Gas to liquid

HRSG:

Heat recovery steam generator

HP:

High pressure

i:

Inlet

k :

kTh component

L:

Loss

LHV:

Lower heating value

LNG:

Liquefied natural gas

Mix:

Mixer

MMSCFD:

Million standard cubic feet per day

o:

Outlet

P:

Product

ph:

Physical

PEC:

Purchased equipment cost

ROR:

Rate of return

ST:

Steam turbine

TEE:

Splitter

V:

Vessel

VLV:

Valve

W:

Related to work

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Authors and Affiliations

  1. Graduate School of Environment, College of Engineering, University of Tehran, Tehran, Iran

    Mahshid Zaresharif

  2. Institute of Liquefied Natural Gas (I-LNG) & School of Chemical Engineering, College of Engineering, University of Tehran, Tehran, Iran

    Ali Vatani

  3. Department of Industrial Engineering & Management Systems, Amirkabir University of Technology, Tehran, Iran

    Mohammadreza Ghasemian

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Zaresharif, M., Vatani, A. & Ghasemian, M. Evaluation of Different Flare Gas Recovery Alternatives with Exergy and Exergoeconomic Analyses. Arab J Sci Eng 47, 5501–5520 (2022). https://doi.org/10.1007/s13369-021-05485-y

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