Natural-gas condensate, also called natural gas liquids, is a low-density mixture of hydrocarbon liquids that are present as gaseous components in the raw natural gas produced from many natural gas fields. Some gas species within the raw natural gas will condense to a liquid state if the temperature is reduced to below the hydrocarbon dew point temperature at a set pressure.
The natural gas condensate is also called condensate, or gas condensate, or sometimes natural gasoline because it contains hydrocarbons within the gasoline boiling range, and is also referred to by the shortened name condy by many workers on gas installations. Raw natural gas used to create condensate may come from any type of gas well such as: [1] [2]
There are many condensate sources, and each has its own unique gas condensate composition. In general, gas condensate has a specific gravity ranging from 0.5 to 0.8, and is composed of hydrocarbons such as propane, butane, pentane, and hexane. Natural gas compounds with more than two carbon atoms exist as liquids at ambient temperatures and pressures. [4] Propane, butane, and isobutane are liquid at normal temperatures only under pressure. Additionally, condensate may contain: [5] [6] [7]
There are hundreds of different equipment configurations to separate natural gas condensate from raw natural gas. The schematic flow diagram to the right depicts just one of the possible configurations. [8]
The raw natural gas feedstock from a gas well or a group of wells is cooled to lower the gas temperature to below its hydrocarbon dew point at the feedstock pressure. This condenses a large part of the gas condensate hydrocarbons. The feedstock mixture of gas, liquid condensate and water is then routed to a high pressure separator vessel where the water and the raw natural gas are separated and removed. If a pressure boost is required, the raw natural gas from the high pressure separator is sent to the main gas compressor, which raises the pressure of the gases to whatever pressure is required for the pipeline transportation of the gas to the raw natural gas processing plant. The main gas compressor discharge pressure will depend upon the operating pressure of and the distance to the raw natural gas processing plant and may require a multi-stage compressor.
The gas condensate from the high pressure separator flows through a throttling control valve to a low pressure separator. The reduction in pressure across the control valve causes the condensate to undergo a partial vaporization referred to as flash vaporization. The raw natural gas from the low pressure separator is sent to a "booster" compressor that raises the gas pressure and sends it through a cooler, and then to the main gas compressor.
At the raw natural gas processing plant, the gas will be dehydrated and acid gases and other impurities will be removed from the gas. Then, the ethane (C
2), propane (C
3), butanes (C
4), and pentanes (C
5)—plus higher molecular weight hydrocarbons referred to as C5+—will also be removed and recovered as byproducts.
The water removed from both the high and low pressure separators may need to be processed to remove hydrogen sulfide (H
2S) before the water can be disposed of underground or reused in some fashion.
Some of the raw natural gas may be re-injected into the producing formation to help maintain the reservoir pressure, or for storage pending later installation of a pipeline.
Natural gas condensate is generally more flammable and explosive than normal crude oil. Operating in areas where condensate has escaped is dangerous for crew due to the danger of explosions, oxygen displacement and the threat of asphyxiating and anaesthetizing, which can occur within a few human breaths. [9]
Because condensate is typically liquid in ambient conditions and also has very low viscosity, condensate is often used to dilute highly viscous heavier oils that cannot otherwise be efficiently transported via pipelines. In particular, condensate is frequently mixed with bitumen from oil sands to create dilbit. In 2013, the increased use of condensate as diluent significantly increased its price in certain regions. [10]
Drip gas, so named because it can be drawn off the bottom of small chambers (called drips) sometimes installed in pipelines from gas wells, is another name for natural-gas condensate, a naturally occurring form of gasoline obtained as a byproduct of natural gas extraction. It is also known as "condensate", "natural gasoline", "casing head gas", "raw gas", "white gas" and "liquid gold". [11] [12] Drip gas is defined in the United States Code of Federal Regulations as consisting of butane, pentane, and hexane hydrocarbons. Within set ranges of distillation, drip gas may be extracted and used to denature fuel alcohol. [13] Drip gas is also used as a cleaner and solvent as well as a lantern and stove fuel.
Some early internal combustion engines—such as the first types made by Karl Benz, and early Wright brothers aircraft engines—used natural gasoline, which could be either drip gas or a similar range of hydrocarbons distilled from crude oil. Natural gasoline has an octane rating of about 30 to 50, sufficient for the low-compression engines of the early 20th century. By 1930, improved engines and higher compression ratios required higher-octane, refined gasolines to produce power without knocking or detonation.
Beginning in the Great Depression, drip gas was used as a replacement for commercial gasoline by people in oil-producing areas. "In the days of simple engines in automobiles and farm tractors it was not uncommon for anyone having access to a condensate well to fill his tank with 'drip,'" according to the Oklahoma Historical Society. Sometimes it worked fine. "At other times it might cause thundering backfires and clouds of foul-smelling smoke." [14]
Certain manufacturers such as John Deere made farm tractors specifically designed to run on heavy, low-octane fuels which were commonly called "distillate" or "tractor fuel". [15] Other names were tractor vaporising oil (United Kingdom) and "power kerosene" (Australia). Often the tractors were referred to as "all-fuel". [16] The most important factor in burning heavy fuels in a spark-ignition engine is proper fuel vaporization. Tractors designed to run on those fuels usually used a "hot" intake air manifold that allowed exhaust heat to warm the manifold and carburetor to aid vaporization. Given the poor vaporization at low temperatures, all-fuel tractors were started on gasoline, then switched to the heavy fuel. They were equipped with a small gasoline tank and a large fuel tank, both of which fed into a common valve supplying the fuel to the carburetor.
The engine would be started on gasoline and the tractor would then be worked until the engine was sufficiently warm to change over. At that point, the fuel valve would be turned to switch the fuel supply from the gasoline tank to the fuel tank and the heavy fuel would flow to the carburetor. Shutters or curtains were typically used to restrict airflow to the radiator, keeping the engine sufficiently hot for efficient operation. Coolant temperatures in the 200 degree F range were normal. John Deere two-cylinder all-fuel tractors worked well on heavy fuel, as their long piston strokes, slow engine speeds and low compression ratios allowed for effective use of the fuel. Most were also equipped with thermosiphon cooling systems that used no water pumps. Natural convection allowed the water to flow up and out of the engine block and into the top of the radiator, where it cooled and dropped and fell to continue the cycle.
Woody Guthrie's autobiographical novel Seeds of Man begins with Woody and his uncle Jeff tapping a natural gas pipeline for drip gas. The gas also has a mention in Terrence Malick's movie Badlands . [17]
Drip gas was sold commercially at gas stations and hardware stores in North America until the early 1950s. The white gas sold today is a similar product but is produced at refineries with the carcinogen benzene removed. [18]
In 1975, the New Mexico State Police's drip gas detail – three men in pickup trucks – began patrolling oil and gas fields, catching thieves and recovering barrels of stolen gas. The detail stopped its work in 1987. [12]
The use of drip gas in cars and trucks is now illegal in many states. It is also harmful to modern engines due to its low octane rating, much higher combustion temperature than that of gasoline, and lack of additives. It has a distinctive smell when used as a fuel, which allowed police to sometimes catch people using drip gas illegally. [19] [15]
Natural gas is a naturally occurring mixture of gaseous hydrocarbons consisting primarily of methane in addition to various smaller amounts of other higher alkanes. Low levels of trace gases like carbon dioxide, nitrogen, hydrogen sulfide, and helium are also usually present. Methane is colorless and odorless, and the second largest greenhouse gas contributor to global climate change after carbon dioxide. So odorizers such as mercaptan are commonly added to natural gas supplies for safety so that leaks can be readily detected.
Propane is a three-carbon alkane with the molecular formula C3H8. It is a gas at standard temperature and pressure, but compressible to a transportable liquid. A by-product of natural gas processing and petroleum refining, it is commonly used as a fuel in domestic and industrial applications and in low-emissions public transportation. Discovered in 1857 by the French chemist Marcellin Berthelot, it became commercially available in the US by 1911. Propane is one of a group of liquefied petroleum gases. The others include butane, propylene, butadiene, butylene, isobutylene, and mixtures thereof. Propane has lower volumetric energy density, but higher gravimetric energy density and burns more cleanly than gasoline and coal.
A refinery is a production facility composed of a group of chemical engineering unit processes and unit operations refining certain materials or converting raw material into products of value.
Liquefied petroleum gas is a fuel gas which contains a flammable mixture of hydrocarbon gases, specifically propane, propylene, butylene, isobutane, and n-butane.
Liquid fuels are combustible or energy-generating molecules that can be harnessed to create mechanical energy, usually producing kinetic energy; they also must take the shape of their container. It is the fumes of liquid fuels that are flammable instead of the fluid. Most liquid fuels in widespread use are derived from fossil fuels; however, there are several types, such as hydrogen fuel, ethanol, and biodiesel, which are also categorized as a liquid fuel. Many liquid fuels play a primary role in transportation and the economy.
Catalytic reforming is a chemical process used to convert petroleum refinery naphthas distilled from crude oil into high-octane liquid products called reformates, which are premium blending stocks for high-octane gasoline. The process converts low-octane linear hydrocarbons (paraffins) into branched alkanes (isoparaffins) and cyclic naphthenes, which are then partially dehydrogenated to produce high-octane aromatic hydrocarbons. The dehydrogenation also produces significant amounts of byproduct hydrogen gas, which is fed into other refinery processes such as hydrocracking. A side reaction is hydrogenolysis, which produces light hydrocarbons of lower value, such as methane, ethane, propane and butanes.
Hydrodesulfurization (HDS), also called hydrotreatment or hydrotreating, is a catalytic chemical process widely used to remove sulfur (S) from natural gas and from refined petroleum products, such as gasoline or petrol, jet fuel, kerosene, diesel fuel, and fuel oils. The purpose of removing the sulfur, and creating products such as ultra-low-sulfur diesel, is to reduce the sulfur dioxide emissions that result from using those fuels in automotive vehicles, aircraft, railroad locomotives, ships, gas or oil burning power plants, residential and industrial furnaces, and other forms of fuel combustion.
Vapour-compression refrigeration or vapor-compression refrigeration system (VCRS), in which the refrigerant undergoes phase changes, is one of the many refrigeration cycles and is the most widely used method for air conditioning of buildings and automobiles. It is also used in domestic and commercial refrigerators, large-scale warehouses for chilled or frozen storage of foods and meats, refrigerated trucks and railroad cars, and a host of other commercial and industrial services. Oil refineries, petrochemical and chemical processing plants, and natural gas processing plants are among the many types of industrial plants that often utilize large vapor-compression refrigeration systems. Cascade refrigeration systems may also be implemented using two compressors.
A turboexpander, also referred to as a turbo-expander or an expansion turbine, is a centrifugal or axial-flow turbine, through which a high-pressure gas is expanded to produce work that is often used to drive a compressor or generator.
A coalescer is a device which induces coalescence in a medium. They are primarily used to separate emulsions into their components via various processes, operating in reverse to an emulsifier.
Natural-gas processing is a range of industrial processes designed to purify raw natural gas by removing contaminants such as solids, water, carbon dioxide (CO2), hydrogen sulfide (H2S), mercury and higher molecular mass hydrocarbons (condensate) to produce pipeline quality dry natural gas for pipeline distribution and final use. Some of the substances which contaminate natural gas have economic value and are further processed or sold. Hydrocarbons that are liquid at ambient conditions: temperature and pressure (i.e., pentane and heavier) are called natural-gas condensate (sometimes also called natural gasoline or simply condensate).
Natural gasoline is a liquid hydrocarbon mixture condensed from natural gas, similar to common gasoline (petrol) derived from petroleum.
An oil production plant is a facility which processes production fluids from oil wells in order to separate out key components and prepare them for export. Typical oil well production fluids are a mixture of oil, gas and produced water. An oil production plant is distinct from an oil depot, which does not have processing facilities.
Onshore, when used in relation to hydrocarbons, refers to an oil, natural gas or condensate field that is under the land or to activities or operations carried out in relation to such a field.
The Central Area Transmission System is a natural gas transportation and processing system that transports natural gas through a 404 kilometre pipeline from the Central North Sea to a reception and processing terminal at Teesside in the North East of England.
Butane or n-butane is an alkane with the formula C4H10. Butane is a highly flammable, colorless, easily liquefied gas that quickly vaporizes at room temperature and pressure. The name butane comes from the root but- (from butyric acid, named after the Greek word for butter) and the suffix -ane. It was discovered in crude petroleum in 1864 by Edmund Ronalds, who was the first to describe its properties, and commercialized by Walter O. Snelling in early 1910s.
A blowtorch, also referred to as a blowlamp, is an ambient air fuel-burning gas lamp used for applying flame and heat to various applications, usually metalworking.
Refining of crude oils essentially consists of primary separation processes and secondary conversion processes. The petroleum refining process is the separation of the different hydrocarbons present in crude oil into useful fractions and the conversion of some of the hydrocarbons into products having higher quality performance.
Crude oil stabilisation is a partial distillation process that renders crude oil suitable for storage in atmospheric tanks, or of a quality suitable for sales or pipeline transportation. Stabilization is achieved by subjecting ‘live’ crude to temperature and pressure conditions in a fractionation vessel, which drives off light hydrocarbon components to form a ‘dead’ or stabilized crude oil with a lower vapor pressure.
The Teesside oil terminal is a major crude oil reception, processing, storage and export facility at Seal Sands, Middlesbrough. It receives and processes crude oil delivered by the subsea NORPIPE pipeline from the Norwegian Ekofisk field and the UK Fulmar and J-Block fields. The terminal includes facilities for exporting stabilised crude oil and liquefied petroleum gases (LPG) by tanker and pipeline.
A final point to consider involves the distinction between the very light grades of lease condensate (which are included in EIA's oil production data) and hydrocarbon gas liquids (HGL) that are produced from the wellhead as gas but are converted to liquids when separated from methane at a natural gas processing plant. These hydrocarbons include ethane, propane, butanes, and hydrocarbons with five or more carbon atoms – referred to as pentanes plus, naptha, or plant condensate. Plant condensate can also be blended with crude oil, which would change both the distribution and total volume of oil received by refineries.