In the oilfields of southeastern Turkey, one upstream energy company faced a recurring issue: large volumes of gaz associé were being flared due to insufficient compression infrastructure. This not only caused environmental penalties but also wasted valuable energy resources.

The customer’s goal was to recover and compress this flare gas—rich in hydrocarbons—for on-site power generation et gas reinjection.

To achieve this, they required a highly customized compressor solution capable of handling complex gas compositions at extreme discharge pressures up to 40 MPa (400 bar).

Gas Composition: Complex & Demanding

The associated gas in this project was a typical multicomponent hydrocarbon stream, primarily consisting of:

• Methane (CH₄): 73.01%

• Ethane (C₂H₆): 9.9%

• Propane (C₃H₈): 9.2%

• Butanes, Pentanes, Hexanes (C₄–C₆): ~4%

• Nitrogen (N₂): 0.96%

• Trace Oxygen (O₂ < 0.005%)

This mixture presented unique challenges in terms of volatility, pressure managementet lubrication safety.

Keepwin’s Solution: Model 2VF-3.6/5-400

To meet these technical demands, Keepwin Technology Hebei Co, Ltd. delivered a fully customized double V-type 5-stage air-cooled reciprocating compressor, model 2VF-3.6/5-400, capable of compressing gas from 0.5 MPa (g) à 40 MPa (g).

Key Specifications:

Turnkey Scope Provided

In addition to the compressor skid, Keepwin supplied:

• PLC explosion-proof control cabinet

• Cooler + axial fan cooling system

• Buffer tank and valve pipeline

• Oil injection + sewage system

• Gas leak detection + safety alarms

• Cabin cover with lighting + environmental heating

• Full accessory kit: random spare parts, tools, manuals

This turnkey design allowed the customer to integrate quickly, with minimal on-site modification.

Results and Impact

After commissioning, the system enabled the client to:

• Recover over 1000 Nm³/h of flare gas

• Use it as fuel for turbine-driven generators

• Cut flaring by 95% and avoid environmental fines

• Prepare for gas reinjection phase in Phase II expansion

Les 2VF-3.6/5-400 unit has operated reliably for over 6,000 hours with only standard maintenance.