EP2981777B1 - Integrally-geared compressors for precooling in lng applications - Google Patents

Integrally-geared compressors for precooling in lng applications Download PDF

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Publication number
EP2981777B1
EP2981777B1 EP14717705.9A EP14717705A EP2981777B1 EP 2981777 B1 EP2981777 B1 EP 2981777B1 EP 14717705 A EP14717705 A EP 14717705A EP 2981777 B1 EP2981777 B1 EP 2981777B1
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EP
European Patent Office
Prior art keywords
compressor
refrigerant
integrally
cooling loop
turbo
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EP14717705.9A
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German (de)
English (en)
French (fr)
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EP2981777A2 (en
Inventor
Antonio Pelagotti
Nicola Banchi
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Nuovo Pignone SpA
Nuovo Pignone SRL
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Nuovo Pignone SpA
Nuovo Pignone SRL
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/0002Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the fluid to be liquefied
    • F25J1/0022Hydrocarbons, e.g. natural gas
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D25/00Pumping installations or systems
    • F04D25/02Units comprising pumps and their driving means
    • F04D25/024Units comprising pumps and their driving means the driving means being assisted by a power recovery turbine
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D25/00Pumping installations or systems
    • F04D25/16Combinations of two or more pumps ; Producing two or more separate gas flows
    • F04D25/163Combinations of two or more pumps ; Producing two or more separate gas flows driven by a common gearing arrangement
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003Processes 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
    • F25J1/0047Processes 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
    • F25J1/0052Processes 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
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003Processes 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
    • F25J1/0047Processes 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
    • F25J1/0052Processes 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
    • F25J1/0055Processes 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
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/006Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
    • F25J1/008Hydrocarbons
    • F25J1/0082Methane
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/006Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
    • F25J1/008Hydrocarbons
    • F25J1/0085Ethane; Ethylene
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/006Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
    • F25J1/008Hydrocarbons
    • F25J1/0087Propane; Propylene
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes 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
    • F25J1/0203Processes 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 single-component refrigerant [SCR] fluid in a closed vapor compression cycle
    • F25J1/0207Processes 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 single-component refrigerant [SCR] fluid in a closed vapor compression cycle as at least a three level SCR refrigeration cascade
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes 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
    • F25J1/0211Processes 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
    • F25J1/0214Processes 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
    • F25J1/0215Processes 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 with one SCR cycle
    • F25J1/0216Processes 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 with one SCR cycle using a C3 pre-cooling cycle
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes 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
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes 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
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0281Compression 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
    • F25J1/0283Gas turbine as the prime mechanical driver
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes 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
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0281Compression 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
    • F25J1/0284Electrical motor as the prime mechanical driver
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes 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
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0289Use of different types of prime drivers of at least two refrigerant compressors in a cascade refrigeration system
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes 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
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0292Refrigerant compression by cold or cryogenic suction of the refrigerant gas
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/20Integrated compressor and process expander; Gear box arrangement; Multiple compressors on a common shaft

Definitions

  • the embodiments disclosed herein relate to processes and systems for liquefying natural gas.
  • EP 2 336 677 A1 discloses a refrigeration system for circulating a refrigerant fluid comprising a first compressor and a second compressor operable to compress the refrigerant fluid in separate stages of compression.
  • US 3 763 658 A1 discloses a propane - precooled mixed refrigerant process, comprising a propane pre-cooling loop comprising a two stage compressor for pressurizing the propane and at least a cooling loop, downstream of said pre-cooling loop, where through a second refrigerant circulates, the natural gas being adapted to be sequentially cooled in the pre-cooling loop and in the cooling loop.
  • Natural gas is becoming an increasingly important source of energy. In order to allow transportation of the natural gas from the source of supply to the place of use, the volume of the gas must be reduced. Cryogenic liquefaction has become a routinely practiced process for converting the natural gas into a liquid, which is more convenient, less expensive and safer to store and transport. Transportation by pipeline or ship vessels of liquefied natural gas (LNG) becomes possible at ambient pressure, by keeping the chilled and liquefied gas at a temperature lower than liquefaction temperature at ambient pressure.
  • LNG liquefied natural gas
  • the natural gas is preferably cooled at around -150 to -170°C, where the gas possesses a nearly atmospheric vapor pressure.
  • the natural gas Prior to passing the natural gas through the cooling stages, the natural gas is pre-treated to remove any impurities that can interfere the processing, damage the machinery or are undesired in the final product. Impurities include acid gases, sulfur compounds, carbon dioxide, mercaptans, water and mercury.
  • the pre-treated gas from which impurities have been removed is then cooled by refrigerant streams to separate heavier hydrocarbons.
  • the remaining gas mainly consists of methane and usually contains less than 0.1% mol of hydrocarbons of higher molecular weight, such as propane or heavier hydrocarbons.
  • the thus cleaned and purified natural gas is cooled down to the final temperature in a cryogenic section.
  • the resulting LNG can be stored and transported at nearly atmospheric pressure.
  • Cryogenic liquefaction is usually performed by means of a multi-cycle process, i.e. a process using different refrigeration cycles.
  • each cycle can use a different refrigerating fluid, or else the same refrigerating fluid can be used in two or more cycles.
  • Fig.1 schematically shows a diagram of a cryogenic natural gas liquefaction system using the so-called APCI process.
  • This known process uses two refrigeration cycles.
  • a first cycle uses propane as a refrigeration fluid and a second cycle uses a mixed refrigerant, usually made of nitrogen, methane, ethane and propane.
  • the system labeled 1 as a whole, comprises a first cycle 2 comprising a line formed by a gas turbine 3, which drives a compressor train.
  • the compressor train comprises a first compressor 5 and a second compressor 7 in series for compressing the mixed refrigerant.
  • An inter-stage cooler (inter-cooler) 9 cools the mixed refrigerant delivered by the first compressor 5 to reduce the temperature and the volume thereof before entering the second compressor 7.
  • the compressed mixed refrigerant delivered by the second compressor 7 is condensed against air or water in a heat exchanger 11.
  • the mixed refrigerant is further cooled and partly liquefied by the propane cycle 12 as disclosed here below.
  • the propane is processed in a second or pre-cooling cycle.
  • the second cycle comprises a line including a gas turbine 13, which drives a multi-stage compressor 15.
  • the compressed propane delivered by compressor 15 is condensed in a condenser 17 against water or air.
  • the condensed propane is used to pre-cool the natural gas down to -40°C and to cool and partially liquefy the mixed refrigerant.
  • the natural gas pre-cooling and the mixed refrigerant partial liquefaction is performed in a multi-pressure process, in the example shown 4-level of pressure.
  • the stream of condensed propane from condenser 17 is delivered to a first set of four, serially arranged heat exchangers to cool and partly liquefy the mixed refrigerant and to a second set of four, serially arranged, pre-cooling heat exchangers to cool the natural gas.
  • a first portion of the compressed propane stream from condenser 17 is delivered through pipe 19 to the first set of heat exchangers and is sequentially expanded in serially arranged expanders 21, 23, 25 and 27 to four different, gradually decreasing pressure levels. Downstream each expander 21, 23 and 25 a portion of the expanded propane flow is diverted to a respective heat exchanger 29, 31, 33.
  • the propane flowing through the last expander 27 is delivered to a heat exchanger 35.
  • the compressed mixed refrigerant delivered from the heat exchanger 11 flows in a pipe 37 towards a main cryogenic heat exchanger 38.
  • the pipe 37 sequentially passes through the heat exchangers 29, 31, 33 and 35, such that the mixed refrigerant is gradually cooled and partly liquefied against the expanded propane.
  • a second fraction of the condensed propane flow from condenser 17 is delivered to a second pipe 39 and expanded sequentially in four serially arranged expanders 41, 43, 45 and 47.
  • a part of the propane expanded in each expander 41, 43 and 45 as well as the propane flowing from the last expander 47 is diverted towards a corresponding pre-cooling heat exchanger 49, 51, 53 and 55, respectively.
  • a main natural gas line 61 flows sequentially through said pre-cooling heat exchangers 49, 51, 53 and 55, such that the natural gas is pre-cooled before entering the main cryogenic heat exchanger 38.
  • Heated propane exiting the pre-cooling heat exchangers 49, 51, 53 and 55 is collected with the propane exiting the heat exchangers 29, 31, 33 and 35 and is fed again to the compressor 15, which recovers the four evaporated propane side streams and compresses the vapor to e.g. 15-25 bar to be condensed again in condenser 17.
  • the current invention provides a natural gas liquefaction system according to claim 1 and a natural gas liquefaction method according to claim 12.
  • the flow rates of first refrigerant elaborated by the present system and method are controllable acting not only to the rotational speed of compressor stages. In this way, a more efficient and reliable LNG circuit is provided.
  • Fig.2 schematically shows a diagram of a cryogenic natural gas liquefaction system based on the APCI process embodying the subject matter disclosed herein.
  • the process uses two refrigeration cycles or loops, wherein a first refrigerant and a second refrigerant, respectively, are processed.
  • the first loop is a pre-cooling loop wherein the natural gas as well as the second refrigerant, circulating in a second loop, are cooled by exchanging heat with the first refrigerant.
  • pre-cooling loop or cycle the second loop will be referred to as the cooling or liquefaction loop or cycle.
  • the first refrigerant circulating in the pre-cooling loop can include or consist of propane.
  • the first refrigerant can have a mean molecular weight of at least 35, for example between 35 and 41.
  • the second refrigerant circulating in the second loop can include a mixed refrigerant, for example comprising nitrogen, methane, ethane and propane.
  • the system is labeled 101 as a whole, the first or pre-cooling loop is labeled 103 and the second liquefaction cycle or loop is labeled 105.
  • Natural gas is delivered to the system 101 along a pipe 107 and is sequentially cooled and finally liquefied by flowing through a plurality of serially arranged heat exchangers of the pre-cooling loop 103 and of the cooling loop 105, respectively.
  • the pre-cooling loop 103 comprises a multi-stage, integrally-geared turbo-compressor 109.
  • the integrally-geared turbo-compressor can be configured as shown in more detail in Fig. 4 , and will be described in greater detail later on, reference being made to said figure.
  • At least one, some, or preferably all the stages of the integrally-geared turbo-compressor are comprised of movable inlet guide vanes, to adjust the operative conditions of said stage(s) according to the actual operative needs of the system 101.
  • Each set of movable inlet guide vanes can be adjusted independently of the other, for instance in order to take into account flow rates which differ from one stage to the other.
  • the integrally-geared turbo-compressor comprises a number of stages comprised between two and eight.
  • the integrally-geared turbo-compressor can comprise from three to six stages.
  • one or more inter-coolers can be provided between one or more pairs of sequentially arranged stages of the integrally-geared turbo-compressor.
  • one or more inter-coolers can be provided between one or more pairs of sequentially arranged stages of the integrally-geared turbo-compressor.
  • the multi-stage, integrally-geared turbo-compressor 109 can be driven by a prime mover, which can include an internal combustion motor, such as a gas turbine, for instance an aeroderivative gas turbine.
  • a prime mover can include an internal combustion motor, such as a gas turbine, for instance an aeroderivative gas turbine.
  • the integrally-geared turbo-compressor 109 is driven by an electric motor 111.
  • Fig.2 an exemplary embodiment is shown, wherein the integrally-geared turbo-compressor 109 is comprised of four stages, labeled 109A, 109B, 109C, 109D, respectively, arranged in sequence, stage 109D being the lowest-pressure stage, and stage 109A being the highest-pressure stage.
  • a flow of compressed first refrigerant is delivered by the integrally-geared turbo-compressor 109 to a condenser 115.
  • the flow of first refrigerant delivered through the condenser 115 is cooled, e.g. against water or air, and condensed.
  • the condensed first refrigerant is circulated in the pre-cooling loop 103 to pre-cool the natural gas and to cool and optionally partially liquefy the second refrigerant circulating in the cooling loop 105.
  • the process is divided into four pressure levels.
  • the number of pressure levels can correspond to the number of stages of the integrally-geared turbo-compressor 109.
  • the flow of first refrigerant delivered through the condenser 115 is divided into a number of partial flows, which are then sequentially expanded at a number of progressively reducing pressure levels.
  • Each partial refrigerant flow circulates in a sub-cycle and is returned as a side flow to the integrally-geared turbo-compressor at the inlet of a corresponding one of the plurality of compressor stages.
  • a delivery line 117 delivers a first part of the condensed first refrigerant flow to a plurality of serially arranged first expansion elements 119A-119D.
  • a second delivery line 118 branched-off the delivery line 117 delivers a second part of the condensed first refrigerant flow to a plurality of serially arranged second expansion elements 121A-121D.
  • the first part of the condensed first refrigerant from condenser 115 is sequentially expanded in the four expansion elements 119A-119B at four different, gradually decreasing pressure levels. Downstream each expansion element 119A-119C a portion of the flow of partly expanded first refrigerant is diverted to a respective one of first, pre-cooling heat exchangers 123A-123C. The remaining part of the partly expanded first refrigerant is caused to flow through the next expansion element 119A-119C and so on. The residual first refrigerant flowing through the most downstream one (119D) of the first expansion elements 119A-119D is delivered to a most downstream pre-cooling heat exchanger 123D.
  • each one of said first heat exchangers 123A-123D the first refrigerant exchanges heat against the natural gas flowing in pipe 107, thus pre-cooling and optionally partly liquefying the natural gas.
  • a part of the first refrigerant expanded in each second expansion elements 121A, 121B, 121C is diverted towards a corresponding one of a plurality of second heat exchangers 125A-125D.
  • the part of refrigerant flow delivered by each one of said second expansion elements 121A-121C and which is not caused to flow through the respective heat exchanger 125A-125C is delivered through the subsequent expansion element.
  • the most downstream one (125D) of said second heat exchangers receives the entire residual fraction of first refrigerant expanding in the most downstream (121D) of said second expansion elements 121A-121D.
  • each one of said second heat exchangers 125A-125D the first refrigerant exchanges heat against the second refrigerant, circulating in the cooling or liquefying loop 105, so that at the delivery side of the heat exchanger 125D the second refrigerant is cooled and at least partly liquefied.
  • Heated first refrigerant exiting the first, pre-cooling heat exchangers 123A-123D is collected with the heated first refrigerant exiting the second heat exchangers 125A-125D and is fed again to the integrally-geared turbo-compressor 109.
  • the heated first refrigerant exiting each second heat exchanger 125A-125D is at around the same pressure as the heated first refrigerant exiting the corresponding first heat exchanger 123A-123D.
  • the refrigerant collected at corresponding pressure levels is delivered at the inlet of corresponding stages of the integrally-geared turbo-compressor 109.
  • a plurality of refrigerant side streams are thus returned at gradually decreasing pressures at the inlet of the serially arranged stages of the integrally-geared turbo-compressor 109.
  • reference numbers 130A-130D indicate return lines, through which the side streams of expanded and exhausted refrigerant fluid delivered from the heat exchangers 123A-123D and 125A-125D are returned to corresponding stages 109A-109D of the integrally-geared turbo-compressor.
  • the cooling or liquefying loop 105 comprises a compressor train.
  • the compressor train can be comprised of a first compressor 131 and a second compressor 133 arranged in series.
  • a single compressor can be provided.
  • Each compressor can be a multi-stage compressor, for example a multi-stage centrifugal compressor.
  • the compressor(s) of the cooling loop 105 are driven by a prime mover, which can include an internal combustion engine.
  • the prime mover can be a gas turbine 135, for instance an aeroderivative gas turbine.
  • An inter-stage cooler (inter-cooler) 137 can be arranged between the first compressor 131 and the second compressor 133, to reduce the temperature and the volume of the second refrigerant delivered by the first compressor 131 before entering the second compressor 133.
  • the compressed second refrigerant delivered by the second compressor 133 is condensed in a condenser 139.
  • the condenser 139 can be an air condenser or a water condenser, where the second refrigerant is condensed by exchanging heat against air or water.
  • the condensed second refrigerant is subsequently delivered by a delivery line 141 through the sequentially arranged second heat exchangers 125A-125D, where the second refrigerant is cooled and possibly liquefied by exchanging heat against the first refrigerant circulating in the pre-cooling loop 103, as described above.
  • Fig.2 the integrally-geared turbo-compressor 109 is represented only schematically.
  • the main components of an exemplary integrally-geared turbo-compressor 109 are illustrated in more detail in Fig.2A .
  • Fig.4 illustrates in more detail an axial section of two compressor stages supported on a common rotary shaft of the integrally-geared turbo-compressor 109. More specifically, Fig.4 illustrates by way of example the first and second stages 109D, 109C.
  • each compressor stage 109A-109D is provided with movable inlet guide vanes, schematically shown at 110A-110D for the four stages 109A-109D.
  • movable inlet guide vanes are provided at the inlet of only some or none of the compressor stages.
  • the inlet guide vanes can be arranged at the axial inlet of the compressor stage.
  • Each set of movable inlet guide vanes can be controlled independently of the other sets for autonomously regulating flows entering in the compressor stages.
  • An intercooler can be provided between two sequentially arranged compressor stages 109A-109D.
  • a first intercooler 153 can be arranged between the delivery side of the first compressor stage 109D and the suction side of the second compressor stage 109C.
  • a second intercooler 155 can be arranged between the delivery side of the second compressor stage 109C and the suction side of the third compressor stage 109B.
  • a third intercooler 157 can be arranged between the delivery side of the third compressor stage 109B and the suction side of the fourth compressor stage 109A.
  • Each compressor stage 109A-109D comprises at least one impeller supported on a rotary shaft.
  • Fig.4 shows two impellers 112D, 112C of the two most upstream compressor stages 109D, 109C, respectively.
  • Each impeller can be a radial impeller, with an axial inlet and a radial outlet.
  • the fluid processed through the impeller is collected in a respective volute, such as volutes 114D, 114C of compressor stages 109D, 109C.
  • the impellers can be paired, each pair of impellers being supported by a common rotary shaft.
  • two rotary shafts 159, 161 are provided.
  • the impellers of the first and second compressor stages 109D, 109C are mounted for rotation on the first rotary shaft 159 and the impellers of the third and fourth compressor stages 109B, 109A are mounted for rotation on the second rotary shaft 161.
  • a different number of rotary shafts and respective compressor stages and impellers can be provided. In some embodiments an odd number of stages can be provided, in which case one of the rotary shafts can support a single impeller instead of paired impellers.
  • Each rotary shaft 159, 161 comprise a pinion 159A, 161A keyed thereon.
  • the pinions 159A, 161A mesh with a central toothed wheel or crown 163 which is driven in rotation by the electric motor 111 through a driving shaft 165.
  • the two rotary shafts 159A, 161A and therefore the respective impellers mounted thereon can rotate at different rotary speeds.
  • the structure of the integrally-geared turbo-compressor 109 is particularly suitable for processing the different side streams of the first refrigerant circulating in the pre-cooling loop 103.
  • the position of each set of movable inlet guide vanes 110A-110D at the inlet of the compressor stages can be adapted to the flow conditions of each side stream, i.e. each refrigerant stream delivered to the respective suction side of the compressor stages, so that the operative conditions of the compressor stages can be adapted to the temperature conditions and flow rates through the different heat exchangers 123A-123D, 125A-125D.
  • the compressor efficiency and operability can thus be maximized.
  • One or more intercoolers, such as intercoolers 153, 155, 157 easily integrated in the structure of the integrally-geared turbo-compressor 109 further increase the efficiency of the compressor and thus of the whole LNG system.
  • the LNG system 200 of Fig.3 comprises three closed loops or cycles, labeled 201, 203 and 205 respectively.
  • Three different refrigerants are processed in the three loops.
  • a first refrigerant processed in loop 201 can be propane.
  • the first loop 201 will be named the pre-cooling loop here below.
  • a second refrigerant processed in loop 203 can be ethylene and a third refrigerant circulating in loop 205 can be methane.
  • a natural gas line 207 flows through three sequentially arranged heat exchangers 209, 211 and 213 of the three loops 201, 203, 205. The natural gas enters the first heat exchanger 209 in the gaseous state and exits the last heat exchanger 213 in the liquid state.
  • the system of Fig.3 is represented in a somewhat simplified manner.
  • the first, pre-cooling loop or cycle 201 comprises an integrally-geared turbo-compressor 229 including a plurality of compressor stages.
  • three compressor stages 229A-229C can be provided, as shown by way of example in the schematic representation of Fig.3 .
  • a different number of compressor stages can be provided.
  • the number of compressor stages can depend upon the number of side streams provided in the pre-cooling loop 201, in a way similar to what has been disclosed in connection with Figs. 2 and 2A .
  • Inlet guide vanes 228C, 228B, 228A can be provided at the inlet of some, and preferably of each compressor stage.
  • Intercoolers can be arranged between pairs of sequentially arranged compressor stages, for example a first intercooler 230 can be arranged between the delivery side of the first compressor stage 229C and the suction side of the second compressor stage 229B.
  • a further intercooler 231 can be arranged between the delivery side of compressor stage 229B and the suction side of compressor stage 229A.
  • the delivery side of the last compressor stage 229A i.e. the most downstream one in the pressure-increasing flow direction, is connected to a condenser 233.
  • the first refrigerant circulating through the integrally-geared turbo-compressor 229 is condensed in the condenser 233 and delivered through a line 235 to the first heat exchanger 209.
  • the compressed and condensed refrigerant flow can be expanded through one or more expansion elements, one of which is shown at 237.
  • the main refrigerant stream flowing in delivery line 235 can be divided into side streams at gradually decreasing pressures and temperatures.
  • the heat exchanger 209 can be comprised of a plurality of heat exchanger sections arranged in series and through which a fraction of the refrigerant is caused to flow at gradually decreasing pressures, in a way quite similar to what has been described in connection with Figs. 2 and 2A .
  • a plurality of side streams are thus formed, each being returned at a respective one of the compressor stages 229A, 229B, 229C.
  • Each compressor stage processes, therefore, a different refrigerant flow rate at variable and gradually increasing pressures from the most upstream compressor stage 229C through the most downstream compressor stage 229A.
  • the integrally-geared turbo-compressor 229 can be driven by a prime mover.
  • the prime mover can be an electric motor, not shown, similarly to motor 111 described with reference to Fig.2 .
  • the prime mover can comprise a gas turbine, for example an aeroderivative gas turbine.
  • the second loop 203 comprises compressor arrangement 241.
  • the compressor arrangement 241 can comprise a single compressor or a plurality of sequentially arranged compressors.
  • One or more of the compressors of the compressor arrangement 241 can be a multi-stage compressor, e.g. a multi-stage centrifugal compressor.
  • the compressor arrangement 241 can be driven by a second prime mover 243.
  • the second prime mover 243 can comprise a gas turbine, for instance an aeroderivative gas turbine.
  • the prime mover can comprise an electric motor. Combinations of different engines or motors can be envisaged as well.
  • the second loop 203 comprises a condenser 245 through which the compressed second refrigerant delivered by the compressor arrangement 241 is condensed.
  • a delivery line 247 delivers the compressed and condensed second refrigerant through the first heat exchanger 209 and through the second exchanger 211.
  • the condensed second refrigerant is cooled by exchanging heat against the first refrigerant circulating in the first loop 201.
  • the second refrigerant is expanded in one or more sequentially arranged expansion elements, one of which is shown at 249.
  • each side stream is injected at the inlet of a respective one of a plurality of serially arranged compressors forming the compressor arrangement 241.
  • Movable inlet guide vanes can be provided at the inlet of each such compressors.
  • the second refrigerant cools and/or partly liquefies the natural gas flowing through gas line 207.
  • the third loop 205 comprises a further compressor arrangement 261.
  • the compressor arrangement 261 can be comprised of a single compressor or a plurality of sequentially arranged compressors.
  • the compressor(s) of the compressor arrangement 261 can be centrifugal compressors, e.g. multi-stage centrifugal compressor.
  • a further prime mover 263 is provided for driving the compressor arrangement 261 into rotation.
  • the prime mover 263 can comprise a gas turbine, for instance an aeroderivative gas turbine.
  • the prime mover 263 can comprise an electric motor. Combinations of different motors and engines can be provided as well.
  • the compressed third refrigerant delivered by the compressor arrangement 261 is condensed in a condenser 265 and delivered in the liquid state through a delivery line 267 through the first, the second and the third heat exchangers 209, 211, 213.
  • the third refrigerant flows in the liquid state and is cooled by exchanging heat against the first refrigerant and the second refrigerant, respectively.
  • the third refrigerant is expanded in one or more sequentially arranged expansion elements 269.
  • the vaporized third refrigerant exchanges heat against the natural gas in the third heat exchanger 213, until the natural gas is liquefied when delivered from the third heat exchanger 213.
  • the third refrigerant can be subdivided into side streams at gradually reducing pressures and each side stream is returned to the compressor arrangement 261 through respective return line 271, 273, 275.
  • side streams can be injected at the inlet of sequentially arranged compressors forming part of the compressor arrangement, each compressor being possibly provided with movable inlet guide vanes.
  • At least the first, pre-cooling loop 201 comprises a multi-stage integrally-geared turbo-compressor.
  • the integrally-geared turbo-compressor 229 of the embodiment of Fig.3 can be conceptually similar to the integrally-geared turbo-compressor described with respect to the embodiment of Figs.2 , 2A and shown in more detail in Fig.4 .
  • the number of compressor stages of the integrally-geared turbo-compressor 229 shown in Fig.3 is different from the number of stages of the embodiment of Figs.2 , 2A , this indicating that the number of stages of the integrally-geared turbo-compressor can vary based on design considerations, for example depending upon the number of side streams into which the main stream of the first refrigerant is divided downstream of the condenser.
  • the integrally-geared turbo-compressor can be driven at a power ranging from about 12 MW to about 40 MW. In some embodiments, the integrally-geared turbo-compressor can have a rated power ranging between about 14 MW and 40 MW and more specifically between about 25 MW and 30MW.
  • a first refrigerant flow rate ranging from about 10,000 m 3 /h to about 70,000m 3 /h can be processed by the integrally-geared turbo-compressor.
  • the first refrigerant in the LNG system is usually expanded at gradually reducing pressure values and divided into side streams, each stream being returned to a respective one of several compressor stages of the integrally-geared turbo-compressor.
  • the delivery pressure of the most downstream compressor stage i.e. the compressor stage at the highest pressure
  • said delivery pressure can range between about 52 bar absolute and about 56 bar absolute.
  • the respective suction pressure i.e. the pressure at the inlet of the most upstream compressor stage, can range between about 2.5 and about 15 bar absolute, and more specifically e.g. between about 3 and about 10 bar absolute, for instance at around 3-3.5 bar absolute.
  • the delivery pressure (discharge pressure) of the last stage in the integrally-geared turbo-compressor can range between about 10 bar absolute and 30 bar absolute, and in some specific embodiments between 15 and 25 bar absolute.
  • the respective suction pressure at the most upstream compressor stage can range between about 1 and about 2.5 bar absolute, more specifically between about 1.5 and about 2 bar absolute, for instance at around 1.6-1.9 bar absolute.
  • a standard configuration using a beam centrifugal compressor for example a 3MCL804 manufactured by GE Oil & Gas, Florence, Italy with an efficiency of "100 %", driven by a PGT25+G4 aeroderivative gas turbine, available from GE Oil & Gas, Florence, Italy, directly coupled to the compressor with the following operating condition:
  • the total cost saving with the integrally geared configuration is 5%.
  • an integrally geared compressor is even more attractive considering a configuration wherein an electric motor is used, instead of a gas turbine, due to the removal of the gearbox.
  • a fixed speed electric motor is drivingly connected to the compressor through a gearbox.
  • the compressor can be designed at the optimum speed without the additional gearbox. The compressor will reach an efficiency up to 104.1%. Under the above mentioned operating conditions this would result in an absorbed power of 20,102kW, which results in a reduction of power consumption of 1006 kW.
  • a solution with an integrally geared compressor and an electric motor is 14% less expensive than a standard solution with electric motor, gearbox and compressor, mainly thanks to the removal of the gearbox.

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  • Engineering & Computer Science (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
  • Chemical & Material Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
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  • Compressor (AREA)
  • Compressors, Vaccum Pumps And Other Relevant Systems (AREA)
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EP14717705.9A 2013-04-04 2014-04-03 Integrally-geared compressors for precooling in lng applications Active EP2981777B1 (en)

Applications Claiming Priority (2)

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IT000076A ITFI20130076A1 (it) 2013-04-04 2013-04-04 "integrally-geared compressors for precooling in lng applications"
PCT/EP2014/056693 WO2014161937A2 (en) 2013-04-04 2014-04-03 Integrally-geared compressors for precooling in lng applications

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BR (1) BR112015023950B1 (it)
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ITUA20164168A1 (it) * 2016-06-07 2017-12-07 Nuovo Pignone Tecnologie Srl Treno di compressione con due compressori centrifughi e impianto lng con due compressori centrifughi
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KR20180096998A (ko) 2017-02-22 2018-08-30 한화파워시스템 주식회사 원심 압축기
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IT202100010475A1 (it) * 2021-04-26 2022-10-26 Nuovo Pignone Tecnologie Srl Hydrogen compressing assembly, hydrogen production plant, and compressing method.
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US20160040927A1 (en) 2016-02-11
CA2907931A1 (en) 2014-10-09
JP2016519277A (ja) 2016-06-30
WO2014161937A3 (en) 2015-07-23
CA2907931C (en) 2021-01-26
ITFI20130076A1 (it) 2014-10-05
MX2015014031A (es) 2016-02-10
BR112015023950A2 (pt) 2017-07-18
MY175304A (en) 2020-06-18
KR102188435B1 (ko) 2020-12-09
BR112015023950B1 (pt) 2021-09-08
AU2014247031B2 (en) 2017-11-02
KR20150140320A (ko) 2015-12-15
PE20160061A1 (es) 2016-01-28
CN105264316A (zh) 2016-01-20
CN105264316B (zh) 2018-06-19
AU2014247031A1 (en) 2015-10-08
WO2014161937A2 (en) 2014-10-09
MX363391B (es) 2019-03-20
EP2981777A2 (en) 2016-02-10
JP6541157B2 (ja) 2019-07-10

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