What are the most effective ways to improve gas processing efficiency?

Start with high level performance review. Are compressors working efficiently? Recycle valves closed? Look for pressure drops along process and eliminate or reduce wherever possible. Make sure you turn data in to information

Implementing APC (advanced process control) systems allows for real-time monitoring and optimization of gas processing operations. These systems can adjust process parameters automatically for optimal performance. Regularly reviewing and optimizing the gas processing steps to minimize waste and maximize yield. Using simulation software to model processes and identify areas for improvement.

Retrofit existing pneumatic devices traditionally controlled by natural gas to operate with compressed air. By substituting natural gas with compressed air, you can significantly reduce methane emissions. Though this, industries not only contribute to reducing greenhouse gas emissions but also can often realize cost savings through improved energy efficiency and reduced need for natural gas.

Improving operational efficiency in oil and gas facilities necessitates a strategic approach to risk management, equipment maintenance, and adherence to standards. The application of API Risk-Based Inspection(RBI), mechanical integrity principles, standards for painting, material selection, and mechanical integrity and inspection are pivotal. These frameworks and guidelines, developed by organizations such as the American Petroleum Institute (API), the International Association of Oil & Gas Producers (IOGP), NORSOK, the International Organization for Standardization (ISO), and the National Association of Corrosion Engineers (NACE), are instrumental in ensuring the reliability, safety, and environmental compliance of oil and gas operations.

A successful example is SLB's Process Live. Process Live is a data-enriched performance service, a multi-faceted solution that provides uptime assurance, process optimization, and greenhouse gas (GHG) control. It integrates digitally-enabled equipment, collaboration with OEM experts, and maintenance to improve asset lifecycle management.

Another condition to watch out for is when process flows conditions change: For example in an oil processing facility, different production rates or changes in the composition of the input, may necessitate adjustments in process equipment settings. In a separator tank, this might mean altering the level at which fluids are separated to optimize efficiency and safety. By fine-tuning the separator level, you can improve the separation process, potentially reducing the amount of water that gets recycled. Efficient separation ensures that less water is carried over with the oil or gas, thereby reducing the need for additional processing or treatment.