Title : Innovative jet-spool gas flow-back system towards circular economy, net-zero emission and energy conservation
Abstract:
The increasing global emphasis on reducing greenhouse gas emissions and improving energy efficiency has prompted the oil and gas industry to explore innovative solutions to minimize routine flaring. One such advancement is the Jet Spool Gas Flow-Back System, an innovative integration of jet pump ejector technology into existing flare gas recovery systems. This study aims to evaluate the effectiveness of this system in capturing and redirecting low-pressure flare gases back into the process, thereby enhancing operational efficiency and reducing environmental impact. The primary objective of this research is to demonstrate how the Jet Spool Gas Flow-Back System can passively recover flare gas without relying on mechanical compressors. The method involves integrating a jet ejector which operates using a high-pressure motive gas to entrain and compress low-pressure waste gas drawn from the flare header. The recovered gas is then re-injected into a suitable point in the processing system, such as the low-pressure suction of a gas compressor or into the fuel gas network. The system was modeled and evaluated through both process simulations and a field-scale pilot test in a gas processing facility, particularly during high-transient events like pigging or slug flow discharges. Results from the pilot deployment revealed that the jet ejector was capable of recovering up to 60%-70% of intermittent flare gas volumes, depending on motive gas availability and system backpressure. Importantly, the ejector maintained stable operation with zero moving parts, which significantly reduced maintenance downtime and costs compared to traditional mechanical recovery units. Additionally, the system’s modular design allowed it to be retrofitted with minimal disruption to existing flare infrastructure. Observations during testing confirmed that the system provided a dynamic response to transient gas flows, such as those seen during emergency depressurization or slug events. The pressure differential created by the motive gas was sufficient to induce a vacuum in the suction leg of the ejector, enabling efficient entrainment of flare gas without exceeding design limits of the downstream systems. The fluid flow was continuously monitored to optimize motive-to-suction ratios and maximize recovery efficiency. In conclusion, the Jet Spool Gas Flow-Back System presents a cost-effective, low-maintenance, and environmentally beneficial solution for flare gas recovery, particularly in facilities facing frequent transient flaring events. The use of jet ejector technology eliminates the need for mechanical compression, offering a robust alternative for brownfield installations and enhancing compliance with global flaring reduction initiatives. Future work will focus on expanding the system’s operational envelope and integrating smart control strategies to further enhance adaptability and performance. The innovation holds strong potential for widespread application in both upstream and downstream hydrocarbon processing facilities aiming for lower emissions and improved gas utilization.
