CN112368532A - 带有预冷却的混合制冷剂液化系统和方法 - Google Patents

带有预冷却的混合制冷剂液化系统和方法 Download PDF

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Publication number
CN112368532A
CN112368532A CN201980027080.0A CN201980027080A CN112368532A CN 112368532 A CN112368532 A CN 112368532A CN 201980027080 A CN201980027080 A CN 201980027080A CN 112368532 A CN112368532 A CN 112368532A
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cooling
heat exchanger
stream
refrigerant
mixed refrigerant
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CN201980027080.0A
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D.A.小杜科特
T.P.古沙纳斯
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Chart Energy and Chemicals Inc
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Chart Energy and Chemicals Inc
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Publication of CN112368532A publication Critical patent/CN112368532A/zh
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/0002—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the fluid to be liquefied
    • F25J1/0022—Hydrocarbons, e.g. natural gas
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0047—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle
    • F25J1/0052—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0032—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration"
    • F25J1/004—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by flash gas recovery
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    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0032—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration"
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    • F25J1/006—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
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    • F25J1/0092—Mixtures of hydrocarbons comprising possibly also minor amounts of nitrogen
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    • F25J1/006—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
    • F25J1/0097—Others, e.g. F-, Cl-, HF-, HClF-, HCl-hydrocarbons etc. or mixtures thereof
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Abstract

用于冷却气体的系统包括预冷却换热器和液化换热器。预冷却换热器使用预冷却制冷剂在将进料气流引导至液化换热器之前对其进行预冷却。液化换热器使用混合制冷剂进一步冷却预冷却的气体。预冷却换热器还对液化换热器使用的液化混合制冷剂进行预冷却。

Description

带有预冷却的混合制冷剂液化系统和方法
优先权要求
本申请要求于2018年4月20日提交的美国临时专利申请第62/660,518号的优先权权益，其全部内容通过引用并入本文。
技术领域
本发明总体上涉及用于冷却或液化气体的系统和方法，更具体地，涉及使用冷蒸汽分离将高压混合制冷剂蒸汽分离成液体和蒸汽流并且包括用于使用第二制冷剂预冷却进料气流和一个或多个混合制冷剂流的子系统的的混合制冷剂液化系统和方法。
背景技术
主要为甲烷的天然气以及其他气体在压力下液化以存储和运输。液化导致的体积减小允许使用具有更实用和经济的设计的容器。通常通过间接热交换通过一个或多个制冷循环冷却气体来实现液化。由于所需设备的复杂性和所需的制冷剂性能效率，这样的制冷循环在设备成本和操作上都是昂贵的。因此，需要具有提高的制冷效率和降低的操作成本以及降低的复杂性的气体冷却和液化系统。
在液化系统的制冷循环中使用混合制冷剂可提高效率，因为制冷剂的升温曲线与气体的冷却曲线更加紧密匹配。液化系统的制冷循环通常将包括用于调节或处理混合制冷剂的压缩系统。混合制冷剂压缩系统通常包括一级或多级，每级包括压缩机、冷却器以及分离和液体蓄积装置。离开压缩机的蒸气在冷却器中被冷却，所产生的两相或混合相流被引导至分离和液体蓄积装置，蒸气和液体从该装置中离开，以进一步处理和/或引导至液化换热器。
来自压缩系统的混合制冷剂的分离的液相和气相可以被引导至换热器的部分以提供更有效的冷却。此类系统的示例在授予Gushanas等人的共同拥有的美国专利第9,441,877号、授予Ducote等人的美国专利申请公开第2014/0260415号、授予Ducote等人的美国专利申请公开第US 2016/0298898号中提供，其全部内容通过引用并入本文。
期望在气体冷却和液化系统中进一步提高冷却效率并降低操作成本。
发明内容
本主题的几个方面可以在下面描述和要求保护的方法、装置和系统中单独或一起实施。这些方面可以单独使用，也可以与本文中描述的主题的其他方面结合使用，并且这些方面的描述在一起并不旨在排除单独使用这些方面或对这些方面的单独要求，或以如在所附的权利要求书中阐述的不同的组合。
在一方面，一种用于用预冷却制冷剂和混合制冷剂冷却气体的系统包括预冷却换热器，该预冷却换热器具有适于接收进料气流的进料气体入口和进料气体出口，预冷却制冷剂入口和预冷却制冷剂出口，以及液化混合制冷剂入口和液化混合制冷剂出口。预冷却换热器被配置为使用预冷却制冷剂来冷却在进料气体入口和出口之间通过预冷却换热器的进料气体，并冷却在液化混合制冷剂入口和出口之间通过预冷却换热器的液化混合制冷剂。一种预冷却压缩机系统，包括具有与所述预冷却换热器的所述预冷却制冷剂出口流体连通的入口的预冷却压缩机。该预冷却压缩机系统还具有预冷却冷凝器，该冷凝器的入口与该预冷却压缩机的出口流体连通。该预冷却冷凝器还具有与该预冷却换热器的预冷却制冷剂入口流体连通的出口。液化换热器包括与预冷却换热器的进料气体出口流体连通的液化通道、主制冷通道、高压蒸气冷却通道和冷分离器蒸气冷却通道，其中，冷分离器蒸气冷却通道具有与主制冷通道流体连通的出口。混合制冷剂压缩系统包括：混合制冷剂压缩机，其入口与主制冷通道的出口流体连通；和混合制冷剂冷却器，其入口与所述混合制冷剂压缩机的出口流体连通。混合制冷剂冷却器还具有与预冷却换热器的液化混合制冷剂入口流体连通的出口。混合制冷剂压缩系统还具有高压蓄积器，该高压蓄积器具有与预冷却换热器的液化混合制冷剂出口流体连通的入口和与液化换热器的高压蒸气冷却通道的入口流体连通的蒸气出口。冷蒸气分离器具有与液化换热器的高压蒸气冷却通道的出口流体连通的入口，与液化换热器的冷分离器蒸气冷却通道的入口流体连通的蒸气出口，和与液化换热器的主制冷通道流体连通的液体出口。
在另一方面，一种用于冷却进料气流的方法包括以下步骤：使用第一制冷剂在预冷却换热器中对进料气流进行预冷却以形成预冷却的进料气流并通过以下方式进一步冷却预冷却的进料气流：i)在预冷却换热器中冷却高压第二制冷剂流以形成冷却的高压第二制冷剂流，ii)分离冷却的高压第二制冷剂流以形成高压蒸气流和高压液体流，iii)在液化换热器中冷却高压蒸汽流，以形成混合相流，iv)用冷蒸汽分离器分离混合相流，以形成冷分离器蒸汽流和冷分离器液体流，v)使用第二制冷剂在液化换热器中冷凝冷分离器蒸气流并闪蒸，以形成低温制冷剂流，vi)引导低温制冷剂流到液化换热器，vii)将高压液体流过冷以形成过冷的高压液体流，并在液化换热器中与低温制冷剂流合并，viii)将冷分离器液体流过冷以形成过冷的冷分离器液体流，并在液化换热器中与低温制冷剂流合并；以及ix)使液化换热器中的预冷却气流与低温制冷剂流热接触。
在另一方面，一种用于用混合制冷剂冷却进料气体的系统包括预冷却换热器，其具有被配置为接收预冷却制冷剂流的预冷却制冷剂入口和预冷却制冷剂出口，以及液化混合制冷剂入口和液化混合制冷剂出口。预冷却换热器被配置为使用预冷却制冷剂来冷却在液化混合制冷剂入口和出口之间通过预冷却换热器的液化混合制冷剂。液化换热器包括：液化通道，其被配置为接收进料气流；主制冷通道；高压蒸气冷却通道和冷分离器蒸气冷却通道，其中，冷分离器蒸气冷却通道具有与主制冷通道流体连通的出口。混合制冷剂压缩系统包括混合制冷剂压缩机，该混合制冷剂压缩机具有与主制冷通道的出口流体连通的入口。混合制冷剂压缩系统还包括混合制冷剂冷却器，其入口与混合制冷剂压缩机的出口流体连通。混合制冷剂冷却器具有与预冷却换热器的液化混合制冷剂入口流体连通的出口。混合制冷剂压缩系统还包括高压蓄积器，该高压蓄积器具有与预冷却换热器的液化混合制冷剂出口流体连通的入口和与液化换热器的高压蒸气冷却通道的入口流体连通的蒸气出口。冷蒸气分离器具有与液化换热器的高压蒸气冷却通道的出口流体连通的入口，与液化换热器的冷分离器蒸气冷却通道的入口流体连通的蒸气出口，和与液化换热器的主制冷通道流体连通的液体出口。
在另一方面，一种用于冷却进料气流的方法包括以下步骤：将进料气流引入液化换热器；在预冷却换热器中冷却高压混合制冷剂流以形成冷却的高压混合制冷剂流，并通过以下方式在液化换热器中冷却进料气流：i)分离冷却的高压混合制冷剂流以形成高压蒸气流和高压液体流，ii)在液化换热器中冷却高压蒸气流以形成混合相流，iii)用冷蒸气分离器分离混合相流以形成冷分离器蒸气流，以及冷分离器液体流，iv)在液化换热器中冷凝冷分离器蒸气流并闪蒸，以形成低温制冷剂流，v)将低温制冷剂流引导至液化换热器，vi)对在液化换热器中的高压液体流进行过冷以形成过冷的高压液体流，并与液化换热器中的低温制冷剂流合并，vii)对冷分离器液体流进行过冷，以形成过冷的冷分离器液体流，并在液化换热器中与低温制冷剂流合并；和viii)使液化换热器中的气流与低温制冷剂流热接触。
附图说明
图1是示出了本公开的系统和方法的第一实施方式的工艺流程示意图；
图2是示出了本公开的系统和方法的第二实施方式的工艺流程示意图；
图3是示出了本公开的系统和方法的第三实施方式的工艺流程示意图；
图4是示出了本公开的系统和方法的第四实施方式的工艺流程示意图；和
图5是示出了本公开的系统和方法的第五实施方式的工艺流程示意图。
具体实施方式
本公开的混合制冷剂液化系统和方法的实施方式在图1-5中示出。应当注意，尽管以下根据液化天然气以产生液态天然气来图示和描述了实施方式，但是本发明可以用于液化或冷却其他类型的气体。
本公开的实施方式可使用在以下中描述的混合制冷剂液化系统和方法：授予Gushanas等人的共同拥有的美国专利第9,441,877号，美国专利申请公开第2014/0260415号，授予Ducote等人的美国专利申请第14/218,949号和授予Ducote等人的美国专利申请第62/561,417号，其各自的内容通过引用并入本文。
在此应注意，有时通道和流两者均由图中列出的相同元件编号来指代。同样，如本文所使用的，并且如本领域中已知的，换热器是如下的装置或装置中的区域：其中在两个或多个不同温度的流之间或在流与环境之间发生间接热交换。如本文所使用的，除非另有说明，否则术语“连通(communication/communicating)”等通常是指流体连通。此外，尽管连通的两种流体可以在混合时交换热，但是这种交换不会被认为与换热器中的热交换相同，尽管这种交换可以在换热器中进行。如本文所使用的，术语“降低……的压力”(或其变型)不涉及相变，而术语“闪蒸”(或其变型)涉及相变，甚至包括部分相变。如本文所用，术语“高”、“中”、“中间”、“热”等是相对于可比较的流而言，如本领域中惯用的。
总体上，参考图1，本公开的第一实施方式的系统包括通常用8表示的混合制冷剂液化系统，包括通常用10表示的多流液化换热器，其具有热端12和冷端14。换热器接收预冷却的天然气进料流16，该天然气进料流16通过与换热器中的制冷流进行热交换而去除热量，从而在冷却或液化通道18中液化。结果，产生了液化天然气(LNG)产物的流20。换热器的多流设计允许将多个流方便、节能地集成到单个换热器中。合适的换热器包括钎焊铝换热器，其可从The Woodlands,Texas的Chart Energy&Chemicals,Inc.购买。这样的板翅式多流换热器提供了在物理上紧凑的另一优点。
包括换热器10的图1的系统可以被配置为执行现有技术中已知的其他气体处理选项。这些处理选项可能需要气流离开或再次进入换热器一次或多次，并且可能包括(例如)天然气液体回收或氮排除。
热量的去除是在换热器中使用混合制冷剂完成的，该混合制冷剂使用液化系统混合制冷剂压缩机系统(通常用22表示)进行处理和调节。混合制冷剂压缩机系统包括第一级吸入鼓24，该吸入鼓24从换热器10的主制冷通道28接收混合的制冷剂蒸气流26。蒸气流在第一级压缩机32(可以是单独的压缩机或单个多级压缩机的一级)中被压缩，然后通过第一级换热器或冷却器34冷却。所得混合制冷剂蒸气流行进到第二级吸入鼓35，然后到第二级压缩机36(可以是单个压缩机或单个多级压缩机的一级)，并且在压缩之后，在第二级换热器或冷却器38中冷却。
如本领域中已知的，第一级和第二级吸入鼓24和35以及下面记录的其余吸入鼓防止液体输送到其随后的压缩机，并且是可选的。
除了液化换热器10，和以下以及在上面通过引用并入的授予Ducote等人的美国专利申请第14/218,949号中描述的相关部件，和混合制冷剂压缩机机系统22外，图1包括通常以40表示的预冷却系统。该预冷却系统包括通常以42a表示的预冷却热换热器(pre-coolwarm heat exchanger)和通常以42b表示的预冷却冷换热器(pro-cool cold heatexchanger)。仅作为示例，热换热器42a和冷换热器42b可以是可购自The Woodlands,Texas的Chart Energy&Chemicals,Inc.的CORE-IN-KETTLE换热器。可替代类型的换热器可以用于热和冷换热器42a和42b，包括但不限于管壳式或热虹吸型换热器。可替代地，预冷却系统可具有单个预冷却换热器或两个以上预冷却换热器。
预冷却系统还包括通常以44表示的压缩机系统，用于处理和调节预冷却系统制冷剂，例如丙烷、丁烷、氨或氯氟烃。尽管本文所述实施方式中的预冷却系统使用丙烷，但是可以使用替代性制冷剂，包括但不限于丁烷、氨或液态氟化烃。
预冷却压缩机系统44包括第一级吸入鼓46，该第一级吸入鼓46接收来自冷换热器42b的丙烷制冷剂蒸气流48，如下面更详细描述的。来自第一级吸入鼓的蒸气流52行进到预冷却压缩机54，并且所得的压缩流行进到预冷却冷凝器56。所得的丙烷制冷剂液体流行进到预冷却的制冷剂蓄积器62。丙烷制冷剂液体物流64从蓄积器行进到膨胀装置66，使得两相流72进入热换热器42a的壳体74。液位传感器76控制膨胀装置66的设置，以便在壳体74内保持适当的液位。
如在此引用的所有膨胀装置的情况一样，膨胀装置66可以是膨胀阀，例如焦耳-汤姆逊阀，或者是包括但不限于涡轮机或节流孔的另一种类型的膨胀装置。
预冷却换热器42a的壳体74容纳接收天然气进料流82的芯部78。热进气换热器的芯部78以及下面仅作为示例讨论的所有此类芯部，可以是钎焊铝换热器(BAHX)或其他换热器类型，例如微通道或焊接板、管或盘管、印刷电路换热器等。天然气流通过芯部78中的丙烷液体制冷剂冷却，冷却的天然气流作为流84离开热换热器42a。在替代实施方式中，在天然气流82比热换热器42a冷的情况下，气体流可以被直接引导到冷换热器42b，如图1中的虚线84′所示。在这样的实施方式中，可以省略芯部78。
热丙烷制冷剂蒸气流86离开预冷却热换热器42a的壳体74，并行进至第二级吸入鼓88和预冷却压缩机54的入口。
丙烷制冷剂液体流作为流92离开热换热器的壳体，并行进至膨胀装置94，使得两相流96进入预冷却冷换热器42b的壳体98。液位传感器102控制膨胀装置94的设置，从而在壳体98内保持适当的液位。
冷换热器42b的壳体98容纳芯部104，该芯部104接收天然气进料流84(或天然气进料流84')。天然气流84被芯部104中的丙烷液体制冷剂进一步冷却(或冷却)，并且冷却的天然气流作为预冷却的流16离开冷换热器42b，并且行进至液化热换热器10的液化通道18。在替代实施方式中，在天然气流82比热换热器42a和42b都冷的情况下，图1的气体流84'可以被直接引导至液化换热器的液化通道。在这样的实施方式中，芯部104也可以被省略。
丙烷制冷剂蒸气流48离开预冷却冷换热器42b的壳体98，并行进至第一级吸入鼓46。
来自第二级压缩机36和混合制冷剂压缩系统的换热器38的高压混合制冷剂流112行进至位于预冷却热换热器42a的壳体74内的芯部114。流过芯114的混合制冷剂被壳体74内的液态丙烷制冷剂冷却，并且所得到的冷却的混合制冷剂流116被引导到位于预冷却冷换热器42b的壳体98内的冷的混合制冷剂芯部118。流过芯部118的混合制冷剂被壳体98内的液态丙烷制冷剂冷却，并且所得到的混合制冷剂(MR)混合相流122被引导至高压蓄积器124。尽管蓄积器鼓被示出为高压蓄积器124，可以使用替代的分离装置，包括但不限于另一种类型的容器、旋风分离器、蒸馏单元、聚结分离器或筛网或叶片式除雾器。这同样适用于本文讨论的其余分离装置或鼓。
高压蒸气制冷剂流126离开蓄积器124的蒸气出口，并行进到换热器10的热端。
高压液态制冷剂流128离开蓄积器124的液体出口，并且还行进到换热器的热端。在换热器10中冷却之后，经由高压液体冷却通道125，其在129闪蒸并行进至高温分离器131。蒸汽流127和液体流133从高温分离器131行进至换热器10的主冷却通道28。
换热器10还经由高压蒸气冷却通道135接收并冷却来自高压蓄积器124的高压蒸气流126并对其进行冷却，以使其部分冷凝。将所得的混合相冷分离器进料流132提供给冷蒸气分离器134，从而产生冷分离器蒸气流136和冷分离器液体流138。
冷分离器蒸气流136在换热器10中经冷分离器蒸气冷却通道141冷却并冷凝成液体流142，通过膨胀装置144闪蒸并引导至低温分离器146以形成低温液体流152和低温蒸气流154，其作为低温制冷剂流被引导到换热器10的主制冷通道28。
冷分离器液体流138在换热器10中经由冷分离器液体冷却通道143冷却，以形成过冷的冷分离器液体160，该过冷的冷分离器液体160在162处闪蒸并被引导至中间温度分离器164。所产生的液体流166和产生的蒸汽流168被引导至换热器10的主制冷通道28。
来自高温分离器131、中间温度分离器164和低温分离器146的组合的制冷剂流提供了用于使换热器10的液化或冷却通道18中的预冷却进气流16液化的制冷，并作为组合的回流制冷剂流26从液化换热器的主制冷通道28离开，所述组合的回流制冷剂流26优选为气相。回流制冷剂流26流到吸入鼓24，这导致蒸汽混合的制冷剂流27，如前所述。
液化天然气流172离开换热器的冷侧，并且可以任选地使用膨胀装置174膨胀，并输送到存储或过程中。
因此，图1的实施方式示出了丙烷(C3)预冷却的混合制冷剂(MR)工艺与位于该工艺的主液化段中的冷蒸汽分离器(CVS)的组合。C3预冷却和MR与CVS的组合导致与没有CVS和设备成本更低的预冷却相比更经济有效的工艺，并且还促进了更高的工厂产能。预冷却和CVS的组合使C3系统能够高效地在显著更高的温度操作，例如仅作为示例，在大约-5℃相对于-35至-40℃的温度，从而减少了丙烷系统成本和功耗。
图1的方法可以与利用CVS的任何MR液化方法一起使用。
应该注意的是，尽管图1示出了预冷却系统40中的两级预冷却，但是也可以选择使用一级或多级预冷却。
此外，尽管图1示出了具有独立的高温、中间温度、低温分离器的MR液化系统8，但是可以将这些分离器中的任何一个组合起来，或者在某些情况下，可以不使用这些分离器。此外，尽管这些分离器被图示为立管，但是可以使用本领域中已知的替代类型的分离器。
除了下面讨论的例外，图2至图4的实施方式具有与参考图1的以上描述相同的混合制冷剂压缩机系统、混合制冷剂液化系统和预冷却压缩机系统的部件和操作，因此使用共同的附图标记表示系统的这些部分和共同的部件。
在图2中示出了本公开的系统的第二实施方式。在该实施方式中，使用两个高压MR蓄积器，而不是图1的单个高压MR蓄积器124。离开MR压缩机系统22的第二级压缩和冷却循环的流182被引导至热预冷却换热器42a的芯部114。芯部114使用壳体74内的液态丙烷制冷剂来冷却流182。所得的冷却的MR流186行进至第一高压MR蓄积器188。所得蒸气MR流192行进至位于预冷却冷换热器42b内的芯部194，在其中通过壳体98内的液态丙烷制冷剂冷却。所得的冷却的流198行进到第二高压MR蓄积器202。
离开第二高压MR蓄积器202的蒸气流204在液化换热器10中经由通道206冷却，并被引导至冷蒸气分离器208。如上所述，关于图1，对离开冷蒸气分离器的蒸气流进行处理。
离开第二高压MR蓄积器202的液体流212在液化换热器10中经由通道214冷却，经由膨胀装置216闪蒸并被引导至中间温度分离器164，在此与来自冷蒸汽分离器208的冷却和闪蒸液体流组合。离开中间温度分离器的蒸汽和液体流被引导至主制冷通道28。
离开第一高压MR蓄积器188的液体MR流行进到位于预冷却冷换热器42b内的芯部196，在其中被壳98中的液态丙烷制冷剂冷却。所得的冷却流218经由通道220在液化换热器10中被冷却，并且所得的冷却的液体流经由膨胀装置222闪蒸并输送至高温分离器131。离开高温分离器的蒸气和液体流被引导至主制冷通道28。
另外，在图2的实施方式中，预冷却系统用于冷却离开MR压缩机系统22的第一级压缩和冷却循环的排出流224。更具体地，预冷却热换热器42a包含芯部226，该芯部226通过级间混合制冷剂入口接收流224，并使用壳74内的丙烷液体制冷剂对其进行冷却。所得冷却的流通过级间混合制冷剂出口离开芯部，并行进至级间或MR低压蓄积器228。所得蒸气流232被引导至MR压缩机系统22的第二级压缩机36的输入。离开MR低压蓄积器228的液体流234被位于冷换热器42b的壳体98内的芯部236接收。所得的冷却的流238在液化换热器10的通道242中被冷却，经由膨胀装置244闪蒸并被引导至换热器10的主制冷通道28。
关于图2的实施方式，应当理解，在第二级压缩之前对MR压缩机系统统22的第一压缩和冷却级的排出流(224)进行预冷却以及在工艺中加入第第一和第二MR高压蓄积器(188和202)是不同的和独立的，并且可以组合或分开地使用。
此外，来自第一压缩和冷却级的预冷却的液体流224可以分别引入MR液化系统8中，如图2所示，或与MR液化系统8的分离器或在没有任何分离器的某些情况下的任何其他制冷流组合。
在图3中示出了本公开的系统的第三实施方式。在该实施方式中，一般用252表示的热混合制冷剂(MR)预冷却系统代替了图1和2的丙烷预冷却系统使用。
MR预冷却系统包括通常以254表示的热MR预冷却换热器，其包括接收天然气进料流82的预冷却通道256。
MR预冷却系统还包括预冷却压缩机系统262，该预冷却压缩机系统262包括第一级吸入鼓264，该第一级吸入鼓264从换热器254的预冷却主制冷通道268接收预冷却MR蒸气流266。来自第一级吸入鼓的蒸气流272行进到预冷却压缩机272的入口，并且所得的压缩流行进到预冷却冷凝器274。来自蓄积器276的蒸汽流可以经由阀278排放，也可以经由第二阀引导至第二级吸入鼓284。来自第二级吸入鼓284的蒸汽流286行进到预冷却压缩机272的入口。
液体预冷却MR流292从蓄积器276通过换热器254的冷却通道294行进，所得冷却的液体流行进到膨胀装置296并闪蒸，所得混合相流进入预冷却冷分离器302。离开换热器的通道294的一部分(或全部)冷却的液体流可根据系统温度和负荷需求使用阀298引导至换热器的二级预冷却制冷通道304。离开二级预冷却制冷通道304的蒸气流306被引导至第二级吸入鼓284。来自预冷却冷分离器302的蒸气和液体预冷却MR流(分别为308和312)都被引导至换热器254的预冷却初级制冷通道268。
流过预冷却换热器254的预冷却通道256的天然气进料流经由换热器的致冷通道268和304预冷却，并且所得的冷却的天然气流314被引导至液化换热器10待液化。
类似于图1和图2的实施方式，液化压缩机系统316具有产生第一级液化MR流318的第一级压缩和冷却循环以及产生第二级液化MR流322的第第二级压缩和冷却循环。液化MR流318和322在预冷却换热器254中经由通道324和326进一步冷却，并且离开通道324的所得的混合相流328行进至液化MR低压蓄积器332，而所得的混合相流334行进至液化MR高压蓄积器336。
液化MR蒸气流338从液化MR低压蓄积器332行进到液化压缩机系统316的第二级吸入鼓342，并将所得的蒸气流引导至第二级压缩和冷却循环。来自液化MR低压蓄积器332的液化MR液体流344在液化换热器350的通道346中被冷却，经由膨胀装置348闪蒸并被引导至换热器350的主制冷通道352。
离开液化MR高压蓄积器336的液化MR蒸气流354在液化换热器350中经由通道356冷却，并被引导到冷蒸气分离器358。离开冷蒸气分离器的蒸气流可以被处理，如以上关于图1所述。
离开液化MR高压蓄积器336的液体流362在液化换热器350中经由通道364冷却，经膨胀装置366闪蒸，并在与来自冷蒸气分离器358的冷却的和闪蒸的液体流组合后被引导至中间温度分离器368(在功能上等同于在中间温度分离器中组合流，如图2所示)。离开中间温度分离器的蒸气和液体流被引导至换热器350的主制冷通道352。
应当注意，关于图3的实施方式，在第二级压缩之前，对液化MR压缩系统316的第一级排放物(318)进行预冷却是可选特征，并且可以结合其他特征使用或根本不使用。另外，在预冷却系统和液化系统中使用的混合制冷剂可以具有相同或不同的组成。
另外，应当注意，图3中以262表示的MR预冷却系统仅是适合MR系统的示例-本领域中已知的其他MR系统和非混合制冷剂系统可以用作替代的预冷却系统。
图4所示的系统的实施方式与图1的实施方式基本相同，包括丙烷预冷却系统，通常以370表示，但预冷却换热器的配置除外。更具体地，在图4所示的系统的实施方式中，预冷却系统370包括通常以372a表示的预冷却热换热器和通常以372b表示的预冷却冷换热器。热和冷换热器372a和372b可以是，仅作为示例，可购自The Woodlands,Texas的ChartEnergy&Chemicals,Inc.的CORE-IN-KETTLE换热器。可以使用替代类型的换热器，包括但不限于管壳式或热虹吸型换热器。
在图4的实施方式中，芯部374(仅作为示例，其可以是钎焊铝换热器(BAHX)或其他换热器类型，例如微通道或焊接板等)延伸通过在热和冷换热器372a和372b的壳体378和382之间的内部头部376，使得作为液化MR压缩机系统386的第二压缩和冷却级的排出流384的工艺流连续通过芯部374。这种布置的好处是，冷却和部分冷凝的工艺流不会受到两相流分布不均(这不利地影响了系统性能)的影响，如果换热器设计是多管芯串联的，则会遇到这种情况，如图1所示。图4的布置降低了工艺的功耗(丙烷系统或液化系统或两者)，这归因于分布不均或简化了设备数量，并降低成本以消除分配不均的影响。
应当注意的是，热和冷换热器372a和372b可以利用任何形状的内部头部376，包括平板。此外，尽管图4示出了丙烷(C3)预冷却的MR工艺，但是图4的实施方式可以与利用至少两种沸腾的制冷剂冷却步骤的任何工艺一起使用。另外，尽管将丙烷(C3)描述为图4的预冷却系统的冷却剂，但是可以使用任何制冷剂，例如但不限于丁烷、氨或液态氟化烃等。尽管图4的系统示出了两级的预冷却，但是可以使用两个或更多个级的冷却。另外，尽管图4示出了单独的进料交换器，但是该进料交换器可以与MR交换器组合。
在图5所示的实施方式中，通常以402表示的冷水冷却系统用于预冷却液化MR压缩机系统406的第二压缩和冷却级的排出物流404。更具体地，水经由泵412被泵送到冷却剂换热器414。换热器还接收MR排出物流404并对其进行冷却。冷水是在预冷却制冷剂系统中冷却的水或水/乙二醇混合物，该预冷却制冷剂系统可以是但不限于机械制冷机或吸附制冷机或热电制冷机或热声制冷机，并且始终比通过空气冷却或水蒸发冷却可达到的温度低。
冷却的MR流416然后流到高压蓄积器124，所产生的液体和蒸汽流被导引至MR液化系统408的液化换热器420，如先前的实施方式中所述。
尽管在图5中示出了单个制冷机换热器414，但是可以替代地使用并联或串联的多个制冷机换热器。
如在先前的实施方式中，液化MR压缩机系统将制冷剂提供给包括冷蒸气分离器(CVS)410的MR液化系统408。带有冷水冷却系统的预冷却和MR与CVS的组合导致与不带CVS的预冷却相比，这种方法效率更高，而且设备成本更低，并且还有助于提高工厂产能。预冷却和CVS的组合使冷水冷却系统可以在显著更高的温度操作，大约为-5℃相对于-35至-40℃。它还允许将制冷机设备放置在远离含烃设备的位置，从而降低系统成本并提供规划方案的灵活性。该方法可以与任何利用CVS的MR液化方法一起使用。
尽管图5示出了冷水预冷却的MR方法，但是可以使用任何冷的冷却液体，例如但不限于氨、水、水乙二醇混合物、溴化锂溶液、液态氟化烃、液态烃等。另外，尽管图5示出了用于预冷却系统换热器414的管壳式换热器，但是可以使用任何类型的换热器。此外，尽管图5示出了分开的热、中间和低温立管422、424和426，但是这些中的任何可以组合，或者在某些情况下，可以省去立管。尽管未明确示出，但冷水冷却系统还可用于冷却进料气和/或冷却第一级排放物(如图2所示)，或为燃气轮机驱动器的涡轮机进气提供冷却或冷却多个液化系统。
本主题的多个方面可以在下面描述和要求保护的方法、设备和系统中单独或一起实施。这些方面可以单独使用，也可以与本文中描述的主题的其他方面结合使用，并且这些方面的描述在一起并不旨在排除单独使用这些方面，或排除对这些方面的单独要求，或排除对这些方面以不同的组合要求，如在所附的权利要求书中阐述。
尽管已经示出和描述了本发明的优选实施方式，但是对于本领域技术人员而言显而易见的是，在不脱离本发明的精神的情况下可以在其中进行改变和修改，本发明的范围由所附权利要求确定。

Claims (30)

1.一种用于用预冷却制冷剂和混合制冷剂冷却气体的系统，包括：
a.预冷却换热器，所述预冷却换热器具有适于接收进料气流的进料气体入口和进料气体出口，预冷却制冷剂入口和预冷却制冷剂出口，以及液化混合制冷剂入口和液化混合制冷剂出口，所述预冷却换热器被配置为使用预冷却制冷剂来冷却在进料气体入口和出口之间通过预冷却换热器的进料气体，并冷却在液化混合制冷剂入口和出口之间通过预冷却换热器的液化混合制冷剂；
b.预冷却压缩机系统，包括：
i)预冷却压缩机，所述预冷却压缩机具有与预冷却换热器的预冷却制冷剂出口流体连通的入口；
ii)预冷却冷凝器，所述预冷却冷凝器具有与预冷却压缩机的出口流体连通的入口，所述预冷却冷凝器还具有与预冷却换热器的预冷却制冷剂入口流体连通的出口；
c.液化换热器，所述液化换热器包括与预冷却换热器的进料气体出口流体连通的液化通道、主制冷通道、高压蒸气冷却通道和冷分离器蒸气冷却通道，其中，该冷分离器蒸气冷却通道具有与主制冷通道流体连通的出口；
d.混合制冷剂压缩系统，包括：
i)混合制冷剂压缩机，所述混合制冷剂压缩机具有与主制冷通道的出口流体连通的入口；
ii)混合制冷剂冷却器，所述混合制冷剂冷却器具有与混合制冷剂压缩机的出口流体连通的入口，所述混合制冷剂冷却器还具有与预冷却换热器的液化混合制冷剂入口流体连通的出口，
iii)高压蓄积器，所述高压蓄积器具有与预冷却换热器的液化混合制冷剂出口流体连通的入口和与液化换热器的高压蒸气冷却通道的入口流体连通的蒸气出口；
e.冷蒸气分离器，所述冷蒸气分离器具有与液化换热器的高压蒸气冷却通道的出口流体连通的入口，与液化换热器的冷分离器蒸气冷却通道的入口流体连通的蒸气出口，和与液化换热器的主制冷通道流体连通的液体出口。
2.根据权利要求1所述的系统，其中所述预冷却换热器包括热预冷却换热器和冷预冷却换热器。
3.根据权利要求2所述的系统，其中所述热预冷却换热器和所述冷预冷却换热器中的每个均包括接收预冷却制冷剂的壳体，以及所述热预冷却换热器和所述冷预冷却换热器中的至少一个包括接收进料气体的进料气体芯部。
4.根据权利要求2所述的系统，其中所述热预冷却换热器和所述冷预冷却换热器中的每个包括液化混合制冷剂芯部，所述液化混合制冷剂芯部被配置为冷却在液化混合制冷剂入口和出口之间通过预冷却换热器的液化混合制冷剂。
5.根据权利要求4所述的系统，其中单个液化混合制冷剂芯部在热和冷预冷却换热器两者的壳体内延伸，并且被配置为冷却在液化混合制冷剂入口和出口之间通过预冷却换热器的液化混合制冷剂。
6.根据权利要求5所述的系统，其中内部头部在热和冷预冷却换热器的壳体的内部空间之间延伸，并且所述单个液化混合制冷剂芯部延伸穿过所述内部头部。
7.根据权利要求1所述的系统，其中所述混合制冷剂压缩系统还包括混合制冷剂第二压缩机或压缩级，所述第二压缩机或压缩级具有与混合制冷剂冷却器的出口流体连通的入口，如果第二混合制冷剂冷却器与所述混合制冷剂第二压缩机或压缩级的出口流体连通则具有入口，所述第二冷却器的出口与预冷却换热器的液化混合制冷剂入口流体连通。
8.根据权利要求7所述的系统，其中所述预冷却换热器包括级间混合制冷剂入口和级间混合制冷剂出口，并且其中所述混合制冷剂压缩机具有与预冷却换热器的级间混合制冷剂入口流体连通的出口，且预冷却换热器的级间混合制冷剂出口与级间蓄积器流体连通，所述级间蓄积器具有与第二压缩机或第二压缩级的入口流体连通的蒸气出口和与液化换热器的主制冷通道流体连通的液体出口。
9.根据权利要求1所述的系统，其中所述高压蓄积器包括液体出口，并且所述液化换热器还包括高压液体冷却通道，所述高压液体冷却通道具有与所述高压蓄积器的液体出口流体连通的入口和与所述液化换热器的主制冷通道流体连通的出口。
10.根据权利要求1所述的系统，其中所述预冷却制冷剂是丙烷、丁烷、氨或氯氟烃。
11.根据权利要求1所述的系统，其中所述预冷却制冷剂是混合制冷剂。
12.根据权利要求11所述的系统，其中所述预冷却制冷剂换热器是板翅式换热器。
13.一种用于冷却进料气流的方法，包括以下步骤：
a.使用第一制冷剂在预冷却换热器中预冷却进料气流以形成预冷却的进料气流；
b.通过以下方式进一步冷却该预冷却的进料气流：
i)在预冷却换热器中冷却高压第二制冷剂流以形成冷却的高压第二制冷剂流，
ii)分离冷却的高压第二制冷剂流以形成高压蒸气流和高压液体流；
iii)在液化换热器中冷却高压蒸汽流以形成混合相流；
iv)用冷蒸汽分离器分离混合相流以形成冷分离器蒸汽流和冷分离器液体流；
v)使用第二制冷剂在液化换热器中冷凝冷分离器蒸气流并闪蒸，以形成低温制冷剂流；
vi)引导低温制冷剂流到液化换热器；
vii)将高压液体流过冷以形成过冷的高压液体流，并在液化换热器中与低温制冷剂流合并；
viii)将冷分离器液体流过冷以形成过冷的冷分离器液体流，并在液化换热器中与低温制冷剂流合并；以及
ix)使液化换热器中的预冷却的气流与低温制冷剂流热接触。
14.根据权利要求13所述的方法，其中所述高压液体流和所述冷分离器液体流在液化换热器中被过冷。
15.根据权利要求13所述的方法，其中步骤b还包括以下步骤：在预冷却换热器中冷却低压混合制冷剂流，将冷却的低压混合制冷剂流分离以形成低压混合制冷剂蒸气流和低压混合制冷剂液体流，压缩低压混合制冷剂蒸汽流以形成高压混合制冷剂蒸汽，然后冷却高压混合制冷剂流以形成冷却的高压混合制冷剂流，并将低压混合制冷剂液体流引导至液化换热器。
16.根据权利要求15所述的方法，其中所述高压混合制冷剂流在预冷却换热器中被冷却以形成冷却的高压混合制冷剂流。
17.根据权利要求15所述的方法，其中所述高压混合制冷剂流在预冷却换热器和液化换热器两者中被冷却以形成冷却的高压混合制冷剂流。
18.根据权利要求13所述的方法，其中所述预冷却制冷剂是丙烷、丁烷、氨或氯氟烃。
19.根据权利要求13所述的方法，其中所述预冷却制冷剂是混合制冷剂。
20.根据权利要求13所述的方法，其中步骤a包括使用热预冷却换热器的第一预冷却级和使用冷预冷却换热器的第二预冷却级。
21.一种用于用混合制冷剂冷却进料气体的系统，包括：
a.预冷却换热器，所述预冷却换热器具有被配置为接收预冷却制冷剂流的预冷却制冷剂入口和预冷却制冷剂出口，以及液化混合制冷剂入口和液化混合制冷剂出口，所述预冷却换热器被配置为使用预冷却制冷剂冷却在液化混合制冷剂入口和出口之间通过预冷却换热器的液化混合制冷剂；
b.液化换热器，所述液化换热器包括被配置为接收进料气流的液化通道、主制冷通道、高压蒸气冷却通道和冷分离器蒸气冷却通道，其中所述冷分离器蒸气冷却通道具有与所述主制冷通道流体连通的出口；
c.混合制冷剂压缩系统，包括：
i)混合制冷剂压缩机，所述混合制冷剂压缩机具有与主制冷通道的出口流体连通的入口；
ii)混合制冷剂冷却器，所述混合制冷剂冷却器具有与混合制冷剂压缩机的出口流体连通的入口，所述混合制冷剂冷却器具有与预冷却换热器的液化混合制冷剂入口流体连通的出口，
iii)高压蓄积器，所述高压蓄积器具有与预冷却换热器的液化混合制冷剂出口流体连通的入口和与液化换热器的高压蒸气冷却通道的入口流体连通的蒸气出口；
d.冷蒸气分离器，所述冷蒸气分离器具有与液化换热器的高压蒸气冷却通道的出口流体连通的入口，与液化换热器的冷分离器蒸气冷却通道的入口流体连通的蒸气出口，和与液化换热器的主制冷通道流体连通的液体出口。
22.根据权利要求21所述的系统，其中所述预冷却换热器还包括适于接收进料气流的进料气体入口和进料气体出口，并且所述预冷却换热器被配置为使用预冷却制冷剂冷却在进料气体入口和进料气体出口之间通过预冷却换热器的进料气体。
23.根据权利要求21所述的系统，其中所述预冷却换热器包括串联或并联连接的多个换热器。
24.根据权利要求21所述的系统，其中所述预冷却制冷剂选自丙烷、丁烷、氨、水、水乙二醇混合物、溴化锂溶液、液态氟化烃和液态烃。
25.根据权利要求21所述的系统，还包括泵，所述泵被配置为将预冷却的制冷剂流泵送到预冷却换热器的预冷却制冷剂入口。
26.根据权利要求21所述的系统，还包括预冷却制冷剂系统，所述预冷却制冷剂系统选自机械制冷机、吸附制冷机、热电制冷机和热声制冷机，其中所述预冷却制冷剂系统被配置为冷却预冷却制冷剂。
27.一种用于冷却进料气流的方法，包括以下步骤：
a.将进料气流引导至液化换热器；
b.在预冷却换热器中冷却高压混合制冷剂流以形成冷却的高压混合制冷剂流；
c.通过以下方式在液化换热器中冷却进料气流：
i)分离冷却的高压混合制冷剂流以形成高压蒸气流和高压液体流；
ii)在液化换热器中冷却高压蒸气流以形成混合相流；
iii)用冷蒸气分离器分离混合相流以形成冷分离器蒸气流和冷分离器液体流；
iv)在液化换热器中冷凝冷分离器蒸气流并闪蒸，以形成低温制冷剂流；
v)将低温制冷剂流引导至液化换热器；
vi)对在液化换热器中的高压液体流进行过冷以形成过冷的高压液体流，并与液化换热器中的低温制冷剂流合并，
vii)对冷分离器液体流进行过冷以形成过冷的冷分离器液体流，并在液化换热器中与低温制冷剂流合并；和
viii)使液化换热器中的气体流与低温制冷剂流热接触。
28.根据权利要求27所述的方法，还包括在步骤a之前在预冷却换热器中预冷却进料气流的步骤。
29.根据权利要求27所述的方法，其中步骤b使用预冷却制冷剂进行，该预冷却制冷剂使用选自机械制冷机、吸附制冷机、热电制冷机和热声制冷机的预冷却制冷剂系统冷却。
30.根据权利要求29所述的方法，其中将预冷却制冷剂冷却至比通过空气冷却或水蒸发冷却所能达到的温度更低的温度。
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