More realistic Oil Production - Use of Separators
Posted: Sat Apr 09, 2016 5:00 pm
While in general, the oil production is modeled pretty accurate, there is one thing that bugs me (but that is not unique to Factorio, it's basically in all games that handle oil production).
There is an intermediate step between the oil pumps and the refinery. (Not talking about tanks).
This step does not take place in refineries as they only receive the already separated crude oil. It takes place in substations near the wells from where the individual products get shipped to the central station that then ships the crude oil out to the harbors, or directly to the refineries.
The natural product of an oil well is Multiphase Flow, a mix of oil, water, and gas. This mix needs to be separated (by using so called Separators - intelligent name, I know, but that's actually what these devices are called) before the pure crude enters the actual oil line. Over the lifetime of a well, the ratio between oil and water changes so that closer to the end of the lifetime of a well, way more water than oil is produced.
A Separator would have one input (the multiphase flow from the pumps) and three outputs (oil, water, and gas). Separators are passive devices that don't need electricity, chemicals, or heat to operate - they work through simple mechanical principles (plates over which the oil flows into the next chamber, the gas evaporates due to pressure loss).
So, the proper chain of oil production would be: well(s) -> pump(s) -> separator(s) (where one separator can handle a couple wells) -> tanks (for oil, water and gas) -> refinery (where the produced water that came along with the oil could be reused - or could be redirected to chemical plants) -> tanks -> chemical plants, etc.
Another thing is sulphur. In natural oil production, sulphur appears as H2S (Hydrogen Sulfide) - a gas. This byproduct actually pollutes the produced gas and makes it unusable for further production.
Source: I've been working on an oilfield for 15 years.
Additional information: The hydraulic Jack pumps (aka "Sucker Rod Pumps" or "Horsehead Pumps", or "Nodding Donkeys") are not the standard in oil production. They can only be used with shallow, low production wells. High production wells (or deep wells) use different methods of lifting the oil, like "Gas injection" (think "spray-can principle), "Water injection" (same idea, different medium), or "Electrical Submersible Pumps" (ESP), all of which produce a way higher (ten to hundredfold) output than Jack pumps. A modern well can barely be seen standing next to it as there is very little on the surface besides a couple of pipelines.
There is an intermediate step between the oil pumps and the refinery. (Not talking about tanks).
This step does not take place in refineries as they only receive the already separated crude oil. It takes place in substations near the wells from where the individual products get shipped to the central station that then ships the crude oil out to the harbors, or directly to the refineries.
The natural product of an oil well is Multiphase Flow, a mix of oil, water, and gas. This mix needs to be separated (by using so called Separators - intelligent name, I know, but that's actually what these devices are called) before the pure crude enters the actual oil line. Over the lifetime of a well, the ratio between oil and water changes so that closer to the end of the lifetime of a well, way more water than oil is produced.
A Separator would have one input (the multiphase flow from the pumps) and three outputs (oil, water, and gas). Separators are passive devices that don't need electricity, chemicals, or heat to operate - they work through simple mechanical principles (plates over which the oil flows into the next chamber, the gas evaporates due to pressure loss).
So, the proper chain of oil production would be: well(s) -> pump(s) -> separator(s) (where one separator can handle a couple wells) -> tanks (for oil, water and gas) -> refinery (where the produced water that came along with the oil could be reused - or could be redirected to chemical plants) -> tanks -> chemical plants, etc.
Another thing is sulphur. In natural oil production, sulphur appears as H2S (Hydrogen Sulfide) - a gas. This byproduct actually pollutes the produced gas and makes it unusable for further production.
Source: I've been working on an oilfield for 15 years.
Additional information: The hydraulic Jack pumps (aka "Sucker Rod Pumps" or "Horsehead Pumps", or "Nodding Donkeys") are not the standard in oil production. They can only be used with shallow, low production wells. High production wells (or deep wells) use different methods of lifting the oil, like "Gas injection" (think "spray-can principle), "Water injection" (same idea, different medium), or "Electrical Submersible Pumps" (ESP), all of which produce a way higher (ten to hundredfold) output than Jack pumps. A modern well can barely be seen standing next to it as there is very little on the surface besides a couple of pipelines.