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1. (WO2017151147) FLARE RECOVERY WITH CARBON CAPTURE
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CLAIMS

What is claimed is:

1. A method for flare recovery, comprising:

receiving a flare gas inlet stream, wherein the flare gas inlet stream comprises C -C& hydrocarbons;

separating the flare gas inlet stream in a recovery column to produce a C1-C2 hydrocarbon stream and a C3-C8 hydrocarbon stream; and

separating the C3-C8 hydrocarbon stream in a separation column to produce a C3 hydrocarbon stream and a C4-C8 hydrocarbon stream.

2. The method of claim 1 , further comprising:

receiving a raw crude oil stream comprising Ci-C9+ hydrocarbons;

separating the raw crude oil stream into a C -C& hydrocarbon stream and a C + hydrocarbon stream, wherein the Ci-C8 hydrocarbon stream is the flare gas inlet stream;

combining the C4-C8 hydrocarbon stream with the C + hydrocarbon stream;

combining the C1-C2 hydrocarbon stream and the C3 hydrocarbon stream to produce a flare gas stream; and

combusting the flare gas stream.

3. The method of claim 2, wherein the method produces fewer carbon emissions as compared to flaring the flare gas inlet stream.

4. The method of claim 1 , further comprising:

receiving a raw crude oil stream comprising Ci-C9+ hydrocarbons;

separating the raw crude oil stream into a C -C& hydrocarbon stream and a C + hydrocarbon stream, wherein the Ci-C8 hydrocarbon stream is the flare gas inlet stream;

combining the C4-C8 hydrocarbon stream with the C + hydrocarbon stream;

recovering the C3 hydrocarbon stream as a saleable product, wherein the saleable product meets energy requirements and vapor pressure requirements for transportation by truck or pipeline; and

combusting the C1-C2 hydrocarbon stream as a flare gas stream.

5. The method of claim 4, further comprising:

expanding the C1-C2 hydrocarbon stream to generate energy; and

compressing the flare gas inlet stream with the energy generated from the expansion.

6. The method of claim 5, further comprising compressing, cooling, and drying the flare gas inlet stream before the flare gas inlet stream is separated by the recovery column.

7. The method of claim 6, wherein the recovery column and the separation column are multi-stage distillation columns, and wherein the recovery column and the separation column are the only two multi-stage distillation columns used in the method.

8. The method of claim 7, wherein no refrigeration processes are used in the flare recovery method.

9. The method of claim 8, wherein the C1-C2 hydrocarbon stream is not compressed after being separated from the C3-C8 hydrocarbon stream.

10. The method of claim 9, wherein the flare gas inlet stream and the C3-C8 hydrocarbon stream are separated in distillation columns operating at 200 pounds per a square inch (psi) to 500 psi.

11. The method of claim 10, wherein the C3-C8 hydrocarbon stream cannot be combined with raw crude oil stream because a combination of the C3-C8 hydrocarbon stream and the raw crude oil stream would not meet a crude oil specification, and wherein a combination of the C4-C8 hydrocarbon stream and the C9+ hydrocarbon stream meets the crude oil specification.

12. The method of claim 11, wherein the flare gas inlet stream comprises 96-100 mole % Ci-C8 hydrocarbons, 0-2 mole % carbon dioxide, and 0-2 mole % nitrogen.

13. The method of claim 12, wherein the C1-C2 hydrocarbon stream comprises 80 mole % C1-C2 hydrocarbons, 10-20 mole % C3 hydrocarbons, 0-2 mole % C4-C8 hydrocarbons, 0-2 mole % carbon dioxide, and 0-2 mole % nitrogen.

14. The method of claim 13, wherein the C3-C8 hydrocarbon stream comprises 5-15 mole % Ci-C2 hydrocarbons, 85-95 mole % C3-C8 hydrocarbons, and 0-2 mole % carbon dioxide.

15. The method of claim 14, wherein the C3 hydrocarbon stream comprises 30-40 mole % C1-C2 hydrocarbons, 60-70 mole % C3 hydrocarbons, 0-2 mole % C4-C8 hydrocarbons, and 0-2 mole % carbon dioxide.

16. The method of claim 15, wherein the C4-C8 hydrocarbon stream comprises 0 mole % C1-C2 hydrocarbons, 0-2 mole % C3 hydrocarbons, and 98-100 mole % C4-C8 hydrocarbons.

17. The method of claim 1, further comprising transporting the C4-C8 hydrocarbon stream to a location for blending with raw crude oil.

18. The method of claim 1, further comprising compressing, cooling, and separating the flare gas inlet stream through a series of compressors, coolers, and separators before separating the flare gas inlet stream in the recovery column.

19. The method of claim 1, further comprising sweetening the C3 hydrocarbon stream to remove hydrogen sulfide from the C3 hydrocarbon stream.

20. A set of process equipment for flare recovery, comprising:

a first multi-stage distillation column that receives a flare gas inlet stream and produces a first overhead stream and a first bottoms stream; and

a second multi-stage distillation column that receives the first bottoms stream and produces a second overhead stream and a second bottoms stream,

wherein the second bottoms stream comprises C4+ hydrocarbons, and

wherein the first multi-stage distillation column and the second multi-stage distillation column are the only two multi-stage distillation columns in the set of process equipment.

21. The set of process equipment according to claim 20, further comprising:

a heavy hydrocarbons separator that receives a raw crude oil stream comprising C1-C9+ hydrocarbons and separates the raw crude oil stream into a Ci-C8 hydrocarbon stream and a C9+ hydrocarbon stream, wherein the Ci-C8 hydrocarbon stream is the flare gas inlet stream; and a mixer that combines the second bottoms stream with the C + hydrocarbon stream.

22. The set of process equipment according to claim 21 , wherein the first bottoms stream cannot be combined with raw crude oil stream because a combination of the first bottoms stream and the raw crude oil stream would not meet a crude oil specification, and wherein a combination of the second bottoms stream and the C + hydrocarbon stream meets the crude oil specification.

23. The set of process equipment according to claim 20, wherein the set or process equipment produces fewer carbon emissions as compared to flaring the flare gas inlet stream.

24. The set of process equipment according to claim 20, wherein the second overhead stream is recovered as saleable C3 product, and wherein the saleable C3 product meets energy requirements and vapor pressure requirements for transportation by truck or pipeline.

25. The set of process equipment according to claim 20, wherein the second overhead stream is combined with the first overhead stream to produce a flare gas stream.

26. The set of process equipment according to claim 20, further comprising an expander, wherein the expander expands the first overhead stream to generate energy, and wherein the energy is used to compress the flare gas inlet stream before the flare gas inlet stream is fed to the first multi-stage distillation column.

27. The set of process equipment according to claim 20, further comprising:

a compressor that compresses the flare gas inlet stream;

a cooler that cools the compressed flare gas inlet stream; and

a dehydrator that removes water from the cooled and compressed flare gas inlet stream.

28. The set of process equipment according to claim 20, wherein no refrigeration equipment is included within the set of process equipment.

29. The set of process equipment according to claim 20, wherein the C4+ hydrocarbons are transported to a location for blending with raw crude oil.

30. The set of process equipment according to claim 20, wherein the first overhead stream is not compressed after being separated from the first bottoms stream.

31. The set of process equipment according to claim 20, wherein the first multi-stage distillation column and the second multi-stage distillation column are operated in a pressure range of 200 pounds per a square inch gauge (psi) to 500 psi.

32. The set of process equipment according to claim 20, wherein the flare gas inlet stream comprises 96-100 mole % Ci-C8 hydrocarbons, 0-2 mole % carbon dioxide, and 0-2 mole % nitrogen.

33. The set of process equipment according to claim 32, wherein the first overhead stream comprises 70-80 mole % Ci-C2 hydrocarbons, 10-20 mole % C3 hydrocarbons, 0-2 mole % C4-C8 hydrocarbons, 0-2 mole % carbon dioxide, and 0-2 mole % nitrogen.

34. The set of process equipment according to claim 33, wherein the first bottoms stream comprises 5-15 mole % Ci-C2 hydrocarbons, 85-95 mole % C3-C8 hydrocarbons, and 0-2 mole % carbon dioxide.

35. The set of process equipment according to claim 34, wherein the second overhead stream comprises 30-40 mole % C1-C2 hydrocarbons, 60-70 mole % C3 hydrocarbons, 0-2 mole % C4-C8 hydrocarbons, and 0-2 mole % carbon dioxide.

36. The set of process equipment according to claim 35, wherein the second bottoms stream comprises 0 mole % C1-C2 hydrocarbons, 0-2 mole % C3 hydrocarbons, and 98-100 mole % C4-C8 hydrocarbons.

37. The set of process equipment according to claim 20, further comprising multiple sets of compressors, coolers, and separators, wherein the multiple sets of compressors coolers, and separators are arranged in series, and wherein the multiple sets of compressors coolers, and separators compress, cool, and separate the flare gas inlet stream before the flare gas inlet stream is fed to the first multi-stage distillation column.

38. The set of process equipment according to claim 20, further comprising a hydrogen sulfide removal unit that removes hydrogen sulfide from a C3 hydrocarbon stream.

39. A set of process equipment, comprising:

a first column that receives a Ci-C8 hydrocarbon stream and produces a C1-C2 hydrocarbon stream and a C3-C8 hydrocarbon stream; and

a second column that receives the C3-C8 hydrocarbon stream and produces a C3 hydrocarbon stream and a C4-C8 hydrocarbon stream;

an expander that expands the C1-C2 hydrocarbon stream to generate energy; and a compressor that compresses the C -Cg hydrocarbon stream using the energy generated by the expander before the Ci-C8 hydrocarbon stream is fed to the first column.

40. The set of process equipment according to claim 39, further comprising:

a heavy hydrocarbons separator that receives a raw crude oil stream comprising Ci-C9+ hydrocarbons and separates the raw crude oil stream into the Ci-C8 hydrocarbon stream and a C + hydrocarbon stream; and

a mixer that combines the C4-C8 hydrocarbon stream with the C + hydrocarbon stream.

41. The set of process equipment according to claim 40, wherein the C3-C8 hydrocarbon stream cannot be combined with the raw crude oil stream because a combination of the C3-C8 hydrocarbon stream and the raw crude oil stream would not meet a crude oil specification, and wherein a combination of the C4-C8 hydrocarbon stream and the C + hydrocarbon stream meets the crude oil specification.

42. The set of process equipment according to claim 39, wherein the set of process equipment produces fewer carbon emissions as compared to flaring the Ci-C8 hydrocarbon stream.

43. The set of process equipment according to claim 39, further comprising piping that transfers the C4-C8 hydrocarbon stream to a location for blending with crude oil.

44. The set of process equipment according to claim 39, further comprising piping that transfers the C3 hydrocarbon stream to a location for removal by truck, rail, or pipe.

45. The set of process equipment according to claim 39, further comprising a molecular sieve that removes water from the Ci-C8 hydrocarbon stream before the Ci-C8 hydrocarbon stream is fed to the first column.

46. The set of process equipment according to claim 39, wherein the first column and the second column are operated at pressures from 200 pounds per a square inch gauge (psi) to 500 psi.

47. The set of process equipment according to claim 39, wherein the set of process equipment reduces an amount of carbon that is released to the environment.

48. The set of process equipment according to claim 39, wherein the set of process equipment recovers more than 50 mole % of the C3 hydrocarbons from the Ci-C8 hydrocarbon stream.

49. The set of process equipment according to claim 39, wherein the C1-C2 hydrocarbon stream is not compressed after being separated from the C3-C8 hydrocarbon stream.

50. The set of process equipment according to claim 39, wherein the first column and the second column are operated in a pressure range of 200 pounds per a square inch gauge (psi) to 500 psi.

51. The set of process equipment according to claim 39, wherein a flare gas inlet stream comprises 96-100 mole % Ci-C8 hydrocarbons, 0-2 mole % carbon dioxide, and 0-2 mole % nitrogen.

52. The set of process equipment according to claim 51, wherein the Ci-C2 hydrocarbon stream comprises 70-80 mole % Ci-C2 hydrocarbons, 10-20 mole % C3 hydrocarbons, 0-2 mole % C4-C8 hydrocarbons, 0-2 mole % carbon dioxide, and 0-2 mole % nitrogen.

53. The set of process equipment according to claim 52, wherein the C3-C8 hydrocarbon stream comprises 5-15 mole % Ci-C2 hydrocarbons, 85-95 mole % C3-C8 hydrocarbons, and 0-2 mole % carbon dioxide.

54. The set of process equipment according to claim 53, wherein the C3 hydrocarbon stream comprises 30-40 mole % C1-C2 hydrocarbons, 60-70 mole % C3 hydrocarbons, 0-2 mole % C4-C8 hydrocarbons, and 0-2 mole % carbon dioxide.

55. The set of process equipment according to claim 54, wherein the C4-C8 hydrocarbon stream comprises 0 mole % C1-C2 hydrocarbons, 0-2 mole % C3 hydrocarbons, and 98-100 mole % C4-C8 hydrocarbons.

56. The set of process equipment according to claim 39, further comprising multiple sets of compressors, coolers, and separators, wherein the multiple sets of compressors coolers, and separators are arranged in series, and wherein the multiple sets of compressors coolers, and separators compress, cool, and separate the Ci-C8 hydrocarbon stream before the Ci-C8 hydrocarbon stream is fed to the first column.

57. The set of process equipment according to claim 39, further comprising a hydrogen sulfide removal unit that removes hydrogen sulfide from the C3 hydrocarbon stream.