Design of a Gas Turbine for the Conversion of Flare Gases to Energy Using Aspen HYSYS: A Case Study of an Oil Field in Niger Delta

Appolos Gombando Osaro; Awajiogak A. Ujile; Falilat Taiwo Ademiluyi

Appolos Gombando Osaro Department of Chemical / Petrochemical Engineering, Rivers State University, Port Harcourt, Rivers State, Nigeria
Awajiogak A. Ujile Department of Chemical / Petrochemical Engineering, Rivers State University, Port Harcourt, Rivers State, Nigeria
Falilat Taiwo Ademiluyi Department of Chemical / Petrochemical Engineering, Rivers State University, Port Harcourt, Rivers State, Nigeria

Keywords: Combined cycle energy, Combined turbine plant, Energy generation, Energy relations, Flare gas treatment, Gas conversion, Simulation software

Abstract

Gas flaring is among the main issues being discussed in the oil and gas industry for decades now. The present study is motivated by concerns over the environmental impact associated with gas flaring activities in the industries and the economic waste. The case study selected was from an oil mining lease in Nigeria. A total volume of gas flared daily for a period of June, July and August, 2022 along with the analyzed composition of the flare gas was collected. The volume of gas flared daily was estimated as 13,000 Sm³ per day which is equivalent to 542 m³/h flowrate. The combined cycle energy plant (gas turbine-steam turbine systems) simulation carried out in Aspen HYSYS v.10 using Peng-Robinson fluid package, a 98.61% removal of CO₂, H₂S and other heavier hydrocarbons in the flare gas was achieved in the flare gas absorber and separator units. The net energy output from the combined turbine plant was found to be 346.5MW of electricity daily; this is sufficient enough to power Port Harcourt city. Estimation of the total capital and operating costs was performed using Aspen Process Economic Analyzer (APEA), total capital cost of 67,907,300 USD, total operating cost of 19,345,800 USD/Year, total utilities cost of 14,247,500 USD/Year, equipment cost of 45,097,500 USD, and total installation cost of 48,724,000 USD. This shows that the model used in this work can solve the problem of gas flaring in an oil mining lease in Niger Delta.

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