Engineered for Zero Emissions
Compression

The new externally pressurized dry gas rod packing provides zero fugitive emissions of process gases in reciprocating compressors. High-pressure nitrogen is injected into two separate porous media packings, encapsulating the rod and allowing a very small gas film to form between the rod and the media.

The result: only pure nitrogen leaks to atmosphere — never process gas. When the compressor shuts down, the packing forms a tight, leak-free mechanical seal automatically.

Why it matters: Newly installed conventional rod packing can leak up to 60 CFH. Worn packing can reach 900 CFH or higher. Rod packing is the single largest source of fugitive methane in compression operations.

• Zero fugitive process gas emissions to atmosphere
• Dual porous media nitrogen injection barrier
• Leak-free shutdown sealing via mechanical closure
• Compatible with existing reciprocating compressor frames
• Eliminates packing vent gas capture/routing requirements
• Addresses EPA Quad Oa / NSPS compliance obligations

High-pressure gas from the compressor cylinder is distributed through a porous media on the piston, forming a thin film of gas between the cylinder bore and the piston. This frictionless, non-contacting seal provides full piston assembly support — without any oil lubrication.

The technology eliminates two simultaneous problems: fugitive methane leakage through conventional piston rings, and the oil consumption and contamination associated with lubricated cylinders. The result is a cleaner, lower-maintenance compression train.

• Frictionless gas film between piston and cylinder bore
• Fully supports piston assembly load — no oil required
• Eliminates cylinder lubrication system and associated maintenance
• Reduces hydrocarbon carryover into downstream systems
• Compatible with non-lube cylinder configurations
• Reduces overall cylinder wear and maintenance intervals

E4's high-speed rotary scrubber provides superior gas-liquid separation using centrifugal force rather than conventional gravitational or mist-pad separation. The new design is modular and compact, making it deployable at well pads and compression stations with minimal footprint.

Fluid-laden gas enters through the bottom center of the rotary scrubber where it contacts a proprietary high-velocity rotating separating turbine. Liquid is centrifugally forced to the outer wall and discharged at high pressure — the liquid-free gas stream (sub-micron particle size) exits through the top center at pressure.

The rotary scrubber product family includes variants for degassing, two-phase separation, multi-phase production separation, acid gas (CO₂, H₂S) separation, and cryogenic centrifugal separation.

• Sub-micron liquid removal from gas stream
• High-pressure liquid discharge — no pump required for re-injection
• Modular, compact design for well pad and station deployment
• Available in 2-phase, multi-phase, and acid gas variants
• No conventional demisters, baffles, or coalescing media

The rotary fuel gas conditioner stabilizes fuel at a constant Lower Heating Value (LHV) and eliminates liquids from entering the engine — extending cylinder life and reducing unplanned downtime at well pad gas-driven compression sites.

Raw well pad gas is accelerated through fuel conditioner nozzles into an expander that drives the rotor. The gas undergoes isentropic expansion at supersonic speeds, dropping temperature into the phase envelope — condensing and nucleating hydrocarbon particles. Under high centrifugal loading, these particles rapidly collect on the outer wall, where liquid is recovered through a standard pump diffuser at high pressure and routed to multiple possible recovery destinations.

• Stabilizes fuel Lower Heating Value for consistent combustion
• Eliminates liquid carry-over into engine manifold
• Supersonic isentropic expansion — no external refrigeration
• High-pressure liquid recovery for re-injection or capture
• Extends engine cylinder life and reduces maintenance
• Designed for well pad gas composition variability

The centrifugal production separator enables zero-methane emissions well pad production. By processing produced fluids through centrifugal separation at sub-atmospheric vapor pressure, the system eliminates the need for flaring associated with conventional production separation.

The result is sub-atmospheric vapor pressure oil production — reducing kg CO₂e per barrel of oil equivalent (BOE) and enabling operators to eliminate flash gas emissions at the wellhead. Submitted to SPE ATCE October 2024.

• Zero methane emissions well pad production configuration
• Eliminates flash gas flaring at separation
• Sub-atmospheric vapor pressure oil output
• Reduces kg CO₂e / BOE across production lifecycle
• High-speed centrifugal separation — no conventional separator vessels