Applied Process Simulation-Driven Oil and Gas Separation Plant Optimization using Surrogate Modeling and Evolutionary Algorithms

In this article the optimization of a realistic oil and gas separation plant has been studied. Two different fluids are investigated and compared in terms of the optimization potential. Using Design of Computer Experiment (DACE) via Latin Hypercube Sampling (LHS) and rigorous process simulations, surrogate models using Kriging have been established for selected model responses. The surrogate models are used in combination with a variety of different evolutionary algorithms for optimizing the operating profit, mainly by maximizing the recoverable oil production. A total of 10 variables representing pressure and temperature various key places in the separation plant are optimized to maximize the operational profit. The optimization is bounded in the variables and a constraint function is included to ensure that the optimal solution allows export of oil with an RVP < 12 psia. The main finding is that, while a high pressure is preferred in the first separation stage, apparently a single optimal setting for the pressure in downstream separators does not appear to exist. In the second stage separator apparently two different, yet equally optimal, settings are revealed. In the third and final separation stage a correlation between the separator pressure and the applied inlet temperature exists, where different combinations of pressure and temperature yields equally optimal results.