Oilfield Wellhead Pre-Cooler

Overview

Yipu Oilfield Wellhead Gas Pre-Cooler delivers three core values through professional technologies:

1. Significant Economic Benefits: Pressure energy recovery reduces energy consumption by over 35%; improves light hydrocarbon recovery rate to increase revenue; adapts to pressure depletion to extend the effective service life of equipment.
2. Stable and Reliable Operation: Ultra-wide operating condition adaptability; intelligent anti-fluctuation control; guaranteed long-term stable operation.
3. Rapid Investment Payback: Modular design enables quick commissioning; intelligent operation and maintenance reduce costs; investment payback period of 1-2 years.

This product is particularly suitable for various oilfield associated gas processing scenarios, serving as a key equipment for efficient recovery of oilfield gas resources, energy conservation, and emission reduction.

I. Market Pain Point Analysis

1. Complex and Volatile Wellhead Gas Compositions
   • Oilfield associated gas compositions change frequently, with methane content fluctuating between 30%-85%.
   • Contains large amounts of impurities such as C3+ heavy hydrocarbons, hydrogen sulfide (H₂S), and carbon dioxide (CO₂).
   • Traditional equipment struggles to adapt to composition changes, resulting in unstable processing effects.
2. Severe Fluctuations in Pressure and Temperature
   • Wellhead pressure rapidly depletes from 8.0MPa to below 0.1MPa.
   • Temperature varies significantly with seasons and production stages (20-80℃).
   • Conventional equipment operates with low efficiency over a wide range of working conditions.
3. Inadequate Energy Efficiency Utilization
   • Wellhead pressure energy is not effectively recovered and utilized.
   • Traditional pre-cooling equipment has high energy consumption, leading to significant operating cost pressure.

II. System Process Flow

Intelligent Five-Stage Processing System:

1. Wellhead Pressure Energy Recovery
   • High-pressure wellhead gas (≤8.0MPa) enters the expander generator set.
   • Pressure energy is recovered for power generation, and the gas is pre-cooled simultaneously.
2. Preliminary Heavy Hydrocarbon Separation
   • Expanded gas enters the cyclone separator.
   • Carried crude oil droplets and solid particles are separated.
3. Deep Pre-Cooling Treatment
   • Gas enters the plate-shell main heat exchanger.
   • Deep heat exchange with the refrigerant enables precise temperature control.
4. Precise Condensate Separation
   • Pre-cooled gas enters the three-phase separator.
   • Effective separation of light hydrocarbons, water, and dry gas is achieved.
5. Intelligent Monitoring and Regulation
   • PLC automatically optimizes operating parameters based on real-time working conditions.
   • Ensures the system operates at the optimal working point.

III. Working Principle

Multiphase Flow Heat Exchange Technology:

• Specially designed heat exchanger flow channels adapt to the complex flow characteristics of oil-gas mixtures.
• Anti-scaling and anti-clogging design ensures long-term stable operation.

Intelligent Control Strategy:

• Adaptive control based on the wellhead pressure depletion curve.
• Multivariable coordinated control algorithm.
• Safety interlock protection system.

IV. Core Advantages

1. Ultra-Wide Pressure Adaptability
   • Operating pressure range: 0.05-8.0MPa, perfectly matching wellhead pressure depletion.
   • Stable processing effect during pressure fluctuations.
2. Efficient Energy Recovery
   • Integrates pressure energy power generation system, reducing energy consumption by 35%.
   • Intelligent thermal management maximizes energy utilization efficiency.
3. Strong Anti-Fluctuation Capability
   • Adapts to severe changes in wellhead gas composition and flow rate.
   • Intelligent regulation system ensures stable outlet parameters.
4. Rapid Deployment and Maintenance
   • Integrated skid-mounted design shortens on-site installation cycle by 60%.
   • Modular design facilitates convenient maintenance.

V. Technical Strength

Core Technology Patents:

• Wellhead gas multiphase flow heat exchange technology.
• High-efficiency pressure energy recovery technology.
• Intelligent anti-fluctuation control algorithm.

Manufacturing Process Advantages:

• Corrosion-resistant materials for acid gas handling.
• Professional manufacturing experience in high-pressure systems.
• Strict quality control system.

VI. Product Series Introduction

Specialized Series Configuration:

• YP-OGP-100 Series: 60-300 Nm³/min (Single Well)
• YP-OGP-300 Series: 350-1000 Nm³/min (Well Group)
• YP-OGP-1000 Series: 1200-3000 Nm³/min (Gathering Station)
• YP-OGP-3000 Series: 3500-10000 Nm³/min (Processing Plant)

Special Configuration Options:

• Hydrogen sulfide (H₂S) corrosion-resistant version.
• Thermal insulation version for extremely cold regions.
• Intelligent remote monitoring system.

VII. Application Scenarios

Oilfield Extraction Scenarios:

• Direct pre-treatment at single wellheads, centralized processing of cluster well groups, associated gas recovery from marginal oilfields.

Gathering and Processing Scenarios:

• Front-end pre-cooling at gathering stations, pre-treatment for light hydrocarbon recovery units, pre-treatment of feed gas for natural gas processing plants.

Energy Utilization Scenarios:

• Feed gas processing for gas-fired power generation, gas source processing for oilfield gas injection systems, gas source processing for fuel gas systems.

Environmental Protection Scenarios:

• Vent gas recovery processing, flare gas recovery and utilization.

VIII. Detailed Technical Specifications

Parameter Category	Technical Indicators	Remarks
Operating Conditions
Inlet Air Temperature	20-80℃	Adapts to wellhead temperature changes
Working Pressure	0.05-8.0 MPa	Standard: 0.7 MPa, ultra-wide pressure range
Gas Composition	Customized on demand	Adapts to different oilfield associated gases
Performance Indicators
Pressure Dew Point	≤2℃~15℃	Precisely controlled to meet subsequent process requirements
Pressure Loss	≤0.05 MPa	Low-resistance energy-saving design
Gas Processing Capacity	60-10000 Nm³/min	Full series coverage
Technical Configuration
Working Cycle	Continuous operation	Adapts to continuous oilfield production
Control Mode	PLC programmable control	Fully automatic intelligent operation
Installation Method	Indoor flat ground, no foundation required	Rapid deployment
Utility Requirements
Cooling Water Pressure	0.2~0.4 MPa	Industrial circulating water
Cooling Water Temperature	≤32℃
Power Supply	380V/50HZ
Structural Parameters
Equipment Weight	4100~18500 kg	Heavy-duty equipment, stable and reliable
Overall Dimensions (L×W×H)	L(1050~8000)×W(2100~3300)×H(2200~3000) mm	Integrated skid-mounted design