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™ modular gas processing plants in sizes from 400 to 10,000+ MSCFD, Vaporcatcher and Dew Point Suppression systems for oil tank battery vapor capture and gas conditioning, at 1,000 and 10,000 MSCFD scales, Fractionation systems which can process liquid hydrocarbons into seperate product streams, Knockouts for removing free liquids from gas streams, and Separators for removing water from condensed hydrocarbons. 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

Pioneer Energy’s Flarecatcher™ line of gas processing systems extract Natural Gas Liquids (NGLs) from gas streams at well sites and centralized processing facilities while conditioning the remaining gas. The systems are offered at a variety of processing temperatures, selected based upon the desired application. Pioneer Energy's flagship systems utilize our propriety Deep Refrigeration™ technology to provide best in class NGL capture performance at -65C or colder. The remaining gas has then been conditioned to meet pipeline quality, making it ideal for on-site power generation, conversion to CNG or LNG, or for injection into a lean gas pipeline. When a lean gas pipeline is available, the Flarecatcher can serve as a complete, modular midstream solution. Flarecatchers are skid mounted to allow fast and easy deployment and redeployment to help meet the often changing needs of oil producers. They are available as standard packages at 500, 1,000, 1,500, 6,000, and 10,000 MSCFD scales.

All of Pioneer Energy’s Flarecatcher units contain a sophisticated SCADA 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. A local field crew can perform routine maintenance and be available to meet on-site needs as they arise.

Each of Pioneer Energy's standard Flarecatcher units is able to process a wide variety of incoming gas compositions and automatically accomodates changing flow rates (every Pioneer Energy unit has infinite turn-down). A given unit has a finite amount of refrigeration duty, so raw gas with higher energy content results in decreased flow capacity (and higher NGL yield), while lower energy content gas results in higher flow capacity (and more lean dry gas for power generation, LNG, CNG, or pipeline injection). Our minimum processing pressure is 150 PSI, meaning that some producers can operate the equipment without any front end compression (saving both cost and operational complexity). Pioneer Energy’s team can assist in selecting the right processing unit and supporting equipment to meet your project needs, based upon the flow rate and composition of gas to be processed, and the objectives of the particular customer. 

 

Flarecatcher 6000 - Gas Prep / Water Management Skid 

Flarecatcher 6000 - Dehydration Skid

Flarecatcher 6000 - Refrigeration & Separation Skid

Flarecatcher 1500-25

Flarecatcher 400-65

The Flarecatcher 400-65 unit is a self-contained gas plant on wheels. Raw associated gas is captured from the separator and boosted to process pressure with on-board compression. The gas is 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 to power the process). The unit has a processing capacity of 400 MSCFD.

Flarecatcher 1000-5

The Flarecatcher 1000-5 unit is a skid mounted system which removes water and condensables from gas streams, making it ideal for tank vapor capture and gas conditioning applications. The unit operates using a modest inlet 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. 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. The unit has a processing capacity of 1,000 MSCFD.

Flarecatcher 1500-25

The Flarecatcher 1500-25 unit is a skid mounted gas processing system. It unit operates using a modest inlet 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. . 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. This unit strikes a good balance between affordability and performance, and is ideal for regulatory gas capture applications. The unit has a processing capacity of 1,500 MSCFD.

Flarecatcher 6000-35

The Flarecatcher 6000-35 is a three skid gas processing system. The unit operates using a modest inlet 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. 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. The unit has a processing capacity of 6,000 MSCFD and is a good option for regulatory gas capture on larger pads.

 

Flarecatcher 10000-65

The Flarecatcher 10000-65 is a three skid 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 NGLs and pipeline quality lean gas. As Pioneer Energy's flagship system, the Flarecatcher 10000-65 employs Deep Refrigeration technology to provide the highest capture efficiency in the industry. When connection to a lean gas pipeline is available, the system can serve as a complete, modular gas processing plant, providing a total midstream solution. This system is also ideally paired with CNG, LNG, or GTL systems. The unit operates using inlet pressures between 150 and 400 PSIG. 

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 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). The unit has a processing capacity of up to 10,000 MSCFD. 

Our proprietary Deep RefrigerationTM technology optimizes separation.

 

Vaporcatchers

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

Designed to work in conjunction with Flarecatcher units or in stand alone applications, Pioneer Energy also offers a line of modular Fractionation Systems. These systems can be used in a number of different applications. These include:

Custom Fractionation Systems

Pioneer Energy offers Fractionation Systems at several standard scales, and can also custom design fractionators at any desired scale.

Dew Point Suppression

 

Pioneer Energy’s Dewpoint Suppression (DPS) system is a modular, skid mounted gas processing plant used primarily to remove the water and condensate from liquid-rich associated gas and tank battery vapors. Because of its more modest refrigeration requirement, the DPS system allows for much larger flows up to 10 MMSCFD on a single skid system. With its versatile design and capabilities, it can be utilized in many applications, from cooling raw gas for injection into gathering systems at individual well pads, to fuel gas conditioning at compression stations.

Similar to other Pioneer Energy units, the DPS system is skid mounted which allows for fast and easy mobilization. The DPS also contains a sophisticated control system that removes the need for on-site operators. The system is monitored through a secure remote connection via local area network, cell phone network, or satellite. This allows Pioneer Energy to monitor the system 24/7 and capture long term performance trends to ensure proper performance.

 

Dew Point Suppression System

 

Dew Point Suppression 10000

The Dew Point Suppression system cools and conditions gas streams, removing water and condensables.

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

Let us provide a no cost/no obligation evaluation of your project.