New ideas for energy savings--Research on innovative energy-saving technologies for oil and gas storage and transportation systems

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Research on Energy-Saving Technologies for Oil and Gas Storage and Transportation Systems Author: Yang Hongqin Source: Fangchenggang Xinrun Petrochemical Co., Ltd., December 18, 2014 【Abstract】In the processes of oil processing and production, oil and gas storage and transportation systems play an extremely important role. Since oil and gas storage and transportation systems consume a large amount of energy, it is imperative to effectively control their energy consumption. By exploring energy-saving technologies for oil and gas storage and transportation systems, the article proposes three technical improvement measures to address the three existing causes, and conducts in-depth research and analysis on them. 【Keywords】Oil and gas ； Storage and transportation system ； Energy saving ； Reducing energy consumption 【Chinese Library Classification Number】TE8 【Document Code】A 【Article Number】1008-1151(2013)07-0044-02 1 The three main reasons for high energy consumption in oil and gas storage and transportation systems Generally speaking, oil and gas storage and transportation systems consist of three elements: steam, electricity, and water. However, within the energy consumption of the entire oil and gas storage and transportation system, steam consumption accounts for a very large proportion, exceeding 80%. Therefore, only by reducing the energy consumption of steam can the overall energy consumption of the oil and gas storage and transportation system be effectively controlled, thereby enabling energy-saving management of this system. There are three main reasons for the high steam energy consumption in oil and gas storage and transportation systems: 1.1 High storage temperature of oil and gas – The storage temperature of oil and gas varies depending on the properties of the oil and gas itself as well as the conditions under which it is stored. In other words, the storage temperature of oil and gas is generally high, which leads to adverse effects such as lower viscosity of the oil and gas and reduced transmission capacity. At the same time, if the heat generated by higher storage temperatures of oil and gas exceeds the energy savings resulting from reduced transportation power, the overall steam energy consumption will also increase. 1.2 Improper insulation of oil tanks: If appropriate insulation measures are not taken for oil tanks, the tank walls come into contact with oil and gas, which in turn increases steam consumption. Previous studies have shown that even when the material of the oil tank and the medium are the same, differences in insulation measures and conditions can result in significant variations in heat loss. It can be seen that whether the insulation measures of the oil tank are appropriate has a significant impact on the steam energy consumption. 1.3 Improper business operations by enterprises: Some enterprises have poor actual operating conditions and inadequate production facilities; they handle oil tanks in an improper manner and fail to clean them regularly, which reduces the heat transfer efficiency of these tanks and increases energy consumption. At the same time, it is also impossible to control the temperature of the oil and gas, which prevents effective dehydration processes from taking place. 2 Energy-saving measures for oil and gas storage and transportation systems 2.1 The two basic principles of energy saving in oil and gas storage and transportation systems (1) Reducing the reserves of oil and gas. The research plans for energy saving in oil and gas storage and transportation systems mainly consist of three key aspects: the use of oil and gas, its recovery, and its utilization. Reducing the reserves of oil and gas not only helps to significantly cut down the energy consumption associated with storage tanks and pipelines, but also lowers the overall transportation costs and capital investment for the enterprise. It allows for minimizing the space required for storage tanks, resulting in a more rational energy allocation structure. Additionally, it lays a solid foundation and provides strong support for expanding equipment capabilities as well as market and production scales. By continuously reducing the reserves of crude oil and taking into account the supply and demand conditions in the market, companies should minimize their existing reserves, stockpile oil at low prices, and keep the storage level sufficient to meet needs in case of emergencies. At the same time, the inventory of refined oil should also be strictly controlled, with its level kept as low as possible. On the one hand, it is possible to reduce the percentage of heavy oil products by reforming crude oil processing technologies, innovating and improving process techniques, and adopting advanced processing methods, thereby increasing the yield of diesel and boosting production volumes. On the other hand, by using quality meters and advanced detection technologies, not only is the energy consumption of oil and gas storage and transportation systems reduced, but resource allocation is also optimized, resulting in savings in labor and materials. (2) Improve the heating method: The heating method for oil tanks generally relies on hot water as a heat transfer medium. By heating and maintaining a steam coil at the bottom of the storage tank, heat transfer is achieved through 1MPa steam; coupled with the low heat transfer coefficient of the oil outside the tubes, this allows for high efficiency with low energy consumption. Therefore, by introducing heat into the oil and utilizing hot water as a heat transfer medium to achieve heat exchange through the coiled tubes, it is ensured that there is sufficient heat transfer, thus guaranteeing the hierarchical use of energy. When using a suction-type heating device, part of the oil that is drawn out should be heated through the suction-type heating device installed at the tank outlet and the pump inlet, provided that the viscosity of the fluid being transported meets the requirements specified by the oil pump. In other words, a relatively low temperature needs to be maintained at normal times, with heating starting only when it’s time to deliver. In this way, not only is the overall energy consumption for storing and transporting oil and gas reduced, but the viscosity standards required for their transportation are also ensured. 2.2 Four key energy-saving measures for oil and gas transportation systems (1) Oil-gas mixed transport method: The technology that is widely used by oil companies today is oil-gas mixed transport technology. Hydrocarbon mixing transportation technology refers to the process of pumping oil, gas, water, and other substances through subsea pipelines using mixing pumps, without separating them first, so as to transport a mixture of these various substances. Unlike traditional transportation methods, mixed oil and gas transport allows for the direct delivery of such mixtures using dedicated mixing pumps and pipelines; in traditional methods, however, the mixed medium must first be collected and processed, with the use of three-phase separators, crude oil transfer pumps, natural gas compressors, and separate submarine pipelines in order to enable the pipeline transport of oil and gas. The new oil-gas mixing transportation method not only reduces the overall energy consumption but also improves the overall production efficiency and economic benefits. (2) Energy-saving method of variable frequency speed control for oil transfer pump units. In the energy-saving plans for oil and gas storage and transportation systems, the variable frequency speed control technology for oil transfer pump units plays a significant role. Through the variable-frequency speed control energy-saving technology of the oil transfer pump unit, and in accordance with the characteristics of centrifugal pumps, flow rate is adjusted to control the oil transfer process. Adjusting the operating conditions of the oil transfer pump by using variable frequency control for the pump is fast, effective, and simple. The variable-frequency speed control energy-saving technology for oil transfer pump units mainly involves modifying the method of regulating valve throttling, thereby creating a unique variable-frequency speed control system specific to oil transfer pumps. It not only avoids losses and waste caused by an oversized outlet valve on the oil transfer pump, but also is easy to operate, thereby improving economic efficiency. At the same time, this energy-saving technology reduces the noise and wear caused by friction during machine operation, making the oil transfer pump units easier to maintain and extending their service life. (3) Normal-temperature transportation of oil and gas: The transportation of crude oil containing water mainly relies on normal-temperature transportation technologies for oil and gas. When the temperature of the fluid produced from oil wells containing water reaches a certain level, even if the phase transition point has not been reached, as long as the oil temperature at the wellhead is above the allowable minimum temperature for transportation, normal-temperature transportation techniques can be employed. Normal-temperature transportation methods mainly include single-tube normal-temperature oil collection, double-tube normal-temperature oil collection, and normal-temperature oil collection with low-temperature water mixed in. Firstly, single-tube normal-temperature oil collection involves shutting down the existing water injection pipeline and cleaning it; then, based on the pressure and temperature generated during oil well production, the liquid is transported to the metering room through the oil collection pipeline. Secondly, the two-pipe normal-temperature oil collection method involves shutting down the existing injection pipeline and replacing it with an oil collection pipeline; the wellhead and the metering station are modified so that oil can flow out from both the main pipe and the secondary pipe simultaneously. Once again, mixing low-temperature water into a ring-shaped normal-temperature oil collection system refers to a method in which several oil wells within an entire metering valve assembly are connected in series through a single oil collection pipeline to form a ring-shaped structure, with the metering valve assembly at one end of the ring being responsible for mixing water in. The other port is responsible for transporting the oil, water, and gas produced by the oil well to the manifold located between the metering valve assemblies. This method of transportation at room temperature has achieved significant results in the energy-saving initiatives of entire oil and gas transmission systems. It **reduces overall energy consumption, simplifies the heating and insulation systems, thereby cutting down overall costs. At the same time, it makes it easier to manage the entire oil transportation enterprise, enhancing overall economic efficiency**. (4) Reducing steam energy consumption: In petrochemical enterprises, since steam energy consumption accounts for over 80% of the total energy consumption in oil and gas storage and transportation systems, reducing steam energy consumption is of great importance in overall energy-saving efforts. To reasonably control the energy consumption of steam, the following three measures can be taken: ① Lower the storage temperature of oil and gas. Strictly control the storage temperature of oil and gas, and operate in accordance with the standard storage temperatures to ensure that the temperature during transportation is appropriate, thereby minimizing both the transportation power and thermal energy required. ②Proper insulation should be provided for the oil tanks. Strictly follow the insulation measures for oil tanks to determine the best insulation material for them. Insulation materials should be selected in strict accordance with the technical standards and methods specified by ** and various testing institutions. For the selection criteria of insulation materials for oil tanks, materials that are stable both physically and chemically should be used; they must not be corrosive to metals and should be non-flammable. One of the most important criteria is that the insulation material should have a maximum safe operating temperature that is higher than the operating temperature required by the tank under normal conditions; only in this way can the tank’s maximum efficiency be achieved and maintained. Ensure proper insulation control for oil tanks. ③Pay attention to the cleaning of oil tanks. It is necessary to strengthen the monitoring of enterprises’ production and operation conditions, pay attention to the daily storage environment and cleaning of oil tanks, and ensure the quality of oil and gas stored in these tanks, in order to reduce the overall energy consumption of the oil and gas storage and transportation system. 3 Conclusions By adopting new oil and gas transportation technologies, focusing on strengthening the daily operational management of enterprises, and ensuring proper daily cleaning of storage tanks as well as proper insulation treatment for oil tanks. It not only helps to reduce the overall energy consumption of oil and gas transportation systems, thereby achieving true energy savings and environmental protection, but it also improves the overall quality of oil and gas, which in turn enhances the economic and social benefits for enterprises. This contributes to improving the overall competitive strength of enterprises as well as the overall efficiency of China’s oil and gas industry. With the rapid advancement of technology, the oil and gas storage and transportation industry is bound to develop swiftly, moving toward an era that is more environmentally friendly and efficient. 【References】 Zhou Chunmao. Oil loss in the storage and transportation systems of refineries cannot be ignored. Oil & Gas Storage and Transportation, 2001. Liu Erheng, Hua Gui. Energy savings in the storage and transportation systems within the overall energy optimization of refineries. China and Foreign Energy, 2009. Tang Jianyi. Several issues related to the technical approaches for the storage and transportation systems in domestic refineries at present. Oil & Gas Storage and Transportation, 2005. Huang Jingli. Discussion on energy-saving technologies for refinery storage and transportation systems. Heilongjiang Science and Technology Information, 2009.