US20100011808A1 - Method and apparatus for liquefying a hydrocarbon stream - Google Patents

Method and apparatus for liquefying a hydrocarbon stream Download PDF

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US20100011808A1
US20100011808A1 US12/374,338 US37433807A US2010011808A1 US 20100011808 A1 US20100011808 A1 US 20100011808A1 US 37433807 A US37433807 A US 37433807A US 2010011808 A1 US2010011808 A1 US 2010011808A1
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refrigerant
stream
cooling stage
cooled
heat exchangers
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US12/374,338
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Marco Dick Jager
Robert Klein Nagelvoort
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Shell USA Inc
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Assigned to SHELL OIL COMPANY reassignment SHELL OIL COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JAGER, MARCO DICK, KLEIN NAGELVOORT, ROBERT
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0292—Refrigerant compression by cold or cryogenic suction of the refrigerant gas
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0032—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration"
    • F25J1/0042—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by liquid expansion with extraction of work
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0047—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle
    • F25J1/0052—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0047—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle
    • F25J1/0052—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream
    • F25J1/0055—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream originating from an incorporated cascade
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0047—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle
    • F25J1/0052—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream
    • F25J1/0057—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream after expansion of the liquid refrigerant stream with extraction of work
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0211—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle
    • F25J1/0214—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0211—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle
    • F25J1/0217—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as at least a three level refrigeration cascade with at least one MCR cycle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0281—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc. characterised by the type of prime driver, e.g. hot gas expander
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0281—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc. characterised by the type of prime driver, e.g. hot gas expander
    • F25J1/0283—Gas turbine as the prime mechanical driver
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0285—Combination of different types of drivers mechanically coupled to the same refrigerant compressor, possibly split on multiple compressor casings
    • F25J1/0288—Combination of different types of drivers mechanically coupled to the same refrigerant compressor, possibly split on multiple compressor casings using work extraction by mechanical coupling of compression and expansion of the refrigerant, so-called companders
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0291—Refrigerant compression by combined gas compression and liquid pumping
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2220/00—Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60—Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/62—Separating low boiling components, e.g. He, H2, N2, Air

Definitions

  • the present invention relates to a method and apparatus for liquefying a hydrocarbon stream, particularly but not exclusively natural gas.
  • LNG liquefied natural gas
  • U.S. Pat. No. 6,105,389A shows a method and device for liquefying natural gas using a compressed coolant mixture which is sub-cooled, expanded and vapourized, followed by a second cooling stage to liquefy the natural gas.
  • the first cooling stage fractions of the first coolant mixture are expanded by expansion valves to cool the coolant mixture.
  • expansion valves are isenthalpic, so that the work which is available from the expansion of a fluid such as a coolant as it is let down in pressure in such a valve, is essentially lost.
  • the present invention providing a method of liquefying a hydrocarbon stream such as natural gas from a feed stream, the method at least comprising the steps of:
  • step (e) passing the cooled hydrocarbon stream through a second cooling stage against a second refrigerant stream to provide a liquefied hydrocarbon stream; wherein at least one expander is an expansion turbine whose work energy created in step (c) is used in the first refrigerant circuit.
  • An advantage of the present invention is that by expanding at least a part of the first refrigerant stream through one or more expansion turbines to decrease the pressure of the first refrigerant prior to its use for cooling the feed stream in the heat exchanger(s), the expansion of the first refrigerant is near isentropic, which improves the efficiency of the first cooling.
  • the near isentropic expansion of any gas to a lower pressure reduces the internal energy out of the gas during the expansion, and produces at least a part of this energy as useful work.
  • This work energy can then be transferred and usefully employed elsewhere in the liquefying method, process and/or apparatus, such as to help drive another unit or device or part thereof, such as a compressor, pump, or electric generator.
  • the hydrocarbon stream may be any suitable gas stream to be liquefied, but is usually a natural gas stream obtained from natural gas or petroleum reservoirs.
  • the natural gas stream may also be obtained from another source, also including a synthetic source such as a Fischer-Tropsch process.
  • the natural gas stream is comprised substantially of methane.
  • the feed stream comprises at least 60 mol % methane, more preferably at least 80 mol % methane.
  • the natural gas may contain varying amounts of hydrocarbons heavier than methane such as ethane, propane, butanes and pentanes, as well as some aromatic hydrocarbons.
  • the natural gas stream may also contain non-hydrocarbons such as H 2 O, N 2 , CO 2 , H 2 S and other sulphur compounds, and the like.
  • the feed stream containing the natural gas may be pre-treated before use.
  • This pre-treatment may comprise reduction and/or removal of undesired components such as CO 2 and H 2 S or other steps such as early cooling, pre-pressurizing or the like. As these steps are well known to the person skilled in the art, they are not further discussed here.
  • feed stream as used herein relates to any hydrocarbon-containing composition usually containing a large amount of methane.
  • natural gas contained various amounts of ethane, propane and heavier hydrocarbons.
  • the composition varies depending upon the type and location of the gas. Hydrocarbons heavier than methane generally need to be removed from natural gas for several reasons, such as having different freezing or liquefaction temperatures that may cause them to block parts of a methane liquefaction plant. C2-4 hydrocarbons can be used as a source of natural gas liquids.
  • feed stream also includes a composition prior to any treatment, such treatment including cleaning, dehydration and/or scrubbing, as well as any composition having been partly, substantially or wholly treated for the reduction and/or removal of one or more compounds or substances, including but not limited to sulfur, sulfur compounds, carbon dioxide, water, and C 2 + hydrocarbons.
  • expander includes any unit, device or apparatus able to reduce the pressure in a stream. This includes valves as well as expansion turbines, and also includes one or two-phase expanders. Where at least one expander of the heat exchangers of the first cooling stage is an expansion turbine, one or more other expanders may be valves. Preferably, all of the heat exchangers of the first cooling stage are expansion turbines.
  • the first cooling stage of the present invention is intended to reduce the temperature of the cooled hydrocarbon stream to below 0° C., usually in the range ⁇ 20° C. to ⁇ 70° C. Such a cooling stage is sometimes also termed a ‘pre-cooling’ stage.
  • the second cooling stage is preferably separate from the first cooling stage. That is, the second cooling stage comprises one or more separate heat exchangers using a second refrigerant circulating in a second refrigerant circuit, although the refrigerant of the second refrigerant stream may also pass through at least one heat exchanger of the first cooling stage, preferably all the heat exchangers of the first cooling stage.
  • the first refrigerant circuit comprises one or more ambient coolers prior to the first heat exchanger.
  • the created work energy is used to increase the pressure of the first refrigerant stream prior to the first heat exchanger.
  • One example of this is to use the work energy to drive one or more pumps circulating the first refrigerant stream.
  • the use of work energy from one or more expansion turbines in a first cooling stage is particularly advantageous where the temperature of the associated refrigerant stream is not intended to be significantly low, such as ⁇ 50° C. or ⁇ 100° C., prior to expansion.
  • the increase in temperature in the refrigerant stream caused by its passage through one or more pumps, (where its increase in pressure causes an increase in temperature) can be more easily extracted by the use of one or more ambient coolers such as water and/or air coolers known in the art.
  • ambient coolers to reduce the temperature of a refrigerant stream intended to cool a hydrocarbon stream to a much lower temperature, such as below ⁇ 100° C., would be clearly insufficient.
  • the present invention is particularly advantageous where the work energy provided by each expansion turbine is used in a first cooling or pre-cooling stage, as no additional cooling is required in a first refrigerant circuit which already involves one or more ambient coolers prior to the heat exchanger(s). In this way, there is maximum usage of the work energy or exergy created, or at least minimum energy wastage, in the overall method of liquefaction.
  • the first cooling stage comprises two or three heat exchangers, and preferably, each heat exchanger has an associated expansion turbine through which at least a part of the first cooled refrigerant stream passes to provide an expanded cooled first refrigerant stream to its respective heat exchanger.
  • the present invention provides apparatus for liquefying a hydrocarbon stream such as natural gas stream from a feed stream, the apparatus at least comprising:
  • a first cooling stage having one or more heat exchangers to receive the first refrigerant stream and to provide a cooled first refrigerant stream
  • one or more expanders to expand at least a part of the cooled first refrigerant stream to provide one or more expanded first refrigerant streams, at least one expander being an expansion turbine whose work energy created by the expansion is used in the first refrigerant circuit;
  • the or each heat exchanger having a first inlet to pass the feed stream thereinto, and a second inlet to pass the or at least one of the expanded first refrigerant streams thereinto to cool the feed stream and so provide a cooled hydrocarbon stream;
  • a second cooling stage comprising one or more heat exchangers arranged to receive the cooled hydrocarbon stream from the first cooling stage and to provide a liquefied hydrocarbon stream.
  • FIG. 1 is a general scheme of a liquefying process according to one embodiment of the present invention.
  • FIG. 1 shows a general scheme for a liquefying a hydrocarbon stream such as natural gas. It shows an initial feed stream containing natural gas 10 , which feed stream may be pre-treated to separate out at least some heavier hydrocarbons and impurities such as carbon dioxide, nitrogen, helium, water, sulfur and sulfur compounds, including but not limited to acid gases.
  • the feed stream 10 passes through a first cooling stage 100 using a first refrigerant being cycled in a first cooling refrigerant circuit 110 , thereby obtaining a cooled hydrocarbon stream 40 b .
  • the first refrigerant may be any suitable component or, preferably, a mixture thereof, including one or more, preferably two or more, of nitrogen, methane, ethane, ethylene, propane, propylene, butane, pentane, etc.
  • the feed stream 10 passes into a first heat exchanger 14 a through inlet 32 a and passes therethrough as line 73 a . Meanwhile, the first refrigerant passes into the first heat exchanger 14 a through inlet 36 a and passes through the first heat exchanger 14 a as line 71 a . In this way, the first refrigerant line 71 a is also cooled in the first heat exchanger 14 a.
  • Outflowing the first heat exchanger 14 a through outlet 38 a is a cooled first refrigerant stream 20 a .
  • a suitable divider such as split piping
  • the first part 21 a is directed towards a first expansion turbine 12 a , which expands the first cooled first refrigerant fraction in a near isentropic manner to provide an expanded cooled first refrigerant stream 30 a .
  • the expanded stream 30 a has an internal energy that is lower than the internal energy of stream 21 a.
  • the difference in energy can be used as work, e.g. to drive a unit or device in the first refrigerant circuit 110 .
  • the energy provided by the first expansion turbine 12 a is used to drive a first pump 28 a which is part of the first refrigeration circuit 110 , and whose function is described hereinafter.
  • the ratio of the first and second parts 21 a , 21 b of the cooled first refrigerant stream 20 a in FIG. 1 can be any suitable ratio known in the art.
  • the first cooling stage 100 has two heat exchangers 14 a , 14 b , and uses a mixed refrigerant
  • an example ratio for two pressure levels is 35/65.
  • An example of possible pressure levels in the heat exchangers 14 a , 14 b is 8 bar for a high pressure exchanger and 3 bar for a low pressure exchanger.
  • the expanded stream 30 a is recycled into the first heat exchanger 14 a at or near the top thereof, and as the expanded stream 30 a passes downwardly through the heat exchanger 14 a and vapourises, it provides cooling to the lines in the first heat exchanger 14 a carrying the feed stream 10 (line 73 a ) and the first refrigerant (line 71 a ), as is known in the art. This provides a cooled hydrocarbon stream 40 a.
  • vapourized first refrigerant can be collected and outflowed via outlet 42 a from the first heat exchanger 14 a as a first vapour exit stream 90 a at or near its bottom end, and passed to the first compressor 22 for recompression and circulation in the first refrigerant circuit 110 .
  • the first refrigerant stream passes through outlet 38 b at or near the top of the second heat exchanger 14 b as a further cooled first refrigerant stream 20 b , and it is expanded through a second expansion turbine 12 b to provide a second expanded first refrigerant stream 30 b , which can then be passed back into the second heat exchanger 14 b via inlet 44 b for downward passage therethrough.
  • the second expanded stream 30 b passes downwardly though the second heat exchanger 14 b , it provides cooling to the lines of hydrocarbon stream (line 73 b ) and first refrigerant (line 71 b ) passing up through the second heat exchanger 14 b in a manner known in the art.
  • the second expanded refrigerant stream 30 b is vapourized during its passage downwardly through the second heat exchanger 14 b , and can be collected through outlet 42 b as a second vapour exit stream 90 b which passes to the first compressor 22 for recompression and circulation in the first refrigeration circuit 110 .
  • the second expanded stream 30 b is expanded by the second expansion turbine 12 b in a near isentropic manner, and the difference in energy between the pre-expanded stream 20 b and the post-expanded stream 30 b can also be used as work in the first refrigeration circuit 110 .
  • the first refrigerant collected from the first and second heat exchangers 14 a , 14 b is compressed by compressor 22 to provide a compressed stream 95 , and cooled by a water and/or air cooler 26 to provide a re-condensed stream 70 for re-entry into the heat exchangers 14 a , 14 b .
  • first and second pumps 28 b , 28 a To assist circulation of the re-condensed first refrigerant stream 70 , it is passed consecutively through the first and second pumps 28 b , 28 a to provide a pumped stream 70 a prior to a final ambient cooler 29 , which may comprise one or more ambient coolers such as water and/or air coolers, to provide a cooled pumped stream 70 b ready for re-use in the heat exchangers 14 a , 14 b.
  • a final ambient cooler 29 which may comprise one or more ambient coolers such as water and/or air coolers
  • Pumps are common in refrigerant circuits, but still require to be driven, i.e. energy input. Moreover, they also increase the temperature of a stream passing therethrough as it is pressurised. In the present invention, it is particularly advantageous to drive or work the pumps 28 a , 28 b by using the work energy created by the close or neighbouring expansion turbines 12 a , 12 b .
  • the work energy of the expansion turbines 12 a , 12 b can be transferred to the associated pumps 28 a , 28 b through any mechanical linkage that interconnects them, such as a common shaft.
  • the temperature of the re-condensed stream 70 is typically 40° C. to 60° C., for example 50° C.
  • Each pump in a first refrigerant circuit can raise the temperature of a re-condensed stream by a few degrees Celsius, so that for the arrangement shown in FIG. 1 based on a hot climate, a typical temperature for the pumped stream 70 a can be for example 53° C. to 56° C.
  • One or more ambient coolers such as the ambient cooler 29 shown in FIG. 1 can then reduce the temperature of the pumped stream 70 a by 10 to 20° C., so that a typical temperature for the cooled pumped stream 70 b is 40° C.
  • the temperatures of these streams may be 10 to 20° C. lower, but the increased temperature effect of the pumps is the same.
  • the drive for one or both of the pumps 28 a , 28 b may be partly, substantially or wholly provided by the work energy from the expansion turbines 12 a , 12 b . In this way, the external energy requirement of the first refrigerant circuit 110 is reduced, thereby making it more efficient.
  • the further cooled first refrigerant stream 20 b could have been split to provide a further line of first refrigerant to pass therethrough, and so forth for any further heat exchangers, until the last heat exchanger recycles all the first refrigerant as shown in FIG. 1 for stream 20 b.
  • the hydrocarbon stream exits the second heat exchanger 14 b through outlet 34 b as a cooled hydrocarbon stream 40 b.
  • Each expansion turbine 12 a , 12 b allows the expansion of the first refrigerant to be near isentropic, which improves the efficiency of the first refrigeration circuit 110 . That is, the internal energy of streams 30 a , 30 b is lowered, which benefits the efficiency of the process. Moreover, a lower internal energy, e.g. lower entropy, of the recycled first refrigerant stream equates to a cooler refrigerant temperature, such that the recycled refrigerant streams provide better cooling to the heat exchangers, and/or less work for the refrigerant compressor(s) to recompress the refrigerant.
  • the first cooling stage 100 cools the feed stream 10 to below 0° C., such as between ⁇ 20° C. and ⁇ 70° C., preferably either between ⁇ 20° C. and ⁇ 35° C., or between ⁇ 40° C. and ⁇ 70° C., generally depending on the type of first cooling stage process.
  • each heat exchanger of a multi-stage first cooling stage 100 involves a different first refrigerant pressure.
  • the expanded refrigerant from each pressure stage could be compressed in one or more compressors, for example, using different compressors for different refrigerant entry pressures.
  • the feed stream does not pass through all the heat exchangers of the first cooling stage, but may only pass through one or more of said heat exchangers.
  • the feed stream 10 could pass through the second heat exchanger 14 b only to achieve the required cooling of the first cooling stage 100 .
  • the final cooled hydrocarbon stream 40 b from the second heat exchanger 14 b is then sent to a second cooling stage 200 using a second refrigerant, preferably a mixed refrigerant as hereinbefore described, circulating in a second refrigerant circuit 80 .
  • a second refrigerant preferably a mixed refrigerant as hereinbefore described
  • cooled hydrocarbon stream 40 b and the second refrigerant circuit 80 in and through the second cooling stage 200 .
  • Such arrangements are known in the art. These can involve one or more cooling stages, optionally at different pressure levels, and optionally within one vessel such as a cryogenic heat exchanger.
  • the second cooling stage 200 may reduce the temperature of the cooled hydrocarbon stream 40 b to provide a liquefied hydrocarbon stream 60 at a temperature of about or lower than ⁇ 130° C.
  • the second refrigerant circuit 80 passes the vapourised second refrigerant exit stream 50 a through two second compressors 52 driven by a driver 54 , and a water and/or air cooler 56 .
  • the condensing second refrigerant can pass through the heat exchangers 14 a , 14 b of the first cooling stage 100 as line 75 a , 75 b , to provide a cooler, liquefied second refrigerant stream 50 for use in the second cooling stage 200 .
  • the second refrigerant is at least partly cooled by the first cooling stage 100 .
  • This arrangement simplifies the method of liquefying a hydrocarbon feed stream such as natural gas by combining a portion of the cooling duty of the first cooling stage of the feed stream with an equivalent portion of the cooling of the second refrigerant using the same equipment, rather than the second refrigeration circuit 200 requiring other heat exchangers to sufficiently cool the second refrigerant for use in the second cooling stage 200 . This therefore reduces the level of apparatus and equipment needed, and reduces the capital and running costs for the process shown in FIG. 1 .
  • Additional cooling of the feed stream, cooled and/or liquefied hydrocarbon stream and/or the refrigerant(s) could be provided by one or more other refrigerants or refrigerant cycles in addition to cooling by the first and second cooling stages, optionally being connected with another part of the method and/or apparatus for liquefying a hydrocarbon stream as described herein.
  • the liquefied stream 60 could then undergo a third cooling stage (not shown), preferably sub-cooling.
  • Sub-cooling can be provided by passing the liquefied stream through one or more stages using one or more sub-cooling heat exchangers.
  • the or each heat exchanger of the sub-cooling would preferably be supplied with cooling by a mixed (third) refrigerant.
  • Additional cooling of the liquefied stream and/or the sub-cooling refrigerant could be provided by one or more other refrigerants or refrigerant circuits, optionally being connected with another part of the method and/or apparatus for liquefying a hydrocarbon stream as described herein.
  • the liquefied natural gas may be further processed, if desired.
  • the obtained LNG may be depressurized by means of a Joule-Thomson valve or by means of a cryogenic turbo-expander.
  • Table I gives an overview of the power requirements in three cases.
  • the specific power of a liquefaction process is defined as the refrigerant compressor power (in KW) required by the process, divided by the quantity (in tpd) of liquefied hydrocarbon stream (for example LNG) provided.
  • Case 1 relates to the power required to drive the compressor of a refrigeration circuit for a first or pre-cooling stage of a liquid natural gas liquefaction system involving two heat exchangers, and using expansion valves as described in U.S. Pat. No. 6,105,389A.
  • Case 2 is the power required to drive the compressor 22 in the liquefying process shown in FIG. 1 as described above, but without any pumps 28 a , 28 b.
  • Case 3 is the power required to drive the compressor 22 in FIG. 1 wherein the first refrigerant circuit 110 includes the pumps 28 a , 28 b as shown.
  • the power requirement for Case 2 is lower than that for Case 1, such that the use of expansion turbines has reduced the power required to recompress the first refrigerant in the first refrigerant circuit 110 .
  • Less compression pressure is required as the expanded first refrigerant (after passing through the expansion turbines) has a lower energy, and is therefore cooler, than by use of expansion valves.
  • Case 3 introduces the pumps 28 a , 28 b driven by the work output of the expansion turbines 12 a , 12 b . It shows that the power requirement of compressor 22 is even lower than that in Case 2, as further efficiency is being created in the first refrigerant circuit 110 by the use of the pumps 28 a , 28 b , thus reducing the general propulsion power created by the compressor 22 in order to maintain circulation of the first refrigerant in the first refrigerant circuit 110 .

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  • Engineering & Computer Science (AREA)
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  • Mechanical Engineering (AREA)
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  • General Engineering & Computer Science (AREA)
  • Separation By Low-Temperature Treatments (AREA)
US12/374,338 2006-07-21 2007-07-19 Method and apparatus for liquefying a hydrocarbon stream Abandoned US20100011808A1 (en)

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EP06117663.2 2006-07-21
EP06117663 2006-07-21
PCT/EP2007/057469 WO2008009721A2 (fr) 2006-07-21 2007-07-19 Procédé et appareil pour liquéfier un courant d'hydrocarbure

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EP2044376A2 (fr) 2009-04-08
JP2009544923A (ja) 2009-12-17
WO2008009721A3 (fr) 2008-11-27
RU2434190C2 (ru) 2011-11-20
AU2007275118A1 (en) 2008-01-24
AU2007275118B2 (en) 2010-08-12
WO2008009721A2 (fr) 2008-01-24

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