Mobile Flare Gas Capture Solutions &
Modular Gas Processing Plants
Pioneer Energy Flarecatcher on-site in North Dakota

Products

Pioneer Energy offers innovative products accompanied by customized services to aid oil & gas producers worldwide in solving their gas processing challenges.

The company’s current product offerings include Flarecatcher™ mobile gas associated gas processing plants in sizes from 400 to 10,000+ MSCFD, Vaporcatcher oil tank battery vapor capture and gas conditioning systems scaled to 1000+ MSCFD, and Fractionation Systems which can either turn off-spec products (y-grade, condesnate) into on-spec products or separate produced NGLs into purity products. The company also produces larger scale modular plants for centralized stationary operations. Working with preferred providers, we can assist customers in obtaining electrical power generators, CNG compressors, NGL/LPG storage and loading systems, CNG/NGL/LPG transports, H2S removal equipment, and other associated technologies. Pioneer Energy also offers custom engineered solutions tailored to meet the unique needs of both domestic and international customers.

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Flarecatcher

Flarecatcher Technology

Pioneer Energy’s Flarecatcher™ line of gas processing plants utilizes our propriety Deep Refrigeration™ technology to provide best in class separation performance. The Flarecatcher extracts natural gas liquids (NGLs) from raw associated gas at nearly twice the recovery rate of any competing system, rejecting excess low-value ethane, and conditioning dry gas for use in power generation or conversion to CNG, LNG or for injection into a lean gas pipeline. Flarecatchers are skid mounted to allow fast and easy deployment and redeployment to help meet the often changing needs of oil producers.

All of Pioneer Energy’s Flarecatcher units contain a sophisticated control system that removes the need for on-site operators. The units are monitored through a secure remote connection via local area network, cell phone network, or satellite. A remote staff member can monitor and control Flarecatcher systems from any convenient location worldwide.

Pioneer Energy offers standard Flarecatcher units in a range of gas processing capacities. These standard units are listed below. Each of these units is able to process a wide variety of incoming gas compositions and energy contents. Each unit has a finite amount of refrigeration duty, so raw gas with higher energy content results in decreased flow (and higher NGL yield), while lower energy content gas results in higher flow (and more lean dry gas for power generation, LNG, CNG, or pipeline injection). Pioneer Energy’s team can assist in selecting the right equipment to meet your project needs based upon the flow rate and composition of gas to be processed. 

 

Flarecatcher 6000 - Gas Prep / Water Management Skid 

Flarecatcher 6000 - Dehydration Skid

Flarecatcher 6000 - Refrigeration & Separation Skid

Flarecatcher 1500-25

Flarecatcher 400-65

Raw associated gas is first compressed then dehydrated through use of a molecular sieve. An economized mechanical refrigerator cools the gas to -65°C, liquefying C3+ components. A sophisticated separation system then dissociates the gas into three streams: Y-Grade NGLs (to be transported to market), lean methane (pipeline quality), and low-value rejected ethane (consumed onboard).

Flarecatcher 1000-5

The Flarecatcher operates at a modest process pressure of 150 to 225 PSIG. This means that if the producer can provide associated gas at this pressure, no front-end compression is required. Lower pressure gas streams can be accommodated by adding separate compression equipment. Methanol injection is used to prevent internal freeze-ups. A mechanical refrigerator cools the gas to -5°C, liquefying C3+ components. A sophisticated separation system then dissociates the gas into two streams: Y-Grade NGLs (to be transported to market) and conditioned gas.

Flarecatcher 1500-25

The Flarecatcher operates at a modest process pressure of 150 to 225 PSIG. This means that if the producer can provide associated gas at this pressure, no front-end compression is required. Lower pressure gas streams can be accommodated by adding separate compression equipment. Methanol injection is used to prevent internal freeze-ups. An economized mechanical refrigerator cools the gas to -25°C, liquefying C3+ components. A sophisticated separation system then dissociates the gas into two streams: Y-Grade NGLs (to be transported to market) and conditioned gas.

Flarecatcher 6000-35

The Flarecatcher operates at a modest process pressure of 150 to 200 PSIG. This means that if a producer can provide associated gas at this pressure, no front-end compression is required. Lower pressure gas streams can be accommodated by adding separate compression equipment. A combination of initial refrigation, a three phase separator, and a molecular sieve are used to dehydrate the incoming gas. A two-stage mechanical refrigerator cools the gas to -35°C, liquefying C3+ components. A sophisticated separation system then dissociates the gas into three streams: Y-Grade NGLs (to be transported to market), conditioned gas, and low-value rejected ethane.

 

Flarecatcher 10000-65

The Flarecatcher 10000-65 is a modular gas processing plant that processes liquid-rich associated gas at the wellsite, at central processing facilities, or at gas plants. It produces Y-Grade Natural Gas Liquids (NGLs) and pipeline quality lean gas. The Flarecatcher reduces or eliminates flaring, enabling monetization of associated gas & reducing environmental footprint.

Raw associated gas is first dehydrated through use of precooling and a three-phase separator. Any remaining water is then removed through use of a molecular sieve. An economized cascade mechanical refrigerator cools the gas to -50°C and a JT expansion cools the gas further to -65°C liquefying C3+ components. A sophisticated separation system then dissociates the gas into three streams: stabilized Y-grade NGLs (to be transported to market), lean methane (pipeline quality), and low-value rejected ethane (consumed onboard or flared).

Flarecatcher Flyer


Our proprietary Deep RefrigerationTM technology optimizes separation.

 

Vaporcatchers

Vaporcatcher Technology

Pioneer Energy’s Vaporcatcher™ line of gas processing units are refrigeration and separation systems that can be used for a variety of applications. When used for emissions mitigation, they capture and monetize the high BTU vapors from oil tanks, producing y-grade NGLs and a conditioned gas stream. The Vaporcatcher captures up to 75% of VOC contributing components from tank vapors, helping producers manage site emissions which enables more oil production. The Vaorcatcher can also be used in gas conditioning applications, cooling the associated gas and removing water and heavy hydrocarbons. When used prior to injection into a gathering system, this helps reduce pooling and hydrate formation while managing injection temperature. The Vaporcatcher can also remove condensables to provide conditioned fuel gas for compressors. and other engine driven equipment.

Pioneer Energy offers a standard Vaporcatcher unit with a capacity of up to 1000 MSCFD.

Vaporcatcher Unit

Vaporcatcher

The Vaporcatcher operates at a modest process pressure of 150 to 225 PSIG. In tank vapor capture applications, a standard vapor recovery unit (VRU) can be utilized to boost the vapors form atmospheric pressure to the processing pressure. A mechanical refrigerator cools the gas to between  +5°C and -10°C (depending upon flow rate and gas composition), condensing water and C3+ components. A sophisticated separation system then dissociates the gas into two streams: on-spec Y-Grade NGLs (to be transported to market) and conditioned gas. Water is separated from the NGLs through use of an external two-phase separator.


Vaporcatcher Flyer

The Vaporcatcher can be used for tank vapor capture for economic return and emissions mitigation, for gas conditioning prior to injection to a gathering system, and for condensable removal to produce conditioned fuel gas for compressors and engine driven equipment.

Fractionation Systems

Fractionation System Technology

Designed to work in conjunction with Flarecatcher units or in stand alone applications, Pioneer Energy also offers modular Fractionation Systems. These systems can be used to convert off-spec products (y-grade, condensate) into on-spec products. They can also be used to seperate y-grade NGLs purity streams of propane, butane, and natural gas condensate. The propane and butane can be recombined to form LPG meeting the specific requirements of any given market, with excess propane (typical for many associated gas streams) being made available for on-site power generation or seperate sale. The remaining heavy hydrocarbons (pentane, hexane+) are referred to as natural gas condensate. This condensate could be blended into transportation fuel, or used to increase the volume of crude oil produced on-site.

Custom Fractionation Systems

Pioneer Energy offers Fractionation Systems scaled to process the NGL output flow from each of the standard Flarecatcher units, and can also custom design fractionators of any desired scale.

Modular Gas Processing Plants and Custom Engineered Solutions

Solutions For Any Scale Project

Pioneer Energy’s propriety Deep Refrigeration™ technology can be deployed in any size plant to achieve the most complete separation and product capture available in the industry.  For larger gas streams, Pioneer Energy can provide a skid mounted, modular, completely integrated processing plant. The specific makeup, size, and design of the modules for the plant are selected based on the composition, pressure and flow of the raw gas to be processed, as well as the desired product specifications. Each module is plug-and-play with the other modules in the plant, with all of them managed through our propriety remote plant management software. Pioneer Energy’s engineering team can further customize our modular plants to address customers’ unique challenges such as high CO2 content, H2S removal, etc.

 
Modular Gas Processing Plants Flyer

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Product Storage Systems

Store Produced Products Until Use or Transport to Market

Pioneer Energy provides, through third party partners, pressurized storage and loading systems that are sized to support the output of our Flarecatchers, Vaporcatchers, and modular plants. The size and composition of the storage system selected for a particular project is dependent on the gas volume, composition, product specifications and the number of days of on-site storage required.