EP2426451A1 - Verfahren und Vorrichtung zur Kühlung eines gasförmigen Kohlenwasserstoffstroms - Google Patents

Verfahren und Vorrichtung zur Kühlung eines gasförmigen Kohlenwasserstoffstroms Download PDF

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Publication number
EP2426451A1
EP2426451A1 EP10175360A EP10175360A EP2426451A1 EP 2426451 A1 EP2426451 A1 EP 2426451A1 EP 10175360 A EP10175360 A EP 10175360A EP 10175360 A EP10175360 A EP 10175360A EP 2426451 A1 EP2426451 A1 EP 2426451A1
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EP
European Patent Office
Prior art keywords
refrigerant
compressor
heat exchanger
stream
drive shaft
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10175360A
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English (en)
French (fr)
Inventor
Carolus Antonius Cornelis Van De Lisdonk
Wouter Jan Meiring
Irina Tanaeva
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Shell Internationale Research Maatschappij BV
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Shell Internationale Research Maatschappij BV
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Priority to EP10175360A priority Critical patent/EP2426451A1/de
Priority to PCT/EP2011/052419 priority patent/WO2012031783A2/en
Publication of EP2426451A1 publication Critical patent/EP2426451A1/de
Withdrawn legal-status Critical Current

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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
    • F25J1/0032—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"
    • F25J1/0042—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 liquid expansion with extraction of work
    • 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
    • F25J1/0047—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
    • F25J1/0055—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 originating from an incorporated cascade
    • 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
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0211—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle
    • F25J1/0214—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle
    • 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
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0228—Coupling of the liquefaction unit to other units or processes, so-called integrated processes
    • F25J1/0235—Heat exchange integration
    • F25J1/0236—Heat exchange integration providing refrigeration for different processes treating not the same feed 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
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0228—Coupling of the liquefaction unit to other units or processes, so-called integrated processes
    • F25J1/0235—Heat exchange integration
    • F25J1/0237—Heat exchange integration integrating refrigeration provided for liquefaction and purification/treatment of the gas to be liquefied, e.g. heavy hydrocarbon removal from natural gas
    • F25J1/0238—Purification or treatment step is integrated within one refrigeration cycle only, i.e. the same or single refrigeration cycle provides feed gas cooling (if present) and overhead gas cooling
    • 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
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0244—Operation; Control and regulation; Instrumentation
    • F25J1/0245—Different modes, i.e. 'runs', of operation; Process control
    • F25J1/0249—Controlling refrigerant inventory, i.e. composition or quantity
    • 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
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0244—Operation; Control and regulation; Instrumentation
    • F25J1/0252—Control strategy, e.g. advanced process control or dynamic modeling
    • 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
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0257—Construction and layout of liquefaction equipments, e.g. valves, machines
    • F25J1/0262—Details of the cold heat exchange system
    • 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
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0281—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc. characterised by the type of prime driver, e.g. hot gas expander
    • F25J1/0283—Gas turbine as the prime mechanical driver
    • 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
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0292—Refrigerant compression by cold or cryogenic suction of the refrigerant 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
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0294—Multiple compressor casings/strings in parallel, e.g. split arrangement
    • 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
    • F25J2220/00—Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60—Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/62—Separating low boiling components, e.g. He, H2, N2, Air
    • 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
    • F25J2220/00—Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60—Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/64—Separating heavy hydrocarbons, e.g. NGL, LPG, C4+ hydrocarbons or heavy condensates in general

Definitions

  • the present invention relates to a method of cooling a gaseous hydrocarbon stream to produce a liquefied hydrocarbon stream.
  • a common hydrocarbon stream to be liquefied is natural gas.
  • processes that can be used to liquefy natural gas. Many of these processes involve two or more successive refrigerant cycles, often in a cascaded arrangement, for progressively lowering the temperature of the natural gas.
  • Such refrigeration cycles typically comprise refrigerant compressors to recompress the refrigerants in the respective cycles after they have absorbed heat from the natural gas.
  • the refrigerant compressors may be driven by gas turbines.
  • gas turbines comprise an air compressor to compress a stream of inlet air. It is a known characteristic of gas turbines that the power that they can generate decreases with increasing ambient temperature. The decrease in generated power may be mitigated at least in part by chilling the inlet air to the gas turbine.
  • US patent 6,324,867 to Exxon Mobil discloses a natural gas liquefaction system and process wherein a first gas turbine drives a first compressor which compresses and circulates a first refrigerant in a first closed refrigerant circuit, and a second gas turbine drives a second compressor which compresses and circulates a second refrigerant in a second closed refrigerant circuit, and wherein natural gas is progressively cooled against the first and second refrigerants.
  • a coolant e.g. water
  • the coolant is cooled with the first refrigerant taken from the first refrigerant circuit in the system which, in turn, is used to initially cool the natural gas which is to be liquefied.
  • a drawback of this method is therefore, that the power that needs to be installed to drive the first refrigerant circuit corresponds to a significant overcapacity at average ambient design conditions. This leads to an inefficient liquefaction process in which the pre-cooling circuit capacity is underused at average ambient temperature conditions.
  • the present invention provides a method of cooling a gaseous hydrocarbon stream to produce a liquefied hydrocarbon stream, comprising:
  • the invention further provides an apparatus for cooling a gaseous hydrocarbon stream to produce a liquefied hydrocarbon stream, comprising:
  • Fig. 1 schematically shows an apparatus and method for cooling and liquefying a hydrocarbon stream according to an embodiment of the invention
  • Fig. 2 schematically shows an example of a chilling refrigerant circuit for actively chilling of the coolant fluid
  • Fig. 3 schematically shows a detailed drive scheme that can be used in the invention
  • Fig. 4 schematically shows a detailed alternative drive scheme that can be used in the invention
  • FIG. 5 schematically shows yet another detailed alternative drive scheme that can be used in the invention.
  • Fig. 6 schematically shows a gas turbine employing intercooling chilling that can be used in the invention.
  • any excess power that is not needed by the first refrigerant circuit can be used by the second refrigerant circuit thereby avoiding over capacity of installed drive power at any ambient temperature (including at, above or below average ambient design temperature).
  • the power available from the single gas turbine is automatically divided in accordance with the demand of each compressor in the first and second compressor trains for each ambient temperature, while the strong degradation of gas turbine output with temperature can be reduced or even avoided.
  • the resulting liquefaction apparatus and process is therefore robust against variations in ambient temperature. It will demonstrate a considerably flatter liquefied hydrocarbon (e.g. LNG) production profile over a larger ambient temperature range. It will, as a result, lead to a much better capital efficiency of the installed equipment.
  • LNG liquefied hydrocarbon
  • common drive shaft is not intended to be limited to a unitary shaft: it is intended to at least cover a composite shaft formed out of two or more interconnected parts as well.
  • chilled coolant is understood to be a fluid that has a temperature lower, preferably by at least 5 °C, than that of the ambient air temperature.
  • the chilled coolant can be prepared by actively chilling the fluid, using refrigeration duty from any refrigerant from any type of refrigerant circuit, or from any cold stream including any cold stream that is available in the liquefaction process.
  • FIG. 1 there is shown an apparatus for cooling a gaseous hydrocarbon stream 10 to produce a liquefied hydrocarbon stream 20.
  • the apparatus comprises a first refrigerant circuit 100 and a second refrigerant circuit 200.
  • the first refrigerant circuit 100 comprises a system of lines containing a first refrigerant that can be cycled through the circuit.
  • the second refrigerant circuit comprises a separate system of lines, containing a second refrigerant that can be cycled through the second refrigerant circuit 200. These first and second refrigerant circuits may be separate from each other at least in the sense that there is no fluid communication between them.
  • the first refrigerant may have a composition, as determined immediately downstream of the first compressor train 110, that is different from the composition of the second refrigerant, as determined immediately downstream of the second compressor train 210.
  • the composition of the second refrigerant is preferably adapted for further cooling from the intermediate temperature to the final temperature.
  • the first refrigerant circuit 100 comprises a first compressor train 110 comprising one or more first compressors on a common drive shaft 215.
  • the first compressor train 110 is arranged to compress at least a first part of the first refrigerant in line 130.
  • the refrigerant in line 130 may have passed through an optional suction drum 132 to ensure that no liquid constituents are fed into any compressor of the first compressor train 110.
  • the second refrigerant circuit 200 comprises a second compressor train 210 comprising one or more second compressors on the common drive shaft 215.
  • the second compressor train 210 is arranged to compress at least a first part of the second refrigerant in line 230.
  • the refrigerant in line 230 may have passed through an optional suction drum 232 to ensure that no liquid constituents are fed into any of the second compressors in the second compressor train 210.
  • An output shaft 115 of one single gas turbine 220 is drivingly connected to the common drive shaft 215 by which all of the first compressors of the first compressor train 110 and all of the second compressors of the second compressor train 210 are driven.
  • the single gas turbine 220 comprises a combustion air inlet system 226, through which a first inlet air stream 225, obtained from an air source being at an ambient temperature, can pass to the single gas turbine 220 for combustion therein.
  • the combustion air inlet system 226 comprises an inlet air cooling heat exchanger 227 in the form of an indirect heat exchanger wherein the first inlet air stream 225 can be heat exchanged against a stream of a chilled coolant 320.
  • the temperature of the air source is what is considered to be “ambient temperature” in the present context.
  • the range of temperatures that typically constitutes “ambient temperature” varies with the geographic location where the apparatus and method would be employed. However the invention is particularly beneficial if the ambient temperature is between about 5 °C and 60 °C, preferably between 10 °C and 60 °C, more preferably between 25 °C and 60 °C.
  • the inlet air cooling heat exchanger 227 is arranged in the first inlet air stream 225 to cool and chill the first inlet air streams.
  • the temperature of the first inlet air stream 225 is lowered to a temperature of lower than at least 5 °C below the ambient temperature.
  • one or more filters may be provided in the first inlet air stream 225 (not shown) to filter the air before it is compressed in the single gas turbine 220.
  • a separator (not shown), such as a vertical vane type separator, and associated drain facilities may be provided downstream of the inlet air cooling heat exchanger 227 to remove moisture that may develop during the cooling of the inlet air stream. Drain facilities may also be provided in the air cooling heat exchangers 227 to drain off moisture from this heat exchanger.
  • One or more first heat exchangers 140a, 140b is/are provided. They are fluidly connected to the first compressor train 110 via a first low pressure path (generally indicated by 101) and a first high pressure path (generally indicated by 102).
  • low pressure path and “high pressure path” are intended as identifiers for various paths in the process scheme and apparatus, and not intented to define a pressure value.
  • low pressure and high pressure may be interpreted relative to each other, whereby the pressure in the low pressure path in a selected refrigerant circuit is lower than the pressure in the high pressure path of that selected refrigerant circuit.
  • the first low pressure path 101 is arranged to convey at least a first part of the first refrigerant from at least one first heat exchanger 140a, 140b to the first compressor train 110. It is free from any other compressor; in any case it is free from any other compressor that is not on the common drive shaft 215.
  • the first low pressure path 101 consists of a line 134a, 134b from at least one of the first heat exchangers 140a, 140b to an optional first suction drum 132 and a first suction line 130 from the optional suction drum 132 to an inlet of the first compressor train 110.
  • the first high pressure path 102 is arranged to convey at least the first part of the first refrigerant from the first compressor train 110 to the at least one first heat exchanger 140a, 140b. It is free from any other compressor; in any case it is free from any other compressor that is not on the common drive shaft 215.
  • the first high pressure path 102 consists of line 119 which passes through one or more first ambient coolers 117.
  • one or more second heat exchangers is/are provided.
  • the second low pressure path 103 is arranged to convey at least a first part of the second refrigerant from the second heat exchanger 260 to the second compressor train 210. It is free from any other compressor; in any case it is free from any other compressor that is not on the common drive shaft 215.
  • the second low pressure path 103 consists of line 265 connecting the second heat exchanger 260 to an optional second suction drum 232 and a second suction line 230 from the optional second suction drum 232 to an inlet of the second compressor train 210.
  • the second high pressure path 104 is arranged to convey at least the first part of the second refrigerant from the second compressor train 210 to the second heat exchanger 260. It is free from any other compressor; in any case it is free from any other compressor that is not on the common drive shaft 215.
  • the second low pressure path 104 consists of line 219 which passes through one or more second ambient coolers 217 and connects the second heat exchanger 260 to one or more of the first heat exchangers 140b; and a line 240 that connects the one or more first heat exchangers 140b to an optional refrigerant gas/liquid separator 250, and lines 252 and 254 each connecting the optional refrigerant gas/liquid separator 250 with the second heat exchanger 260.
  • a hydrocarbon path (generally indicated by 105) is present, which connects a source of a gaseous hydrocarbon stream, in this case line 10, to a discharge channel for a liquefied hydrocarbon stream, in this case represented by line 20. It passes through the at least one of the one or more first heat exchangers (140a), in indirect heat exchanging arrangement with the first refrigerant, and through the second heat exchanger 260, in indirect heat exchanging arrangement with the second refrigerant.
  • first heat exchangers 140a
  • the hydrocarbon path 105 consists of inlet line 10, a connected to a warm tube or warm tube bundle 141a of the first heat exchanger 140a, optional withdrawing means in the form of an optional gas/liquid separator 50 connected to the first heat exchanger 140a via a line 40, a vapour line 60 connecting the optional gas/liquid separator to line 80, which leads to the second heat exchanger 260.
  • the suction inlet of the second compressor train 210 is connected to a second refrigerant outlet 262 of the second heat exchanger 260 via the line 230 and the optional suction drum 232.
  • the second heat exchanger 260 is one of one or more second heat exchangers, arranged to receive and liquefy a cooled hydrocarbon stream in line 80, so as to provide a liquefied hydrocarbon stream 20.
  • the outlet of the second compressor train 210 is connected to line 219 that is provided with one or more second ambient coolers 217.
  • the outlet of the first compressor train 110 is connected to one or more first heat exchangers 140a, 140b via the refrigerant line 119. Upstream of the one or more first heat exchangers 140a, 140b, one or more first ambient coolers 117 are provided in the refrigerant line 119. Pressure reduction devices 142a, 142b are provided upstream of the one or more first heat exchangers 140a, 140b to regulate the pressure in these heat exchangers.
  • the one or more heat exchangers 140a, 140b have refrigerant outlets that are connected to the first refrigerant compressor train 110 via lines 134a and 134b. In the embodiment shown in Figure 1 , the lines 134a and 134b connect to the first refrigerant compressor train 110 via the optional first suction drum 132.
  • two of the one or more heat exchangers 140a, 140b are arranged in a parallel configuration, and each have a single warm tube or warm tube bundle 141a, 141b.
  • the one or more first heat exchangers and the one or more second heat exchangers may be provided in the form of a combined heat exchanger unit, for instance in the form of a plate-type heat exchanger such as a plate-fin heat exchanger and/or a printed circuit heat exchanger, optionally in a cold box.
  • the first heat exchanger(s) and the second heat exchanger can be separate sections in the combined heat exchanger unit.
  • An example of such a combined heat exchanger unit employed as single thermal exchange assembly to support cooling and liquefaction of gases by refrigeration using multiple refrigerant circuits is published in US Patent 4,181,174 .
  • One of the one or more first heat exchangers is arranged to receive and cool the gaseous hydrocarbon stream 10. This one will be referred to as first hydrocarbon feed heat exchanger 140a.
  • first hydrocarbon feed heat exchanger 140a there are one or more other first heat exchangers arranged in the hydrocarbon feed line 10 upstream of the first hydrocarbon feed heat exchanger 140a, to be operated at higher pressures than the first hydrocarbon feed heat exchanger 140a.
  • Line 40 downstream of the first hydrocarbon feed heat exchanger may be connected directly to line 80 that connects to the second heat exchanger 260 in order to provide the cooled hydrocarbon stream to line 80.
  • the line 40 is connected to withdrawing means in the form of an optional gas/liquid separator 50 that is provided to receive the hydrocarbon stream 40 at approximately the hydrocarbon feed gas pressure, after it has passed through the first hydrocarbon feed heat exchanger 140a.
  • the optional gas/liquid separator 50 may suitably be a natural gas liquids extraction column and/or employed for the purpose of extraction of natural gas liquids.
  • Typical examples of extraction columns used in a hydrocarbon liquefaction line-up for extraction of natural gas liquids include a simple gas/liquid phase separator vessel, or a more advanced distillation column such as a scrub column and a natural gas liquids extraction column, which typically operates at a lower pressure than a scrub column.
  • the optional gas/liquid separator is provided in the form of a scrub column.
  • the optional gas/liquid separator 50 has an overhead outlet for discharging a vaporous overhead stream 60 and a bottom outlet for discharging a liquid bottom stream 70.
  • Line 60 for the vaporous overhead stream 60 may be connected to line 80 to provide the cooled hydrocarbon stream in line 80.
  • a splitter 63 may be provided in line 60 or line 80, to draw off a fuel gas stream 62 from the vaporous overhead stream 60.
  • the liquid bottom stream 70 which may typically comprise C 2 to C 4 constituents as well as C 5 +, may be connected to an optional fractionation train 75 to fractionate at least a part of the bottom stream 70 into fractionation product streams 76.
  • a bottom stream heat exchanger 73 may optionally be provided to add heat to at least a part of the bottom stream 70.
  • Part of the bottom stream 70 may be fed back to the optional gas/liquid separator 50 as a reboiled stream 74, preferably comprising, more preferably consisting of, vapour to function as stripping vapour in the optional gas/liquid separator 50.
  • second first refrigerant heat exchanger 140b Another one of the one or more first heat exchangers, which will hereinafter be referenced as second first refrigerant heat exchanger 140b, is arranged to receive the second refrigerant from line 219.
  • line 219 is connected to the warm tube (or warm tube bundle) 141b.
  • first heat exchangers arranged in the second refrigerant line 219 upstream of the second first refrigerant heat exchanger 140b, to be operated at higher pressures than the second first refrigerant heat exchanger 140b.
  • an optional refrigerant gas/liquid separator 250 is provided downstream of the second first refrigerant heat exchanger to receive the cooled second refrigerant stream 240 after it has passed through the second first refrigerant heat exchanger 140b and separate it into cooled at least by heat exchanging with said first refrigerant from the first refrigerant circuit.
  • the second refrigerant from line 219 may be passed through the same one or more first heat exchangers as the hydrocarbon stream instead of passing these streams each through pairs of individual first heat exchangers as shown in Fig. 1 .
  • the cooled hydrocarbon stream 80 and the second refrigerant stream 240 are connected to the one or more second heat exchangers 260, to further cool and liquefy the cooled hydrocarbon stream 80 to obtain at least an intermediate liquefied hydrocarbon stream 90 and an at least partially or fully evaporated refrigerant stream 265 at the outlet 262.
  • Line 90 may be connected to depressurizing equipment comprising optional phase separation equipment to separate flash vapour from the remaining liquid.
  • depressurizing equipment is here embodied as one or more expansion devices 97 to produce a depressurized stream 98 followed by a phase separator 99.
  • the expansion devices may be embodied in the form of an isentropic expander such as work-expander 95 which may be provided in the form of a turbine, and/or an isenthalpic expander such as a Joule-Thomson valve 96.
  • the isenthalpic expander 96 is suitably be provided downstream of the isentropic expander 95.
  • the apparatus further comprises a coolant circuit 300, wherein a coolant fluid can be circulated for chilling the first inlet air stream 225.
  • a storage tank 310 wherein the coolant fluid can be stored.
  • the coolant fluid is preferably a liquid and/or inflammable for safety reasons. Suitable coolants include water and brine, possibly admixed with an anti-freezant such as a glycol and/or a corrosion inhibitor.
  • the coolant circuit 300 further comprises means for actively chilling the coolant fluid to provide a chilled coolant 320.
  • a chiller 325 is provided for that purpose.
  • the chiller 325 is arranged to receive a cold fluid CF capable of withdrawing heat from the coolant fluid and thereby to provide the chilled coolant in line 320.
  • the cold fluid CF can be obtained from numerous sources, as will be further illustrated hereinbelow.
  • the cold fluid CF may be obtained from a single source or it may comprise a mixture of fluids from two or more sources.
  • a separate chiller is provided for each source of cold fluid.
  • a pump 305 is provided.
  • the pump may be provided anywhere in the circuit.
  • the pump 305 has its low pressure inlet connected to the storage tank 310 via line 315 and its high-pressure outlet connected to the chiller 325.
  • the first inlet air cooling heat exchanger 227 is arranged in line 320 to cool the first inlet air stream 225 with the chilled coolant 320.
  • a flow control valve 339 may optionally be provided in line 320.
  • the apparatus works as follows.
  • the single gas turbine 220 takes in an inlet air stream 225 and a fuel stream (not shown) and provides mechanical power on the common drive shaft 215.
  • the drive shaft is mechanically coupled to each compressor in the respective first and second compressor trains 110, 210, and thus all compressors in these first and second compressor trains, are driven by the single gas turbine 220.
  • the first refrigerant in the first refrigerant circuit 100 is compressed in the first compressor train 110, cooled against ambient in the one or more coolers first 117 and distributed over one or more first heat exchangers 140a, 140b. Between the first compressor train 110 and the one or more first heat exchangers 140a, 140b the first refrigerant does not pass through any other compressor that is not on the common drive shaft. Typically, cooling of the first refrigerant in the first ambient cooler(s) 117 causes it to partially, preferably fully, condense. Upstream of each of the first heat exchangers the first refrigerant the pressure is let down in the reduction devices 142a, 142b.
  • the first refrigerant is then allowed to evaporate in the first heat exchangers 140a, 140b by drawing heat from the warm tubes or tube bundles 141a, 141b.
  • the evaporated first refrigerant is passed back to the first compressor train 110, without passing through any other compressor that is not on the common drive shaft.
  • the second refrigerant in the second refrigerant circuit 200 after having been passed from the second heat exchanger 260 to the second compressor train 210 without passing through any other compressor that is not on the common drive shaft 215, is compressed in the second compressor train 210, cooled against ambient in one or more second ambient coolers 217 and then further cooled in one or more of the first heat exchangers.
  • the further cooling of the second refrigerant is achieved by passing it through warm tube 141b in second first refrigerant heat exchanger 140b where it is cooled at least by heat exchanging with said first refrigerant, to produce a partially condensed second refrigerant stream 240.
  • the partially condensed second refrigerant stream 240 is separated into vapour and liquid second refrigerant phases 252 respectively 254. These streams are then condensed and sub-cooled, respectively subcooled, in the one or more second heat exchangers 260 in a manner well known in the art.
  • the second refrigerant coming from the second compressor train 210 is passed from the second compressor train 210 to the second heat exchanger 260 without passing through any other compressor that is not on the common drive shaft 215.
  • the liquefied hydrocarbon stream 20 is produced comprising heat exchanging of the hydrocarbon stream against the first refrigerant in the one or more first heat exchangers and against the second refrigerant in the one or more second heat exchangers.
  • the hydrocarbon stream being heat exchanged in the one or more second heat exchangers has passed through the one or more first heat exchangers.
  • the gaseous hydrocarbon stream 10 is cooled, and thereby partially condensed, in one or more of the first heat exchangers, as shown in Figure 1 by passing the gaseous hydrocarbon stream through the warm tube 141a in first hydrocarbon feed heat exchanger 140a, to produce a partially condensed hydrocarbon stream 40.
  • the partially condensed hydrocarbon stream 40 is passed into the optional gas/liquid separator 50 wherein it is separated into vaporous overhead stream 60 and liquid bottom stream 70.
  • the vaporous overhead stream 60 against at least the second refrigerant 240 in the at least one second heat exchanger 260.
  • at least a part of the bottom stream 70 is warmed in bottom stream heat exchanger 73 and at least part of the warmed bottom stream 74 may be fed back to the optional gas/liquid separator 50 as a reboiled stream.
  • the remaining part is typically led to the fractionation train 75 where it is fractionated into one or more fractionation product streams.
  • Typical fractionation columns in use in a natural gas liquids fractionation train 75 are a demethanizer, a deethanizer, a depropanizer and a debutanizer.
  • the vaporous overhead stream 60 is fed into line 80 as a cooled hydrocarbon stream 80.
  • the cooled hydrocarbon stream 80 is then fed to one or more of the second heat exchangers 260 in a manner known in the art where it is liquefied using the second refrigerant.
  • an intermediate liquefied hydrocarbon stream 90 is produced.
  • This intermediate liquefied hydrocarbon stream 90 may be depressurized in the one or more expansion devices 97 and the depressurized stream 98 led to phase separator 99, where any vaporous constituents, mainly flash vapour, are separated from the liquid hydrocarbons in stream 98.
  • the liquid hydrocarbons are removed from the phase separator 99 as liquefied hydrocarbon product stream 20; the vaporous constituents are drawn from the phase separator 99 as end flash stream 92.
  • the coolant fluid in the storage tank 310 is pumped or otherwise led to chiller 325, wherein it is actively chilled to provide chilled coolant 320 by heat exchanging against cold fluid CF.
  • the cooling duty available in the chilled coolant 320 is used to chill the inlet air stream of the single gas turbine. After having cooled the first inlet air streams 225, the coolant may led back via line 324 to the storage tank 310 for re-use.
  • the first air inlet stream 225 leaving the inlet air heat exchanger 227 has a temperature of below 30 °C, more preferably below 25 °C, even more preferably below 20 °C.
  • the first inlet air stream 225 is preferably not cooled to lower than about 5 °C to ensure that formation of ice is avoided.
  • a suitable target temperature for the first air inlet stream 225 leaving the inlet air heat exchanger 227, in particular when outside ambient air is used, is 10 °C.
  • the cooling duty for actively chilling of the coolant fluid in the one or more chillers 325 may be obtained from a wide variety of sources. For instance, it may use chilling duty provided by a thermally driven chilling process.
  • the one or more chillers 325 may comprise one or more thermally driven chillers.
  • the thermally driven chilling process and/or the thermally driven chillers may be operated using waste heat from the liquefaction process, e.g. the waste heat from the gas turbine 220.
  • Thermally driven chillers are known in the art.
  • a relatively common example is formed by the group consisting of absorption chillers.
  • An absorption chilling is based on evaporating liquid ammonia in the presence of hydrogen gas, providing the cooling.
  • lithium/bromide absorption chillers More common in large commercial plants are so-called lithium/bromide absorption chillers.
  • a lithium/bromide absorption chiller uses a solution of lithium/bromide salt and water.
  • thermally driven chillers known in the art is formed by the group consisting of adsorption chillers.
  • Still another example is formed by the group consisting of absorption heat pumps. Their principle of operation is similar to absorption chillers.
  • the ultimate power source for the active chilling may be solar power, including photovoltaic solar power or thermal solar power (e.g. in the form of steam).
  • solar power including photovoltaic solar power or thermal solar power (e.g. in the form of steam).
  • thermal solar power e.g. in the form of steam.
  • An example of a gas turbine provided with solar powered inlet air chilling based on absorption chilling is for instance shown in US application publication 2003/0074901 .
  • the actively chilling of the coolant fluid may use a chilling refrigerant from a dedicated mechanically driven chilling refrigerant circuit.
  • the dedicated chilling refrigerant circuit 380 is provided with its own compressor 381 and means for rejecting heat from the compressed chilling refrigerant to the ambient such as cooler 382.
  • the compressor 381 may be driven by any suitable driver 383, suitably an electric motor but not necessarily so.
  • the chiller 325 is depicted in the form of a kettle.
  • a Joule Thomson valve 386 is provided between the kettle 325 and the cooler 382, downstream of an optional accumulator 385.
  • a knockout drum 384 may be provided between the kettle 325 and the suction inlet of the compressor 381 as a precaution.
  • the chilling refrigerant may consist of any component or mixture suitable for removing heat at approximately the temperature level of the ambient temperature. Examples include butane, iso-butane, propane, ammonia.
  • it may use refrigeration duty from a stream that is already available in the liquefaction line-up. For instance, it may use refrigeration duty taken from the first refrigerant circuit and/or the second refrigerant circuit.
  • first refrigerant circuit 100 it is preferred to use refrigeration duty from the first refrigerant circuit 100 because the refrigerant in the first refrigeration circuit 100 is generally more efficient at removing heat at the desired temperature level of the chilling coolant.
  • This can or instance be done by providing chiller 325 in the form of a kettle wherein the first refrigerant from line 119 is evaporated at a desired suitable pressure level. Downstream of the chiller 325 the first refrigerant may be recompressed via first refrigerant compressor train 110 itself, for instance by feeding the refrigerant downstream of chiller 325 to the knock out drum 132, or by a dedicated compressor that is also driven on the common drive shaft 215.
  • Refrigeration duty from the second refrigerant circuit may be used by allowing a slip stream from for instance line 240 to evaporate in and/or pass through chiller 325 at a desired pressure level as cold stream CF.
  • the slip stream may also be drawn from other suitable places in the second refrigerant circuit 200, such as from the liquid second refrigerant stream in line 254 if optional refrigerant gas/liquid separator 250 is present. Irrespective of the origin of the slipstream, downstream of the chiller the slip stream may be fed back to the second compressor 210 and/or recompressed using a dedicated compressor driven on the common drive shaft 215.
  • a controller (not shown) is arranged to control the selection of the source of refrigeration duty between first and second refrigeration circuit based on the refrigeration circuit that is the least constraining of the two.
  • the coolant may be chilled using refrigeration duty provided by any other cold stream available in the process.
  • this can be implemented by:
  • a fraction is withdrawn from the hydrocarbon stream after it has been heat exchanged in at least one of one or more of the first and second heat exchangers, thus suitably downstream of at least one of one or more of the heat exchangers, to provide a stream of a chilled coolant that, in turn, is used to produce a chilled inlet air stream at least by heat exchanging the chilled coolant with the inlet air stream.
  • the chilled inlet air stream to the gas turbine that drives the refrigerant circuits employed for cooling the hydrocarbon stream in the one or more heat exchangers, and producing the liquefied hydrocarbon stream therefrom.
  • Such fractions of hydrocarbon stream are often removed from the hydrocarbon stream to be liquefied anyway, for various uses or reasons. Since the fraction is removed downstream of at least one of the one or more heat exchangers, it has the ability to chill the inlet air stream before its other use or before being discarded.
  • Any cooling duty that can be provided from the removed fraction for the purpose of gas turbine inlet air chilling, does not need to be removed from a refrigerant cycle that is intended to cool the hydrocarbon stream to be liquefied. This helps to further increase the production rate of the liquefied hydrocarbon without a need to install additional refrigeration power.
  • removed fractions that can be employed for chilling the inlet air stream of the gas turbine include:
  • Favorable examples include the liquid bottom stream of an extraction column and/or a fractionation column and/or an overhead stream from a fractionation column, a stream of end-flash gas that may be generated when letting down the pressure of the liquefied hydrocarbon stream, a stream of boil-off gas that may be evaporated off of the liquefied hydrocarbon while in storage.
  • the cold fluid CF may be derived from, or contain, the liquid bottom stream 70.
  • optional heat exchanger 73 may be in communication with stream 320 or the optional heat exchanger 73 may be one of the one or more chillers 325.
  • the heat source for generating the stripping vapour in optional heat exchanger 73 comprises stream 320.
  • cold streams that may be used to provide part of or all of the refrigeration duty for the active cooling of the coolant include fuel gas stream 62 drawn from the vapourous overhead stream 60, end flash stream 92, and any cold stream from (optional) fractionation train 75.
  • Figure 1 shows symbolically optional chillers 61 and 91 that could be used as chiller(s) 325 or be otherwise positioned in communication with line 320.
  • Boil off gas for instance from a storage tank wherein the liquefied hydrocarbon stream 20 may be stored, may also be used to provide part of or all of the refrigeration duty for the active cooling of the coolant.
  • the second refrigerant may be fully condensed after its cooling against the first refrigerant.
  • the optional refrigerant gas/liquid separator 250 needs not be provided.
  • the second refrigerant is not fully condensed but wherein nevertheless no gas/liquid phase separation is needed, for instance because full condensation is achieved in a subsequent heat exchanging against a further refrigerant or by auto-cooling.
  • first compressor train 110 may have a multiple of inlets at different pressure levels in a manner known in the art.
  • the first compressor train 110 and/or the second compressor train 210 may each be embodied in the form of two or more frames arranged on the common drive shaft 215, in a manner known in the art.
  • the invention does not exclude the possibility to provide a duplicate a single gas turbine with first and second compressor trains, as described above, in a parallel configuration with the (original) single gas turbine with first and second compressor trains. All lines to and from the single gas turbine with first and second compressor trains (coolant lines, lines to supply and discharge first and second refrigerant streams to and from the first and second compressor trains) should be branched off to the duplicate and appropriate valving arrangement should be provided to isolate the single gas turbine and first and second compressor trains so that the duplicate can perform its function instead. If desired, both the original and the duplicate can be operated simultaneously in parallel with each other to produce more of liquefied hydrocarbons per unit of time.
  • the single gas turbine 220 may be of an aeroderivative type, such as for example a Rolls Royce Trent 60 or RB211, and General Electric LMS100 TM , LM6000, LM5000 and LM2500.
  • the presently proposed inlet air chilling is particularly advantageous when using an aeroderivative type turbine, as this can replace the need for helper drivers (typically a steam turbine or electric motor) to compensate for power loss.
  • the single gas turbine may be of a heavy industrial frame type, such as for example a General Electric Frame 6, Frame 7 or Frame 9 to enhance the efficiency, although in this case an additional driver may still need to be provided for starting up the turbine.
  • equivalent gas turbines from other manufactures may be employed as well.
  • single gas turbine 220 has a nominal shaft power for mechanical drive of at least 40 MW under ISO conditions.
  • the relevant ISO conditions are specified in ISO standard 2314.
  • the nominal shaft power for mechanical drive is normally measured flange-to-flange in simple cycle.
  • an overhead heat exchanger may be provided in line 60 in a way known in the art.
  • Such an overhead heat exchanger may form part of the one or more first heat exchangers, and it may for instance be connected to line 119 to obtain a fraction of the first refrigerant.
  • an optional overhead gas/liquid separator is provided downstream of the overhead heat exchanger in order to remove any condensed fraction from stream downstream of the overhead heat exchanger.
  • the vapour outlet of the overhead gas/liquid separator may then be connected to line 80 to provide the cooled hydrocarbon stream.
  • the bottom liquid outlet of the overhead gas/liquid separator may be connected to the gas/liquid separator 50 to feed back at least a portion of the condensed fraction as a reflux stream.
  • the fuel gas stream 62 may be drawn from the vapour stream.
  • the optional gas/liquid separator 50 is located upstream of the first hydrocarbon feed heat exchanger 140a.
  • the overhead outlet of the gas/liquid separator could in such an alternative embodiment be connected to line 10 in Figure 1 , and line 40 could the be connected directly to line 80 to provide the cooled hydrocarbon stream to the second heat exchanger 260.
  • Such embodiments may have an expander upstream of the optional gas/liquid separator 50, and typically one or more recompressors and/or booster compressors upstream of the first hydrocarbon feed heat exchanger 140a, and/or other heat exchangers to pre-cool the feed to the optional gas/liquid separator 50.
  • Such embodiments are known in the art and need not be further detailed here.
  • the first refrigerant is a single component refrigerant consisting essentially of propane, while the second refrigerant is a mixed refrigerant.
  • a mixed refrigerant or a mixed refrigerant stream as referred to herein comprises at least 5 mol% of two different components.
  • the mixed refrigerant may contain two or more components selected from the group consisting of: nitrogen, methane, ethane, ethylene, propane, propylene, butanes.
  • a common composition for a mixed refrigerant can be: Nitrogen 0-10 mol% Methane (C1) 30-70 mol% Ethane (C2) 30-70 mol% Propane (C3) 0-30 mol% Butanes (C4) 0-15 mol%
  • the total composition comprises 100 mol%.
  • the methods and apparatus disclosed herein may further involve the use of one or more other refrigerants, in separate or overlapping refrigerant circuits or other cooling circuits.
  • the first refrigerant may be a mixed refrigerant (such as described for instance in US Pat. 6,370,910 ) and/or the second refrigerant may be a single component refrigerant (such as consisting essentially of ethane, ethylene, methane or nitrogen).
  • the invention may also be applied in the so-called Axens LIQUEFIN process, such as described in for instance the paper entitled “LIQUEFIN: AN INNOVATIVE PROCESS TO REDUCE LNG COSTS” by P-Y Martin et al, presented at the 22 nd World Gas Conference in Tokyo, Japan (2003).
  • the gaseous hydrocarbon stream 10 to be cooled and liquefied may be derived from any suitable gas stream to be cooled and liquefied, such as a natural gas stream obtained from natural gas or petroleum reservoirs or coal beds.
  • the gaseous hydrocarbon stream 10 may also be obtained from another source, including as an example a synthetic source such as a Fischer-Tropsch process.
  • the gaseous hydrocarbon stream 10 is a natural gas stream, it is usually comprised substantially of methane.
  • the gaseous hydrocarbon stream 10 comprises at least 50 mol% methane, more preferably at least 80 mol% methane.
  • natural gas may contain varying amounts of hydrocarbons heavier than methane such as in particular ethane, propane and the butanes, and possibly lesser amounts of pentanes and aromatic hydrocarbons.
  • hydrocarbons heavier than methane such as in particular ethane, propane and the butanes, and possibly lesser amounts of pentanes and aromatic hydrocarbons.
  • the composition varies depending upon the type and location of the gas.
  • hydrocarbons heavier than methane are removed as far as needed to produce a liquefied hydrocarbon product stream in accordance with a desired specification.
  • Hydrocarbons heavier than butanes (C4) are removed as far as efficiently possible from the natural gas prior to any significant cooling for several reasons, such as having different freezing or liquefaction temperatures that may cause them to block parts of a methane liquefaction plant.
  • the natural gas may also contain non-hydrocarbons such as H 2 O, N 2 , CO 2 , Hg, H 2 S and other sulphur compounds, and the like.
  • the gaseous hydrocarbon stream 10 comprising the natural gas may be pre-treated before cooling and at least partial liquefaction. This pre-treatment may comprise reduction and/or removal of undesired components such as CO 2 and H 2 S or other steps such as early cooling, pre-pressurizing or the like. As these steps are well known to the person skilled in the art, their mechanisms are not further discussed here.
  • Figure 3 shows the first refrigerant in line 130 being offered to a plurality of inlets in the first compressor train 110 each at a different pressure, such as shown in for instance US Pat. 6,370,910 or US Pat. 4,698,080 in the context of various process types.
  • the second compressor train 210 for compressing the second refrigerant is embodied in successively arranged low pressure second refrigerant compressor 210a and high pressure second refrigerant compressor 210b, both being driven on the common shaft 215 by the single gas turbine 220.
  • the second refrigerant in line 230 is fed to the low pressure second refrigerant compressor 210a and the high pressure second refrigerant compressor 210b discharges into line 219.
  • Figure 4 shows the first refrigerant in line 130 being offered to a plurality of inlets in the first compressor train 110 each at a different pressure such as is described in more detail in embodiments disclosed in for instance US Pat. 6,637,238 (advertised under the name "split propane”); US application publication 2008/0289360 ; US Pat. 6,962,060 .
  • the first compressor train 110 is embodied in two compressor casings 110a, 110b, both being driven on the common shaft 215 by the single gas turbine 220.
  • Figure 5 shows an embodiment wherein all of the first refrigerant substreams eventually pass through the highest compression stage of one of the compressor casings (e.g. casing 110b) in the first compressor train 110, such as is described more broadly and in more detail in for instance WO 2009/071538 .
  • the invention can be applied on still other drive schemes as well.
  • the invention described hereinabove is not limited to two refrigeration circuits: it can also be applied in liquefaction processes and apparatuses employing three or more compressor trains for three or more refrigeration cycles such as known from for example US Pat. 6,962,060 ; WO 2008/020044 ; US Pat. 7,127,914 ; DE3521060A1 ; US Pat. 5,669,234 (commercially known as optimized cascade process); US Pat. 6,253,574 (commercially known as mixed fluid cascade process); US Pat. 6,308,531 ; US application publication 2008/0141711 ; Mark J. Roberts et al "Large capacity single train AP-X(TM) Hybrid LNG Process", Gastech 2002, Doha, Amsterdam (13-16 October 2002 ).
  • at least two, possibly all, of the three or more refrigeration circuits are fully driven by compressor trains on the common drive shaft.
  • Some commercially available gas turbines comprise a low pressure compressor, a high pressure compressor, a combustion chamber, and an expansion turbine.
  • the combustion air inlet system comprises a first air inlet into the gas turbine 220 for taking in the first inlet air stream 225 from the air source being at ambient temperature.
  • a low pressure compression stage 150 connects the first air inlet with a low pressure compressed air stream outlet 52.
  • An intercooling stage 120 is arranged to receive a low pressure compressed air stream 55 passing through the low pressure compressed air stream outlet 52.
  • the intercooling stage 120 comprises one or more cooling units, such as intercooling ambient coolers and other intercooling heat exchangers, to produce an intercooled air stream 25 from the low pressure compressed air stream 55.
  • a second air inlet 161 is provided into the gas turbine 220, for taking in the intercooled air stream 25 from the intercooling stage 120, whereby the combustion chamber 170 is fluidly connected to the second air inlet 161 via a high pressure compressor 160, and to the expansion turbine 180. Furthermore, a fuel stream inlet 71 is provided into the gas turbine 220, for allowing a fuel stream 195 into the combustion chamber 170.
  • First and second mechanical drive shafts (22,24) are provided connecting the expansion turbine 180 with the low pressure compressor 150 and with the high pressure compressor 160.
  • a further expansion turbine is provided (not shown), in which case the first and second mechanical drive shafts are independently rotatable from each other, and the low pressure compressor 150 is connected to the further expansion turbine instead.
  • the combustion air inlet system may be provided with the indirect inlet air heat exchanger 227 as described above.
  • the intercooling stage 120 may comprise an intercooling chilling heat exchanger 125 arranged to chill the low pressure compressed air 55 to a temperature that is lower than the ambient temperature.
  • the intercooling stage 120 may further comprise an intercooling ambient cooler 30 upstream of the intercooling chilling heat exchanger 125, preferably between the intercooling chilling heat exchanger 125 and the low pressure compressed air stream outlet 52.
  • the LMS100TM system as described in the incorporated publication GER-422A includes a 3-spool gas turbine that uses an intercooler between the low pressure compressor (LPC) and the high pressure compressor (HPC).
  • LPC low pressure compressor
  • HPC high pressure compressor
  • the LPC compressor discharges through an exit guide vane and diffuser into an aerodynamically designed scroll case.
  • the scroll case is designed to minimize pressure losses and has been validated through 1/6 scale model testing. Air leaving the scroll case is delivered to the intercooler through stainless steel piping. Air exiting the intercooler is directed to the HPC compressor inlet scroll case.
  • the HPC inlet collector scroll case is aerodynamically designed for low pressure loss. This scroll case is mechanically isolated from the HPC by an expansion bellows to eliminate loading on the case from thermal growth of the core engine.
  • the HPC discharges into the combustor.
  • the expansion stage comprises a 2 stage high pressure turbine (HPT), a 2 stage intermediate pressure turbine (IPT) and a 5 stage power turbine (PT).
  • the IPT drives the LPC through a mid-shaft and flexible coupling.
  • the IPT rotor/stator assembly and mid-shaft are assembled to the core engine to create a 'Supercore.'
  • the PT rotor/stator assembly is connected to the power turbine shaft assembly forming a free PT which is aerodynamically coupled to the Supercore.
  • low and high pressure compression stages used herein are intended to encompass compressors housed in a single casing, or those in which multiple compressors are arranged in series on, to sequentially compress the air inlet stream 225.
  • the low pressure compressed air stream 55 is passed via the low pressure compressed air stream outlet 52 from the gas turbine 220 to the intercooling stage 120.
  • the intercooling stage 120 discharges a discharge stream in the form of a chilled low pressure air stream 25, which is fed back into the gas turbine 220 via the second air inlet 161 provided therein.
  • the intercooling ambient cooler 30 may be provided in the form of a conventional air-to-air or air-to-water heat exchanger which cools the low pressure compressed air stream 55 to provide an ambient-cooled compressed air stream 35.
  • the effectiveness of the intercooling ambient cooler 30 is dependent upon the prevailing ambient conditions. As the ambient temperature increases, the temperature of the ambient-cooled compressed air stream 35 will also increase.
  • the intercooling stage preferably further comprises an intercooling chilling step to bring the low pressure compressed air stream 55 to an intercooling temperature that is lower than ambient temperature. This can be accomplished in various ways.
  • the cooled compressed air stream 35 is passed to intercooling chilling heat exchanger 125, wherein it is further cooled to provide the chilled low pressure compressed air stream 25 by consuming cooling duty as described above in relation to the chilling of the first inlet air stream 225.
  • the chilled coolant 320 is divided into two substreams (320a, 320b) upstream of the inlet air cooling heat exchanger 227, each of the substreams passed through one of the inlet air cooling heat exchanger 227 and the intercooling chilling heat exchanger 125, and optionally recombined downstream of the inlet air cooling heat exchanger 227 and the intercooling chilling heat exchanger 125 to eventually form one single coolant fluid stream 315.
  • the density of the stream is increased beyond that which can be achieved using ambient cooler 30 alone, such that the mass flow to the compressor blades or cylinders of high pressure compression stage 160 is increased, improving the power output of the gas turbine 220.
  • the pressure of the chilled low pressure air stream 25 is then increased in the high pressure compression stage 160 to provide a high pressure compressed air stream 65.
  • the high pressure compressed air stream 65 is passed to the combustion chamber 170, where it is mixed with the fuel stream 195 which enters into the gas turbine 220 via a fuel inlet 71 where it is allowed to oxidize the fuel from the fuel stream 195 to produce a combusted stream 175 comprising combustion products.
  • Combusted stream 175 is passed to the expansion turbine 180 of the expansion stage 180, where there may be an adiabatic expansion of the combustion products against the turbine blades, cooling the gas and extracting thermal energy as work to turn output shaft 115.
  • the expanded combustion products exit the expansion stage 180 and the gas turbine 220 via exhaust outlet 82 as turbine exhaust stream 85.

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  • Oil, Petroleum & Natural Gas (AREA)
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EP10175360A 2010-09-06 2010-09-06 Verfahren und Vorrichtung zur Kühlung eines gasförmigen Kohlenwasserstoffstroms Withdrawn EP2426451A1 (de)

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EP10175360A EP2426451A1 (de) 2010-09-06 2010-09-06 Verfahren und Vorrichtung zur Kühlung eines gasförmigen Kohlenwasserstoffstroms
PCT/EP2011/052419 WO2012031783A2 (en) 2010-09-06 2011-02-18 Method and apparatus for cooling a gaseous hydrocarbon stream

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