University scientists have found a way to provide Russia with more affordable gas condensate.
Scientists from Gubkin Russian State University of Oil and Gas (National Research University) have developed the world's first technology for low-temperature stabilization of gas condensate. It has been implemented in a mobile unit that can operate at remote gas condensate fields, including those on the Arctic shelf.
Gas condensate is a mixture of liquid hydrocarbons condensed from natural gases during their production.
"This is a very valuable raw material due to its high content of high-octane gasoline fractions – tens of times more expensive than crude oil," explained Alexey Dengaev, Associate Professor of the Department of Oil Field Development and Operation at Gubkin University.
The main challenge in developing fields containing gas condensate is its primary processing. The gas condensate mixture brought to the surface is unstable due to its high content of light hydrocarbon gases. For storage and transportation, it must be stabilized, or degassed.
Currently, expensive permanent installations are being built in Russia to stabilize gas condensate. Existing technologies rely on intense heating of the feedstock in a reboiler to 120–220 degrees Celsius. Steam or an oil-based heat transfer fluid is used for this, and these are then brought to the required temperature using fuel gas. This requires a significant amount of energy. Furthermore, large gas condensate processing facilities are not feasible at every field.
"Our technology makes primary gas condensate processing cheaper and safer. The mobile complex can operate directly at the well pad, in close proximity to the wells producing this valuable product. Explosive feedstock will no longer need to be transported tens of kilometers to permanent installations," explained Alexey Dengaev.
The method involves the application of controlled cavitation fields to liquid hydrocarbons, created using acoustic vibrations. An ultrasonic generator converts voltage into high-frequency mechanical vibrations of a specified amplitude. These vibrations are transmitted into the liquid medium as ultrasonic waves, creating microscopic bubbles. This leads to intensive degassing of light hydrocarbon fractions dissolved in the gas condensate.
Test results confirmed that the technology improves the quality of gas condensate processing compared to traditional methods. Stabilization using cavitation fields preserves up to 62% of valuable C5-C7 hydrocarbons, compared to heat treatment, which is widely used in industry, where their share reaches only 38%.
"The method does not require heating, meaning it is suitable for use in permafrost conditions without harming the fragile ecosystem of the Arctic zone," noted Alexey Dengaev.
The technology has passed laboratory and field testing and is ready for dynamic testing on primary processing lines. A number of domestic oil and gas companies have expressed interest in Gubkin University's development.
In recent decades, gas condensate production in Russia has grown by 6.7% annually. From 2000 to 2020, its production increased from 10.2 to 41.1 million tons and could reach 57 million tons by 2030. Almost 85% of gas condensate is used domestically, demonstrating its value..
The main producers of stable condensate are PJSC Gazprom, PJSC NOVATEK, PJSC NK Rosneft, JSC Achimgaz, Sakhalin Energy LLC, and PJSC Gazprom Neft.
