US20070012072A1 - Lng facility with integrated ngl extraction technology for enhanced ngl recovery and product flexibility - Google Patents
Lng facility with integrated ngl extraction technology for enhanced ngl recovery and product flexibility Download PDFInfo
- Publication number
- US20070012072A1 US20070012072A1 US11/426,026 US42602606A US2007012072A1 US 20070012072 A1 US20070012072 A1 US 20070012072A1 US 42602606 A US42602606 A US 42602606A US 2007012072 A1 US2007012072 A1 US 2007012072A1
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- US
- United States
- Prior art keywords
- stream
- distillation column
- lng
- volatile fraction
- conduit
- Prior art date
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- Abandoned
Links
- 238000011084 recovery Methods 0.000 title abstract description 91
- 238000000605 extraction Methods 0.000 title 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 474
- 239000003949 liquefied natural gas Substances 0.000 claims abstract description 267
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- OTMSDBZUPAUEDD-UHFFFAOYSA-N Ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 claims description 17
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- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
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- 238000012546 transfer Methods 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
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- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
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- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 1
- LSDPWZHWYPCBBB-UHFFFAOYSA-N Methanethiol Chemical compound SC LSDPWZHWYPCBBB-UHFFFAOYSA-N 0.000 description 1
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- 230000010354 integration Effects 0.000 description 1
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- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
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- 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
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- 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
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Abstract
Process for efficiently operating a natural gas liquefaction system with integrated heavies removal/natural gas liquids recovery to produce liquefied natural gas (LNG) and/or natural gas liquids (NGL) products with varying characteristics, such as, for example higher heating value (HHV) and/or propane content. Resulting LNG and/or NGL products are capable of meeting the significantly different specifications of two or more markets.
Description
- This application claims priority benefit under 35 U.S.C. Section 119(e) of U.S. Provisional Patent Ser. No. 60/698,402 filed Jul. 12, 2005, the entire disclosure of which is incorporated herein by reference.
- 1. Field of the Invention
- This invention relates generally to a method and apparatus for liquefying natural gas. In another aspect, the invention concerns an improved liquefied natural gas (LNG) facility capable of efficiently supplying LNG products meeting significantly different product specifications.
- 2. Description of the Prior Art
- The cryogenic liquefaction of natural gas is routinely practiced as a means of converting natural gas into a more convenient form for transportation and/or storage. Generally, liquefaction of natural gas reduces its volume by about 600-fold, thereby resulting in a liquefied product that can be readily stored and transported at near atmospheric pressure.
- Natural gas is frequently transported by pipeline from the supply source to a distant market. It is desirable to operate the pipeline under a substantially constant and high load factor, but often the deliverability or capacity of the pipeline will exceed demand while at other times the demand will exceed the deliverability of the pipeline. In order to shave off the peaks where demand exceeds supply or the valleys where supply exceeds demand, it is desirable to store the excess gas in such a manner that it can be delivered as the market dictates. Such practice allows future demand peaks to be met with material from storage. One practical means for doing this is to convert the gas to a liquefied state for storage and to then vaporize the liquid as demand requires.
- The liquefaction of natural gas is of even greater importance when transporting gas from a supply source that is separated by great distances from the candidate market, and a pipeline either is not available or is impractical. This is particularly true where transport must be made by ocean-going vessels. Ship transportation of natural gas in the gaseous state is generally not practical because appreciable pressurization is required to significantly reduce the specific volume of the gas, and such pressurization requires the use of more expensive storage containers.
- In view of the foregoing, it would be advantageous to store and transport natural gas in the liquid state at approximately atmospheric pressure. In order to store and transport natural gas in the liquid state, the natural gas is cooled to −240° F. to −260° F. where the liquefied natural gas (LNG) possesses a near-atmospheric vapor pressure.
- Numerous systems exist in the prior art for the liquefaction of natural gas in which the gas is liquefied by sequentially passing the gas at an elevated pressure through a plurality of cooling stages whereupon the gas is cooled to successively lower temperatures until the liquefaction temperature is reached. Cooling is generally accomplished by indirect heat exchange with one or more refrigerants such as propane, propylene, ethane, ethylene, methane, nitrogen, carbon dioxide, or combinations of the preceding refrigerants (e.g., mixed refrigerant systems). A liquefaction methodology that may be particularly applicable to one or more embodiments of the present invention employs an open methane cycle for the final refrigeration cycle wherein a pressurized LNG-bearing stream is flashed and the flash vapors are subsequently employed as cooling agents, recompressed, cooled, combined with the processed natural gas feed stream, and liquefied, thereby producing the pressurized LNG-bearing stream.
- In the past, LNG facilities have been designed and operated to provide LNG to a single market in a certain region of the world. As global demand for LNG increases, it would be advantageous for a single LNG facility to be able to supply LNG to multiple markets in different regions of the world. However, natural gas specifications vary greatly throughout the world. Typically, such natural gas specifications include criteria such as higher heating value (HHV), Wobbe index, methane content, ethane content, C3+ content, and inerts content. For example, different world markets demand an LNG product having an HHV anywhere between 950 and 1160 BTU/S CF. Existing LNG facilities are optimized to meet a certain set of specifications for a single market. Thus, changing the operating parameters of an LNG facility in an effort to make LNG that would meet the non-design specifications of a different market creates significant operating inefficiencies in the facility. These operating inefficiencies associated with producing LNG for non-design specifications generally makes it economically unfeasible to serve more than one market with a single LNG facility.
- In one embodiment of the present invention there is provided a process for producing liquefied natural gas (LNG). The process includes the following steps: (a) operating an LNG facility in a first mode of operation to thereby produce a first LNG product; (b) adjusting at least one non-feed operating parameter of the LNG facility so that the LNG facility operates in a second mode of operation; and (c) operating the LNG facility in the second mode of operation to thereby produce a second LNG product. The first and second modes of operation are not to be carried out during start-up or shut-down of the LNG facility. Steps (a) and (c) can, optionally, include producing first and second natural gas liquids (NGL) products respectively. The average higher heating value (HHV) of the second LNG product is at least about 10 BTU/SCF different than the average HHV of the first LNG product and/or the average propane content of the second NGL product is at least about 1 mole percent different than the average propane content of the first NGL product.
- In another embodiment of the present invention there is provided a method of varying the heating value of LNG produced from an LNG facility. The method includes the following steps: (a) cooling natural gas by indirect heat exchange to thereby produce a first cooled stream; (b) using a first distillation column to separate at least a portion of the first cooled stream into a first relatively more volatile fraction and a first relatively less volatile fraction; (c) cooling at least a portion of the first relatively more volatile fraction to thereby produce LNG; and (d) adjusting at least one operating parameter of the first distillation column to thereby vary the HHV of the produced LNG by at least about 1 percent over a time period of less than about 72 hours.
- A preferred embodiment of the present invention is described in detail below with reference to the attached drawing figures, wherein:
-
FIG. 1 a is a simplified flow diagram of a cascaded refrigeration process for producing LNG to meet significantly different specifications of two or more different markets with certain portions of the LNG facility connecting to lines A, B, and C being illustrated inFIG. 1 b; -
FIG. 1 b is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 1 a via lines A, B, and C; -
FIG. 2 a is a simplified flow diagram of a cascaded refrigeration process for producing LNG to meet significantly different specifications of two or more different markets with certain portions of the LNG facility connecting to lines B, F, N, O, and P being illustrated inFIG. 2 b; -
FIG. 2 b is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 2 a via lines B, F, N, O, and P; -
FIG. 3 a is a simplified flow diagram of a cascaded refrigeration process for producing LNG to meet significantly different specifications of two or more different markets with certain portions of the LNG facility connecting to lines D, J, B, F, E, L, K, M, and G being illustrated inFIGS. 3 b, 3 c, 3 d, and 3 e; -
FIG. 3 b is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 3 a via lines D, J, B, F, E, L, K, M, and G; -
FIG. 3 c is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 3 a via lines D, J, B, F, E, L, K, M, and G; -
FIG. 3 d is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 3 a via lines D, J, B, F, E, L, K, M, and G; -
FIG. 3 e is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 3 a via lines D, J, B, F, E, L, K, M, and G; -
FIG. 4 a is a simplified flow diagram of a cascaded refrigeration process for producing LNG to meet significantly different specifications of two or more different markets with certain portions of the LNG facility connecting to lines D, B, F, E, I, and G being illustrated inFIG. 4 b; -
FIG. 4 b is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 4 a via lines D, B, F, E, I, and G; -
FIG. 5 a is a simplified flow diagram of a cascaded refrigeration process for producing LNG to meet significantly different specifications of two or more different markets with certain portions of the LNG facility connecting to lines D, B, F, E, and G being illustrated inFIG. 5 b; -
FIG. 5 b is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 5 a via lines D, B, F, E, and G; -
FIG. 6 a is a simplified flow diagram of a cascaded refrigeration process for producing LNG to meet significantly different specifications of two or more different markets with certain portions of the LNG facility connecting to lines H, D, B, F, E, I, and G being illustrated inFIG. 6 b; -
FIG. 6 b is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 6 a via lines H, D, B, F, E, I, and G; -
FIG. 7 a is a simplified flow diagram of a cascaded refrigeration process for producing LNG to meet significantly different specifications of two or more different markets with certain portions of the LNG facility connecting to lines H, D, B, F, E, and G being illustrated inFIG. 7 b; and -
FIG. 7 b is a flow diagram showing an integrated heavies removal/NGL recovery system connected to the LNG facility ofFIG. 7 a via lines H, D, B, F, E, and G. - The present invention can be implemented in a process/facility used to cool natural gas to its liquefaction temperature, thereby producing liquefied natural gas (LNG). The LNG process generally employs one or more refrigerants to extract heat from the natural gas and then reject the heat to the environment. In one embodiment, the LNG process employs a cascade-type refrigeration process that uses a plurality of multi-stage cooling cycles, each employing a different refrigerant composition, to sequentially cool the natural gas stream to lower and lower temperatures. In another embodiment, the LNG process is a mixed refrigerant process that employs at least one refrigerant mixture to cool the natural gas stream.
- Natural gas can be delivered to the LNG process at an elevated pressure in the range of from about 500 to about 3,000 pounds per square in absolute (psia), about 500 to about 1,000 psia, or 600 to 800 psia. Depending largely upon the ambient temperature, the temperature of the natural gas delivered to the LNG process can generally be in the range of from about 0 to about 180° F., about 20 to about 150° F., or 60 to 125° F.
- In one embodiment, the present invention can be implemented in an LNG process that employs cascade-type cooling followed by expansion-type cooling. In such a liquefaction process, the cascade-type cooling may be carried out at an elevated pressure (e.g., about 650 psia) by sequentially passing the natural gas stream through first, second, and third refrigeration cycles employing respective first, second, and third refrigerants. In one embodiment, the first and second refrigeration cycles are closed refrigeration cycles, while the third refrigeration cycle is an open refrigeration cycle that utilizes a portion of the processed natural gas as a source of the refrigerant. The third refrigeration cycle can include a multi-stage expansion cycle to provide additional cooling of the processed natural gas stream and reduce its pressure to near atmospheric pressure.
- In the sequence of first, second, and third refrigeration cycles, the refrigerant having the highest boiling point can be utilized first, followed by a refrigerant having an intermediate boiling point, and finally by a refrigerant having the lowest boiling point. In one embodiment, the first refrigerant has a mid-boiling point within about 20, about 10, or 5° F. of the boiling point of pure propane at atmospheric pressure. The first refrigerant can contain predominately propane, propylene, or mixtures thereof. The first refrigerant can contain at least about 75 mole percent propane, at least 90 mole percent propane, or can consist essentially of propane. In one embodiment, the second refrigerant has a mid-boiling point within about 20, about 10, or 5° F. of the boiling point of pure ethylene at atmospheric pressure. The second refrigerant can contain predominately ethane, ethylene, or mixtures thereof. The second refrigerant can contain at least about 75 mole percent ethylene, at least 90 mole percent ethylene, or can consist essentially of ethylene. In one embodiment, the third refrigerant has a mid-boiling point within about 20, about 10, or 5° F. of the boiling point of pure methane at atmospheric pressure. The third refrigerant can contain at least about 50 mole percent methane, at least about 75 mole percent methane, at least 90 mole percent methane, or can consist essentially of methane. At least about 50, about 75, or 95 mole percent of the third refrigerant can originate from the processed natural gas stream.
- The first refrigeration cycle can cool the natural gas in a plurality of cooling stages/steps (e.g., two to four cooling stages) by indirect heat exchange with the first refrigerant. Each indirect cooling stage of the refrigeration cycles can be carried out in a separate heat exchanger. In one embodiment, core-and-kettle heat exchangers are employed to facilitate indirect heat exchange in the first refrigeration cycle. After being cooled in the first refrigeration cycle, the temperature of the natural gas can be in the range of from about −45 to about −10° F., about −40 to about −15° F., or −20 to −30° F. A typical decrease in the natural gas temperature across the first refrigeration cycle may be in the range of from about 50 to about 210° F., about 75 to about 180° F., or 100 to 140° F.
- The second refrigeration cycle can cool the natural gas in a plurality of cooling stages/steps (e.g., two to four cooling stages) by indirect heat exchange with the second refrigerant. In one embodiment, the indirect heat exchange cooling stages in the second refrigeration cycle can employ separate, core-and-kettle heat exchangers. Generally, the temperature drop across the second refrigeration cycle can be in the range of from about 50 to about 180° F., about 75 to about 150° F., or 100 to 120° F. In the final stage of the second refrigeration cycle, the processed natural gas stream can be condensed (i.e., liquefied) in major portion, preferably in its entirety, thereby producing a pressurized LNG-bearing stream. Generally, the process pressure at this location is only slightly lower than the pressure of the natural gas fed to the first stage of the first refrigeration cycle. After being cooled in the second refrigeration cycle, the temperature of the natural gas may be in the range of from about −205 to about −70° F., about −175 to about −95° F., or −140 to −125° F.
- The third refrigeration cycle can include both an indirect heat exchange cooling section and an expansion-type cooling section. To facilitate indirect heat exchange, the third refrigeration cycle can employ at least one brazed-aluminum plate-fin heat exchanger. The total amount of cooling provided by indirect heat exchange in the third refrigeration cycle can be in the range of from about 5 to about 60° F., about 7 to about 50° F., or 10 to 40° F.
- The expansion-type cooling section of the third refrigeration cycle can further cool the pressurized LNG-bearing stream via sequential pressure reduction to approximately atmospheric pressure. Such expansion-type cooling can be accomplished by flashing the LNG-bearing stream to thereby produce a two-phase vapor-liquid stream. When the third refrigeration cycle is an open refrigeration cycle, the expanded two-phase stream can be subjected to vapor-liquid separation and at least a portion of the separated vapor phase (i.e., the flash gas) can be employed as the third refrigerant to help cool the processed natural gas stream. The expansion of the pressurized LNG-bearing stream to near atmospheric pressure can be accomplished by using a plurality of expansion steps (i.e., two to four expansion steps) where each expansion step is carried out using an expander. Suitable expanders include, for example, either Joule-Thomson expansion valves or hydraulic expanders. In one embodiment, the third refrigeration cycle can employ three sequential expansion cooling steps, wherein each expansion step can be followed by a separation of the gas-liquid product. Each expansion-type cooling step can cool the LNG-bearing stream in the range of from about 10 to about 60° F., about 15 to about 50° F., or 25 to 35° F. The reduction in pressure across the first expansion step can be in the range of from about 80 to about 300 psia, about 130 to about 250 psia, or 175 to 195 psia. The pressure drop across the second expansion step can be in the range of from about 20 to about 110 psia, about 40 to about 90 psia, or 55 to 70 psia. The third expansion step can further reduce the pressure of the LNG-bearing stream by an amount in the range of from about 5 to about 50 psia, about 10 to about 40 psia, or 15 to 30 psia. The liquid fraction resulting from the final expansion stage is the final LNG product. Generally, the temperature of the final LNG product can be in the range of from about −200 to about −300° F., about −225 to about −275° F., or −240 to −260° F. The pressure of the final LNG product can be in the range of from about 0 to about 40 psia, about 10 to about 20 psia, or 12.5 to 17.5 psia.
- The natural gas feed stream to the LNG process usually contains such quantities of C2+ components so as to result in the formation of a C2+ rich liquid in one or more of the cooling stages of the second refrigeration cycle. Generally, the sequential cooling of the natural gas in each cooling stage is controlled so as to remove as much of the C2 and higher molecular weight hydrocarbons as possible from the gas, thereby producing a vapor stream predominating in methane and a liquid stream containing significant amounts of ethane and heavier components. This liquid can be further processed via gas-liquid separators employed at strategic locations downstream of the cooling stages. In one embodiment, one objective of the gas/liquid separators is to maximize the rejection of the C5+ material to avoid freezing in downstream processing equipment. The gas/liquid separators may also be utilized to vary the amount of C2 through C4 components that remain in the natural gas product to affect certain characteristics of the finished LNG product. The exact configuration and operation of gas-liquid separators may be dependant on a number of parameters, such as the C2+ composition of the natural gas feed stream, the desired BTU content (i.e., heating value) of the LNG product, the value of the C2+ components for other applications, and other factors routinely considered by those skilled in the art of LNG plant and gas plant operation.
- In one embodiment of the present invention, the LNG process can include natural gas liquids (NGL) integration within the LNG facility. One may significantly enhance the efficiency of LNG production and NGL recovery by integrating the two functions in one facility. In addition, the present invention can employ an integrated heavies removal/NGL recovery system that allows for prompt and economical variation in the BTU content (i.e., higher heating value (HHV)) of the LNG product stream so that various LNG markets can be served by one facility.
- Accordingly, in one embodiment of the present invention, an LNG facility is provided that can be operated in different modes of operation to produce LNG and/or NGL products that meet different product specifications. For example, the LNG facility can be operated in a low-BTU mode to produce an LNG product having a low BTU content (e.g., 950-1060 BTU/SCF) or in a high-BTU mode to produce an LNG product having a high BTU content (e.g., 1070-1160 BTU/SCF). The LNG facility can also be operated in different modes of operation to produce different NGL products. For example, the LNG facility can be operated in a propane rejection mode to produce an NGL product having a low propane content (e.g., 0-20 mole percent) or in a propane recovery mode to produce an NGL product having a high propane content (e.g., 40-85 mole percent).
- The average higher heating value (HHV) of LNG produced during different modes of operation of the LNG facility can differ from one another by at least about 10 BTU/SCF, at least about 20 BTU/SCF, or at least 50 BTU/SCF. Further, the average HHV of the LNG products produce by different modes of operation can vary by at least about 1 percent, at least about 3 percent, or at least 5 percent in the different modes of operation. In one embodiment, the difference in the average propane content of NGL produced during different modes of operation can be at least about 1 mole percent, at least about 2 mole percent, or at least 5 mole percent. The different modes of operation discussed herein are steady-state modes of operation, not operation during start-up or shut-down of the LNG facility. In one embodiment, each of the different steady-state modes of operation is carried out over a time period of at least one week, at least two weeks, or at least four weeks (as opposed to a lesser period of time that would typically be required for start-up or shut-down).
- It is known that the HHV of produced LNG in conventional LNG plants may vary slightly over long periods of time do to changes in feed composition and/or changes in ambient conditions. However, in one embodiment, the present invention allows for relatively large and rapid adjustments in the HHV value of the LNG product and/or the propane content of the NGL product. To accomplish the relatively large and rapid adjustment in the HHV of the LNG product and/or the propane content of the NGL product, the LNG facility can be transition between the different modes of operation over a time period of less than 1 week, less than 3 days, less than 1 day, or less than 12 hours. In accordance with an embodiment of the present invention, the production of LNG does not cease during transitioning between different modes of operation. Rather, the LNG facility can be rapidly transitioned from one steady-state operating mode to another steady-state operating mode without requiring shut-down of the facility.
- To transition the LNG facility from a first mode of operation to a second mode of operation, one or more operating parameters of the LNG facility can be adjusted. The operating parameter adjusted to transition the LNG facility between different modes of operation can be a non-feed operating parameter of the LNG facility (i.e., the transition between modes of operation is not caused by adjusting the composition of the feed to the LNG facility). For example, when the LNG facility includes a heavies removal/NGL recovery system that employs a distillation column to separate the processed natural gas stream into different components based on relative volatilities, the operating parameter adjusted to transition the LNG facility between different modes of operation can be an operating parameter of the distillation column. Such distillation column operating parameters may include, for example, column feed composition, column feed temperature, column overhead pressure, reflux stream flow rate, reflux stream composition, reflux stream temperature, stripping gas flow rate, stripping gas composition, and stripping gas temperature.
- In one embodiment, the heavies removal/NGL recovery system of the LNG facility can employ a two column configuration. Such a system can include a first distillation column (e.g., a heavies removal column) and a second distillation column (e.g., a demethanizer, deethanizer, or depropanizer). Heavy liquids can be concentrated and removed from the bottom of the heavies removal column and can thereafter be routed to the second distillation column. The second column can be operated to stabilize the bottoms product and send lighter components overhead, eventually ending up in the LNG product. In accordance with one embodiment, the distillation columns are operated in a manner that produces only enough heavy material in the overhead to provide the LNG BTU content desired, as well as to stabilize the bottoms stream by removing undesired light components. In such a two column configuration, one or more operating parameters of one or both of the distillation columns can be adjusted to transition the LNG facility between different modes of operation. The various operating parameters that can be adjusted to transition the LNG facility between different modes of operation are discussed in detail below with reference to
FIGS. 1-7 . - LNG facilities capable of being operated in accordance with the present invention can have a variety of configurations. The flow schematics and apparatuses illustrated in
FIGS. 1-7 represent several embodiments of inventive LNG facilities capable of efficiently supplying LNG products to two or more markets with different specifications.FIGS. 1 b, 2 b, 3 b, 3 c, 3 d, 3 e, 4 b, 5 b, 6 b, and 7 b represent various embodiments of the integrated heavies removal/NGL recovery system of the inventive LNG facility. Those skilled in the art will recognize thatFIGS. 1-7 are schematics only and, therefore, many items of equipment that would be needed in a commercial plant for successful operation have been omitted for the sake of clarity. Such items might include, for example, compressor controls, flow and level measurements and corresponding controllers, temperature and pressure controls, pumps, motors, filters, additional heat exchangers, and valves, etc. These items would be provided in accordance with standard engineering practice. - To facilitate an understanding of
FIGS. 1-7 , Table 1, below, provides a summary of the numeric nomenclature that was employed to denote vessels, equipment, and conduits for the embodiments represented inFIGS. 1 a through 7 b.TABLE 1 FIGS. 1 through 7 - SUMMARY OF NUMERIC NOMENCLATUREReference # Item(s) Applicable Figures 1-99 Vessels and equipment FIGS. 1a, 2a , 3a, 4a, 5a, 6a, 7a100-199 Conduits containing FIGS. 1a, 2a , 3a, 4a, 5a, 6a, 7amainly methane 200-299 Conduits containing FIGS. 1a, 2a , 3a, 4a, 5a, 6a, 7amainly ethane 300-399 Conduits containing FIGS. 1a, 2a , 3a, 4a, 5a, 6a, 7amainly propane 400-499 Vessels, equipment, or 500-599 Vessels, equipment, or 600-699 Vessels, equipment, or FIG. 3, 3c , 3d, 3e700-799 Vessels, equipment, or 800-899 Vessels, equipment, or conduits 900-999 Vessels, equipment, or conduits 1000-1099 Vessels, equipment, or conduits - The inventive LNG facilities illustrated in
FIGS. 1-7 cool the natural gas to its liquefaction temperature using cascade-type cooling in combination with expansion-type cooling. The cascade-type cooling is carried out in three mechanical refrigeration cycles; a propane refrigeration cycle, followed by an ethylene refrigeration cycle, followed by a methane refrigeration cycle. The methane refrigeration cycle includes a heat exchange cooling section followed by an expansion-type cooling section. The LNG facilities ofFIGS. 1-7 also include a heavies removal/NGL recovery system downstream of the propane refrigeration cycle for removing heavy hydrocarbon components from the processed natural gas and recovering the resulting NGL. -
FIGS. 1 a and 1 b illustrate one embodiment of the inventive LNG facility. The system inFIG. 1 a can sequentially cool natural gas to its liquefaction temperature via three mechanical refrigeration stages in combination with an expansion-type cooling section as described in detail below.FIG. 1 b illustrates one embodiment of a heavies removal/NGL recovery system. Lines A, B, and C show how the heavies removal/NGL recovery system illustrated inFIG. 1 b is integrated into the LNG facility ofFIG. 1 a. In accordance with one embodiment of the present invention, the LNG facility can be operated in such a way to maximize propane and heavier component recovery in the NGL product (also referred to herein as “C3+ recovery”). - As illustrated in
FIG. 1 a, the main components of the propane refrigeration cycle include apropane compressor 10, apropane cooler 12, a high-stage propane chiller 14, an intermediatestage propane chiller 16, and a low-stage propane chiller 18. The main components of the ethylene refrigeration cycle include anethylene compressor 20, anethylene cooler 22, a high-stage ethylene chiller 24, an intermediate-stage ethylene chiller 26, a low-stage ethylene chiller/condenser 28, and anethylene economizer 30. The main components of the indirect heat exchange portion of the methane refrigeration cycle include amethane compressor 32, amethane cooler 34, amain methane economizer 36, and asecondary methane economizer 38. The main components of the expansion-type cooling section of the methane refrigeration cycle include a high-stage methane expander 40, a high-stagemethane flash drum 42, an intermediate-stage methane expander 44, an intermediate-stagemethane flash drum 46, a low-stage methane expander 48, and a low-stagemethane flash drum 50. - The operation of the LNG facility illustrate in
FIG. 1 a will now be described in more detail, beginning with the propane refrigeration cycle. Propane is compressed in multi-stage (e.g., three-stage)propane compressor 10 driven by, for example, a gas turbine driver (not illustrated). The three stages of compression preferably exist in a single unit, although each stage of compression may be a separate unit and the units mechanically coupled to be driven by a single driver. Upon compression, the propane is passed throughconduit 300 topropane cooler 12 wherein it is cooled and liquefied via indirect heat exchange with an external fluid (e.g., air or water). A representative pressure and temperature of the liquefied propane refrigerant exitingpropane cooler 12 is about 100° F. and about 190 psia. The stream frompropane cooler 12 is passed throughconduit 302 to a pressure reduction means, illustrated asexpansion valve 56, wherein the pressure of the liquefied propane is reduced, thereby evaporating or flashing a portion thereof. The resulting two-phase product then flows throughconduit 304 into high-stage propane chiller 14. High-stage propane chiller 14 cools the incoming gas streams, including the methane refrigerant recycle stream inconduit 152, the natural gas feed stream inconduit 100, and the ethylene refrigerant recycle stream inconduit 202 via indirect heat exchange means 4, 6, and 8, respectively. Cooled methane refrigerant gas exits high-stage propane chiller 14 throughconduit 154 and is fed tomain methane economizer 36, which will be discussed in greater detail in a subsequent section. - The cooled natural gas stream from high-
stage propane chiller 14, also referred to herein as the methane-rich stream, flows viaconduit 102 to aseparation vessel 58 wherein gas and liquid phases are separated. The liquid phase, which can be rich in C3+ components, is removed viaconduit 303. The vapor phase is removed viaconduit 104 and fed to intermediate-stage propane chiller 16 wherein the stream is cooled via an indirect heat exchange means 62. The resultant vapor/liquid stream is then routed to low-stage propane chiller 18 viaconduit 112 wherein it is cooled by an indirect heat exchange means 64. The cooled methane-rich stream then flows throughconduit 114 and enters high-stage ethylene chiller 24, which will be discussed further in a subsequent section. - The propane gas from high-
stage propane chiller 14 is returned to the high-stage inlet port ofpropane compressor 10 viaconduit 306. The residual liquid propane is passed viaconduit 308 through a pressure reduction means, illustrated here asexpansion valve 72, whereupon an additional portion of the liquefied propane is flashed or vaporized. The resulting cooled, two-phase stream enters intermediate-stage propane chiller 16 by means ofconduit 310, thereby providing coolant forchiller 16. The vapor portion of the propane refrigerant exits intermediate-stage propane chiller 16 viaconduit 312 and is fed to the intermediate-stage inlet port ofpropane compressor 10. The liquid portion flows from intermediate-stage propane chiller 16 throughconduit 314 and is passed through a pressure-reduction means, illustrated here asexpansion valve 73, whereupon a portion of the propane refrigerant stream is vaporized. The resulting vapor/liquid stream then enters low-stage propane chiller 18 viaconduit 316, wherein it acts as a coolant. The vaporized propane refrigerant stream then exits low-stage propane chiller 18 viaconduit 318 and is routed to the low-stage inlet port ofpropane compressor 10, whereupon it is compressed and recycled through the previously described propane refrigeration cycle. - As previously noted, the ethylene refrigerant stream in
conduit 202 is cooled in high-stage propane chiller 14 via indirect heat exchange means 8. The cooled ethylene refrigerant stream then exits high-stage propane chiller 14 viaconduit 204. The partially condensed stream enters intermediate-stage propane chiller 16, wherein it is further cooled by an indirect heat exchange means 66. The two-phase ethylene stream is then routed to low-stage propane chiller 18 by means ofconduit 206 wherein the stream is totally condensed or condensed nearly in its entirety via indirect heat exchange means 68. The ethylene refrigerant stream is then fed viaconduit 208 to aseparation vessel 70 wherein the vapor portion, if present, is removed viaconduit 210. The liquid ethylene refrigerant is then fed to theethylene economizer 30 by means ofconduit 212. The ethylene refrigerant at this location in the process is generally at a temperature of about −24° F. and a pressure of about 285 psia. - Turning now to the ethylene refrigeration cycle illustrated in
FIG. 1 a, the ethylene inconduit 212 entersethylene economizer 30 and is cooled via an indirect heat exchange means 75. The sub-cooled liquid ethylene stream flows throughconduit 214 to a pressure reduction means, illustrated here asexpansion valve 74, whereupon a portion of the stream is flashed. The cooled, vapor/liquid stream then enters high-stage ethylene chiller 24 throughconduit 215. The methane-rich stream exiting low-stage propane chiller 18 viaconduit 114 enters the high-stage ethylene chiller 24, wherein it is further condensed via an indirect heat exchange means 82. The cooled methane-rich stream exits high-stage ethylene chiller 24 viaconduit 116, whereupon a portion of the stream is routed via conduit B to the heavies removal/NGL recovery system of the process inFIG. 1 b. Details ofFIG. 1 b will be discussed in a subsequent section. The remaining cooled methane-rich stream enters the intermediate-stage ethylene chiller 26. - The ethylene refrigerant vapor exits high-
stage ethylene chiller 24 viaconduit 216 and is routed back to theethylene economizer 30, warmed via an indirect heat exchange means 76, and subsequently fed viaconduit 218 to the high-stage inlet port ofethylene compressor 20. The liquid portion of the ethylene refrigerant stream exits high-stage ethylene chiller 24 viaconduit 220 and is then further cooled in an indirect heat exchange means 78 ofethylene economizer 30. The resulting cooled ethylene stream exitsethylene economizer 30 viaconduit 222 and passes through a pressure reduction means, illustrated here asexpansion valve 80, whereupon a portion of the ethylene is flashed. - In a manner similar to high-
stage ethylene chiller 24, the two-phase refrigerant stream enters intermediate-stage ethylene chiller 26 viaconduit 224, wherein it acts as a coolant for the natural gas stream flowing through an indirect heat exchange means 84. The cooled methane-rich stream exiting intermediate-stage ethylene chiller 24 via conduit A is totally condensed or condensed nearly in its entirety. The stream is then routed to the heavies removal/NGL recovery system of the process inFIG. 1 b, as discussed later. - The vapor and liquid portions of the ethylene refrigerant stream exit intermediate-
stage ethylene chiller 26 viaconduits conduit 226 combines with a yet to be described ethylene vapor stream inconduit 238. The combined ethylene refrigerant stream entersethylene economizer 30 viaconduit 239, is warmed by an indirect heat exchange means 86, and is fed to the low-stage inlet port ofethylene compressor 20 viaconduit 230. The effluent from the low-stage of theethylene compressor 20 is routed to aninter-stage cooler 88, cooled, and returned to the high-stage port of theethylene compressor 20. Preferably, the two compressor stages are a single module although they may each be a separate module, and the modules may be mechanically coupled to a common driver. The compressed ethylene product flows to ethylene cooler 22 viaconduit 236 wherein it is cooled via indirect heat exchange with an external fluid (e.g., air or water). The resulting condensed ethylene stream is then introduced viaconduit 202 to high-stage propane chiller 14 for additional cooling as previously noted. - The liquid portion of the ethylene refrigerant stream from intermediate-
stage ethylene chiller 26 inconduit 228 enters low-stage ethylene chiller/condenser 28 and cools the methane-rich stream inconduit 120 via an indirect heat exchange means 90. The stream inconduit 120 is a combination of a heavies-depleted (i.e., light hydrocarbon rich) stream from the heavies removal/NGL recovery system of the process in conduit C and a recycled methane refrigerant stream inconduit 158. As noted previously, details of the heavies removal/NGL recovery system will be described in further detail below. The vaporized ethylene refrigerant from low-stage ethylene chiller/condenser 28 flows viaconduit 238 and joins the ethylene vapors from the intermediate-stage ethylene chiller inconduit 226. The combined ethylene refrigerant vapor stream is then heated by the indirect heat exchange means 86 in theethylene economizer 30 as described previously. The pressurized, LNG-bearing stream exiting the ethylene refrigeration cycle viaconduit 122 can be at a temperature in the range of from about −200 to about −50° F., about −175 to about −100° F., or −150 to −125° F. and a pressure in the range from about 500 to about 700 psia, or 550 to 725 psia. - The pressurized, LNG-bearing stream is then routed to
main methane economizer 36, wherein it is further cooled by an indirect heat exchange means 92. The stream exits throughconduit 124 and enters the expansion-cooling section of the methane refrigeration cycle. The liquefied methane-rich stream is then passed through a pressure-reduction means, illustrated here as high-stage methane expander 40, whereupon a portion of the stream is vaporized. The resulting two-phase product enters high-stagemethane flash drum 42 viaconduit 163 and the gaseous and liquid phases are separated. The high-stage methane flash gas is transported tomain methane economizer 36 viaconduit 155 wherein it is heated via an indirect heat exchange means 93 and exitsmain methane economizer 36 viaconduit 168 and enters the high-stage inlet port ofmethane compressor 32. - The liquid product from high-
stage flash drum 42 enterssecondary methane economizer 38 viaconduit 166, wherein the stream is cooled via an indirect heat exchange means 39. The resulting cooled stream flows viaconduit 170 to a pressure reduction means, illustrated here as intermediate-stage methane expander 44, wherein a portion of the liquefied methane stream is vaporized. The resulting two-phase stream inconduit 172 then enters intermediate-stagemethane flash drum 46 wherein the liquid and vapor phases are separated and exit viaconduits secondary methane economizer 38, is heated by an indirect heat exchange means 41, and then reentersmain methane economizer 36 viaconduit 188. The stream is further heated by indirect heat exchange means 95 before being fed into the intermediate-stage inlet port ofmethane compressor 32 viaconduit 190. - The liquid product from the bottom of intermediate-stage
methane flash drum 46 then enters the final stage of the expansion cooling section as it is routed viaconduit 176 through a pressure reduction means, illustrated here as low-stage methane expander 48, whereupon a portion of the liquid stream is vaporized. The cooled, mixed-phase product is routed viaconduit 186 to low-stagemethane flash drum 50, wherein the vapor and liquid portions are separated. The LNG product, which is at approximately atmospheric pressure, exits low-stagemethane flash drum 50 viaconduit 198 and is routed to storage, represented byLNG storage vessel 99. - As shown in
FIG. 1 a, the vapor stream exits low-stagemethane flash drum 50 viaconduit 196 and enterssecondary methane economizer 38 wherein it is heated via an indirect heat exchange means 43. The stream then travels viaconduit 180 tomain methane economizer 36 wherein it is further cooled by an indirect heat exchange means 97. The vapor then enters the intermediate-stage inlet port ofmethane compressor 32 by means ofconduit 182. The effluent from the low-stage ofmethane compressor 32 is routed to aninter-stage cooler 29, cooled, and returned to the intermediate-stage port of themethane compressor 32. Analogously, the intermediate-stage methane vapors are sent to aninter-stage cooler 31, cooled, and returned to the high-stage inlet port ofmethane compressor 32. Preferably, the three compressor stages are a single module, although they may each be a separate module and the modules may be mechanically coupled to a common driver. The resulting compressed methane product flows throughconduit 192 to ethylene cooler 34 for indirect heat exchange with an external fluid (e.g., air or water). The product of cooler 34 is then introduced viaconduit 152 to high-stage propane chiller 14 for additional cooling as previously discussed. - As previously noted, the methane refrigerant stream from high-
stage propane chiller 14 inconduit 154 entersmain methane economizer 36. The stream is then further cooled via indirect heat exchange means 98. The resulting methane refrigerant stream flows viaconduit 158 and is combined with the heavies-depleted vapor stream in conduit C prior to entering low-stage ethylene chiller/condenser 28 viaconduit 120, as previously discussed. -
FIG. 1 b illustrates one embodiment of the heavies removal/NGL recovery system of the inventive LNG facility. The main components of the system shown inFIG. 1 b include afirst distillation column 452, asecond distillation column 454, and an economizingheat exchanger 402. In one embodiment,first distillation column 452 is operated as a demethanizer andsecond distillation column 454 is operated as a deethanizer. According to one embodiment of the present invention, the reflux stream tofirst distillation column 452 is comprised predominately of ethane. - The operation of the heavies removal/NGL recovery system illustrated in
FIG. 1 b will now be described in more detail. A partially vaporized, methane-rich stream in conduit B enters economizingheat exchanger 402, wherein the stream is further condensed via an indirect heat exchange means 404. The cooled stream exits economizingheat exchanger 402 viaconduit 453 and combines with the stream in conduit A. The resulting stream then enters a first distillation columnfeed separation vessel 406 wherein vapor and liquid phases are separated. The vapor components are removed viaconduit 455 and are then passed through a pressure reduction means, illustrated as aturbo expander 408, whereupon the resulting two-phase stream is fed tofirst distillation column 452 viaconduit 456. The liquid phase exiting first distillation columnfeed separation vessel 406 viaconduit 458 passes through a pressure reduction means, illustrated here asexpansion valve 410, wherein a portion of the stream is vaporized. The resulting vapor/liquid stream is introduced intofirst distillation column 452 viaconduit 460. - A predominantly methane overhead product exits
first distillation column 452 viaconduit 462 and passes through a pressure control means 412, which is preferably a flow control valve, and reenters the liquefaction stage via conduit C. - As shown in
FIG. 1 b, a side stream is drawn viaconduit 464 fromfirst distillation column 452 and is routed to economizingheat exchanger 402 wherein the liquid is heated (reboiled) by an indirect heat exchange means 414. The resulting, partially vaporized stream is transferred viaconduit 466 tofirst distillation column 452, wherein it is employed as a stripping gas. The stripping gas imparts energy to and vaporizes a portion of the heavier hydrocarbon components in the column that would typically remain in the liquid product in the absence of the stripping gas. Stripping gas allows more precise control of the separation of light and heavy components infirst distillation column 452 that ultimately leads to the ability to methodically adjust the characteristics of the final LNG product, such as, for example, the heating value. - As shown in
FIG. 1 b, the bottoms liquid product fromfirst distillation column 452 exits throughconduit 468 and passes through a pressure reduction means, illustrated by anexpansion valve 416, wherein a portion of the stream is vaporized. The resulting two-phase stream from theexpansion valve 416 is then fed tosecond distillation column 454 viaconduit 470. A stream is drawn from a port between the overhead and bottom column ports ofsecond distillation column 454 viaconduit 472 and routed toheater 418, wherein the stream is partially vaporized (reboiled) by indirect heat exchange with an external fluid (e.g., steam or other heat transfer fluid). The resultant vapor stream is returned viaconduit 474 tosecond distillation column 454 as a stripping gas. The resulting liquid stream is removed fromindirect heat exchanger 418 viaconduit 476 and is thereafter combined with the liquid bottom product fromsecond distillation column 454 inconduit 478. This combined stream is the recovered NGL product and is routed to storage or further processing viaconduit 480. - The overhead vapor product of
second distillation column 454 flows viaconduit 482 through a pressure control means 420, which is preferably a flow control valve, to economizingheat exchanger 402 viaconduit 483. The stream is cooled and partially condensed via an indirect heat exchange means 422. This two-phase stream is then passed to a second distillation columnreflux separation vessel 424 viaconduit 486 wherein the liquid and vapor phases are separated. The liquid stream is refluxed back tosecond distillation column 454 by means ofconduit 488. The vapor stream passes throughconduit 490 and into economizingheat exchanger 402, wherein the vapor is cooled and partially condensed via an indirect heat exchange means 426. The stream exits economizingheat exchanger 402 viaconduit 492 and is routed to cooler 428, wherein it is further cooled and condensed, preferably condensed in its entirety, via indirect heat exchange.Cooler 428 can be an external cooler, or can be a pass in one of the chillers (e.g., ethylene chiller 28) illustrated inFIG. 1 a. The resulting condensed stream enters first distillationcolumn separation vessel 430 viaconduit 494, and is thereafter transferred to areflux pump 432 viaconduit 496. The sub-cooled liquid stream is then discharged fromreflux pump 432 viaconduit 498 as reflux tofirst distillation column 452. - Generally, the characteristics of the final LNG product can be altered to meet the different specifications of two or more markets by manipulating one or more key process parameters, such as, for example, the temperature or pressure of process vessels or the temperature, pressure, flow, or composition of streams associated with the process vessels. Such associated streams include, for example, a column reflux stream, a column stripping gas stream, and a column feed stream. In order to affect changes to process variables, the configuration of related process equipment may be modified. For example, the number, arrangement, operation, and/or type of equipment utilized can be changed to achieve the desired result.
- In accordance with one embodiment of the present invention, the higher heating value (HHV) of the LNG product can be adjusted by varying one or more operating parameters of the system illustrated in
FIG. 1 b. For example, in order to produce LNG of lower heating value the following adjustments could be made to the operating parameters of columns 452 and/or 454: (1) lower the amount of C2+ components contained in feed stream(s) 456 and/or 460 to first distillation column 452; (2) lower the temperature of feed streams 456,460 to first distillation column 454; (3) increase the flow rate of reflux stream 498 to first distillation column 452; (4) lower the temperature of reflux stream 498 to first distillation column 452; (5) increase the amount of C2+ components contained in reflux stream 498 to first distillation column 452; (6) lower the flow rate of stripping gas stream 466 to first distillation column 452; (7) lower the temperature of stripping gas stream 466 to first distillation column 452; (8) increase the overhead pressure of first distillation column 452; (9) lower the amount of C3+ components contained in feed stream 470 to second distillation column 454; (10) lower the temperature of feed stream 470 to second distillation column 454; (11) increase the flow rate of reflux stream 488 to second distillation column 454; (12) lower the temperature of reflux stream 488 to second distillation column 454; (13) lower the flow rate of reboil stream 474 to second distillation column 454; (14) lower the temperature of reboil stream 474 to second distillation column 454; and (15) increase the overhead pressure of second distillation column 454. - There are a number of ways to affect the adjustments of items (1)-(15) listed above. For example, the amount of C2+ components contained in feed stream(s) 456 and/or 460 to
first distillation column 452 can be adjusted using additional upstream separation techniques. For example, the temperature of feed streams 456,460 tofirst distillation column 452 can be lowered at least about 1° F. or at least 3° F. by adjusting flow rates inheat exchanger 402 or other upstream heat exchangers. For example, the flow rate ofreflux stream 498 tofirst distillation column 452 can be increased by providing more cooling of overhead stream 149 ofsecond distillation column 454 in heat exchanger 402 (pass 422). For example, the temperature ofreflux stream 498 tofirst distillation column 452 can be lowered by at least 5° F. by providing more cooling in heat exchanger 402 (pass 426) orheat exchanger 428. For example, the amount of C2+ components contained inreflux stream 498 tofirst distillation column 452 can be increased by at least 10 mole percent by altering the operation ofsecond distillation column 454. For example, the flow rate of strippinggas stream 466 tofirst distillation column 452 can be lowered via control valves (not shown). For example, the temperature of strippinggas stream 466 tofirst distillation column 452 can be lowered at least 5° F. by providing less heating in heat exchanger 402 (pass 414). For example, the overhead pressure of first distillation column can be increased by restricting overhead flow inline 462 viavalve 412. For example, the amount of C3+ components contained infeed stream 470 tosecond distillation column 454 can be lowered by including additional separation means or combining a methane-rich stream betweencolumns feed stream 470 tosecond distillation column 454 can be lowered by providing additional cooling to the stream inconduit 470. For example, the flow rate ofreflux stream 488 tosecond distillation column 454 can be increased by providing more cooling tooverhead stream 482 ofsecond distillation column 454 in heat exchanger 402 (pass 422). For example, the temperature ofreflux stream 488 tosecond distillation column 454 can be lowered by providing more cooling tooverhead stream 482 ofsecond distillation column 454 in heat exchanger 402 (pass 422). For example, the flow rate ofreboil stream 472 tosecond distillation column 454 can be lowered by decreasing the amount of heat transfer taking place in the reboiler ofsecond distillation column 454. For example, the temperature ofreboil stream 472 tosecond distillation column 454 can be lowered by decreasing the amount of heat transfer taking place in the reboiler ofsecond distillation column 454. For example, the overhead pressure ofsecond distillation column 454 can be increased by restricting overhead flow inline 482 viavalve 420. - It should be understood that the HHV of the LNG product from the LNG facility of
FIGS. 1 a and 1 b can be increased by performing the converse of one or more of the above-described operations. - Table 2, below, provides a summary of broad and narrow ranges for various properties of selected streams from
FIG. 1 b.TABLE 2 FIG. 1b - STREAM PROPERTIESTemperature (° F.) Pressure (psia) C2+ (mole %) Stream Broad Narrow Broad Narrow Narrow Number Range Range Range Range Broad Range Range 456 −125 to − −115 to −65 300-1,200 400-800 2-30 4-15 460 −110 to −25 −80 to −40 300-1,200 400-800 5-50 10-40 466 −50 to 100 0 to 50 300-1,200 400-800 30-90 50-80 498 −180 to −80 −160 to −110 300-1,200 400-800 20-80 40-70 462 −140 to −60 −110 to −75 300-1,200 400-800 1-25 2-15 468 −50 to 120 −10 to 50 200-1,000 300-600 30-90 50-80 470 −60 to 100 −20 to 45 200-1,000 300-600 30-90 50-80 474 0 to 200 30 to 150 200-1,000 300-600 40-99 75-95 488 −75 to 75 −25 to 25 200-1,000 300-600 30-95 40-80 482 −50 to 120 −10 to 50 200-1,000 300-600 20-80 40-70 478 −100 to 60 −60 to 10 200-1,000 300-600 40-99 75-95 -
FIGS. 2 a and 2 b illustrate another embodiment of the inventive LNG facility capable of efficiently supplying LNG products meeting significantly different product specifications.FIG. 2 b illustrates one embodiment of the heavies removal/NGL recovery system of the present invention. Lines B, F, N, O, and P show how the liquefaction section shown inFIG. 2 a is integrated with the heavies removal/NGL recovery system of LNG facility illustrated inFIG. 2 b. In accordance with one embodiment of the present invention, the LNG facility may be configured and operated in such a way as to maximize C3+ recovery in the NGL product. - The main components of the propane and ethylene refrigeration cycles of the liquefaction stage represented by
FIG. 2 a are numbered the same as those listed previously forFIG. 1 a. In addition, the methane refrigeration cycle inFIG. 2 a employs arecycle compressor 31. - The operation of the LNG facility illustrated in
FIG. 2 a, as it differs from that previously detailed with respect toFIG. 1 a, will now be described in detail. InFIG. 2 a, the cooled, methane-rich stream exits low-stage propane chiller 18 viaconduit 114. The stream then enters high-stage ethylene chiller 24, wherein it is further cooled via indirect heat exchange means 82. The resulting methane-rich stream exits intermediate-stage ethylene chiller 24 via conduit B and is routed to the heavies removal/NGL recovery system illustrated inFIG. 2 b, whereupon it undergoes additional processing, as described in detail in a subsequent section. - The methane-rich stream then enters intermediate-
stage ethylene chiller 26 inFIG. 2 a from the yet-to-be-described heavies removal/NGL recovery system ofFIG. 2 b via conduit F. The stream is then further cooled in intermediate-stage ethylene chiller 26 via indirect heat exchange means 84. The sub-cooled liquid stream exits intermediate-stage ethylene chiller 26 and combines with the liquid methane refrigerant exitingmain methane economizer 36 viaconduit 158. The combined stream is routed viaconduit 120 into low-stage ethylene chiller/condenser 28, wherein it is cooled by indirect heat exchange means 90. In addition to cooling the methane-rich stream, low-stage ethylene chiller 28 also acts as a condenser via indirect heat exchange means 91 for a yet-to-be-discussed stream from conduit N inFIG. 2 b. The pressurized, LNG-bearing stream inFIG. 2 a exits low-stage ethylene chiller/condenser 28 viaconduit 122 and proceeds through the indirect heat exchange and expansion cooling stages of the methane refrigeration cycle as detailed previously. The resulting liquid from the final-stage expansion is the LNG product. - In the methane refrigeration cycle of
FIG. 2 a, a yet-to-be-discussed stream from the heavies removal/NGL recovery system entersmain methane economizer 36 via conduit P, wherein the stream is cooled via an indirect heat exchange means 81. The resulting stream is then routed viaconduit 191 to recyclecompressor 31, whereupon the compressed effluent travels viaconduit 193 and combines with the methane refrigerant recycle stream inconduit 154 from the outlet of high-stage propane chiller 14. The composite stream then entersmain methane economizer 36, wherein it is cooled via indirect heat exchange means 98. The stream is then recycled viaconduit 158 and joins the methane-rich stream exiting intermediate-stage ethylene chiller 26, as previously noted. The total stream then enters low-stage ethylene chiller/condenser 28 viaconduit 120 and proceeds through the process steps as previously described with respect toFIG. 1 a. - Turning now to
FIG. 2 b, another embodiment of the heavies removal/NGL recovery system of the inventive LNG facility is illustrated. The main components of the system inFIG. 2 b includefirst distillation column 552,second distillation column 554, economizingheat exchanger 502,expander 504, and feedsurge vessel 506. According to one embodiment of the present invention, thefirst distillation column 552 can be operated as a demethanizer and thesecond distillation column 554 may be operated as a deethanizer. In one embodiment of the inventive LNG facility,first distillation column 552 can be refluxed with a predominantly ethane stream. - The operation of the heavies removal/NGL recovery system of the inventive LNG facility presented in
FIG. 2 b will now be described in detail. The partially condensed effluent from high-stage ethylene chiller 24 flows into conduit B inFIG. 2 a, as noted previously, and then entersfeed surge vessel 506 inFIG. 2 b, wherein the vapor and liquid are separated. The vapor portion enters first distillationcolumn feed expander 504 viaconduit 520, wherein a portion of the stream is condensed. The cooled, vapor/liquid stream is fed viaconduit 524 proximate to the lower portion offirst distillation column 552. The vapor product from the overhead port offirst distillation column 552 inFIG. 2 b is routed via conduit F into the inlet of intermediatestage ethylene chiller 26 inFIG. 2 a, as noted previously. The predominantly methane stream is subsequently cooled and will ultimately become the final LNG product. - The liquid stream exits feed
surge vessel 506 viaconduit 522, whereupon it combines with the liquid product from the bottom port offirst distillation column 552 inconduit 526. The composite stream travels viaconduit 528 to economizingheat exchanger 502, wherein it is heated via an indirect heat exchange means 514. The resulting stream feedssecond distillation column 554 viaconduit 530. The liquid product from the bottom port ofsecond distillation column 554 is the final NGL product. InFIG. 2 b, the NGL product is routed to further processing or storage viaconduit 550. - A stream is drawn from a side port of
second distillation column 554 viaconduit 540. The stream entersheater 512, wherein it is heated (reboiled) via indirect heat exchange with an external fluid (e.g., steam or heat transfer fluid). The resulting vapor is returned tosecond distillation column 554 viaconduit 542, wherein it is employed as a stripping gas. The vapor stream from the overhead port ofsecond distillation column 554 travels by way ofconduit 532 to economizingheat exchanger 502, wherein it is partially condensed via indirect heat exchange means 516. The resulting, partially liquefied stream is routed viaconduit 534 to the second distillation columnoverhead surge vessel 508, wherein the vapor and liquid are separated. - The vapor stream exits
overhead surge vessel 508 via conduit P inFIG. 2 b and entersmain methane economizer 36 inFIG. 2 a. The stream is cooled, compressed, and recycled back to the inlet of low-stage ethylene chiller/condenser 28, as previously discussed. As shown inFIG. 2 b, the liquid phase from second distillationcolumn separation vessel 508 enters the suction ofreflux pump 510 viaconduit 536. A portion of thereflux pump 510 discharge is sent to thesecond distillation column 554 as reflux viaconduit 538. The remainder of the stream is routed via conduit N inFIG. 2 b to the inlet of low-stage ethylene chiller/condenser 28 inFIG. 2 a, as previously noted. As shown inFIG. 2 a, a portion of the stream enters low-stage ethylene chiller/condenser 28, wherein it is cooled via an indirect heat exchange means 91. The cooled stream exits low-stage ethylene chiller via conduit O. For the purpose of controlling the temperature of the stream in conduit O, a portion of the liquid in conduit N can bypass low-stage ethylene chiller viaconduit 121 as controlled byvalve 125. For example, to decrease the temperature of the stream in conduit O,valve 125 can be closed to decrease the flow throughconduit 121, thereby allowing more of the stream to be cooled by low-stage ethylene chiller/condenser 28. The resulting stream in conduit O is then sent tofirst distillation column 552 as reflux. - According to one embodiment of the present invention, the heating value of the LNG product can be adjusted by varying one or more operating parameters of the system illustrated in
FIG. 2 b. For example, in order to produce LNG of lower heating value, one or more of the following adjustments could be made to the operating parameters ofdistillation columns 552 and/or 554: (1) lower the temperature offeed stream 524 tofirst distillation column 552; (2) increase the flow rate of reflux stream O tofirst distillation column 552; (3) lower the temperature of reflux stream O tofirst distillation column 552; (4) increase the overhead pressure offirst distillation column 552; (5) lower the temperature offeed stream 530 tosecond distillation column 554; (6) increase the flow rate ofreflux stream 538 tosecond distillation column 554; (7) lower the temperature ofreflux stream 538 tosecond distillation column 554; (8) lower the flow rate of strippinggas 542 tosecond distillation column 554; (9) lower the temperature of strippinggas 542 tosecond distillation column 554; and (10) increase the overhead pressure ofsecond distillation column 554. - As detailed previously with respect to
FIG. 1 b, several methods, including those well-known to one skilled in the art of distillation and LNG plant operation, exist to affect the adjustments of items (1)-(10). For example, in accordance with this embodiment, the temperature of the reflux stream O tofirst distillation column 552 can be reduced by closingvalve 125 to force more flow through low-stage ethylene chiller/condenser 28 to be cooled, as previously discussed. - Similarly to
FIGS. 1 a and 1 b, it should be understood that the heating value of the LNG product from the LNG facility ofFIGS. 2 a and 2 b can be increased by performing the converse of one or more of the above-described operations. - A further embodiment of the inventive LNG facility capable of efficiently supplying LNG product to meet significantly different specifications of two or more markets is illustrated in
FIG. 3 a.FIGS. 3 b through 3 e represent several embodiments of the heavies removal/NGL recovery system of the present invention.FIG. 3 b represents one embodiment of the heavies removal/NGL recovery system of the LNG facility employing a reflux compressor.FIG. 3 c illustrates another embodiment of the inventive heavies removal/NGL recovery system that utilizes a reflux pump.FIG. 3 d shows a further embodiment of the heavies removal/NGL recovery system, which employs an expander to cool and partially condense distillation column feed. Yet another embodiment illustrated inFIG. 3 e seeks to maximize C3+ recovery (98+%) in the NGL product by incorporating heavier hydrocarbons (i.e., C4's and C5's) into the column reflux. Lines D, J, B, F, E, L, K, M, and G show how the systems presented inFIGS. 3 b through 3 e are integrated into the LNG facility ofFIG. 3 a. - The main components of the liquefaction step of the inventive LNG facility shown in
FIG. 3 a are the same as those described for the embodiment described with respect toFIG. 1 a. The operation of the facility illustrated inFIG. 3 a, as it differs from the operation ofFIG. 1 a discussed in detail previously, will now be presented. - The partially vaporized, methane-rich stream exits low-stage propane chiller 18 via
conduit 114, whereupon a portion of the stream is routed via conduit D to the heavies removal/NGL recovery system of the LNG facility illustrated inFIGS. 3 b, 3 c, 3 d, or 3 e. Several alternate embodiments of the inventive heavies removal/NGL recovery system are illustrated inFIGS. 3 b through 3 e; each will be discussed in detail in subsequent sections. Prior to entering high-stage ethylene chiller 24, a stream from the heavies removal/NGL recovery system in conduit J fromFIGS. 3 b, 3 c, 3 d, or 3 e combines with the methane-rich stream inconduit 114. InFIG. 3 a, the combined stream enters high-stage ethylene chiller 24, wherein it is further cooled via indirect heat exchange means 82. The resulting stream is then routed to the heavies removal/NGL recovery system inFIGS. 3 b, 3 c, 3 d, or 3 e via conduit B. The stream undergoes further processing, as described in detail later, and is then returned via conduit F to intermediate-stage ethylene chiller 26, wherein it is cooled via an indirect heat exchange means 84. The resulting stream exits intermediate-stage ethylene chiller 26, whereupon it combines with the methane refrigerant recycle stream inconduit 158 in a manner similar to the one detailed in the description ofFIG. 1 a. - According to
FIG. 3 a, the combined stream flows viaconduit 120 into low-stage ethylene chiller/condenser 28, wherein it is cooled via indirect heat exchange means 90. In addition to cooling the methane-rich stream, low-stage ethylene chiller inFIG. 3 a also acts as a condenser for a yet-to-be-discussed stream from conduit N in the heavies removal/NGL recovery systems represented byFIGS. 3 b, 3 c, 3 d, or 3 e. The resulting methane-rich stream is at least partially condensed, or condensed in its entirety, and exits low-stage ethylene chiller/condenser 28 inFIG. 3 a, whereupon it combines with a stream from the heavies removal/NGL recovery system in conduit M. The composite stream entersmain methane economizer 36 and proceeds through the indirect heat exchange and expansion cooling segments of the methane refrigeration cycle, as detailed previously with respect toFIG. 1 a. Analogously, the liquid portion of the final expansion stage is the LNG product. - In the methane refrigeration cycle of
FIG. 3 a an additional stream in conduit G from the yet-to-be-discussed heavies removal/NGL recovery system combines with the effluent frommain methane economizer 36 inconduit 168, prior to entering the high-stage inlet port ofmethane compressor 32. The resulting compressed methane refrigerant stream is routed viaconduit 192 tomethane cooler 34, wherein the stream is cooled via indirect heat exchange with an external fluid (e.g., air or water). Prior to entering high-stage propane chiller 14, a portion of the methane refrigerant is routed to the heavies removal/NGL recovery system inFIGS. 3 b, 3 c, 3 d, or 3 e via conduit E. The remainder of the methane refrigerant stream inFIG. 3 a is routed viaconduit 152 to high-stage propane chiller 14, as described previously. - Turning now to
FIG. 3 b, one embodiment of the heavies removal/NGL recovery system of the LNG facility will now be described. The main components ofFIG. 3 b include afirst distillation column 652, asecond distillation column 654, an economizingheat exchanger 602, and areflux compressor 608. In accordance with one embodiment of the present invention,first distillation column 652 can be refluxed with a stream predominately comprised of ethane. - The operation of the inventive system illustrated in
FIG. 3 b will now be described in more detail. As noted previously, the streams in conduits D and B originate in the liquefaction system illustrated inFIG. 3 a. Conduit D contains a portion of the partially condensed methane-rich stream exiting low-stage propane chiller 18 as shown inFIG. 3 a. The stream in conduit B represents the cooled effluent of the high-stage ethylene chiller 24, represented inFIG. 3 a. As shown inFIG. 3 b, the streams in conduits B and D combine prior to feedingfirst distillation column 652. In one embodiment, the stream in conduit B is cooler, and the flow in conduit D can be increased viavalve 625 as needed to adjust the temperature of the feed to first distillation column inconduit 626. The vapor product from the overhead port offirst distillation column 652 inFIG. 3 b exits via conduit F and enters intermediate-stage ethylene chiller 26 inFIG. 3 a, as previously noted, to ultimately become the final LNG product. - Two side streams via
conduits first distillation column 652. The stream inconduit 628 enters economizingheat exchanger 602, wherein it is heated (reboiled) and at least partially vaporized via an indirect heat exchange means 618. The side stream inconduit 630 acts as a coolant for a yet-to-be-discussed overhead vapor product fromsecond distillation column 654 in acondenser 620. The resulting, at least partially, and preferably totally, vaporized streams, combine inconduit 636 prior to reenteringfirst distillation column 652. These primarily vaporized streams then act as a stripping gas infirst distillation column 652. - The liquid product from the bottom port of
first distillation column 652 feedssecond distillation column 654 viaconduit 638. A side stream is drawn fromsecond distillation column 654 viaconduit 666 and passes throughheater 612, wherein the stream is reboiled (heated) via indirect heat exchange with an external fluid (e.g., steam or other heat transfer fluid). A portion of the stream vaporizes and is routed fromheater 612 viaconduit 668 tosecond distillation column 654, wherein it is employed as stripping gas. The remaining liquid flows fromheat exchanger 612 throughconduit 672 and combines with the liquid product from the bottom port ofsecond distillation column 654 inconduit 670. The composite stream is the final NGL product, which can be, in one embodiment, predominantly made up of propane and heavier components. The NGL stream is routed viaconduit 676 to further processing and/or storage. - The vapor product from the overhead port of
second distillation column 654 exits viaconduit 640 and is thereafter condensed viacondenser 620 by indirect heat exchange with the side stream fromfirst distillation column 652 inconduit 630 as described previously. The resulting cooled, at least partially condensed stream flows viaconduit 642 to second distillationcolumn separation vessel 604, wherein the vapor and liquid phases are separated. The liquid portion flows viaconduit 662 to the suction of areflux pump 606. The stream then discharges intoconduit 664 and is employed as afirst distillation column 652 reflux stream. - The vapor stream exits second distillation
column separation vessel 604 viaconduit 634. One portion of the vapor stream can be routed by way ofconduit 644 for use in other applications or as fuel. Another fraction of the vapor product can be routed via conduit G to the high-stage inlet port ofmethane compressor 32 inFIG. 3 a, as previously described. - According to
FIG. 3 b, the remaining vapor product is routed viaconduit 646 to the inlet suction port of areflux compressor 608. The compressed vapor travels viaconduit 648 and enters economizingheat exchanger 602, wherein the vapor is cooled via an indirect heat exchange means 616. The resulting stream exits economizingheat exchanger 602 via conduit K and enters low-stage ethylene chiller/condenser 28 inFIG. 3 a, wherein the vapor is further cooled and condensed via indirect heat exchange means 91. The partially condensed, preferably totally condensed, stream exits low-stage ethylene chiller 26 via conduit L and is sent tofirst distillation column 652 inFIG. 6 b as reflux. A portion of the reflux stream may be routed via conduit M to combine with the pressurized, LNG bearing stream inconduit 122, inFIG. 3 a. As discussed previously, this composite stream will eventually become the finished LNG product. - As mentioned previously, prior to entering high-
stage propane chiller 14, a portion of the methane refrigerant stream inconduit 152 is routed via conduit E to the heavies removal/NGL recovery system inFIG. 3 b, 3 c, 3 d, or 3 e. InFIG. 3 b, the stream in conduit E enters economizingheat exchanger 602, wherein it is cooled via an indirect heat transfer means 614. The resulting stream flows via conduit J and combines with the effluent of low-stage propane chiller 18 inconduit 114 as discussed earlier. - Referring now to
FIG. 3 c, another embodiment of the heavies removal/NGL recovery system of the LNG facility is illustrated. The main components and the operation of the system inFIG. 3 c are the same as those described inFIG. 3 b. However, the embodiment shown inFIG. 3 c utilizes areflux pump 609 instead of the reflux compressor used inFIG. 3 b. The cooled stream in conduit L exits low-stage ethylene chiller inFIG. 3 a and then enters the suction ofreflux pump 609 inFIG. 3 c. The stream is discharged intoconduit 660, whereupon a portion can be routed to the pressurized, LNG-bearing stream inconduit 122 inFIG. 3 a via conduit M, as discussed previously. According toFIG. 3 c, the remaining portion of the stream returns inconduit 660 tofirst distillation column 652 as reflux. - Referring now to
FIG. 3 d, yet another embodiment of the heavies removal/NGL recovery system of the LNG facility is illustrated. The main components of the system illustrated inFIG. 3 d are the same as those described inFIG. 3 b. However,FIG. 3 d employs aseparator vessel 611 and anexpander 613 for the feed tofirst distillation column 652. - The operation of the system illustrated in
FIG. 3 d will now be described in detail, as it differs from the operation of the system described with respect toFIG. 3 b. According toFIG. 3 d, the streams in conduits B and D enter fromFIG. 3 a. InFIG. 3 d, the streams inconduit 626 is routed toseparator vessel 611, wherein the vapor and liquid portions are separated and exit viaconduits first distillation column 652. The vapor portion fromseparation vessel 611 entersexpander 613, whereupon the pressure is reduced and a portion of the stream is condensed. The resulting vapor/liquid stream is then fed tofirst distillation column 652 viaconduit 664. The remainder of the process operates in a like manner as described according to the embodiment illustrated inFIG. 3 b. - Still another embodiment of the heavies removal/NGL recovery system of the LNG facility is illustrated in
FIG. 3 e. The main components ofFIG. 3 e are the same as those listed in the embodiment illustrated inFIG. 3 b. In addition, the system illustrated inFIG. 3 e can be operated in a like manner to the heavies removal/NGL recovery system shown inFIG. 3 b. However,FIG. 3 e employs an additional reflux stream comprising heavier hydrocarbon components (e.g., C4's and C5's) to achieve a high propane recovery in the NGL product. - The operation of the system illustrated in
FIG. 3 e will now be described in detail, as it differs from the system presented inFIG. 3 b. The vapor fromsecond distillation column 654 inconduit 646 is compressed byrecycle compressor 608. The resulting stream flows viaconduit 648, whereupon it combines with an additional reflux stream comprising heavier hydrocarbon components, preferably C4's and C5's, inconduit 680. The composite stream enters economizingheat exchanger 602, wherein it is cooled via indirect heat exchange means 616. The cooled stream travels via conduit K to the low-stage ethylene chiller/condenser 28 inFIG. 3 a. As previously described inFIGS. 3 a and 3 b, the stream is further cooled and condensed prior to returning tofirst distillation column 652 as reflux. - According to one embodiment of the present invention, the HHV of the LNG product can be adjusted by varying one or more operating parameters of the system illustrated in
FIGS. 3 b through 3 e. For example, in order to produce LNG of lower heating value, one or more of the following adjustments could be made to the operating parameters ofdistillation columns 652 and/or 654: (1) lower temperature offeed stream 626 tofirst distillation column 652; (2) lower the temperature of reflux stream L tofirst distillation column 652; (3) lower the temperature of strippinggas 636 tofirst distillation column 652; (4) increase the flow of reflux stream L tofirst distillation column 652; (5) lower the temperature offeed stream 638 tosecond distillation column 654; (6) lower the temperature ofreflux stream 664 tosecond distillation column 654; (7) lower the temperature of strippinggas 668 tosecond distillation column 654; (8) increase the flow ofreflux stream 664 tosecond distillation column 654; (9) increase the flow of overhead vapor stream ofsecond distillation column 654 to fuel viaconduit 644. As detailed previously with respect toFIG. 1 b, several methods, including those well known to one skilled in the art of LNG facilities and distillation, exist to affect the adjustments of items (1)-(9). - Similarly to
FIGS. 1 a and 1 b, it should be understood that the heating value of the LNG product from the LNG facility ofFIGS. 3 a, 3 b, 3 c, 3 d, and 3 e can be increased by performing the converse of one or more of the above-described operations. - Still another embodiment of the inventive LNG facility is illustrated in
FIG. 4 a.FIG. 4 b illustrates a further embodiment of the heavies removal/NGL recovery system of the LNG facility. Lines D, B, F, E, I, and G demonstrate how the system illustrated inFIG. 4 b is integrated into the inventive LNG facility shown inFIG. 4 a. According to one embodiment of the present invention, the LNG facility can be operated in such a way as to maximize C3+ recovery in the NGL product. In accordance with another embodiment, the facility can be operated to maximize C5+ recovery in the NGL product. - Referring now to
FIG. 4 a, the main components of the inventive LNG facility are the same as those listed previously with respect toFIG. 1 a. The operation of the system presented inFIG. 4 a, as it differs from the system described in reference toFIG. 1 a, will now be described in detail. - According to
FIG. 4 a, the methane-rich stream exits low-stage propane chiller 18 viaconduit 114, whereupon a portion is routed via conduit D to the heavies removal/NGL recovery system illustrated toFIG. 4 b. The details of the heavies removal/NGL recovery system shown inFIG. 4 b will be discussed in detail in a subsequent section. The remaining methane-rich stream inFIG. 4 a enters high-stage ethylene chiller 24, wherein it is further cooled via indirect heat exchange means 82. The resulting stream exits high-stage ethylene chiller 24 via conduit B and flows to the heavies removal/NGL recovery system inFIG. 4 b. After additional processing, to be discussed later, the methane-rich stream returns toFIG. 4 a via conduit F and enters intermediate-stage ethylene chiller 26, wherein the stream is cooled via indirect heat exchange means 84. The resulting stream subsequently flows viaconduit 120 to the low-stage ethylene chiller/condenser 28, is cooled via indirect heat exchange means 90, and exits low-stage ethylene chiller/condenser 28 viaconduit 122. The pressurized, LNG-bearing stream inconduit 122 is then routed through the indirect heat exchange and expansion-type cooling portions of the methane refrigeration cycle as discussed previously, in regard toFIG. 1 a. As noted previously, the liquid resulting after the final stage of expansive cooling is the final LNG product. - In the methane refrigeration cycle of
FIG. 4 a, a yet-to-be-discussed stream from the heavies removal/NGL recovery system illustrated inFIG. 4 b in conduit G combines with the methane refrigerant stream inFIG. 4 a exitingmain methane economizer 36 viaconduit 168 prior to being injected into the high-stage inlet port ofmethane compressor 32. The compressed methane refrigerant stream is routed viaconduit 192 tomethane cooler 34, wherein the stream is cooled via indirect heat exchange with an external fluid (e.g., air or water). A portion of the stream exiting methane cooler 34 viaconduit 152 is then routed toFIG. 4 b via conduit E for further processing. The remaining refrigerant enters high-stage propane chiller 14, wherein it is further cooled by indirect heat exchange means 4, as previously noted. The resulting stream flows throughconduit 154 and entersmain methane economizer 36, wherein the methane refrigerant stream is further cooled via indirect heat exchange means 98. The resulting stream exitsmain methane economizer 36 viaconduit 158 and enters low-stage ethylene chiller/condenser 28. Subsequently, the methane refrigerant stream is further cooled via indirect heat exchange means 91, which utilizes the ethylene refrigerant described in detail inFIG. 1 a as a coolant. The resulting stream inFIG. 4 a exits low-stage ethylene chiller/condenser 28 via conduit I and is routed to the heavies removal/NGL recovery system illustrated inFIG. 4 b. - Turning now to
FIG. 4 b, a still further embodiment of the heavies removal/NGL recovery system of the LNG facility is shown. The main components of the system illustrated inFIG. 4 b include afirst distillation column 752, asecond distillation column 754, and an economizingheat exchanger 702. In accordance with one embodiment of the present inventive LNG facility,first distillation column 752 can be operated as a demethanizer andsecond distillation column 754 can be operated as a deethanizer. According to one embodiment of the present invention,first distillation column 752 is refluxed with a stream comprising primarily of methane. - The operation of the system illustrated in
FIG. 4 b will now be described in more detail. As previously mentioned, inFIG. 4 a, conduits B and D exit low-stage propane chiller 18 and high-stage ethylene chiller 24, respectively. InFIG. 4 b, the streams in conduits B and D combine prior to enteringfirst distillation column 752 viaconduit 726. As described according toFIG. 2 b, the relative flows of streams B and D can be adjusted viavalve 725 to affect a specified temperature of the feed stream inconduit 726. The vapor product from the overhead port offirst distillation column 752 exits via conduit F, whereupon it is routed to the inlet of high-stage ethylene chiller 24 inFIG. 4 a. As previously described, the methane-rich stream exiting high-stage ethylene chiller 24 inFIG. 4 a is subsequently cooled to become the final LNG product. - As previously noted in
FIG. 4 a, a portion of the methane refrigerant recycle stream is routed toFIG. 4 b via conduit E. The stream enters economizingheat exchanger 702, wherein the stream is heated via indirect heat exchange means 716. The resulting, at least partially vaporized stream entersfirst distillation column 752 viaconduit 736, wherein the heated vapor is employed as a stripping gas. - As also previously noted in
FIG. 4 a, the methane refrigerant recycle stream inconduit 158 is cooled in the low-stage ethylene chiller/condenser 28 via indirect heat exchange means 93. The resulting stream exits the low-stage ethylene chiller/condenser 28 via conduit I. This cooled, primarily methane-rich stream is routed toFIG. 4 b, wherein it serves as reflux forfirst distillation column 752. - According to
FIG. 4 b, the liquid product from the bottom port offirst distillation column 752 exits viaconduit 788, whereupon the stream splits intoconduits conduit 732 enters economizingheat exchanger 702, wherein the stream is cooled via indirect heat exchange means 718. The resulting cooled stream exits economizingheat exchanger 702 viaconduit 738. A portion of the stream inconduit 738 may be routed throughconduit 744 viavalve 743 in order to bypasscondenser 720. Theconduit 744 bypass aroundcondenser 720 can be one mechanism for second distillation column feed and/or overhead vapor product temperature control. - Referring now to the remaining portion of second distillation column bottom liquid product in
conduit 730 inFIG. 4 b, the stream bypasses economizingheat exchanger 702, passes throughvalve 737, and recombines with the cooled stream inconduit 747. The composite stream enterscondenser 720 viaconduit 740. The temperature of the stream inconduit 740 can be controlled by adjusting the flow rate throughconduit 730 by opening or closingvalve 737. For example, to decrease the temperature of the stream inconduit 740, one can further closevalve 737, thereby forcing a larger portion of flow through economizingheat exchanger 702 to be cooled, therefore reducing the temperature of the compositestream entering condenser 720.Condenser 720 acts an indirect heat exchange means to cool a yet-to-be discussed stream by usingstream 740 as a coolant. The coolant exitscondenser 720 viaconduit 742. Thereafter, the streams inconduits conduit 746 feedssecond distillation column 754. - A side stream is drawn from
second distillation column 754 viaconduit 766 and sent to aheater 712, wherein the stream is heated (reboiled) via indirect heat exchange with an external fluid (e.g., steam or heat transfer fluid). The vaporized portion of the stream is returned tosecond distillation column 754 viaconduit 768, wherein it is employed as a stripping gas. The resulting liquid portion exits seconddistillation column reboiler 712 viaconduit 727, whereupon it combines with the liquid product from the bottom port ofsecond distillation column 754 inconduit 770. The resulting composite stream inconduit 776 is the final NGL product. According to one embodiment, the NGL product can be rich in propane and heavier components. According to another embodiment of the present invention,second distillation column 754 may be operated in such a way as to maximize C5+ component recovery in the final NGL product. By maximizing the C5+ component recovery in the NGL product, an LNG product with a relatively higher HHV can be produced. - The vapor product from the overhead port of
second distillation column 754 exits viaconduit 778, whereupon the stream is cooled and at least partially condensed bycondenser 720. The resulting stream exitscondenser 720 viaconduit 780 and enters second distillationcolumn separation vessel 704, wherein the vapor and liquid phases are separated. The vapor portion, comprised primarily of ethane, is routed via conduit G toFIG. 4 a, whereupon it combines with the stream inconduit 168 prior to being injected into the high-stage inlet port of the methane compressor, as discussed previously. The liquid phase exits second distillationcolumn separation vessel 704 viaconduit 762 and enters the suction of areflux pump 706. The liquid is refluxed tosecond distillation column 754 viaconduit 764. - According to one embodiment of the present invention, the heating values of the LNG product can be adjusted by varying one or more operating parameters of the system illustrated in
FIG. 4 b. For example, in order to produce LNG of lower heating value, one or more of the following adjustments could be made to the operating parameters ofdistillation columns 752 and/or 754: (1) lower the temperature offeed stream 726 tofirst distillation column 752; (2) lower the flow of strippinggas stream 736 tofirst distillation column 752; (3) increase the flow of reflux stream I tofirst distillation column 752; (4) lower the temperature ofreflux stream 764 tosecond distillation column 754; and (5) lower the temperature of strippinggas stream 768 tosecond distillation column 754. As discussed previously with reference toFIG. 1 b, several methods, including those well known to a skilled artisan, exist to affect the adjustments listed in items (1)-(5) above. - Similarly to
FIGS. 1 a and 1 b, it should be understood that the heating value of the LNG product from the LNG facility ofFIGS. 4 a and 4 b can be increased by performing the converse of one or more of the above-described operations. -
FIG. 5 a represents still another embodiment of the LNG facility capable of efficiently supplying an LNG product with significantly different product specifications to meet the needs of two or more markets.FIG. 5 b illustrates a still further embodiment of the heavies removal/NGL recovery system of the inventive LNG facility. Lines D, B, F, E, and G illustrate how the system shown inFIG. 5 b is integrated with the LNG facility ofFIG. 5 a. According to one embodiment of the present invention, the LNG facility can be operated in such a way as to maximize the recovery of propane and heavier components in the NGL product. In accordance with another embodiment, the facility can be operated to maximize C5+ recovery in the NGL product. - The main components of the system in
FIG. 5 a are the same as those listed inFIG. 1 a. The operation ofFIG. 5 a, as it differs fromFIG. 1 a, will now be explained in detail. The methane-rich stream exits the low-stage propane chiller 18 viaconduit 114, whereupon a portion of the stream is routed via conduit D for further processing in the heavies removal/NGL recovery system shown inFIG. 5 b. The details of the system illustrated inFIG. 5 b will be described in a later section. - The remaining methane-rich stream enters high-
stage ethylene chiller 24, wherein it is cooled via indirect heat exchange means 82. The resulting stream is routed via conduit B to the heavies removal/NGL recovery system inFIG. 5 b. After additional processing, to be discussed later, the methane-rich stream returns toFIG. 5 a via conduit F, whereupon it enters intermediate-stage ethylene chiller 26 and is cooled via indirect heat exchange means 84. The resulting stream flows viaconduit 119 and combines with the methane refrigerant recycle stream inconduit 158. The composite stream flows viaconduit 120 into low-stage ethylene chiller/condenser 28, wherein it is further cooled via indirect heat exchange means 90. The resulting pressurized, LNG-bearing stream exits low-stage ethylene chiller/condenser 28 viaconduit 122 and is routed tomain methane economizer 36. The pressurized, LNG-bearing stream then continues through the indirect heat exchange and expansion cooling stages of the methane refrigeration cycle, as previously described in reference toFIG. 1 a. Similarly toFIG. 1 a, the resultant liquid from the final expansion stage is the final LNG product inFIG. 5 a. - In the methane refrigeration cycle illustrated in
FIG. 5 a, a yet-to-be-discussed stream in conduit G originates in the heavies removal/NGL recovery system illustrated inFIG. 5 b and entersFIG. 5 a, wherein it combines with the methane refrigerant stream inconduit 168 upstream of the high-stage inlet port ofmethane compressor 32. The compressed composite stream is routed viaconduit 192 tomethane cooler 34, wherein the stream is cooled via indirect heat exchange with an external fluid (e.g., air or water). A portion of the resulting stream is routed toFIG. 5 b via conduit E for further processing. The remainder of the refrigerant stream flows viaconduit 152 to high-stage propane chiller 18 and is processed as described previously with respect toFIG. 1 a. - Turning now to
FIG. 5 b, still another embodiment of the heavies removal/NGL recovery system of the LNG facility is shown. The main components of the system shown inFIG. 5 b include afirst distillation column 852, asecond distillation column 854, and an economizingheat exchanger 802. In accordance with one embodiment of the LNG facility,first distillation column 852 can be operated as a demethanizer andsecond distillation column 854 can be operated as a deethanizer. In another embodiment,first distillation column 852 can be operated as a demethanizer andsecond distillation column 854 can be operated as a debutanizer. According to one embodiment of the present invention,first distillation column 852 is not refluxed. - The operation of the system illustrated in
FIG. 5 b is analogous to the operation as described with respect to the heavies removal/NGL recovery system illustrated inFIG. 4 b. However,first distillation column 852 inFIG. 5 b can be operated without a reflux stream. The lines and components inFIG. 5 b are numerically labeled with a value that is 100 greater than the corresponding lines inFIG. 4 b. Lettered lines (e.g., B, D, E, F, G) are the same inFIGS. 5 b and 4 b. The function and operation of the corresponding lines and components inFIG. 5 b are analogous to those described previously in reference toFIG. 4 b. For example, the function and operation of strippinggas stream 836 tofirst distillation column 852 inFIG. 5 b directly corresponds to the function and operation of strippinggas stream 736 tofirst distillation column 752 inFIG. 4 b. - In accordance to one embodiment of the present invention, the heating values of the LNG product can be adjusted by varying one or more operating parameters of the system illustrated in
FIG. 5 b. For example, in order to produce LNG of lower heating value, one or more of the following adjustments could be made to the operating parameters ofdistillation columns 852 and/or 854: (1) lower the temperature offeed stream 826 tofirst distillation column 852; (2) lower the flow of strippinggas stream 836 tofirst distillation column 852; (3) increase the flow of reflux stream I tofirst distillation column 852; (4) lower the temperature ofreflux stream 864 tosecond distillation column 854; and (5) lower the temperature of strippinggas stream 868 tosecond distillation column 854. As discussed previously with reference toFIG. 1 b, several methods, including those well known to one skilled in the art, exist to affect the adjustments listed in items (1)-(5) above. - Similarly to
FIGS. 1 a and 1 b, it should be understood that the heating value of the LNG product from the LNG facility ofFIGS. 5 a and 5 b can be increased by performing the converse of one or more of the above-described operations. - Yet another embodiment of the inventive facility capable of supplying an LNG product with significantly different specifications meeting the needs of two or more different markets is presented in
FIG. 6 a.FIG. 6 b illustrates yet another embodiment of the heavies removal/NGL recovery system of the present invention. Lines H, D, B, F, E, I, and G illustrate how the system shown inFIG. 6 b is integrated with the LNG facility ofFIG. 6 a. According to one embodiment of the present invention, the LNG facility can be operated to maximize the recovery of ethane and heavier components in the final NGL product. - The main components of the system in
FIG. 6 a are the same as those listed inFIG. 1 a. The operation ofFIG. 6 a, as it differs from the operation of the system inFIG. 1 a as described previously, will now be explained in detail. The methane-rich stream exits intermediate-stage propane chiller 16 viaconduit 112, whereupon it combines with a yet-to-be discussed stream in conduit H fromFIG. 6 b. The operation of the heavies removal/NGL recovery system illustrated inFIG. 6 b will be discussed in detail shortly. The composite stream enters low-stage propane chiller 18, wherein the stream is cooled via indirect heat exchange means 64. The resulting, cooled stream exits low-stage propane chiller 18 viaconduit 114, whereupon a portion of the stream is routed via conduit D for further processing in the heavies removal/NGL recovery system shown inFIG. 6 b, to be discussed in detail later. - The remaining methane-rich stream in
FIG. 6 a enters high-stage ethylene chiller 24, wherein it is further cooled via indirect heat exchange means 82. The resulting stream exits high-stage ethylene chiller 24 via conduit B and flows to the heavies removal/NGL recovery system inFIG. 6 b. After additional processing, to be discussed later, the methane-rich stream returns toFIG. 6 a via conduit F and enters intermediate-stage ethylene chiller 26, wherein the stream is cooled via indirect heat exchange means 84. The resulting stream subsequently flows viaconduit 120 to the low-stage ethylene chiller/condenser 28, is cooled via indirect heat exchange means 90, and exits low-stage ethylene chiller/condenser 28 viaconduit 122. The pressurized, LNG-bearing stream inconduit 122 is then routed through the indirect heat exchange and expansion-type cooling portions of the methane refrigeration cycle as discussed previously, regardingFIG. 1 a. As noted previously, the liquid resulting after the last stage of expansive cooling is the final LNG product. - In the methane refrigeration cycle of
FIG. 6 a, a yet-to-be-discussed stream from the heavies removal/NGL recovery system illustrated inFIG. 6 b in conduit G combines with the methane refrigerant stream inconduit 168 inFIG. 6 a exitingmain methane economizer 36 prior to being injected into the high-stage inlet port ofmethane compressor 32. The compressed methane refrigerant stream is routed viaconduit 192 tomethane cooler 34, wherein the stream is cooled via indirect heat exchange with an external fluid (e.g., air or water). The resulting stream exitsmethane cooler 34, whereupon a portion of the recycled methane refrigerant stream is routed toFIG. 6 b via conduit E for further processing. The remaining methane refrigerant stream inconduit 152 inFIG. 6 a enters high-stage propane chiller 18, wherein it is further cooled by indirect heat exchange means 4, as previously noted. The resulting stream then flows throughconduit 154 and entersmain methane economizer 36, wherein the methane refrigerant stream is further cooled via indirect heat exchange means 98. The resulting stream exitsmain methane economizer 36 viaconduit 158 and enters low-stage ethylene chiller/condenser 28. Subsequently, the methane refrigerant stream is further cooled via indirect heat exchange means 91, which utilizes the ethylene refrigerant described in detail inFIG. 1 a as a coolant. The resulting stream inFIG. 6 a exits low-stage ethylene chiller/condenser 28 via conduit I and is routed to the heavies removal/NGL recovery system illustrated inFIG. 6 b. - Turning now to
FIG. 6 b, a further embodiment of the heavies removal/NGL recovery system of the LNG facility is shown. The main components of the system illustrated inFIG. 6 b include afirst distillation column 952, asecond distillation column 954, a maineconomizing heat exchanger 904, a first distillation column economizingheat exchanger 902, an intermediate stageseparator heat exchanger 906, and an intermediate-stage flash drum 956. In one embodiment of the present invention,first distillation column 952 can be operated as a demethanizer and thesecond distillation column 954 can be operated as a deethanizer. According to one embodiment,first distillation column 952 is refluxed by a stream comprised primarily of methane. - The operation of the system illustrated in
FIG. 6 b will now be described in detail, beginning withfirst distillation column 952. Streams in conduits B and D enter from the outlets of low-stage propane chiller 18 and high-stage ethylene chiller 24, respectively, as discussed previously with respect toFIG. 6 a. According toFIG. 6 b, the two streams combine inconduit 926 prior to enteringfirst distillation column 952. The flow of relatively warmer stream D can be manipulated viavalve 925 to maintain a desired temperature to firstdistillation column feed 926. The vapor product inFIG. 6 b from the overhead port offirst distillation column 952 exits via conduit F and enters intermediate-stage ethylene chiller 26, as discussed previously inFIG. 6 a. This stream will ultimately become the finished LNG product. - A portion of the methane recycle stream in
FIG. 6 a is routed toFIG. 6 b via conduit E. Thereafter, the stream in conduit E splits into several conduits. One portion of the stream in conduit E flows throughconduit 928, whereupon a further portion of the stream is routed by way ofconduit 936 to the maineconomizing heat exchanger 904, wherein the stream is heated and at least partially vaporized via an indirect heat exchange means 963. The resultant stream exits maineconomizing heat exchanger 904 viaconduit 938 and combines with a yet-to-be-discussed stream inconduit 934. Referring back toconduit 928, the remaining portion of the stream enters intermediate stage separator economizingheat exchanger 906, wherein the stream is cooled via an indirect heat exchange means 930. The resulting, cooled stream exits via conduit H and is routed to the inlet of low-stage propane chiller 18 inFIG. 6 a, as previously noted. InFIG. 6 b, the remainder of the stream in conduit E enters the first distillation column economizingheat exchanger 902, wherein the stream is heated (reboiled) via an indirect heat exchanges means 916. The resulting, at least partially vaporized stream, exits first distillation column economizingheat exchanger 902 viaconduit 934, whereupon it combines with the heated stream inconduit 938, as noted previously. The composite stream flows viaconduit 940 intofirst distillation column 952, wherein it is employed as a stripping gas. The stream in conduit I enters from the outlet of intermediate-stage ethylene chiller 26 inFIG. 6 a, as previously noted. According toFIG. 4 b, this primarily methane stream is refluxed back tofirst distillation column 952 inFIG. 6 b. - The liquid product from the bottom port of
first distillation column 952 exits viaconduit 942. A portion of the stream is then routed viaconduit 944 to intermediate-stage separator 956, wherein the vapor and liquid phases are separated. The vapor phase exits viaconduit 946 and is routed to intermediate stage separator economizingheat exchanger 906, wherein the stream is warmed via an indirect heat exchange means 932. The resulting stream exits intermediate stage separator economizingheat exchanger 906 and is routed via conduit G to the high-stage inlet port ofmethane compressor 32 inFIG. 6 a as previously described. - According to
FIG. 6 b, a liquid stream exits intermediate-stage separation vessel 956 viaconduit 948 and combines with a yet-to-be-discussed stream inconduit 974. Two side streams are removed from intermediatestage flash drum 956. One side stream is drawn fromintermediate separation vessel 956 viaconduit 950. The side stream flows to maineconomizing heat exchanger 904, wherein it is heated (reboiled) via an indirect heat exchange means 962. The resulting stream combines with a yet-to-be-discussed stream inconduit 964 and returns to the intermediate-stage separation vessel 956 viaconduit 960. Another side stream is drawn fromintermediate separation vessel 956 and routed to maineconomizing heat exchanger 904 viaconduit 966. The stream is then heated and at least partially vaporized via an indirect heat exchange means 970. The resulting stream exits maineconomizing heat exchanger 904 viaconduit 972 and is returned to intermediate-stage separation vessel 956. - Turning now to the remainder of the bottom liquid product from
first distillation column 952 inconduit 942, the stream enters first distillation column economizingheat exchanger 902, wherein it is cooled via indirect heat exchange means 918. The resulting cooled liquid is travels viaconduit 976 to acondenser 920, wherein the stream inconduit 976 acts as a coolant for a yet to be discussed stream inconduit 978. After exitingcondenser 920, the resulting, heated stream inconduit 968 divides into two streams inconduits conduit 964 combines with the stream exiting maineconomizing heat exchanger 904 inconduit 960 prior to entering intermediate-stage separation vessel 956, as discussed previously. The portion of the heated stream inconduit 974 combines with the liquid phase exitingintermediate separation vessel 956 viaconduit 948. The resulting composite stream enterssecond distillation column 954 viaconduit 980. - The vapor product from the overhead port of
second distillation column 954 exits viaconduit 978 and enterscondenser 920, wherein the stream is condensed via indirect heat exchange with the liquid stream from the bottom port offirst distillation column 952 inconduit 976, as discussed previously. The at least partially condensed stream travels viaconduit 982 to second distillationcolumn separation vessel 908, wherein the vapor and liquid phases are separated. The predominantly ethane-rich vapor phase exits second distillationcolumn separation vessel 908 and is routed for further processing and/or storage viaconduit 984. The liquid phase leaves second distillationcolumn separation vessel 908 viaconduit 986 and enters the suction of areflux pump 910.Reflux pump 910 discharges the stream as reflux tosecond distillation column 954 viaconduit 988. - A side stream is drawn from
second distillation column 954 viaconduit 990. The stream is routed to aheater 912, wherein it is heated (reboiled) via indirect heat exchange with an external fluid (e.g., steam or heat transfer fluid). The vaporized portion of the stream is returned tosecond distillation column 954 viaconduit 992, wherein it is employed as a stripping gas. The resulting liquid portion exits seconddistillation column reboiler 912 viaconduit 994, whereupon it combines with the liquid product from the bottom port ofsecond distillation column 954 inconduit 996. The resulting composite stream is the final NGL product. The final NGL product is comprised of ethane and heavier components and is routed to storage and/or further processing viaconduit 998. - In accordance to one embodiment of the present invention, the heating values of the LNG product can be adjusted by varying one or more operating parameters of the system illustrated in
FIG. 6 b. For example, in order to produce LNG of lower heating value, one or more of the following adjustments could be made to the operating parameters ofdistillation columns 952 and/or 954: (1) lower the temperature offeed stream 26 tofirst distillation column 952; (2) lower the flow of strippinggas stream 940 tofirst distillation column 952; and (3) increase the flow of reflux stream I tofirst distillation column 952. As discussed previously with reference toFIG. 1 b, several methods, including those well known to one skilled in the art, exist to affect the adjustments listed in items (1)-(3) above. - Similarly to
FIGS. 1 a and 1 b, it should be understood that the heating value of the LNG product from the LNG facility ofFIGS. 6 a and 6 b can be increased by performing the converse of one or more of the above-described operations. - Still another embodiment of the inventive LNG facility is illustrated in
FIGS. 7 a and 7 b. Another embodiment of the heavies removal/NGL recovery system of the facility is illustrated inFIG. 7 b. Lines H, D, B, F, E, and G illustrate how the system shown inFIG. 7 b is integrated with the LNG facility inFIG. 7 a. According to one embodiment of the present invention, the LNG facility can be operated to maximize C2+ recovery in the final NGL product. - The main components of the system in
FIG. 7 a are the same as those listed inFIG. 1 a. The operation ofFIG. 7 a, as it differs from the operation of the system previously described with respect toFIG. 1 a, will now be explained in detail. The methane-rich stream exits intermediate-stage propane chiller 16 viaconduit 112, whereupon it combines with a yet-to-be discussed stream in conduit H fromFIG. 7 b. The operation of the system illustrated inFIG. 7 b will be discussed in detail shortly. The composite stream enters low-stage propane chiller 18, wherein the stream is cooled via indirect heat exchange means 64. The resulting, cooled stream exits low-stage propane chiller 18 viaconduit 114, whereupon a portion of the stream is routed via conduit D for further processing in the heavies removal/NGL recovery system shown inFIG. 7 b, to be discussed in detail later. - The remaining methane-rich stream enters high-
stage ethylene chiller 24, wherein it is cooled via indirect heat exchange means 82. The resulting stream is routed via conduit B to the heavies removal/NGL recovery system inFIG. 7 b. After additional processing, to be discussed later, the methane-rich stream returns toFIG. 7 a via conduit F, whereupon it enters intermediate-stage ethylene chiller 26 and is cooled via indirect heat exchange means 84. The resulting stream flows viaconduit 119 and combines with the methane refrigerant recycle stream inconduit 158. The composite stream flows viaconduit 120 into low-stage ethylene chiller/condenser 28, wherein it is further cooled via indirect heat exchange means 90. The resulting pressurized, LNG-bearing stream exits low-stage ethylene chiller/condenser 28 viaconduit 122 and is routed tomain methane economizer 36. The pressurized, LNG-bearing stream then continues through the indirect heat exchange and expansion cooling stages of the methane refrigeration cycle, as previously described in reference toFIG. 1 a. Similarly toFIG. 1 a, the resultant liquid from the last expansion stage is the final LNG product inFIG. 7 a. - In the methane refrigeration cycle illustrated in
FIG. 7 a, a yet-to-be-discussed stream in conduit G originates in the heavies removal/NGL recovery system illustrated inFIG. 7 b and entersFIG. 7 a, wherein it combines with the methane refrigerant stream inconduit 168 upstream of the high-stage inlet port ofmethane compressor 32. The compressed composite stream is routed viaconduit 192 tomethane cooler 34, wherein the stream is cooled via indirect heat exchange with an external fluid (e.g., air or water). A portion of the resulting stream is routed toFIG. 7 b via conduit E for further processing. The remainder of the refrigerant stream flows viaconduit 152 to high-stage propane chiller 14 and is processed as described previously with respect toFIG. 1 a. - Turning now to
FIG. 7 b, the heavies removal/NGL recovery system of the inventive LNG facility is shown. The main components of the system shown inFIG. 7 b include afirst distillation column 1052, asecond distillation column 1054, a maineconomizing heat exchanger 1004, a first distillation column economizingheat exchanger 1002, an intermediate stageseparator heat exchanger 1006, and an intermediate-stage flash drum 1056. In one embodiment of the present invention,first distillation column 1052 can be operated as a demethanizer and thesecond distillation column 1054 can be operated as a deethanizer. According to one embodiment,first distillation column 1052 is not refluxed. - The operation of the system illustrated in
FIG. 7 b is analogous to the operation as described with respect to the heavies removal/NGL recovery system illustrated inFIG. 6 b, exceptfirst distillation column 1052 inFIG. 7 b has no reflux stream. The lines and components inFIG. 7 b are numerically labeled with a value that is 100 greater than the corresponding lines inFIG. 6 b. Lettered lines (e.g., B, D, E, F, G, H) are the same inFIGS. 7 b and 6 b. The function and operation of the corresponding lines and components inFIG. 7 b are analogous to those described previously in reference toFIG. 6 b. For example, strippinggas stream 1040 tofirst distillation column 1052 inFIG. 7 b directly corresponds to the function and operation of strippinggas stream 940 tofirst distillation column 952 inFIG. 6 b. - In accordance to one embodiment of the present invention, the heating values of the LNG product can be adjusted by varying one or more operating parameters of the system illustrated in
FIG. 7 b. For example, in order to produce LNG of lower heating value, one or more of the following adjustments could be made to the operating parameters ofdistillation columns 1052 and/or 1054: (1) lower the temperature offeed stream 26 tofirst distillation column 1052; (2) lower the flow of strippinggas stream 1040 tofirst distillation column 1052; and/or (3) increase the flow ofreflux stream 1088 tosecond distillation column 1054. As discussed previously with reference toFIG. 1 b, several methods, including those well known to one skilled in the art, exist to affect the adjustments listed in items (1)-(3) above. - Similarly to
FIGS. 1 a and 1 b, it should be understood that the heating value of the LNG product from the LNG facility ofFIGS. 7 a and 7 b can be increased by performing the converse of one or more of the above-described operations. - In one embodiment of the present invention, the LNG production systems illustrated in
FIGS. 1-7 are simulated on a computer using conventional process simulation software. Examples of suitable simulation software include HYSYS™ from Hyprotech, Aspen Plus® from Aspen Technology, Inc., and PRO/II® from Simulation Sciences Inc. - The preferred forms of the invention described above are to be used as illustration only, and should not be used in a limiting sense to interpret the scope of the present invention. Obvious modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.
- The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.
- Numerical Ranges
- The present description uses numerical ranges to quantify certain parameters relating to the invention. It should be understood that when numerical ranges are provided, such ranges are to be construed as providing literal support for claim limitations that only recite the lower value of the range as well as claims limitation that only recite the upper value of the range. For example, a disclosed numerical range of 10 to 100 provides literal support for a claim reciting “greater than 10” (with no upper bounds) and a claim reciting “less than 100” (with no lower bounds).
- The present description uses specific numerical values to quantify certain parameters relating to the invention, where the specific numerical values are not expressly part of a numerical range. It should be understood that each specific numerical value provided herein is to be construed as providing literal support for a broad, intermediate, and narrow range. The broad range associated with each specific numerical value is the numerical value plus and minus 60 percent of the numerical value, rounded to two significant digits. The intermediate range associated with each specific numerical value is the numerical value plus and minus 30 percent of the numerical value, rounded to two significant digits. The narrow range associated with each specific numerical value is the numerical value plus and minus 15 percent of the numerical value, rounded to two significant digits. For example, if the specification describes a specific temperature of 62° F., such a description provides literal support for a broad numerical range of 25° F. to 99° F. (62° F.+/−37° F.), an intermediate numerical range of 43° F. to 81° F. (62° F.+/−19° F.), and a narrow numerical range of 53° F. to 71° F. (62° F.+/−9° F.). These broad, intermediate, and narrow numerical ranges should be applied not only to the specific values, but should also be applied to differences between these specific values. Thus, if the specification describes a first pressure of 110 psia and a second pressure of 48 psia (a difference of 62 psi), the broad, intermediate, and narrow ranges for the pressure difference between these two streams would be 25 to 99 psi, 43 to 81 psi, and 53 to 71 psi, respectively.
- Definitions
- As used herein, the term “natural gas” means a stream containing at least 65 mole percent methane, with the balance being ethane, higher hydrocarbons, nitrogen, carbon dioxide, and/or a minor amount of other contaminants such as mercury, hydrogen sulfide, and mercaptan.
- As used herein, the term “mixed refrigerant” means a refrigerant containing a plurality of different components, where no single component makes up more than 75 mole percent of the refrigerant.
- As used herein, the term “pure component refrigerant” means a refrigerant that is not a mixed refrigerant.
- As used herein, the term “cascade refrigeration process” means a refrigeration process that employs a plurality of refrigeration cycles, each employing a different pure component refrigerant to successively cool natural gas.
- As used herein, the term “open-cycle cascaded refrigeration process” refers to a cascaded refrigeration process comprising at least one closed refrigeration cycle and one open refrigeration cycle, where the boiling point of the refrigerant employed in the open cycle is less than the boiling point of the refrigerant employed in the closed cycle, and a portion of the cooling duty to condense the open-cycle refrigerant is provided by one or more of the closed cycles. In one embodiment of the present invention, a predominately methane stream is employed as the refrigerant in the open refrigeration cycle. This predominantly methane stream originates from the processed natural gas feed stream and can include the compressed open methane cycle gas streams.
- As used herein, the term “expansion-type cooling” refers to cooling which occurs when the pressure of a gas, liquid, or two-phase system is decreased by passage through a pressure reduction means. In one embodiment, the expansion means is a Joule-Thompson expansion valve. In another embodiment of the present invention, the expansion means is a hydraulic or gas expander.
- As used herein, the term “mid-boiling point” refers to the temperature at which half of the weight of a mixture of physical components has been vaporized (i.e., boiled off) at a specific pressure.
- As used herein, the term “indirect heat exchange” refers to a process wherein the refrigerant cools the substance to be cooled without actual physical contact between the refrigerating agent and the substance to be cooled. Core-in-kettle heat exchangers and brazed aluminum plate-fin heat exchangers are specific examples of equipment that facilitate indirect heat exchange.
- As used herein, the terms “economizer” or “economizing heat exchanger” refer to a configuration utilizing a plurality of heat exchangers employing indirect heat exchange means to efficiently transfer heat between process streams. Generally, economizers minimize outside energy inputs by heat integrating process streams with each other.
- As used herein, the term “higher heating value” or “HHV” refers to a measure of the heat released when an LNG product is combusted, accounting for the energy required to vaporize the water that results from the combustion reaction.
- As used herein, the term “BTU content” is synonymous with the term “higher heating value.”
- As used herein, the term “distillation column” or “separator” refer to a device for separating a stream based on relative volatility.
- As used herein, the term “steady state operation” shall mean periods of relatively steady and continuous operation between start-up and shut-down.
- As used herein, the term “non-feed operating parameter” shall mean any operating parameter of an item of equipment or a facility other than the composition of the main feed(s) to that item of equipment or facility.
- As used herein, the terms “natural gas liquids” or “NGL” refer to mixtures of hydrocarbons whose components are, for example, typically heavier than ethane. Some examples of hydrocarbon components of NGL streams include propane, butane, and pentane isomers, benzene, toluene, and other aromatic molecules. Ethane may also be included in an NGL mixture.
- As used herein, the terms “upstream” and “downstream” refer to the relative positions of various components of a natural gas liquefaction facility along the main flow path of natural gas through the plant.
- As used herein, the terms “predominantly,” “primarily,” “principally,” and “in major portion,” when used to describe the presence of a particular component of a fluid stream, means that the fluid stream comprises at least 50 mole percent of the stated component. For example, a “predominantly” methane stream, a “primarily” methane stream, a stream “principally” comprised of methane, or a stream comprised “in major portion” of methane each denote a stream comprising at least 50 mole percent methane.
- As used herein, the term “and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.
- As used herein, the terms “comprising,” “comprises,” and “comprise” are open-ended transition terms used to transition from a subject recited before the term to one or elements recited after the term, where the element or elements listed after the transition term are not necessarily the only elements that make up of the subject.
- As used herein, the terms “including,” “includes,” and “include” have the same open-ended meaning as “comprising,” “comprises,” and “comprise.”
- As used herein, the terms “having,” “has,” and “have” have the same open-ended meaning as “comprising,” “comprises,” and “comprise.”
- As used herein, the terms “containing,” “contains,” and “contain” have the same open-ended meaning as “comprising,” “comprises,” and “comprise.”
- As used herein, the terms “a,” “an,” “the,” and “said” means one or more.
- The preferred forms of the invention described above are to be used as illustration only, and should not be used in a limiting sense to interpret the scope of the present invention. Obvious modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.
Claims (62)
1. A process for producing liquefied natural gas (LNG), said process comprising:
(a) operating an LNG facility in a first mode of operation to thereby produce a first LNG product;
(b) adjusting at least one non-feed operating parameter of the LNG facility so that the LNG facility operates in a second mode of operation; and
(c) operating the LNG facility in the second mode of operation to thereby produce a second LNG product, wherein said first and second modes of operation are not carried out during start-up or shut-down of the LNG facility, wherein said operating of steps (a) and (c) optionally includes producing first and second natural gas liquids (NGL) products respectively, wherein the average higher heating value (HHV) of the second LNG product is at least about 10 BTU/SCF different than the average HHV of the first LNG product and/or the average propane content of the second NGL product is at least about 1 mole percent different than the average propane content of the first NGL product.
2. The process of claim 1 , wherein said adjusting of step (b) includes transitioning said LNG facility from said first mode of operation to said second mode of operation without ceasing the production of LNG.
3. The process of claim 1 , wherein said adjusting of step (b) includes adjusting at least one operating parameter of a distillation column of the LNG facility.
4. The process of claim 3 , wherein said operating parameter of said distillation column includes at least one operating parameter selected from the group consisting of column feed composition, column feed temperature, column overhead pressure, reflux stream flow rate, reflux stream composition, reflux stream temperature, stripping gas flow rate, stripping gas composition, and stripping gas temperature.
5. The process of claim 3 , wherein said operating of steps (a) and (c) includes using said distillation column to separate a stream into a relatively more volatile fraction and a relatively less volatile fraction, wherein said first and second LNG products comprise at least a portion of said relatively more volatile fraction and/or said first and second NGL products comprise at least a portion of said relatively less volatile fraction.
6. The process of claim 5 , wherein said first and second LNG products comprise at least a portion of said relatively more volatile fraction and said first and second NGL products comprise at least a portion of said relatively less volatile fraction.
7. The process of claim 1 , wherein said operating of steps (a) and (c) includes cooling a natural gas feed stream, separating the cooled natural gas feed stream into a first relatively more volatile fraction and a first relatively less volatile fraction using a first distillation column, and further cooling at least a portion of the first relatively more volatile fraction to thereby produce at least a portion of the first and second LNG products.
8. The process of claim 7 , wherein said operating of steps (a) and (c) includes separating at least a portion of the first relatively less volatile fraction into a second relatively more volatile fraction and a second relatively less volatile fraction using a second distillation column.
9. The process of claim 8 , wherein said operating of steps (a) and (c) include further cooling at least a portion of the second relatively more volatile fraction to thereby produce at least a portion of said first and second LNG products.
10. The process of claim 8 , wherein said first and second NGL products comprise at least a portion of the second relatively less volatile fraction.
11. The process of claim 7 , wherein at least a portion of said cooling of the natural gas feed stream is carried out using a first refrigeration cycle employing a first refrigerant having a mid-boiling point within about 20° F. of the boiling point of pure propane at atmospheric pressure.
12. The process of claim 11 , wherein at least a portion of said further cooling of the first relatively more volatile fraction is carried out using a second refrigeration cycle employing a second refrigerant having a mid-boiling point within about 20° F. of the boiling point of pure methane at atmospheric pressure.
13. The process of claim 12 , wherein at least a portion of said further cooling of the first relatively more volatile fraction is carried out using a third refrigeration cycle employing a third refrigerant having a mid-boiling point within about 20° F. of pure ethylene at atmospheric pressure.
14. The process of claim 13 , wherein said first, second, and third refrigerants are pure component refrigerants.
15. The process of claim 1 , wherein said operating of steps (a) and (c) includes using a first distillation column to separate a first stream into a first relatively more volatile fraction and a first relatively less volatile fraction and using a second distillation column to separate at least a portion of said first relatively less volatile fraction into a second relatively more volatile fraction and a second relatively less volatile fraction.
16. The process of claim 15 , wherein said first and second LNG products comprise at least a portion of the first and second relatively more volatile fractions.
17. The process of claim 15 , wherein said first and second NGL products comprise at least a portion of the second relatively less volatile fraction.
18. The process of claim 15 , wherein said at least one non-feed operating parameter is an operating parameter of the first and/or second distillation column.
19. The process of claim 17 , wherein said first distillation column is refluxed with at least a portion of the second relatively more volatile fraction.
20. The process of claim 19 , wherein said adjusting of step (b) includes adjusting the temperature and/or flow rate of the reflux into the first distillation column.
21. The process of claim 1 , wherein the average HHV of the second LNG product is at least about 10 BTU/SCF different than the average HHV of the first LNG product.
22. The process of claim 1 , wherein the average propane content of the second NGL product is at least about 1 mole percent different than the average propane content of the first NGL product.
23. The process of claim 1 , wherein the average HHV of the second LNG product is at least about 20 BTU/SCF different than the average HHV of the first LNG product.
24. The process of claim 1 , wherein the average propane content of the second NGL product is at least about 2 mole percent different than the average propane content of the first NGL product.
25. The process of claim 1 , wherein said first LNG product is produced over a first production time period of at least one week, wherein said second LNG product is produced over a second production time period of at least one week, wherein said first and second production time periods are separated by a transition time period of less than one week.
26. The process of claim 1 , wherein said transition time period is less than one day.
27. A method of varying the heating value of LNG produced from an LNG facility, said method comprising:
(a) cooling natural gas by indirect heat exchange to thereby produce a first cooled stream;
(b) using a first distillation column to separate at least a portion of the first cooled stream into a first relatively more volatile fraction and a first relatively less volatile fraction;
(c) cooling at least a portion of said first relatively more volatile fraction to thereby produce LNG; and
(d) adjusting at least one operating parameter of the first distillation column to thereby vary the higher heating value (HHV) of the produced LNG by at least about 1 percent over a time period of less than about 72 hours.
28. The method according to claim 27 , wherein said at least one operating parameter of the first distillation column is selected from the group consisting of temperature of the first cooled stream, composition of the first cooled stream, and overhead pressure of the first distillation column.
29. The method according to claim 27 , wherein said at least one operating parameter of the first distillation is a non-feed operating parameter.
30. The method according to claim 27 , wherein step (d) includes adjusting the overhead pressure in the first distillation column.
31. The method according to claim 27 , wherein step (d) includes adjusting the temperature of the first cooled stream prior to introduction into the first distillation column.
32. The method according to claim 31 , wherein step (d) includes reducing the temperature of the first cooled stream to thereby lower the HHV of the produced LNG.
33. The method according to claim 32 , wherein said first cooled stream has a temperature in the range of from about −125 to about −50° F. when introduced into the first distillation column, wherein step (d) includes reducing the temperature of the first cooled stream by at least about 1° F.
34. The method according to claim 32 , wherein said first cooled stream has a temperature in the range of from about −115 to about −65° F. when introduced into the first distillation column, wherein step (d) includes reducing the temperature of the first cooled stream by at least about 3° F.
35. The method according to claim 27 , wherein step (b) includes introducing a predominately vapor stripping gas stream into a lower section of the first distillation column.
36. The method according to claim 35 , wherein said at least one operating parameter of the first distillation column is selected from the group consisting of flow rate of the stripping gas stream, temperature of the stripping gas stream, composition of the stripping gas stream, temperature of the first cooled stream, composition of the first cooled stream, and overhead pressure of the first distillation column.
37. The method according to claim 35 , wherein step (d) includes varying the flow rate of the stripping gas stream to the first distillation column.
38. The method according to claim 35 , wherein step (d) includes lowering the flow rate of the stripping gas stream to the first distillation column to thereby lower the HHV of the produced LNG.
39. The method according to claim 35 , wherein said first cooled stream has a temperature in the range of from about −125 to about −50° F. when introduced into the first distillation column, wherein said stripping gas stream has a temperature in the range from about −50 to about 100° F. when introduced into the first distillation column, wherein step (d) includes lowering the temperature of the stripping gas stream by at least 5° F. to thereby lower the HHV of the produced LNG.
40. The method according to claim 27 , wherein step (b) includes introducing a predominately liquid reflux stream into an upper section of the first distillation column.
41. The method according to claim 40 , wherein said at least one operating parameter of the first distillation column is selected from the group consisting of flow rate of the reflux stream, temperature of the reflux stream, composition of the reflux stream, temperature of the first cooled stream, composition of the first cooled stream, and overhead pressure in the first distillation column.
42. The method according to claim 40 , wherein step (d) includes varying the flow rate of the reflux stream to the first distillation column.
43. The method according to claim 40 , wherein step (d) includes increasing the flow rate of the reflux stream to the first distillation column to thereby lower the HHV of the produced LNG.
44. The method according to claim 40 , wherein step (d) includes varying the C2+ content of the reflux stream.
45. The method according to claim 40 , wherein step (d) includes increasing the C2+ content of the reflux stream from an initial C2+ content to an adjusted C2+ content to thereby lower the HHV of the LNG product.
46. The method according to claim 45 , wherein said adjusted C2+ content is at least about 10 percent more than the initial C2+ content on a molar basis.
47. The method according to claim 45 , wherein said initial C2+ content is less than about 75 mole percent and said adjusted C2+ content is at least about 25 mole percent.
48. The method according to claim 40 , wherein step (d) includes varying the temperature of the reflux stream.
49. The method according to claim 40 , wherein said first cooled stream has a temperature in the range of from about −125 to about −50° F. when introduced into the first distillation column, wherein said reflux stream has a temperature in the range from about −180 to about −80° F. when introduced into the first distillation column, wherein step (d) includes lowering the temperature of the reflux stream by a least about 5° F. to thereby lower the HHV of the produced LNG.
50. The method according to claim 40 , wherein step (d) includes varying the flow rate of the LNG stream to the first distillation column.
51. The method according to claim 40 , wherein step (d) includes increasing the flow rate of the LNG stream to the first distillation column to thereby lower the HHV of the produced LNG.
52. The method according to claim 27 , further comprising:
(e) using a second distillation column to separate at least a portion of said first relatively less volatile fraction into a second relatively more volatile fraction and a second relatively less volatile fraction.
53. The method according to claim 52 , further comprising:
(f) introducing at least a portion of said second relatively less volatile fraction into an upper section of said first distillation column as a reflux stream.
54. The method according to claim 52 , further comprising:
(g) adjusting at least one operating parameter of the second distillation column to thereby vary the HHV of the produced LNG.
55. The method according to claim 54 , wherein said at least one operating parameter of the second distillation column is selected from the group consisting of temperature of said first relatively less volatile fraction introduced into the second distillation column, composition of said first relatively less volatile fraction introduced into the second distillation column, and overhead pressure in the second distillation column.
56. The method according to claim 54 , further comprising:
(h) introducing at least a portion of said second relatively less volatile fraction into an upper section of said first distillation column as a reflux stream, wherein step (g) includes varying the C2+ content of the reflux stream.
57. The method according to claim 27 , wherein step (a) includes using a first refrigeration cycle employing a first refrigerant comprising predominantly propane to cool at least a portion of the natural gas.
58. The method according to claim 57 , wherein step (c) includes using a second refrigeration cycle employing a second refrigerant comprising predominantly ethane, ethylene, and/or methane to cool at least a portion of the first separated stream.
59. The method according to claim 58 , wherein said second refrigerant comprises predominately methane.
60. The method according to claim 59 , further comprising:
(i) using a third refrigeration cycle employing a third refrigerant comprising predominately ethane and/or ethylene to cool at least a portion of the first cooled stream and/or at least a portion of the first separated stream.
61. The method according to claim 27 , wherein step (d) includes varying the HHV of the produced LNG by at least about 3 percent over a time period of less than about 24 hours.
62. The method according to claim 27 , wherein step (d) includes varying the HHV of the produced LNG by at least 5 percent over a time period of less than 12 hours.
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EA200800296A EA015525B1 (en) | 2005-07-12 | 2006-07-06 | Process for producing liquefied natural gas with different average higher heating value |
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CN2006800333003A CN101506605B (en) | 2005-07-12 | 2006-07-06 | LNG facility with integrated NGL for enhanced liquid recovery and product flexibility |
JP2008521451A JP5256034B2 (en) | 2005-07-12 | 2006-07-06 | LNG facility with integrated NGL extending the versatility of liquid restoration and production |
MYPI20063288 MY152617A (en) | 2005-07-12 | 2006-07-11 | Lng facility with integrated ngl for enhanced liquid recovery and product flexibility |
PE2010000383A PE20100530A1 (en) | 2005-07-12 | 2006-07-12 | METHOD TO VARY THE HEATING VALUE OF LIQUEFIED NATURAL GAS (LNG) PRODUCED IN AN LNG INSTALLATION |
PE2006000828A PE20070467A1 (en) | 2005-07-12 | 2006-07-12 | PROCESS TO OBTAIN LIQUEFIED NATURAL GAS (LNG) AND / OR LIQUID FROM NATURAL GAS (NGL) OPERATING AN LNG INSTALLATION |
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CL2012001129A CL2012001129A1 (en) | 2005-07-12 | 2012-04-30 | Method to vary the heating value hhv of liquefied natural gas gnl, which comprises cooling the natural gas to obtain a cooled stream, distilling said stream, cooling part of the most volatile fraction to obtain gnl, and adjusting at least one or more parameter of the distillation column to vary the hhv. |
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JP2012141128A (en) | 2012-07-26 |
MY152617A (en) | 2014-10-31 |
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KR101319793B1 (en) | 2013-10-22 |
EA200800296A1 (en) | 2008-06-30 |
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CN101506605B (en) | 2013-04-24 |
EA015525B1 (en) | 2011-08-30 |
PE20100530A1 (en) | 2010-08-20 |
JP2009503127A (en) | 2009-01-29 |
PE20070467A1 (en) | 2007-06-14 |
AU2006269366B2 (en) | 2012-03-08 |
CN101506605A (en) | 2009-08-12 |
WO2007008638A3 (en) | 2009-05-07 |
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