US20110185767A1 - Method and apparatus for liquefying a hydrocarbon-containing feed stream - Google Patents

Method and apparatus for liquefying a hydrocarbon-containing feed stream Download PDF

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US20110185767A1
US20110185767A1 US12/377,655 US37765507A US2011185767A1 US 20110185767 A1 US20110185767 A1 US 20110185767A1 US 37765507 A US37765507 A US 37765507A US 2011185767 A1 US2011185767 A1 US 2011185767A1
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cooling
refrigerant
stream
heat exchanger
sub
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Marco Dick Jager
Suyog Kalyanji Kotecha
Irina Tanaeva
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Shell USA Inc
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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
    • F25J1/0002—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the fluid to be liquefied
    • F25J1/0022—Hydrocarbons, e.g. natural gas
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0047—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle
    • F25J1/0052—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0047—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
    • F25J1/006—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
    • F25J1/007—Primary atmospheric gases, mixtures thereof
    • F25J1/0072—Nitrogen
    • 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
    • F25J1/006—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
    • F25J1/008—Hydrocarbons
    • F25J1/0087—Propane; Propylene
    • 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
    • F25J1/006—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
    • F25J1/008—Hydrocarbons
    • F25J1/0092—Mixtures of hydrocarbons comprising possibly also minor amounts of nitrogen
    • 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
    • F25J1/0218—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 with one or more SCR cycles, e.g. with a C3 pre-cooling 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
    • F25J1/0257—Construction and layout of liquefaction equipments, e.g. valves, machines
    • F25J1/0262—Details of the cold heat exchange system
    • F25J1/0264—Arrangement of heat exchanger cores in parallel with different functions, e.g. different cooling streams
    • F25J1/0265—Arrangement of heat exchanger cores in parallel with different functions, e.g. different cooling streams comprising cores associated exclusively with the cooling of a refrigerant stream, e.g. for auto-refrigeration or economizer
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0257—Construction and layout of liquefaction equipments, e.g. valves, machines
    • F25J1/0262—Details of the cold heat exchange system
    • F25J1/0264—Arrangement of heat exchanger cores in parallel with different functions, e.g. different cooling streams
    • F25J1/0265—Arrangement of heat exchanger cores in parallel with different functions, e.g. different cooling streams comprising cores associated exclusively with the cooling of a refrigerant stream, e.g. for auto-refrigeration or economizer
    • F25J1/0268—Arrangement of heat exchanger cores in parallel with different functions, e.g. different cooling streams comprising cores associated exclusively with the cooling of a refrigerant stream, e.g. for auto-refrigeration or economizer using a dedicated refrigeration means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2220/00—Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60—Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/64—Separating heavy hydrocarbons, e.g. NGL, LPG, C4+ hydrocarbons or heavy condensates in general

Definitions

  • the present invention relates to a method and apparatus for liquefying a hydrocarbon-containing feed stream, particularly but not exclusively a natural gas feed stream.
  • LNG liquefied natural gas
  • EP 1 340 951 A2 describes a process for liquefying a natural gas stream using three refrigerant cycles.
  • the first and second cooling stages are against a mixed refrigerant while the third cooling stage can be against nitrogen.
  • the second cooling stage is carried out in a single heat exchanger at a single pressure of mixed refrigerant.
  • US 2005/056051 describes a process for liquefying a natural gas stream using three refrigerant cycles.
  • the first cooling stage is against a propane refrigerant
  • the second cooling stage is against a mixed refrigerant
  • the third cooling stage can be against nitrogen.
  • the second cooling stage is carried out in a single heat exchanger at a single pressure of mixed refrigerant.
  • DE 3521060 describes a process for liquefying a natural gas stream using three refrigerant cycles.
  • the first and third cooling stages are against a mixed refrigerant or propane refrigerant, while the second cooling stage is against a mixed refrigerant.
  • U.S. Pat. No. 6,253,574 B1 describes a process for liquefying a natural gas stream using a mixed-refrigerant cascade cycle of three-mixed refrigerant cycles having different refrigerant compositions.
  • the refrigerant for the first cycle is a mixture of ethylene or ethane, propane and butane.
  • the refrigerant for the second cycle is a mixture of methane, ethylene or ethane and propane
  • the third refrigerant is a mixture of nitrogen, methane and ethylene or ethane.
  • mixed refrigerant can have some advantages in certain situations, for example in a large spool-wound cryogenic heat exchanger, which is efficient when providing cooling to go down to or below ⁇ 100° C.
  • spool-wound heat exchangers are expensive for pre-cooling.
  • the present invention provides a method of liquefying a hydrocarbon stream such as natural gas from a feed stream, the method at least comprising the steps of:
  • step (c) second cooling the cooled gas stream obtained in step (b) into a liquid against a first mixed refrigerant being cycled in a first mixed refrigerant circuit, wherein said second cooling is in two or more heat exchangers, at least two of which are operating at different pressures, thereby obtaining a liquefied stream;
  • step (d) sub-cooling the liquefied stream obtained in step (c) against a second mixed refrigerant or against a nitrogen refrigerant being cycled in a sub-cooling refrigerant circuit, thereby obtaining a sub-cooled hydrocarbon stream.
  • the present invention provides apparatus for liquefying a hydrocarbon stream such as natural gas stream from a feed stream, the apparatus at least comprising:
  • FIG. 1 is a first general scheme of an LNG plant according to one embodiment of the present invention.
  • FIG. 2 is a second general scheme of an LNG plant according to another embodiment of the present invention.
  • Embodiments of the present invention may include cooling of a feed stream into a liquefied stream in at least first and second cooling stages.
  • First cooling in the first stage may hereinafter be referred to as “step (b)” while second cooling in the second stage may hereinafter be referred to as “step (c)”.
  • the second cooling stage is advantageously operated using a first mixed refrigerant in the second cooling stage in two or more heat exchangers, at least two of which heat exchangers are operating at different pressures. Expanding the first mixed refrigerant at two different pressure levels achieves a reduction of the low-pressure compressor suction flow. This provides a reduction in the required compressor power, and improvement in the process efficiency. In addition, reduced compressor suction flow allows a reduction in the size of the compressor.
  • At least one of the two or more heat exchangers is operating at a pressure of from 4 to 15 bar and at least one other of the two or more heat exchangers is operating at a pressure of from 1 to 8 bar.
  • bar this is a reference to bar absolute.
  • the pressure difference between at least two heat exchangers is 3 bar or more.
  • at least one heat exchanger is operating at a pressure that is 1.5 times higher than the pressure at which at least one other heat exchanger is operating.
  • the other of the two or more heat exchangers may for example operate at 11 bar.
  • the other of the two or more heat exchangers may for example operate at 5.7 bar.
  • the feed stream may be cooled against a first cooling refrigerant comprising more than 90 mol % propane.
  • a first cooling refrigerant comprising more than 90 mol % propane.
  • Propane can be more conveniently used at different pressure levels than a mixed-refrigerant, such that the first cooling of the feed stream can be more efficiently arranged.
  • Recompression of the first cooling refrigerant is also more efficient because the fraction of the refrigerant that is compressed over the full pressure ratio of the refrigerant compressor is reduced.
  • a propane refrigeration circuit is less expensive than a mixed refrigerant refrigeration circuit, more particularly in the use of multiple heat exchangers and/or multiple pressure levels to effect the cooling. This is because with a single component refrigerant shell and tube heat exchangers can be used, while this is not possible if a mixed refrigerant is used.
  • Apparatus, installations and equipment that can be used as shell and tube heat exchangers are well known the art, and include for example kettles which are relatively inexpensive compared with spool-wound heat exchangers. A line of kettles can be quickly and easily located to allow a stream of single component refrigerant to pass there along, each kettle using a different pressure.
  • the first cooling refrigerant used in step (b) comprises >95 mol % propane, preferably >98 mol % propane, more preferably >99 mol % propane.
  • the first cooling of step (b) may be provided by the passage of the feed stream through a first cooling stage having one or more heat exchangers.
  • the one or each heat exchanger is preferably wholly or substantially supplied with cooling by the first cooling refrigerant.
  • the first cooling comprises at least two, optionally three, four or five, heat exchangers.
  • each heat exchanger of a multi-exchanger first cooling stage involves a different first cooling refrigerant pressure.
  • pressures are often referred to as: low pressure, medium pressure, high pressure and high high pressure.
  • the low pressure may be 1 bar, the medium pressure 2 bar, the high pressure 4 bar and the high high pressure 8 bar.
  • the expanded refrigerant from each pressure stage could be compressed in one or more compressors known in the art, for example to a pressure in the range of from 16 to 20 bar.
  • An advantage of the use of different first cooling refrigerant pressures is the better efficiency of providing cooling and/or the recompression of propane over a fraction of the pressure range compared with other refrigerants hitherto used for pre-cooling natural gas, most especially mixed refrigerants.
  • the second cooling of step (c) is provided by passing the cooled gas stream through a second cooling stage having at least two heat exchangers. At least two heat exchangers of the second cooling stage are supplied with cooling by the first mixed refrigerant in the first mixed refrigerant circuit at different pressures.
  • the heat exchangers may preferably be arranged in series such that the cooled gas stream passes through each exchanger.
  • Additional cooling of the gas stream and/or the first mixed 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 heat exchangers in the second cooling of step (c) are preferably spool-wound heat exchangers. Spool-wound heat exchangers provide improved efficiency for the second cooling step.
  • the circulation of the first mixed refrigerant in step (c) comprises compressing, cooling, and separating the refrigerant into a first high pressure fraction that is evaporated at a high pressure in one heat exchanger, and a second low pressure fraction that is evaporated at a low pressure in another heat exchanger, and recollection of the first and second evaporated fractions, wherein the high pressure fraction is evaporated at a higher temperature than the low pressure fraction.
  • a fraction of the first mixed refrigerant in step (c) does not pass through every heat exchanger of the second cooling step.
  • the first mixed refrigerant is separated into two or more fractions after passing through at least the first heat exchanger of step (c), and at least one of said fractions is expanded and returned to the first heat exchanger. Separating the first mixed refrigerant after passing through at least the first heat exchanger splits the refrigerant at a point other that the coldest point of the full stream, providing more cooling to the cooled gas stream in second cooling.
  • the liquefied stream obtained from step (c) may then be sub-cooled in a step (d).
  • the sub-cooling of step (d) may be provided by passing the liquefied stream through a third cooling stage having one or more sub-cooling heat exchangers.
  • the or each heat exchanger of the sub-cooling is preferably supplied with cooling by the second mixed refrigerant or a nitrogen refrigerant in the sub-cooling refrigerant circuit.
  • Additional cooling of the liquefied stream and/or the second mixed 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.
  • An example of this is passing the sub-cooling refrigerant circuit through the second cooling step.
  • the feed stream may be any suitable gas stream to be liquefied. It may comprise a hydrocarbon stream, usually a natural gas stream obtained from natural gas or petroleum reservoirs. As an alternative 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 undesired non-hydrocarbons such as Hg, H 2 O, N 2 , CO 2 , H 2 S and other sulphur compounds.
  • the feed stream containing the natural gas may be pre-treated to remove any undesired components present such as CO 2 and H 2 S, or there may be other steps such as pre-cooling or pre-pressurizing. 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 ethane 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-C4 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 sulphur, sulphur compounds, carbon dioxide, water, and C2+ hydrocarbons.
  • FIG. 1 shows a general scheme for a liquid natural gas (LNG plant). It shows an initial feed stream containing natural gas 10 , which feed stream may be pre-treated to separate out any of at least some heavier hydrocarbons and impurities such as carbon dioxide, nitrogen, mercury, helium, water, sulphur and sulphur compounds, including but not limited to acid gases, which may be present.
  • LNG plant liquid natural gas
  • the feed stream 10 undergoes first cooling in a first cooling stage 110 against a first cooling refrigerant being circulated in a first cooling refrigerant circuit 100 , thereby obtaining a cooled gas stream 20 .
  • the first cooling stage 110 is shown in simplified form, and generally involves a first refrigerant circuit 110 , four first heat exchangers 112 , a first compressor 114 , driven by a driver 116 , and a water and/or air cooler 118 .
  • the refrigerant of the first cooling refrigerant circuit 100 comprises >90 mol % propane.
  • the first cooling stage 110 may comprise any suitable number of heat exchangers, e.g. two, three or four, through which the feed stream 10 passes, and each heat exchanger may also have a different pressure level.
  • each of the four heat exchangers 112 shown in FIG. 1 makes a more efficient arrangement where the refrigerant is propane.
  • the use and arrangement of four different pressure levels in a refrigeration circuit allows the use of inexpensive kettle heat exchangers.
  • vapour released from each heat exchanger 112 passes to and along the first compressor 114 in an arrangement known in the art, and the compressed refrigerant is then cooled by the cooler 118 before recirculation through the heat exchangers 112 . See in this respect WO01/44734A2 and WO2005/057110A1.
  • the first cooled feed stream 20 is then passed into a separation column (not shown), which column can separate the cooled gas stream 20 into a more liquid or heavier stream, generally being a heavier hydrocarbon rich stream, and a more gaseous or lighter stream, generally being a methane enriched stream, for subsequent cooling and liquefaction.
  • the heavier stream can be recycled or used for other product production.
  • the first cooling cools down the feed stream 10 to approximately ⁇ 20 to ⁇ 50° C., such as about ⁇ 25° C.
  • the cooled gas stream 20 then undergoes second cooling into a liquid in a second cooling stage 210 against a first mixed refrigerant being circulated in a first mixed refrigerant circuit 200 .
  • the first mixed refrigerant circuit 200 includes a second compressor 202 driven by a driver 204 , a water and/or air cooler 206 and one or more dedicated heat exchangers (e.g. kettle 208 ) that could be cooled by a refrigerant circuit, preferably provided by or connected with the first refrigerant circuit 100 .
  • the first mixed refrigerant may be any suitable mixture of components including two or more of nitrogen, methane, ethane, ethylene, propane, propylene, butane, pentane, etc.
  • a refrigerant is referred to as “mixed” if each component is present in the mixture in an amount of less than 90 mol %, preferably less than 80 mol %.
  • the first mixed refrigerant used in step (c) comprises: >50 mol % of a compound selected from the group consisting of ethane and ethylene or a mixture thereof; and >10 mol % of a compound selected from the group consisting of propane and propylene or a mixture thereof.
  • the amount of a compound selected from the group consisting of propane and propylene or a mixture thereof is not more than 30 mol % and the amount of methane is less than 20 mol %.
  • the first mixed refrigerant used in step (c) comprises: >30 mol % of a compound selected from the group consisting of ethane and ethylene or a mixture thereof; and >30 mol % of a compound selected from the group consisting of propane and propylene or a mixture thereof.
  • the first mixed refrigerant circuit 200 comprises a second heat exchanger 42 and a third heat exchanger 44 , both being provided with first mixed refrigerant being circulated in the first mixed refrigerant circuit 200 .
  • the second and third heat exchangers 42 , 44 provide a condensed gas stream 60 .
  • the second and third heat exchangers 42 , 44 operate at different pressures, to increase the efficiency of cooling provided to the stream being liquefied.
  • One manner of achieving this is the first mixed refrigerant in the first mixed refrigerant circuit 200 being split prior to the third heat exchanger 44 , to provide a separate (high pressure) refrigerant stream that passes via valve 214 into the second heat exchanger 42 .
  • Valve 214 reduces the pressure of the high pressure refrigerant stream to medium pressure, preferably in the range of from 4 to 15 bar.
  • Valve 212 reduces the pressure of the remaining first mixed refrigerant prior to entry into the third heat exchanger 44 to a low pressure, preferably in the range of from 1 to 8 bar, to provide a low pressure fraction into heat exchanger 44 .
  • the pressure of the low pressure fraction is at least 3 bar lower than the pressure of the refrigerant stream that is passed into heat exchanger 42 .
  • the pressure of the refrigerant stream that is passed into heat exchanger 42 is at least 1.5 times the pressure of the low pressure fraction that is passed into heat exchanger 44 .
  • the circulation of the first mixed refrigerant comprises compressing, cooling, and separating the refrigerant into a first high pressure fraction and a second low pressure fraction, evaporation of the first and second fractions in different heat exchangers 42 , 44 , so that the high pressure fraction is evaporated at a higher temperature than the low pressure fraction.
  • the cooled gas stream 30 may optionally also provide an intermediate temperature stream that can be used to provide reflux for a scrub column when provided as optional gas/liquid separator 52 .
  • cooling in the second heat exchanger 42 may reduce the temperature of the gas stream 20 to provide a gas stream 30 at a temperature in the range of from ⁇ 30 to ⁇ 70° C., such as about ⁇ 50° C.
  • cooling in the third heat exchanger 44 may reduce the temperature of the gas stream 30 to provide a liquefied hydrocarbon stream 60 at a temperature in the range of from ⁇ 70 to ⁇ 120° C., such as about ⁇ 80° C.
  • the exit stream 30 from the second heat exchanger 42 passes through a separation vessel 52 , so as to provide a lighter gas stream 50 , being methane-enriched, and a heavier liquid stream 40 which can be recycled in the liquefaction plant, or used for production of other hydrocarbon streams.
  • the liquefied stream 60 then undergoes a third cooling, preferably sub-cooling, in a third cooling stage 310 using a fourth heat exchanger 46 and against a second mixed refrigerant or a nitrogen refrigerant being circulated in a sub-cooling refrigerant circuit 300 , thereby obtaining a sub-cooled liquefied natural gas stream 70 .
  • the sub-cooling refrigerant circuit 300 involves a third compressor 302 driven by a driver 304 , an air and/or water cooler 306 , and one or more dedicated heat exchanger(s) such as a sub-cooler, e.g. a kettle 308 .
  • any mixed refrigerant used in step (d) comprises: >30 mol % of a compound selected from the group consisting of ethane and ethylene or a mixture thereof; and >30 mol % methane.
  • the sub-cooling refrigerant circuit 300 may include a heat exchanger 312 , which could comprise more than one heat exchanger, to provide additional cooling to the refrigerant of the sub-cooling refrigerant circuit 300 .
  • a heat exchanger 312 which could comprise more than one heat exchanger, to provide additional cooling to the refrigerant of the sub-cooling refrigerant circuit 300 .
  • the refrigerant is a nitrogen refrigerant
  • the nitrogen refrigerant could be cooled in the heat exchanger 312 against a mixed refrigerant.
  • the first mixed refrigerant circuit 200 could separately or additionally cool or provide direct or indirect cooling to, the refrigerant of the sub-cooling refrigerant circuit 300 , optionally to the same temperature as the liquefied stream 60 , and further optionally to the heat exchanger 312 .
  • the scheme shown in FIG. 2 is similar to that shown in FIG. 1 . It has four refrigerant pressure levels in the first cooling stage 110 , using kettles 112 a , 112 b , 112 c and 112 d , having refrigerant outflow streams 101 , 102 , 103 and 104 respectively to the first compressor 114 .
  • FIG. 2 also shows two alternative embodiments according to the present invention.
  • the sub-cooling refrigerant circuit 300 using a second mixed refrigerant can separate the refrigerant into light and heavy fractions, similar to that described above for the first mixed refrigerant circuit 200 .
  • Both mixed refrigerants also can be let down to the same pressure level in one cryogenic heat exchanger, where the light fraction cools the coldest end.
  • the recombined refrigerant can then be sent from the bottom of the cryogenic heat exchanger to the accompanying refrigerant compressor.
  • FIG. 2 this is shown by the introduction of a separator 54 in the sub-cooling refrigerant circuit 300 .
  • the separator can separate the mixed refrigerant into a liquid heavy fraction 303 and a vapour light fraction 305 , which can both pass into the fourth heat exchanger 46 .
  • the light fraction 305 and the heavy fraction 303 can both be passed into the same shell side of the heat exchanger 46 , and the light fraction 305 can be used to cool the liquefied hydrocarbon stream 60 entering the fourth heat exchanger 46 at the low end of the temperature interval of the third cooling, and the heavy fraction 303 can be used to cool the liquefied hydrocarbon stream 60 at the high end of the temperature interval of the third cooling.
  • the passage, operation and expansion of the refrigerant lines in the fourth heat exchanger 46 of FIG. 2 are known to those skilled in the art. In this way, the heavy fraction 303 and light fraction 305 of the second mixed refrigerant can evaporate in the fourth heat exchanger 46 at the same or substantially the same pressure as is known in the art.
  • the first mixed refrigerant circuit 200 still comprises a second heat exchanger 42 and a third heat exchanger 44 , but the first mixed refrigerant, after condensing and cooling through a water and/or air cooler 206 and one or more dedicated heat exchangers (e.g. kettle 208 or provided by the first cooling stage 100 ), all passes through the second heat exchanger 42 to be cooled.
  • a water and/or air cooler 206 and one or more dedicated heat exchangers e.g. kettle 208 or provided by the first cooling stage 100
  • the cooled refrigerant stream 203 is then divided between a first fraction which is expanded by a valve 214 to provide a separate low pressure refrigerant stream 205 which is used to provide cooling in the heat exchanger 42 , and whose exit stream 201 is passed into the second compressor 202 , and a second fraction 207 which passes through the third heat exchanger 44 for cooling, prior to expansion to provide a refrigerant stream 209 which provides cooling in the third heat exchanger 44 .
  • the refrigerant exit stream 211 passes to the compressor 202 .
  • the division of the condensed first mixed refrigerant stream 203 may take place at a temperature between ⁇ 30° C. and ⁇ 70° C.
  • any air cooler at the exit of the compressor for the first mixed refrigerant may not be necessary, as the temperature of the compressor suction flow can be close to, such as only a few degrees different, that of the first mixed refrigerant temperature when divided, which results in the compressor outlet temperature being below the ambient temperature. This is especially where cooling of the first mixed refrigerant from the compressor is provided, either directly or indirectly, by the first cooling stage 110 .
  • additional cooling of the refrigerant in the sub-cooling refrigerant circuit 300 can be provided by the second cooling, generally by passing the sub-cooling refrigerant circuit 300 through part or all of the second cooling step, or having an intermediate circuit(s) thereinbetween.
  • the liquefied natural gas may be further processed, if desired.
  • the obtained LNG may be depressurized by means of a Joule-Thomson valve or cryogenic turbo-expander.
  • Table I gives an overview of the separate and overall power requirements for one example of the process shown in FIG. 1 .
  • FIG. 1 First Cooling power MW 88.5 91.8 Second Cooling power MW 97.5 87.1 Third Cooling power MW 86.2 76.3 Total power MW 272.2 255.2 Production tpd 21109 21116 Specific Power KW/tpd 12.9 12.1
  • the power requirements for the example of FIG. 1 are compared with a comparative scheme using a mixed refrigerant in its first cooling cycle, as shown for instance in U.S. Pat. No. 6,253,574 B1.
  • first cooling power is increased
  • power for the second and third cooling cycles is reduced, so that for a similar production of LNG, there is an overall reduction of 17 MW (7%) achieved by the present invention. This is significant in relation to the size and energy requirements of an LNG plant.
  • the first or pre-cooling cycle is loaded to a higher extent than the other cooling cycles.
  • One consequence is that the internal flows of the first or pre-cooling compressor are higher, even though a split propane line-up is used: that is, the propane refrigerant flow rate is higher than in the comparative scheme.
  • the third or sub-cooling cycle has a reasonable suction volume for its compressor and a main cryogenic exchanger area that is well in line with the current main cryogenic exchangers.
  • Table II gives an overview of the overall power requirements of an example of the process represented in FIG. 2 and a further example of the process represented in FIG. 1 .
  • FIG. 1 Total cooling MW 412 403 395 power Production Mtpa 10.14 10.14 10.12 Specific power kW/tpd 13.6 13.2 13.1
  • FIGS. 1 and 2 The power requirements for this example process of the invention represented in FIGS. 1 and 2 are compared with a comparative scheme using a mixed refrigerant in its first and second cooling cycles in which the second cooling cycle is carried out in a single heat exchanger operated at a single pressure of mixed refrigerant.
  • nitrogen was used as the second single refrigerant in the process of FIG. 1 and a mixed refrigerant was used as the second mixed refrigerant in the process of FIG. 2 .
  • Table III gives a representative working example of temperatures, pressures and flows of streams at various parts in an example process referring to FIG. 2 .
  • Streams 100 a , 200 a and 300 a refer to the respective refrigerant streams of the first, second and third refrigerant circuits 100 , 200 and 300 , after their compression and cooling.

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US12/377,655 2006-08-17 2007-08-15 Method and apparatus for liquefying a hydrocarbon-containing feed stream Abandoned US20110185767A1 (en)

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EP2977431A1 (fr) 2014-07-24 2016-01-27 Shell Internationale Research Maatschappij B.V. Stabilisateur de condensat d'hydrocarbure et procédé de production d'un flux de condensat d'hydrocarbure stabilisé
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EP3032204A1 (fr) 2014-12-11 2016-06-15 Shell Internationale Research Maatschappij B.V. Procédé et système de production d'un flux d'hydrocarbures refroidis
US20160298899A1 (en) * 2015-04-07 2016-10-13 Conocophillips Company Quench system for a refrigeration cycle of a liquefied natural gas facility and method of quenching
US10480851B2 (en) 2013-03-15 2019-11-19 Chart Energy & Chemicals, Inc. Mixed refrigerant system and method
US11274880B2 (en) * 2017-05-16 2022-03-15 Exxonmobil Upstream Research Company Method and system for efficient nonsynchronous LNG production using large scale multi-shaft gas turbines
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EP2426452A1 (fr) 2010-09-06 2012-03-07 Shell Internationale Research Maatschappij B.V. Procédé et appareil de refroidissement d'un flux gazeux d'hydrocarbure
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EP2791601B1 (fr) 2011-12-12 2020-06-24 Shell International Research Maatschappij B.V. Procédé et appareil pour retirer l'azote d'une composition d'hydrocarbures cryogéniques
CN103998882B (zh) 2011-12-12 2016-04-13 国际壳牌研究有限公司 用于从低温烃类组合物中去除氮气的方法和装置
EP2604960A1 (fr) 2011-12-15 2013-06-19 Shell Internationale Research Maatschappij B.V. Procédé de fonctionnement d'un compresseur et système et procédé pour la production de flux d'hydrocarbures liquéfié
JP6322195B2 (ja) 2012-08-31 2018-05-09 シエル・インターナシヨネイル・リサーチ・マーチヤツピイ・ベー・ウイＳｈｅｌｌ Ｉｎｔｅｒｎａｔｉｏｎａｌｅ Ｒｅｓｅａｒｃｈ Ｍａａｔｓｃｈａｐｐｉｊ Ｂｅｓｌｏｔｅｎ Ｖｅｎｎｏｏｔｓｈａｐ 可変速度駆動システム、可変速度駆動システムの運転方法、および炭化水素流の冷却方法
CA2909614C (fr) 2013-04-22 2021-02-16 Shell Internationale Research Maatschappij B.V. Procede et appareil de production d'un flux d'hydrocarbure liquefie
EP2857782A1 (fr) 2013-10-04 2015-04-08 Shell International Research Maatschappij B.V. Échangeur de chaleur à bobine enroulée et procédé de refroidissement d'un flux de procédé
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US20130333403A1 (en) * 2010-08-23 2013-12-19 Dresser-Rand Company Process for throttling a compressed gas for evaporative cooling
US11408673B2 (en) 2013-03-15 2022-08-09 Chart Energy & Chemicals, Inc. Mixed refrigerant system and method
US11428463B2 (en) 2013-03-15 2022-08-30 Chart Energy & Chemicals, Inc. Mixed refrigerant system and method
US10480851B2 (en) 2013-03-15 2019-11-19 Chart Energy & Chemicals, Inc. Mixed refrigerant system and method
EP2977431A1 (fr) 2014-07-24 2016-01-27 Shell Internationale Research Maatschappij B.V. Stabilisateur de condensat d'hydrocarbure et procédé de production d'un flux de condensat d'hydrocarbure stabilisé
EP2977430A1 (fr) 2014-07-24 2016-01-27 Shell Internationale Research Maatschappij B.V. Stabilisateur de condensat d'hydrocarbure et procédé de production d'un flux de condensat d'hydrocarbure stabilisé
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WO2008020044A3 (fr) 2008-11-27
RU2447382C2 (ru) 2012-04-10
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EP2052197B1 (fr) 2018-05-16
AU2007285734B2 (en) 2010-07-08
AU2007285734A1 (en) 2008-02-21
EP2052197A2 (fr) 2009-04-29

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