Comparative analysis of separation technologies for processing carbon dioxide rich natural gas in ultra-deepwater oil fields

Abstract

Offshore oil production in ultra-deepwater, with associated natural gas showing high carbon dioxide content and high gas to oil ratio, poses stringent constraints to upstream gas processing technologies. Under such circumstances, oil and gas are processed in Floating Production Storage and Offloading rigs, whose topside facilities are limited in terms of weight and footprint of equipment. Energy demands, supplied by on-site generation, also reduce the availability of space and weight to oil and gas processing. This work evaluates carbon dioxide separation alternatives applicable to this challenging scenario in terms of technical, economic and environmental aspects, considering early enhanced oil recovery as the destination of carbon dioxide. The Brazilian Pre-Salt fields are used as case study due to their unusual high capacity gas processing on the production topside, a consequence of the high gas to oil ratio and carbon dioxide content. The set of studied carbon dioxide separation technologies encompasses membrane permeation, chemical absorption by aqueous methyl diethanolamine with piperazine, physical absorption with propylene carbonate and hybrid variants physical absorption and membranes, membranes and chemical absorption, and two stages membrane, technically assessed by process simulation. Due to the continuous injection of carbon dioxide to enhanced oil recovery, the reservoir content of carbon dioxide increases along production life-cycle, which means that the performances of technologies have to be compared under short-term, mid-term and long-term carbon dioxide content in the associated gas, respectively, of 10%, 30% and 50% (mol), for gas production of 6 million sm3/d. Chemical absorption exhibits the lowest hydrocarbon losses and the lowest specific electric power consumption at the expense of the highest footprint, for all investigated scenarios. The lowest life-cycle costs are for chemical absorption and two stages membrane, respectively $0.57 and $0.46 million/GJ of exported gas, while the largest cost belongs to the hybrid membrane and chemical absorption ($1.78 million/GJ of exported gas). Chemical absorption holds the lowest carbon dioxide emission per ton of injected carbon dioxide (0.15 t/t), seconded by membrane permeation (0.19 t/t). Hybrid membrane and chemical absorption inherits the small footprint of membrane permeation and, despite its highest life-cycle cost, is recommended for flexibility reasons due to increasing carbon dioxide content in the reservoir life-time in cases of ultra-deepwater fields with high gas to oil ratio, high carbon dioxide content and early carbon dioxide enhanced oil recovery. Contrarily to the widely acceptance of membrane permeation as a leading small footprint solution, the overall performance analysis, under the adopted premises, remarkably favors chemical absorption.