CA3159303C - Gas processing methodology utilizing reflux and additionally synthesized stream optimization - Google Patents

Abstract

Gas processing methodology for high efficiency recovery of propane and/or ethane from a natural gas feed stream. The method is conducted without turboexpansion. A natural gas stream is processed to have gas and liquid portions. The gas portion is cooled and flows to a refluxed absorber column and the liquid portion flows to a lower pressure distillation column. Bottoms of the absorber column are depressurized directly into a lower pressure distillation column and the overhead vapor stream is used to cool the feed and/or reflux streams. The overhead vapour stream from the lower pressure distillation column split into at least two streams with one being depressurized into the absorber to provide reflux and the second passed into the absorber column to provide further reflux.

Description

GAS PROCESSING METHODOLOGY UTILIZING REFLUX AND
ADDITIONALLY SYNTHESIZED STREAM OPTIMIZATION
FIELD OF THE INVENTION
[0001] The present invention relates to gas processing and more particularly the present invention relates to the recovery of selected fractions from a natural gas feed stream.
BACKGROUND OF THE INVENTION
[00021 A variety of gas processing plant configurations exist for the extraction of hydrocarbon fractions from natural gas streams. Most industrial processing facilities seeking high levels of propane and ethane extraction from natural gas utilize turboexpanders for cryogenic recovery of these components, and such processes have become a preferred method. Examples of such processes are documented in United States Patent No. 4,157,904, Campbell et at, issued June 12, 1979, United States Patent. No. 4,690,702, Paradowski et at, issued September 1, 1987, and United States Patent. No. 5,275,005 Campbell et at, issued January 4, 1994.
[0003] In a typical natural gas separation process, a natural gas stream under pressure is cooled by heat exchange with a cold fluid stream, condensing liquids from the natural gas. The condensed liquids are then separated and fractionated in a distillation column to provide the desired separation of components. In some configurations, an additional lean liquids stream is condensed for use as reflux in the distillation, to absorb the components desired for extraction.
[00041 The majority of the commercial extraction processes employ a turboexpander in order to achieve high propane and ethane recovery. One major drawback to the use of a turboexpander is that turboexpanders have high operating efficiency at their design operating conditions, but lose efficiency at other operating Date Recue/Date Received 2022-05-18 conditions. The loss of turboexpander efficiency results in significant reductions of propane or ethane recovery at off-design conditions, such as at plant throughputs below the design rate. Existing designs that do not employ a turboexpander and instead use mechanical refrigeration such as propane refrigeration for cooling are not capable of achieving very high propane or ethane recoveries.
[0005] Mak describes in United States Patent No. 6,837,070, issued January 4, 2005, an extraction process which does not require a turboexpander, yet can achieve propane recoveries in excess of 95%. This process utilizes the depressurized absorber bottoms as a coolant for the absorber reflux, however the process does not cool the reflux to low enough temperatures to efficiently achieve high levels of propane recovery and lowers the attainable ethane recovery to levels that are not competitive with turboexpander based processes.
[0006] In the disclosure of the Mak document, there is a very good discussion of other relevant art. The Mak disclosure states:
"Various improvements on the basic concept of cryogenic gas separation have been developed. For example, Rambo et al. describe in U.S. Pat. No. 5,890,378 a system in which (a) the absorber is refluxed, (b) in which the de-ethanizer condenser provides the reflux for both the absorber and the de-ethanizer while the cooling requirements are met using a turboexpander, and (c) in which the absorber and the de-ethanizer operate at substantially the same pressure. Although Rambo's configuration advantageously reduces capital cost for equipment associated with providing reflux for the absorption section and the de-ethanizer, propane recovery significantly decreases as the operating pressure in the absorber rises, especially at a pressure above 500 psig, where separation of ethane from propane in the de-ethanizer becomes increasingly difficult. Consequently, Rambo's system is generally limited by the upper operating limit of the de-ethanizer pressure. Increasing of the absorber pressure while maintaining

2 Date Recue/Date Received 2022-05-18 desirable propane recovery becomes difficult, if not impossible in Rambo's process configuration. Moreover, operating the absorber and de-ethanizer at a pressure at or below 500 psig typically necessitates higher residue gas recompression, thereby incurring relatively high operating cost. To circumvent at least some of the problems associated with relatively high cost associated with residue gas recompression, Sorensen describes in U.S. Pat. No. 5,953,935 a plant configuration in which an additional fractionation column is included. The absorber reflux in Sorensen's plant configuration is produced by compressing, cooling, and Joule Thomson expansion of a slipstream of feed gas.
Although Sorensen's configuration generally provides an improved propane recovery with substantially no increase in plant residue compression horsepower, propane recovery significantly decreases as the operating pressure in the absorber rises, especially at a pressure above about 500 psig. Furthermore, ethane recovery using such known systems designed for propane recovery is normally limited to about 20% recovery."
[0007] Stothers, in United States Patent No. 6,098,425, issued August 8, 2000, discloses a thermodynamic separation process. The process continues to rearrange and introduce new operations to facilitate component separation. In the teachings, it is indicated that a gas fractionator tower, de-ethanizer, and recycle gas fractionator tower can produce high propane recoveries, in a configuration such that the fractionator vessel pressure is higher than the de-ethanizer pressure, and uses a reflux stream distilled from the de-ethanizer overheads in a third column.
[0008] In furtherance of developments to this area of technology, Mak, in United States Patent No. 7,051,553, issued May 30, 2006, teaches that in systems with a de-ethanizer and chilled overheads condenser, the de-ethanizer overheads stream can be used as a source of reflux in in the absorber column to achieve high propane and improved ethane recoveries in a turboexpanded process. The text states:

3 Date Recue/Date Received 2022-05-18 "In especially preferred configurations ranging from propane recovery to ethane recovery, the typical temperature ranges are illustrated as follows. The further cooled vapor stream 108 is split into a first portion that is expanded in a turbo-expander 150 to form expanded stream 109, typically at -100 F. to -115 F., which is introduced into the absorber 110, and a second portion stream 130 is still further cooled in heat exchanger 120 to typically -90 F. to -135 F., and reduced in pressure via a Joule-Thomson valve 132 before entering the absorber 110 as a reflux stream, typically at -125 F. to -1400 F.
Absorber 110 forms an overhead product 114, typically at -100 F. to -135*, which is employed as a refrigerant in heat exchangers 120, 122, and 124 before a residue gas re-compressor 160 recompresses the residue gas. Thus, it should be recognized that the overhead product cools the first and second absorber reflux, 146 and 130, respectively, and may further be employed as refrigerant to cool at least one of the vapor portions of the natural gas feed from the first and second separators. The absorber 110 further produces bottoms product 112, typically at -100 F. to -115 F., which also acts as a refrigerant in heat exchanger 120 to further cool the first and second reflux streams 146 and 130. The heated bottoms product 112, typically at -65 F. to -85 F., is then introduced into the distillation column 140, which separates the desired bottom product 142 (e.g., propane, or ethane/propane) from lean residue gas 144. The lean residue gas 144 may then be cooled with a cooler before entering separator 190 that produces a distillation column reflux 148 and the lean absorber reflux stream 146, typically at -85 F. to -115 F".

4 Date Recue/Date Received 2022-05-18 [0009] This process presents another representation in the evolution of reflux streams, turbo expansion and sequenced operations which are rearranged or with some operations removed for attaining improved recoveries.
[0010] In a later publication, Mak et al., teach in United States Patent Publication No. 20210095921, published April 1, 2021, integrated methods and configurations for propane recovery in both ethane recovery and ethane rejection. There is a discussion regarding the introduction of bottoms from the absorber being introduced into the stripper and further the use of multiple reflux streams. Although a meritorious procedure, the protocol still relies on turbo expansion. Mak et al., teach at paragraph [00410]:
70040] NGL recovery system 100 can comprise turbo expander 56. Turbo expander 561s configured to reduce the pressure of the vapor introduced thereto via vapor line 10 and second vapor line 14 and provide an expander discharge stream.
Turbo expander 56 is any expander known in the art to be operable to provide the expansion described herein while producing work. An absorber inlet line 15 can fluidly connect turbo expander 56 and absorber 59, whereby the expander discharge stream produced in turbo expander 56 can be introduced into absorber 59. A stripper overhead line 218 can fluidly connect stripper 62 with absorber inlet line 15, via stripper overhead line 21, such that (during ethane recovery) substantially all of the stripper overhead in stripper overhead line 2/ can be combined with the expanded second portion of the separator vapor in second vapor line /4 via absorber inlet line 15 and introduced into absorber 59." [Emphasis mine]
[0011] Accordingly, the techniques disclosed in the Mak et al. would present disadvantageous economics relative to a recovery process which does not rely on turbo expansion. These are particularly noteworthy in respect of turndown in a protocol not using turbo expansion.
Date Recue/Date Received 2022-05-18 [0012] Other generally relevant documents in this area include Canadian Patent Nos. 2,388,266, 2,562,828, 2,593,886, European Patent No. EP 0721557, United States Patent Publication Nos. U520090107175, U520090293537, US20120096895, US20140007616, US20140130541, US20140260420, US20160187058, United States Patent Nos. 4496380, 4507133, 4511381, 5152148, 5497626, 5685170, 5953935, 6098425, 6516631, 6837070, 7051553, 7191617, 7793517, 9103585, 9377239 and WIPO documents W02008005518, W02009087307 and W02014036322.
[0013] From a review of the rather extensive prior art in tato for this area of technology, it is evident that similarities exist in terms of reflux streams, towers, bottoms streams etc. Each one of the prior art references has merit, however the art has not unified select unit operations which have firstly been optimized and then rearranged in a novel manner to exploit substantial recovery percentages with commensurate economy and efficiency. Accordingly, there is still a need to provide improved methods and configurations for achieving very high propane and ethane recoveries, under variable flow conditions.
[0014] The present technologies to be discussed in detail herein after provide for such requisite improved methods.
SUMMARY OF THE INVENTION
[0015] One object of the present invention is to provide a method of recovering selected fractions of a natural gas feed stream with high efficiency in the absence of turbo expansion.
[0016] The technology has several aspects which provide for ethane recovery, propane recovery and methodology to switch between these.

Date Recue/Date Received 2022-05-18 [0017] By way of a preface to the details of the technologies, the present invention is directed to methods for gas processing, operational sequences for the processing and configurations of a gas plant.
[0018] Generally, the methods include cooling, partially condensing and separating a natural gas feed stream into gas and liquids streams. As a preliminary operation the gas may be treated to remove undesirable compounds by any of the known techniques. From the separation, the gas portion may be further cooled and passed into a refluxed absorber column called a fractionator. The liquid may be depressurized and passed into a distillation column.
[0019] The fractionator is utilized to contact a portion of the feed stream with cold and compositionally lean reflux liquids to absorb heavier hydrocarbons into the liquid and allow lean gas to leave the top of the absorber as overheads gas.
[0020] The fractionator overheads gas may be used to cool the reflux and feed gas streams before leaving the process as sales gas. The bottoms product of the absorber may be depressurized directly into a distillation column allowing for energy efficiency and operating pressures that avoid a turboexpansion operation which is designated as a pervasive operation in the prior art.
[0021] The distillation column, in the practicing of the method, receives the liquid portion of the feed stream as well as the bottoms from the fractionator and distills them to produce a liquid product and an overheads stream.
[0022] The recovered liquids leave the process as the distillation column bottoms.
The distillation column overhead stream may then be utilized to cool the feed stream and/or fractionator reflux, prior to being compressed and split or segregated into at least two streams. One of the streams can be further compressed, cooled, and depressurized into the top of the fractionator column, creating cold and lean liquids that serve as fractionator reflux. The second stream may be cooled and depressurized into Date Recue/Date Received 2022-05-18 a lower location on the fractionator, creating further liquids that are used as additional reflux. In one aspect of the inventive subject matter, the distillation column comprises a deethanizer column. The distillation column produces an overhead stream that is used to cool the feed stream and/or absorber reflux, and is then compressed, cooled, partially condensed, and separated. The gas fraction is then split into two streams, wherein one stream is further compressed, cooled, and depressurized into the top of the fractionator column, creating liquids that serve as absorber reflux. The second gas stream is depressurized directly into the fractionator column at a position partway down the column. The liquid fraction is depressurized into the fractionator column at a location further down the column. This configuration allows for propane recovery in excess of 99%, while rejecting over 99% of the ethane, with overall utility requirements that are similar to those used in turboexpander based processes.
[0023] Accordingly, a further object of one embodiment of the present invention is to provide a method of processing natural gas to recover selected hydrocarbons contained therein, comprising: cooling and partially condensing a natural gas feed stream; separating the cooled and partially condensed stream into a liquid stream and a gas stream; passing the gas stream into a fractionator column and the liquid stream into a distillation column; recovering an overheads stream from the distillation column;
treating the overheads stream to form a plurality of overhead streams; passing at least one of the overhead streams into the fractionator column as reflux and a second stream at a second point in the fractionator column; contacting the reflux and the second stream with the natural gas feed stream in the fractionator column to liquify hydrocarbon components present in the natural gas feed stream; recovering a bottoms stream from the fractionator column; depressurizing and passing the bottoms stream directly into the distillation column; and recovering selected hydrocarbon components from the bottoms stream.
[0024] As a particular benefit the method is conducted absent the use of turboexpansion as a unit operation.

Date Recue/Date Received 2022-05-18 [0025] The formation of the overheads stream forms a plurality of overhead streams utilized as reflux streams at different pressures.
[0026] As a significant point of distinction from the prior art, the depressurizing and feeding the bottoms stream directly into the distillation column absent any additional unit operations.
[0027] It has been found that the unification of meritorious unit operations from the prior art with unique interplay and heat exchange, solves the issues currently in this area of technology. This has also been realized in turndown benefits; the methodology allows for varying fluid flow rates at least between the fractionator column and the distillation column.
[0028] The 'present methodology has a turndown range between 30% and 100%

of flowrate in where 99% recovery is maintained.
[0029] In respect of implementation into a plant, the technology is readily suited for plant implementation. As such, another object of one embodiment of the present invention is to provide a gas processing plant, comprising: a separator for receiving a cooled and partially condensed natural gas feed stream to separate the feed stream into a liquid stream and a gas stream; a fractionator column for receiving the 'gas stream and reflux streams produced from a distillation column; and a distillation column in fluid communication with the fractionator for producing an overheads stream, the overheads stream being utilized in the absorber column as reflux streams to liquify hydrocarbons present in the feed stream, the distillation column producing a bottoms stream which is depressurized in the distillation column to recover selected hydrocarbons in the absence of further unit operations.
[0030] Contributory to the effectiveness of the technology herein is the heat exchange between the streams for exemplary heat recovery and utilization. With the stream heat exchange, synthesis commingling and redirection, high process energy Date Recue/Date Received 2022-05-18 efficiency is attainable. This is a further benefit of the novel operation unification discussed herein, supra.
[0031] The unification of the operations is yet another object of the present invention. This object is directed to a method of processing natural gas with a fractionator column and distillation column in fluid communication to recover selected hydrocarbons contained therein, comprising a plurality of operations, comprising: a separation operation where a natural gas stream is processed to form a liquid stream and a gas stream which are separated; an overheads processing and distribution operation where an overheads stream is recovered from the distillation column and processed into a plurality of overhead streams distributed into predetermined locations in the fractionator column; a refrigeration operation in the fractionator column where the natural gas feed stream contacts the overhead streams to liquify hydrocarbon components present in the natural gas stream; and a bottoms recovery and processing operation where a bottoms stream is recovered from the fractionator column and processed by depressurization directly in the distillation column in the absence of turboexpansion to recover selected hydrocarbons.
[0032] Advantageously, exchange operations between each of the separation, overheads processing and distribution, refrigeration and bottoms recovery operations recover and distribute heat between all streams associated with the operations.
[0033] Where the distillation tower is operated as a deethanizer, propane recovery is in excess of 99%, without the required use of turboexpanders or cryogenic pumps. Further, the method accepts a range of natural gas feed pressures, including low pressures such as approximately 5000 kPag and can operate at an increased natural gas feed pressure and a higher chiller temperature with reduced chilling duty.
For chilling, the method uses refrigerants such as propane, or ammonia at temperatures of approximately -40 C.
Date Recue/Date Received 2022-05-18 [0034] Heat for the deethanizer reboiler may be provided by heat exchange with a heat medium fluid or the hot discharge gas of a compressor. Other scenarios are within the purview of one skilled.
[0035] As an option, the deethanizer may use a side reboiler heated by the process fluid to further improve the recovery and energy efficiency of the process.
[0036] Regarding the reflux streams, the same may be compressed to pressures in the range of approximately 6000kPag to 10000 kPag and depressurized into the fractionator.
[0037] Owing to the flexibility of the methods, some heat exchangers or chillers may be removed from the process and the stream flows altered to reduce the equipment costs, such that the propane recovery is reduced.
[0038] Where the distillation column is operated as a demethanizer. The ethane recovery is in excess of 99% similarly as above in the case of the deethanizer, without the required use of turboexpanders or cryogenic pumps within the process.
[0039] In this variation of the process, a range of natural gas feed pressures may be utilized, including pressures above approximately 7000 kPag.
[0040] For bottoms recovery and processing operations, the method may include introducing the bottoms stream at a pressure of between 500 kPag and 2000 kPag into the distillation column relative to the pressure of between 2000 and 7000 kPag prior to introduction.
[0041] For switching between the propane or ethane recovery the method can selectively recover either ethane and lower boiling point components, or propane and lower boiling point components, from a natural gas stream. It has been found that propane recovery is in excess of 99% in a propane recovery mode with ethane rejection Date Recue/Date Received 2022-05-18 and ethane recovery is in excess of 99% in ethane recovery mode, without the required use of turboexpanders or cryogenic pumps within the process.
[0042] For the chilling, the method uses refrigerants such as propane, or ammonia, at temperatures of approximately -40 C for ethane recovery, and -40 C or lower temperatures for propane recovery.
[0043] Having thus generally described the invention, reference will now be made to the accompanying drawings, illustrating preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] Figure 1 is a process flow diagram in accordance with a first embodiment of the present invention;
[0045] Figure 2 is a process flow diagram in accordance with a second embodiment of the present invention;
[0046] Figure 3 is a is a process flow diagram in accordance with a third embodiment of the present invention;
[0047] Figure 4 is a is a process flow diagram in accordance with a fourth embodiment of the present invention; and [0048] Figure 5 is a process flow diagram in accordance with a fifth embodiment of the present invention.
[0049] Similar numerals used in the figures denote similar elements.

Date Recue/Date Received 2022-05-18 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] Referring now to Figure 1, shown is a process flow diagram for a first embodiment of the present invention for propane recovery and ethane rejection.
[0051] A natural gas feed stream 10 at a pressure above, for example, approximately 5000 kPag flows through heat exchanger 12 cooling the gas by exchanging heat with the cold sales gas leaving the process, generally denoted by numeral 14. The natural gas stream 16 leaving exchanger 12 is then passed through a chiller 18, which partially condenses the natural gas stream. The chiller 18 may operate at, for example, approximately -40 C and may use common refrigerants such as propane, or ammonia. Other suitable refrigerant examples are well within the purview of one skilled in the art.
[0052] The partially condensed natural gas stream 20 is then separated in separator 22 and the gas portion 24 leaving separator 22 is further cooled by heat exchange at 26 with a sales gas stream 28 and a reflux stream 30, discussed in greater detail herein after. The gas stream 32 is then depressurized across a valve 34 entering, as stream 36, to the bottom of a refluxed fractionator tower 38 at, for example, approximately 3500 kPag. The gas flows upwardly through tower 38 where it is contacted with the downwardly flowing reflux liquids. The fractionator tower 38 bottoms liquids 40 exit the bottom of tower 38 as illustrated and are depressurized across a valve 42 directly into the top of a second distillation column 44, operating in the example as a deethanizer at approximately 1000 kPag. The deethanizer (second distillation column 44) is also fed the condensed liquids 46 from the separator 22. Liquids 46 are depressurized via valve 48 into the deethanizer 44.
[0053] Distillation of these liquids occurs in the deethanizer 44, with the bottoms product reboiled in circuit 50 to produce a low ethane content C3+ liquid product 52.
The deethanizer reboiler circuit can be heated using a heat medium, or by heat exchange with a hot compressor discharge stream.

Date Recue/Date Received 2022-05-18 [0054] The deethanizer overheads 54 flow to a heat exchanger 56, which is used to further cool the stream after compression in compressor 58 to a pressure above the fractionator operating pressure followed by cooling in an air exchanger 60.
The overheads stream 62 is then chilled and partially condensed in a chiller 64, and further condensed in an exchanger 66 with the sales gas, prior to being separated in separator 68.
[0055] The liquid stream 70 from the separator 68 is used as a medium quality source of reflux, with a composition that is approximately half methane and half ethane.
The medium quality reflux stream 70 is fed into a mid-point of the fractionator tower 38 as illustrated in the Figure.
[0056] The gas stream 72 from the separator 68 can optionally be split into two streams 30 (referenced herein previously) and 74, with the ratio of the split determining the degree of propane recovery versus the refrigeration and reflux compression energy requirement. For the highest propane recovery, all of the gas stream from separator 68 can be used to generate high quality reflux liquids. The stream 30 is used to cool the feed to the fractionator 38 in a heat exchanger 76. The stream 74 then flows to another heat exchanger 78 which is used to further cool the stream after compression in compressor 80 and cooling in an air exchanger 82.
[0057] The stream 84 is compressed to approximately 7000 kPag, and then chilled in chiller 86 and cooled with heat exchanger 88 with the sales gas stream 90 from fractionator tower 38. Depressurization of this stream 92 is achieved by valve 94 to the fractionator tower 38 and this depressurization condenses a portion of the stream into high quality liquefied natural gas reflux, composed mainly of liquid methane. This reflux stream flows downwardly through the fractionator tower 38, effectively absorbing the propane and heavier components from the upwardly flowing natural gas into the liquid phase. The fractionator overheads 90 have propane and heavier components effectively absorbed by the reflux and this exits the fractionator 38 as sales gas. The Date Recue/Date Received 2022-05-18 sales gas is used to cool the reflux streams, fractionator feed, and inlet natural gas in heat exchangers 88, 66, and 12 and then the sales gas exits the process for further compression, if required.
[0058] Turning now to Figure 2, shown is a process flow diagram in another embodiment of the invention for ethane recovery.
[0059] In this embodiment, natural gas stream 10 at a pressure above approximately 7000 kPag flows through a heat exchanger 12, cooling the gas by exchanging heat with the cold sales gas leaving the process, generally denoted by numeral 14. The natural gas stream 16 is then passed through a series of heat exchangers and a chiller, 18, 100 and 102, respectively, which partially condenses the natural gas stream. The chiller 100 may operate at approximately -40 C, and may use common refrigerants such as propane, or ammonia. The partially condensed natural gas stream 109 is then separated in separator 22 and the gas portion 24 is then depressurized across a valve 34, entering the bottom of fractionator tower 38 at approximately 3500 kPag.
[0060] The gas flows upwards through the refluxed fractionator tower 38 where it is contacted with the downwards flowing reflux liquids. The fractionator tower bottoms liquids 40 exit the bottom of the tower 38 and are depressurized across a valve 42 directly into the top of second distillation column 44 operating as a demethanizer at approximately 1000 kPag. The demethanizer 44 is also fed the condensed liquids from the separator 22 which are depressurized across a valve 48 into the demethanizer.
[0061] Distillation of these liquids occurs in the demethanizer 44 with the bottoms product reboiled in a reboiler circuit 50 to produce a low methane content C2+
liquid product 106. The demethanizer reboiler circuit 50 can be heated by heat exchange with the feed gas stream, another process stream of appropriate temperature, or a heat medium stream. The demethanizer overheads 34 flows to a series of heat exchangers 102, 18 which are used to cool the feed gas stream.
Date Recue/Date Received 2022-05-18 [0062] The demethanizer overheads then flow to a compressor 58 which compresses the gas stream 106 to a pressure above the fractionator operating pressure, and then the gas is cooled in an air exchanger 60. This gas is then split into two streams 108, 110 with the ratio of the split determining the degree of ethane recovery versus the refrigeration and reflux compression energy requirement.
[0063] One of these two streams 108 can be chilled and depressurized into a mid-point of the fractionator tower 38. The other of these two split streams, can be further compressed to approximately 9000 kPag in compressor 110, cooled with an air cooler 112, chilled with chiller 114, cooled by heat exchangers 116, 118 with the fractionator tower overheads 120 and depressurized across a valve 122 into the fractionator tower 38 to generate high quality reflux liquids.
[0064] Depressurization of this stream 124 to the fractionator tower 38 pressure condenses a portion of the stream into high quality liquefied natural gas reflux, consisting primarily of liquid methane. This reflux stream flows downwardly through the fractionator tower 38, effectively absorbing the ethane and heavier components from the upwards flowing natural gas, into the liquid phase. The fractionator overheads have had ethane and heavier components effectively absorbed by the reflux, and exits the fractionator 38 as sales gas. The sales gas is used to cool the reflux stream, and inlet natural gas in heat exchangers (118, 116, 12), and then the sales gas exits the process for further compression, if required.
[0065] Figure 3 illustrates yet another variation of the present invention for switchable ethane recovery.
[0066] The process may be arranged so that the ethane recovery can be switched on and off. The figure illustrates the ethane rejection mode.
Generally speaking, the process is very similar to that discussed regarding Figure 1, with the exception of the following:

Date Recue/Date Received 2022-05-18 [0067] The feed gas pressure for high ethane recovery is desirably above approximately 7000 kPag. The distillation column 44 operates as a demethanizer as opposed to a deethanizer. Overheads stream 54 from the demethanizer 44 is redirected from the exchanger 56 to the exchanger 76.
[0068] The gaseous stream 72 from the separator 68 is redirected from exchanger 76 to exchanger 78.
[0069] Stream 74 from the exchanger 76 is redirected from the exchanger 76 to the exchanger 56. The demethanizer reboiler 44 can instead be heated using a heat medium, or by heat exchange with process streams such as the feed gas stream 16.
[0070] Turning now to Figure 4, shown is a propane recovery, ethane rejection process flow diagram.
[0071] Natural gas stream 10 at a pressure above approximately 5000 kPag flows through heat exchanger 12, cooling the gas by exchanging heat with the cold sales gas leaving the process at 14.
[0072] The natural gas stream 16 is then passed through a heat exchanger which partially condenses the natural gas stream. The partially condensed natural gas stream 128 is then separated in separator 22 and the gas portion 24 is further cooled in a chiller 27. The chiller 27 may operate at approximately -40 C, and may use common refrigerants such as propane, or ammonia.
[0073] The partially condensed gas stream is then depressurized across valve 34, entering the bottom of a fractionator tower 38 at approximately 3500 kPag.
The gas flows upwardly through the refluxed fractionator tower 38 where it is contacted with the downwardly flowing reflux liquids.

Date Recue/Date Received 2022-05-18 [0074] The fractionator tower 38 bottoms liquid 40 exit the bottom of the tower 38 and are depressurized across valve 42 directly into the top of a second distillation column 44 operating as a deethanizer at approximately 1000 kPag.
[0075] The deethanizer 44 is also fed the condensed liquids 46 from separator 22, which are depressurized across valve 48 into the deethanizer 44.
[0076] Distillation of these liquids occurs in the deethanizer 44 with the bottoms product reboiled in circuit 50 to produce a liquid product 52, in this example, a low ethane content C3+.
[0077] The deethanizer reboiler circuit 50 can be heated using a heat medium, or by heat exchange with a hot compressor discharge stream.
[0078] The deethanizer overheads 54 flow to heat exchanger 126 which uses the overheads to cool the feed gas. The overheads then flow to another heat exchanger 56 which is used to further cool the stream after compression with compressor 58 to a pressure above the fractionator operating pressure, and cooling in air exchanger 60.
[0079] The overheads stream is then split into two streams 108 and 110 each to be used as a source of reflux in the absorber.
[0080] Reflux stream 108 is cooled by heat exchange 126 with the deethanizer overheads stream, then chilled with chiller 132, partially condensed and depressurized across valve134 into a mid point of the fractionator tower 38 as a source of medium quality reflux.
[0081] The other split reflux stream 110 is further compressed at 111, cooled with air exchanger 112, chilled at 114, and further cooled and condensed by heat exchange at 116 with the sales gas. Depressurization of this stream across valve 122 to the fractionator tower 38 pressure condenses a portion of the stream into high quality reflux, Date Recue/Date Received 2022-05-18 This reflux stream flows downwardly through the fractionator tower 38, effectively absorbing the propane and heavier components from the upwardly flowing natural gas, into the liquid phase.
[0082] The fractionator overheads 120 at this pint in the process have had propane and heavier components effectively absorbed by the reflux and the exit the fractionator 38 as sales gas.
[0083] The sales gas is used to cool the reflux streams, fractionator feed, and inlet natural gas in heat exchangers and then the sales gas exits the process for further compression, if required.
[0084] Figure 5 is a process flow diagram depicting propane recovery with ethane rejection).
[0085] Similar to the previous embodiments, natural gas stream 10 at a pressure above approximately 5000 kPag flows through heat exchanger 12, cooling the gas by exchanging heat with the cold sales gas leaving the process at 14.
[0086] The natural gas stream 16 is then passed through heat exchanger 126, which partially condenses the natural gas stream. The partially condensed natural gas stream 128 is then separated with separator 22 with gas portion 24 further cooled in chiller 27.
[0087] Chiller 27 may operate at approximately -40 C.
[0088] The partially condensed gas stream (9) is further cooled by heat exchange with the sales gas stream as shown and depressurized across valve 34, entering the bottom of a fractionator tower 38 at a pressure of approximately 3500 kPag.

Date Recue/Date Received 2022-05-18 [0089] The gas flows upwardly through the refluxed fractionator tower 38 where it is contacted with the downwardly flowing reflux liquids.
[0090] The fractionator tower 38 bottoms liquids 40 exit the bottom of the tower 38. and are depressurized across valve 42 directly into the top of distillation column 44, operating as a deethanizer at approximately 1000 kPag.
[0091] The deethanizer 44 is also fed the condensed liquids 46 from the separator 22, which are depressurized across valve 48 into the deethanizer 44.

Distillation of these liquids occurs in the deethanizer 44, with the bottoms product reboiled in circuit 50 to produce liquid product 52 which in this example is a low ethane content C3+ product.
[0092] The deethanizer reboiler circuit 50 can be heated using a heat medium, or by heat exchange with a hot compressor discharge stream.
[0093] The deethanizer overheads 54 flow to heat exchanger 126 which uses the overheads to cool the feed gas. The overheads then flow to another heat exchanger 56, which is used to further cool the stream after compression at 58 to a pressure above the fractionator operating pressure, and cooling in air exchanger 60.
[0094] The overheads stream is then split into two streams 108 and 110 each to be used as a source of reflux in the absorber.
[0095] Reflux stream 108 is cooled by heat exchanger 56 with the deethanizer overheads stream, then chilled at 132, further cooled and condensed by heat exchange at 138 with the sales gas, and depressurized across valve 134 into a mid point of the fractionator tower 38 as a source of medium quality reflux.
Date Recue/Date Received 2022-05-18 [0096] The other split reflux stream 110 is further compressed at 111, cooled with air exchanger 112, chilled at 114 and further cooled and condensed by heat exchange with the sales gas.
[0097] Depressurization of this stream across a valve 122 to the fractionator tower pressure condenses a portion of the stream into high quality reflux.
This reflux stream flows downwardly through the fractionator tower 38, effectively absorbing the propane and heavier components from the upwards flowing natural gas, into the liquid phase.
[0098] The fractionator overheads 120 at this point have had propane and heavier components effectively absorbed by the reflux, and the exits the fractionator 38 as sales gas. The sales gas is used to cool the reflux streams, fractionator feed, and inlet natural gas in heat exchangers and then the sales gas exits the process for further compression, if required.
[0099] These processes can economically achieve higher ethane and/or propane recoveries than the traditional turbo-expander processes with lower plant inlet pressures. Generally, depending upon gas composition, it is desired to have a plant inlet pressure of approximately 7000 kPa to achieve 99% ethane recovery. When inlet pressures are higher, energy, capital cost, and operating cost can be saved by having lower refrigerant temperatures than -40 C. Depending upon markets conditions for ethane sales and energy purchase, some scenarios may favor lower ethane recovery for reasons of economics. Lower ethane recovery can be easily achieved with warmer refrigerant temperatures, but raising the demethanizer pressure and/or the gas fractionator pressure can also be considered.
[0100] Similarly, an inlet pressure of approximately 5000 kPa is generally desired for 99% propane recovery, but with higher inlet pressures, lower refrigerant temperatures can save capital cost, energy cost, and operating cost and still achieve an economical 99% propane recovery.

Date Recue/Date Received 2022-05-18

Claims (21)

WE CLAIM

1. A method of processing natural gas to recover hydrocarbons contained therein, comprising:
cooling and partially condensing a natural gas feed stream;
separating the cooled and partially condensed stream into a liquid stream and a gas stream;
passing said gas stream into a fractionator column and said liquid stream into a distillation column;
recovering an overheads stream from said distillation column;
treating said overheads stream to form a plurality of overhead streams;
passing at least one of said overhead streams into said fractionator column as reflux and a second stream at a second point in said fractionator column;
contacting said reflux and said second stream with said natural gas feed stream in said fractionator column to liquify hydrocarbon components present in said natural gas feed stream;
recovering a bottoms stream from said fractionator column;
depressurizing and passing said bottoms stream directly into said distillation column; and recovering hydrocarbon components from said bottoms stream.

2. The method as set forth in claim 1, wherein said method is conducted absent the use of turboexpansion as a unit operation.

3. The method as set forth in claim 1 or 2, wherein said treating said overheads stream to form a plurality of overhead streams includes forming a plurality of reflux streams at different pressures.

4. The method as set forth in any one of claims 1 through 3, wherein said depressurizing and passing said bottoms stream directly into said distillation column is absent any additional unit operations.

5. The method as set forth in any one of claims 1 through 4, further including the step of varying fluid flow rates at least between said fractionator column and said distillation column.

6. The method as set forth in any one of claims 1 through 5, wherein said method has a turndown range between 30% and 100% of flowrate in said method where 99%

recovery is maintained.

7. The rnethod as set forth in any one claims 1 through 6, wherein said plurality of overheads streams comprise at least one liquid strearn and at least one gas stream.

8. The method as set forth in claim 7, wherein said gas stream is passed into said fractionator column at said second point.

9. A gas processing plant, comprising:
a separator for receiving a cooled and partially condensed natural gas feed stream to separate said feed stream into a liquid stream and a gas stream;
a fractionator column for receiving said gas stream and reflux streams produced from a distillation column; and the distillation column in fluid communication with said fractionator for producing an overheads stream, said overheads stream being utilized in said fractionator column as reflux streams to liquify hydrocarbons present in said feed stream, said fractionator column produdng a bottoms strearn which is depressurized into said distillation column to recover hydrocarbons in the absence of further unit operations.

10. The gas processing plant as set forth in claim 9, further including a network of heat exchangers positioned to recover and distribute heat from all streams of said streams during processing.

11. The gas processing plant as set forth in claim 9 or 10, wherein said overheads stream is compressed, cooled and divided into a plurality of overhead streams.

12. The gas processing plant as set forth in claim 11, wherein at least one of said overhead streams is compressed, cooled and depressurized for use in said fractionator column as a reflux stream.

13. The gas processing plant as set forth in claim 11 or 12, wherein said overhead streams are pressurized at a different pressure relative to one another.

14. The gas processing plant as set forth in claim 13, wherein said overhead streams may exist in a gas, partially condensed, or liquid state.

15. A method of processing natural gas with a fractionator column and distillation column in fluid communication to recover hydrocarbons contained therein, comprising a plurality of operations, comprising;
a separation operation where a natural gas stream is processed to form a liquid stream and a gas stream which are separated;
an overheads processing and distribution operation where an overheads stream is recovered from said distillation column and processed into a plurality of overhead streams distributed into predetermined locations in said fractionator column;
a distillation operation in said fractionator column where said natural gas feed stream contacts said overhead streams to liquify hydrocarbon components present in said natural gas stream; and a bottoms recovery and processing operation where a bottoms stream is recovered from said fractionator column and processed by depressurization directly in said distillation column in the absence of turboexpansion to recover hydrocarbons.

16. The method as set forth in claim 15, wherein said method further includes heat exchange operations between each of the separation, overheads processing and distribution and bottoms recovery operations to recover and distribute heat between all streams associated with said operations.

17. The method as set forth in claim 15 or 16, wherein said distillation column is operated as a deethanizer.

18. The method as set forth in any one of claims 15 through 17, wherein said distillation column is operated as a demethanizer.

19. The method as set forth in any one of claims 15 through 18, wherein said operations are modifiable to recover ethane, propane, hydrocarbons, or a combination thereof.

20. The method as set forth in any one of claims 15 through 19, wherein said separation operation includes cooling and partially condensing said natural gas feed stream.

21. The method as set forth in any one of claims 15 though 20, wherein said bottoms recovery and processing operation includes introducing said bottoms stream at a pressure of between 500 kPag and 2000 kPag into said distillation column relative to a pressure of between 2000 and 7000 kPag prior to introduction.